Professional Documents
Culture Documents
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1.1 1.2 2.0 3.0 SYSTEM COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SIX-STEP TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . .1
IDENTIFICATION OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . .1 3.1 3.2 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 JTEC CONTROLLER AND OPERATING MODES . . . . . . . . . . . . . . . . . . . . . . . .1 3.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 3.2.2 Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 3.2.3 Software Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 3.2.4 Spark Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 3.2.5 Fuel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 3.2.6 On Board Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 3.2.7 Transmission Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 3.2.8 Other Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 3.2.9 PCM Operating Modes (Gasoline & Eng.) . . . . . . . . . . . . . . . . . . . . . . . . .6 3.2.10 PCM Operating Modes (Diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 3.2.11 Non-Monitored Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 3.3.1 Hard Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 3.3.2 Intermittent Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 3.3.3 Reset Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 3.3.4 Handling No Trouble Code Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 USING THE DRB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 DRB ERROR MESSAGES AND BLANK SCREEN. . . . . . . . . . . . . . . . . . . . . . .12 3.5.1 DRB Does Not Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 3.5.2 Display Is Not Visible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.3
3.4 3.5
4.0
SYSTEM COMPONENT LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 POWERTRAIN CONTROL MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 CONTROLS & SOLENOIDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 DATA LINK CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 LAMPS & INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
5.0
DISCLAIMERS, SAFETY, WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 5.1 5.2 DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 5.2.1 Technician Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 5.2.2 Vehicle Preparation for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 5.2.3 Servicing Sub-Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 5.2.4 DRBIII Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 5.3.1 Vehicle Damage Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 5.3.2 Road Testing a Complaint Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
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5.3
iii
NO TROUBLE CODE TESTS NTC-1A NO TROUBLE CODE TEST MENU . . . . . . . . . . . . . . . . . . . . . . . . . .666 NTC-2A CHECKING SECONDARY IGNITION AND TIMING . . . . . . . . . . . . . .668 NTC-3A CHECKING FUEL PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .670 NTC-4A CHECKING COOLANT SENSOR CALIBRATION . . . . . . . . . . . . . . . .676 NTC-5A CHECKING THROTTLE POSITION SENSOR . . . . . . . . . . . . . . . . . .678 NTC-6A CHECKING MAP SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .680 NTC-7A CHECKING OXYGEN SENSOR SWITCHING . . . . . . . . . . . . . . . . . .682 NTC-8A CHECKING THE OXYGEN SENSOR HEATER . . . . . . . . . . . . . . . . .688 NTC-9A CHECKING IDLE AIR CONTROL MOTOR . . . . . . . . . . . . . . . . . . . . .690 NTC-10A CHECKING THE PARK/NEUTRAL POSITION SWITCH. . . . . . . . . . .698 NTC-11A CHECKING THE PCM POWER AND GROUND CIRCUITS . . . . . . . .702 NTC-12A CHECKING THE EVAP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . .704 NTC-13A CHECKING EGR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .708 NTC-14A CHECKING THE ENGINE VACUUM . . . . . . . . . . . . . . . . . . . . . . . . .714 NTC-15A CHECKING THE INTAKE AIR TEMP SENSOR . . . . . . . . . . . . . . . . .716 NTC-16A CHECKING MINIMUM AIR FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . .718 NTC-17A CHECKING THE AIR INTAKE HEATER #1. . . . . . . . . . . . . . . . . . . . .720 NTC-18A CHECKING THE AIR INTAKE HEATER #2. . . . . . . . . . . . . . . . . . . . .726 NTC-19A CHECKING THE FUEL HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . .732 NTC-20A CHECKING THE WAIT-TO-START LAMP. . . . . . . . . . . . . . . . . . . . . .736 NTC-21A CHECKING THE WATER-IN-FUEL LAMP & SENSOR . . . . . . . . . . . .740 NTC-22A CHECKING THE ENGINE MECHANICAL SYSTEMS. . . . . . . . . . . . .748 SPEED CONTROL TESTS SC-1A CHECKING THE SPEED SC-2A CHECKING THE SPEED SC-3A CHECKING THE SPEED SC-4A CHECKING THE SPEED SC-5A CHECKING THE SPEED CHARGING TESTS
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CONTROL OPERATION CONTROL OPERATION CONTROL OPERATION CONTROL OPERATION CONTROL OPERATION
10.0
SCHEMATIC DIAGRAMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .895 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.11 10.12 1996 1996 1996 1996 1996 1996 1996 1996 1996 1996 1996 1996 DODGE 2.5L JTEC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .895 JEEP XJ 2.5L JTEC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .896 JEEP XJ 4.0L JTEC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .897 JEEP ZJ 4.0L JTEC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .898 DODGE 3.9L JTEC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .899 DODGE 5.2/5.9L JTEC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .900 JEEP ZJ 5.2L JTEC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .901 DODGE 5.9L-HD JTEC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .902 DODGE 5.9L CUMMINS DIESEL JTEC SYSTEM. . . . . . . . . . . . . . . . . .903 DODGE 8.0L V10-MD SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .904 DODGE 8.0L V10-HD SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .905 DODGE 5.2L CNG, AB, AN, AND BR SYSTEM . . . . . . . . . . . . . . . . . . .906
11.0
vi
1.0
INTRODUCTION
The procedures contained in this manual include all the specifications, instructions, and graphics needed to diagnose powertrain control module (PCM) problems; they are no start, diagnostic trouble code, and no trouble code problems for the PCM. The diagnostics in this manual are based on the trouble condition or symptom being present at the time of diagnosis. When repairs are required, refer to the appropriate volume of the service manual for the proper removal and repair procedure. Diagnostic procedures change every year. New diagnostic systems may be added; carryover systems may be enhanced. READ THE GENERAL INFORMATION SECTIONS IN THIS MANUAL BEFORE TRYING TO DIAGNOSE A VEHICLE TROUBLE CODE. It is recommended that you review the entire manual to become familiar with new or revised diagnostic procedures. This book reflects many suggested changes from readers of past issues. After using this book, if you have any comments or recommendations, please fill out the form at the back of the book and mail it back to us.
G E N E R A L I N F O R M A T I O N
1.1
System Coverage
This diagnostic procedures manual covers all 1996 Jeep and Dodge Truck vehicles with a new PCM (JTEC Engine and 42RX Transmission Controller).
1.2
Diagnosis of the powertrain control module PCM is done in six basic steps:
verification of complaint verification of any related symptoms symptom analysis problem isolation repair of isolated problem verification of proper operation
2.0
IDENTIFICATION OF SYSTEM
The powertrain control module PCM monitors and controls the engine, fuel system, ignition system, and automatic transmission.
3.0 3.1
The Jeep and Dodge Truck engine and Auto Transmission systems have the latest in technical advances. The on-board OBDII diagnostics incorporated with the PCM controller are intended to assist the field technician in repairing vehicle problems by the quickest means.
3.2 3.2.1
The Jeep-Truck PCM features a multi-processor environment (one 16 bit microcomputer, two 8 bit microcomputers) allowing parallel processing of time critical operations. Dedication of one 8 bit processor (K4) to spark control and the other 8 bit processor (D3) to fuel control allows increases in throughput and reduced software complexity in the 16 bit microcomputer (Z2). The result is
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G E N E R A L I N F O R M A T I O N
increased capability in the Z2 to handle overall strategy implementation, OBDII, and other computation-intensive processes. This approach allows control of ten cylinder engines in running excess of 6,500 RPM.
3.2.2
Hardware Architecture
The design of the PCM can be broken up into about eight major sections. The main microcontroller, a Motorola MC68HC16Z2, is attached to a 256k byte memory device (flash memory) which is programmed after manufacture of the module. (This memory can be reprogrammed at the factory or at a dealership. The MC68HC11D3 and MC68HC11K4 microcomputers have memories which are permanently programmed during their manufacture, and therefore cannot be reprogrammed.) The microcomputers communicate over a bus which allows for rapid transmission of high priority messages. The Z2 executes the primary powertrain control strategy; transmits fuel and spark requirements to the D3 and K4; communicates with outside devices; and processes 14 analog inputs and about half of the one bit inputs and outputs. The D3 microcomputer controls fuel injector timing pulses and a small number of one bit inputs and outputs. The K4 controls spark timing pulses, processes 8 analog inputs and a number of one bit inputs and outputs. Other major sections of the PCM design include the power supply, input conditioning circuits, output driver circuits, serial communication interface circuits, and a device which controls ignition coil currents.
3.2.3
Software Architecture
The 68HC16Z2 microcontroller is the main computing unit of the PCM. The 68HC11D3 and K4 microcontrollers control fuel and spark respectively. They handle the critical timing requirements of their tasks, communicating with the Z2 using high level commands. The Z2 operating system is the heart of the software and was written expressly for this PCM. Every 500 microseconds the Z2 interrupts what it is doing to perform periodic tasks such as updating sensor inputs values and checking for the occurrence of a crank position pulse. If this pulse is observed, a program known as the decision maker is executed and performs high priority tasks such as fuel and spark calculations, and RPM processing. Low priority tasks (i.e. OBDII processing, SCI and CCD communications) are executed during the time between crank pulses. The Z2 software is divided into a main operating strategy and three separate calibration areas. The main strategy contains information specific to the various engines and transmissions supported by this PCM. Once installed, the information contained in this area is fixed for a given engine and transmission. Changes to this data, if required, can be performed only by computer programming personnel. The calibration areas (engine, transmission and OBDII) contain information relating to emissions, fuel economy and driveability and can be altered directly by calibration personnel.
3.2.4
Spark Control
The K4 microcomputer controls the generation and timing of spark pulses. The spark advance and dwell characteristics are determined by: engine speed, throttle position, MAP, coolant temperature, barometric air pressure, air temperature, and vehicle speed.
3.2.5
Fuel Control
The PCM controls the air/fuel ratio of the engine by varying fuel injector on time. Mass air flow is calculated using the speed density method using engine speed, manifold absolute pressure, and air charge temperature. Different fuel calculation strategies are used dependent on the operational state of the engine. During crank mode, a prime shot fuel pulse is delivered followed by fuel pulses determined by a
2
crank time strategy. Cold engine operation is determined via an open loop strategy until the O2 sensors have reached operating temperature. At this point, the strategy enters a closed loop mode where fuel requirements are based upon the state of the O2 sensors, engine speed, MAP, throttle position, air temperature, battery voltage, and coolant temperature. Additional factors can influence fuel pulse width. Asynchronous acceleration enrichment is a technique whereby the duration of injector on time can be increased for injectors already firing, providing improved acceleration response. The D3 microcomputer controls fuel injector timing in response to high level commands from the Z2 microcomputer. Injector timing with respect to engine position is determined by the D3 and is transparent to the Z2.
G E N E R A L I N F O R M A T I O N
3.2.6
On Board Diagnostics
The PCM has been programmed to monitor many different circuits of the fuel injection system. This monitoring is called on-board diagnosis. Certain criteria, or arming conditions, must be met for a trouble code to be entered into the PCM memory. The criteria may be a range of: engine rpm, engine temperature, and/or input voltage to the PCM. If a problem is sensed with a monitored circuit, and all of the criteria or arming conditions are met, a trouble code will be stored in the PCM. It is possible that a trouble code for a monitored circuit may not be entered into the PCM memory even though a malfunction has occurred. This may happen because one of the trouble code criteria (arming conditions) has not been met. The PCM compares input signal voltages from each input device with specifications (the established high and low limits of the range) that are programmed into it for that device. If the input voltage is not within specifications and other trouble code criteria (arming conditions) are met, a trouble code will be stored in the PCM memory. The On Board Diagnostics have evolved to the second Generation of Diagnostics referred to as OBDII. These OBDII Diagnostics control the functions necessary to meet the requirements of California OBDII and Federal OBD regulations. These requirements specify the inclusion of a malfunction indicator light (MIL) located on the instrument panel for all 1994 and subsequent model-year passenger cars, light duty trucks, and medium-duty vehicles. The purpose of the MIL is to inform the vehicle operator in the event of malfunction of any powertrain components which can affect emissions and which provide input to, or receive output from, the engine controller module. Control of OBDII functions is separated into two areas: the Task Manager and the Comprehensive Component Manager. Task Manager The Task Manager controls the execution of some component/systems tests, control of MIL illumination, storage of fault codes, and storage of vehicle data at time of fault detection (freeze frame). This routine performs the following monitoring requirements: Fuel System Monitoring Misfire Detection EGR System Monitor Oxygen Sensor Upstream Heater Monitor Oxygen Sensor Upstream Monitor Evaporative System Monitor Catalyst Monitor
G E N E R A L I N F O R M A T I O N
Purge Flow Monitor 02 Heater Downstream Monitor 02 Sensor Downstream Monitor Another function of the task manager is control of the Disable Tables. These tables are used to discontinue testing when a condition specified in the tables are met. Testing of a component or system is disabled if a fault or failure occurs which would render the test useless. (For example, the Catalyst Monitor test will not be run unless the O2 Sensor test has passed.) Comprehensive Component Manager The Comprehensive Component Manager controls the testing of all powertrain components/ systems which can affect emissions and were not otherwise tested by the Task Manager. This routine is organized into three areas: D3 and K4 CIRCUIT CHECKS Performed on sensor inputs connected to the D3 and K4 to determine out-of-range or high/flow input conditions. Performed on outputs to check for open/short conditions. The components tested are: IAC Open/Short Circuit Generator Field TCC Solenoid Fan Relay A/C Relay Air Switch / Shift Lock Solenoid Transmission Relay Output ASD Relay Fuel Pump Relay EVAP Purge Solenoid EGR Solenoid Ignition Coils (1 thru 5) Injector Failure (1-10) Z2 CIRCUIT CHECKS Performed on sensor inputs connected to the Z2 to determine out-of-range or high/low input conditions. Performed on outputs to check for open/short conditions. The components tested are: MAP Sensor Voltage (high/low) Intake Air Temperature Sensor Voltage (high/low) Coolant Temperature Sensor Voltage (high/low) Throttle Position Sensor Voltage (high/low) MAP Sensor 5 Volt Supply Check CNG Pressure Sensor Voltage (high/low) CNG Temperature Sensor Voltage (high/low) Battery Temperature Sensor Voltage (high/low) Fuel Level Sensor Voltage (high/low) Transmission Temperature Sensor Voltage (high/low) Governor Pressure Sensor Voltage (high/low) Governor Pressure Solenoid (open/short) ASD Relay Voltage (out of range) Battery Voltage (too high) Overdrive Override Switch (fault) Leak Detection Pump Solenoid (open/short) 3/4 Shift Solenoid (open/short) Speed Control Vac and Vent Solenoids (open/short)
FUNCTIONALITY/RATIONALITY CHECKS These tests determine if a component is working correctly through methods other than voltage limit tests and open/short tests. Solenoids in this section are checked for proper operation (functionality) and sensors are checked for meaningful output values (rationality). The components/systems checked are: Cam Sensor Pulses Present Crank Sensor Pulses Present MAP Sensor Output in Range Coolant Temperature in Range Throttle Position Sensor in Range Vehicle Speed Sensor Output Correct Park/Neutral Switch Working Fuel Level Sensor Output Correct Transmission Temperature Sensor Output Correct Transmission Governor Pressure in Range Output Shaft Speed Sensor Output Correct AIS Motor Working Lock-up Solenoid Working 3/4 Shift Solenoid Working Governor Pressure Solenoid Working O2 Sensor 1/1 Output Voltage Low O2 Sensor 1/2 Output Voltage Low O2 Sensor 2/1 Output Voltage Low O2 Sensor 2/2 Output Voltage Low Charging System Working Power Steering Switch Working Thermostat Working O2 Sensor 1/1 (open circuit or high voltage) O2 Sensor 1/2 (open circuit or high voltage) O2 Sensor 2/1 (open circuit or high voltage) O2 Sensor 1/2 (open circuit or high voltage)
G E N E R A L I N F O R M A T I O N
3.2.7
Transmission Control
The PCM operation includes control of 3 and 4 speed automatic transmissions utilizing electronic governor pressure control, eliminating the need for a separate transmission controller. Transmission control is achieved through regulation of governor pressure using a variable force solenoid valve. (Valve position is controlled by pulse width modulation. Torque convertor lock-up and overdrive solenoids are also controlled by the PCM, as are the transmission protection relay and dashboard overdrive lamp. PCM inputs affecting transmission operation include the throttle position sensor, output shaft speed sensor, vehicle speed sensor, engine speed sensor, brake switch, cruise control switches, ignition, overdrive on/off switch and sump fluid temperature thermistor. Electronic Governor Pressure Control Regulation of governor pressure by enables control of WOT shift points to within +/- 50 RPM resulting in improved shift quality (as opposed to control to within +/- 300 RPM in transmission utilizing mechanical governors). The elimination of the mechanical governor resulted in a physically smaller and lighter package. Torque calculation can be used to determine when upshifting is advantageous. Anti-Hunt Shift Strategy This strategy was added in order to maintain fuel economy over a variety of load conditions. This technique allows for relatively early upshift in mid-range throttle settings under light load conditions, resulting in improved fuel economy. Under heavier loading, shifts are delayed to prevent upshifting into a condition where insufficient torque is available to maintain vehicle speed, resulting in downshift/upshift cycling.
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G E N E R A L I N F O R M A T I O N
Sump Pump Temperature Sensing A themistor is attached to the lock-up solenoid and submerged in the sump fluid. The sump fluid temperature is a factor in the calculation of WOT shift strategy, low temperature shift compensation, sump temperature limiting strategy, overdrive strategy, torque converter clutch strategy, and governor pressure transducer calibration.
3.2.8
Other Controls
Cruise Control The PCM controls vehicle speed by operation of the speed control servo vacuum and vent solenoids. Energizing the vacuum solenoid applies vacuum to the servo to increase throttle position. Operation of the vent solenoid slowly releases the vacuum allowing throttle position to decrease. A special dump solenoid allows immediate release of throttle position caused by braking, cruise control turn off, or ignition key off. Exhaust Gas Recirculation The PCM controls a solenoid which enables/disables EGR. Control of exhaust gas recirculation (using exhaust gas pressure to modulate the vacuum supply to the EGR valve) is enabled only after the engine has warmed. Fuel Vapor Recovery System (Duty Cycle Purge Control) Duty Cycle Purge is a system that feeds fuel gases from the purge canister and gasoline tank into the throttle body for mixing with incoming air. Metering of the gases is performed by duty cycling the purge solenoid by the PCM. The system is disabled during wide open throttle conditions and while the engine is below a specified coolant temperature. When engine temperature becomes greater than a calibrated parameter, duty cycle purge is delayed for a calibrated time. Once purge delay is over, purge will be ramped in to soften the effect of dumping additional fuel into the engine. The PCM provides a modulated 5 hz signal (at closed throttle) or 10 hz signal (at open throttle) to control this system. Modulation of the signal is based upon a calculated air flow (based upon known fuel flow through the injector at a given pulsewidth and RPM) and is adjusted to compensate for changes in flow due to varying engine vacuum.
3.2.9
As Input signals to the PCM change, the PCM adjusts its response to output devices. For example, the PCM must calculate a different injector pulse width and ignition timing for idle than it does for wide open throttle. There are several different modes of operation that determine how the PCM responds to the various input signals. There are two types of engine control operation: open loop and closed loop. In open loop operation, the PCM receives input signals and responds according to preset programming. Inputs from the heated oxygen sensors are not monitored. In closed loop operation, the PCM monitors the inputs from the heated oxygen sensors. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio of 14.7 parts air to 1 part fuel. By monitoring the exhaust oxygen content through the oxygen sensor, the PCM can fine tune injector pulse width. Fine tuning injector pulse width allows the PCM to achieve optimum fuel economy combined with low emissions. The engine start-up (crank), engine warm-up, and wide open throttle modes are open loop modes. Under most operating conditions, the acceleration, deceleration, and cruise modes, with the engine at operating temperature, are closed loop modes.
Ignition Switch On (Engine Off) Mode When the ignition switch activates the fuel injection system, the following actions occur: 1. The PCM determines atmospheric air pressure form the MAP sensor input to determine basic fuel strategy. 2. The PCM monitors the engine coolant temperature sensor and throttle position sensor input. The PCM modifies fuel strategy based on this input. When the Ignition key is in the on position and the engine is not running (zero rpm), the auto shutdown relay and fuel pump relay are not energized. Therefore, voltage is not supplied to the fuel pump, ignition coil, and fuel injectors. Engine Start-Up Mode This is an open loop mode. The following actions occur when the starter motor is engaged: 1. The auto shutdown and fuel pump relays are energized. If the PCM does not receive the camshaft and crankshaft signals within approximately one second, these relays are de-energized. 2. The PCM energizes all fuel injectors until it determines crankshaft position from the camshaft and crankshaft signals. The PCM determines crankshaft position within one engine revolution. After the crankshaft position has been determined, the PCM energizes the fuel injectors in sequences. The PCM adjusts the injector pulse width and synchronizes the fuel injectors by controlling the fuel injectors ground paths. Once the auto shutdown and fuel pump relays have been energized, the PCM determines the fuel injector pulse width based on the following: engine coolant temperature manifold absolute pressure intake air temperature engine revolutions throttle position
G E N E R A L I N F O R M A T I O N
The PCM determines the spark advance based on the following: engine coolant temperature crankshaft position camshaft position intake air temperature manifold absolute pressure throttle position
Engine Warm-Up Mode This is an open loop mode. The PCM adjusts injector pulse width and controls injector synchronization by controlling the fuel injectors ground paths. The PCM adjusts ignition timing and engine idle speed. The PCM adjusts the idle speed by controlling the idle air control motor. Cruise or Idle Mode When the engine is at normal operating temperature, this is a closed loop mode. During certain idle conditions, the PCM may enter into a variable idle speed strategy. At this time, the PCM adjusts engine speed based on the following inputs: throttle position battery voltage engine coolant temperature
Acceleration Mode This is a closed loop mode. The PCM recognizes an increase in throttle position and a decrease in Manifold Vacuum as engine load increases. In response, the PCM increases the injector pulse width to meet the increased load.
7
G E N E R A L I N F O R M A T I O N
Deceleration Mode This is a closed loop mode. The PCM recognizes a decrease in throttle position and an increase in Manifold Vacuum as engine load decreases. In response, the PCM decreases the injector pulse width to meet the decreased load. Wide Open Throttle Mode This is an open loop mode. The throttle position sensor notifies the PCM of a wide open throttle condition. The PCM adjusts injector pulse width to supply a predetermined amount of additional fuel.
3.2.10
As input signals to the powertrain control module (PCM) change, the PCM adjusts its response to output devices. There are several different modes of operation that determine how the PCM responds to the various input signals. In all modes, the wait-to-start lamp will flash if an open circuit is detected in the intake air temperature sensor circuit. Ignition Switch On (Engine Off) Mode When the ignition switch is in the on position, the following actions occur: 1. When the PCM receives an ignition sense input, it powers up. Battery voltage is supplied through the battery voltage input. 2. The wait-to-start, water-in-fuel, check engine and transmission temperature (auto trans only) lamps are turned on by the PCM for at least 2 seconds as a bulb test. 3. The PCM monitors the intake air temperature signal. If the intake air temperature is below a predetermined temperature, the PCM will start the air intake heater preheat cycle. The PCM will energize the intake heaters by grounding the air intake heater relays. The PCM will turn the wait-to-start lamp on until the preheat cycle is over. If the PCM receives a crank signal before the preheat cycle is over, the preheat cycle will be aborted. 4. The PCM will turn on the water-in-fuel lamp if a signal is received from the water-in-fuel sensor. NOTE: If the water-in-fuel lamp remains illuminated after the 2-second bulb check, the vehicle should not be started until the fuel filter has been drained and primed. Engine Start-Up Mode When the ignition key is held in the start position, the following occurs: 1. The PCM receives the crank signal input from the crank position sensor. 2. The air intake heaters are not energized during cranking. 3. The PCM monitors engine speed and when the engine speed is above 375 rpm, the PCM determines that the engine is running. 4. If the PCM receives a crank signal before the preheat cycle is over, the heaters will be de-energized. However, the post-heat cycle will begin if the engine speed is above 375 rpm. Engine Warm-Up Mode 1. The PCM may start the air intake heater post-heat cycle depending on intake air temperature. If manifold air temperature was at 66F or less when the ignition was turned on, the cycle is started. 2. If the transmission temperature sensor determines it is below 59F, the automatic transmission will not be allowed to enter overdrive. 3. If the transmission temperature sensor determines it is below 69F, the transmissions torque converter clutch will not be allowed to engage. 4. The PCM will turn on the water-in-fuel lamp if a signal is received from the water-in-fuel sensor.
8
Cruise or Idle Mode During cruising speed, the following inputs are received by the PCM: 1. The PCM monitors intake manifold air temperature through the intake air temperature sensor. 2. The intake air heater post-heat cycle will be completed, if it is not already over. 3. The vehicle speed, crank position, and throttle position sensors are used to control the transmission overdrive and torque converter clutch operation. 4. If the transmission temperature sensor determines it is below 59F or above 275F, the automatic transmission will not be allowed to enter overdrive. If the transmission is in overdrive when the transmission temperature is above 275F, the transmission will downshift and not upshift again until the transmission temperature drops to 240F. 5. The water in-fuel sensor signal is used by the PCM to turn on the water-in-fuel lamp, if water is sensed in the fuel. Acceleration Mode When there is an abrupt demand for increased engine output and vehicle acceleration, the following occurs: 1. The vehicle speed, crank position, and throttle position sensors are used to control transmission overdrive and torque converter clutch operation. 2. If the transmission temperature sensor determines it is below 69F, the transmissions torque converter clutch will not be allowed to engage. 3. If the transmission temperature sensor determines it is below 59F or above 275F, the automatic transmission will not be allowed to enter overdrive. If the transmission is in overdrive when the transmission temperature is above 275F, the transmission will downshift and not upshift again until the transmission temperature drops to 240F. 4. If the speed control system resume/accelerate function is being used, the PCM will only allow the vehicle to accelerate at a predetermined rate. If a speed control has been set and the resume/accelerate button is momentarily pushed in, the PCM will increase vehicle speed by two miles per hour. 5. The PCM will disable the speed control when: the brakes are applied the clutch is disengaged (manual transmission) the gear selector is shifted to neutral (automatic transmission) the speed control off switch is activated Deceleration Mode During deceleration, the following inputs are received by the PCM: 1. The vehicle speed, crank position, and throttle position sensors are used to control transmission overdrive and torque converter clutch operation. 2. The torque converter clutch will disengage, if the brakes are applied. 3. If the transmission temperature sensor determines it is below 59 or above 275F, the automatic transmission will not be allowed to enter overdrive. If the transmission is in overdrive when the transmission temperature is above 275F, the transmission will downshift and not upshift again until the transmission temperature drops to 240F.
G E N E R A L I N F O R M A T I O N
G E N E R A L I N F O R M A T I O N
4. The PCM will disable the speed control when: the brakes are applied the clutch is disengaged (manual transmission) the gear selector is shifted to neutral (automatic transmission) the speed control off switch is activated Ignition Switch Off Mode When the ignition switch is turned to the off position, the PCM still receives battery voltage through the battery input. Battery voltage is needed to keep PCM memory alive. The Memory stores trouble codes and the throttle position sensor value from the previous key-on.
3.2.11
Non-Monitored Circuits
The PCM does not monitor the following circuits, systems, and conditions even though they could have malfunctions that result in driveability problems. A diagnostic code may not be displayed for the following conditions. However, problems with these systems may cause a diagnostic code to be displayed for other systems. For example, a fuel pressure problem will not register a diagnostic code directly, but could cause a rich or lean condition. This could cause an oxygen sensor, fuel system, or misfire monitor trouble code to be stored in the PCM. Engine Timing The PCM cannot detect an incorrectly indexed timing chain, camshaft sprocket, or crankshaft sprocket. The PCM also cannot detect an incorrectly indexed distributor.(*) Fuel Pressure (Monitored on CNG) Fuel pressure is controlled by the fuel pressure regulator. The PCM cannot detect a clogged fuel pump inlet filter, clogged in-line fuel filter, or a pinched fuel supply.(*) Fuel Injectors The PCM cannot detect if the fuel injector is clogged, the pintle is sticking, or the wrong injectors are installed.(*) Fuel Requirements Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. Use of methanol-gasoline blends may result in starting and driveability problems. (See individual symptoms and their definitions in Section 12.0 (Glossary of Terms) at the back of this book.) PCM Grounds The PCM cannot detect a poor system ground. However, a diagnostic trouble code may be stored in the PCM as a result of this condition. Throttle Body Air Flow The PCM cannot detect a clogged or restricted air cleaner inlet or filter element.(*) Exhaust System The PCM cannot detect a plugged, restricted, or leaking exhaust system.(*) Cylinder Compression The PCM cannot detect uneven, low, or high engine cylinder compression.(*) Excessive Oil Consumption Although the PCM monitors the exhaust stream oxygen content through the oxygen sensor when the system is in a closed loop, it cannot determine excessive oil consumption. (*)NOTE: Any of these conditions could result in a rich or lean condition causing an oxygen sensor trouble code to be stored in the PCM, or the vehicle may exhibit one or more of the driveability symptoms listed in TEST NTC-1A - No Trouble Code Test Menu.
10
3.3
Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic test procedures contain step-by-step instructions for determining the cause of trouble codes as well as no trouble code problems. It is not necessary to perform all of the tests in this book to diagnose an individual code. Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins in the DTC TEST Checking the System for Diagnostic Trouble Codes. This will direct you to the specific test(s) that must be performed.
G E N E R A L I N F O R M A T I O N
3.3.1
Hard Code
A diagnostic trouble code that comes back within one cycle of the ignition key is a hard code. This means that the defect is there every time the powertrain control module checks that circuit or function. Procedures in this manual verify if the trouble code is a hard code at the beginning of each test. When it is not a hard code, an intermittent test must be performed.
3.3.2
Intermittent Code
A diagnostic trouble code that is not there every time the powertrain control module checks the circuit is an intermittent code. Most intermittent codes are caused by wiring or connector problems. Defects that come and go like this are the most difficult to diagnose; they must be looked for under specific conditions that cause them. The following checks may assist you in identifying a possible intermittent problem:
Visually inspect related wire harness connectors. Look for broken, bent, pushed out, or corroded terminals. Visually inspect the related harnesses. Look for chafed, pierced, or partially broken wire. Refer to any hotlines or technical service bulletins that may apply.
3.3.3
Reset Counter
The reset counter counts the number of times the vehicle has been started since codes were last set, erased, or the battery was disconnected. The reset counter will count up to 255 start counts. The number of starts helps determine when the trouble code actually happened. This is recorded by the PCM and can be viewed on the DRB as the RESET COUNTER. When there are no trouble codes stored in memory, the DRB will display NO TROUBLE CODES FOUND and the reset counter will show RESET COUNT = XXX.
3.3.4
After reading Section 3.0 (System Description and Functional Operation), you should have a better understanding of the theory and operation of the on-board diagnostics, and how this relates to the diagnosis of a vehicle that may have a driveability-related symptom or complaint. The no code system is broken down into three test methods: No Code Complete Test No Code Quick Individual Test No Code Quick Symptom Test
3.4
Refer to the DRB users guide for instructions and assistance with reading trouble codes, erasing trouble codes, and other DRB functions.
11
G E N E R A L I N F O R M A T I O N
3.5
Under normal operation, the DRB will display one of only two error messages: User-Requested WARM Boot or User-Requested COLD Boot If the DRB should display any other error message, record the entire display and call the MDS Hotline, or call for information and assistance at 1-800-825-8737. This is a sample of such an error message display: ver: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul 26 1993 line: 548 err: 0x1 User-Requested COLD Boot Press MORE to switch between this display and the application screen. Press F4 when done noting information.
3.5.1
If the LEDs do not light or no sound is emitted at start up, check for loose cable connections or a bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts is required to adequately power the DRB. If all connections are proper between the DRB and the vehicle or other devices, and the vehicle battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. For a blank screen, refer to the appropriate body diagnostics manual.
3.5.2
Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this condition.
12
4.0 4.1
AB BODY
G E N E R A L I N F O R M A T I O N
CAV A2 A4 A6 A7 A8 A10 A11 A15 A16 A17 A18 A19 A20 A22 A23 A24 A25 A27 A31 A32 B1 B2 B4 B5 B6 B8 B10 B11 B12 B13 B15
CIRCUIT F18 LG/BK K4 BK/LB T41 BR/OR K19 GY K24 GY/BK K60 YL/BK K40 BR/WT K21 BK/RD K2 TN/BK K6 VT/WT K44 TN/YL K39 GY/RD K59 VT/BK A14 RD/WT K22 OR/DB K41 BK/LG K341 TN/WT K1 DG/RD Z1 BK/TN Z1 BK/TN T34 GY/BK K26 VT K11 WT/DB K13 YL/WT K38 GY T59 PK K20 K54 K58 K28 K12 DG/WT OR/BK BR/DB GY/LB TN
FUNCTION Fused Ignition Switch Output Sensor Ground P/N Position Switch Sense Ignition Coil Driver #1 Crank Position Sensor Signal Idle Air Control #2 Driver Idle Air Control #3 Driver Intake Air Temp Sensor Signal ECT Sensor Signal 5-Volt Supply Camshaft Position Sensor Signal Idle Air Control #1 Driver Idle Air Control #4 Driver Fused B(+) Throttle Position Sensor Signal Upstream O2 Sensor Signal Downstream O2 Sensor Signal MAP Sensor Signal Ground Ground Trans Temp Sensor Signal Injector #7 Driver Injector #1 Driver Injector #3 Driver Injector #5 Driver Governor Pressure Solenoid Control Generator Field Driver TCC Solenoid Control Injector #6 Driver Injector #8 Driver Injector #2 Driver
CAV B16 B21 B22 B25 B27 B28 B29 B30 B31 C1 C3 C4 C5 C6 C11 C12 C13 C15 C16 C17 C19 C20 C22 C23 C24 C26 C27 C29 C32
CIRCUIT K14 LB/BR T60 OR/WT G79 TN/PK T13 DB/BK G7 WT/OR T14 LG/WT T25 LG/RD T30 VT/LB K7 OR C13 DB/OR K51 DB/YL V36 TN/RD V35 LG/RD T18 LG/OR V32 YL/RD A142 DG/OR T6 OR/WT K118 PK/YL G12 TN/BK G3 BK/PK K31 BR K52 PK/BK C20 BR/WT C90 LG K29 WT/PK G8 LB/BK D21 PK D20 LG/WT V33 WT/LG
FUNCTION Injector #4 Driver Solenoid Control 3-4 Shift Fuel Temp Sensor Signal Output Shaft Speed Sensor Ground Vehicle Speed Sensor Signal Output Shaft Speed Sensor Signal Governor Pressure Signal Transmission Relay Control 5-Volt Supply A/C Comp Clutch Relay Control Auto Shutdown Relay Control S/C Vacuum Solenoid Control S/C Vent Solenoid Control Overdrive Off Lamp Driver 12 Volt Supply Auto Shutdown Relay Output Overdrive Off Switch Sense Battery Temp Sensor Signal Generator Lamp Driver MIL (Check Engine) Lamp Driver Fuel Pump Relay Control Evaporative Emission Solenoid Ctrl A/C Request Signal A/C Select Signal Brake Switch Sense Low Fuel Sense SCI Transmit SCI Receive Speed Control Switch Signal
13
G E N E R A L I N F O R M A T I O N
4.1
AN BODY
CAV A2 A4 A6 A7 A8 A10 A11 A15 A16 A17 A18 A19 A20 A22 A23 A24 A25 A27 A28 A31 A32 B1 B2 B4 B5 B6 B8 B10 B11 B12 B13 B15 B16 B21
CIRCUIT A21 DB K4 BK/LB T41 BR/YL K19 GY K24 GY/BK K60 YL/BK K40 BR/WT K21 BK/RD K2 TN/BK K6 VT/WT K44 TN/YL K39 GY/RD K59 VT/BK A14 RD/WT K22 OR/DB K141 TN/WT K341 TN/PK K1 DG/RD K242 DG/LB Z12 BK/TN Z12 BK/TN T54 VT K26 DB K11 WT/DB K13 YL/WT K38 GY T59 PK K20 DG K54 OR/BK K58 BR/DB K28 GY/LB K12 TN K14 LB/BR T60 BR
FUNCTION Fused Ignition Switch Output Sensor Ground P/N Position Switch Sense Ignition Coil Driver #1 Crank Position Sensor Signal Idle Air Control #2 Driver Idle Air Control #3 Driver Intake Air Temp Sensor Signal ECT Sensor Signal 5-Volt Supply Camshaft Position Sensor Signal Idle Air Control #1 Driver Idle Air Control #4 Driver Fused B(+) Throttle Position Sensor Signal Upstream O2 Sensor Signal Downstream O2 Sensor Signal MAP Sensor Signal Fuel Pressure Sensor Signal Ground Ground Trans Temp Sensor Signal Injector #7 Driver Injector #1 Driver Injector #3 Driver Injector #5 Driver Governor Pressure Solenoid Control Generator Field Driver TCC Solenoid Control Injector #6 Driver Injector #8 Driver Injector #2 Driver Injector #4 Driver Solenoid Control 3-4 Shift
CAV B22 B25 B27 B28 B29 B30 B31 C1 C2 C3 C4 C5 C6 C7 C11 C12 C13 C15 C16 C17 C19 C20 C22 C23 C24 C26 C27 C28 C29 C30 C31 C32
CIRCUIT K221 TN/PK T13 DB/BK G7 WT/OR T14 LG/WT T25 LG/RD T30 VT/LB T33 RD/YL C13 DB/OR C27 DB/PK K51 DB/YL V36 TN/RD V35 LG/RD T18 LG/OR G14 PK/BK V32 YL/RD A142 DG/OR T6 OR/WT K118 PK/YL G12 DG/YL G3 BK/PK K31 BR K52 PK/BK C20 BR C90 LG K29 WT/PK G8 LB/BK D21 PK D2 WT/PK D20 LG D1 VT/BR G21 GY/LB V33 WT/LG
FUNCTION Fuel Temperature Sensor Signal Output Shaft Speed Sensor Ground Vehicle Speed Sensor Signal Output Shaft Speed Sensor Signal Governor Pressure Signal Transmission Relay Control 5-Volt Supply A/C Comp Clutch Relay Control Radiator Fan Relay Control Auto Shutdown Relay Control S/C Vacuum Solenoid Control S/C Vent Solenoid Control Overdrive Off Lamp Driver Trans Temp Lamp Driver 12 Volt Supply Auto Shutdown Relay Output Overdrive Off Switch Sense Battery Temp Sensor Signal Generator Lamp Driver MIL (Check Engine) Lamp Driver Fuel Pump Relay Control Evaporative Emission Solenoid Ctrl A/C Request Signal A/C Select Signal Brake Switch Sense Low Fuel Sense SCI Transmit CCD Bus (-) SCI Receive CCD Bus (+) Tachometer Signal Speed Control Switch Signal
14
BR BODY (Gasoline Engines) The PCM is located in the rear engine compartment, passenger side.
G E N E R A L I N F O R M A T I O N
CAV A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A15 A16 A17 A18 A19 A20 A22 A23 A24 A24 A25 A26 A26 A27 A28 A29 A31 A32 B1 B2 B3 B4 B5 B6 B8 B10 B11
CIRCUIT K32 YL/GY F18 LG/BK K18 RD/BK K4 BK/LB K43 DG/GY T41 BK/WT K19 BK/GY K24 GY/BK K17 DB/WT K60 YL/BK K40 BR/WT K21 BK/RD K2 TN/BK K6 VT/WT K44 TN/YL K39 GY/RD K59 VT/BK A14 RD/WT K22 OR/DB K141 TN/WT K41 BK/DG K341 OR/BK K41 BK/DG K241 BK/DG K1 DG/RD K242 DG/LB K441 TN/RD Z12 BK/TN Z12 BK/TN K54 VT K26 VT/TN K115 TN K11 WT/DB K13 YL/WT K38 GY K88 VT/WT K20 DG K54 OR/BK
FUNCTION Ignition Coil Driver #4 Fused Ignition Switch Output Ignition Coil Driver #3 Sensor Ground Ignition Coil Driver #5 P/N Position Switch Sense Ignition Coil Driver #1 Crank Position Sensor Signal Ignition Coil Driver #2 Idle Air Control #2 Driver Idle Air Control #3 Driver Intake Air Temp Sensor Signal ECT Sensor Signal 5-Volt Supply Camshaft Position Sensor Signal Idle Air Control #1 Driver Idle Air Control #4 Driver Fused B(+) Throttle Position Sensor Signal Upstream O2 Sensor Signal Upstream O2 Sensor Signal Downstream O2 Sensor Signal Right Upstream O2 Sensor Signal Right Upstream O2 Sensor Signal MAP Sensor Signal Fuel Pressure Sensor Signal Center O2 Sensor Signal Ground Ground Trans Temp Sensor Signal Injector #7 Driver Injector #9 Driver Injector #1 Driver Injector #3 Driver Injector #5 Driver Governor Pressure Solenoid Control Generator Field Driver TCC Solenoid Control
CAV B12 B13 B14 B15 B16 B21 B22 B25 B27 B28 B29 B30 B31 B32 C1 C3 C4 C5 C6 C7 C11 C12 C13 C15 C16 C17 C18 C19 C20 C22 C23 C24 C26 C27 C29 C31 C32
CIRCUIT K58 BR/DB K28 GY/LB K116 WT/DB K12 TN K14 LB/BR T60 BR K221 TN/PK T13 DB/BK G7 WT/OR T14 LG/BK T25 LG/WT K30 PK K7 OR K35 GY/YL C13 DB/OR K51 DB/YL V36 TN/RD V35 LG/RD T18 LG/OR G14 PK/BK V32 YL/RD A142 DG/OR T6 OR/WT K118 PK/YL G12 TN/YL G3 BK/PK G24 GY/PK K31 BR/WT K52 PK C20 BR C90 LG V40 WT/PK K226 DB/WT D21 PK/DB D20 DG G21 GY/LB V37 RD/LG
FUNCTION Injector #6 Driver Injector #8 Driver Injector #10 Driver Injector #2 Driver Injector #4 Driver Solenoid Control 3-4 Shift Fuel Temp Sensor Signal Output Shaft Speed Sensor Ground Vehicle Speed Sensor Signal Output Shaft Speed Sensor Signal Governor Pressure Signal Transmission Relay Control 5-Volt Supply EGR Solenoid Control A/C Comp Clutch Relay Control Auto Shutdown Relay Control S/C Vacuum Solenoid Control S/C Vent Solenoid Control Overdrive Off Lamp Driver Trans Temp Lamp Driver 12 Volt Supply Auto Shutdown Relay Output Overdrive Off Switch Sense Battery Temp Sensor Signal Generator Lamp Driver MIL (Check Engine) Lamp Driver Service Reminder Indicator Driver Fuel Pump Relay Control Evaporative Emission Solenoid Ctrl A/C Request Signal A/C Select Signal Brake Switch Sense Low Fuel Sense SCI Transmit SCI Receive Tachometer Signal Speed Control Switch Signal
15
G E N E R A L I N F O R M A T I O N
4.1
CAV A2 A4 A6 A7 A8 A9 A12 A15 A17 A22 A23 A27 A31 A32 B1 B8 B10 B11 B20 B21 B25 B27 B28
CIRCUIT F18 LG/BK K4 BK/LB T41 BK/WT S21 YL/BK K24 GY/BK S22 OR/BK D28 LG/RD K21 BK/RD K6 VT/WT A14 RD/WT K22 OR/DB K1 DG/RD Z12 BK/TN Z12 BK/TN K54 VT K88 VT/WT K20 DG K54 OR/BK G85 OR/BK T60 BR T13 DB/BK G7 WT/OR T14 LG/BK
FUNCTION Fused Ignition Switch Output Sensor Ground P/N Position Switch Sense Air Intake Heater Relay #1 Control Crank Position Sensor Signal Air Intake Heater Relay #2 Control EGR Fault Monitor Intake Air Temp Sensor Signal 5-Volt Supply Fused B(+) Throttle Position Sensor Signal Water-In-Fuel Sensor Signal Ground Ground Trans Temp Sensor Signal Governor Pressure Solenoid Control Generator Field Driver TCC Solenoid Control Wait to Start Lamp Driver Solenoid Control 3-4 Shift Output Shaft Speed Sensor Ground Vehicle Speed Sensor Signal Output Shaft Speed Sensor Signal
CAV B29 B30 B31 C1 C3 C4 C5 C6 C7 C9 C11 C12 C13 C15 C16 C17 C18 C22 C23 C24 C27 C29 C31 C32
CIRCUIT T25 LG/WT K30 PK K7 OR C13 DB/OR K51 DB/YL V36 TN/RD V35 LG/RD T18 LG/OR G14 PK/BK D29 PK/DG V32 YL/RD A142 DG/OR T6 OR/WT K118 PK/YL G12 TN/YL G3 BK/PK G86 TN/OR C20 BR C90 LG V40 WT/PK D21 PK/DB D20 DG G21 GY/LB V37 RD/LG
FUNCTION Governor Pressure Signal Transmission Relay Control 5-Volt Supply A/C Comp Clutch Relay Control Auto Shutdown Relay Control S/C Vacuum Solenoid Control S/C Vent Solenoid Control Overdrive Off Lamp Driver Trans Temp Lamp Driver EGR Test Mode 12 Volt Supply Auto Shutdown Relay Output Overdrive Off Switch Sense Battery Temp Sensor Signal Generator Lamp Driver MIL (Check Engine) Lamp Driver Water-in-Fuel Lamp Driver A/C Request Signal A/C Select Signal Brake Switch Sense SCI Transmit SCI Receive Tachometer Signal Speed Control Switch Signal
16
XJ BODY
G E N E R A L I N F O R M A T I O N
CAV A2 A4 A6 A7 A8 A10 A11 A12 A15 A16 A17 A18 A19 A20 A22 A23 A24 A25 A27 A31 A32 B4 B5 B6 B10 B11 B12
CIRCUIT A21 DB K4 BK/LB T41 BR/YL K19 GY K24 GY/BK K60 YL/BK K40 BR/WT K10 DB/OR K21 BK/RD K2 TN/BK K6 VT/WT K44 TN/YL K39 GY/RD K59 VT/BK A14 RD K22 OR/DB K41 BK/LG K341 TN/WT K1 DG/RD Z12 BK/TN Z12 BK/TN K11 WT/DB K13 YL/WT K38 GY K20 DG K54 OR/BK K58 BR/DB
FUNCTION Fused Ignition Switch Output Sensor Ground P/N Position Switch Sense Ignition Coil Driver #1 Crank Position Sensor Signal Idle Air Control #2 Driver Idle Air Control #3 Driver Power Steering Pressure Switch Sense Intake Air Temp Sensor Signal ECT Sensor Signal 5-Volt Supply Camshaft Position Sensor Signal Idle Air Control #1 Driver Idle Air Control #4 Driver Fused B(+) Throttle Position Sensor Signal Upstream O2 Sensor Signal Downstream O2 Sensor Signal MAP Sensor Signal Ground Ground Injector #1 Driver Injector #3 Driver Injector #5 Driver Generator Field Driver TCC Solenoid Control Injector #6 Driver
CAV B15 B16 B27 B31 C1 C2 C3 C4 C5 C11 C12 C15 C16 C17 C19 C20 C22 C23 C24 C26 C27 C28 C29 C30 C31 C32
CIRCUIT K12 TN K14 LB/BR G7 WT/OR K7 OR C13 DB/OR C27 DB/PK K51 DB/YL V36 TN/RD V35 LG/RD V32 YL/RD A142 DG/OR K118 PK/YL G14 PK/BK G3 BK/PK K31 BR K52 PK/BK C21 DB/OR C90 LG K29 WT/PK G4 DB D21 PK D2 WT/BK D20 LG D1 VT/BR G21 GY/LB V33 WT/LG
FUNCTION Injector #2 Driver Injector #4 Driver Vehicle Speed Sensor Signal 5-Volt Supply A/C Comp Clutch Relay Control Radiator Fan Relay Control Auto Shutdown Relay Control S/C Vacuum Solenoid Control S/C Vent Solenoid Control 12 Volt Supply Auto Shutdown Relay Output Battery Temp Sensor Signal Generator Lamp Driver MIL (Check Engine) Lamp Driver Fuel Pump Relay Control Evaporative Emission Solenoid Ctrl A/C Request Signal A/C Select Signal Brake Switch Sense Low Fuel Sense SCI Transmit CCD Bus (-) SCI Receive CCD Bus (+) Tachometer Signal Speed Control Switch Signal
17
G E N E R A L I N F O R M A T I O N
4.1
ZJ BODY
CAV A2 A4 A6 A7 A8 A10 A11 A15 A16 A17 A18 A19 A20 A22 A23 A24 A25 A27 A31 A32 B1 B2 B4 B5 B6 B8 B10 B11 B12 B13 B15 B16 B21
CIRCUIT F99 RD/OR K4 BK/LB T41 BK/WT K19 GY/WT K27 RD/LG K59 VT/BK K40 BR/WT K21 BK/RD K2 TN/BK K25 WT/BK K24 GY/BK K60 YL/BK K39 GY/RD F5 RD/YL K22 OR/DB K41 BK/OR K141 BK/PK K70 RD/WT Z12 BK/TN Z12 BK/TN T54 VT K17 DB/WT K11 WT/DB K13 YL/WT K38 GY T59 PK K20 DG T22 DG/LB K58 BR/YL K18 DB/YL K12 TN K14 LB/BR T60 BR
FUNCTION Fused Ignition Switch Output Sensor Ground P/N Position Switch Sense Ignition Coil Driver #1 Crank Position Sensor Signal Idle Air Control #2 Driver Idle Air Control #3 Driver Intake Air Temp Sensor Signal ECT Sensor Signal 5-Volt Supply Camshaft Position Sensor Signal Idle Air Control #1 Driver Idle Air Control #4 Driver Fused B(+) Throttle Position Sensor Signal Upstream O2 Sensor Signal Downstream O2 Sensor Signal MAP Sensor Signal Ground Ground Trans Temp Sensor Signal Injector #7 Driver Injector #1 Driver Injector #3 Driver Injector #5 Driver Governor Pressure Solenoid Control Generator Field Driver TCC Solenoid Control Injector #6 Driver Injector #8 Driver Injector #2 Driver Injector #4 Driver Solenoid Control 3-4 Shift
CAV B23 B25 B27 B28 B29 B30 B31 B32 C1 C3 C4 C5 C6 C10 C11 C12 C13 C14 C15 C19 C20 C22 C24 C26 C27 C28 C29 C30 C32
CIRCUIT G6 GY/WT T13 DB/BK G7 WT/OR T14 LG/WT T25 LG T66 BR/OR K6 VT/WT K35 GY/YL C13 DB/RD K900 PK/BK V36 TN/RD V35 LG/RD G68 BR/YL J95 DG/RD V32 YL/RD A142 DG/OR T9 OR J96 VT/RD T222 YL/RD K81 PK K52 PK/BK C3 DB/BK L53 BR G40 LB/BK D83 BK/PK D2 WT/BK D84 BK/WT D1 VT/BR K95 PK
FUNCTION Oil Pressure Switch Signal Output Shaft Speed Sensor Ground Vehicle Speed Sensor Signal Output Shaft Speed Sensor Signal Governor Pressure Signal Transmission Relay Control 5-Volt Supply EGR Solenoid Control A/C Comp Clutch Relay Control Auto Shutdown Relay Control S/C Vacuum Solenoid Control S/C Vent Solenoid Control Overdrive Off Lamp Driver Leak Detection Pump Solenoid Ctrl 12 Volt Supply Auto Shutdown Relay Output Overdrive Off Switch Sense Leak Detection Pump Switch Sense Battery Temp Sensor Signal Fuel Pump Relay Control Evaporative Emission Solenoid Ctrl A/C Request Signal Brake Switch Sense Low Fuel Sense SCI Transmit CCD Bus (-) SCI Receive CCD Bus (+) Speed Control Switch Signal
18
4.2
BR 5.9L HD GASOLINE
G E N E R A L I N F O R M A T I O N
BR BODY
AN 2.5L
BR 8.0L
19
G E N E R A L I N F O R M A T I O N
4.2
ZJ 4.0L
XJ BODY
AB BODY
AN XJ BODIES
BR BODY
20
ZJ BODY
AB BODY
G E N E R A L I N F O R M A T I O N
AN 2.5L
BR 8.0L
XJ BODY
21
G E N E R A L I N F O R M A T I O N
4.2
BR DIESEL
ZJ 5.2L
AB BODY
AN BODY
22
BR BODY
ZJ BODY
G E N E R A L I N F O R M A T I O N
BR 8.0L
AB BODY
23
G E N E R A L I N F O R M A T I O N
4.2
AN BR BODIES
ZJ BODY
BR 8.0L
24
BR EXCEPT 8.0L
G E N E R A L I N F O R M A T I O N
ZJ
BR 8.0L
AN XJ 2.5L
25
G E N E R A L I N F O R M A T I O N
4.2
BR 8.0L
XJ BODY
ZJ BODY
26
ZJ 4.0L
ZJ 4.0L
G E N E R A L I N F O R M A T I O N
AB BODY
AN BODY
BR BODY
27
G E N E R A L I N F O R M A T I O N
4.2
ZJ BODY
BR BODY
XJ BODY
ZJ BODY
ALL BODIES
28
AB 3.9L
AB BODY
G E N E R A L I N F O R M A T I O N
4.3
AB BODY
AN BODY
AN BODY
29
G E N E R A L I N F O R M A T I O N
4.3
BR BODY
XJ BODY
XJ BODY
4.4
Sensors
ZJ BODY
ZJ BODY
30
AB BODY
AN BODY
G E N E R A L I N F O R M A T I O N
BR BODY
XJ BODY
ZJ BODY
AB, AN , BR , XJ BODIES
31
G E N E R A L I N F O R M A T I O N
4.4
Sensors (Continued)
AB, AN, BR EXCEPT 2.5L, 8.0L AND DIESEL
ZJ BODY
BR 8.0L
ZJ 5.2L
BR 5.9L DIESEL
32
XJ BODY
G E N E R A L I N F O R M A T I O N
ZJ BODY
BR 8.0L
33
G E N E R A L I N F O R M A T I O N
4.4
Sensors (Continued)
ZJ BODY
BR 8.0L
34
XJ BODY
ZJ 4.0L
G E N E R A L I N F O R M A T I O N
5.2L CNG
5.2L CNG
AB BODY
35
G E N E R A L I N F O R M A T I O N
4.4
Sensors (Continued)
BR BODY
AN BODY
ZJ BODY
BR 5.9L DIESEL
36
BR 8.0L
G E N E R A L I N F O R M A T I O N
ZJ BODY
BR 8.0L
37
G E N E R A L I N F O R M A T I O N
4.4
Sensors (Continued)
BR 8.0L
ZJ BODY
38
AB 5.9L 1/1
G E N E R A L I N F O R M A T I O N
39
G E N E R A L I N F O R M A T I O N
4.4
Sensors (Continued)
AN BODY 1/1
AB BODY 1/1
40
AB BODY 1/2
G E N E R A L I N F O R M A T I O N
ZJ BODY 1/2
AB BODY 1/2
AN BODY1/2
41
G E N E R A L I N F O R M A T I O N
4.4
Sensors (Continued)
BR 8.0L 1/2
ZJ BODY 1/2
BR 8.0L 1/3
42
ZJ 4.0L
ZJ 5.2L
G E N E R A L I N F O R M A T I O N
ZJ BODY
BR BODY
43
G E N E R A L I N F O R M A T I O N
4.4
Sensors (Continued)
AN 2.5L XJ AND ZJ 4.0L
ZJ 5.2L
BR 5.9L DIESEL
BR 8.0L
44
BR 5.9L DIESEL
XJ BODY
G E N E R A L I N F O R M A T I O N
ZJ BODY
AB BODY
45
G E N E R A L I N F O R M A T I O N
4.4
Sensors (Continued)
BR BODY
AN BODY
ZJ BODY
46
AN BODY
G E N E R A L I N F O R M A T I O N
ZJ BODY
BR 5.9L DIESEL
BR 5.9L DIESEL
47
G E N E R A L I N F O R M A T I O N
4.5
Fuel System
AB BODY
AB BODY
AN BODY
AN BODY
BR BODY
BR BODY
48
XJ BODY
XJ BODY
G E N E R A L I N F O R M A T I O N
ZJ BODY
ZJ BODY
BR 5.9L DIESEL
BR 5.9L DIESEL
49
G E N E R A L I N F O R M A T I O N
4.5
BR 5.9L DIESEL
BR 5.9L DIESEL
AB 5.2L CNG
AN, BR BODIES
50
AB 5.2L CNG
G E N E R A L I N F O R M A T I O N
AB 5.2L CNG
4.6
Relays
AN BODY
AB BODY
51
G E N E R A L I N F O R M A T I O N
4.6
Relays (Continued)
XJ BODY
BR BODY
ZJ BODY
AB BODY
AN BODY
BR BODY
52
XJ BODY
ZJ BODY
G E N E R A L I N F O R M A T I O N
BR 5.9L DIESEL
BR 5.9L DIESEL
AB BODY
AN BODY
53
G E N E R A L I N F O R M A T I O N
4.6
Relays (Continued)
XJ BODY
BR BODY
ZJ BODY
AB EXCEPT CNG
AN EXCEPT CNG
BR EXCEPT CNG
54
XJ BODY
ZJ BODY
G E N E R A L I N F O R M A T I O N
AB CNG
AN CNG
BR CNG
BR 5.9L DIESEL
55
G E N E R A L I N F O R M A T I O N
4.6
Relays (Continued)
BR 5.9L DIESEL
BR 5.9L DIESEL
AN 2.5L
XJ 4.0L
AB BODY
AN BODY
56
BR BODY
XJ BODY
G E N E R A L I N F O R M A T I O N
ZJ BODY
AB EXCEPT 3.9L
AB EXCEPT 3.9L
AN EXCEPT DIESEL
57
G E N E R A L I N F O R M A T I O N
4.6
Relays (Continued)
ZJ BODY
BR BODY
4.7
Switches
XJ AND ZJ BODIES
AB BODY
AN AND XJ BODIES
58
BR BODY
ZJ BODY
G E N E R A L I N F O R M A T I O N
AB BODY
AN BODY
BR BODY
ZJ BODY
59
G E N E R A L I N F O R M A T I O N
4.7
Switches (Continued)
BR BODY
AB, AN BODIES
ZJ BODY
XJ BODY
AB BODY
60
AN BODY
BR BODY
G E N E R A L I N F O R M A T I O N
XJ BODY
ZJ BODY
ZJ BODY
61
G E N E R A L I N F O R M A T I O N
4.7
Switches (Continued)
ALL EXCEPT ZJ
XJ BODY
ZJ BODY
4.8
AB BODY
62
BR BODY
XJ BODY
G E N E R A L I N F O R M A T I O N
AB BODY
AN BODY
BR BODY
XJ BODY
63
G E N E R A L I N F O R M A T I O N
4.8
AB BODY
BR BODY
ZJ BODY
AB, AN BODIES
BR BODY
64
ZJ BODY
AN BODY
G E N E R A L I N F O R M A T I O N
BR BODY
XJ BODY
AN BODY
65
G E N E R A L I N F O R M A T I O N
4.8
BR BODY
BR 5.9L DIESEL
BR 5.9L DIESEL
5.0 5.1
All information, illustrations, and specifications contained in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.
5.2 5.2.1
WARNING: Engines produce carbon monoxide that is odorless, causes slower reaction time, and can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED or attach the vehicle exhaust system to the shop exhaust removal system.
66
Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially important to block the wheels on front-wheel drive vehicles; the parking brake does not hold the drive wheels. When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as watchbands or bracelets that might make an inadvertent electrical contact. When diagnosing a body system problem, it is important to follow approved procedures where applicable. These procedures can be found in General Information Section 9.0 (Specifications) or in service manual procedures. Following these procedures is very important to the safety of individuals performing diagnostic tests.
G E N E R A L I N F O R M A T I O N
5.2.2
Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes or error messages may occur.
5.2.3
Servicing Sub-Assemblies
Some components of the powertrain system are intended to be serviced in assembly only. Attempting to remove or repair certain system sub-components may result in personal injury and/or improper system operation. Only those components with approved repair and installation procedures in the service manual should be serviced.
5.2.4
WARNING: Exceeding the limits of the DRB multimeter is dangerous. It can expose you to serious or possibly fatal injury. Carefully read and understand the cautions and the specification limits.
Follow the vehicle manufacturers service specifications at all times. Do not use the DRB if it has been damaged. Do not use the test leads if the insulation is damaged or if metal is exposed. To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested. Choose the proper range and function for the measurement. Do not try voltage or current measurements that may exceed the rated capacity. Do not exceed the limits shown in the table below: FUNCTION Volts Ohms (resistance)* Frequency Measured Frequency Generated Temperature INPUT LIMIT 0 - 500 peak volts AC 0 - 500 volts DC 0 - 1.12 megohms 0 - 10 kHz -58 - 1100F -50 - 600C
* Ohms cannot be measured if voltage is present. Ohms can be measured only in a non-powered circuit.
Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC.
67
G E N E R A L I N F O R M A T I O N
Use caution when measuring voltage above 25v DC or 25v AC. The circuit being tested must be protected by a 10A fuse or circuit breaker. Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure circuits exceeding 10A. When testing for the presence of voltage or current, make sure the meter is functioning correctly. Take a reading of a known voltage or current before accepting a zero reading. When measuring current, connect the meter in series with the load. Disconnect the live test lead before disconnecting the common test lead. When using the meter function, keep the DRB away from spark plug or coil wires to avoid measuring error from outside interference.
5.3 5.3.1
Before disconnecting any control module, make sure the ignition is off. Failure to do so could damage the module. When testing voltage or continuity at the powertrain control module, use the terminal side (not the wire end) of the connector. Do not probe a wire through the insulation; this will damage it and eventually cause it to fail because of corrosion. Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of the original problem more difficult.
5.3.2
Some complaints will require a test drive as part of the repair verification procedure. The purpose of the test drive is to try to duplicate the diagnostic code or symptom condition. CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the test drive, do not try to read the DRB screen while in motion. Do not hang the DRB from the rear view mirror or operate it yourself. Have an assistant available to operate the DRB.
68
7.0
69
T R O U B L E C O D E T E S T S
DTC TEST
NOTE: The battery must be fully charged for any test in this manual. 1. Attempt to start the engine. Crank for up to 10 seconds if necessary. 2. Connect the DRB to the engine diagnostic connector. Write down the trouble codes that are displayed. 3. If the DRB screen displays No Response, go the TEST NS-SEL. 4. If the DRB screen is blank or has a DRB message, go to General Information Section 3.5 in this manual. 5. If trouble code messages are displayed, refer to the trouble code list below and on the next page for the appropriate test. 6. If there are no trouble codes displayed, refer to one of the following: For Driveability problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-1A For No Start problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NS-SEL For Speed Control problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SC-1A For Charging problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CH-1A NOTE: The decimal test numbers for these trouble codes were derived from the hexadecimal codes as set in the PCM. Therefore, some test numbers will be missing because all codes are not applicable to the vehicles covered in this manual.
TROUBLE CODE DESCRIPTION [SDD] 3-4 SHIFT SOL, NO RPM DROP @ 3-4 SHIFT A/C CLUTCH RELAY CIRCUIT AUTO SHUTDOWN RELAY CONTROL CIRCUIT BATTERY TEMP SENSOR VOLTAGE TOO HIGH BATTERY TEMP SENSOR VOLTAGE TOO LOW CATALYTIC CONVERTER EFFICIENCY FAILURE CHARGING SYSTEM VOLTAGE TOO HIGH CHARGING SYSTEM VOLTAGE TOO LOW CLOSED LOOP TEMP NOT REACHED CNG PRESSURE SENSOR VOLTAGE TOO HIGH CNG PRESSURE SENSOR VOLTAGE TOO LOW CNG TEMP SENSOR VOLTAGE TOO HIGH CNG TEMP SENSOR VOLTAGE TOO LOW CYLINDER #1 MIS-FIRE CYLINDER #2 MIS-FIRE CYLINDER #3 MIS-FIRE CYLINDER #4 MIS-FIRE CYLINDER #5 MIS-FIRE CYLINDER #6 MIS-FIRE CYLINDER #7 MIS-FIRE CYLINDER #8 MIS-FIRE TC-165 TC-16 TC-10 TC-153 TC-153 TC-112 TC-6 TC-5 TC-128 TC-98 TC-99 TC-95 TC-94 TC-107 TC-107 TC-107 TC-107 TC-107 TC-107 TC-107 TC-107 Test # MIL Code 45 33 42 44 44 72,64 46 47 17 64 64 64 64 43 43 43 43 43 43 43 43 DTC HEX A5 10 0A 9A 99 70 06 05 80 62 63 5F 5E 6B 6C 6D 6E AE AF B0 B1 P 0783 N/A N/A P 1492 P 1493 P 0420 N/A N/A P 0125 P 1292 P 1293 P 0183 P 0182 P 0301 P 0302 P 0303 P 0304 P 0305 P 0306 P 0307 P 0308 Scan Tool
70
DTC TEST
TROUBLE CODE DESCRIPTION [SDD] (Pre-Cat) DOWNSTREAM O2 SENSOR HEATER FAILURE (Pre-Cat) DOWNSTREAM O2S VOLTS SHORTED TO GND (Pre-Cat) DOWNSTREAM O2S SHORTED TO VOLTAGE ECT SENSOR VOLTAGE TOO HIGH ECT SENSOR VOLTAGE TOO LOW EGR SOLENOID CIRCUIT EGR SYSTEM FAILURE ENGINE IS COLD TOO LONG EVAP LEAK MONITOR LARGE LEAK DETECTED EVAP LEAK MONITOR PINCHED HOSE FOUND EVAP LEAK MONITOR SMALL LEAK DETECTED EVAP PURGE FLOW MONITOR FAILURE EVAP PURGE SOLENOID CIRCUIT FUEL LEVEL SENDING UNIT VOLTS TOO HIGH FUEL LEVEL SENDING UNIT VOLTS TOO LOW FUEL LEVEL UNIT NO CHANGE OVER MILES FUEL PUMP RELAY CONTROL CIRCUIT FUEL SYSTEM LEAN FUEL SYSTEM RICH GENERATOR FIELD NOT SWITCHING PROPERLY GOV PRES ABOVE 3 PSI IN GEAR WITH 0 MPH GOV PRESS NOT EQUAL TO TARGET @ 15-20 PSI GOV PRESS SEN OFFSET VOLTS TOO LOW OR HIGH GOVERNOR PRESSURE SENSOR VOLTS TOO HI GOVERNOR PRESSURE SENSOR VOLTS TOO LOW GOVERNOR PRESSURE SOLENOID/TRANS RELAY CKTS IDLE AIR CONTROL MOTOR CIRCUIT IGNITION COIL #1 PRIMARY CIRCUIT IGNITION COIL #2 PRIMARY CIRCUIT IGNITION COIL #3 PRIMARY CIRCUIT IGNITION COIL #4 PRIMARY CIRCUIT IGNITION COIL #5 PRIMARY CIRCUIT INJECTOR #1 CONTROL CIRCUIT INJECTOR #2 CONTROL CIRCUIT INJECTOR #3 CONTROL CIRCUIT INJECTOR #4 CONTROL CIRCUIT INJECTOR #5 CONTROL CIRCUIT INJECTOR #6 CONTROL CIRCUIT INJECTOR #7 CONTROL CIRCUIT INJECTOR #8 CONTROL CIRCUIT INJECTOR #9 CONTROL CIRCUIT INJECTOR #10 CONTROL CIRCUIT INTAKE AIR TEMP SENSOR VOLTAGE HIGH INTAKE AIR TEMP SENSOR VOLTAGE LOW INTERMITTENT LOSS OF CMP OR CKP
Test #
MIL Code
DTC HEX 69 9C 7E 1F 1E 11 8C 21 A1 BB A0 71 12 96 95 97 65 77 76 0B 8E 8D A9 A8 A7 AB 19 2B 2A 29 4C 4D 15 14 13 3D 45 46 4F 50 37 38 3A 39 9D
Scan Tool P 0141 P 0137 P 0138 P 0118 P 0117 P 0403 P 0400 N/A P 0455 P 1486 P 0442 P 0441 P 0443 N/A N/A N/A N/A P 0171 P 0172 N/A P 1757 P 1756 P 1762 P 1763 P 1764 P 0748 P 0505 P 0351 P 0351 P 0351 P 0351 P 0351 P 0201 P 0202 P 0203 P 0204 P 0205 P 0206 P 0207 P 0208 P 0209 P 0210 P 0113 P 0112 P 1391
TC-105 TC-156 TC-126 TC-31 TC-30 TC-17 TC-140 ** TC-161 TC-187 TC-160 TC-113 TC-18 TC-150 TC-149 TC-151 TC-101 TC-119 TC-118 TC-11 TC-142 TC-141 TC-169 TC-168 TC-167 TC-171 TC-25 TC-43 TC-42 TC-41 TC-76 TC-77 TC-21 TC-21 TC-21 TC-21 TC-21 TC-21 TC-21 TC-21 TC-21 TC-21 TC-58 TC-57 TC-157
21 21 21 22 22 32 68 17 31 31 31 31 31 42 42 42 42 51 52 41 45 45 45 45 45 45 25 43 43 43 43 43 27 27 27 27 27 27 27 27 27 27 23 23 11
T R O U B L E C O D E T E S T S
T R O U B L E C O D E T E S T S
DTC TEST
TROUBLE CODE DESCRIPTION [SDD] INTERNAL CONTROLLER FAILURE LEAK DETECT PUMP SW OR MECHANICAL FAULT LEAK DETECTION PUMP SOLENOID CIRCUIT LOW OUTPUT SPD SENSOR RPM, ABOVE 15 MPH * MAP SENSOR VOLTAGE TOO HIGH * MAP SENSOR VOLTAGE TOO LOW MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT * MULTIPLE CYLINDER MIS-FIRE NO 5 VOLTS TO MAP SENSOR NO ASD RELAY OUTPUT VOLTAGE AT PCM NO CAM SIGNAL AT PCM NO CHANGE IN MAP FROM START TO RUN NO CRANK REFERENCE SIGNAL AT PCM NO TEMP RISE SEEN FROM INTAKE HEATERS NO VEHICLE SPEED SENSOR SIGNAL O/D SWITCH PRESSED (LO) MORE THAN 5 MIN P/N SWITCH STUCK IN PARK OR IN GEAR PCM FAILURE EEPROM WRITE DENIED PCM FAILURE SPI COMMUNICATIONS PCM FAILURE SRI MILE NOT STORED POST-CATALYST O2 SEN SHORTED TO GROUND POST-CATALYST O2 SEN SHORTED TO VOLTAGE POST-CATALYST O2S HEATER FAILURE POST-CATALYST O2 SLOW RESPONSE POWER STEERING SWITCH FAILURE PRE-CATALYST O2 SENSOR SLOW RESPONSE RAD FAN CONTROL RELAY CIRCUIT RIGHT BANK FUEL SYSTEM LEAN RIGHT BANK FUEL SYSTEM RICH RIGHT BANK UPSTRM O2S SHORTED TO GROUND RIGHT O2 SENSOR SHORTED TO VOLTAGE RIGHT UPSTREAM O2 SENSOR HEATER FAILURE RIGHT UPSTREAM O2 SENSOR SLOW RESPONSE SPEED CONTROL POWER RELAY CIRCUIT SPEED CONTROL SOLENOIDS CIRCUITS SPEED CONTROL SWITCH ALWAYS LOW TARGET IDLE NOT REACHED * THROTTLE POSITION SENSOR VOLTAGE HIGH * THROTTLE POSITION SENSOR VOLTAGE LOW TORQ CONV CLU, NO RPM DROP AT LOCKUP TORQUE CONVERTER CLUCTH SOLENOID/TRANS RELAY CKT * TPS VOLTAGE DOES NOT AGREE WITH MAP
Test #
MIL Code
DTC HEX 02 B8 B7 A6 25 24 BA 6A 87 2C 01 27 28 A2 23 BC 72 31 44 30 90 93 BD 9F 73 68 0E 79 78 B5 42 7C 7A 52 0F 57 8A 1B 1A 94 0C 84
Scan Tool P 0601 P 1494 P 1495 P 0720 P 0108 P 0107 P 1398 P 0300 P 1296 N/A P 0340 P 1297 N/A P 1291 P 0500 N/A P 1899 P 1698 P 0600 P 1697 P 0143 P 0144 P 0147 P 0145 P 0551 P 0139 P 1491 P 0174 P 0175 P 0151 P 0152 P 0155 P 0153 N/A N/A N/A P 1294 P 0123 P 0122 P 0740 P 0743 P 0121
** TC-184 TC-183 TC-166 TC-37 TC-36 TC-186 TC-106 TC-135 TC-44 TC-1 TC-39 TC-40 TC-162 TC-35 TC-188 TC-114 TC-49 ** TC-48 TC-144 TC-147 TC-189 TC-159 TC-115 TC-104 TC-14 TC-121 TC-120 TC-181 TC-66 TC-124 TC-122 TC-15 TC-15 TC-87 TC-138 TC-27 TC-26 TC-148 TC-12 TC-132
53 31 31 15 14 14 11 43 14 42 54 13 11 23 15 45 37 63 53 62 21 21 21 21 65 21 35 51 52 21 21 21 21 77 34 34 25 24 24 37 37 24
* = These DTCs can be set by Low Fuel Level, add fuel to 1/4 tank and test for DTC to set again. ** = Trouble code information on last page of DTC test.
72
DTC TEST
TROUBLE CODE DESCRIPTION [SDD] TRANS 12 VOLT SUPPLY RELAY CNTRL CIRCUIT TRANS 3-4 SOLENOID/TRANS RELAY CKTS TRANS TEMP SENSOR VOLTAGE TOO HIGH TRANS TEMP SENSOR VOLTAGE TOO LOW TRANS TEMP SENSOR, NO TEMP RISE AFTER START (Left) UPSTREAM O2 SENSOR HEATER FAILURE (Left) UPSTREAM O2S VOLTAGE SHORTED TO GROUND (Left) UPSTREAM O2 SENSOR SLOW RESPONSE (Left) UPSTREAM O2 SENSOR SHORTED TO VOLTAGE
Test #
MIL Code
DTC HEX AD 32 4B 4A A4 67 9B 66 3E
Scan Tool P 1765 P 0753 P 0713 P 0712 P 0711 P 0135 P 0131 P 0133 P 0132
45 45 37 37 37 21 21 21 21
T R O U B L E C O D E T E S T S
For an ENGINE IS COLD TOO LONG trouble code, the engine does not warm to 176F while driving for 20 minutes after start. See the service manual for cooling system repair (thermostat). For an INTERNAL CONTROLLER FAILURE trouble code, replace the powertrain control module and go to Verification TEST VER-2A. For a PCM FAILURE SPI COMMUNICATIONS trouble code, replace the powertrain control module and go to Verification TEST VER-2A. * These DTCs can be set by Low Fuel Level, add fuel to
1 4
73
T TEST TC-1A REPAIRING - NO CAM SIGNAL AT PCM R O Perform DTC TEST Before Proceeding U ZJ BODY ALL OTHERS B L E C O D E T E S T S
FIG. 1
ALL EXCEPT 8.0L ENGINE 8.0L ENGINE
FIG. 2
74
TEST TC-1A
T R O U B L E C O D E
ATTEMPT TO START THE ENGINE. IF IT DOES NOT START, CRANK FOR AT LEAST 15 SECONDS.
NO
YES
T E S T S
KEY OFF, DISCONNECT THE CAMSHAFT POSITION SENSOR CONNECTOR.** SEE GENERAL INFO 4.4
YES
REPAIR AS NECESSARY.*
NO
NO
REPAIR THE OPEN CMP SENSOR GROUND CIRCUIT TO THE HARNESS SPLICE.*
YES
NO
YES
CONNECT ONE END OF A JUMPER WIRE TO THE CMP SENSOR SIGNAL CIRCUIT. FIG. 1 OR 2
WITH THE DRB MONITOR THE CMP COUNT WHILE TAPPING THE OTHER END OF THE JUMPER TO SENSOR GROUND.
YES
NO
FIG. 1
ALL OTHERS
FIG. 2
76
TEST TC-1A
T R O U B L E C O D E
DISCONNECT THE POWERTRAIN CONTROL MODULE CONNECTORS.** SEE GENERAL INFO 4.1
T E S T S
CIRCUIT FROM THE CMP SENSOR CONNECTOR TO THE PCM. FIG. 1 OR 2 YES
USE AN OHMMETER IN THE FOLLOWING STEPS, MEASURE THE RESISTANCE OF THE CMP SENSOR SIGNAL...
NO
AND THE CMP SENSOR GROUND CIRCUIT AT THE CMP SENSOR CONNECTOR. FIG. 1 OR 2
YES
REPAIR THE CMP SENSOR SIGNAL CIRCUIT FOR A SHORT TO THE SENSOR GROUND.*
NO
YES
NO
MEASURE THE RESISTANCE BETWEEN THE CMP SENSOR SIGNAL CIRCUIT AND THE...
YES
REPAIR THE CMP SENSOR SIGNAL CIRCUIT FOR A SHORT TO THE 5-VOLT SUPPLY CIRCUIT.*
NO
T TEST TC-1B REPAIRING - NO CAM SIGNAL AT PCM R O Perform TEST TC-1A Before Proceeding U B L E C O D E T E S T S
FIG. 1
78
TEST TC-1B
T R O U B L E C O D E T E S T S
YES
NO
NO
YES
T TEST TC-1B R O U B L E C O D E T E S T S
FIG. 1
80
TEST TC-1B
T R O U B L E C O D E T E S T S
YES
NO
REPAIR AS NECESSARY.*
T TEST TC-1C REPAIRING - NO CAM SIGNAL AT PCM R O Perform TEST TC-1A Before Proceeding U B L E C O D E T E S T S
FIG. 1
ZJ BODY ALL OTHERS
82
TEST TC-1C
T R O U B L E C O D E T E S T S
NO
YES
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
T TEST TC-5A REPAIRING - CHARGING SYSTEM VOLTAGE TOO LOW R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
XJ BODY ZJ BODY
FIG. 2
84
FIG. 3
TEST TC-5A
T R O U B L E C O D E
NOTE: GENERATOR BELT TENSION AND CONDITION MUST BE CHECKED BEFORE CONTINUING.
NO
YES
T E S T S
YES
NO
DISCONNECT THE BATTERY TEMPERATURE SENSOR CONNECTOR.** SEE GENERAL INFO 4.4
CONNECT A JUMPER ACROSS THE TERMINALS OF THE BATTERY TEMPERATURE SENSOR. FIG. 1, 2 OR 3
NO
YES
T TEST TC-5A R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
86
TEST TC-5A
NO
T R O U B L E C O D E T E S T S
NO
YES
CAUTION: IF THIS IS A DIESEL, DO NOT DO ANY CHARGING SYSTEM TEST WITH INTAKE HEATERS ON.
MEASURE VOLTAGE BETWEEN THE GEN B+ TERMINAL AND THE BATTERY (+) POST. FIG. 1
CAUTION: ENSURE ALL WIRES ARE CLEAR OF THE ENGINES MOVING PARTS.
YES
REPAIR THE B (+) CIRCUIT FOR HIGH RESISTANCE BETWEEN THE GENERATOR AND THE BATTERY.*
NO
MEASURE VOLTAGE BETWEEN THE GENERATOR CASE AND BATTERY (-) POST. FIG. 2
CAUTION: ENSURE ALL WIRES ARE CLEAR OF THE ENGINES MOVING PARTS.
YES
REPAIR GENERATOR GROUND FOR HIGH RESISTANCE, GENERATOR CASE TO BATTERY (-) SIDE.*
NO
TURN ON ALL ACCESSORIES, MANUALLY SET ENGINE SPEED TO 1600 RPM. WITH THE DRB...
READ TARGET CHARGING AND CHARGING VOLTAGE. COMPARE THE TWO READINGS.
YES
NO
RECORD ALL DTCS AND FREEZE FRAME DATA, NOW ERASE CODES.
T TEST TC-6A REPAIRING - CHARGING SYSTEM VOLTAGE TOO HIGH R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
88
FIG. 3
TEST TC-6A
READ FIGURE 1 TO DETERMINE WHICH TERMINAL IS THE GENERATOR FIELD DRIVER CIRCUIT.
T R O U B L E C O D E T E S T S
YES
NO
T TEST TC-6A R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
90
TEST TC-6A
T R O U B L E C O D E T E S T S
MEASURE THE GENERATOR FIELD DRIVER CIRCUIT FROM THE PCM CONNECTOR TO GROUND. FIG. 1
YES
NO
YES
NO
T TEST TC-6B REPAIRING - CHARGING SYSTEM VOLTAGE TOO HIGH R O Perform TEST TC-6A Before Proceeding U AB BODY B L E C O D E T E S T S
AN AND BR BODIES
92
TEST TC-6B
WITH THE DRB, STOP THE GENERATOR FIELD DRIVER ACTUATION. READ THE TARGET CHARGING VOLTAGE.
YES
T R O U B L E C O D E
NO
YES
NO
T E S T S
T TEST TC-6B CONTINUED - REPAIRING - CHARGING SYSTEM VOLTAGE TOO HIGH R O Perform TEST TC-6A Before Proceeding U NOTES B L E C O D E T E S T S
94
TEST TC-6B
T R O U B L E C O D E
T E S T S
WITH THE DRB, READ BOTH THE BATTERY VOLTAGE AND THE TARGET CHARGING VOLTAGE.
MONITOR VOLTAGE FOR 5 MINUTES, IF NECESSARY. LOOK FOR A 1.0 VOLT DIFFERENCE OR MORE.
YES
NO
RECORD ALL DTCS AND FREEZE FRAME DATA, NOW ERASE CODES.
T TEST TC-10A REPAIRING - AUTO SHUTDOWN RELAY CONTROL CIRCUIT R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
96
WITH THE DRB, ACTUATE THE AUTO SHUTDOWN RELAY. SEE GENERAL INFO 4.6
NO
T R O U B L E C O D E
YES
THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
T E S T S
NO
WIGGLE THE WIRING HARNESS FROM THE RELAY TO THE POWERTRAIN CONTROL MODULE.
DISCONNECT THE INTAKE AIR TEMP HEATER RELAY CONTROL WIRES. SEE GENERAL INFO 4.6
YES
REPAIR CIRCUIT AS NECESSARY WHERE WIGGLING CAUSED THE ENGINE TO DIE OUT.*
TURN THE HEADLAMPS ON & WIGGLE THE WIRING HARNESS FROM ASD RELAY TO THE PCM.
TEST COMPLETE.*
NO DID WIGGLING CAUSE THE HEADLAMPS TO FLICKER? YES REPAIR AS NECESSARY WHERE WIGGLING CAUSED THE HEADLAMPS TO FLICKER.*
FIG. 1
BR BODY XJ BODY
FIG. 2
FIG. 3
ZJ BODY
FIG. 4
FIG. 5
98
FIG. 6
T R O U B L E C O D E
USING A VOLTMETER, MEASURE THE FUSED IGN SWITCH OUTPUT CKT AT RELAY. FIG. 1, 2, 3, 4 OR 5
NO
YES
T E S T S
MEASURE THE RESISTANCE BETWEEN TERMINALS 85 AND 86 OF THE ASD RELAY. FIG. 6
NO
YES
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE GREY CONNECTOR.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE ASD RLY CONTROL CIRCUIT AT PCM TO GROUND. FIG. 1, 2, 3, 4 OR 5
YES
REPAIR THE AUTO SHUTDOWN RELAY CONTROL CKT FOR A SHORT TO GROUND.*
NO
USING AN OHMMETER, MEASURE THE RESISTANCE OF THE ASD RELAY CONTROL CIRCUIT...
NO
YES
T TEST TC-11A REPAIRING - GENERATOR FIELD NOT SWITCHING PROPERLY R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
100
FIG. 3
RECORD ALL DTCS AND FREEZE FRAME DATA, NOW ERASE CODES.
T R O U B L E C O D E
READ FIGURE 1 TO DETERMINE WHICH TERMINAL IS THE GENERATOR FIELD DRIVER CIRCUIT.
T E S T S
REPAIR THE OPEN ASD RELAY OUTPUT CIRCUIT, GENERATOR TO HARNESS SPLICE.*
BACKPROBE THE ASD RELAY OUTPUT CIRCUIT AT THE BACK OF THE GENERATOR. FIG. 2
NO
YES
BACKPROBE THE GEN FIELD DRIVER CIRCUIT AT THE BACK OF THE GENERATOR. FIG. 2
NO
YES
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 3
YES
REPAIR AS NECESSARY.*
NO
WITH THE DRB, READ CODES. NOTE: ACTUATOR TEST SHOULD STILL BE RUNNING.
YES
NO
TEST COMPLETE.*
T TEST TC-11A R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
FIG. 3
102
FIG. 4
READ FIGURE 1 TO DETERMINE WHICH TERMINAL IS THE GENERATOR FIELD DRIVER CIRCUIT.
T R O U B L E C O D E
TURN IGNITION OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
DISCONNECT THE GEN FIELD HARNESS CONNECTOR AT BACK OF THE GENERATOR.** SEE GENERAL INFO 4.2
T E S T S
MEASURE RESISTANCE OF THE GEN FIELD DRIVER CKT, GEN CONN TO PCM CONN. FIG. 2
NO
YES
MEASURE THE RESISTANCE ACROSS THE GENERATOR FIELD TERMINALS AT THE GENERATOR. FIG. 3
NO
YES
MEASURE THE GEN FIELD DRIVER CIRCUIT AT GENERATOR HARNESS CONN TO GROUND. FIG. 4
YES
NO
T TEST TC-12A REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CKT R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
104
NO
T R O U B L E C O D E
YES
YES
NO
T E S T S
NO
YES
AT THIS TIME, THE CONDITION REQUIRED TO SET THIS CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
WHILE READING DTCS WITH THE DRB, WIGGLE THE WIRING HARNESS FROM THE SOLENOID TO THE PCM.
YES
NO
TEST COMPLETE.
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
106
FIG. 4
- REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANS TEST TC-12A CONTINUED RELAY CKT
T R O U B L E C O D E T E S T S
DISCONNECT THE TRANS SOLENOID PACK CONNECTOR.** SEE GENERAL INFO 4.2
KEY ON. WITH THE DRB, ACTUATE THE TRANS CONTROL RELAY.
NO
YES
KEY ON. MEASURE THE VOLTAGE AT THE TCC SOLENOID CONTROL CIRCUIT. FIG. 1, 2, 3 OR 4
YES
NO
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
108
FIG. 4
- REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANS TEST TC-12A CONTINUED RELAY CKT
KEY OFF. MEASURE THE RESISTANCE BETWEEN THE TCC SOLENOID CONTROL CIRCUIT...
T R O U B L E C O D E T E S T S
YES
NO
YES
NO
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
110
FIG. 4
- REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANS TEST TC-12A CONTINUED RELAY CKT
T R O U B L E C O D E T E S T S
MEASURE THE RESISTANCE BETWEEN THE TRANS CONTROL RELAY OUTPUT CIRCUIT AT THE RELAY...
AND THE TCC SOLENOID CONTROL CIRCUIT AT THE PCM CONNECTOR. FIG. 1, 2, 3 OR 4
YES
NO
NO
YES
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
112
FIG. 4
- REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANS TEST TC-12A CONTINUED RELAY CKT
T R O U B L E C O D E T E S T S
DISCONNECT THE TRANS SOLENOID PACK CONNECTOR.** SEE GENERAL INFO 4.2
NO
YES
T TEST TC-12B REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CKT R O Perform TEST TC-12A Before Proceeding U AB BODY AN BODY B L E C O D E T E S T S
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
114
FIG. 4
T R O U B L E C O D E T E S T S
KEY OFF. MEASURE THE RESISTANCE BETWEEN THE TRANS CONTROL RELAY OUTPUT CIRCUIT...
YES
NO
YES
NO
KEY ON, MEASURE THE VOLTAGE AT THE FUSED B(+) CIRCUIT IN THE RELAY CONNECTOR. FIG. 1, 2, 3 OR 4
NO
REPAIR THE OPEN FUSED B(+) FEED TO THE TRANS CONTROL RELAY.*
YES
T TEST TC-12C CONTINUED - REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CKT R Perform TEST TC-12A Before Proceeding O U AB BODY AN BODY B L E C O D E T E S T S
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
116
FIG. 4
- REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANS TEST TC-12C CONTINUED RELAY CKT Perform TEST TC-12A Before Proceeding
T R O U B L E C O D E T E S T S
MEASURE AND RECORD THE RESISTANCES BETWEEN THE TCC SOLENOID CONTROL CIRCUIT...
REPAIR TCC SOLENOID YES CONTROL CKT SHORTED TO CIRCUIT(S) THAT MEASURED BELOW 5.0 OHMS.*
NO
REPLACE THE SOLENOID HARNESS INSIDE THE TRANSMISSION AND THE SOLENOID PACK.*
YES
TEST COMPLETE.
T TEST TC-12D REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CKT R O Perform TEST TC-12A Before Proceeding U NOTES B L E C O D E T E S T S
118
T R O U B L E C O D E T E S T S
NO
YES
TEST COMPLETE.
T TEST TC-12E REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CKT R O Perform TEST TC-12A Before Proceeding U AB AND XJ BODIES WITH 3 SPD RH TRANS B L E C O D E T E S T S
FIG. 1
AB BODY WITH 3 SPD RH TRANS
FIG. 2
120
T R O U B L E C O D E
MEASURE THE VOLTAGE AT THE FUSED IGNITION SWITCH OUTPUT CIRCUIT. FIG. 1
YES
NO
T E S T S
NO
YES
MEASURE THE VOLTAGE AT THE TCC SOLENOID CONTROL CIRCUIT AT PCM CONNECTOR. FIG. 2
NO
YES
T TEST TC-14A REPAIRING - RAD FAN CONTROL RELAY CIRCUIT R O Perform DTC TEST Before Proceeding U AN BODY XJ BODY B L E C O D E T E S T S
AN BODY
XJ BODY
FIG. 1
FIG. 2
FIG. 3
122
FIG. 4
T R O U B L E C O D E T E S T S
NO
YES
THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 3
YES
REPAIR AS NECESSARY.*
NO
WIGGLE THE WIRING HARNESS FROM THE RELAY TO THE POWERTRAIN CONTROL MODULE.
NOTE: THE DRB MUST STILL BE ACTUATING THE RADIATOR FAN RELAY.
YES
NO
TEST COMPLETE.*
FIG.1
XJ BODY
FIG. 2
AN BODY XJ BODY
FIG. 3
FIG. 4
124
FIG. 5
T R O U B L E C O D E
USING A VOLTMETER, MEASURE THE FUSED IGN SWITCH OUTPUT CIRCUIT. FIG. 1 OR 2
NO
YES
T E S T S
MEASURE THE RESISTANCE BETWEEN TERMINALS 85 AND 86 OF THE RAD FAN RELAY. FIG. 3
NO
YES
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE GREY CONNECTOR.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE RAD FAN RELAY CONTROL CKT AT PCM TO GROUND. FIG. 4 OR 5
YES
REPAIR THE RADIATOR FAN RELAY CONTROL CKT FOR A SHORT TO GROUND.*
NO
NO
YES
T TEST TC-15A REPAIRING - SPEED CONTROL SOLENOID CIRCUITS OR SPEED CONTROL POWER RELAY CIRCUITS R Perform DTC TEST Before Proceeding O U B L E C O D E T E S T S
ALL OTHERS
FIG. 1
ZJ BODY
FIG. 2
FIG. 3
126
- SPEED CONTROL SOLENOID CIRCUITS OR SPEED CONTROL POWER T TEST TC-15A REPAIRING RELAY CIRCUITS R Perform DTC TEST Before Proceeding
WITH DRB, READ, RECORD AND CLEAR ALL FAULTS. IF S/C FAULTS EXISTS, THE PCM WILL...
START ENGINE.
O U B L E C O D E
PRESS THE S/C ON/OFF SWITCH TO ON AND OFF WHILE MONITORING DISPLAY.
DID THE SPEED CONTROL ON/OFF SWITCH STATE CHANGE ON THE DRB DISPLAY? NO
YES
T E S T S
NO
YES
WITH THE S/C SWITCH ON, DISCONNECT THE SPEED CONTROL SERVO 4-WAY CONNECTOR.** SEE GENERAL INFO 4.2
NOTE: ENSURE THE BRAKE PEDAL IS NOT DEPRESSED DURING THE FOLLOWING STEPS.
MEASURE THE SWITCHED SPEED CONTROL POWER SUPPLY CIRCUIT AT S/C SERVO CONNECTOR. FIG. 1
YES
NO
T TEST TC-15B REPAIRING - SPEED CONTROL SOLENOID CIRCUITS OR SPEED CONTROL POWER RELAY CIRCUIT R Perform TEST TC-15A Before Proceeding O U AB, AN AND XJ BODIES B L E C O D E T E S T S
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
128
FIG. 4
- SPEED CONTROL SOLENOID CIRCUITS OR SPEED CONTROL POWER T TEST TC-15B REPAIRING RELAY CIRCUIT R Perform TEST TC-15A Before Proceeding
NOTE: ENSURE THE BRAKE PEDAL IS NOT DEPRESSED DURING THE FOLLOWING STEPS.
O U B L E C O D E T E S T S
NO
YES
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
RECONNNECT SPEED CONTROL SERVO 4-WAY CONNECTOR. SEE GENERAL INFO 4.2
WITH AN OHMMETER, MEASURE THE RESISTANCE FROM THE 12-VOLT POWER SUPPLY...
TO THE SPEED CONTROL VENT SOLENOID CONTROL FROM PCM CONN. FIG. 2, 3 OR 4
YES
NO
T TEST TC-15B CONTINUED - REPAIRING - SPEED CONTROL SOLENOID CIRCUITS OR SPEED CONTROL POWER RELAY CIRCUIT R O U AB, AN AND XJ BODIES B L E C O D E T E S T S
FIG. 1
BR BODY
FIG. 2
ZJ BODY
FIG. 3
130
- REPAIRING - SPEED CONTROL SOLENOID CIRCUITS OR SPEED TEST TC-15B CONTINUED CONTROL POWER RELAY CIRCUIT
T R O U B L E C O D E T E S T S
YES
NO
WITH AN OHMMETER, MEASURE THE S/C VACUUM SOLENOID CONTROL CIRCUIT. FIG. 1, 2 OR 3
NO
YES
WITH AN OHMMETER, MEASURE THE S/C VENT SOLENOID CONTROL CIRCUIT. FIG. 1, 2 OR 3
NO
YES
T TEST TC-15C REPAIRING - SPEED CONTROL SOLENOID CIRCUITS OR SPEED CONTROL POWER RELAY CIRCUIT R Perform TEST TC-15A Before Proceeding O U AB BODY B L E C O D E T E S T S
FIG. 1
AN AND XJ BODIES BR BODY
FIG. 2
FIG. 3
ZJ BODY
FIG. 4
FIG. 5
132
- SPEED CONTROL SOLENOID CIRCUITS OR SPEED CONTROL POWER T TEST TC-15C REPAIRING RELAY CIRCUIT R Perform TEST TC-15A Before Proceeding
O U B L E C O D E T E S T S
NO
YES
FROM THE SPEED CONTROL SERVO 4-WAY CONNECTOR SWITCHED S/C POWER SUPPLY....
TO THE BRAKE SWITCH CONNECTOR SWITCHED S/C BRAKE SWITCH OUTPUT CIRCUIT. FIG. 1, 2, 3, 4 OR 5
YES
NO
T TEST TC-15D REPAIRING - SPEED CONTROL SOLENOID CIRCUITS OR SPEED CONTROL POWER RELAY CIRCUIT R Perform TEST TC-15C Before Proceeding O U AB BODY AN AND XJ BODIES B L E C O D E T E S T S
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
134
FIG. 4
- SPEED CONTROL SOLENOID CIRCUITS OR SPEED CONTROL POWER T TEST TC-15D REPAIRING RELAY CIRCUIT R Perform TEST TC-15C Before Proceeding
O U B L E C O D E T E S T S
YES
NO
135
T TEST TC-16A REPAIRING - A/C CLUTCH RELAY CIRCUIT R O Perform DTC TEST Before Proceeding U ALL BODIES B L E C O D E T E S T S
FIG. 1
136
FIG. 2
T R O U B L E C O D E T E S T S
NO
YES
THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
WIGGLE THE WIRING HARNESS FROM THE RELAY TO THE POWERTRAIN CONTROL MODULE.
NOTE: THE DRB MUST STILL BE ACTUATING THE A/C CLUTCH RELAY.
YES
NO
TEST COMPLETE.*
FIG. 1
BR BODY XJ BODY
FIG. 2
FIG. 3
ZJ BODY
FIG. 4
FIG. 5
138
FIG. 6
T R O U B L E C O D E
USING A VOLTMETER, MEASURE THE FUSED IGN SWITCH OUTPUT CIRCUIT. FIG. 1, 2, 3, 4 OR 5
NO
YES
T E S T S
MEASURE THE RESISTANCE BETWEEN TERMINALS 85 AND 86 OF THE A/C CLUTCH RELAY. FIG. 6
NO
YES
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE GREY CONNECTOR.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE A/C CLUTCH CONTROL CKT AT PCM TO GROUND. FIG. 1, 2, 3, 4 OR 5
YES
REPAIR THE A/C CLUTCH RELAY CONTROL CIRCUIT FOR A SHORT TO GROUND.*
NO
NO
YES
T TEST TC-17A REPAIRING - EGR SOLENOID CIRCUIT R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
5.9L HD
FIG. 1
5.9L DIESEL
FIG. 2
140
T R O U B L E C O D E T E S T S
YES
NO
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1 OR 2
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
T TEST TC-17A R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
142
KEY OFF, DISCONNECT THE EGR SOLENOID CONNECTOR.** SEE GENERAL INFO 4.0
T R O U B L E C O D E
MEASURE THE FUSED IGNITION SWITCH OUTPUT CKT. AT THE SOLENOID CONNECTOR. FIG. 1
NO
YES
T E S T S
MEASURE THE RESISTANCE OF THE CONTROL CKT FROM PCM TO EGR SOLENOID. FIG. 2
NO
YES
YES
NO
MEASURE THE EGR SOLENOID CONTROL CIRCUIT AT THE PCM CONNECTOR. FIG. 2
NO
YES
T TEST TC-18A REPAIRING - EVAP PURGE SOLENOID CIRCUIT R O Perform DTC TEST Before Proceeding U AB BODY AN AND XJ BODIES B L E C O D E T E S T S
BR BODY
ZJ BODY
FIG. 1
144
FIG. 2
RECORD ALL DTCS AND FREEZE FRAME DATA, NOW ERASE CODES.
T R O U B L E C O D E
START ENGINE. ALLOW ENGINE TO REACH NORMAL OPERATING TEMPERATURE. (ABOVE 170 DEG.).
T E S T S
DISCONNECT THE PURGE VACUUM HOSE AT THE SOLENOID THAT GOES TO THE CANISTER. SEE GENERAL INFO 4.2
IS PURGE SOLENOID ALLOWING VACUUM THROUGH WHEN THE DRB SHOWS DUTY CYCLE MORE THAN O PERCENT? YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
WITH THE DRB, READ CODES. NOTE: ACTUATOR TEST SHOULD STILL BE RUNNING.
YES
NO
TEST COMPLETE.*
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
146
FIG. 4
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT EVAP PURGE SOLENOID CONNECTOR.** SEE GENERAL INFO 4.2
KEY ON, USING A VOLTMETER, MEASURE THE VOLTAGE OF THE FUSED IGNITION SWITCH OUTPUT...
NO
YES
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
148
FIG. 4
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.2
T R O U B L E C O D E T E S T S
WITH AN OHMMETER, MEASURE THE EVAP PURGE SOLENOID CONTROL CIRCUIT... FIG. 1, 2, 3 OR 4
NO
YES
USING AN OHMMETER, MEASURE THE EVAP PURGE SOLENOID CONTROL CIRCUIT TO GROUND...
YES
NO
MEASURE THE EVAP PURGE SOLENOID CONTROL CIRCUIT AT THE PCM CONNECTOR. FIG. 1, 2, 3 OR 4
NO
YES
T TEST TC-19A REPAIRING - INJECTOR #3 CONTROL CIRCUIT R O Perform TEST TC-21A Before Proceeding U AB, AN AND BR BODIES B L E C O D E T E S T S
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
150
FIG. 4
T R O U B L E C O D E T E S T S
NO REPLACE THE FUEL INJECTOR.*
YES START TEST TC-19A IS THIS A CNG VEHICLE? PERFORM TEST TC-19B.
NO
KEY OFF, DISCONNECT THE INJECTOR #3 CONNECTOR.** SEE GENERAL INFO 4.2
YES
KEY ON, WITH THE DRB, ACTUATE THE AUTO SHUTDOWN RELAY.
NO
YES
T TEST TC-19A R O U B L E C O D E T E S T S
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
152
FIG. 4
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE INJECTOR #3 DRIVER CIRCUIT IN THE PCM TO GROUND. FIG. 1
YES
NO
NO
YES
T TEST TC-19B REPAIRING - INJECTOR #3 CONTROL CIRCUIT R O Perform TEST TC-19A Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
154
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE INJECTOR #3 CONNECTOR.** SEE GENERAL INFO 4.2
NO
YES
KEY ON, WITH THE DRB, ACTUATE THE AUTO SHUTDOWN RELAY.
NO
YES
T TEST TC-19B R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
156
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE INJECTOR #3 DRIVER CIRCUIT IN THE PCM TO GROUND. FIG. 1
YES
NO
NO
YES
T TEST TC-20A REPAIRING - INJECTOR #2 CONTROL CIRCUIT R O Perform TEST TC-21A Before Proceeding U AB, AN AND BR BODIES B L E C O D E T E S T S
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
158
FIG. 4
T R O U B L E C O D E T E S T S
NO REPLACE THE FUEL INJECTOR.*
YES START TEST TC-20A IS THIS A CNG VEHICLE? PERFORM TEST TC-20B.
NO
KEY OFF, DISCONNECT THE INJECTOR #2 CONNECTOR.** SEE GENERAL INFO 4.2
YES
KEY ON, WITH THE DRB, ACTUATE THE AUTO SHUTDOWN RELAY.
NO
YES
T TEST TC-20A R O U B L E C O D E T E S T S
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
160
FIG. 4
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE INJECTOR #2 DRIVER CIRCUIT IN THE PCM TO GROUND. FIG. 1
YES
NO
NO
YES
T TEST TC-20B REPAIRING - INJECTOR #2 CONTROL CIRCUIT R O Perform TEST TC-20A Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
162
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE INJECTOR #2 CONNECTOR.** SEE GENERAL INFO 4.2
NO
YES
KEY ON, WITH THE DRB, ACTUATE THE AUTO SHUTDOWN RELAY.
NO
YES
T TEST TC-20B R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
164
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE INJECTOR #2 DRIVER CIRCUIT IN THE PCM TO GROUND. FIG. 1
YES
NO
NO
YES
T TEST TC-21A REPAIRING - INJECTOR CONTROL CIRCUITS R O Perform DTC TEST Before Proceeding U ALL 4-CYLINDER ENGINES ALL 6-CYLINDER ENGINES B L E C O D E T E S T S
FIG. 1
166
FIG. 2
T R O U B L E C O D E T E S T S
DOES THE DRB SHOW ANY "INJECTOR CONTROL CIRCUIT" CODE WITH A START RUN COUNT OF ZERO? NO
YES
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
START ENGINE.
YES
NO
TEST COMPLETE.*
T TEST TC-21A R O U B L E C O D E T E S T S
NOTES
168
T R O U B L E C O D E T E S T S
TROUBLE CODE INJECTOR #1 CONTROL CIRCUIT INJECTOR #2 CONTROL CIRCUIT INJECTOR #3 CONTROL CIRCUIT INJECTOR #4 CONTROL CIRCUIT INJECTOR #5 CONTROL CIRCUIT INJECTOR #6 CONTROL CIRCUIT INJECTOR #7 CONTROL CIRCUIT INJECTOR #8 CONTROL CIRCUIT INJECTOR #9 CONTROL CIRCUIT INJECTOR #10 CONTROL CIRCUIT
DIAGNOSTIC TEST TC-21B TC-20A TC-19A TC-61A TC-69A TC-70A TC-79A TC-80A TC-55A TC-56A
169
T TEST TC-21B REPAIRING - INJECTOR #1 CONTROL CIRCUIT R O Perform TEST TC-21A Before Proceeding U AB, AN AND BR BODIES B L E C O D E T E S T S
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
170
FIG. 4
T R O U B L E C O D E T E S T S
NO REPLACE THE FUEL INJECTOR.*
YES START TEST TC-21B IS THIS A CNG VEHICLE? PERFORM TEST TC-21C
NO
KEY OFF, DISCONNECT THE INJECTOR #1 CONNECTOR.** SEE GENERAL INFO 4.2
YES
NO
YES
T TEST TC-21B R O U B L E C O D E T E S T S
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
172
FIG. 4
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE INJECTOR #1 DRIVER CIRCUIT IN THE PCM TO GROUND. FIG. 1
YES
NO
NO
YES
T TEST TC-21C REPAIRING - INJECTOR #1 CONTROL CIRCUIT R O Perform TEST TC-21B Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
174
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE INJECTOR #1 CONNECTOR.** SEE GENERAL INFO 4.2
NO
YES
NO
YES
T TEST TC-21C R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
176
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE INJECTOR #1 DRIVER CIRCUIT IN THE PCM TO GROUND. FIG. 1
YES
NO
NO
YES
T TEST TC-25A REPAIRING - IDLE AIR CONTROL MOTOR CIRCUITS R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
AB, AN, BR AND XJ BODIES ZJ BODY
178
T R O U B L E C O D E
NOTE: IF THE ENGINE WILL NOT IDLE, HOLD THE THROTTLE OPEN SLIGHTLY TO KEEP ENGINE RUNNING.
WITH THE DRB ACTUATE THE IDLE AIR CONTROL MOTOR TO 1400 RPM.
NOTE: RELEASE THROTTLE. IS THE ENGINE SPEED 1400 +/- 100 RPM? YES
NO
T E S T S
WITH THE DRB ACTUATE THE IDLE AIR CONTROL MOTOR TO 900 RPM.
NO
YES
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
START ENGINE. WITH THE DRB IN SYSTEMS TESTS, PERFORM THE IAC WIGGLE TEST.
THE IDLE SPEED SHOULD RAISE AND LOWER WITH THE DISPLAY.
NO
YES
WIGGLE THE WIRING HARNESS FROM THE IAC MOTOR TO THE PCM.
YES
NO
TEST COMPLETE.*
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
180
FIG. 4
T R O U B L E C O D E
WITH THE ENGINE STILL RUNNING, DISCONNECT THE IAC MOTOR CONNECTOR.**
T E S T S
WAS THE VOLTAGE OVER 5.0 VOLTS AT ANY TIME? NO PERFORM TEST TC-25B
YES
NO
YES
NO
YES
NO
YES
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
182
FIG. 4
T R O U B L E C O D E
YES
NO
T E S T S
YES
NO
YES
NO
YES
NO
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
184
FIG. 4
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.0
YES
REPAIR AS NECESSARY.*
T R O U B L E C O D E T E S T S
NO
THE FOLLOWING STEPS ARE CHECKING FOR A SHORT BETWEEN THE DRIVER CIRCUITS...
YES
NO
YES
NO
YES
NO
T TEST TC-25B REPAIRING - IDLE AIR CONTROL MOTOR CIRCUITS R O Perform TEST TC-25A Before Proceeding U AB BODY AN AND BR BODIES B L E C O D E T E S T S
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
186
FIG. 4
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE CONNECTOR.** SEE GENERAL INFO 4.0
YES
REPAIR AS NECESSARY.*
NO
USING AN OHMMETER, MEASURE THE RESISTANCE OF THE IAC #1 DRIVER CKT... FIG. 1, 2, 3 OR 4
YES
NO
T TEST TC-25C REPAIRING - IDLE AIR CONTROL MOTOR CIRCUITS R O Perform TEST TC-25A Before Proceeding U AB BODY AN AND BR BODIES B L E C O D E T E S T S
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
188
FIG. 4
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE CONNECTOR.** SEE GENERAL INFO 4.1
YES
REPAIR AS NECESSARY.*
NO
USING AN OHMMETER, MEASURE THE RESISTANCE OF THE IAC #2 DRIVER CKT... FIG. 1, 2, 3 OR 4
YES
NO
T TEST TC-25D REPAIRING - IDLE AIR CONTROL MOTOR CIRCUITS R O Perform TEST TC-25A Before Proceeding U AB BODY AN AND BR BODIES B L E C O D E T E S T S
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
190
FIG. 4
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE CONNECTOR.** SEE GENERAL INFO 4.1
YES
REPAIR AS NECESSARY.*
NO
USING AN OHMMETER, MEASURE THE RESISTANCE OF THE IAC #3 DRIVER CKT... FIG. 1, 2, 3 OR 4
YES
NO
T TEST TC-25E REPAIRING - IDLE AIR CONTROL MOTOR CIRCUITS R O Perform TEST TC-25A Before Proceeding U AB BODY AN AND BR BODIES B L E C O D E T E S T S
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
192
FIG. 4
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE CONNECTOR.** SEE GENERAL INFO 4.1
YES
REPAIR AS NECESSARY.*
NO
USING AN OHMMETER, MEASURE THE RESISTANCE OF THE IAC #4 DRIVER CKT... FIG. 1, 2, 3 OR 4
YES
NO
T TEST TC-26A REPAIRING - THROTTLE POSITION SENSOR VOLTAGE LOW R O Perform DTC TEST Before Proceeding U ZJ BODY ALL OTHERS B L E C O D E T E S T S
FIG. 1
194
FIG. 2
WITH THE DRB, READ THE THROTTLE POSITION SENSOR (TP SENSOR) VOLTAGE.
T R O U B L E
CONTINUE TEST TC-26A ON THE NEXT PAGE.
YES
NO
C O D E T E S T S
WHILE MONITORING THE DRB, SLOWLY OPEN AND CLOSE THE THROTTLE.
NO
YES
STOP MOVING LINKAGE. WIGGLE THROTTLE POSITION SENSOR CONNECTORS AND HARNESS.
WAS THERE ANY CHANGE IN THROTTLE POSITION SENSOR VOLTAGE WHEN WIGGLED? NO
YES
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
T TEST TC-26A CONTINUED - REPAIRING - THROTTLE POSITION SENSOR VOLTAGE LOW R O U AB, AN, BR AND XJ BODIES B L E C O D E T E S T S
FIG. 1
BR DIESEL
FIG. 2
ZJ BODY
FIG. 3
196
DISCONNECT THE THROTTLE POSITION (TP) SENSOR.** SEE GENERAL INFO 4.4
T R O U B L E C O D E
YES
NO
T E S T S
YES
NO
YES
NO
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.0
YES
REPAIR THE THROTTLE POSITION SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND.*
NO
MEASURE BETWEEN THE SENSOR SIGNAL CKT AND THE SENSOR GROUND CKT. FIG. 1, 2 OR 3
YES
NO
T TEST TC-26A R O U B L E C O D E T E S T S
FIG. 1
198
T R O U B L E C O D E T E S T S
KEY ON. WITH THE DRB, READ THE THROTTLE POSITION SENSOR VOLTAGE.
YES
NO
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
YES
REPAIR THE THROTTLE POSITION SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND.*
NO
MEASURE BETWEEN THE SENSOR SIGNAL CIRCUIT AND THE SENSOR GROUND CKT. FIG. 1
YES
NO
T TEST TC-27A REPAIRING - THROTTLE POSITION SENSOR VOLTAGE HIGH R O Perform DTC TEST Before Proceeding U ZJ BODY ALL OTHERS B L E C O D E T E S T S
FIG. 1
200
FIG. 2
T R O U B L E
CONTINUE TEST TC-27A ON THE NEXT PAGE.
YES
NO
C O D E T E S T S
WHILE MONITORING THE DRB, SLOWLY OPEN AND CLOSE THE THROTTLE.
NO
YES
WAS THERE ANY CHANGE IN THROTTLE POSITION SENSOR VOLTAGE WHEN WIGGLED? NO
YES
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
T TEST TC-27A CONTINUED - REPAIRING - THROTTLE POSITION SENSOR VOLTAGE HIGH R O U AB, AN, BR AND XJ BODIES B L E C O D E T E S T S
FIG. 1
BR DIESEL
FIG. 2
ZJ BODY
FIG. 3
202
T R O U B L E C O D E T E S T S
CONNECT A JUMPER WIRE BETWEEN THE TP SENSOR SIGNAL CKT AND SENSOR GND CKT.FIG. 1, 2 OR 3
YES
NO
YES
NO
MOVE THE JUMPER WIRE BETWEEN THE SENSOR SIGNAL CIRCUIT AND A GOOD ENGINE GROUND. FIG. 1, 2 OR 3
YES
T TEST TC-27A CONTINUED - REPAIRING - THROTTLE POSITION SENSOR VOLTAGE HIGH R O U AB, AN, BR AND XJ BODIES B L E C O D E T E S T S
FIG. 1
BR DIESEL
FIG. 2
ZJ BODY
FIG. 3
204
T R O U B L E C O D E T E S T S
MEASURE THE THROTTLE POSITION SENSOR SIGNAL CIRCUIT FOR RESISTANCE. FIG. 1, 2 OR 3
YES
NO
T TEST TC-30A REPAIRING - ECT SENSOR VOLTAGE TOO LOW R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
206
T R O U B L E C O D E T E S T S
WITH THE DRB, READ THE ENGINE COOLANT TEMPERATURE SENSOR (ECT) VOLTAGE.
YES
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
T TEST TC-30A CONTINUED - REPAIRING - ECT SENSOR VOLTAGE TOO LOW R O U AB, AN, BR AND ZJ 5.2L B L E C O D E T E S T S
FIG. 1
XJ BODY
FIG. 2
ZJ 4.0L
FIG. 3
208
T R O U B L E C O D E T E S T S
DISCONNECT THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR CONNECTOR.** SEE GENERAL INFO 4.4
YES
NO
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE ECT SENSOR SIGNAL CIRCUIT TO GROUND. FIG. 1, 2 OR 3
YES
NO
ECT SENSOR SIGNAL CIRCUIT AND THE SENSOR GROUND CIRCUIT. FIG. 1, 2 OR 3
YES
REPAIR THE ECT SENSOR SIGNAL CIRCUIT SHORTED TO THE SENSOR GROUND CIRCUIT.*
NO
T TEST TC-31A REPAIRING - ECT SENSOR VOLTAGE TOO HIGH R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
210
T R O U B L E C O D E T E S T S
WITH THE DRB, READ THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR VOLTAGE.
YES
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
T TEST TC-31A CONTINUED - REPAIRING - ECT SENSOR VOLTAGE TOO HIGH R O U AB, AN, BR AND ZJ 5.2L XJ BODY B L E C O D E T E S T S
FIG. 1
ZJ 4.0L
FIG. 2
AB, AN, BR AND ZJ 5.2L
FIG. 3
XJ BODY ZJ 4.0L
FIG. 4
FIG. 5
212
FIG. 6
DISCONNECT THE ENGINE COOLANT TEMPERATURE (ECT) SENSOR.** SEE GENERAL INFO 4.4
T R O U B L E C O D E
YES
NO
T E S T S
CONNECT A JUMPER BETWEEN THE ECT SENSOR SIGNAL AND SENSOR GROUND CKT. FIG. 1, 2 OR 3
YES
NO
MOVE THE JUMPER WIRE FROM THE SENSOR GROUND TO AN ENGINE GROUND. FIG. 1, 2 OR 3
WITH THE DRB, READ THE ENGINE COOLANT TEMPERATURE SENSOR VOLTAGE.
YES
NO
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
YES
NO
T TEST TC-35A REPAIRING - NO VEHICLE SPEED SENSOR SIGNAL R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
214
T R O U B L E C O D E T E S T S
NO CONTINUE TEST TC-35A ON THE NEXT PAGE.
START ENGINE, WITH THE DRB, READ THE VEHICLE SPEED SENSOR.
YES
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY. *
NO
TEST COMPLETE.*
FIG. 1
ALL OTHER BODIES
FIG. 2
216
YES
T R O U B L E C O D E
NO
HOIST VEHICLE, CHECK THE VSS ADAPTER FOR PROPER SEATING AND POSITIONING. SEE SERVICE MANUAL.
NO
REPAIR AS NECESSARY.*
YES
T E S T S
KEY OFF, DISCONNECT THE VEHICLE SPEED SENSOR(VSS) CONNECTOR.** SEE GENERAL INFO 4.4
KEY ON, MEASURE THE VOLTAGE AT THE 5-VOLT SUPPLY CIRCUIT. FIG. 1 OR 2
NO
YES
KEY ON. MEASURE THE VOLTAGE AT THE VEHICLE SPEED SENSOR SIGNAL CIRCUIT. FIG. 1 OR 2
NO
YES
CONNECT ONE END OF A JUMPER WIRE TO THE VSS SENSOR SIGNAL CIRCUIT. FIG. 1 OR 2
WHILE OBSERVING DISPLAY, TAP THE OTHER END OF JUMPER TO THE SENSOR GROUND CIRCUIT.
NO
YES
REMOVE THE VEHICLE SPEED SENSOR. INSPECT THE SPEEDOMETER PINION GEAR.
NO
REPAIR AS NECESSARY.*
YES
FIG. 1
AN BODY ALL OTHER BODIES
FIG. 2
FIG. 3
218
FIG. 4
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
NO IS THE RESISTANCE BELOW 5.0 OHMS? REPAIR THE OPEN SPEED SENSOR SIGNAL CIRCUIT.*
YES
MEASURE THE RESISTANCE BETWEEN THE VSS SIGNAL CIRCUIT AND GROUND. FIG. 3 OR 4
YES
NO
FIG. 1
ALL OTHER BODIES
FIG. 2
220
T R O U B L E C O D E T E S T S
NO
REPAIR THE VEHICLE SPEED SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND.*
YES
MEASURE THE RESISTANCE BETWEEN THE VSS SIGNAL CIRCUIT AND GROUND FIG. 1 OR 2
YES
NO
T TEST TC-35B REPAIRING - NO VEHICLE SPEED SENSOR SIGNAL R O Perform TEST TC-35A Before Proceeding U AN BODY B L E C O D E T E S T S
FIG. 3
ALL OTHER BODIES
FIG. 2
222
T R O U B L E C O D E
CONNECT ONE END OF A JUMPER WIRE TO THE VSS SENSOR SIGNAL CIRCUIT. FIG. 1 OR 2
T E S T S
YES
NO
T TEST TC-35C REPAIRING - NO VEHICLE SPEED SENSOR SIGNAL R O Perform TEST TC-35A Before Proceeding U AN BODY B L E C O D E T E S T S
FIG. 1
ALL OTHER BODIES
FIG. 2
224
T R O U B L E C O D E T E S T S
YES
NO
REPAIR THE OPEN VSS SIGNAL CIRCUIT BETWEEN THE VSS AND THE PCM.*
T TEST TC-36A REPAIRING - MAP SENSOR VOLTAGE TOO LOW - NO 5 VOLTS TO MAP SENSOR R O Perform DTC TEST Before Proceeding U ZJ BODY ALL OTHERS B L E C O D E T E S T S
FIG. 1
FIG. 2
FIG. 3
226
TEST TC-36A REPAIRING - MAP SENSOR VOLTAGE TOO LOW - NO 5 VOLTS TO MAP SENSOR
Perform DTC TEST Before Proceeding
T R O U B L E C O D E
YES
NO
T E S T S
YES
NO
WIGGLE THE MAP SENSOR CONNECTOR & HARNESS. SEE GENERAL INFO 4.4
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1 OR 2
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
T TEST TC-36A CONTINUED - REPAIRING - MAP SENSOR VOLTAGE TOO LOW - NO 5 VOLTS TO MAP SENSOR R O U AB, AN, BR AND XJ BODIES B L E C O D E T E S T S
FIG. 1
BR 8.0L
FIG. 2
ZJ BODY
FIG. 3
228
- REPAIRING - MAP SENSOR VOLTAGE TOO LOW - NO 5 VOLTS TO TEST TC-36A CONTINUED MAP SENSOR
DISCONNECT THE MAP SENSOR ELECTRICAL CONNECTOR.** SEE GENERAL INFO 4.4
T R O U B L E C O D E
USING A VOLTMETER, MEASURE THE VOLTAGE OF THE MAP SENSOR 5-VOLT SUPPLY CIRCUIT AT THE...
NO
YES
T E S T S
YES
NO
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
MEASURE THE RESISTANCE BETWEEN THE MAP SENSOR SIGNAL CIRCUIT AND...
YES
REPAIR MAP SENSOR SIGNAL CIRCUIT SHORTED TO MAP SENSOR GROUND CIRCUIT.*
NO
USING AN OHMMETER, MEASURE THE RESISTANCE OF THE MAP SENSOR SIGNAL CIRCUIT...
YES
NO
T TEST TC-36A CONTINUED - REPAIRING - MAP SENSOR VOLTAGE TOO LOW - NO 5 VOLTS TO MAP SENSOR R O U AB, AN, BR AND XJ BODIES B L E C O D E T E S T S
FIG. 1
BR 8.0L
FIG. 2
ZJ BODY
FIG. 3
230
- REPAIRING - MAP SENSOR VOLTAGE TOO LOW - NO 5 VOLTS TO TEST TC-36A CONTINUED MAP SENSOR
T R O U B L E C O D E T E S T S
NO
YES
WITH AN OHMMETER.
MEASURE THE MAP SENSOR 5-VOLT SUPPLY CKT FOR RESISTANCE TO GROUND. FIG. 1, 2 OR 3
YES
NO
T TEST TC-37A REPAIRING - MAP SENSOR VOLTAGE TOO HIGH R O Perform DTC TEST Before Proceeding U ZJ BODY ALL OTHERS B L E C O D E T E S T S
FIG. 1
232
FIG. 2
T R O U B L E C O D E T E S T S
YES
NO
WIGGLE MAP SENSOR CONNECTOR & HARNESS. SEE GENERAL INFO 4.4
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
T TEST TC-37A CONTINUED - REPAIRING - MAP SENSOR VOLTAGE TOO HIGH R O U AB, AN, BR AND XJ BODIES B L E C O D E T E S T S
FIG. 1
BR 8.0L
FIG. 2
ZJ BODY
FIG. 3
234
DISCONNECT THE MAP SENSOR ELECTRICAL CONNECTOR.** SEE GENERAL INFO 4.4
T R O U B L E C O D E
USING A VOLTMETER IN THE FOLLOWING STEP, MEASURE THE VOLTAGE OF THE MAP SENSOR SIGNAL...
YES
NO
T E S T S
KEY OFF, USING AN OHMMETER, MEASURE THE RESISTANCE OF THE MAP SENSOR SIGNAL...
YES
NO
CONNECT A JUMPER WIRE BETWEEN THE SENSOR SIGNAL AND SENSOR GROUND CKTS. FIG. 1, 2 OR 3
YES
NO
MOVE THE JUMPER WIRE FROM THE SENSOR GROUND CIRCUIT TO ENGINE GROUND. FIG. 1, 2 OR 3
YES
T TEST TC-37A CONTINUED - REPAIRING - MAP SENSOR VOLTAGE TOO HIGH R O U AB, AN, BR AND XJ BODIES B L E C O D E T E S T S
FIG. 1
BR 8.0L
FIG. 2
ZJ BODY
FIG. 3
236
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
MEASURE THE MAP SENSOR SIGNAL CIRCUIT BETWEEN THE PCM CONNECTOR...
YES
NO
T TEST TC-39A REPAIRING - NO CHANGE IN MAP FROM START TO RUN R O Perform DTC TEST Before Proceeding U ZJ BODY B L E C O D E T E S T S
ALL OTHERS
FIG. 1
238
WITH THE DRB, READ CODES. IS "MAP SENSOR VOLTAGE TOO LOW" CODE SET?
YES
T R O U B L E C O D E
NO
WITH THE DRB, ERASE CODES, START ENGINE, AND ALLOW ENGINE TO IDLE FOR 30 SECONDS.
DOES THE DRB SHOW "NO CHANGE IN MAP FROM START TO RUN"?
YES
NO
T E S T S
WHILE MONITORING THE VOLTAGE, WIGGLE THE WIRING FROM THE MAP SENSOR TO THE PCM.
YES
REPAIR THE WIRING OR CONNECTOR DEFECT BETWEEN THE MAP SENSOR AND THE PCM.*
NO
STOP ACTUATION.
WHILE MONITORING THE DRB DISPLAY, SNAP THE THROTTLE OPEN AND CLOSED.
YES
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT.TEST COMPLETE.* FIG. 1
NO
REMOVE MAP SENSOR AND INSPECT CONDITON OF VACUUM PORT. SEE GENERAL INFO 4.4
YES
NO
T TEST TC-39A CONTINUED - REPAIRING - NO CHANGE IN MAP FROM START TO RUN R O U AB, AN, BR AND XJ BODIES B L E C O D E T E S T S
FIG. 1
BR 8.0L
FIG. 2
ZJ BODY
FIG. 3
240
T R O U B L E C O D E T E S T S
REMOVE MAP SENSOR AND INSPECT CONDITON OF VACUUM PORT. SEE GENERAL INFO 4.4
YES
NO
NO
YES
T TEST TC-40A REPAIRING - NO CRANK REFERENCE SIGNAL AT PCM R O Perform DTC TEST Before Proceeding U 5.9L DIESEL B L E C O D E T E S T S
FIG. 1
ALL OTHERS
FIG. 2
242
T R O U B L E C O D E T E S T S
WITH THE DRB, READ THE CURRENT CKP COUNT AND ATTEMPT TO START THE ENGINE.
DOES THE CURRENT CKP COUNT CHANGE WHILE ATTEMPTING TO START THE ENGINE? YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 1 OR 2
YES
REPAIR AS NECESSARY.*
NO
WIGGLE THE WIRING HARNESS FROM CKP SENSOR TO THE POWERTRAIN CONTROL MODULE.
YES
REPAIR CIRCUIT AS NECESSARY WHERE WIGGLING CAUSED THE ENGINE TO DIE OUT.*
TEST COMPLETE.*
T TEST TC-40A CONTINUED - REPAIRING - NO CRANK REFERENCE SIGNAL AT PCM R O U AB, AN AND BR BODIES XJ BODY B L E C O D E T E S T S
FIG. 1
ZJ BODY
FIG. 2
AB, AN AND BR BODIES
FIG. 3
XJ BODY ZJ BODY
FIG. 4
FIG. 5
244
FIG. 6
KEY OFF, DISCONNECT THE CRANKSHAFT POSITION SENSOR CONNECTOR.** SEE GENERAL INFO 4.4
YES
REPAIR AS NECESSARY.*
T R O U B L E C O D E
NO
NO
YES
T E S T S
TURN IGNITION OFF. USING AN OHMMETER, MEASURE THE SENSOR GROUND CIRCUIT...
NO
YES
DISCONNECT THE PCM BLACK CONNECTOR. INSPECT ALL TERMINALS.** SEE GENERAL INFO 4.1
YES
REPAIR AS NECESSARY.*
NO
NO
YES
USING AN OHMMETER, MEASURE THE RESISTANCE BETWEEN THE CKP SIGNAL CIRCUIT...
NO
YES
T TEST TC-40A CONTINUED - REPAIRING - NO CRANK REFERENCE SIGNAL AT PCM R O U AB, AN AND BR BODIES B L E C O D E T E S T S
FIG. 1
XJ BODY
FIG. 2
ZJ BODY
FIG. 3
246
T R O U B L E C O D E T E S T S
KEY OFF. DISCONNECT THE PCM BLACK CONNECTOR. INSPECT ALL TERMINALS.** SEE GENERAL INFO 4.1
YES
REPAIR AS NECESSARY.*
NO
NO
YES
YES
NO
T TEST TC-41A REPAIRING - IGNITION COIL #3 PRIMARY CIRCUIT R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
FIG. 3
248
FIG. 4
T R O U B L E C O D E
T E S T S
NO
YES
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 3
YES
REPAIR AS NECESSARY.*
NO
WIGGLE WIRING HARNESS FROM THE REAR COIL PACK TO THE POWERTRAIN CONTROL MODULE.
YES
NO
TEST COMPLETE.*
T TEST TC-41A R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
FIG. 3
250
KEY OFF, DISCONNECT THE REAR IGNITION COIL CONNECTOR.** SEE GENERAL INF0 4.0
YES
REPAIR AS NECESSARY.*
T R O U B L E C O D E
NO
YES
T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE IGNITION COIL #3 PRIMARY CIRCUIT TO GROUND. FIG. 2
YES
NO
MEASURE THE IGNITION COIL #3 DRIVER CIRCUIT FROM THE PCM CONNECTOR...
NO
YES
NO
YES
T TEST TC-42A REPAIRING - IGNITION COIL #2 PRIMARY CIRCUIT R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
FIG. 3
252
FIG. 4
T R O U B L E C O D E
T E S T S
NO
YES
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 3
YES
REPAIR AS NECESSARY.*
NO
WIGGLE WIRING HARNESS FROM THE REAR COIL PACK TO THE POWERTRAIN CONTROL MODULE.
YES
NO
TEST COMPLETE.*
T TEST TC-42A R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
FIG. 3
254
KEY OFF, DISCONNECT THE REAR IGNITION COIL CONNECTOR.** SEE GENERAL INFO 4.0
YES
REPAIR AS NECESSARY.*
T R O U B L E C O D E
NO
YES
T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE IGNITION COIL #2 PRIMARY CIRCUIT TO GROUND. FIG. 2
YES
NO
MEASURE THE IGNITION COIL #2 DRIVER CIRCUIT FROM THE PCM CONNECTOR...
NO
YES
NO
YES
T TEST TC-43A REPAIRING - IGNITION COIL #1 PRIMARY CIRCUIT R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG.1
FIG. 2
FIG. 3
256
FIG. 4
NO
T R O U B L E C O D E T E S T S
YES
KEY OFF. DISCONNECT THE SPARK PLUG CABLE AT SPARK PLUG #6. FIG. 1
NO
YES
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 3
YES
REPAIR AS NECESSARY.*
NO
WIGGLE WIRING HARNESS FROM THE FRONT COIL PACK TO THE POWERTRAIN CONTROL MODULE.
YES
NO
TEST COMPLETE.*
T TEST TC-43A R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
FIG. 3
258
KEY OFF, DISCONNECT THE FRONT IGNITION COIL CONNECTOR.** SEE GENERAL INFO 4.0
YES
REPAIR AS NECESSARY.*
T R O U B L E C O D E
NO
YES
T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE IGNITION COIL #1 PRIMARY CIRCUIT TO GROUND. FIG. 1
YES
NO
MEASURE THE IGNITION COIL #1 DRIVER CIRCUIT FROM THE PCM CONNECTOR...
NO
YES
NO
YES
T TEST TC-43B REPAIRING - IGNITION COIL #1 PRIMARY CIRCUIT R O Perform DTC TEST Before Proceeding U BR BODY AB, AN AND XJ BODIES B L E C O D E T E S T S
FIG. 1
ZJ BODY
FIG. 2
FIG. 3
260
FIG. 4
KEY OFF, DISCONNECT THE IGNITION COIL CONNECTOR.** SEE GENERAL INFO 4.0
T R O U B L E
YES REPAIR AS NECESSARY.*
NO
C O D E T E S T S
NO
YES
NO
YES
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
MEASURE THE RESISTANCE OF THE IGNITION COIL DRIVER CKT TO GND. FIG. 1, 2 OR 3
YES
NO
T TEST TC-43B CONTINUED - REPAIRING - IGNITION COIL #1 PRIMARY CIRCUIT R O U AB AND AN BODIES BR BODY B L E C O D E T E S T S
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
262
FIG. 4
T R O U B L E C O D E T E S T S
NO
YES
T TEST TC-44A REPAIRING - NO ASD RELAY OUTPUT VOLTAGE AT PCM R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
264
IS A TROUBLE CODE ALSO SET FOR "AUTO SHUTDOWN RELAY CONTROL CIRCUIT"?
T R O U B L E
PERFORM TEST TC-10A.
YES
NO
C O D E T E S T S
START ENGINE, ALLOW ENGINE TO IDLE FOR AT LEAST 10 SECONDS. RE-READ CODES.
DOES THE DRB SHOW "NO ASD RELAY OUTPUT VOLTAGE AT PCM" WITH A START/RUN COUNT OF ZERO? NO
YES
THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
WIGGLE WIRING HARNESS FROM ASD RELAY TO THE PCM. RE-CHECK FAULT CODES.
YES
NO
TEST COMPLETE.*
FIG. 1
BR BODY XJ BODY
FIG. 2
FIG. 3
ZJ BODY
FIG. 4
FIG. 5
266
YES
T R O U B L E C O D E
YES
NO
T E S T S
NO
YES
YES
NO
IGNITION OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE GREY CONN.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE RESISTANCE OF THE ASD RELAY OUTPUT CIRCUIT...
YES
NO
FIG. 1
BR BODY XJ BODY
FIG. 2
FIG. 3
ZJ BODY
FIG. 4
FIG. 5
268
T R O U B L E C O D E T E S T S
IGNITION OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE GREY CONN.** SEE GENERAL INFO 4.1
YES
NO
T TEST TC-44B REPAIRING - NO ASD RELAY OUTPUT VOLTAGE AT PCM R O Perform TEST TC-44A Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
270
T R O U B L E C O D E
NO
YES
T E S T S
ERASE FAULT CODES. INSTALL A SUBSTITUTE RELAY FOR THE AUTO SHUTDOWN RELAY.
DID THE FAULT CODE "NO ASD RELAY OUTPUT VOLTAGE AT PCM" RETURN?
NO
YES
IGNITION OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE GREY CONN.** SEE GENERAL INFO 4.1
YES
NO
T TEST TC-48A REPAIRING - PCM FAILURE SRI MILE NOT STORED R O Perform DTC TEST Before Proceeding U B L START TEST WITH THE DRB DOES THE DRB E TC-48A. PERFORM THE SRI DISPLAY "WRITE
MEMORY TEST. FAILURE"?
YES
C O D E T E S T S
NO
NO
YES
WITH THE DRB, PERFORM THE SRI MEMORY TEST A SECOND TIME.
YES
NO
YES
NO
COMPARE SRI MILEAGE STORED VALUE TO THE INSTRUMENT PANEL ODOMETER MILEAGE.
YES
NO
T R O U B L E C O D E T E S T S
NO TEST COMPLETE.*
YES
WITH THE DRB, PERFORM THE SRI MEMORY TEST A SECOND TIME.
YES
NO
TEST COMPLETE.*
T TEST TC-50A REPAIRING - TRANS 3-4 SOLENOID/TRANS RELAY CKTS R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
274
T R O U B L E
PERFORM TEST TC-173.
YES
NO
C O D E T E S T S
PUSH OD SWITCH 4 TIMES SUCH THAT VEHICLE ATTEMPTS TO SHIFT FROM 4TH TO 3RD AND BACK.
NO
YES
AT THIS TIME THE CONDITION REQUIRED TO SET THIS CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
WHILE READING DTCS WITH THE DRB, WIGGLE THE WIRING HARNESS FROM THE SOLENOID TO THE PCM.
YES
NO
TEST COMPLETE.*
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
276
FIG. 4
T R O U B L E C O D E T E S T S
DISCONNECT THE TRANS SOLENOID PACK CONNECTOR.** SEE GENERAL INFO 4.2
NO
YES
KEY ON. MEASURE THE VOLTAGE AT THE 3-4 SHIFT SOLENOID CONTROL CIRCUIT. FIG. 1, 2, 3 OR 4
YES
NO
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
278
FIG. 4
KEY OFF. MEASURE THE RESISTANCE BETWEEN THE 3-4 SHIFT SOLENOID CONTROL CIRCUIT...
T R O U B L E C O D E T E S T S
YES
NO
MEASURE THE RESISTANCE BETWEEN THE 3-4 SHIFT SOLENOID CONTROL CIRCUIT...
YES
NO
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
280
FIG. 4
T R O U B L E C O D E T E S T S
MEASURE THE RESISTANCE BETWEEN THE TRANS CONTROL RELAY OUTPUT CIRCUIT AT THE RELAY...
AND THE 3-4 SOLENOID CONTROL CIRCUIT AT THE PCM CONNECTOR. FIG. 1,2,3 OR 4
NO
NO
YES
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
282
FIG. 4
T R O U B L E C O D E T E S T S
DISCONNECT THE TRANS SOLENOID PACK CONNECTOR.** SEE GENERAL INFO 4.2
NO
YES
T TEST TC-50B REPAIRING - TRANS 3-4 SOLENOID/TRANS RELAY CKTS R O Perform TEST TC-50A Before Proceeding U AB BODY AN BODY B L E C O D E T E S T S
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
284
FIG. 4
T R O U B L E C O D E T E S T S
YES
NO
YES
NO
KEY ON, MEASURE THE VOLTAGE AT THE FUSED B(+) CIRCUIT IN THE RELAY CONNECTOR. FIG. 1, 2, 3 OR 4
NO
REPAIR THE OPEN FUSED B(+) FEED TO THE TRANS CONTROL RELAY.*
YES
T TEST TC-50C CONTINUED - TRANS 3-4 SOLENOID/TRANS RELAY CKTS R O Perform TEST TC-50A Before Proceeding U AB BODY AN BODY B L E C O D E T E S T S
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
286
FIG. 4
T R O U B L E C O D E T E S T S
MEASURE AND RECORD THE RESISTANCES BETWEEN THE 3-4 SHIFT SOLENOID CONTROL CIRCUIT...
REPAIR 3-4 SOLENOID YES CONTROL CKT SHORTED TO CIRCUIT(S) THAT MEASURED BELOW 5.0 OHMS.
NO
REPLACE THE SOLENOID HARNESS INSIDE THE TRANSMISSION AND THE SOLENOID PACK.*
PUSH OD SWITCH 4 TIMES SUCH THAT VEHICLE ATTEMPTS TO SHIFT FROM 4TH TO THIRD AND BACK.
YES
TEST COMPLETE.
T TEST TC-50D REPAIRING - TRANS 3-4 SOLENOID/TRANS RELAY CKTS R O Perform TEST TC-50A Before Proceeding U NOTES B L E C O D E T E S T S
288
T R O U B L E C O D E T E S T S
PUSH OD SWITCH 4 TIMES SUCH THAT VEHICLE ATTEMPTS TO SHIFT FROM 4TH TO 3RD AND BACK.
YES
TEST COMPLETE.
T TEST TC-55A REPAIRING - INJECTOR #9 CONTROL CIRCUIT R O Perform TEST TC-21A Before Proceeding U BR BODY B L E C O D E T E S T S
FIG. 1
BR BODY BR BODY
FIG. 2
FIG. 3
290
FIG. 4
KEY OFF, DISCONNECT THE INJECTOR #9 CONNECTOR.** SEE GENERAL INFO 4.2
T R O U B L E C O D E
NO
YES
T E S T S
NO
YES
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE INJECTOR #9 DRIVER CIRCUIT IN THE PCM TO GROUND. FIG. 3
YES
NO
NO
YES
T TEST TC-56A REPAIRING - INJECTOR #10 CONTROL CIRCUIT R O Perform TEST TC-21A Before Proceeding U BR BODY B L E C O D E T E S T S
FIG. 1
BR BODY BR BODY
FIG. 2
FIG. 3
292
FIG. 4
NOTE: ON SOME ENGINES, IT MAY BE NECESSARY TO REMOVE THE INTAKE PLENUM. SEE SERVICE MANUAL.
T R O U B L E C O D E
KEY OFF, DISCONNECT THE INJECTOR #10 CONNECTOR.** SEE GENERAL INFO 4.2
NO
YES
T E S T S
NO
YES
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE INJECTOR #10 DRIVER CKT IN THE PCM TO GROUND. FIG. 3
YES
NO
USING AN OHMMETER, MEASURE ACROSS THE INJECTOR #10 DRIVER CIRCUIT. FIG. 4
NO
YES
T TEST TC-57A REPAIRING - INTAKE AIR TEMP SENSOR VOLTAGE LOW R O Perform DTC TEST Before Proceeding U CNG AND GAS ENGINES B L E C O D E T E S T S
FIG. 1
DIESEL ENGINES
FIG. 2
294
FIG. 3
T R O U B L E C O D E T E S T S
WITH THE DRB, READ THE INTAKE AIR TEMPERATURE SENSOR VOLTAGE.
YES
NO
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1 OR 2
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
T TEST TC-57A CONTINUED - REPAIRING - INTAKE AIR TEMP SENSOR VOLTAGE LOW R O U AB, AN AND BR BODIES B L E C O D E T E S T S
FIG. 1
XJ BODY
FIG. 2
ZJ BODY
FIG. 3
296
TEST TC-57A CONTINUED - REPAIRING - INTAKE AIR TEMP SENSOR VOLTAGE LOW
DISCONNECT THE INTAKE AIR TEMPERATURE SENSOR.** SEE GENERAL INFO 4.4
T R O U B L E C O D E
WITH THE DRB, READ THE INTAKE AIR TEMPERATURE SENSOR VOLTAGE.
YES
NO
T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
MEASURE THE RESISTANCE BETWEEN THE SENSOR SIGNAL AND SENSOR GND CKT. FIG. 1, 2 OR 3
YES
NO
YES
NO
T TEST TC-58A REPAIRING - INTAKE AIR TEMP SENSOR VOLTAGE HIGH R O Perform DTC TEST Before Proceeding U CNG AND GAS ENGINES B L E C O D E T E S T S
FIG. 1
DIESEL ENGINES
FIG. 2
298
FIG. 3
T R O U B L E C O D E T E S T S
WITH THE DRB, READ THE INTAKE AIR TEMPERATURE SENSOR VOLTAGE.
YES
NO
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1 OR 2
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
T TEST TC-58A CONTINUED - REPAIRING - INTAKE AIR TEMP SENSOR VOLTAGE HIGH R O U AB, AN AND BR BODIES XJ BODY B L E C O D E T E S T S
FIG. 1
ZJ BODY
FIG. 2
AB, AN AND BR BODIES
FIG. 3
XJ BODY ZJ BODY
FIG. 4
FIG. 5
300
FIG. 6
TEST TC-58A CONTINUED - REPAIRING - INTAKE AIR TEMP SENSOR VOLTAGE HIGH
DISCONNECT THE INTAKE AIR TEMPERATURE (IAT) SENSOR.** SEE GENERAL INFO 4.4
T R O U B L E C O D E
USING A VOLTMETER, MEASURE THE VOLTAGE OF THE IAT SIGNAL CIRCUIT. FIG. 1, 2 OR 3
YES
NO
T E S T S
CONNECT A JUMPER WIRE ACROSS THE IAT SIGNAL AND SENSOR GROUND CIRCUITS. FIG. 1, 2 OR 3
WITH THE DRB, READ THE INTAKE AIR TEMPERATURE SENSOR VOLTAGE.
YES
NO
MOVE THE JUMPER WIRE FROM THE SENSOR GROUND TO AN ENGINE GROUND. FIG. 1, 2 OR 3
YES
NO
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
FROM THE PCM TO THE INTAKE AIR TEMPERATURE SENSOR CONNECTOR. FIG. 4, 5 OR 6
YES
NO
T TEST TC-61A REPAIRING - INJECTOR #4 CONTROL CIRCUIT R O Perform TEST TC-21A Before Proceeding U AB, AN AND BR BODIES B L E C O D E T E S T S
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
302
FIG. 4
YES START TEST TC-61A IS THIS A CNG VEHICLE? PERFORM TEST TC-61B.
T R O U B L E C O D E T E S T S
NO
NOTE: ON SOME ENGINES, IT MAY BE NECESSARY TO REMOVE THE INTAKE PLENUM. SEE SERVICE MANUAL.
KEY OFF, DISCONNECT THE INJECTOR #4 CONNECTOR.** SEE GENERAL INFO 4.2
NO
YES
KEY ON, WITH THE DRB, ACTUATE THE AUTO SHUTDOWN RELAY.
NO
YES
T TEST TC-61A R O U B L E C O D E T E S T S
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
304
FIG. 4
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE INJECTOR #4 DRIVER CIRCUIT IN THE PCM TO GROUND. FIG. 1
YES
NO
NO
YES
T TEST TC-61B REPAIRING - INJECTOR #4 CONTROL CIRCUIT R O Perform TEST TC-61A Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
306
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE INJECTOR #4 CONNECTOR.** SEE GENERAL INFO 4.2
NO
YES
KEY ON, WITH THE DRB, ACTUATE THE AUTO SHUTDOWN RELAY.
NO
YES
T TEST TC-61B R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
308
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE INJECTOR #4 DRIVER CIRCUIT IN THE PCM TO GROUND. FIG. 1
YES
NO
NO
YES
T TEST TC-62A REPAIRING - 1/1 O2 SENSOR SHORTED TO VOLTAGE R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
5.9L HD AND 8.0L BR ALL OTHERS
310
T R O U B L E C O D E T E S T S
YES
NO
WIGGLE THE 1/1 O2 SENSOR CONNECTOR AND HARNESS. SEE GENERAL INFO 4.4
DID THE 1/1 O2 SENSOR VOLTAGE GO ABOVE 1.5 VOLTS AT ANY TIME?
YES
REPAIR THE HARNESS OR CONNECTOR THAT HAS THE INTERMITTENT SHORT TO VOLTAGE.*
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
FIG. 1
5.9L HD AND 8.0L XJ BODY
FIG. 2
FIG. 3
ZJ BODY ALL OTHERS
FIG. 4
FIG. 5
312
FIG. 6
YES
T R O U B L E C O D E
NO
NO
YES
T E S T S
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE CONNECTORS.** SEE GENERAL INFO 4.1
YES
NO
MEASURE THE 1/1 02 SENSOR SIGNAL CIRCUIT AT THE PCM CONNECTOR. FIG. 1,2,3,4,5 OR 6
YES
NO
WIGGLE THE O2 SENSOR HARNESS WHILE CHECKING FOR VOLTAGE IN THE O2 SENSOR SIGNAL CIRCUIT.
NO
YES
T TEST TC-66A REPAIRING - 2/1 O2 SENSOR SHORTED TO VOLTAGE R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
8.0L MD CAL ALL OTHERS
314
T R O U B L E C O D E T E S T S
YES
NO
WIGGLE THE 2/1 O2 SENSOR CONNECTOR AND HARNESS. SEE GENERAL INFO 4.4
DID THE 2/1 O2 SENSOR VOLTAGE GO ABOVE 1.5 VOLTS AT ANY TIME?
YES
REPAIR THE HARNESS OR CONNECTOR THAT HAS THE INTERMITTENT SHORT TO VOLTAGE.*
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
T TEST TC-66A R O U B L E C O D E T E S T S
FIG. 1
316
YES
T R O U B L E C O D E
NO
NO
YES
T E S T S
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE CONNECTORS.** SEE GENERAL INFO 4.1
YES
NO
MEASURE THE 2/1 02 SENSOR SIGNAL CIRCUIT AT THE PCM CONNECTOR. FIG. 1
YES
NO
WIGGLE THE O2 SENSOR HARNESS WHILE CHECKING FOR VOLTAGE IN THE O2 SENSOR SIGNAL CIRCUIT.
NO
YES
T TEST TC-69A REPAIRING - INJECTOR #5 CONTROL CIRCUIT R O Perform TEST TC-21A Before Proceeding U AB, AN AND BR BODIES B L E C O D E T E S T S
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
318
FIG. 4
T R O U B L E C O D E T E S T S
NO REPLACE THE FUEL INJECTOR.*
YES
NO
KEY OFF, DISCONNECT THE INJECTOR #5 CONNECTOR.** SEE GENERAL INFO 4.2
YES
NO
YES
T TEST TC-69A R O U B L E C O D E T E S T S
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
320
FIG. 4
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE INJECTOR #5 DRIVER CIRCUIT IN THE PCM TO GROUND. FIG. 1
YES
NO
NO
YES
T TEST TC-69B REPAIRING - INJECTOR #5 CONTROL CIRCUIT R O Perform TEST TC-69A Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
FIG. 3
322
FIG. 4
KEY OFF, DISCONNECT THE INJECTOR #5 CONNECTOR.** SEE GENERAL INFO 4.2
T R O U B L E C O D E
NO
YES
T E S T S
NO
YES
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE INJECTOR #5 DRIVER CIRCUIT IN THE PCM TO GROUND. FIG. 3
YES
NO
NO
YES
T TEST TC-70A REPAIRING - INJECTOR #6 CONTROL CIRCUIT R O Perform TEST TC-21A Before Proceeding U AB, AN AND BR BODIES B L E C O D E T E S T S
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
324
FIG. 4
T R O U B L E
YES PERFORM TEST TC-70B.
NO
C O D E T E S T S
NOTE: ON SOME ENGINES, IT MAY BE NECESSARY TO REMOVE THE INTAKE PLENUM. SEE SERVICE MANUAL.
KEY OFF, DISCONNECT THE INJECTOR #6 CONNECTOR.** SEE GENERAL INFO 4.2
NO
YES
NO
YES
T TEST TC-70A CONTINUED - REPAIRING - INJECTOR #6 CONTROL CIRCUIT R O U AB, AN, BR AND XJ BODIES ZJ BODY B L E C O D E T E S T S
FIG. 1
AB, AN AND BR BODIES XJ BODY
FIG. 2
FIG. 3
ZJ BODY
FIG. 4
FIG. 5
326
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE INJECTOR #6 DRIVER CIRCUIT IN THE PCM TO GROUND. FIG. 1 OR 2
YES
NO
NO
YES
T TEST TC-70B REPAIRING - INJECTOR #6 CONTROL CIRCUIT R O Perform TEST TC-70A Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
FIG. 3
328
FIG. 4
KEY OFF, DISCONNECT THE INJECTOR #6 CONNECTOR.** SEE GENERAL INFO 4.2
T R O U B L E C O D E
NO
YES
T E S T S
NO
YES
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE INJECTOR #6 DRIVER CIRCUIT IN THE PCM TO GROUND. FIG. 3
YES
NO
NO
YES
T TEST TC-74A REPAIRING - TRANS TEMP SENSOR VOLTAGE TOO LOW R O Perform DTC TEST Before Proceeding U AB BODY B L E C O D E T E S T S
FIG. 1
AN BODY BR BODY
FIG. 2
ZJ BODY
FIG. 3
FIG. 4
330
FIG. 5
T R O U B L E C O D E
MEASURE THE RESISTANCE BETWEEN THE TRANS TEMP SIGNAL CIRCUIT AND THE...
YES
NO
T E S T S
YES
NO
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 5
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
332
FIG. 4
TEST TC-74A CONTINUED - REPAIRING - TRANS TEMP SENSOR VOLTAGE TOO LOW
T R O U B L E C O D E
USE AN OHMMETER IN THE FOLLOWING STEPS. MEASURE THE RESISTANCE BETWEEN THE TRANS TEMP...
SIGNAL CIRCUIT AND THE SENSOR GROUND CIRCUIT AT PCM CONNECTOR. FIG. 1, 2, 3 OR 4
YES
REPAIR THE TRANS TEMP SIGNAL CIRCUIT SHORTED TO SENSOR GROUND CIRCUIT.*
NO
T E S T S
YES
NO
MEASURE THE RESISTANCE BETWEEN THE TRANS TEMP SIGNAL CIRCUIT AND...
YES
NO
YES
NO
T TEST TC-75A REPAIRING - TRANS TEMP SENSOR VOLTAGE TOO HIGH R O Perform DTC TEST Before Proceeding U AB BODY B L E C O D E T E S T S
FIG. 1
AN BODY BR BODY
FIG. 2
ZJ BODY
FIG. 3
FIG. 4
334
FIG. 5
KEY OFF. DISCONNECT ALL PCM CONNECTORS.** SEE GENERAL INFO 4.1
T R O U B L E C O D E
KEY ON. MEASURE THE VOLTAGE AT THE TRANS TEMP SIGNAL CIRCUIT. FIG. 1, 2, 3 OR 4
YES
NO
T E S T S
KEY OFF. MEASURE THE RESISTANCE BETWEEN THE TRANS TEMP SIGNAL CIRCUIT...
YES
NO
YES
NO
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 5
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
FIG. 4
FIG. 5
336
TEST TC-75A CONTINUED - REPAIRING - TRANS TEMP SENSOR VOLTAGE TOO HIGH
T R O U B L E C O D E T E S T S
YES
NO
REMOVE THE TRANS OIL PAN AND DISCONNECT THE TRANS PRESSURE /TEMP SENSOR.** SEE GENERAL INFO 4.4
YES
NO
T TEST TC-75B REPAIRING - TRANS TEMP SENSOR VOLTAGE TOO HIGH R O Perform TEST TC-75A Before Proceeding U AB BODY AN BODY B L E C O D E T E S T S
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
338
FIG. 4
T R O U B L E C O D E T E S T S
NO
YES
NO
YES
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
340
FIG. 4
T R O U B L E C O D E T E S T S
MEASURE THE RESISTANCE OF TRANS TEMP SENSOR SIGNAL CIRCUIT FROM THE PCM CONNECTOR...
YES
NO
MEASURE THE RESISTANCE OF SENSOR GROUND CIRCUIT FROM THE PCM CONNECTOR...
YES
NO
T TEST TC-76A REPAIRING - IGNITION COIL #4 PRIMARY CIRCUIT R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
FIG. 3
342
FIG. 4
T R O U B L E C O D E
T E S T S
NO
YES
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 3
YES
REPAIR AS NECESSARY.*
NO
WIGGLE WIRING HARNESS FROM THE FRONT COIL PACK TO THE POWERTRAIN CONTROL MODULE.
YES
NO
TEST COMPLETE.*
T TEST TC-76A R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
FIG. 3
344
KEY OFF, DISCONNECT THE FRONT IGNITION COIL CONNECTOR.** SEE GENERAL INFO 4.0
YES
REPAIR AS NECESSARY.*
T R O U B L E C O D E
NO
YES
T E S T S
KEY OFF, DISCONNECT POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.0
USING AN OHMMETER, MEASURE THE IGNITION COIL #4 PRIMARY CIRCUIT TO GROUND. FIG. 1
YES
NO
MEASURE THE IGNITION COIL #4 DRIVER CIRCUIT FROM THE PCM CONNECTOR...
NO
YES
NO
YES
T TEST TC-77A REPAIRING - IGNITION COIL #5 PRIMARY CIRCUIT R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
FIG. 3
346
FIG. 4
T R O U B L E C O D E
T E S T S
NO
YES
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 3
YES
REPAIR AS NECESSARY.*
NO
WIGGLE WIRING HARNESS FROM THE FRONT COIL PACK TO THE POWERTRAIN CONTROL MODULE.
YES
NO
TEST COMPLETE.*
T TEST TC-77A R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
FIG. 3
348
KEY OFF, DISCONNECT THE FRONT IGNITION COIL CONNECTOR.** SEE GENERAL INFO 4.0
YES
REPAIR AS NECESSARY.*
T R O U B L E C O D E
NO
YES
T E S T S
KEY OFF, DISCONNECT POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.0
USING AN OHMMETER, MEASURE THE IGNITION COIL #5 DRIVER CIRCUIT TO GROUND. FIG. 1
YES
NO
MEASURE THE IGNITION COIL #5 DRIVER CIRCUIT FROM THE PCM CONNECTOR...
NO
YES
NO
YES
T TEST TC-79A REPAIRING - INJECTOR #7 CONTROL CIRCUIT R O Perform TEST TC-21A Before Proceeding U B L E C O D E T E S T S
FIG. 1
AB BODY AN BODY
FIG. 2
BR BODY ZJ BODY
FIG. 3
FIG. 4
350
FIG. 5
T R O U B L E C O D E T E S T S
NO REPLACE THE FUEL INJECTOR.*
YES
NO
KEY OFF, DISCONNECT THE INJECTOR #7 CONNECTOR.** SEE GENERAL INFO 4.2
YES
KEY ON, WITH THE DRB, ACTUATE THE AUTO SHUTDOWN RELAY.
NO
YES
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
352
FIG. 4
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE INJECTOR #7 DRIVER CIRCUIT IN THE PCM TO GROUND. FIG. 1, 2, 3 OR 4
YES
NO
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
354
FIG. 4
T R O U B L E C O D E T E S T S
NO
YES
T TEST TC-79B REPAIRING - INJECTOR #7 CONTROL CIRCUIT R O Perform TEST TC-79A Before Proceeding U AB BODY B L E C O D E T E S T S
FIG. 1
AN BODY BR BODY
FIG. 2
FIG. 3
356
FIG. 4
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE INJECTOR #7 CONNECTOR.** SEE GENERAL INFO 4.2
NO
YES
KEY ON, WITH THE DRB, ACTUATE THE AUTO SHUTDOWN RELAY.
NO
YES
FIG. 1
AN BODY
FIG. 2
BR BODY
FIG. 3
358
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE INJECTOR #7 DRIVER CIRCUIT IN THE PCM TO GROUND. FIG. 1, 2 OR 3
YES
NO
NO
YES
T TEST TC-80A REPAIRING - INJECTOR #8 CONTROL CIRCUIT R O Perform TEST TC-21A Before Proceeding U B L E C O D E T E S T S
FIG. 1
AB, AN AND BR BODIES
FIG. 2
ZJ BODY
FIG. 3
360
T R O U B L E
YES PERFORM TEST TC-80B.
NO
C O D E T E S T S
NOTE: ON SOME ENGINES, IT MAY BE NECESSARY TO REMOVE THE INTAKE PLENUM. SEE SERVICE MANUAL.
KEY OFF, DISCONNECT THE INJECTOR #8 CONNECTOR.** SEE GENERAL INFO 4.2
NO
YES
KEY ON, WITH THE DRB, ACTUATE THE AUTO SHUTDOWN RELAY.
NO
YES
T TEST TC-80A CONTINUED - REPAIRING - INJECTOR #8 CONTROL CIRCUIT R O U AB, AN AND BR BODIES ZJ BODY B L E C O D E T E S T S
FIG. 1
AB, AN AND BR BODIES ZJ BODY
FIG. 2
FIG. 3
362
FIG. 4
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE INJECTOR #8 DRIVER CIRCUIT IN THE PCM TO GROUND. FIG. 1 OR 2
YES
NO
NO
YES
T TEST TC-80B REPAIRING - INJECTOR #8 CONTROL CIRCUIT R O Perform TEST TC-80A Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
FIG. 3
364
FIG. 4
KEY OFF, DISCONNECT THE INJECTOR #8 CONNECTOR.** SEE GENERAL INFO 4.2
T R O U B L E C O D E
NO
YES
T E S T S
KEY ON, WITH THE DRB, ACTUATE THE AUTO SHUTDOWN RELAY.
NO
YES
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE INJECTOR #8 DRIVER CIRCUIT IN THE PCM TO GROUND. FIG. 3
YES
NO
NO
YES
T TEST TC-87A REPAIRING - SPEED CONTROL SWITCH ALWAYS LOW R O Perform DTC TEST Before Proceeding U AB, AN AND XJ BODIES B L E C O D E T E S T S
BR BODY
FIG. 1
AB, AN AND XJ BODIES BR BODY
FIG. 2
366
FIG. 3
RECORD ALL DTCS AND FREEZE FRAME DATA, NOW ERASE CODES BEFORE PROCEEDING.
YES
T R O U B L E C O D E
NO
NO
AT THIS TIME THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. SEE GEN INFO 3.3.2
T E S T S
YES
USING AN OHMMETER, MEASURE THE RESISTANCE BETWEEN THE S/C SIGNAL CIRCUIT...
YES
NO
WITH AN OHMMETER, MEASURE RESISTANCE OF S/C SWITCH SIGNAL CKT TO GND AT THE PCM. FIG. 1 OR 2
NO
YES
T TEST TC-87B REPAIRING - SPEED CONTROL SWITCH ALWAYS LOW R O Perform TEST TC-87A Before Proceeding U B L E C O D E T E S T S
ZJ BODY
ZJ BODY
FIG. 1
368
NO
AT THIS TIME THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT SEE GEN INFO 3.3.2
T R O U B L E C O D E
YES
T E S T S
YES
USING AN OHMMETER, MEASURE THE RESISTANCE BETWEEN THE S/C SIGNAL CIRCUIT...
YES
NO
TO GROUND AT THE PCM. IS THE RESISTANCE BELOW 5.0 OHMS? FIG. 1 YES
NO
T TEST TC-94A REPAIRING - CNG TEMP SENSOR VOLTAGE TOO LOW R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
370
T R O U B L E C O D E T E S T S
YES IS THE FUEL TEMP SENSOR VOLTAGE BELOW 0.29 VOLTS? CONTINUE TEST TC-94A ON THE NEXT PAGE.
NO
YES MONITOR THE DRB DISPLAY. WAS THERE ANY FUEL TEMP SENSOR VOLTAGE CHANGE?
REPAIR THE CONNECTOR OR HARNESS WIRES THAT CAUSED THE VOLTAGE CHANGE.*
NO
AT THIS TIME THE CONDITION REQUIRED TO SET THIS CODE IS NOT PRESENT. FIG. 1
NO
TEST COMPLETE.*
T TEST TC-94A R O U B L E C O D E T E S T S
FIG. 1
372
TEST TC-94A CONTINUED - REPAIRING - CNG TEMP SENSOR VOLTAGE TOO LOW
DISCONNECT THE FUEL TEMP SENSOR CONNECTOR.** SEE GENERAL INFO 4.4
T R O U B L E C O D E T E S T S
RELEASE THE FUEL PRESSURE. SEE GENERAL INFO 9.1 REPLACE THE FUEL TEMP SENSOR.*
NO
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE FUEL TEMP SENSOR SIGNAL CIRCUIT TO GROUND. FIG. 1
REPAIR THE FUEL TEMP SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND.*
NO
NO
YES
T TEST TC-95A REPAIRING - CNG TEMP SENSOR VOLTAGE TOO HIGH R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
374
T R O U B L E C O D E T E S T S
YES IS THE FUEL TEMP SENSOR VOLTAGE ABOVE 4.6 VOLTS? CONTINUE TEST TC-95A ON THE NEXT PAGE.
NO
YES MONITOR THE DRB DISPLAY. WAS THERE ANY FUEL TEMP SENSOR VOLTAGE CHANGE?
REPAIR THE CONNECTOR OR HARNESS WIRES THAT CAUSED THE VOLTAGE CHANGE.*
NO
AT THIS TIME THE CONDITION REQUIRED TO SET THIS CODE IS NOT PRESENT. FIG. 1
NO
TEST COMPLETE.*
T TEST TC-95A R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
376
TEST TC-95A CONTINUED - REPAIRING - CNG TEMP SENSOR VOLTAGE TOO HIGH
DISCONNECT THE FUEL TEMP SENSOR CONNECTOR.** SEE GENERAL INFO 4.4
T R O U B L E C O D E
YES
NO
T E S T S
CONNECT A JUMPER WIRE ACROSS THE SENSOR SIGNAL AND SENSOR GROUND CKTS. FIG. 1
YES
RELEASE THE FUEL PRESSURE. SEE GENERAL INFO 9.1 REPLACE THE FUEL TEMP SENSOR.*
NO
MOVE THE JUMPER WIRE FROM THE SENSOR GROUND TO AN ENGINE GROUND. FIG. 1
YES
NO
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
WITH AN OHMMETER, MEASURE THE FUEL TEMP SENSOR SIGNAL CIRCUIT FROM PCM TO CONN. FIG. 2
NO IS THE RESISTANCE BELOW 5.0 OHMS? REPAIR THE OPEN FUEL TEMP SENSOR SIGNAL CIRCUIT.*
YES
T TEST TC-98A REPAIRING - CNG PRESSURE SENSOR VOLTAGE TOO HIGH R O Perform DTC TEST Before Proceeding U AN AND BR BODIES AB BODY B L E C O D E T E S T S
FIG. 1
378
FIG. 2
T R O U B L E C O D E
DID THE "CNG PRESSURE SENSOR VOLTAGE TOO HIGH" CODE RETURN?
YES
NO
T E S T S
WIGGLE THE FUEL PRESSURE SENSOR CONNECTORS AND HARNESS. SEE GENERAL INFO 4.0
WITH THE DRB, MONITOR THE FUEL PRESSURE SENSOR VOLTAGE WHILE WIGGLING.
WAS THERE ANY CHANGE IN FUEL PRESSURE SENSOR VOLTAGE WHEN WIGGLED? NO
YES
DID THE "CNG PRESSURE SENSOR VOLTAGE TOO HIGH" CODE RETURN?
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
T TEST TC-98A CONTINUED - REPAIRING - CNG PRESSURE SENSOR VOLTAGE TOO HIGH R O U AN AND BR BODIES AB BODY B L E C O D E T E S T S
FIG. 1
AN AND BR BODIES AB BODY
FIG. 2
FIG. 3
380
FIG. 4
TEST TC-98A CONTINUED - REPAIRING - CNG PRESSURE SENSOR VOLTAGE TOO HIGH
DISCONNECT THE CNG FUEL PRESSURE SENSOR CONNECTOR.** SEE GENERAL INFO 4.0
T R O U B L E C O D E
YES
NO
T E S T S
KEY OFF, MEASURE THE CNG FUEL PRESSURE SENSOR GROUND CIRCUIT. FIG. 1 OR 2
NO
YES
MEASURE THE CNG FUEL PRESSURE SENSOR SIGNAL CIRCUIT FOR RESISTANCE. FIG. 3 OR 4
NO
YES
T TEST TC-98A CONTINUED - REPAIRING - CNG PRESSURE SENSOR VOLTAGE TOO HIGH R O U AN AND BR BODIES B L E C O D E T E S T S
FIG. 1
AB BODY
FIG. 2
382
TEST TC-98A CONTINUED - REPAIRING - CNG PRESSURE SENSOR VOLTAGE TOO HIGH
T R O U B L E C O D E T E S T S
WITH THE DRB, READ THE CNG FUEL PRESSURE SENSOR PRESSURE AND NOTE PRESSURE READING.
JUMPER THE CNG FUEL PRESSURE SIGNAL CIRCUIT TO THE SENSOR GROUND CIRCUIT. FIG. 1 OR 2
WITH THE DRB, READ THE CNG FUEL PRESSURE SENSOR PRESSURE.
DID THE CNG FUEL PRESSURE SENSOR PRESSURE DROP TO 0 WHEN JUMPERED?
YES
NO
T TEST TC-99A REPAIRING - CNG PRESSURE SENSOR VOLTAGE TOO LOW R O Perform DTC TEST Before Proceeding U AN AND BR BODIES AB BODY B L E C O D E T E S T S
FIG. 1
384
FIG. 2
T R O U B L E C O D E
DID THE "CNG PRESSURE SENSOR VOLTAGE TOO LOW" CODE RETURN?
YES
NO
T E S T S
WIGGLE THE FUEL PRESSURE SENSOR CONNECTORS AND HARNESS. SEE GENERAL INFO 4.0
WITH THE DRB, MONITOR THE FUEL PRESSURE SENSOR VOLTAGE WHILE WIGGLING HARNESS.
YES
NO
DID THE "CNG PRESSURE SENSOR VOLTAGE TOO LOW" CODE RETURN?
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
T TEST TC-99A CONTINUED - REPAIRING - CNG PRESSURE SENSOR VOLTAGE TOO LOW R O U AN AND BR BODIES B L E C O D E T E S T S
FIG. 1
AB BODY
FIG. 2
386
TEST TC-99A CONTINUED - REPAIRING - CNG PRESSURE SENSOR VOLTAGE TOO LOW
DISCONNECT THE FUEL PRESSURE SENSOR CONNNECTOR.** SEE GENERAL INFO 4.4
T R O U B L E C O D E
NO
YES
T E S T S
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
MEASURE BETWEEN THE FUEL PRESSURE SENSOR SIGNAL CIRCUIT AND THE GROUND CIRCUIT. FIG. 1 OR 2
YES
REPAIR THE FUEL PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND CIRCUIT.*
NO
YES
REPAIR THE FUEL PRESSURE SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND.*
NO
T TEST TC-99A CONTINUED - REPAIRING - CNG PRESSURE SENSOR VOLTAGE TOO LOW R O U AN AND BR BODIES B L E C O D E T E S T S
FIG. 1
AB BODY
FIG. 2
388
TEST TC-99A CONTINUED - REPAIRING - CNG PRESSURE SENSOR VOLTAGE TOO LOW
T R O U B L E C O D E T E S T S
YES
NO
T TEST TC-101A REPAIRING - FUEL PUMP (SYSTEM) RELAY CONTROL CIRCUIT R O Perform DTC TEST Before Proceeding U AB BODY AN AND BR BODIES B L E C O D E T E S T S
XJ BODY
ZJ BODY
FIG. 1
390
FIG. 2
T R O U B L E
PERFORM TEST TC-101B.
YES
NO
C O D E T E S T S
WITH THE DRB, ACTUATE THE FUEL PUMP RELAY. SEE GENERAL INFO 4.6
NO
YES
THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
WITH THE DRB, ACTUATE THE FUEL PUMP RELAY. SEE GENERAL INFO 4.6
WIGGLE THE WIRING HARNESS FROM THE RELAY TO THE POWERTRAIN CONTROL MODULE.
DID THE RELAY CLICKING STOP OR BECOME IRREGULAR WHEN WIGGLING THE WIRES? NO
YES
REPAIR CIRCUIT AS NECESSARY WHERE WIGGLING CAUSED THE CLICKING TO STOP OR BECOME IRREGULAR.*
TEST COMPLETE.*
FIG. 1
BR BODY XJ BODY
FIG. 2
FIG. 3
ZJ BODY
FIG. 4
FIG. 5
392
FIG. 6
TEST TC-101A CONTINUED - REPAIRING - FUEL PUMP (SYSTEM) RELAY CONTROL CIRCUIT
T R O U B L E C O D E
USING A VOLTMETER, MEASURE THE FUSED IGN SWITCH OUTPUT CKT AT RELAY. FIG. 1, 2, 3, 4 OR 5
NO
YES
T E S T S
MEASURE THE RESISTANCE BETWEEN TERMINALS 85 AND 86 OF THE FUEL SYSTEM RELAY. FIG. 6
NO
YES
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE GREY CONNECTOR.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE FUEL PUMP RELAY CONTROL CKT AT PCM TO GND. FIG. 1, 2, 3, 4 OR 5
YES
REPAIR THE FUEL PUMP RELAY CONTROL CIRCUIT FOR A SHORT TO GROUND.*
NO
USING AN OHMMETER, MEASURE THE RESISTANCE OF THE FUEL SYSTEM RELAY CONTROL CIRCUIT...
NO
YES
T TEST TC-101B REPAIRING - FUEL PUMP (SYSTEM) RELAY CONTROL CIRCUIT R O Perform TEST TC-101A Before Proceeding U AB BODY B L E C O D E T E S T S
AN BODY
BR BODY
FIG. 1
394
FIG. 2
T R O U B L E C O D E T E S T S
WITH THE DRB, ACTUATE THE HI PRESSURE FUEL SHUTOFF RELAY. SEE GENERAL INFO 4.6
NO
YES
THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
WITH THE DRB, ACTUATE THE HI PRESSURE FUEL SHUTOFF RELAY. SEE GENERAL INFO 4.6
WIGGLE THE WIRING HARNESS FROM THE RELAY TO THE POWERTRAIN CONTROL MODULE.
DID THE RELAY CLICKING STOP OR BECOME IRREGULAR WHILE WIGGLING THE WIRES? NO
YES
REPAIR CIRCUIT AS NECESSARY WHERE WIGGLING CAUSED THE CLICKING TO STOP OR BECOME IRREGULAR.
TEST COMPLETE.*
FIG. 1
BR BODY
FIG. 2
FIG. 3
396
FIG. 4
TEST TC-101B CONTINUED - REPAIRING - FUEL PUMP (SYSTEM) RELAY CONTROL CIRCUIT
T R O U B L E C O D E
USING A VOLTMETER, MEASURE THE FUSED IGN SWITCH OUTPUT CKT AT RELAY. FIG. 1, 2 OR 3
NO
YES
T E S T S
MEASURE THE RESISTANCE BETWEEN TERMINALS 85 & 86 OF THE FUEL SYSTEM RLY. FIG. 4
NO
YES
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE GREY CONNECTOR.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE FUEL SYSTEM RELAY CONTROL CKT AT PCM TO GROUND. FIG. 1, 2 OR 3
YES
REPAIR THE FUEL SYSTEM RELAY CONTROL CKT FOR A SHORT TO GROUND.*
NO
USING AN OHMMETER, MEASURE THE RESISTANCE OF THE FUEL SYSTEM RELAY CONTROL CIRCUIT...
NO
YES
T TEST TC-102A REPAIRING - 1/1 O2 SENSOR SLOW RESPONSE R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
TYPICAL CONNECTOR
FIG. 2
398
T R O U B L E C O D E
CHECK THE EXHAUST SYSTEM FOR LEAKS BETWEEN THE ENGINE AND THE CATALYST.
YES
NO
T E S T S
NOTE: CHECK THE EXHAUST FOR EXCESSIVE SMOKE CAUSED BY OIL OR COOLANT CONSUMPTION.
YES
NO
TURN IGNITION OFF. DISCONNECT THE 1/1 O2 SENSOR.** SEE GENERAL INFO 4.4
YES
NO
NO
YES
YES
REPAIR AS NECESSARY.*
NO
T TEST TC-103A REPAIRING - 1/1 O2 SENSOR HEATER FAILURE R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
400
YES
T R O U B L E C O D E T E S T S
NO
WAIT 3 MINUTES.
WITH THE DRB IN ACTUATOR TESTS, PERFORM THE O2 SENSOR HEATER TEST.
YES
NO
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 1
T TEST TC-103A CONTINUED - REPAIRING - 1/1 O2 SENSOR HEATER FAILURE R O U TYPICAL CONNECTOR B L E C O D E T E S T S
FIG. 1
TYPICAL CONNECTOR
FIG. 2
402
T R O U B L E C O D E T E S T S
YES
NO
NO
YES
NO
YES
NO
YES
T TEST TC-104A REPAIRING - 1/2 O2 SENSOR SLOW RESPONSE R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
404
T R O U B L E C O D E
CHECK THE EXHAUST SYSTEM FOR LEAKS BETWEEN THE ENGINE AND THE CATALYST.
YES
NO
T E S T S
NOTE: CHECK THE EXHAUST FOR EXCESSIVE SMOKE CAUSED BY OIL OR COOLANT CONSUMPTION.
YES
NO
TURN IGNITION OFF. DISCONNECT THE 1/2 O2 SENSOR.** SEE GENERAL INFO 4.4
YES
NO
NO
YES
YES
REPAIR AS NECESSARY.*
NO
T TEST TC-105A REPAIRING - 1/2 O2 SENSOR HEATER FAILURE R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
8.0L CAL/MD ALL OTHERS
406
YES
T R O U B L E C O D E T E S T S
NO
WAIT 3 MINUTES.
WITH THE DRB IN ACTUATOR TESTS, PERFORM THE O2 SENSOR HEATER TEST.
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 1
T TEST TC-105A R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
408
T R O U B L E C O D E T E S T S
YES
NO
NO
YES
NO
YES
NO
YES
T TEST TC-106A REPAIRING - MULTIPLE CYLINDER MIS-FIRE R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
410
NOTE: YOU MUST REPAIR ANY NON-MISFIRE TROUBLE CODES BEFORE CONTINUING.
THIS CODE WILL ONLY SET IF THE CONDITION OCCURS DURING THE ROAD TEST.
T R O U B L E C O D E
NOTE: IN THE NEXT STEP, YOU MUST STOP IN THE MIDDLE OF YOUR ROAD TEST, KEY OFF, THEN BACK ON...
T E S T S
YES
NO
YES
NO
NO
YES
WITH A SPRAY BOTTLE SPRAY IGNITION CABLES WITH WATER AND MONITOR IGNITION PATTERN.
YES
NO
NOTE: AN INACURRATE SPEED SENSOR READING (TOO HIGH) MAY CAUSE THIS CODE TO SET INTERMITTENTLY.
AT THIS TIME, THE CONDITIONS REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 2
REFER TO GEN INFO 3.3.2 FOR ADDITIONAL INFORMATION ON INACTIVE TROUBLE CODES.*
TEST COMPLETE.*
FIG. 1
3.9L ENGINES
FIG. 2
5.2L AND 5.9L ENGINES
FIG. 3
412
FIG. 4
T R O U B L E
REPAIR AS NECESSARY.*
NO
YES
C O D E T E S T S
TURN IGNITION OFF. CONNECT A SUITABLE ENGINE ANALYZER,THEN START ENGINE AND LET IDLE FOR 2 MINUTES.
NO
YES
MOMENTARILY REMOVE & REINSTALL SPARK PLUG WIRES FROM IGNITION COIL OR DISTRIBUTOR ONE AT A TIME.
IS THE OPEN CIRCUIT SECONDARY VOLTAGE AT LEAST 25KV FOR EACH WIRE? YES
NO
TURN ENGINE OFF. REMOVE ALL SPARK PLUGS & ASD RELAY.
USING APPROPRIATE PRESSURE GAUGE, TEST ALL CYLINDERS FOR PROPER COMPRESSION.
DO ALL CYLINDERS HAVE A MINIMUM COMPRESSION OF 100 PSI AND WITHIN 25% OF EACH OTHER? YES
NO
T TEST TC-106A R O U B L E C O D E T E S T S
FIG. 1
414
T R O U B L E C O D E
DEPRESS PARKING BRAKE AND PUT SHIFT LEVER IN THE NEUTRAL POSITION. READ VACUUM GAUGE.
DOES THE VACUUM GAUGE READ AT LEAST 13 INCHES. OF VACUUM? FIG. 1 YES
NO
T E S T S
WHILE MONITORING THE VACUUM GAUGE, SNAP THE THROTTLE OPEN AND CLOSED.
NO
YES
WARNING: THE FUEL SYSTEM MUST BE OPENED AND MAY BE UNDER PRESSURE. SEE GENERAL INFO 9.1
CONNECT A FUEL PRESSURE GAUGE TO THE FUEL RAIL. SEE APPROPRIATE SERVICE MANUAL.
TURN IGNITION ON. WITH THE DRB, ACTUATE THE FUEL SYSTEM TEST.
ALLOW TIME FOR FUEL PRESSURE GAUGE TO STABILIZE TO NORMAL FUEL PRESSURE.
WITH THE DRB, STOP FUEL SYSTEM TEST. MONITOR THE FUEL PRESSURE GAUGE FOR 1 MINUTE.
YES
NO
YES
NO
NOTE: AN INACCURATE SPEED SENSOR READING (TOO HIGH) MAY CAUSE THIS CODE TO SET INTERMITTENTLY.
T TEST TC-106A R O U B L E C O D E T E S T S
NOTES
416
T R O U B L E C O D E T E S T S
T TEST TC-107A REPAIRING - CYLINDER #1, #2, #3, #4, #5, #6, #7, OR #8 MISFIRE R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
2.5L ENGINES 4.0L ENGINES
FIG. 2
3.9L ENGINES 5.2L 5.9L ENGINES
FIG. 3
FIG. 4
418
FIG. 5
TEST TC-107A REPAIRING - CYLINDER #1, #2, #3, #4, #5, #6, #7, OR #8 MISFIRE
Perform DTC TEST Before Proceeding
NOTE: YOU MUST REPAIR MULTIPLE MISFIRE OR ANY NON-MISFIRE TROUBLE CODES FIRST.
T R O U B L E C O D E
NOTE: READ FIGURE 1 TO GET A CLEAR UNDERSTANDING OF THIS CODE BEFORE PROCEEDING.
NO
REPAIR AS NECESSARY.*
YES
T E S T S
TURN IGNITION OFF. CONNECT A SUITABLE ENGINE ANALYZER,THEN START ENGINE AND LET IDLE FOR 2 MINUTES.
NO
YES
MOMENTARILY REMOVE & REINSTALL EACH PLUG WIRE FROM THE IGNITION COIL OR DISTRIBUTOR...
IS THE OPEN CIRCUIT SECONDARY VOLTAGE AT LEAST 25KV FOR EACH WIRE? YES
NO
WITH A SPRAY BOTTLE SPRAY THE IGNITION CABLES WITH WATER AND MONITOR IGNITION PATTERN.
YES
NO
TURN ENGINE OFF. REMOVE ALL SPARK PLUGS & ASD RELAY.
USING APPROPRIATE PRESSURE GAUGE, TEST ALL CYLINDERS FOR PROPER COMPRESSION.
DO ALL CYLINDERS HAVE A MINIMUM COMPRESSION OF 100 PSI AND WITHIN 25% OF EACH OTHER? YES
NO
T TEST TC-107A R O U B L E C O D E T E S T S
CONTINUED - REPAIRING - CYLINDER #1, #2, #3, #4, #5, #6, #7, OR #8 MISFIRE
420
TEST TC-107A CONTINUED - REPAIRING - CYLINDER #1, #2, #3, #4, #5, #6, #7, OR #8 MISFIRE
T R O U B L E C O D E T E S T S
MONITOR SCOPE PATTERN AND ENGINE RPM WHEN INJECTOR KILL IS ACTUATED.
YES
INSPECT LOW CYLINDER FOR MECHANICAL PROBLEMS, IF OK. REPLACE APPROPRIATE INJECTOR.*
NO
TURN ENGINE OFF, CONNECT A VACUUM GAUGE TO MANIFOLD VACUUM. START ENGINE, LET IDLE.
PARKING BRAKE ON GEAR SHIFT IN THE NEUTRAL POSITION. READ VACUUM GAUGE.
NO
YES
INSPECT VALVE TRAIN AND TIMING OF THE CYLINDER WITH THE TROUBLE CODE.
NO
YES
NOTE: AN INACCURATE SPEED SENSOR READING (TOO HIGH) MAY CAUSE THIS CODE TO SET INTERMITTENTLY.
NOTE: CHECK TSBS AND FLASH UPDATES THAT MAY APPLY TO THIS CODE BEFORE NEXT REPAIR.
T TEST TC-112A REPAIRING - CATALIYTIC CONVERTER EFFICIENCY FAILURE R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
422
NOTE: ANY OTHER O2 SENSOR TROUBLE CODES OR T.S.B.S SHOULD BE REPAIRED BEFORE PROCEEDING.
YES
T R O U B L E C O D E T E S T S
NO
CHECK THE EXHAUST SYSTEM FOR LEAKS BETWEEN THE ENGINE AND THE 1/2 O2 SENSOR.
YES
NO
NOTE: CHECK THE EXHAUST FOR EXCESSIVE SMOKE FROM INTERNAL OIL OR COOLANT LEAKS.
YES
NO
HAS THE DOWNSTREAM OXYGEN SENSOR BEEN REPLACED WITHIN THE LAST 5000 MILES? YES
NO
HAS THE UPSTREAM OXYGEN SENSOR BEEN REPLACED WITHIN THE LAST 5000 MILES? NO
YES
T TEST TC-113A REPAIRING - EVAP PURGE FLOW MONITOR FAILURE R O Perform TEST DTC Before Proceeding U 1996 2.5/4.0/5.2/5.9/8.0L Jeep and Truck Engine Publication No. 81-699-96103 B TSB 26-06-97 June, 1997 L E C O D E T E S T S
FIG. 1
WITHOUT LDP
WITH LDP
424
T R O U B L E C O D E T E S T S
NO
YES
START ENGINE. ALLOW ENGINE TO REACH NORMAL OPERATING TEMPERATURE (ABOVE 170 DEG.).
DISCONNECT THE PURGE VACUUM HOSE AT THE SOLENOID THAT GOES TO THE CANISTER.
START THE ENGINE. THERE SHOULD BE NO FLOW THROUGH THE SOLENOID FROM 1 TO 2 MINUTES.
IS THE PURGE SOLENOID ALLOWING VACUUM THROUGH THE SOLENOID WITHIN 1 MINUTE? NO
YES
IS PURGE SOLENOID ALLOWING VACUUM TO CYCLE THROUGH INTERMITTENTLY AT A STEADY RATE? YES
NO
NOTE: IN THE NEXT STEPS, DO NOT USE MORE THAN FIVE (5) PSI.
KEY OFF, ATTEMPT TO BLOW AIR THROUGH VACUUM LINE THAT GOES TO CANISTER.
YES
NO
T TEST TC-113A CONTINUED - REPAIRING - EVAP PURGE FLOW MONITOR FAILURE R O Perform TEST DTC Before Proceeding U AB BODY AN BODY 1996 2.5/4.0/5.2/5.9/8.0L Jeep and Truck Engine Publication No. 81-699-96103 B TSB 26-06-97 June, 1997 L E C O D E T E S T S
FIG. 1
BR BODY XJ BODY
FIG. 2
FIG. 3
ZJ 4.0L ZJ 5.2L
FIG. 4
FIG. 5
426
FIG. 6
T R O U B L E C O D E
CONNECT A VACUUM GAUGE TO THE VACUUM HOSE THAT GOES TO THE THROTTLE BODY. FIG.1,2,3,4,5 OR 6
NO
YES
T E S T S
RECONNECT THE VACUUM LINE FROM THE THROTTLE BODY TO THE EVAP SOLENOID. FIG.1,2,3,4,5 OR 6
CONNECT A VACUUM GAUGE TO THE CANISTER SIDE OF THE EVAP SOLENOID. FIG.1,2,3,4,5 OR 6
NO
YES
CONNECT AN AUXILIARY VACUUM SUPPLY TO THE HOSE GOING TO THE CANISTER. ACHIEVE > 2" OF VACUUM.
NO
YES
YES
REPAIR AS NECESSARY.*
NO
YES
NO
T TEST TC-113B CONTINUED - REPAIRING - EVAP PURGE FLOW MONITOR FAILURE R O Perform TEST TC-113A Before Proceeding U AB BODY AN BODY 1996 2.5/4.0/5.2/5.9/8.0L Jeep and Truck Engine Publication No. 81-699-96103 B TSB 26-06-97 June, 1997 L E C O D E T E S T S
FIG. 1
BR BODY XJ BODY
FIG. 2
FIG. 3
ZJ 4.0L ZJ 5.2L
FIG. 4
FIG. 5
428
FIG. 6
T R O U B L E C O D E
ATTEMPT TO BLOW AIR THROUGH THE VACUUM LINE THAT GOES TO THE CANISTER.
NO
YES
T E S T S
NO
YES
T TEST TC-113C REPAIRING - EVAP PURGE FLOW MONITOR FAILURE R O Perform TEST TC-113A Before Proceeding U NOTES B L E C O D E T E S T S
430
REMOVE THE PURGE SOLENOID AND TAP THE PORTS AGAINST A CLEAN SOLID SURFACE.
T R O U B L E C O D E T E S T S
NO
YES
NO
CLEAN OUT LINE AND REPLACE THE EVAP PURGE SOLENOID AND CANISTER.*
T TEST TC-114A REPAIRING - P/N SWITCH STUCK IN PARK OR IN GEAR R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
432
T R O U B L E C O D E T E S T S
WHILE MOVING GEAR SELECTOR IN & OUT OF PARK & REVERSE, WATCH THE DRB DISPLAY.
NO
YES
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1
INSPECT THE WIRING AND CONNECTORS RELATING TO PARK NEUTRAL POSITION SWITCH.
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
FIG. 1
AN AND XJ BODIES
FIG. 2
BR AND ZJ BODIES
FIG. 3
434
T R O U B L E C O D E
T E S T S
OBSERVE OHMMETER DISPLAY WHILE MOVING GEAR SELECTOR FROM PARK TO REVERSE AND BACK TO PARK. DID THE DISPLAY SWITCH FROM BELOW 10.0 OHMS TO ABOVE 10.0 OHMS?
MEASURE THE RESISTANCE BETWEEN THE P/N SWITCH SENSE CIRCUIT AND GROUND. FIG. 1, 2 OR 3.
YES
NO
NO
YES
MEASURE THE RESISTANCE BETWEEN THE P/N SWITCH SENSE CIRCUIT AND GROUND. FIG. 1, 2 OR 3.
YES
NO
FIG. 1
BR BODY XJ BODY 4.0L AUTO
FIG. 2
FIG. 3
XJ BODY ALL OTHERS ZJ BODY
FIG. 4
FIG. 5
436
FIG. 6
T R O U B L E C O D E T E S T S
DISCONNECT THE PARK/NEUTRAL POSITION SWITCH CONNECTOR.** SEE GENERAL INFO 4.7
FROM THE PCM CONNECTOR TO THE P/N SWITCH CONNECTOR. FIG. 1,2,3,4,5 OR 6
YES
NO
T TEST TC-115A REPAIRING - POWER STEERING SWITCH FAILURE R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
XJ BODY
FIG. 1
FIG. 2
438
T R O U B L E C O D E T E S T S
START ENGINE. WITH THE DRB, MONITOR THE P/S SW. TURN THE STEERING WHEEL TO BOTH EXTREMES.
NO
YES
YES
REPAIR AS NECESSARY.*
NO
WITH THE DRB MONITOR THE PS SWITCH STATE, WHILE WIGGLING THE HARNESS
YES
NO
TEST COMPLETE.*
439
T TEST TC-115A R O U B L E C O D E T E S T S
XJ BODY
FIG. 1
XJ BODY
FIG. 2
440
KEY OFF. DISCONNECT THE POWER STEERING PRESSURE SWITCH.** SEE GENERAL INFO 4.7
CONNECT A JUMPER WIRE TO THE POWER STEERING PRESSURE SWITCH CIRCUIT. FIG. 1
T R O U B L E C O D E T E S T S
NO
WITH AN OHMMETER, MEASURE THE P/S PRESSURE SW CKT FROM THE PCM TO THE CONN. FIG. 2
NO
YES
USING AN OHMMETER, MEASURE THE P/S PRESSURE SWITCH CKT AT THE P/S SW TO GROUND. FIG. 1
YES
REPAIR THE POWER STEERING PRESSURE SWITCH CIRCUIT FOR A SHORT TO GROUND.*
NO
FIG. 1
442
T R O U B L E C O D E T E S T S
USING AN OHMMETER, MEASURE THE GROUND CIRCUIT AT P/S PRESSURE SW CONN. FIG. 1
NO
YES
T TEST TC-118A REPAIRING - FUEL SYSTEM 1/1 RICH R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
FIG. 1
444
NOTE: ANY OTHER O2 SENSOR TROUBLE CODES OR T.S.B.S SHOULD BE REPAIRED BEFORE PRODEEDING.
YES
T R O U B L E C O D E T E S T S
NO
NO TEST COMPLETE. *
YES
WITH THE DRB, READ THE LONG TERM ADAPTIVE MEMORY VALUE.
NO
THE CONDITION REQUIRED TO SET THIS TROUBLE CODE IS NO LONGER PRESENT. TEST COMPLETE.*
YES
T TEST TC-118B REPAIRING - FUEL SYSTEM 1/1 RICH R O Perform TEST TC-118A Before Proceeding U 5.9L HD, 8.0L HD AND 8.0L CAL/MD B L E C O D E T E S T S
ALL CNG
ALL OTHERS
446
Using the test schematic as a guide, make sure all the wiring and connectors are okay. Perform each of the following tests in the order listed below. If a test passes, continue to the next test until the problem is found. Fuel Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-3A Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-4A Throttle Position Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST-NTC5A MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-6A Evaporative Emission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-12A Engine Mechanical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-22A
T R O U B L E C O D E T E S T S
T TEST TC-119A REPAIRING - FUEL SYSTEM 1/1 LEAN R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
FIG. 1
448
NOTE: VERY LOW FUEL LEVEL COULD CAUSE THIS TROUBLE CODE TO SET. MAKE SURE TANK IS AT LEAST 1/4 FULL
DID THE VEHICLE RUN OUT OF FUEL SHORTLY BEFORE COMING IN?
YES
T R O U B L E C O D E
NO
YES
NO
T E S T S
YES
NO
IS THE 1/1 O2S STATE SWITCHING BETWEEN "LEAN-CENTER-RICH" TWICE OR MORE IN 20 SECONDS? NO
THE CONTITION YES REQUIRED TO SET THIS TROUBLE CODE IS NO LONGER PRESENT. TEST COMPLETE.*
WITH THE DRB, READ THE LONG TERM ADAPTIVE MEMORY VALUES.
ARE ANY OF THE LONG TERM ADAPTIVE MEMORY BETWEEN +18% AND +25% ?
NO
THE CONDITION REQUIRED TO SET THIS TROUBLE CODE IS NO LONGER PRESENT. TEST COMPLETE.*
YES
T TEST TC-119B REPAIRING - FUEL SYSTEM 1/1 LEAN R O Perform TEST TC-119A Before Proceeding U 5.9L HD, 8.0L HD AND 8.0L CAL/MD B L E C O D E T E S T S
ALL CNG
ALL OTHERS
450
Using the test schematic as a guide, make sure all the wiring and connectors are okay. Perform each of the following tests in the order listed below. If a test passes, continue to the next test until the problem is found. Fuel Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-3A Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-4A Throttle Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-5A MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-6A Evaporative Emission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-13A Engine Mechanical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST-NTC22A
T R O U B L E C O D E T E S T S
T TEST TC-120A REPAIRING - FUEL SYSTEM 2/1 RICH R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
FIG. 1
452
NOTE: ANY OTHER O2 SENSOR TROUBLE CODES OR T.S.B.S MUST BE REPAIRED BEFORE PROCEEDING.
YES
T R O U B L E C O D E T E S T S
NO
NO TEST COMPLETE. *
YES
WITH THE DRB, READ THE LONG TERM ADAPTIVE MEMORY VALUE.
NO
THE CONDITION REQUIRED TO SET THIS TROUBLE CODE IS NO LONGER PRESENT. TEST COMPLETE.*
YES
T TEST TC-120B REPAIRING - FUEL SYSTEM 2/1 RICH R O Perform TEST TC-120A Before Proceeding 5.9L HD, 8.0L HD AND 8.0L CAL/MD U B L E C O D E T E S T S
454
Using the test schematic as a guide, make sure all the wiring and connectors are okay. Perform each of the following tests in the order listed below. If a test passes, continue to the next test until the problem is found. Fuel Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-3A Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-2A Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-4A MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-6A Engine Mechanical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-22A
T R O U B L E C O D E T E S T S
T TEST TC-121A REPAIRING - FUEL SYSTEM 2/1 LEAN R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
FIG. 1
456
NOTE: VERY LOW FUEL LEVEL COULD CAUSE THIS TROUBLE CODE TO SET. MAKE SURE TANK IS AT LEAST 1/4 FULL
DID THE VEHICLE RUN OUT OF FUEL SHORTLY BEFORE COMING IN?
YES
T R O U B L E C O D E
NO
YES
NO
T E S T S
YES
NO
IS THE 2/1 O2S STATE SWITCHING BETWEEN "LEAN-CENTER-RICH" TWICE OR MORE IN 20 SECONDS? NO
THE CONTITION YES REQUIRED TO SET THIS TROUBLE CODE IS NO LONGER PRESENT. TEST COMPLETE.*
WITH THE DRB, READ THE LONG TERM ADAPTIVE MEMORY VALUES.
ARE ANY OF THE LONG TERM ADAPTIVE MEMORY BETWEEN +20% AND +32% ?
NO
THE CONDITION REQUIRED TO SET THIS TROUBLE CODE IS NO LONGER PRESENT. TEST COMPLETE.*
YES
T TEST TC-121B REPAIRING - FUEL SYSTEM 2/1 LEAN R O Perform TEST TC-120A Before Proceeding 5.9L HD, 8.0L HD AND 8.0L CAL/MD U B L E C O D E T E S T S
458
Using the test schematic as a guide, make sure all the wiring and connectors are okay. Perform each of the following tests in the order listed below. If a test passes, continue to the next test until the problem is found. Fuel Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-3A Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-2A Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-4A MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-6A Engine Mechanical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-22A
T R O U B L E C O D E T E S T S
T TEST TC-122A REPAIRING - 2/1 O2 SENSOR SLOW RESPONSE R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
FIG. 1
TYPICAL CONNECTOR
FIG. 2
460
T R O U B L E C O D E
CHECK THE EXHAUST SYSTEM FOR LEAKS BETWEEN THE ENGINE AND THE CATALYST.
YES
NO
T E S T S
NOTE: CHECK THE EXHAUST FOR EXCESSIVE SMOKE CAUSED BY OIL OR COOLANT CONSUMPTION.
YES
NO
KEY OFF. DISCONNECT THE 2/1 OXYGEN SENSOR.** SEE GENERAL INFO 4.4
YES
NO
NO
YES
NO
REPAIR AS NECESSARY.*
YES
T TEST TC-124A REPAIRING - 2/1 O2 SENSOR HEATER FAILURE R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
FIG. 1
462
T R O U B L E C O D E T E S T S
WITH THE DRB, MONITOR THE 2/1 O2 SENSOR VOLTAGE FOR A FEW MINUTES.
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 1
T TEST TC-124A CONTINUED - REPAIRING - 2/1 O2 SENSOR HEATER FAILURE R O U TYPICAL CONNECTOR B L E C O D E T E S T S
FIG. 1
TYPICAL CONNECTOR
FIG. 2
464
DISCONNECT THE 2/1 O2 SENSOR CONNECTOR AND INSPECT ALL TERMINALS.** SEE GENERAL INFO 4.4
T R O U B L E
REPAIR AS NECESSARY.*
YES
NO
C O D E T E S T S
YES
NO
USING AN OHMMETER, MEASURE THE 2/1 O2 SENSOR HEATER ELEMENT FROM THE ASD RELAY...
NO
YES
NO
YES
T TEST TC-126A REPAIRING - 1/2 O2 SENSOR SHORTED TO VOLTAGE R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
466
T R O U B L E C O D E T E S T S
NO
YES
NO
YES
T TEST TC-126A R O U B L E C O D E T E S T S
468
T R O U B L E C O D E
DID THE 1/2 O2 SENSOR VOLTAGE GO ABOVE 1.2 VOLTS AT ANY TIME?
YES
REPAIR THE HARNESS OR CONNECTOR THAT HAS THE INTERMITTENT SHORT TO VOLTAGE.*
NO
T E S T S
AT THIS TIME, THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT.
TURN KEY OFF. DISCONNECT THE PCM AND THE 1/2 O2 SENSOR CONNECTOR.**
YES
REPAIR AS NECESSARY.*
NO
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
T TEST TC-128A REPAIRING - CLOSED LOOP TEMP NOT REACHED R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
FIG. 1
470
NO
T R O U B L E C O D E T E S T S
YES
KEY OFF, DISCONNECT THE ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR.** SEE GENERAL INFO 4.4
YES
NO
NO
YES
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
YES
NO
T TEST TC-132A REPAIRING - TPS VOLTAGE DOES NOT AGREE WITH MAP R O Perform TEST DTC Before Proceeding U ZJ BODY B L E C O D E T E S T S
ALL OTHERS
FIG. 1
472
TEST TC-132A REPAIRING - TPS VOLTAGE DOES NOT AGREE WITH MAP
Perform TEST DTC Before Proceeding
T R O U B L E C O D E T E S T S
YES
NO
YES
NO
START ENGINE.
DID THE MAP SENSOR VOLTAGE DROP FROM ABOVE 3.5 VOLTS TO BELOW 2.0 VOLTS?
NO
YES
T TEST TC-132A CONTINUED - REPAIRING - TPS VOLTAGE DOES NOT AGREE WITH MAP R O U AB, AN, BR AND XJ BODIES B L E C O D E T E S T S
FIG.1
BR DIESEL
FIG. 2
ZJ BODY
FIG. 3
474
TEST TC-132A CONTINUED - REPAIRING - TPS VOLTAGE DOES NOT AGREE WITH MAP
T R O U B L E C O D E
NOTE: TP SENSOR GND CIRCUIT AND THE 5-VOLT SUPPLY CKT SWITCHED WILL CAUSE THIS CODE TO APPEAR.
T E S T S
YES
NO
YES
NO
YES
NO
ALL OTHERS
FIG.1
476
TEST TC-132A CONTINUED - REPAIRING - TPS VOLTAGE DOES NOT AGREE WITH MAP
WHILE MONITORING THE DRB, SLOWLY OPEN AND CLOSE THE THROTTLE PLATE.
T R O U B L E C O D E T E S T S
NOTE: YOU MUST MOVE THE LINKAGE VERY SLOWLY WHILE LOOKING FOR A JUMP IN VOLTAGE.
NO
YES
WHILE MONITORING THE DRB, OPEN THE THROTTLE PLATE TO WIDE OPEN THROTTLE.
NO
YES
USING THE SCHEMATIC AS A GUIDE, WIGGLE THE TP SENSOR HARNESS AND CONNECTORS TO PCM.
WHILE MONITORING THE DRB, OBSERVE FOR THE TP SENSOR VOLTAGE TO CHANGE.
YES
NO
TEST COMPLETE.*
T TEST TC-138A REPAIRING - TARGET IDLE NOT REACHED R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
FIG.1
AB, AN, BR AND XJ BODIES
ZJ BODY
478
T R O U B L E C O D E
ENSURE THE THROTTLE PLATE IS FULLY CLOSED AND AGAINST ITS STOP.
NO
REPAIR AS NECESSARY.*
YES
T E S T S
START ENGINE, ALLOW TO IDLE FOR 60 SECONDS, IF THIS IS AN AUTO TRANS, PUT IN DRIVE.
YES
NO
FOR THIS TEST TO BE VALID THE ENGINE MUST NOT HAVE ANY VACUUM LEAKS.
YES
REPAIR AS NECESSARY.*
NO
WITH THE DRB IN SYSTEM TESTS, PERFORM THE IAC WIGGLE TEST.
THE IDLE SPEED SHOULD RAISE AND LOWER WITH THE DISPLAY.
NO
YES
T TEST TC-138A R O U B L E C O D E T E S T S
FIG.1
AB, AN, BR AND XJ BODIES
ZJ BODY
480
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG.1
T R O U B L E C O D E T E S T S
YES
REPAIR AS NECESSARY.*
NO
START ENGINE. WITH THE DRB IN SYSTEM TESTS, PERFORM THE IAC WIGGLE TEST.
THE IDLE SPEED SHOULD RAISE AND LOWER WITH THE DISPLAY.
NO
YES
WIGGLE THE WIRING HARNESS FROM THE IAC MOTOR TO THE POWERTRAIN CONTROL MODULE.
YES
NO
TEST COMPLETE.*
T TEST TC-138B R O U B L E C O D E T E S T S
ZJ BODY
482
DISCONNECT THE PCV VALVE HOSE FROM THE INTAKE MANIFOLD AND CAP PORT AT INTAKE MANIFOLD.
T R O U B L E C O D E T E S T S
INSTALL MILLER TOOL #6714 TO THE PURGE HOSE PORT OF THE THROTTLE BODY.
START ENGINE. ALLOW ENGINE TO REACH OPERATING TEMPERATURE. (ABOVE 180 DEG.)
NO
YES
WARNING: CLEAN THE THROTTLE BODY IN A WELL VENTILATED AREA AND WEAR RUBBER GLOVES.
WHILE HOLDING THE THROTTLE OPEN, SPRAY ENTIRE THROTTLE BODY BORE WITH MOPAR PARTS CLEANER.
USING A SOFT SCUFF PAD, CLEAN THE THROTTLE BODY BORE AND THROTTLE PLATE.
USING COMPRESSED AIR, DRY THE THROTTLE BODY AND INSTALL THROTTLE BODY ON MANIFOLD.
START ENGINE AND LET IDLE. WITH THE DRB, ACTUATE THE MIN. AIR FLOW.
YES
NO
TEST COMPLETE.*
T TEST TC-140A REPAIRING - EGR SYSTEM FAILURE R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
484
T R O U B L E C O D E T E S T S
DISCONNECT THE EGR SOLENOID VACUUM SUPPLY AT THE EGR SOLENOID. FIG. 1
NO
YES
RECONNECT THE EGR SOLENOID VACUUM SUPPLY AT THE EGR SOLENOID. FIG. 1
NO
YES
AFTER 40 SECONDS OF FLOW OPERATION. RECORD THE VACUUM READING TO THE EGR VALVE.
NO
YES
RESELECT #3 (FLOW) FOR 40 SECONDS. CONNECT A VACUUM PUMP TO THE VACUUM PUMP SIDE OF THE...
VACUUM SUPPLY LINE TO THE EGR VALVE VACUUM REGULATOR SOLENOID AND APPLY 20" OF VACUUM.
MONITOR VACUUM FOR ONE MINUTE. DOES VACUUM DROP BELOW 8" OF VACUUM? NO
YES
NOTE: IS NO UP ON THE
INTAKE AIR TEMP SENSOR, EGR TUBE, INTAKE AND EXHAUST MANIFOLDS.
T TEST TC-140A R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
486
T R O U B L E C O D E
YES REPLACE INTAKE AIR TEMPERATURE SENSOR.*
TURN IGNITION OFF. REMOVE THE INTAKE AIR TEMP SENSOR AND INSPECT SENSOR FOR HEAVY SOOTING.
DOES THE INTAKE AIR TEMPERATURE SENSOR HAVE A HEAVY SOOT ACCUMULATION? NO
T E S T S
USING A VOLTMETER, MEASURE THE VOLTAGE TO THE EGR SOLENOID AT THE CONNECTOR.
NO
YES
T TEST TC-141A REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20 PSI R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
488
TEST TC-141A REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20 PSI
Perform TEST DTC Before Proceeding
YES
T R O U B L E C O D E T E S T S
NO
NOTE: YOU MAY BE REMOVING THE TRANS CONTROL RELAY DURING THIS TEST...
START ENGINE.
APPLY BRAKES. WITH THE DRB, READ THE GOVERNOR PRESSURE SENSOR. PLACE GEAR SELECT LEVER IN DRIVE. IS THE GOVERNOR PRESSURE ABOVE 3 PSI? YES PERFORM TEST TC-141B.
NO
PUT GEAR SELECT LEVER IN PARK. WITH ENGINE STILL RUNNING, REMOVE THE TRANS CONTROL RELAY.
APPLY BRAKES. PLACE GEAR SELECT LEVER IN DRIVE. IS THE GOVERNOR PRESSURE BETWEEN 40 AND 55 PSI? NO PERFORM TEST TC-141C.
YES
T TEST TC-141A R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
490
- REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20 TEST TC-141A CONTINUED PSI
WHILE MONITORING TARGET GOVERNOR PRESSURE AND ACTUAL GOVERNOR PRESSURE WITH THE DRB...
T R O U B L E C O D E
NOTE: ACTUAL GOVERNOR PRESSURE SHOULD BE WITHIN 5 PSI OF TARGET WITHIN 3 SECONDS.
THE CONDITIONS YES REQUIRED TO SET THIS CODE ARE NOT PRESENT AT THIS TIME. FIG. 1 AND 2
NO
T E S T S
TEST COMPLETE.
NOTE: ACTUAL GOVERNOR PRESSURE SHOULD BE WITHIN 5 PSI OF TARGET WITHIN 3 SECONDS.
NO
YES
TEST COMPLETE.
T TEST TC-141B REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20 PSI R O Perform TEST TC-141A Before Proceeding U B L E C O D E T E S T S
FIG. 1
492
TEST TC-141B REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20 PSI
Perform TEST TC-141A Before Proceeding
KEY OFF. INSTALL A PRESSURE GAUGE AT THE GOVERNOR TEST PORT. FIG. 1
T R O U B L E C O D E
YES
NO
T E S T S
YES
NO
NO
T TEST TC-141C REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20 PSI R O Perform TEST TC-141A Before Proceeding U B L E C O D E T E S T S
FIG. 1
494
TEST TC-141C REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20 PSI
Perform TEST TC-141A Before Proceeding
T R O U B L E C O D E
T E S T S
YES
NO
TURN ENGINE OFF. INSTALL THE TRANS RELAY. DRAIN AND REMOVE THE TRANS OIL PAN.
YES
NO
START ENGINE. REMOVE THE TRANS RELAY. READ THE GAUGE PRESSURE IN DRIVE.
NO
T TEST TC-141D REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20 PSI R O Perform TEST TC-141A Before Proceeding U AB BODY AN BODY B L E C O D E T E S T S
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
496
FIG. 4
TEST TC-141D REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20 PSI
Perform TEST TC-141A Before Proceeding
T R O U B L E C O D E T E S T S
KEY ON. MEASURE THE VOLTAGE AT THE 5-VOLT SUPPLY CIRCUIT. FIG. 1, 2, 3 OR 4
NO
YES
T TEST TC-142A REPAIRING - GOVERNOR PRESSURE ABOVE 3 PSI IN GEAR WITH 0 MPH R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
498
TEST TC-142A REPAIRING - GOVERNOR PRESSURE ABOVE 3 PSI IN GEAR WITH 0 MPH
Perform TEST DTC Before Proceeding
T R O U B L E C O D E T E S T S
YES
NO
START ENGINE.
YES
NO
T TEST TC-142A R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
500
- REPAIRING - GOVERNOR PRESSURE ABOVE 3 PSI IN GEAR WITH 0 TEST TC-142A CONTINUED MPH
T R O U B L E C O D E
NOTE: ACTUAL GOVERNOR PRESSURE SHOULD BE WITHIN 5 PSI OF TARGET WITHIN 3 SECONDS.
THE CONDITIONS YES REQUIRED TO SET THIS CODE ARE NOT PRESENT AT THIS TIME. FIG. 1 AND 2
NO
T E S T S
TEST COMPLETE.
NOTE: ACTUAL GOVERNOR PRESSURE SHOULD BE WITHIN 5 PSI OF TARGET WITHIN 3 SECONDS.
NO
YES
TEST COMPLETE.
T TEST TC-142B REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20 PSI R O Perform TEST TC-142A Before Proceeding U B L E C O D E T E S T S
FIG. 1
502
TEST TC-142B REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20 PSI
Perform TEST TC-142A Before Proceeding
T R O U B L E C O D E T E S T S
YES
NO
YES
NO
NO
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
504
FIG. 4
- REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20 TEST TC-142B CONTINUED PSI
T R O U B L E C O D E T E S T S
KEY ON. MEASURE THE VOLTAGE AT THE 5-VOLT SUPPLY CIRCUIT. FIG. 1, 2, 3 OR 4
NO
YES
T TEST TC-144A REPAIRING - 1/3 O2 SENSOR SHORTED TO GROUND R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
FIG. 1
8.0L CAL/MD
506
T R O U B L E C O D E T E S T S
IF ENGINE IS WARM, TURN ENGINE OFF FOR 15 MINUTES TO ALLOW O2 SENSOR TO COOL DOWN.
YES
NO
NOTE: A SHORTED LOW CONDITION DUE TO WATER IN THE SENSOR CONNECTOR, MAY BE TEMPORARY.
DID THE 1/3 O2 SENSOR VOLTAGE CHANGE WHILE WIGGLING THE HARNESS? YES
NO
THE CONDITION REQUIRED TO SET THIS TROUBLE CODE IS NOT PRESENT AT THIS TIME.*
REPAIR THE HARNESS OR WIRING THAT HAS THE INTERMITTENT SHORT TO GROUND.*
T TEST TC-144A R O U B L E C O D E T E S T S
FIG. 1
508
YES
T R O U B L E C O D E
NO
NO
YES
T E S T S
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE CONNECTORS.** SEE GENERAL INFO 4.1
YES
NO
MEASURE THE 1/3 02 SENSOR SIGNAL CIRCUIT FROM THE PCM CONNECTOR TO GROUND. FIG. 1
YES
NO
WIGGLE THE O2 SENSOR HARNESS WHILE CHECKING RESISTANCE OF O2 SENSOR SIGNAL CIRCUIT.
NO
YES
T TEST TC-147A REPAIRING - 1/3 O2 SENSOR SHORTED TO VOLTAGE R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
FIG. 1
510
T R O U B L E C O D E T E S T S
YES
NO
WIGGLE THE 1/3 O2 SENSOR CONNECTOR AND HARNESS. SEE GENERAL INFO 4.4
DID THE 1/3 O2 SENSOR VOLTAGE GO ABOVE 1.5 VOLTS AT ANY TIME?
YES
REPAIR THE HARNESS OR CONNECTOR THAT HAS THE INTERMITTENT OPEN CIRCUIT OR SHORT TO VOLTAGE.*
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
T TEST TC-147A R O U B L E C O D E T E S T S
FIG. 1
512
YES
T R O U B L E C O D E
NO
NO
YES
T E S T S
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE CONNECTORS.** SEE GENERAL INFO 4.1
YES
NO
MEASURE THE 1/3 02 SENSOR SIGNAL CIRCUIT AT THE PCM CONNECTOR. FIG. 1
YES
NO
WIGGLE THE O2 SENSOR HARNESS WHILE CHECKING FOR VOLTAGE IN THE O2 SENSOR SIGNAL CIRCUIT.
NO
YES
T TEST TC-148A REPAIRING - TORQ CONV CLU, NO RPM DROP AT LOCKUP R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
ALL OTHERS
514
YES
T R O U B L E C O D E
NO
YES
NO
T E S T S
YES
NO
YES
NO
YES
NO
YES
NO
T TEST TC-148A R O U B L E C O D E T E S T S
FIG. 1
ALL BODIES WITH 3 SPD RH TRANS ALL OTHERS
516
TEST TC-148A CONTINUED - REPAIRING - TORQ CONV CLU, NO RPM DROP AT LOCKUP
NO
REPAIR AS NECESSARY.*
T R O U B L E C O D E
YES
YES
NO
T E S T S
NO
YES
START VEHICLE.
PERFORM THE GOV AND 3-4 SHIFT VALVE SYSTEM TEST. SELECT 4TH GEAR.
YES
NO
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
T TEST TC-148A R O U B L E C O D E T E S T S
NOTES
518
TEST TC-148A CONTINUED - REPAIRING - TORQ CONV CLU, NO RPM DROP AT LOCKUP
T R O U B L E C O D E T E S T S
KEY OFF. CONNECT A PRESSURE GAUGE TO THE TRANSMISSION COOLER OUT PORT WITH A "T" CONNECTOR.
START ENGINE.
DID THE COOLER OUT PRESSURE INCREASE WHEN THE TCC WAS ACTUATED?
YES
NO
REPAIR VALVE BODY PER SERVICE MANUAL. CHECK FOR BLOCKAGE OR LEAKS IN THE TCC HYDRAULIC CIRCUIT.*
T TEST TC-148B REPAIRING - TORQ CONV CLU, NO RPM DROP AT LOCKUP R O Perform TEST TC-148A Before Proceeding U B L E C O D E T E S T S
PERFORM THE GOV AND 3-4 SHIFT VALVE SYSTEM TEST. SELECT 4TH GEAR.
NO TEST COMPLETE.*
YES
520
ROAD TEST VEHICLE WHILE MONITORING TCC STATE AND ENGINE RPM WITH THE DRB.
DOES THE ENGINE RPM DROP WHEN THE TCC STATE GOES TO ON?
YES
AT THIS TIME, THE CONDITIONS REQUIRED TO SET THIS CODE ARE NOT PRESENT.
T R O U B L E C O D E T E S T S
NO
TEST COMPLETE.
DOES THE PAN CONTAIN EXCESSIVE DEBRIS AND/OR IS THE FLUID BURNT?
YES
NO
ROAD TEST VEHICLE WHILE MONITORING THROTTLE ANGLE WITH THE DRB.
NO TEST COMPLETE.*
YES
T TEST TC-148C R O U B L E C O D E T E S T S
NOTES
522
TEST TC-148C CONTINUED - REPAIRING - TORQ CONV CLU, NO RPM DROP AT LOCKUP
T R O U B L E C O D E T E S T S
REMOVE THE OIL PAN AND INSPECT FOR EXCESSIVE DEBRIS AND BURNT OIL.
YES
NO
AT THIS TIME, THE CONDITIONS REQUIRED TO SET THIS CODE ARE NOT PRESENT.
TEST COMPLETE.*
T TEST TC-149A REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO LOW R O Perform TEST DTC Before Proceeding U AB BODY XJ BODY B L E C O D E T E S T S
ZJ BODY
FIG. 1
524
TEST TC-149A REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO LOW
Perform TEST DTC Before Proceeding
T R O U B L E C O D E T E S T S
WITH THE DRB, READ THE FUEL LEVEL SENDING UNIT VOLTAGE.
YES
NO
USING THE SCHEMATIC, WIGGLE THE FUEL PUMP MODULE CONNECTOR & HARNESS.
WAS THERE ANY FUEL LEVEL SENDING UNIT SENSOR VOLTAGE CHANGE?
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
FIG. 1
XJ BODY
FIG. 2
ZJ BODY
FIG. 3
526
TEST TC-149A CONTINUED - REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO LOW
DISCONNECT THE FUEL PUMP MODULE CONNECTOR.** SEE GENERAL INFO 4.0
T R O U B L E C O D E
WITH THE DRB, READ THE FUEL LEVEL SENDING UNIT VOLTAGE.
YES
NO
T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
MEASURE THE FUEL LEVEL SENSOR SIGNAL CIRCUIT (OBDII) TO GROUND. FIG. 1, 2 OR 3
YES
NO
FUEL LEVEL SENSOR SIGNAL CIRCUIT (OBDII) AND THE SENSOR GROUND CKT. FIG. 1, 2 OR 3
REPAIR THE FUEL YES LEVEL SENSOR SIGNAL CIRCUIT SHORTED TO THE SENSOR GROUND CIRCUIT.*
NO
T TEST TC-150A REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO HIGH R O Perform TEST DTC Before Proceeding U AB BODY XJ BODY B L E C O D E T E S T S
ZJ BODY
FIG. 1
528
TEST TC-150A REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO HIGH
Perform TEST DTC Before Proceeding
T R O U B L E C O D E T E S T S
WITH THE DRB, READ THE FUEL LEVEL SENDING UNIT VOLTAGE.
YES
NO
USE THE SCHEMATIC AS A GUIDE AND WIGGLE THE FUEL PUMP MODULE CONNECTOR & HARNESS.
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
FIG. 1
XJ BODY
FIG. 2
ZJ BODY
FIG. 3
530
TEST TC-150A CONTINUED - REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO HIGH
DISCONNECT THE FUEL PUMP MODULE CONNECTOR.** SEE GENERAL INFO 4.4
T R O U B L E C O D E T E S T S
WITH A VOLTMETER, MEASURE THE FUEL LEVEL SIGNAL CIRCUIT FOR VOLTAGE. FIG. 1, 2 OR 3
YES
NO
CONNECT A JUMPER BETWEEN FUEL LEVEL SIGNAL (OBDII) AND SENSOR GND CKT. FIG. 1, 2 OR 3
WITH THE DRB, READ THE FUEL LEVEL SENDING UNIT VOLTAGE.
YES
NO
MOVE THE JUMPER WIRE FROM THE SENSOR GROUND TO A KNOWN GOOD GROUND. FIG. 1, 2 OR 3
WITH THE DRB, READ THE FUEL LEVEL SENDING UNIT VOLTAGE.
YES
NO
FIG. 1
XJ BODY
FIG. 2
ZJ BODY
FIG. 3
532
TEST TC-150A CONTINUED - REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO HIGH
T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.0
USING AN OHMMETER, MEASURE THE FUEL LEVEL SENSOR SIGNAL CIRCUIT (OBD II)... FIG. 1, 2 OR 3
YES
NO
T TEST TC-151A REPAIRING - FUEL LEVEL UNIT NO CHANGE OVER MILES R O Perform TEST DTC Before Proceeding U AB BODY XJ BODY B L E C O D E T E S T S
ZJ BODY
FIG. 1
534
WITH THE DRB, READ THE FUEL LEVEL SENDING UNIT VOLTAGE AND MAKE A NOTE OF VOLTAGE.
YES
T R O U B L E C O D E
NO
YES
NO
T E S T S
IS THE FUEL LEVEL SENDING UNIT VOLTAGE BETWEEN 2.5 AND 4.7 VOLTS?
NO
YES
WITH THE DRB, READ THE FUEL LEVEL SENDING UNIT VOLTAGE.
DID THE FUEL LEVEL SENDING UNIT VOLTAGE DECREASE BY AT LEAST 0.2 VOLTS? YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
XJ BODY
FIG. 1
536
TEST TC-151A CONTINUED - REPAIRING - FUEL LEVEL UNIT NO CHANGE OVER MILES
T R O U B L E C O D E T E S T S
NO
YES
IS THE FUEL LEVEL SENDING UNIT VOLTAGE BETWEEN 0.2 AND 1.0 VOLTS?
NO
AT THIS TIME THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. TEST COMPLETE.
YES
WITH THE DRB, READ THE FUEL LEVEL SENDING UNIT VOLTAGE.
DID THE FUEL LEVEL SENDING UNIT VOLTAGE INCREASE BY AT LEAST O.2 VOLTS? YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1
NO TEST COMPLETE.*
YES
REPAIR AS NECESSARY.*
T TEST TC-153A REPAIRING - BATTERY TEMP SENSOR VOLTAGE TOO LOW/TOO HIGH R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
538
TEST TC-153A REPAIRING - BATTERY TEMP SENSOR VOLTAGE TOO LOW/TOO HIGH
Perform TEST DTC Before Proceeding
WITH THE DRB, READ THE BATTERY TEMPERATURE SENSOR (BTS) VOLTAGE.
T R O U B L E C O D E T E S T S
YES
NO
YES
NO
USE THE SCHEMATIC AS A GUIDE AND WIGGLE THE BTS CONNECTOR AND HARNESS.
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1
USING THE SCHEMATIC AS A GUIDE, INSPECT THE CONNECTORS AND HARNESS WIRING.
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
T TEST TC-153A CONTINUED - REPAIRING - BATTERY TEMP SENSOR VOLTAGE TOO LOW R O U AB, AN AND BR BODIES B L E C O D E T E S T S
FIG. 1
XJ BODY
FIG. 2
ZJ BODY
FIG. 3
540
TEST TC-153A CONTINUED - REPAIRING - BATTERY TEMP SENSOR VOLTAGE TOO LOW
DISCONNECT THE BATTERY TEMPERATURE SENSOR (BTS). SEE GENERAL INFO 4.4
T R O U B L E C O D E T E S T S
NO
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
YES
NO
WITH AN OHMMETER, MEASURE THE BTS SIGNAL CIRCUIT TO SENSOR GROUND. FIG. 1, 2 OR 3
NO
YES
T TEST TC-153B REPAIRING - BATTERY TEMP SENSOR VOLTAGE TOO HIGH R O Perform TEST TC-153A Before Proceeding U AB, AN AND BR BODIES XJ BODY B L E C O D E T E S T S
FIG. 1
ZJ BODY
FIG. 2
AB, AN AND BR BODIES
FIG. 3
XJ BODY ZJ BODY
FIG. 4
FIG. 5
542
FIG. 6
DISCONNECT THE BATTERY TEMPERATURE SENSOR (BTS).** SEE GENERAL INFO 4.4
T R O U B L E C O D E
USING A VOLTMETER, MEASURE THE VOLTAGE OF THE SENSOR GROUND CIRCUIT. FIG. 1, 2 OR 3
YES
NO
T E S T S
CONNECT A JUMPER ACROSS THE SENSOR SIGNAL AND THE SENSOR GROUND. FIG. 1, 2 OR 3
NO
MOVE THE JUMPER WIRE FROM THE SENSOR GROUND TO AN ENGINE GROUND. FIG. 1, 2 OR 3
YES
NO
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
YES
NO
T TEST TC-155A REPAIRING - 1/1 O2 SENSOR SHORTED TO GROUND R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
FIG. 1
544
T R O U B L E C O D E T E S T S
IF ENGINE IS WARM, TURN ENGINE OFF FOR 15 MINUTES TO ALLOW O2 SENSOR TO COOL DOWN.
YES
NO
NOTE: A SHORTED LOW CONDITION DUE TO WATER IN THE SENSOR CONNECTOR, MAY BE TEMPORARY.
NO
THE CONDITION REQUIRED TO SET THIS TROUBLE CODE IS NOT PRESENT AT THIS TIME.*
YES
REPAIR THE HARNESS OR WIRING THAT HAS THE INTERMITTENT SHORT TO GROUND.*
T TEST TC-155A R O U B L E C O D E T E S T S
FIG. 1
546
YES
T R O U B L E C O D E
NO
NO
YES
T E S T S
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE CONNECTORS.** SEE GENERAL INFO 4.1
YES
NO
MEASURE THE 1/1 02 SENSOR SIGNAL CIRCUIT FROM THE PCM CONNECTOR TO GROUND. FIG. 1
YES
NO
WIGGLE THE O2 SENSOR HARNESS WHILE CHECKING RESISTANCE OF O2 SENSOR SIGNAL CIRCUIT.
NO
YES
T TEST TC-156A REPAIRING - 1/2 O2 SENSOR SHORTED TO GROUND R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
FIG. 1
548
T R O U B L E C O D E T E S T S
IF ENGINE IS WARM, TURN ENGINE OFF FOR 15 MINUTES TO ALLOW O2 SENSOR TO COOL DOWN.
YES
NO
NOTE: A SHORTED LOW CONDITION DUE TO WATER IN THE SENSOR CONNECTOR, MAY BE TEMPORARY.
DID THE 1/2 O2 SENSOR VOLTAGE CHANGE WHILE WIGGLING THE HARNESS? YES
NO
THE CONDITION REQUIRED TO SET THIS TROUBLE CODE IS NOT PRESENT AT THIS TIME.*
REPAIR THE HARNESS OR WIRING THAT HAS THE INTERMITTENT SHORT TO GROUND.*
T TEST TC-156A R O U B L E C O D E T E S T S
FIG. 1
550
YES
T R O U B L E C O D E
NO
NO
YES
T E S T S
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE CONNECTORS.** SEE GENERAL INFO 4.1
YES
NO
MEASURE THE 1/2 02 SENSOR SIGNAL CIRCUIT FROM THE PCM CONNECTOR TO GROUND. FIG. 1
YES
NO
WIGGLE THE O2 SENSOR HARNESS WHILE CHECKING RESISTANCE OF O2 SENSOR SIGNAL CIRCUIT.
NO
YES
T TEST TC-157A REPAIRING - INTERMITTENT LOSS OF CMP OR CKP R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
FIG. 1
552
T R O U B L E C O D E T E S T S
YES
NO
WITH DRB, CHECK THE DISTRIBUTOR POSITION WITH SET SYNC SIGNAL UNDER MISC. FUNCTIONS.
NO
SET DISTRIBUTOR POSITION WITH DRB USING STEPS GIVEN IN TEST NS-8A.*
YES
T TEST TC-157A CONTINUED - REPAIRING - INTERMITTENT LOSS OF CMP OR CKP R O U AB, AN, BR, AND XJ BODIES B L E C O D E T E S T S
FIG. 1
ZJ BODY
FIG. 2
554
NOTE: CMP OR CKP SIGNAL LOSS CAN BE DETECTED BY A RPM CHANGE, TROUBLE CODE, OR...
T R O U B L E C O D E
DO YOU WANT TO DIAGNOSE CMP OR CKP SIGNAL LOSS WITH AN OSCILLOSCOPE? YES
NO
T E S T S
AT THE CMP SENSOR, BACKPROBE THE SENSOR SIGNAL CKT WITH THE VOLTAGE LEAD. FIG. 1 OR 2
START THE ENGINE AND OBSERVE THE CMP SENSOR VOLTAGE PATTERN ON THE SCOPE.
NO
YES
DISCONNECT THE CMP SENSOR CONNECTOR. INSPECT ALL TERMINALS.** SEE GENERAL INFO 4.4
YES
REPAIR AS NECESSARY.*
NO
DISCONNECT THE PCM BLACK CONNECTOR. INSPECT ALL TERMINALS.** SEE GENERAL INFO 4.1
YES
REPAIR AS NECESSARY.*
NO
T TEST TC-157A CONTINUED - REPAIRING - INTERMITTENT LOSS OF CMP OR CKP R O U AB, AN, BR AND XJ BODIES ZJ BODY B L E C O D E T E S T S
FIG. 1
AB, AN AND BR BODIES XJ BODY
FIG. 2
FIG. 3
ZJ BODY
FIG. 4
FIG. 5
556
AT THE PCM, BACKPROBE THE CMP SENSOR SIGNAL CKT WITH THE VOLTAGE LEAD. FIG. 1 OR 2
T R O U B L E C O D E
WHILE OBSERVING THE SCOPE PATTERN, WIGGLE THE CMP SENSOR CIRCUIT FROM THE SENSOR TO PCM.
WERE ANY SIGNALS MISSING WHEN THE WIGGLE TEST WAS CONDUCTED?
YES
NO
T E S T S
AT THE CRANKSHAFT POSITION SENSOR, BACKPROBE THE CKP SENSOR SIGNAL CIRCUIT...
START THE ENGINE AND OBSERVE THE CKP SENSOR VOLTAGE PATTERN ON THE SCOPE.
NO
YES
DISCONNECT THE CKP SENSOR. INSPECT ALL TERMINALS.** SEE GENERAL INFO 4.4
YES
REPAIR AS NECESSARY.*
NO
DISCONNECT THE PCM BLACK CONNECTOR.** INSPECT ALL TERMINALS. SEE GENERAL INFO 4.1
YES
REPAIR AS NECESSARY.*
NO
T TEST TC-157A CONTINUED - REPAIRING - INTERMITTENT LOSS OF CMP OR CKP R O U AB, AN, BR AND XJ BODIES B L E C O D E T E S T S
FIG. 1
ZJ BODY
FIG. 2
558
T R O U B L E C O D E T E S T S
AT PCM, BACKPROBE CKP SENSOR SIGNAL CKT WITH SCOPES VOLTAGE LEAD. FIG. 1 OR 2
WHILE OBSERVING THE SCOPE PATTERN, WIGGLE CKP SENSOR CIRCUIT FROM SENSOR TO PCM.
WERE ANY CKP SENSOR SIGNALS MISSING WHEN THE WIGGLE TEST WAS CONDUCTED? NO
YES
NOTE WHERE WIGGLING THE WIRES CAUSED A MISSING CKP SENSOR SIGNAL.
TEST COMPLETE.
T TEST TC-157B REPAIRING - INTERMITTENT LOSS OF CMP OR CKP R O Perform TEST TC-157A Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
560
KEY OFF. DISCONNECT THE PCM BLACK CONNECTOR.** INSPECT ALL TERMINALS. SEE GENERAL INFO 4.1
YES
REPAIR AS NECESSARY.*
T R O U B L E C O D E
NO
DISCONNECT THE CMP SENSOR CONNECTOR.** INSPECT ALL TERMINALS. SEE GENERAL INFO 4.4
YES
REPAIR AS NECESSARY.*
NO
T E S T S
DISCONNECT THE CKP SENSOR CONNECTOR.** INSPECT ALL TERMINALS. SEE GENERAL INFO 4.4
YES
REPAIR AS NECESSARY.*
NO
WITH THE DRB, MONITOR THE RPM WHILE WIGGLING CMP & CKP HARNESS WIRING.
DOES THE ENGINE SPEED CHANGE WHEN WIGGLING THE WIRE HARNESS?
YES
NOTE WHERE WIGGLING WIRES CAUSED A ENG SPEED CHANGE & REPAIR WIRE HARNESS AS NECESSARY.*
NO
YES
NO PROBLEM HAS BEEN FOUND. DO YOU WANT TO WIGGLE ANOTHER WIRE HARNESS SECTION? NO
THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT FIG.1
TEST COMPLETE.*
T TEST TC-157C REPAIRING - INTERMITTENT LOSS OF CMP OR CKP R O Perform TEST TC-157A Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
562
REMOVE THE CAMSHAFT YES POSITION SENSOR AND INSPECT THE CAMSHAFT SPROCKET. FIG. 1
T R O U B L E C O D E T E S T S
NO
INSPECT THE ROTOR AND ROTOR DRIVE SYSTEM FOR LOOSENESS PER SERVICE MANUAL INSTRUCTIONS.
YES
NO
REPAIR AS NECESSARY.*
NO
YES
T TEST TC-157D REPAIRING - INTERMITTENT LOSS OF CMP OR CKP R O Perform TEST TC-157A Before Proceeding U 2.5L AND 4.0L ENGINES B L E C O D E T E S T S
FIG. 1
3.9L, 5.2L AND 5.9L ENGINES
FIG. 2
8.0L ENGINES
FIG. 3
564
NO
REPAIR AS NECESSARY.*
T R O U B L E C O D E T E S T S
YES
NO
YES
NO
REPAIR AS NECESSARY.*
YES
YES
REPAIR AS NECESSARY.*
NO
T TEST TC-160A REPAIRING - EVAP LEAK MONITOR SMALL LEAK DETECTED R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
FIG. 3
566
FIG. 4
NOTE: A LOOSE GAS CAP COULD CAUSE THIS TROUBLE CODE TO SET.
NOTE: THE FUEL TANK MUST HAVE AT LEAST THREE GALLONS OF FUEL TO PERFORM THIS TEST.
T R O U B L E C O D E
WITH HAND PUMP, APPLY 18 INCHES OF VACUUM TO LEAK DETECTION PUMP (LDP).
NO
ENSURE VACUUM LINES ARE OK BEFORE REPLACING LDP. PERFORM TC-160A TO VERIFY.
YES
T E S T S
REPLACE LDP. IGNITION KEY ON. WITH THE DRB, GO TO ACTUATIONS, ACTUATE LDP. DID VACUUM DROP WHEN SOLENOID WAS ACTUATED? NO PERFORM TEST TC-160A TO VERIFY.
YES
TO CONTINUE TESTING YOU WILL NEED MILLER TOOL KIT #6872A. FIG. 2
PERFORM EVAPORATIVE SYSTEM PRESSURE PUMP SELF TEST THAT IS SPECIFIED ON THE TESTER COVER.
CONNECT THE EVAP PRESSURE PUMP SUPPLY HOSE TO VEHICLE PRESSURE TEST PORT. SEE GENERAL INFO 4.2
USING AN AUXILIARY CONSTANT VACUUM SUPPLY, DRB IN LDP SYSTEM TEST, PRESS 3 TO HOLD,...
DISCONNECT PURGE SOLENOID. SET PRESSURE HOLD TO OPEN, AND SET VENT TO CLOSED.
TURN PUMP TIMER ON. PERFORM IM240 SIMULATION THAT IS DESCRIBED ON COVER OF TOOL #6872.
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 3
USING THE SCHEMATIC AS A GUIDE, INSPECT THE WIRING, CONNECTORS AND HOSES.
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
T TEST TC-160A R O U B L E C O D E T E S T S
FIG. 1
568
TEST TC-160A CONTINUED - REPAIRING - EVAP LEAK MONITOR SMALL LEAK DETECTED
T R O U B L E C O D E T E S T S
TO CONTINUE TESTING, YOU WILL NEED MILLER TOOL ULTRASONIC LEAK DETECTOR (PARADISE 300).
SET PRESSURE HOLD TO OPEN AND SET VENT TO CLOSED. TURN PUMP TIMER ON.
TO PREVENT NOISE FROM INTERFERING WITH TEST MOVE TOOL #6872A AWAY FROM VEHICLE.
USING THE ULTRASONIC LEAK DETECTOR, START LISTENING FOR LEAKS AT GAS CAP...
YES
NO
T TEST TC-161A REPAIRING - EVAP LEAK MONITOR LARGE LEAK DETECTED R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
FIG. 3
570
FIG. 4
NOTE: A LOOSE GAS CAP COULD CAUSE THIS TROUBLE CODE TO SET.
NOTE: THE FUEL TANK MUST HAVE AT LEAST THREE GALLONS OF FUEL TO PERFORM THIS THIS.
T R O U B L E C O D E
WITH HAND PUMP, APPLY 18 INCHES OF VACUUM TO LEAK DETECTION PUMP (LDP).
NO
ENSURE VACUUM LINES ARE OK BEFORE REPLACING LDP. PERFORM TC-161A TO VERIFY.
YES
T E S T S
REPLACE LDP. IGNITION KEY ON. WITH THE DRB, GO TO ACTUATIONS, ACTUATE LDP. DID VACUUM DROP WHEN SOLENOID WAS ACTUATED? NO PERFORM TEST TC-161A TO VERIFY.
YES
TO CONTINUE TESTING YOU WILL NEED MILLER TOOL KIT #6872A. FIG. 2
PERFORM EVAPORATIVE SYSTEM PRESSURE PUMP SELF TEST THAT IS SPECIFIED ON THE TESTER COVER.
CONNECT THE EVAP PRESSURE PUMP SUPPLY HOSE TO VEHICLE PRESSURE TEST PORT. SEE GEN INFO 4.2
USING AN AUXILARY CONTANT VACUUM SUPPLY, DRB IN LDP SYSTEM TEST PRESS 3 TO HOLD,...
DISCONNECT PURGE SOLENOID. SET PRESSURE HOLD TO OPEN, AND SET VENT TO CLOSED.
TURN PUMP TIMER ON. PERFORM IM240 SIMULATION THAT IS DESCRIBED ON COVER OF TOOL #6872.
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 3
USING THE SCHEMATIC AS A GUIDE, INSPECT THE WIRING, CONNECTORS AND HOSES.
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
T TEST TC-161A R O U B L E C O D E T E S T S
FIG. 1
572
TEST TC-161A CONTINUED - REPAIRING - EVAP LEAK MONITOR LARGE LEAK DETECTED
TO CONTINUE TESTING YOU WILL NEED MILLER TOOL ULTRASONIC LEAK DETECTOR (PARADISE 300).
T R O U B L E C O D E
SET PRESSURE HOLD TO OPEN, AND SET VENT TO CLOSED. TURN PUMP TIMER ON.
TO PREVENT NOISE FROM INTERFERING WITH TEST MOVE TOOL #6872A (ESPP) AWAY FROM VEHICLE.
IF PUMP NOISE STILL INTERFERES WITH ULTRSASONIC LEAK TESTER TURN PRESSURE HOLD TO CLOSED...
T E S T S
NOTE: SYSTEM MUST HAVE PRESSURE TO DETECT A LEAK, IF THE EVAP SYSTEM CANNOT MAINTAIN...
USING MILLER TOOL #6904 ULTRASONIC LEAK DETECTOR, START LISTENING FOR LEAKS AT GAS CAP...
YES
NO
T TEST TC-162A REPAIRING - NO TEMP RISE SEEN FROM INTAKE HEATERS R O Perform TEST DTC Before Proceeding U 1996 2.5/4.0/5.2/5.9/8.0L Jeep and Truck Engine Publication No. 81-699-96103 B TSB 26-06-97 June, 1997 L E C O D E T E S T S
FIG. 1
FIG. 2
574
NO
T R O U B L E C O D E
YES
NO
YES
T E S T S
NOTE: BECAUSE HEATERS DRAW A LARGE AMOUNT OF CURRENT, ENSURE ACTUATION TIME IS BRIEF.
USING A VOLTMETER, MEASURE THE #1 HEATER RELAY OUTPUT CKT AT THE INTAKE MANIFOLD. FIG. 1
STOP ACTUATION. NO DID THE VOLTAGE TOGGLE ABOVE 9.6 VOLTS? YES CONTINUE TEST TEST 162A ON THE NEXT PAGE.
USING A VOLTMETER, MEASURE THE #2 HEATER RELAY OUTPUT CKT AT THE INTAKE MANIFOLD. FIG. 1
STOP ACTUATION. NO DID THE VOLTAGE TOGGLE ABOVE 9.6 VOLTS? YES PERFORM TEST TC-162B.
YES
NO
INSPECT THE INTAKE AIR TEMP SENSOR FOR HEAVY SOOT. REPLACE IF NECESSARY.
AT THIS TIME THE CONDITIONS REQUIRED TO SET THE CODE ARE NOT PRESENT. FIG. 2
TEST COMPLETE.*
T TEST TC-162A R O U B L E C O D E T E S T S
1996 2.5/4.0/5.2/5.9/8.0L Jeep and Truck Engine Publication No. 81-699-96103 TSB 26-06-97 June, 1997
FIG. 1
576
TEST TC-162A CONTINUED - REPAIRING - NO TEMP RISE SEEN FROM INTAKE HEATERS
1996 2.5/4.0/5.2/5.9/8.0L Jeep and Truck Engine Publication No. 81-699-96103 TSB 26-06-97 June, 1997
T R O U B L E C O D E
USING A VOLTMETER, MEASURE THE #2 HEATER RELAY OUTPUT CKT AT THE RELAY. FIG. 1
STOP ACTUATION. YES DID THE VOLTAGE TOGGLE ABOVE 9.6 VOLTS? NO
REPAIR THE OPEN #2 HEATER RELAY OUTPUT CIRCUIT.* NOTE: CHECK CIRCUIT FOR HIGH RESISTANCE
T E S T S
YES
NO
T TEST TC-162B REPAIRING - NO TEMP RISE SEEN FROM INTAKE HEATERS R O Perform TEST TC-162A Before Proceeding U 1996 2.5/4.0/5.2/5.9/8.0L Jeep and Truck Engine Publication No. 81-699-96103 B TSB 26-06-97 June, 1997 L E C O D E T E S T S
FIG. 1
578
T R O U B L E C O D E
USING A VOLTMETER, MEASURE THE #2 HEATER RELAY OUTPUT CKT AT THE RELAY. FIG. 1
STOP ACTUATION. YES DID THE VOLTAGE TOGGLE ABOVE 9.6 VOLTS? NO
REPAIR THE OPEN #2 HEATER RELAY OUTPUT CIRCUIT.* NOTE: CHECK CIRCUIT FOR HIGH RESISTANCE
T E S T S
YES
NO
T TEST TC-162C REPAIRING - NO TEMP RISE SEEN FROM INTAKE HEATERS R O Perform TEST TC-162A Before Proceeding 1996 2.5/4.0/5.2/5.9/8.0L Jeep and Truck Engine U Publication No. 81-699-96103 B TSB 26-06-97 June, 1997 L E C O D E T E S T S
FIG. 1
FIG. 2
580
T R O U B L E C O D E
DISCONNECT THE FUSED IGN SWITCH OUTPUT CKT CONNECTOR FROM #1 HEATER RLY.** FIG. 1
USING A VOLTMETER, MEASURE FUSED IGNITION SWITCH OUTPUT CKT AT RLY CONN. FIG. 1
NO
YES
T E S T S
DISCONNECT THE AIT HEATER RELAY #1 CONTROL CIRCUIT AT THE RELAY.** FIG. 1
NO
YES
TURN IGNITION OFF. DISCONNECT THE PCM BLACK CONNECTOR.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE #1 HEATER CONTROL CIRCUIT AT PCM TO GROUND. FIG. 2
YES
NO
YES
NO
T TEST TC-162D REPAIRING - NO TEMP RISE SEEN FROM INTAKE HEATERS R O Perform TEST TC-162A Before Proceeding 1996 2.5/4.0/5.2/5.9/8.0L Jeep and Truck Engine U Publication No. 81-699-96103 B TSB 26-06-97 June, 1997 L E C O D E T E S T S
FIG. 1
FIG. 2
581A
T R O U B L E C O D E
DISCONNECT THE FUSED IGN SWITCH OUTPUT CKT CONNECTOR FROM #1 HEATER RLY.** FIG. 1
USING A VOLTMETER, MEASURE FUSED IGNITION SWITCH OUTPUT CKT AT RLY CONN. FIG. 1
NO
YES
T E S T S
DISCONNECT THE AIT HEATER RELAY #1 CONTROL CIRCUIT AT THE RELAY.** FIG. 1
NO
YES
TURN IGNITION OFF. DISCONNECT THE PCM BLACK CONNECTOR.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE #1 HEATER CONTROL CIRCUIT AT PCM TO GROUND. FIG. 2
YES
NO
YES
NO
T TEST TC-164A REPAIRNG - TRANS TEMP SENSOR, NO RISE AFTER START R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
FIG. 1
582
CHECK FOR A P/N SWITCH, TRANS TEMP SENSOR VOLTAGE TOO LOW OR TOO HIGH FAULT CODE.
YES
T R O U B L E C O D E
NO
T0 TEST THE TRANS TEMP SENSOR, THE ENGINE AND TRANS TEMPERATURE MUST BE LESS THAN 85 DEG F.
NO
YES
T E S T S
NO
YES
START ENGINE AND LET IDLE IN DRIVE WITH PARKING BRAKE ON, WHILE MONITORING THE TRANS TEMP SENSOR.
LOOK FOR THE TEMPERATURE TO RAISE 15 DEGREES F OVER A TEN MINUTE PERIOD.
DID TRANS TEMP INCREASE AT A STEADY RATE AND INCREASE 15 DEGREES F OVER A TEN MINUTE PERIOD? YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
T TEST TC-164A R O U B L E C O D E T E S T S
NOTES
584
TEST TC-164A CONTINUED - REPAIRNG - TRANS TEMP SENSOR, NO RISE AFTER START
T R O U B L E C O D E T E S T S
DISCONNECT THE TRANSMISSION SOLENOID EIGHT WAY CONNECTOR.** SEE GENERAL INFO 4.2
NO
YES
T TEST TC-165A REPAIRING - 3-4 SHIFT SOLENOID, NO RPM DROP 3-4 SHIFT R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
586
TEST TC-165A REPAIRING - 3-4 SHIFT SOLENOID, NO RPM DROP 3-4 SHIFT
Perform TEST DTC Before Proceeding
IS THE "TRANS 12 VOLT SUPPLY RELAY CONTROL CIRCUIT" TROUBLE CODE PRESENT? NO
YES
T R O U B L E C O D E
YES
NO
T E S T S
IS THE "TRANS 3-4 SHIFT SOLENOID/TRANS RELAY CIRCUIT" TROUBLE CODE PRESENT? NO
YES
YES
NO
YES
NO
YES
NO
T TEST TC-165A R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
588
TEST TC-165A CONTINUED - REPAIRING - 3-4 SHIFT SOLENOID, NO RPM DROP 3-4 SHIFT
NO
REPAIR AS NECESSARY.*
T R O U B L E C O D E T E S T S
YES
CONNECT A ZERO TO 300 PSI PRESSURE GAUGE TO THE OVERDRIVE CLUTCH TEST PORT...
CONNECT ANOTHER ZERO TO 300 PSI GAUGE TO THE GOVERNOR TEST PORT. FIG. 1
START ENGINE AND ALLOW TRANS TEMP TO RISE TO NORMAL OPERATING TEMP.
WHILE OBSERVING THE PRESSURE GAUGES, SELECT 4TH GEAR FROM GOV AND 3-4 SYSTEM TEST.
THE GOVERNOR PRESSURE SHOULD RISE TO ABOVE 20 PSI. SHORTLY AFTER THIS,...
YES
NO
START ENGINE AND ALLOW THE TRANS TEMP TO RISE TO NORMAL OPERATING TEMP.
WHILE OBSERVING THE PRESSURE GAUGES, ACTUATE THE 3-4 SHIFT SOLENOID WITH THE DRB.
THE GOVERNOR PRESSURE SHOULD RISE TO ABOVE 20 PSI. SHORTLY AFTER THIS,...
NO
T TEST TC-165A R O U B L E C O D E T E S T S
NOTES
590
TEST TC-165A CONTINUED - REPAIRING - 3-4 SHIFT SOLENOID, NO RPM DROP 3-4 SHIFT
T R O U B L E C O D E T E S T S
REMOVE THE OIL PAN AND CHECK FOR EXCESSIVE DEBRIS AND/OR BURNT OIL.
YES
NO
AT THIS TIME, THE CONDITIONS REQUIRED TO SET THIS CODE ARE NOT PRESENT.
TEST COMPLETE.*
T TEST TC-166A REPAIRING - LOW OUTPUT SPEED SENSOR RPM, ABOVE 15 MPH R O Perform TEST DTC Before Proceeding U B L E C O D E T E S T S
FIG. 1
592
TEST TC-166A REPAIRING - LOW OUTPUT SPEED SENSOR RPM, ABOVE 15 MPH
Perform TEST DTC Before Proceeding
YES
T R O U B L E C O D E T E S T S
NO
RAISE THE DRIVE WHEELS OFF THE GROUND AND PROPERLY SUPPORT VEHICLE.
START ENGINE, WITH THE DRB, READ THE OUTPUT SPEED SENSOR.
PUT TRANSMISSION IN ANY FORWARD GEAR. RELEASE BRAKES TO LET WHEELS ROLL.
NO
YES
WHILE STILL MONITORING THE OUTPUT SPEED SENSOR, WIGGLE THE WIRES FROM ...
DID THE READING DROP TOWARD ZERO WHILE WIGGLING THE WIRES?
YES
NO
ROAD TEST VEHICLE. WITH THE DRB, CLEAR TROUBLE CODES. WITH THE DRB, READ TROUBLE CODES. DID THE CODE RETURN? NO
THE CONDITIONS REQUIRED TO SET THIS CODE ARE NOT PRESENT AT THIS TIME. FIG. 1
YES
ROAD TEST VEHICLE. WITH THE DRB, READ TROUBLE CODES. DID THE CODE RETURN? NO TEST COMPLETE.*
YES
T TEST TC-166A CONTINUED - REPAIRING - LOW OUTPUT SPEED SENSOR RPM, ABOVE 15 MPH R O U AB AND AN BODIES BR AND ZJ BODIES B L E C O D E T E S T S
FIG. 1
AB, AN AND ZJ BODIES BR BODY
FIG. 2
FIG. 3
594
FIG. 4
TEST TC-166A CONTINUED - REPAIRING - LOW OUTPUT SPEED SENSOR RPM, ABOVE 15 MPH
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
T R O U B L E C O D E
MEASURE THE RESISTANCE BETWEEN THE OSS SIGNAL CIRCUIT AND GROUND. FIG. 1 OR 2
YES
NO
T E S T S
MEASURE THE RESISTANCE BETWEEN THE OSS GROUND CIRCUIT AND GROUND. FIG. 1 OR 2
NO
YES
NO
MEASURE THE RESISTANCE ACROSS BOTH TERMINALS OF THE OUTPUT SPEED SENSOR.
NO
YES
MEASURE THE RESISTANCE OF THE OSS SIGNAL CIRCUIT FROM THE OSS CONNECTOR...
YES
NO
T TEST TC-167A REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO LOW R O Perform TEST DTC Before Proceeding U AB BODY B L E C O D E T E S T S
FIG. 1
AN BODY BR BODY
FIG. 2
ZJ BODY
FIG. 3
FIG. 4
596
FIG. 5
KEY OFF. DISCONNECT THE TRANS SOLENOID CONNECTOR.** SEE GENERAL INFO 4.2
T R O U B L E C O D E
KEY ON, MEASURE THE VOLTAGE AT THE 5-VOLT SUPPLY CIRCUIT. FIG. 1, 2, 3 OR 4
NO
YES
T E S T S
KEY ON, WITH THE DRB, MONITOR THE GOVERNOR PRESSURE VOLTAGE.
YES
NO
YES
NO
NO
YES
WHILE MONITORING GOVERNOR PRESSURE VOLTAGE WITH DRB, WIGGLE THE WIRING AND CONNECTORS...
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 5
TEST COMPLETE.*
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
598
FIG. 4
TEST TC-167A CONTINUED - REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO LOW
T R O U B L E C O D E T E S T S
MEASURE THE RESISTANCE BETWEEN THE GOVERNOR PRESSURE SENSOR SIGNAL CIRCUIT...
YES
REPAIR THE GOVERNOR PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO SENSOR GROUND CIRCUIT.*
NO
MEASURE THE RESISTANCE BETWEEN THE GOVERNOR PRESSURE SENSOR SIGNAL CIRCUIT...
REMOVE THE TRANS OIL PAN. DISCONNECT THE PRESSURE/TEMP SENSOR CONNECTOR.** SEE GENERAL INFO 4.4
MEASURE THE RESISTANCE BETWEEN THE GOVERNOR PRESSURE SENSOR SIGNAL CIRCUIT...
YES
NO
MEASURE THE RESISTANCE BETWEEN THE GOVERNOR PRESSURE SENSOR SIGNAL CIRCUIT...
YES
T TEST TC-168A REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO HIGH R O Perform TEST DTC Before Proceeding U AB BODY B L E C O D E T E S T S
FIG. 1
AN BODY BR BODY
FIG. 2
ZJ BODY
FIG. 3
FIG. 4
600
FIG. 5
KEY OFF. DISCONNECT THE TRANS SOLENOID CONNECTOR.** SEE GENERAL INFO 4.2
T R O U B L E C O D E
KEY ON, MEASURE THE VOLTAGE AT THE 5-VOLT SUPPLY CIRCUIT. FIG. 1, 2, 3 OR 4
NO
YES
T E S T S
KEY ON, WITH THE DRB, MONITOR THE GOVERNOR PRESSURE VOLTAGE.
YES
NO
YES
NO
NO
YES
WHILE MONITORING GOVERNOR PRESSURE VOLTAGE WITH DRB, WIGGLE THE WIRING AND CONNECTORS...
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 5
TEST COMPLETE.*
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
602
FIG. 4
TEST TC-168A CONTINUED - REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO HIGH
T R O U B L E C O D E T E S T S
KEY OFF. DISCONNECT THE TRANSMISSION SOLENOID CONNECTOR.** SEE GENERAL INFO 4.2
MEASURE THE RESISTANCE OF THE GOVERNOR PRESSURE SENSOR SIGNAL CIRCUIT FROM...
YES
NO
YES
NO
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
604
FIG. 4
TEST TC-168A CONTINUED - REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO HIGH
T R O U B L E C O D E T E S T S
CONNECT A JUMPER WIRE FROM THE FUSED B(+) CIRCUIT TO THE TRANS CONTROL...
KEY ON. MEASURE THE VOLTAGE AT THE GOVERNOR PRESSURE SIGNAL CIRCUIT...
YES
NO
REMOVE THE TRANS OIL PAN. DISCONNECT THE PRESSURE/TEMP SENSOR CONNECTOR.** SEE GENERAL INFO 4.4
FIG. 1
AB BODY AN BODY
FIG. 2
BR BODY ZJ BODY
FIG. 3
FIG. 4
606
FIG. 5
TEST TC-168A CONTINUED - REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO HIGH
T R O U B L E C O D E
KEY ON. MEASURE THE VOLTAGE AT THE GOVERNOR PRESSURE SIGNAL CIRCUIT. FIG. 1
YES
NO
T E S T S
KEY OFF. MEASURE THE RESISTANCE OF THE GOVERNOR PRESSURE SENSOR SIGNAL CIRCUIT FROM THE...
YES
NO
MEASURE THE RESISTANCE OF THE SENSOR GROUND CIRCUIT FROM THE PCM...
YES
NO
CAREFULLY INSERT A JUMPER WIRE BETWEEN THE GOVERNOR PRESSURE SENSOR SIGNAL CIRCUIT...
KEY ON. MONITOR THE GOVERNOR PRESSURE SENSOR VOLTAGE WITH THE DRB.
NO
YES
T TEST TC-168B REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO HIGH R O Perform TEST TC-168A Before Proceeding U AB BODY AN BODY B L E C O D E T E S T S
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
608
FIG. 4
T R O U B L E C O D E
START ENGINE.
YES
T E S T S
MEASURE THE RESISTANCE OF THE GOVERNOR PRESSURE SENSOR SIGNAL CIRCUIT FROM...
YES
NO
YES
NO
KEY ON. MEASURE THE VOLTAGE AT THE GOVERNOR PRESSURE SIGNAL CIRCUIT...
YES
REPAIR THE GOVERNOR PRESSURE SENSOR SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE.*
NO
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
610
FIG. 4
TEST TC-168B CONTINUED - REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO HIGH
T R O U B L E C O D E T E S T S
REMOVE THE TRANS OIL PAN. DISCONNECT THE PRESSURE/TEMP SENSOR CONNECTOR.** SEE GENERAL INFO 4.4
KEY ON. MEASURE THE VOLTAGE AT THE GOVERNOR PRESSURE SIGNAL CIRCUIT. FIG. 1, 2, 3 OR 4
YES
NO
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
612
FIG. 4
TEST TC-168B CONTINUED - REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO HIGH
T R O U B L E C O D E T E S T S
REMOVE THE TRANS OIL PAN. DISCONNECT THE PRESSURE/TEMP SENSOR CONNECTOR.** SEE GENERAL INFO 4.4
MEASURE THE RESISTANCE OF THE GOVERNOR PRESSURE SENSOR SIGNAL CIRCUIT FROM THE...
YES
NO
MEASURE THE RESISTANCE OF THE SENSOR GROUND CIRCUIT FROM THE PCM...
YES
NO
T TEST TC-169A REPAIRING - GOVERNOR PRESSURE SENSOR OFFSET VOLTS TOO LOW OR HIGH R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
614
TEST TC-169A REPAIRING - GOVERNOR PRESSURE SENSOR OFFSET VOLTS TOO LOW OR HIGH
Perform DTC TEST Before Proceeding
START ENGINE, ALLOW TO WARM UP AND CHECK FLUID LEVEL AND CONDITION OF FLUID.
NO
T R O U B L E C O D E T E S T S
YES
NO
YES
PLACE VEHICLE IN NEUTRAL, WITH THE DRB, READ THE GOVERNOR PRESSURE SENSOR VOLTAGE.
NO
YES
WHILE MONITORING GOVERNOR PRESSURE VOLTAGE WITH DRB, WIGGLE THE WIRING AND CONNECTORS...
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 1
TEST COMPLETE.*
CONTINUED - REPAIRING GOVERNOR PRESSURE SENSOR OFFSET VOLTS TOO LOW OR HIGH
AN BODY
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
616
FIG. 4
- REPAIRING GOVERNOR PRESSURE SENSOR OFFSET VOLTS TOO TEST TC-169A CONTINUED LOW OR HIGH
KEY ON, ENGINE OFF. DISCONNECT THE TRANS SOLENOID CONNECTOR.** SEE GENERAL INFO 4.2
T R O U B L E C O D E
MEASURE VOLTAGE AT THE 5-VOLT SUPPLY CIRCUIT IN TRANS SOLENOID CONNECTOR. FIG. 1, 2, 3 OR 4
NO
YES
T E S T S
TURN KEY OFF. DISCONNECT THE PCM CONNECTOR.** SEE GENERAL INFO 4.1
MEASURE THE RESISTANCE OF THE SENSOR GROUND CIRCUIT FROM THE PCM CONNECTOR...
NO
YES
WIGGLE THE WIRES BETWEEN THE PCM AND THE SOLENOID CONNECTOR.
DID THE GOVERNOR PRESSURE SENSOR VOLTAGE FLUCTUATE WHILE WIGGLING THE WIRES? NO
YES
T TEST TC-169A R O U B L E C O D E T E S T S
CONTINUED - REPAIRING GOVERNOR PRESSURE SENSOR OFFSET VOLTS TOO LOW OR HIGH
FIG. 1
FIG. 2
618
- REPAIRING GOVERNOR PRESSURE SENSOR OFFSET VOLTS TOO TEST TC-169A CONTINUED LOW OR HIGH
T R O U B L E C O D E T E S T S
NO
THE CONDITIONS REQUIRED TO SET THIS CODE ARE NOT PRESENT AT THIS TIME. FIG. 1 AND 2
YES
CHECK PAN AND/OR FILTER FOR EXCESSIVE DEBRIS WHILE CHANGING SENSOR.
YES
NO
TEST COMPLETE.
T TEST TC-171A REPAIRING - GOVERNOR PRESSURE SOLENOID/TRANS RELAY CKTS R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
620
T R O U B L E C O D E T E S T S
YES
NO
WITH THE DRB, PERFORM A GOV AND 3-4 SHIFT VALVE SYSTEM TEST.
SELECT 1ST GEAR. READ GOVERNOR PRESSURE VOLTAGE. IS THE GOVERNOR PRESSURE VOLTAGE BELOW 1.0 VOLTS? NO CONTINUE TEST TC-171A ON THE NEXT PAGE.
YES
AT THIS TIME, THE CONDITION REQUIRED TO SET THIS CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
WHILE READING DTCS WITH THE DRB, WIGGLE THE WIRING HARNESS FROM THE SOLENOID TO THE PCM.
DOES THE GOVERNOR PRESSURE SOLENOID CONTROL CIRCUIT FAULT CODE APPEAR?
YES
NO
TEST COMPLETE.*
AN BODY
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
622
FIG. 4
R O U B L E C O D E
DISCONNECT THE TRANS SOLENOID PACK CONNECTOR.** SEE GENERAL INFO 4.2
T E S T S
KEY ON. WITH THE DRB, ACTUATE THE TRANS CONTROL RELAY.
NO
YES
AN BODY
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
624
FIG. 4
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE WHITE CONNECTOR.** SEE GENERAL INFO 4.1
R O U B L E C O D E T E S T S
KEY ON. MEASURE THE VOLTAGE AT THE GOV. PRESSURE SOLENOID CONTROL CIRCUIT. FIG. 1, 2, 3 OR 4
YES
NO
KEY OFF. MEASURE THE RESISTANCE BETWEEN THE GOVERNOR PRESSURE SOLENOID CONTROL CIRCUIT...
NO
YES
AN BODY
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
626
FIG. 4
R O U B L E C O D E T E S T S
MEASURE THE RESISTANCE BETWEEN THE TRANS CONTROL RELAY OUTPUT CIRCUIT AT THE RELAY...
AND THE GOVERNOR PRESSURE SOLENOID CONTROL CIRCUIT AT THE PCM CONNECTOR. FIG. 1, 2, 3 OR 4
NO
NO
YES
AN BODY
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
628
FIG. 4
R O U B L E C O D E T E S T S
DISCONNECT THE TRANS SOLENOID PACK CONNECTOR.** SEE GENERAL INFO 4.2
YES
NO
DRAIN AND REMOVE OIL PAN. DISCONNECT THE GOVERNOR PRESSURE SOLENOID.** SEE GENERAL INFO 4.2
NO
YES
T TEST TC-171B REPAIRING - GOVERNOR PRESSURE SOLENOID/TRANS RELAY CKTS R O Perform TEST TC-171A Before Proceeding U AB BODY AN BODY B L E C O D E T E S T S
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
630
FIG. 4
T R O U B L E C O D E T E S T S
KEY OFF. MEASURE THE RESISTANCE BETWEEN THE TRANS RELAY OUTPUT CIRCUIT...
YES
NO
YES
NO
KEY ON, MEASURE THE VOLTAGE AT THE FUSED B(+) CIRCUIT IN THE RELAY CONNECTOR. FIG. 1, 2, 3 OR 4
NO
REPAIR THE OPEN FUSED B(+) FEED TO THE TRANS CONTROL RELAY.
YES
T TEST TC-171C REPAIRING - GOVERNOR PRESSURE SOLENOID/TRANS RELAY CKTS R O Perform TEST TC-171A Before Proceeding U AB BODY AN BODY B L E C O D E T E S T S
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
632
FIG. 4
T R O U B L E C O D E
MEASURE AND RECORD THE RESISTANCES BETWEEN THE GOVERNOR PRESSURE SOLENOID CONTROL CIRCUIT...
YES
REPAIR GOVERNOR PRESSURE SOLENOID CONTROL CKT SHORTED TO CIRCUIT(S) THAT WERE BELOW 2.5 OHMS.
NO
T E S T S
REMOVE THE TRANS OIL PAN. DISCONNECT THE GOVERNOR PRESSURE SOLENOID.**
MEASURE THE RESISTANCE ACROSS BOTH TERMINALS OF THE GOVERNOR PRESSURE SOLENOID.
YES
NO
WITH THE DRB, PERFORM THE GOV AND 3-4 SHIFT VALVE SYSTEM TEST.
SELECT 1ST GEAR. READ THE GOVERNOR PRESSURE VOLTAGE. IS THE GOVERNOR PRESSURE VOLTAGE BELOW 1.0 VOLT? NO REPLACE THE PCM.*
YES
TEST COMPLETE.
T TEST TC-171D REPAIRING - TRANS 3-4 SOLENOID/TRANS RELAY CKT R O Perform TEST TC-171A Before Proceeding U NOTES B L E C O D E T E S T S
634
T R O U B L E C O D E T E S T S
WITH THE DRB, PERFORM THE GOV AND 3-4 SHIFT VALVE SYSTEM TEST.
SELECT 1ST GEAR. READ THE GOVERNOR PRESSURE VOLTAGE. IS THE GOVERNOR PRESSURE VOLTAGE BELOW 1.0 VOLT? NO REPLACE THE PCM.*
YES
TEST COMPLETE.
T TEST TC-173A REPAIRING - TRANS 12 VOLT SUPPLY RELAY CNTRL CIRCUIT R O Perform DTC TEST Before Proceeding U AB BODY AN BODY B L E C O D E T E S T S
BR BODY
ZJ BODY
FIG. 1
636
FIG. 2
T R O U B L E
CONTINUE TEST TC-173A ON THE NEXT PAGE.
NO
YES
C O D E T E S T S
THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
WIGGLE THE WIRING HARNESS FROM THE RELAY TO THE POWERTRAIN CONTROL MODULE.
NOTE: THE DRB MUST STILL BE ACTUATING THE TRANS CONTROL RELAY.
YES
NO
TEST COMPLETE.*
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
FIG. 4
FIG. 5
638
FIG. 6
TEST TC-173A CONTINUED - REPAIRING - TRANS 12 VOLT SUPPLY RELAY CNTRL CIRCUIT
T R O U B L E C O D E
MEASURE THE VOLTAGE AT THE FUSED IGN SW OUTPUT CIRCUIT IN THE RELAY CONNECTOR. FIG. 1, 2, 3 OR 4
NO
YES
T E S T S
NO
YES
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE WHITE CONNECTOR.** SEE GENERAL INFO 4.1
NO
YES
T TEST TC-181A REPAIRING - 2/1 O2 SENSOR SHORTED TO GROUND R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
640
T R O U B L E C O D E T E S T S
IF ENGINE IS WARM, TURN THE ENGINE OFF FOR 15 MINUTES TO ALLOW O2 SENSOR TO COOL DOWN.
YES
NO
NOTE: A SHORTED LOW CONDITION DUE TO WATER IN THE SENSOR CONNECTOR, MAY BE TEMPORARY.
DID THE 2/1 O2 SENSOR VOLTAGE CHANGE WHILE WIGGLING THE HARNESS? YES
NO
THE CONDITION REQUIRED TO SET THIS TROUBLE CODE IS NOT PRESENT AT THIS TIME.*
REPAIR THE HARNESS OR WIRING THAT HAS THE INTERMITTENT SHORT TO GROUND.*
T TEST TC-181A R O U B L E C O D E T E S T S
FIG. 1
642
YES
T R O U B L E C O D E
NO
NO
YES
T E S T S
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE CONNECTORS.** SEE GENERAL INFO 4.1
YES
NO
MEASURE THE 2/1 02 SENSOR SIGNAL CIRCUIT FROM THE PCM CONNECTOR TO GROUND. FIG. 1
YES
NO
WIGGLE THE O2 SENSOR HARNESS WHILE CHECKING RESISTANCE OF O2 SENSOR SIGNAL CIRCUIT.
NO
YES
T TEST TC-183A REPAIRING - LEAK DETECTION PUMP SOLENOID CIRCUIT R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG.1
FIG. 2
644
WITH THE DRB, READ THE LDP PRESSURE SWITCH STATE AND NOTE POSITION.
T R O U B L E C O D E
DID THE DRB SHOW THE LEAK DETECTION PRESSURE SWITCH CHANGE FROM DOWN TO UP? YES
NO
T E S T S
DID THE DRB SHOW THE LEAK DETECTION PRESSURE SWITCH CHANGE FROM UP TO DOWN? YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
WHILE MONITORING THE LDP SWITCH STATE, WIGGLE WIRING HARNESS FROM THE LDP SOLENOID TO PCM.
DID THE LDP SWITCH STATE EVER CHANGE FROM UP TO DOWN WHEN WIGGLED?
YES
NO
TEST COMPLETE.*
T TEST TC-183A R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
646
KEY OFF, DISCONNECT THE LEAK DETECTION PUMP SOLENOID.** SEE GENERAL INFO 4.0
T R O U B L E C O D E
MEASURE THE FUSED IGNITION SWITCH OUTPUT CKT AT SOLENOID CONN. FIG. 1
NO
YES
T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.0
NO
YES
USING AN OHMMETER, MEASURE THE LEAK DETECTION PUMP SOLENOID CONTROL CIRCUIT...
YES
REPAIR THE LEAK DETECTION PUMP SOLENOID CIRCUIT FOR A SHORT TO GROUND.*
NO
RECONNECT THE LEAK DETECTION PUMP CONNECTOR. KEY ON, WITH A VOLTMETER, MEASURE...
THE LEAK DETECTION PUMP SOLENOID CONTROL CIRCUIT AT THE PCM CONNECTOR. FIG. 2
NO
YES
T TEST TC-184A REPAIRING - LEAK DETECTION PUMP SW OR MECHANICAL FAULT R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
FIG. 2
648
T R O U B L E C O D E
DID THE DRB SHOW THE LEAK DETECTION PRESSURE SWITCH CHANGE FROM UP TO DOWN? YES
NO
T E S T S
DID THE DRB SHOW THE LEAK DETECTION PRESSURE SWITCH CHANGE FROM DOWN TO UP? YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 1
YES
REPAIR AS NECESSARY.*
NO
WHILE MONITORING THE LDP SWITCH STATE, WIGGLE WIRING HARNESS FROM THE LDP SOLENOID TO PCM.
DID THE LDP SWITCH STATE EVER CHANGE FROM UP TO DOWN WHEN WIGGLED?
YES
NO
TEST COMPLETE.*
T TEST TC-184A R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
650
CONNECT A VACUUM GAUGE INTO THE VACUUM TEE TO THE LDP. SEE GENERAL INFO 4.0
T R O U B L E C O D E
NO
YES
T E S T S
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.0
KEY ON. USING A VOLTMETER, MEASURE THE LDP PRESSURE SWITCH CIRCUIT. FIG. 1
YES
NO
DISCONNECT THE LEAK DETECTION PUMP CONNECTOR.** SEE GENERAL INFO 4.0
NO
YES
NO
YES
T TEST TC-186A REPAIRING - MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
ZJ BODY
652
DISCONNECT THE CRANKSHAFT POSITION CONNECTOR.** INSPECT ALL TERMINALS. SEE GENERAL INFO 4.4
YES
REPAIR AS NECESSARY.*
T R O U B L E C O D E
NO
INSPECT THE CRANKSHAFT POSITION SENSOR FOR PROPER INSTALLATION. SEE GENERAL INFO 4.4
NO
YES
T E S T S
NO
YES
NO
REPAIR AS NECESSARY.*
YES
YES
REPAIR AS NECESSARY.*
NO
T TEST TC-187A REPAIRING - EVAP LEAK MONITOR PINCHED HOSE R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
654
FIG. 2
TO PERFORM THIS TEST YOU WILL NEED MILLER TOOL KIT #6872A. FIG. 1
T R O U B L E C O D E T E S T S
PERFORM EVAPORATIVE SYSTEM PRESSURE PUMP SELF TEST THAT IS SPECIFIED ON THE TESTER COVER.
CONNECT THE EVAP PRESSURE PUMP SUPPLY HOSE TO VEHICLE PRESSURE TEST PORT. SEE GENERAL INFO 4.2
USING AN AUXIILIARY CONSTANT VACUUM SUPPLY, WITH THE DRB, GO TO LDP SYSTEM TEST,...
USING PRESSURE TOOL #6872A SET PRESSURE HOLD TO OPEN, AND SET VENT CLOSED. TURN PUMP TIMER ON.
NO
YES
NO
T TEST TC-187A R O U B L E C O D E T E S T S
FIG. 1
656
T R O U B L E C O D E T E S T S
REMOVE THE GAS TANK ROLLOVER HOSE FROM THE EVAP CANISTER.
YES
REPAIR THE PINCHED HOSE FROM THE GAS TANK TO THE EVAP CANISTER.*
YES
NO
T TEST TC-188A REPAIRING - O/D SWITCH PRESSED (LO) MORE THAN 5 MIN. R O Perform DTC TEST Before Proceeding U AB, AN, AND BR BODIES ZJ BODY B L E C O D E T E S T S
ZJ BODY
FIG. 1
FIG. 2
FIG. 3
658
FIG. 4
TEST TC-188A REPAIRING - O/D SWITCH PRESSED (LO) MORE THAN 5 MIN.
Perform DTC TEST Before Proceeding
T R O U B L E C O D E T E S T S
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE CODE IS NOT PRESENT. FIG. 3
YES
REPAIR AS NECESSARY. *
NO
TEST COMPLETE.*
T TEST TC-188A CONTINUED - REPAIRING - O/D SWITCH PRESSED (LO) MORE THAN 5 MIN. R O U AB, AN, AND BR BODIES B L E C O D E T E S T S
FIG. 1
ZJ BODY
FIG. 2
660
TEST TC-188A CONTINUED - REPAIRING - O/D SWITCH PRESSED (LO) MORE THAN 5 MIN.
T R O U B L E C O D E
YES
NO
T E S T S
T TEST TC-189A REPAIRING - 1/3 O2 SENSOR HEATER FAILURE R O Perform DTC TEST Before Proceeding U B L E C O D E T E S T S
FIG. 1
662
YES
T R O U B L E C O D E T E S T S
NO
WAIT 3 MINUTES.
WITH THE DRB IN ACTUATOR TESTS, PERFORM THE O2 SENSOR HEATER TEST.
YES
NO
AT THIS TIME, THE CONDITION REQUIRED TO SET THE TROUBLE CODE IS NOT PRESENT. FIG. 1
T TEST TC-189A R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
664
T R O U B L E C O D E T E S T S
YES
NO
NO
YES
NO
YES
NO
YES
N TEST NTC-1A O T R O U B L E C O D E T E S T S
Perform DTC Test Before Proceeding. For Diesel Vehicles Perform NTC-1B.
First, check all Technical Service Bulletins and Hotline Newsletters that relate to this driveability problem. Perform corrective actions if indicated, otherwise continue. 1. NO TROUBLE CODE COMPLETE TEST (non-monitored & monitored circuits) Perform TESTS NTC-2A through NTC-18 in sequence until the driveability problem is found. NO TROUBLE CODE MENU CHECKING SECONDARY IGNITION AND TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-2A CHECKING THE FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-3A CHECKING COOLANT SENSOR CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-4A CHECKING THROTTLE POSITION SENSOR CALIBRATION. . . . . . . . . . . . . . . . . . . . . . . .NTC-5A CHECKING MAP SENSOR CALIBRATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-6A CHECKING FOR OXYGEN SENSOR SWITCHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-7A CHECKING THE OXYGEN SENSOR HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-8A CHECKING THE IDLE AIR CONTROL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-9A CHECKING THE PARK/NEUTRAL SWITCH (AUTO ONLY) . . . . . . . . . . . . . . . . . . . . . . . .NTC-10A CHECKING THE PCM POWER AND GROUND CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . .NTC-11A CHECKING THE EVAP SYSTEM (GASOLINE ENGINE). . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-12A CHECKING THE EGR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-13A CHECKING THE ENGINE VACUUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-14A CHECKING THE INTAKE AIR TEMP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-15A CHECKING THE MINIMUM IDLE AIR FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-16A CHECKING THE ENGINE MECHANICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-22A 2. NO TROUBLE CODE QUICK INDIVIDUAL TEST (individual test only) If you suspect any of the above items to be the cause of the vehicles driveability problem, perform the associated test(s) individually. Return No Trouble Code Menu if driveability problem still exists, or perform No Trouble Code Complete Test. 3. NO TROUBLE CODE QUICK SYMPTOM TEST (symptom test only) Symptom checks cannot be used properly unless the driveability problem characteristic actually happens while the vehicle is being tested. To reduce diagnostic time, ensure that the DTC-Test and appropriate General Information sections have been reviewed before attempting to diagnose a symptom. Select the symptom that most accurately describes the vehicles driveability problem and then perform the test routine that pertains to this symptom. Perform each routine test in sequence until the problem is found. For definitions, see Section 12.0 in the General Information section in this manual.
SYMPTOM HARD START START AND STALL HESITATION/SAG/STUMBLE SURGE LACK OF POWER/SLUGGISH SPARK KNOCK/DETONATION CUTS OUT/MISSES BACKFIRE/POPBACK RUNS ROUGH/UNSTABLE/ERRATIC IDLE POOR FUEL ECONOMY DIAGNOSTIC TEST ROUTINE NTC-2A, 3A, 4A, 5A, 6A, 7A, 9A, 11A, 16A, 22A NTC-2A, 3A, 4A, 5A, 6A, 9A, 11A, 22A NO TROUBLE CODE COMPLETE TEST (STEP 1) NTC-2A, 3A, 4A, 5A, 6A, 7A, 9A, 11A, 12A, 13A, 22A NTC-2A, 3A, 4A, 5A, 6A, 7A, 9A, 11A, 12A, 14A, 22A NTC-2A, 3A, 4A, 5A, 6A, 7A, 9A, 11A, 13A, 22A NTC-2A, 3A, 7A, 11A, 14A, 22A NTC-2A, 3A, 6A, 7A, 11A, 14A, 22A NO TROUBLE CODE COMPLETE TEST (STEP 1) NO TROUBLE CODE COMPLETE TEST (STEP 1)
666
N O T R O U B L E C O D E T E S T S
First, check all Technical Service Bulletins and Hotline Newsletters that relate to this driveability problem. Perform corrective actions indicated; otherwise continue. 1. NO TROUBLE CODE COMPLETE TEST (non-monitored & monitored circuits) Perform TESTS NTC-17A through NTC-22A in sequence until the driveability problem is found. NO TROUBLE CODE MENU CHECKING AIR INTAKE HEATER #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-17A CHECKING AIR INTAKE HEATER #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-18A CHECKING FUEL HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-19A CHECKING THE WAIT-TO-START LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-20A CHECKING THE WATER-IN-FUEL LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-21A CHECKING THE ENGINE MECHANICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-22A 2. NO TROUBLE CODE QUICK INDIVIDUAL TEST (individual test only) If you suspect any of the above items to be the cause of the vehicles driveability problem, perform the associated test(s) individually. Return No Trouble Code Menu if driveability problem still exists, or perform No Trouble Code Complete Test.
667
N TEST NTC-2A O T R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
FIG. 3
668
FIG. 4
N O T R O U B L E C O D E T E S T S
ENGINE OFF.
NOTE: IF ENGINE WILL NOT IDLE, MAINTAIN A CONSTANT RPM ABOVE IDLE.
NO
YES
NO
YES
NOTE: THE ENGINE TEMPERATURE MUST BE ABOVE 180F FOR THE FOLLOWING TEST.
NO
YES
N TEST NTC-3A O T R O U B L E C O D E T E S T S
FIG.1
670
N O T R O U B L E C O D E T E S T S
YES
WARNING: THE FUEL SYSTEM MUST BE OPENED AND MAY BE UNDER HIGH PRESSURE.
NO
WARNING: THE FUEL SYSTEM MUST BE OPENED AND MAY BE UNDER HIGH PRESSURE.
RELIEVE FUEL PRESSURE AND REPAIR AS NECESSARY.* SEE GENERAL INFO 9.0
RECONNECT FUEL PRESSURE GAUGE TO THE FUEL SYSTEM. TURN IGNITION ON.
YES
NO
RELIEVE FUEL PRESSURE AND REPLACE FUEL PUMP MODULE.* SEE GENERAL INFO 9.0
N TEST NTC-3B O T R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
672
N O T R O U B L E C O D E
YES CONTINUE TEST NTC-3B ON THE NEXT PAGE.
NOTE: THE FUEL TANK MUST BE AT LEAST 1/4 FULL TO PERFORM THE FOLLOWING TEST.
TURN IGNITION OFF. INSTALL A PRESSURE GAUGE (0-300 PSI) AT SERVICE PORT. FIG. 1
NO
T E S T S
YES
FOLLOW STEPS IN THE SERVICE MANUAL TO REPLACE DAMAGED FUEL PRESSURE REGULATOR.*
NO
YES
NO
N TEST NTC-3B O T R O U B L E C O D E T E S T S
NOTES
674
N O T R O U B L E C O D E T E S T S
WITH THE DRB, READ THE FUEL PRESSURE, AND COMPARE THE READING TO THE MECHANICAL GAUGE.
IS THE CNG FUEL PRESSURE WITHIN 5 PSI OF THE MECHANICAL FUEL PRESSURE GAUGE? NO
YES
N TEST NTC-4A O T R O U B L E C O D E T E S T S
676
N O T R O U B L E C O D E T E S T S
NOTE: INSPECT FOR A MECHANICAL COOLING PROBLEM BEFORE REPLACING SENSOR.
WITH THE DRB, READ THE ENGINE COOLANT TEMPERATURE SENSOR VALUE.
NOTE: IF VEHICLE TEMP IS ABOVE 180F, ALLOW ENGINE TO COOL UNTIL 150F IS REACHED.
WHILE MONITORING THE DRB, ALLOW ENGINE TO REACH NORMAL OPERATING TEMP. (ABOVE 180F)
NO
YES
NO
YES
N TEST NTC-5A O T R O U B L E C O D E T E S T S
ZJ BODY
678
N O T R O U B L E C O D E T E S T S
KEY ON. WITH THE DRB, READ THE TP SENSOR VOLTAGE. THROTTLE MUST BE AGAINST STOP.
YES
IF A DIESEL CHECK ADJUSTMENT OF IDLE SPEED AND THROTTLE LINKAGE ROD PER...
NO
WHILE MONITORING THE DRB, SLOWLY OPEN AND CLOSE THE THROTTLE.
NO
YES
STOP MOVING LINKAGE. WIGGLE THE THROTTLE POSITION SENSOR CONNECTORS AND HARNESS.
WAS THERE ANY CHANGE IN THROTTLE POSITION SENSOR VOLTAGE WHEN WIGGLED? NO
YES
START THE ENGINE. WIGGLE THE THROTTLE POSITION SENSOR CONNECTORS AND HARNESS.
YES
REPAIR THE HARNESS OR CONNECTOR THAT CAUSED THE ENGINE RPM TO CHANGE.*
NO
YES
REPAIR AS NECESSARY.*
NO
N TEST NTC-6A O T R O U B L E C O D E T E S T S
ZJ BODY
ALL OTHERS
680
N O T R O U B L E C O D E
T E S T S
NOTE: IF THE ENGINE WILL NOT IDLE, MAINTAIN A CONSTANT RPM ABOVE IDLE.
YES
NO
N TEST NTC-7A O T R O U B L E C O D E T E S T S
ALL CNG
ALL OTHERS
682
N O T R O U B L E C O D E T E S T S
NOTE: THE 1/2 AND 1/3 O2 SENSORS SHOULD SWITCH SLOWER THAN THE 1/1 OR 2/1 O2 SENSORS.
NO
YES
NO
INSTALL A FUEL PRESSURE GAUGE TO THE FUEL LINE. USE SPECIAL TOOLS IF NECESSARY.
WITH THE DRB, STOP FUEL SYSTEM TEST. MONITOR THE PRESSURE GAUGE FOR 1 MINUTE.
YES
IF FUEL PUMP AND LINES ARE OK, REPLACE LEAKING INJECTOR(S) AS NECESSARY.*
NO
INSPECT THE AIR FILTER AND INLET DUCTS FOR RESTRICTION(S). SEE GENERAL INFO 4.4
YES
NO
N TEST NTC-7B O T R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
684
N O T R O U B L E C O D E T E S T S
YES
NO
NO
YES
DISCONNECT THE O2 SENSOR CONNECTOR THAT THE VOLTAGE IS BELOW 0.10 VOLT.
YES
NO
N TEST NTC-7B O T R O U B L E C O D E T E S T S
NOTES
686
N O T R O U B L E
C O D E T E S T S
NOTE: THE 1/2 AND 1/3 O2 SENSOR SHOULD SWITCH SLOWER THAN THE 1/1 OR 2/1 O2 SENSOR.
NO
N TEST NTC-8A O T R O U B L E C O D E T E S T S
FIG. 1
5.9L HD,8.0L HD AND 8.0L CAL/MD ALL OTHERS
688
N O T R O U B L E C O D E T E S T S
TURN IGNITION ON. WITH THE DRB, ACTUATE THE O2 SENSOR HEATER TEST.
ARE ANY OF THE VOLTAGES FOR THE O2 SENSORS ABOVE 1.0 VOLT?
NO
YES
NOTE: THE O2 SENSOR VOLTAGE STAYING ABOVE 1.0 VOLT INDICATES A PROBLEM WITH THAT SENSOR.
DISCONNECT THE O2 SENSOR CONNECTOR THAT HAS VOLTAGE ABOVE 1.0 VOLT.** SEE GENERAL INFO 4.4
USING A VOLTMETER, MEASURE THE ASD RELAY OUTPUT CIRCUIT AT SENSOR CONNECTOR. FIG. 1
NO
REPAIR THE OPEN ASD RELAY OUTPUT CIRCUIT TO THE O2 SENSOR CONNECTOR.*
YES
NO
YES
N TEST NTC-9A O T R O U B L E C O D E T E S T S
ZJ BODY
690
N O T R O U B L E C O D E T E S T S
USING THE DRB IN ACTUATOR TESTS, SET ENGINE SPEED TO 1400 RPM.
YES
WITH THE DRB, STOP ALL TESTS. IAC MOTOR IS OPERATING OK. TEST PASSED.
NO
YES
NO
DISCONNECT THE IDLE AIR CONTROL MOTOR CONNECTOR.** SEE GENERAL INFO 4.0
YES
REPAIR AS NECESSARY.*
NO
N TEST NTC-9A O T R O U B L E C O D E T E S T S
AB BODY
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
692
FIG. 4
N O T R O U B L E C O D E T E S T S
YES REPAIR THE IAC #2 DRIVER CIRCUIT SHORTED TO GROUND.*
KEY OFF, DISCONNECT THE IAC MOTOR CONNECTOR.** SEE GENERAL INFO 4.0
YES
REPAIR AS NECESSARY.*
NO
YES
NO
NO
YES
NO
YES
NO
N TEST NTC-9A O T R O U B L E C O D E T E S T S
AB BODY
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
694
FIG. 4
N O T R O U B L E C O D E T E S T S
TURN IGNITION ON. WITH THE DRB IN ACTUATOR TESTS, ACTUATE THE IAC STEPPER MOTOR.
NOTE: THE VOLTAGE MAY SWITCH OR REMAIN CONSTANT DURING THIS TEST.
NO
YES
NO
YES
NO
YES
NO
YES
N TEST NTC-9B O T R O U B L E C O D E T E S T S
AB BODY
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
696
FIG. 4
N O T R O U B L E C O D E T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.0
YES
REPAIR AS NECESSARY.*
NO
THE FOLLOWING STEPS ARE CHECKING FOR A SHORT BETWEEN THE DRIVER CIRCUITS.
YES
NO
YES
NO
YES
NO
N TEST NTC-10A O T R O U B L E C O D E T E S T S
FIG. 1
AN AND XJ BODIES BR AND ZJ BODIES
FIG. 2
698
FIG. 3
N O T R O U B L E C O D E T E S T S
WHILE MOVING GEAR SELECTOR FROM PARK TO 1 AND BACK TO PARK, WATCH DRB DISPLAY.
DID THE DISPLAY SHOW "P/N" AND "D/R" IN THE CORRECT POSITIONS?
YES
NO
MEASURE THE RESISTANCE BETWEEN THE P/N SWITCH SENSE CKT AND GROUND. FIG. 1, 2 OR 3
OBSERVE THE OHMMETER DISPLAY WHILE MOVING GEAR SELECTOR FROM PARK TO 1 AND BACK TO PARK.
DID THE DISPLAY SWITCH FROM BELOW 10.0 OHMS TO ABOVE 10.0 OHMS?
YES
NO
YES
NO
N TEST NTC-10A O T R O U B L E C O D E T E S T S
AN BODY AB BODY
FIG. 1
BR BODY
FIG. 2
XJ BODY ZJ BODY
FIG. 3
FIG. 4
700
FIG. 5
N O T R O U B L E C O D E T E S T S
DISCONNECT THE PARK/NEUTRAL POSITION SWITCH CONNECTOR.** SEE GENERAL INFO 4.4
YES
NO
N TEST NTC-11A O T R O U B L E C O D E T E S T S
AN BODY
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
702
FIG. 4
N O T R O U B L E C O D E T E S T S
NO REPAIR THE OPEN GROUND CIRCUIT.*
KEY OFF. DISCONNECT THE BLACK POWERTRAIN CONTROL MODULE CONNECTOR.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE CAVITY A31 IN THE BLACK PCM CONNECTOR. FIG. 1, 2, 3 OR 4
NO
YES
USING AN OHMMETER, MEASURE CAVITY A32 IN THE BLACK PCM CONNECTOR. FIG. 1, 2, 3 OR 4
YES
USING A VOLTMETER, MEASURE CAVITY A22 IN THE BLACK PCM CONNECTOR. FIG. 1, 2, 3 OR 4
NO
YES
NO
YES
N TEST NTC-12A O T R O U B L E C O D E T E S T S
BR BODY AB BODY
XJ BODY
ZJ 4.0L
ZJ 5.2L
704
N O T R O U B L E C O D E T E S T S
NOTE: CAREFULLY INSPECT ALL VACUUM HOSES FOR PROPER ROUTING AND FOR PINCHED OR...
PLUGGED HOSES FROM THE ENGINE TO THE EVAP SOLENOID TO THE GAS TANK.
NO
YES
START THE ENGINE AND ALLOW IT TO REACH NORMAL OPERATING TEMPERATURE (170 DEG F).
DISCONNECT THE PURGE VACUUM HOSE AT THE SOLENOID THAT GOES TO THE CANISTER.
START THE ENGINE. THERE SHOULD BE NO FLOW THE THROUGH SOLENOID FROM 1 TO 2 MINUTES.
IS THE PURGE SOLENOID ALLOWING VACUUM THROUGH THE SOLENOID WITHIN 1 MINUTE? NO
YES
IS THE EVAP SOLENOID ALLOWING VACUUM TO CYCLE THROUGH INTERMITTENTLY AT A STEADY RATE? YES
NO
NOTE: IN THE NEXT STEPS, DO NOT USE MORE THAN FIVE PSI.
KEY OFF, ATTEMPT TO BLOW AIR THROUGH THE VACUUM LINE THAT GOES TO THE CANISTER.
YES
NO
N TEST NTC-12A O T R O U B L E C O D E T E S T S
REMOVE THE PURGE SOLENOID AND TAP THE PORTS AGAINST A CLEAN, SOLID SURFACE.
NO
YES
NO
CLEAN OUT THE LINE AND REPLACE THE EVAP PURGE SOLENOID AND CANISTER.*
N O T R O U B L E C O D E T E S T S
REPAIR OR REPLACE THE VACUUM LINE.*
DISCONNECT THE VACUUM LINE AT THE CANISTER THAT GOES TO THE EVAP SOLENOID.
ATTEMPT TO BLOW AIR THROUGH THE VACUUM LINE THAT GOES TO THE CANISTER.
YES
NO
N TEST NTC-13A O T R O U B L E C O D E T E S T S
TYPICAL CONFIGURATION
FIG. 1
708
N O T R O U B L E C O D E T E S T S
YES
NO
NO
YES
WITH THE DRB IN EGR SYSTEM TEST PRESS #2 TO BLOCK EGR FLOW.
ACTUATE THE EGR SOLENOID AND ALLOW EGR TO FLOW. MONITOR INTAKE AIR TEMPERATURE.
DID THE INTAKE AIR TEMPERATURE RISE AFTER THE EGR WAS ACTUATED?
NO
YES
YES
REPAIR AS NECESSARY.*
NO
TEST COMPLETE.*
N TEST NTC-13A O T R O U B L E C O D E T E S T S
TYPICAL CONFIGURATION
FIG. 1
710
N O T R O U B L E C O D E T E S T S
DISCONNECT THE EGR SOLENOID VACUUM SUPPLY AT THE EGR SOLENOID. FIG. 1
NO
YES
RECONNECT THE EGR SOLENOID VACUUM SUPPLY AT THE EGR SOLENOID. FIG. 1
DISCONNECT THE EGR VACUUM LINE AT THE EGR SOLENOID THAT GOES TO THE EGR.
NO
YES
RECONNECT THE EGR VACUUM LINE AT THE EGR SOLENOID THAT GOES TO THE EGR.
NO
YES
REMOVE EGR VALVE AND CONNECT A HAND OPERATED VACUUM PUMP TO FITTING. FIG. 1
SLOWLY APPLY 10 INCHES OF VACUUM TO EGR VALVE AND MONITOR POPPET VALVE.
NO
YES
ENSURE THERE IS NO CARBON BUILD UP IN EGR TUBE, INTAKE AND EXHAUST MANIFOLDS AND RETEST EGR.
N TEST NTC-13B O T R O U B L E C O D E T E S T S
FIG. 1
712
N O T R O U B L E C O D E
T E S T S
WHILE SLOWLY APPLYING VACUUM TO THE EGR VALVE, LISTEN FOR AN ENGINE SPEED CHANGE. DID THE ENGINE SPEED STAY THE SAME? YES INSPECT PASSAGES, IF OK, REPLACE THE EGR VALVE ASSEMBLY.*
NO
NO
YES
N TEST NTC-14A O T R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
714
N O T R O U B L E
C O D E T E S T S
NOTE: A NORMAL VACUUM READING WILL VARY ACCORDING TO THE ALTITUDE. FIG. 1
WHILE MONITORING THE VACUUM GAUGE, SNAP THE THROTTLE OPEN A FEW TIMES.
NO
YES
N TEST NTC-15A O T R O U B L E C O D E T E S T S
FIG. 1
AN 2.5L, XJ, AND 4.0L ZJ AN 5.2L
FIG. 2
BR 8.0L ZJ 5.2L
FIG. 3
FIG. 4
716
FIG. 5
N O T R O U B L E C O D E T E S T S
NOTE: MAKE SURE THE IGNITION KEY IS ON AT THIS TIME (ENGINE OFF).
CAUTION: DO NOT ALLOW MORE THAN 5 MINUTES DELAY BETWEEN NEXT STEPS.
WITH THE DRB, READ THE INTAKE AIR TEMPERATURE (IAT) SENSOR AND RECORD THE READING.
USING A TEMP PROBE, MEASURE THE IAT INSIDE MAP SENSOR OPENING. FIG. 1, 2, 3, 4 OR 5
NO
YES
N TEST NTC-16A O T R O U B L E C O D E T E S T S
FIG. 1
718
N O T R O U B L E C O D E T E S T S
YES
2.5L AND 4.0L ENGINES DO NOT HAVE A MINIMUM IDLE AIR FLOW TEST.
NO
AND INSTALL THE 0.185 ORIFICE INTO THE VACUUM LINE. FIG. 1
DISCONNECT THE 3/16" EVAPORATIVE EMISSION HOSE ON THE SIDE OF THE THROTTLE BODY...
START ENGINE. ALLOW ENGINE TO REACH NORMAL OPERATING TEMPERATURE. (ABOVE 180F)
YES
NO
STOP ACTUATION TEST. TURN ENGINE OFF. USING AN APPROVED CLEANER, CLEAN THE THROTTLE BODY.
START THE ENGINE. WITH THE DRB, ACTUATE THE MINIMUM AIR FLOW.
NO
NOTE: A VACUUM LEAK MAY CAUSE THE IAC MOTOR NOT TO PERFORM CORRECTLY.
N TEST NTC-17A O T R O U B L E C O D E T E S T S
FIG. 1
720
N O T R O U B L E C O D E T E S T S
CAUTION: AIR INTAKE HEATER ACTUATION TIME MUST BE KEPT AT A MINIMUM DUE TO HIGH CURRENT DRAW.
USING A VOLTMETER, MEASURE THE BATTERY B(+) TERMINAL AND RECORD THE RESULT.
WHILE ACTUATING, USE A VOLTMETER AND MEASURE THE BATTERY B(+) TERMINAL.
DID THE BATTERY VOLTAGE DROP 0.5 VOLT OR MORE DURING ACTUATION TEST? NO
YES
YES
NO
DISCONNECT THE FUSED IGNITION SWITCH OUTPUT CIRCUIT AT HEATER RLY #1 CAV.2 FIG. 1
USING A VOLTMETER, MEASURE THE FUSED IGN SWITCH OUTPUT CIRCUIT. FIG. 1
NO
YES
DISCONNECT THE AIR INTAKE HEATER RELAY #1 CONTROL CIRCUIT, CAVITY 1 FIG. 1
CONNECT ONE END OF A JUMPER WIRE TO THE OPEN RELAY TERMINAL AND BRIEFLY TAP...
NO
YES
N TEST NTC-17A O T R O U B L E C O D E T E S T S
FIG. 1
722
N O T R O U B L E
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE BLACK CONNECTOR.** SEE GENERAL INFO 4.1
C O D E T E S T S
USING AN OHMMETER, MEASURE THE RESISTANCE OF THE AIR INTAKE HEATER RELAY #1...
NO
YES
USING AN OHMMETER, MEASURE AIR INTAKE HEATER RLY #1 CONTROL CKT AT PCM TO GROUND. FIG. 1
YES
REPAIR THE AIR INTAKE HEATER RELAY #1 CONTROL CIRCUIT FOR A SHORT TO GROUND.*
NO
N TEST NTC-17B O T R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
724
N O T R O U B L E C O D E T E S T S
USING A VOLTMETER, MEASURE THE B(+) CIRCUIT FOR AIR INTAKE HEATER #1. FIG. 1
NO
REPAIR THE OPEN B(+) CIRCUIT BETWEEN THE BATTERY AND INTAKE HEATER RELAY #1.*
YES
WITH THE DRB, ACTUATE THE AIR INTAKE HEATER RELAY #1.
USING A VOLTMETER, MEASURE THE AIR INTAKE HEATER RELAY #1 OUTPUT CIRCUIT. FIG. 2
NO
YES
N TEST NTC-18A O T R O U B L E C O D E T E S T S
FIG. 1
726
N O T R O U B L E C O D E T E S T S
CAUTION: AIR INTAKE HEATER ACTUATION TIME MUST BE KEPT AT A MINIMUM DUE TO HIGH CURRENT DRAW.
USING A VOLTMETER, MEASURE THE BATTERY B(+) TERMINAL AND RECORD THE RESULT.
DID THE BATTERY VOLTAGE DROP 0.5 VOLT OR MORE DURING ACTUATION TEST? NO
YES
YES
NO
DISCONNECT THE FUSED IGNITION SWITCH OUTPUT CIRCUIT AT HEATER RLY #2 CAV.4 FIG.1
USING A VOLTMETER, MEASURE THE FUSED IGN SWITCH OUTPUT CIRCUIT. FIG. 1
NO
YES
DISCONNECT THE AIR INTAKE HEATER RELAY #2 CONTROL CIRCUIT, CAVITY 3. FIG. 1
CONNECT ONE END OF A JUMPER WIRE TO THE OPEN RELAY TERMINAL AND BRIEFLY TAP...
NO
YES
N TEST NTC-18A O T R O U B L E C O D E T E S T S
FIG. 1
728
N O T R O U B L E
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE BLACK CONNECTOR.** SEE GENERAL INFO 4.1
C O D E T E S T S
USING AN OHMMETER, MEASURE THE RESISTANCE OF THE AIR INTAKE HEATER RELAY #2...
NO
YES
USING AN OHMMETER, MEASURE AIR INTAKE HEATER RLY #2 CONTROL CKT AT PCM TO GROUND. FIG. 1
YES
REPAIR THE AIR INTAKE HEATER RELAY #2 CONTROL CIRCUIT FOR A SHORT TO GROUND.*
NO
N TEST NTC-18B O T R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
730
N O T R O U B L E C O D E T E S T S
USING A VOLTMETER, MEASURE THE B(+) CIRCUIT FOR AIR INTAKE HEATER #2. FIG. 1
NO
REPAIR THE OPEN B(+) CIRCUIT BETWEEN THE BATTERY AND INTAKE HEATER RELAY #2.*
YES
WITH THE DRB, ACTUATE THE AIR INTAKE HEATER RELAY #2.
USING A VOLTMETER, MEASURE THE AIR INTAKE HEATER RELAY #2 OUTPUT CIRCUIT. FIG. 2
NO
YES
N TEST NTC-19A O T R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
732
N O T R O U B L E C O D E
DID THE RELAY CLICK? YES CONTINUE TEST NTC-19A ON THE NEXT PAGE.
NOTE: TO HEAR CLICK IN THE NEXT STEP. IT MAY BE NECESSARY TO DISCONNECT THE RELAY MORE THAN ONCE.
WHILE LISTENING FOR THE RELAY TO CLICK, DISCONNECT THE FUEL HEATER RLY.** FIG. 1
NO
T E S T S
WITH A VOLTMETER, MEASURE THE FUSED IGN SWITCH OUTPUT CIRCUIT. FIG. 2
NO
YES
WITH AN OHMMETER, MEASURE THE FUEL HEATER RELAY GROUND CIRCUIT. FIG. 2
YES
NO
N TEST NTC-19A O T R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
FIG. 3
FIG. 4
734
FIG. 5
N O T R O U B L E C O D E T E S T S
WITH A VOLTMETER, MEASURE THE FUSED B(+) IN HEATER RELAY CONNECTOR. FIG. 1
NO
YES
NO
YES
USING AN OHMMETER, MEASURE THE RESISTANCE OF THE FUEL HEATER RELAY OUTPUT CIRCUIT...
YES
NO
YES
NO
NOTE: THE FUEL HEATER TEMPERATURE MUST BE BELOW 40F FOR THE NEXT STEP.
USING AN OHMMETER, MEASURE THE RESISTANCE OF THE FUEL HEATER. FIG. 2 AND 5
NO
THE NO START CONDITION IS DUE TO A MECHANICAL PROBLEM. SEE SERVICE MANUAL FOR REPAIRS.
YES
N TEST NTC-20A O T R O U B L E C O D E T E S T S
736
N O T R O U B L E C O D E T E S T S
NO TEST PASSED.
YES
NO
YES
NO
YES
KEY OFF, DISCONNECT POWERTRAIN CONTROL MODULE CONNECTOR.** SEE GENERAL INFO 4.1
YES
NO
N TEST NTC-20A O T R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
738
N O T R O U B L E C O D E T E S T S
DISCONNECT THE POWERTRAIN CONTROL MODULE CONNECTOR.** SEE GENERAL INFO 4.1
YES
NO
YES
BACKPROBE THE FUSED IGNITION SWITCH OUTPUT CKT AT THE MESSAGE CENTER CONN. FIG. 2
NO
REPAIR THE OPEN FUSED IGNITION SWITCH OUTPUT CIRCUIT.* TO MESSAGE CENTER.
YES
CONNECT A JUMPER BETWEEN MESSAGE CENTER CONNECTOR AND A GOOD GROUND. FIG. 2
YES
REPAIR THE OPEN WAIT-TO-START LAMP DRIVER CIRCUIT.* PCM TO MESSAGE CENTER.
NO
N TEST NTC-21A O T R O U B L E C O D E T E S T S
FIG. 1
740
N O T R O U B L E
NO TEST PASSED.
YES
C O D E T E S T S
YES
NO
DISCONNECT THE POWERTRAIN CONTROL MODULE CONNECTOR.** SEE GENERAL INFO 4.1
N TEST NTC-21A O T R O U B L E C O D E T E S T S
FIG. 1
FIG. 2
742
N O T R O U B L E C O D E
MEASURE ACROSS THE WATER-IN-FUEL SENSE CKT FROM THE PCM TO THE WIF CONNECTOR. FIG. 1
NO
YES
T E S T S
YES
NO
N TEST NTC-21A O T R O U B L E C O D E T E S T S
FIG. 1
744
N O T R O U B L E C O D E
YES
T E S T S
BACKPROBE THE FUSED IGN. SWITCH OUTPUT CKT. AT MESSAGE CTR CONN. FIG. 1
NO
YES
NO
YES
N TEST NTC-21B O T R O U B L E C O D E T E S T S
FIG. 1
746
N O T R O U B L E C O D E
T E S T S
IS THE RESISTANCE ABOVE 5.0 OHMS? YES REPAIR THE OPEN SENSOR GROUND CIRCUIT.*
NO
N TEST NTC-22A O T R O U B L E C O D E T E S T S
The components and systems that you have checked before this are operating properly. Here are additional non-monitored components or systems to check, that could cause a driveability problem. 1. DISTRIBUTOR POSITION must be within specifications 2. ENGINE VACUUM must be at least 13 inches in neutral (see below) 3. ENGINE VALVE TIMING must be within specifications 4. ENGINE COMPRESSION must be within specifications 5. ENGINE EXHAUST SYSTEM must be free of any restrictions 6. ENGINE PCV SYSTEM must flow freely 7. ENGINE DRIVE SPROCKET must be properly positioned 8. TORQUE CONVERTER STALL SPEED must be within specifications (auto only) 9. POWER BRAKE BOOSTER no internal vacuum leaks 10. FUEL must be free of contamination 11. FUEL INJECTOR plugged or restricted injector; control wire not connected to correct injector NOTE: If you came to this test from the oxygen sensor, and the rich or lean condition is not caused by one of the first items above, replace the powertrain control module and perform TEST VER-2A (Road Test Verification). Checking Distributor Position With DRB Connect the DRB to the data link connector and select SET SYNC from the menu. WARNING: The following test will be performed with the engine running: avoid contact with rotating components. Start the engine and observe the DRB display. When the distributor is correctly positioned, the IN RANGE message should appear along with 0. If the distributor needs to be adjusted, loosen the distributor hold-down clamp bolt. Rotate the distributor until reading is as close as to 0 as possible and the IN RANGE message displayed. Tighten the clamp bolt to 22.5 Nm (200 in. lbs.) torque. NOTE: Setting the distributor position does not adjust the ignition timing. Ignition timing values are determined by the powertrain control module. The readings below are only indicators of possible mechanical engine problems.
748
N O T R O U B L E C O D E T E S T S
The components and systems that you have checked before this are operating properly. Here are additional non-monitored components or systems to check, that could cause a driveability problem. 1. FUEL INJECTION PUMP malfunction, or not adjusted properly or incorrect pump timing. 2. AIR IN FUEL SYSTEM 3. RESTRICTED OR DAMAGED INJECTOR NOZZLE 4. IMPROPER FUEL 5. CLOGGED FUEL FILTER 6. RESTRICTED OR BLOCKED FUEL INJECTION LINES 7. LEAKING INJECTION LINES, DAMAGED LINES OR LOOSE CONNECTIONS 8. EMPTY FUEL TANK OR FUEL TANK VENT BLOCKED 9. CLOGGED OR RESTRICTED AIR FILTER 10. INTERCOOLER INTERNALLY BLOCKED OR LEAKING 11. LOW OR UNEVEN ENGINE COMPRESSION 12. LOW IDLE MISADJUSTED 13. CONTROL LEVER NOT GOING TO FULL THROTTLE POSITION
749
S TEST SC-1A CHECKING THE SPEED CONTROL OPERATION P E Perform DTC TEST Before Proceeding E AB, AN AND XJ BODIES D C O N T R O L T E S T S
BR BODY
ZJ BODY
750
TEST SC-1A
S P E E D C O N T R O L
START ENGINE.
KEY ON, WITH THE DRB, MONITOR THE SPEED CONTROL SWITCH INPUTS.
NO
YES
T E S T S
WHILE OBSERVING THE DISPLAY, PRESS THE BRAKE PEDAL SEVERAL TIMES.
NO
YES
NO
YES
S TEST SC-1A P E E D C O N T R O L T E S T S
NOTES
752
TEST SC-1A
S P E E D C O N T R O L T E S T S
WHILE OBSERVING THE DISPLAY, PRESS THE SET SWITCH SEVERAL TIMES.
DOES THE DRB SHOW THE SET SWITCH "PRESSED" AND "RELEASED"?
NO
YES
WHILE OBSERVING THE DISPLAY, PRESS THE RESUME SWITCH SEVERAL TIMES.
DOES THE DRB SHOW THE RESUME SWITCH "PRESSED" AND "RELEASED"? YES
NO
WHILE OBSERVING THE DISPLAY, PRESS THE CANCEL SWITCH SEVERAL TIMES. (ZJ BODY ONLY)
DOES THE DRB SHOW THE CANCEL SWITCH "PRESSED" AND "RELEASED"? YES
NO
S TEST SC-1A P E E D C O N T R O L T E S T S
FIG. 1
754
TEST SC-1A
S P E E D
REPAIR AS NECESSARY.*
KEY OFF, DISCONNECT THE SPEED CONTROL SERVO CONNECTOR.** SEE GENERAL INFO 4.2
YES
NO
C O N T R O L T E S T S
NO
YES
KEY ON. WITH THE DRB, ACTUATE THE SPEED CONTROL VENT SOLENOID.
NO
YES
RECONNECT THE SPEED CONTROL SERVO CONNECTOR. START ENGINE, ALLOW TO IDLE 1 MINUTE.
TURN ENGINE OFF, (IGNITION ON) WITH THE DRB, ACTUATE THE SPEED CONTROL SERVO SOLENOIDS.
YES
NO
KEY OFF, DISCONNECT THE VACUUM SUPPLY TO THE SPEED CONTROL SERVO.
NO
YES
NO
YES
S TEST SC-1A CONTINUED - CHECKING THE SPEED CONTROL OPERATION P E E AB, AN AND XJ BODIES BR BODY D C O N T R O L T E S T S
ZJ BODY AB, AN AND XJ BODIES
FIG. 1
BR BODY ZJ BODY
FIG. 2
756
FIG. 3
TEST SC-1A
S P E E D
REPAIR AS NECESSARY.*
YES
NO
C O N T R O L T E S T S
KEY OFF. DISCONNECT THE SPEED CONTROL SERVO 4 WAY CONNECTOR.** SEE GENERAL INFO 4.2
SPEED CONTROL VACUUM SOLENOID CONTROL CIRCUIT TO THE PCM CONNECTOR. FIG. 1, 2 OR 3
NO
YES
SPEED CONTROL VENT SOLENOID CONTROL CIRCUIT TO THE PCM CONNECTOR. FIG. 1, 2 OR 3
NO
YES
S TEST SC-1B CHECKING THE SPEED CONTROL OPERATION P E Perform TEST SC-1A Before Proceeding E D C O N T R O L T E S T S
FIG. 1
AB BODY AN AND XJ BODIES
FIG. 2
BR BODY ZJ BODY
FIG. 3
FIG. 4
758
FIG. 5
TEST SC-1B
S P E E D
YES REPAIR THE SWITCHED S/C POWER SUPPLY OUTPUT CICUIT SHORTED TO GROUND.*
USING AN OHMMETER, MEASURE THE SWITCHED S/C POWER SUPPLY CKT AT S/C SERVO TO GND. FIG. 1
NO
C O N T R O L T E S T S
YES
REPAIR AS NECESSARY.*
NO
NO
YES
MEASURE THE SWITCHED S/C BRAKE SWITCH OUTPUT CIRCUIT FOR RESISTANCE....
FROM BRAKE SWITCH CONNECTOR TO SPEED CONTROL SERVO. FIG. 1 AND 2 THRU 5
NO
YES
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
760
FIG. 4
TEST SC-1B
S P E E D C O N T R O L
T E S T S
NO
REPAIR THE OPEN S/C POWER SUPPLY CIRCUIT, PCM TO BRAKE SWITCH.*
YES
S TEST SC-2A CHECKING THE SPEED CONTROL OPERATION P E Perform TEST SC-1A Before Proceeding E AB, AN, BR AND XJ BODIES 1996 2.5/3.9/4.0/5.2/5.9/8.0L AB/AN/BR/XJ/ZJ Publication No. 81-699-96103 D TSB 26-03-98 March, 1998 C O N T R O L T E S T S
FIG. 1
ZJ BODY AB, AN AND XJ BODIES
FIG. 2
BR BODY ZJ BODY
FIG. 3
FIG. 4
762
FIG. 5
TEST SC-2A
S P E E D
YES REPAIR AS NECESSARY.*
KEY OFF, DISCONNECT THE SPEED CONTROL SWITCH(S).** SEE GENERAL INFO 4.7
NO
WITH AN OHMMETER, MEASURE THE SPEED CONTROL SWITCH SIGNAL TO GROUND. FIG. 1 OR 2
YES
REPAIR THE SPEED CONTROL SWITCH SIGNAL CIRCUIT, FOR A SHORT TO GROUND.*
C O N T R O L T E S T S
NO
THE SPEED CONTROL SENSOR GROUND CIRCUIT AT THE SWITCH TO GROUND. FIG. 1 OR 2
NO
YES
CONNECT A JUMPER ACROSS SIGNAL CKT AND GROUND CKT AT SWITCH CONNECTOR. FIG. 1 OR 2
YES
NO
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE S/C SWITCH SIGNAL CKT, SWITCH TO PCM. FIG. 3, 4 OR 5
YES
NO
DISCONNECT THE CLOCKSPRING 4-WAY TO I/P HARNESS.** SEE GENERAL INFO 4.7
USING AN OHMMETER, MEASURE THE S/C SWITCH SIGNAL CKT CLOCKSPRING TO PCM. FIG. 3, 4 OR 5
YES
NO
S TEST SC-3A CHECKING THE SPEED CONTROL OPERATION P E Perform TEST SC-1A Before Proceeding E AB BODY AN AND XJ BODY D C O N T R O L T E S T S
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
764
FIG. 4
TEST SC-3A
S P E E D C O N T R O L T E S T S
KEY ON, WITH A VOLTMETER, MEASURE THE BRAKE SWITCH SENSE CIRCUIT. FIG. 1, 2, 3 OR 4
NO
YES
CONNECT A JUMPER BETWEEN THE BRAKE SWITCH SENSE AND GROUND. FIG. 1, 2, 3 OR 4
YES
NO
S TEST SC-3A CONTINUED - CHECKING THE SPEED CONTROL OPERATION P E E AB, AN AND XJ BODIES D C O N T R O L T E S T S
FIG. 1
BR BODY
FIG. 2
ZJ BODY
FIG. 3
766
TEST SC-3A
S P E E D C O N T R O L
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
YES
REPAIR AS NECESSARY.*
NO
T E S T S
YES
NO
FIG. 1
BR BODY ZJ BODY
FIG. 2
FIG. 3
768
FIG. 4
TEST SC-3A
S P E E D C O N T R O L T E S T S
MEASURE THE BRAKE SWITCH SENSE CKT FROM PCM TO BRAKE SWITCH CONNECTOR. FIG. 1, 2, 3 OR 4
YES
NO
S TEST SC-4A CHECKING THE SPEED CONTROL OPERATION P E Perform TEST SC-1A Before Proceeding E AB BODY D C O N T R O L T E S T S
FIG. 1
AN BODY BR BODY
FIG. 2
XJ BODY ZJ BODY
FIG. 3
FIG. 4
770
FIG. 5
TEST SC-4A
S P E E D C O N T R O L T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
WITH AN OHMMETER, MEASURE THE P/N POSITION SWITCH SENSE CIRCUIT. FIG. 1, 2, 3, 4 OR 5
NO
YES
WITH AN OHMMETER, MEASURE THE P/N POSITION SWITCH SENSE CKT AT PCM. FIG. 1, 2, 3, 4 OR 5
NO
YES
S TEST SC-5A CHECKING THE SPEED CONTROL OPERATION P E Perform TEST SC-1A Before Proceeding E NOTES D C O N T R O L T E S T S
772
TEST SC-5A
At this time the speed control switch and servo functions appear to operate properly. Using the DRB, monitor the speed control cutout status. Road test the vehicle at speeds over 35 mph and attempt to set the speed control. The following items will not allow the speed control to set. The last or most recent cause for speed control not to set is indicated by the Denied status. Denied Message ON/OFF SPEED RPM BRAKE The powertrain control module does not see an ON signal from the switch. The vehicle speed as seen by the powertrain control module is not greater than 36 mph. The engine rpm is excessively high. The brake switch sense circuit is open indicating to the powertrain control module that the brakes are applied. The sense circuit is grounded through the brake pedal switch when the brakes are released. The park/neutral switch sense circuit is grounded indicating to the powertrain control module that the transmission is not in gear. The sense circuit is grounded through the park/neutral switch when the transmission is in park or neutral. The PCM senses excessive engine rpm for a given vehicle speed. The powertrain control module senses a servo solenoid circuit trouble code that is maturing or set in memory.
S P E E D C O N T R O L T E S T S
P/N
C TEST CH-1A CHARGING SYSTEM NO CODE TEST H A Perform DTC TEST Before Proceeding R AB BODY AN AND BR BODIES G I N G T E S T S
ZJ BODY
XJ BODY
FIG. 1
774
TEST CH-1A
C H A R G I N G T E S T S
NO
REPAIR AS NECESSARY.*
YES
START ENGINE, TURN ON ALL ACCESSORIES AND RAISE THE ENGINE SPEED TO 2000 RPM FOR 30 SECONDS.
YES
NO
NOTE: THE VOLTAGE SHOULD CYCLE FROM 0 TO BATTERY VOLTAGE EVERY 1.4 SECONDS.
WHILE MONITORING THE VOLTMETER, WIGGLE THE FIELD TERMINALS BACK TO THE PCM AND ASD RELAY.
WAS THERE ANY INTERRUPTION IN THE NORMAL CYCLE BETWEEN 0 AND BATTERY VOLTAGE? NO
YES
STOP ACTUATION.
YES
NO
ZJ BODY
XJ BODY
FIG. 1
776
TEST CH-1A
TEST BETWEEN THE GENERATOR (12V) B(+) TERMINAL AND THE BATTERY (+) SIDE. FIG. 1
C H A R G I N G T E S T S
CAUTION: ENSURE ALL WIRES ARE CLEAR OF THE ENGINES MOVING PARTS.
YES
REPAIR THE B(+) CIRCUIT FOR HIGH RESISTANCE BETWEEN THE GENERATOR AND THE BATTERY.*
NO
CAUTION: ENSURE ALL WIRES ARE CLEAR OF THE ENGINES MOVING PARTS.
YES
REPAIR GENERATOR GROUND HIGH RESISTANCE GENERATOR CASE TO BATTERY (-) SIDE.*
NO
NO
C TEST CH-1A H A R G I N G T E S T S
FIG. 1
778
TEST CH-1A
C H A R G I N G T E S T S
TURN IGNITION ON, USING A VOLTMETER, MEASURE THE FUSED B(+) AT THE PCM. FIG. 1
NO
YES
REPAIR THE B(+) CIRCUIT FOR HIGH RESISTANCE BETWEEN THE PCM FUSED B(+) AND THE BATTERY.*
N TEST NS-SEL O S T A R T T E S T S
CONDITION
TEST
Engine will not crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NS-9 Engine starts and the DRB displays No Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NS-6B Engine does not start and the DRB displays No Response . . . . . . . . . . . . . . . . . . . . . . . . .NS-6A All gasoline engine except 8.0L no-start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NS-1 Compressed natural gas no-start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NS-11 8.0L engine no-start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NS-10 Diesel engine no-start only when engine temp is 40F or below . . . . . . . . . . . . . . . . . . . . . . .NS-14 Diesel engine no-start independent of temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NS-15
780
N O S T A R T T E S T S
NOTES
781
N TEST NS-1A O S T A R T T E S T S
FIG. 1
782
TEST NS-1A
N O S T A R T T E S T S
KEY OFF. DISCONNECT THE SPARK PLUG CABLE AT SPARK PLUG #1. SEE GENERAL INFO 4.2
NO
YES
YES
NO
N TEST NS-1A O S T A R T T E S T S
FIG. 1
FIG. 2
784
TEST NS-1A
N O S T A R T T E S T S
YES
NO
YES
NO
NO
YES
YES
NO
WITH GENERATOR FIELD STILL ACTUATING, USE A VOLTMETER IN THE NEXT STEP.
N TEST NS-1A O S T A R T T E S T S
FIG. 1
BR BODY
FIG. 2
ZJ BODY
FIG. 3
786
TEST NS-1A
N O S T A R T T E S T S
MEASURE THE ASD RELAY OUTPUT CIRCUI IN THE COIL CONNECTOR. FIG. 1, 2, OR 3
NO
REPAIR THE OPEN ASD RELAY OUTPUT CKT FROM COIL CONNECTOR TO SPLICE.*
YES
N TEST NS-1A O S T A R T T E S T S
FIG. 1
FIG. 2
788
TEST NS-1A
N O S T A R T T E S T S
TURN IGNITION OFF. TEST NS-1A CONTINUED FROM PREVIOUS PAGE USE AN OHMMETER IN THE FOLLOWING STEPS.
MEASURE THE RESISTANCE BETWEEN THE PRIMARY TERMINALS OF THE IGNITION COIL.FIG. 1
NO
YES
MEASURE THE RESISTANCE BETWEEN THE PRIMARY AND SECONDARY TERMINALS OF THE COIL. FIG. 2
NO
YES
N TEST NS-1A O S T A R T T E S T S
FIG. 1
BR BODY
FIG. 2
ZJ BODY
FIG. 3
790
TEST NS-1A
N O S T A R T T E S T S
DISCONNECT THE POWERTRAIN CONTROL MODULE BLACK CONNECTOR.** SEE GENERAL INFO 4.1
USING AN OHMMETER, MEASURE THE IGNITION COIL DRIVER CKT AT THE PCM...
YES
NO
YES
NO
NO
YES
N TEST NS-2A O S T A R T T E S T S
ENSURE THE THROTTLE CABLE IS NOT HOLDING THE THROTTLE OPEN. SEE GENERAL INFO 4.0
YES
NO
WITH THE DRB, GO INTO THEFT ALARM AND SELECT MONITORED DISPLAY.
YES
NO
PERFORM THE THEFT ALARM TEST IN THE BODY DIAGNOSTIC PROCEDURES MANUAL.*
TEST NS-2A
N O S T A R T T E S T S
NO
YES
WARNING: THE FUEL SYSTEM MUST BE OPENED AND MAY BE UNDER HIGH PRESSURE. SEE GENERAL INFO 9.0
NOTE: THE FUEL TANK MUST BE AT LEAST 1/4 FULL FOR THE FOLLOWING TESTS.
TURN IGNITION ON. WITH THE DRB, ACTUATE THE FUEL SYSTEM. READ THE FUEL PRESSURE GAUGE. IS THE FUEL PRESSURE ABOVE 54.2 PSI? YES
NO
YES
NO
YES
NO
N TEST NS-3A O S T A R T T E S T S
8.0L
FIG. 1
AB, AN AND BR 3.9L AB, AN, BR AND ZJ 5.2L AND 5.9L
FIG. 2
XJ 2.5L XJ AND ZJ 4.0L
FIG. 3
FIG. 4
794
FIG. 5
TEST NS-3A
N O S T A R T T E S T S
REMOVE ALL SPARK PLUGS & INSPECT THE TIPS FOR WET FUEL.
YES
NO
NO
NO
YES
NO
REPAIR AS NECESSARY.*
YES
NO
REPAIR AS NECESSARY.*
YES
N TEST NS-4A O S T A R T T E S T S
NOTES
796
TEST NS-4A
N O S T A R T T E S T S
INSPECT FUEL LINES FROM TANK TO FUEL RAIL FOR RESTRICTION. SEE GENERAL INFO 4.0
YES
NO
N TEST NS-5A O S T A R T T E S T S
AB BODY
FIG. 1
BR BODY XJ BODY
FIG. 2
FIG. 3
ZJ BODY
FIG. 4
FIG. 5
798
TEST NS-5A
N O S T A R T T E S T S
DOES THE FUEL PUMP RELAY PULSATE WITH ACTUATION? NO PERFORM TEST TC-101A.
YES
USING A VOLTMETER, MEASURE THE FUEL PUMP RLY FUSED B(+) CIRCUIT. FIG. 1, 2, 3, 4 OR 5
NO
REPAIR THE FUEL PUMP RELAY B(+) CIRCUIT FOR AN OPEN TO SPLICE.*
YES
N TEST NS-5A O S T A R T T E S T S
AB BODY
FIG. 1
BR BODY XJ BODY
FIG. 2
FIG. 3
ZJ BODY
FIG. 4
FIG. 5
800
TEST NS-5A
N O S T A R T T E S T S
INSTALL A SUBSTITUTE RELAY OF THE SAME PART NUMBER FOR THE FUEL PUMP RELAY.
YES
NO
DISCONNECT THE FUEL PUMP HARNESS CONNECTOR.** SEE GENERAL INFO 4.5
CAUTION: IT IS CRITICAL THAT THE FUEL PUMP CONNECTOR HAS A CLEAN AND TIGHT CONNECTION.**
USING A VOLTMETER, MEASURE THE FUEL PUMP RLY OUTPUT CIRCUIT. FIG. 1, 2, 3, 4 OR 5
NO
YES
USING AN OHMMETER, MEASURE THE FUEL PUMP GROUND CKT IN THE FUEL PUMP CONN. FIG. 1, 2, 3, 4 OR 5
NO
YES
N TEST NS-6A O S T A R T T E S T S
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
802
FIG. 4
TEST NS-6A
N O S T A R T T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE BLACK CONNECTOR.** SEE GENERAL INFO 4.1
NO
YES
USING A VOLTMETER, MEASURE THE FUSED IGN SWITCH OUTPUT CIRCUIT. FIG. 1, 2, 3 OR 4
NO
REPAIR THE OPEN FUSED IGN SWITCH OUTPUT CIRCUIT BETWEEN PCM & IGNITION SWITCH.*
YES
N TEST NS-6A O S T A R T T E S T S
AB BODY
FIG. 1
BR BODY XJ BODY
FIG. 2
FIG. 3
ZJ BODY
FIG. 4
FIG. 5
804
TEST NS-6A
N O S T A R T T E S T S
MEASURE THE FUSED B(+) CKT IN THE PCM CONNECTOR. SEE FIG. 1, 2, 3 OR 4 ON PREVIOUS PAGE
YES
NO
REMOVE THE FUSE IN THE PDC THAT SUPPLIES FUSED B(+) TO PCM CAVITY A22. FIG. 1, 2, 3, 4 OR 5
YES
USING A VOLTMETER, MEASURE THE B(+) SIDE OF THE FUSE SOCKET. FIG. 1, 2, 3, 4 OR 5
NO
YES
N TEST NS-6A O S T A R T T E S T S
AB AND BR BODIES
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
806
FIG. 4
TEST NS-6A
N O S T A R T T E S T S
TURN IGNITION OFF. DISCONNECT THE AUTO SHUTDOWN RELAY.** SEE GENERAL INFO 4.6
WITH AN OHMMETER, MEASURE THE FUSED B(+) CIRCUIT IN PCM CONNECTOR TO GND. FIG. 1, 2, 3, 4 OR 5
YES
REPAIR THE FUSED B(+) CIRCUIT FOR A SHORT TO GROUND. REPLACE FUSE.*
NO
MEASURE THE ASD RELAY OUTPUT CKT IN THE ASD RELAY CONNECTOR...
YES
NO
NO
YES
NOTE: AN INTERMITTENT ASD RELAY OUTPUT CKT SHORT TO GROUND MAY EXIST.
REPLACE FUSE.*
N TEST NS-6A O S T A R T T E S T S
AB BODY
FIG. 1
BR BODY XJ BODY
FIG. 2
FIG. 3
ZJ BODY
FIG. 4
FIG. 5
808
TEST NS-6A
N O S T A R T T E S T S
YES
NO
DISCONNECT THE CONNECTORS FOR EACH OXYGEN SENSOR.** SEE GENERAL INFO 4.4
WITH AN OHMMETER, MEASURE THE ASD RLY OUTPUT CIRCUIT FOR RESISTANCE TO GND. FIG. 1, 2, 3, 4 OR 5
MEASURE THE ASD YES RELAY OUTPUT CKT IN EACH O2 SENSOR FOR RESISTANCE TO GND. SEE GENERAL INFO 4.4
NO
NOTE: THE OXYGEN SENSORS MUST REMAIN DISCONNECTED FOR THE REMAINDER OF THE TEST.
REPLACE THE OXYGEN SENSOR THAT HAS CONTINUITY TO GROUND. REPLACE FUSE.*
WITH AN OHMMETER, MEASURE THE ASD RLY OUTPUT CIRCUIT FOR RESISTANCE TO GND. FIG. 1, 2, 3, 4 OR 5
YES
NO
WITH AN OHMMETER, MEASURE THE ASD RLY OUTPUT CIRCUIT FOR RESISTANCE TO GND. FIG. 1, 2, 3, 4 OR 5
YES
NO
CONTINUE TO MONITOR OHMMETER DISPLAY WHILE DISCONNECTING EACH FUEL INJECTOR. SEE GENERAL INFO 4.2
IS THE RESISTANCE ABOVE 5.0 OHMS WHEN ANY OF THE INJECTORS ARE DISCONNECTED? NO
YES
REPLACE THE FUEL INJECTOR THAT CAUSED A CHANGE IN RESISTANCE. REPLACE FUSE.*
REPAIR ASD RELAY OUTPUT CIRCUIT FOR HARNESS SHORT TO GROUND. REPLACE FUSE.*
N TEST NS-6B O S T A R T T E S T S
AB BODY
FIG. 1
BR BODY XJ BODY
FIG. 2
FIG. 3
ZJ BODY
FIG. 4
FIG. 5
810
TEST NS-6B
N O S T A R T T E S T S
N TEST NS-6B O S T A R T T E S T S
AB BODY
FIG. 1
BR BODY XJ BODY
FIG. 2
FIG. 3
ZJ BODY
FIG. 4
FIG. 5
812
TEST NS-6B
N O S T A R T T E S T S
MEASURE THE RESISTANCE OF THE SCI RECEIVE CKT FROM THE PCM TO THE DLC. FIG. 1, 2, 3, 4 OR 5
NO
YES
NO
YES
NO
YES
N TEST NS-6C O S T A R T T E S T S
AB BODY
FIG. 1
BR BODY XJ BODY
FIG. 2
FIG. 3
ZJ BODY
FIG. 4
FIG. 5
814
TEST NS-6C
N O S T A R T T E S T S
YES
NO
DISCONNECT THE FUEL PUMP ELECTRICAL CONNECTOR.** SEE GENERAL INFO 4.5
WITH AN OHMMETER, MEASURE THE FUEL PUMP RLY OUTPUT CKT IN THE RELAY CONN. FIG. 1, 2, 3, 4 OR 5
YES
REPAIR THE FUEL PUMP RELAY OUTPUT CIRCUIT FOR A SHORT TO GROUND. REPLACE FUSE.*
NO
NOTE: AN INTERMITTENT FUEL PUMP RELAY OUTPUT CIRCUIT SHORT TO GROUND MAY EXIST.
N TEST NS-6C O S T A R T T E S T S
AB BODY
FIG. 1
AN BODY
FIG. 2
BR BODY
FIG. 3
816
TEST NS-6C
N O S T A R T T E S T S
DISCONNECT THE HIGH PRESSURE SHUT-OFF SOLENOID CONNECTOR.** SEE GENERAL INFO 4.5
USING AN OHMMETER, MEASURE THE FUEL SYSTEM RELAY OUTPUT CKT IN THE RELAY CONN. FIG. 1, 2 OR 3
YES
REPAIR THE FUEL SYSTEM RELAY OUTPUT CIRCUIT FOR A SHORT TO GROUND. REPLACE FUSE.*
NO
N TEST NS-6D O S T A R T T E S T S
FIG. 1
AB, AN AND BR BODIES BR DIESEL
FIG. 2
XJ BODY ZJ BODY
FIG. 3
FIG. 4
818
FIG. 5
TEST NS-6D
N O S T A R T T E S T S
BACKPROBE THE CKP SENSOR 5-VOLT SUPPLY AND SKIP THE TPS DISCONNECT STEP. FIG. 1
ALL OTHER VEHS, BACKPROBE THE TP SENSOR 5-VOLT SUPPLY CIRCUIT. FIG. 2, 3, 4 OR 5
IGNITION KEY ON. RECORD VOLTMETER READING. IS THE VOLTAGE BELOW 4.0 VOLTS? NO PERFORM TEST NS-6E.
YES
NO
YES
DISCONNECT THE CRANKSHAFT SENSOR.** READ VOLTMETER. SEE GENERAL INFO 4.0
NO
YES
N TEST NS-6D O S T A R T T E S T S
820
TEST NS-6D
N O S T A R T
YES
T E S T S
NO
DISCONNECT THE CAMSHAFT SENSOR.** READ VOLTMETER. SEE GENERAL INFO 4.0
NO
YES
DISCONNECT THE MAP SENSOR.** READ VOLTMETER. SEE GENERAL INFO 4.0
NO
YES
N TEST NS-6D O S T A R T T E S T S
FIG. 1
822
TEST NS-6D
N O S T A R T T E S T S
DISCONNECT THE VEHICLE SPEED SENSOR.** READ THE VOLTMETER. SEE GENERAL INFO 4.4
NO
YES
DISCONNECT THE TRANSMISSION SOLENOID CONNECTOR IF EQUIPPED.** SEE GENERAL INFO 4.0
READ VOLTMETER.
NO
YES
YES
NO
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.1
WITH AN OHMMETER, MEASURE THE RESISTANCE OF THE 5-VOLT PRIMARY SUPPLY CIRCUIT...
YES
NO
YES
NO
N TEST NS-6E O S T A R T T E S T S
BR DIESEL
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
824
FIG. 4
TEST NS-6E
N O S T A R T T E S T S
NO
YES
N TEST NS-7A O S T A R T T E S T S
AB BODY
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
826
FIG. 4
TEST NS-7A
N O S T A R T T E S T S
HOLD THE ENGINE THROTTLE 1/4 OF THE WAY DOWN AND ATTEMPT TO START ENGINE.
DOES THE ENGINE START AND STAY RUNNING AND THEN STALL WHEN THROTTLE IS RELEASED? YES
NO
DISCONNECT THE IDLE AIR CONTROL MOTOR CONNECTOR.** SEE GENERAL INFO 4.0
YES
NO
YES
NO
YES
NO
YES
NO
N TEST NS-7A O S T A R T T E S T S
FIG. 1
828
TEST NS-7A
N O S T A R T
T E S T S
RECONNECT IDLE AIR CONTROL MOTOR ELECTRICAL CONNECTOR.
REMOVE THE IDLE AIR CONTROL MOTOR FROM THE THROTTLE BODY. SEE GENERAL INFO 4.0
WITH THE DRB, ACTUATE THE IDLE AIR CONTROL MOTOR. FIG. 1
NO
YES
NO
YES
N TEST NS-7A O S T A R T T E S T S
AB BODY
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
830
FIG. 4
TEST NS-7A
N O S T A R T T E S T S
KEY OFF, DISCONNECT THE POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.0
THE FOLLOWING STEPS ARE CHECKING FOR A SHORT BETWEEN THE DRIVER CIRCUITS.
YES
NO
YES
NO
YES
NO
N TEST NS-7B O S T A R T T E S T S
AB BODY
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
832
FIG. 4
TEST NS-7B
N O S T A R T T E S T S
KEY OFF. DISCONNECT POWERTRAIN CONTROL MODULE.** SEE GENERAL INFO 4.0
YES
NO
TEST THE IDLE AIR CONTROL MOTOR #3 DRIVER CKT FOR RESISTANCE. FIG. 1, 2, 3 OR 4
YES
NO
N TEST NS-7C O S T A R T T E S T S
AB BODY
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
834
FIG. 4
TEST NS-7C
N O S T A R T T E S T S
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE CONNECTOR.** SEE GENERAL INFO 4.0
YES
NO
TEST THE IDLE AIR CONTROL MOTOR #1 DRIVER CKT FOR RESISTANCE. FIG. 1, 2, 3 OR 4
YES
NO
N TEST NS-7D O S T A R T T E S T S
AB BODY
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
836
FIG. 4
TEST NS-7D
N O S T A R T T E S T S
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE CONNECTOR.** SEE GENERAL ONFO 4.0
YES
NO
TEST THE IDLE AIR CONTROL MOTOR #4 DRIVER CKT FOR RESISTANCE. FIG. 1, 2, 3 OR 4
YES
NO
N TEST NS-7E O S T A R T T E S T S
AB BODY
FIG. 1
XJ BODY ZJ BODY
FIG. 2
FIG. 3
838
FIG. 4
TEST NS-7E
N O S T A R T T E S T S
KEY OFF. DISCONNECT THE POWERTRAIN CONTROL MODULE CONNECTOR.** SEE GENERAL INFO 4.0
YES
NO
TEST THE IDLE AIR CONTROL MOTOR #2 DRIVER CKT FOR RESISTANCE. FIG. 1, 2, 3 OR 4
YES
NO
N TEST NS-8A O S T A R T T E S T S
NOTES
TEST NS-8A
N O S T A R T T E S T S
At this point in the diagnostic test procedure, you have determined that all of the engine electrical systems are operating as designed; therefore, they are not the cause of the start and stall problem. The following additional items should be checked as possible mechanical causes of the no start condition. Any one or more of these items can produce a no start condition; none can be overlooked as a possible cause. 1. DISTRIBUTOR POSITION must be within specifications* 2. ENGINE VALVE TIMING must be within specifications 3. ENGINE COMPRESSION must be within specifications 4. ENGINE EXHAUST must be free of any restrictions 5. ENGINE PCV SYSTEM must flow freely 6. ENGINE DRIVE SPROCKETS must be properly positioned 7. FUEL must be free of contamination 8. ENGINE SECONDARY IGNITION CHECK must exhibit a normal scope pattern Always look for any Technical Service Bulletins that may relate to this condition. Checking Distributor Position With DRB Connect the DRB to the Data Link Connector and select the set SYNC from the menu. WARNING: The following test will be performed with the engine running: avoid contact with rotating components. Start the engine and observe the DRB display. When the distributor is correctly positioned, the IN RANGE message should appear along with 0. If the distributor needs to be adjusted, loosen the distributor hold-down clamp bolt. Rotate the distributor until reading is as close to 0 as possible and the IN RANGE message is displayed. Tighten the clamp bolt to 22.5 Nm (200 in. lbs.) torque. NOTE: Setting the distributor position does not adjust the ignition timing. Ignition timing values are determined by the powertrain control module.
841
N TEST NS-9A O S T A R T T E S T S
AB BODY
FIG. 1
BR BODY XJ BODY
FIG. 2
FIG. 3
ZJ BODY
FIG. 4
FIG. 5
842
TEST NS-9A
N O S T A R T T E S T S
YES
NO
WITH THE DRB, SELECT INPUTS/OUTPUTS AND READ THE PARK/NEUTRAL POSITION.
NO
YES
WITH A VOLTMETER, MEASURE THE FUSED B(+) CIRCUIT AT THE RELAY CONN. FIG. 1, 2, 3, 4 OR 5
NO
YES
WITH A VOLTMETER, MESURE THE IGNITION SWITCH OUTPUT CKT AT RELAY CONN. FIG. 1, 2, 3, 4 OR 5
NO
YES
WARNING: THE TRANS MUST BE IN PARK AND THE PARKING BRAKE MUST BE ON FOR THE NEXT STEP.
WARNING: THE ENGINE MAY BE CRANKED IN THE NEXT STEP. KEEP AWAY FROM MOVING ENGINE PARTS.
BRIEFLY CONNECT A JUMPER WIRE BETWEEN STARTER RLY FUSED (B+) & OUTPUT CKTS. FIG. 1, 2, 3, 4 OR 5
N TEST NS-9B O S T A R T T E S T S
AB BODY
FIG. 1
BR BODY XJ BODY
FIG. 2
FIG. 3
ZJ BODY
FIG. 4
FIG. 5
844
TEST NS-9B
N O S T A R T T E S T S
YES
NO
YES
NO
WHILE OBSERVING VOLTMETER, HOLD IGNITION KEY IN THE START POSITION AND DEPRESS CLUTCH PEDAL
YES
NO
DISCONNECT THE CLUTCH PEDAL POSITION SWITCH LOCATED ON CLUTCH MASTER CYLINDER.
JUMPER ACROSS THE CLUTCH PEDAL POSITION SWITCH WITH A JUMPER WIRE.
YES
NO
N TEST NS-9B O S T A R T T E S T S
NOTES
846
TEST NS-9B
N O S T A R T T E S T S
WITH A VOLTMETER, MEASURE THE IGNITION SWITCH OUTPUT AT THE CLUTCH PEDAL POSITION SWITCH.
CHECK FOR VOLTAGE AT THE CONNECTOR, WITH THE IGNITION SWITCH IN THE START POSITION.
NO
YES
REPAIR THE OPEN IGNITION SWITCH OUTPUT CIRCUIT BETWEEN THE CLUTCH SWITCH AND RELAY.*
N TEST NS-9C O S T A R T T E S T S
AB BODY
FIG. 1
BR BODY XJ BODY
FIG. 2
FIG. 3
ZJ BODY
FIG. 4
FIG. 5
848
TEST NS-9C
N O S T A R T T E S T S
YES
NO
NOTE IF THE STARTER SOLENOID CLICKED WHEN THE JUMPER WIRE WAS CONNECTED.
DISCONNECT STARTER RELAY OUTPUT WIRE FROM THE STARTER SOLENOID.** SEE GENERAL INFO 4.2
NO
YES
CHECK THE BATTERY CABLES FOR HIGH RESISTANCE.(USE SERVICE MANUAL PROCECURE)
DID EITHER BATTERY CIRCUIT HAVE A VOLTAGE DROP GREATER THAT 0.2 VOLT? NO
YES
DID THE STARTER SOLENOID CLICK WHEN THE JUMPER WIRE WAS PREVIOUSLY CONNECTED? YES
NO
N TEST NS-9C O S T A R T T E S T S
AB BODY
FIG. 1
BR BODY XJ BODY
FIG. 2
FIG. 3
ZJ BODY
FIG. 4
FIG. 5
850
TEST NS-9C
N O S T A R T T E S T S
YES
NO
YES
NO
REPAIR THE OPEN PARK/NEUTRAL SWITCH SENSE CIRCUIT BETWEEN STARTER RELAY AND SPLICE.*
N TEST NS-10A O S T A R T T E S T S
FIG. 1
FIG. 2
852
N O S T A R T T E S T S
YES
NO
N TEST NS-10A O S T A R T T E S T S
FIG. 1
854
N O S T A R T T E S T S
YES
NO
DISCONNECT THE FRONT IGNITION COIL CONNECTOR.** INSPECT ALL TERMINALS. FIG. 1
YES
NO
N TEST NS-10A O S T A R T T E S T S
FIG. 1
856
N O S T A R T T E S T S
ENSURE KEY IS ON. WITH THE DRB, ACTUATE IGNITION COIL #1.
USING A VOLTMETER, MEASURE THE ASD RELAY OUTPUT CKT IN THE IGNITION COIL CONNECTOR. FIG. 1
NO
REPAIR THE OPEN ASD RELAY OUTPUT CKT FROM COIL CONNECTOR TO SPLICE.*
YES
NO
YES
N TEST NS-11A O S T A R T T E S T S
AB BODY
FIG. 1
AB BODY AN AND BR BODIES
FIG. 2
FIG. 3
858
FIG. 4
N O S T A R T T E S T S
NO
YES
NOTE: FUEL CYLINDERS MUST BE AT LEAST 1/4 FULL FOR THE FOLLOWING TEST.
NO
YES
NO
YES
TURN IGNITION ON. ACTUATE THE ASD RELAY. CONTINUE TEST NS-11A ON THE NEXT PAGE.
N TEST NS-11A O S T A R T T E S T S
FIG. 1
AN AND BR BODIES
FIG. 2
AB BODY
FIG. 3
860
N O S T A R T T E S T S
NO PERFORM TEST NS-12B.
DOES THE LOW PRESSURE FUEL SHUT-OFF SOLENOID PULSATE WITH ACTUATION? YES
NO
IS THE HIGH PRESSURE FUEL SHUT-OFF SOLENOID PULSATING WITH ACTUATION? YES
NOTE: THE FUEL GAUGE MUST INDICATE FUEL IS PRESENT BEFORE PERFORMING NEST STEP.
YES
NO
NO
YES
TURN IGNITION OFF. WITH THE DRB, ACTUATE THE FUEL SYSTEM. IS THE FUEL GAUGE PRESSURE ABOVE 140 PSI? YES REPLACE THE FUEL PRESSURE REGULATOR.*
NO
N TEST NS-11A O S T A R T T E S T S
FIG. 1
FIG. 2
862
N O S T A R T T E S T S
REINSTALL THE FUEL PRESSURE SENSOR.
DOES THE VEHICLE HAVE A FUEL PRESSURE SERVICE PORT ON THE FUEL RAIL? FIG. 1 YES
NO
PURGE NATURAL GAS FROM THE FUEL RAIL. SEE GENERAL INFO 9.0
YES
NO
NO
YES
DISCONNECT THE THROTTLE POSITION SENSOR CONNECTOR.** SEE GENERAL INFO 4.0
INSPECT THE CONNECTOR FOR PROPER WIRING AND IS FREE OF DIRT. FIG. 2
YES
NO
N TEST NS-11A O S T A R T T E S T S
FIG. 1
864
N O S T A R T T E S T S
NO
REPAIR THE OPEN AUTO SHUTDOWN RELAY OUTPUT CIRCUIT FROM INJECTOR TO SPLICE.*
YES
NOTE: THE FUEL PRESSURE MUST BE READ IMMEDIATELY AFTER THE NEXT STEP.
DISCONNECT THE LOW PRESSURE FUEL SHUT-OFF SOLENOID.** SEE GENERAL INFO 4.0
NO
YES
N TEST NS-11A O S T A R T T E S T S
FIG. 1
866
N O S T A R T T E S T S
WITH THE DRB, STOP ACTUATOR TEST AND IMMEDIATELY READ THE FUEL PRESSURE.
YES
NO
HOLD THE THROTTLE OPEN AND LISTEN FOR ESCAPING GAS. FIG. 1
TURN IGNITION OFF. IS ESCAPING GAS HEARD FROM THE THROTTLE AREA? YES ONE OF THE FUEL INJECTORS IS LEAKING.
NO
NOTE: THE FUEL LEAK HAS BEEN ISOLATED TO THE FUEL RAIL AREA.
N TEST NS-11B O S T A R T T E S T S
FIG. 1
AN AND BR BODIES BR BODY
FIG. 2
FIG. 3
868
FIG. 4
N O S T A R T T E S T S
DISCONNECT THE FUEL LOW PRESSURE SENSOR CONNECTOR.** SEE GENERAL INFO 4.0
CONNECT JUMPER WIRE FROM FUEL PRESSURE SENSOR SIGNAL TO 5-VOLT SUPPLY CKT. FIG. 1 OR 2
NO
YES
YES
NO
PURGE NATURAL GAS FROM THE FUEL RAIL. TURN IGNITION OFF. SEE GENERAL INFO 9.0
DOES THE VEHICLE HAVE A FUEL PRESSURE SERVICE PORT ON THE FUEL RAIL? NO
YES
CONNECT A FUEL PRESSURE GAUGE TO THE FUEL SERVICE PORT. THEN WITH DRB, ACTUATE FUEL SYSTEM.
REMOVE FUEL PRESS SENSOR & CONNECT A 0-300 PSI PRESS GAUGE TO FUEL RAIL SEE GENERAL INFO 4.0
YES
NO
NO
N TEST NS-11B O S T A R T T E S T S
AN AND BR BODIES
FIG. 1
AB BODY
FIG. 2
870
N O S T A R T T E S T S
NO
REPAIR THE OPEN 5-VOLT SUPPLY CKT FROM FUEL PRESSURE SENSOR TO SPLICE.*
YES
USING AN OHMMETER, MEASURE THE FUEL PRESSURE SENSOR SIGNAL CKT TO GROUND FIG. 1 OR 2
NO
YES
N TEST NS-12A O S T A R T T E S T S
AB BODY
BR BODY
AB BODY
FIG. 1
AN BODY BR BODY
FIG. 2
872
FIG. 3
N O S T A R T T E S T S
DISCONNECT THE LOW PRESS FUEL SHUT-OFF SOLENOID CONN.** SEE GENERAL INFO 4.2
WITH AN OHMMETER, MEASURE THE GND CIRCUIT IN LOW PRESS SHUT-OFF SOL CONN. FIG. 1, 2 OR 3
NO
REPAIR THE OPEN GROUND FROM LOW PRESSURE SHUT-OFF SOLENOID TO SPLICE.*
YES
WITH A VOLTMETER, MEASURE THE AUTO SHUTDOWN RELAY OUTPUT CIRCUIT. FIG. 1, 2 OR 3
YES
NO
DISCONNECT THE AUTO SHUTDOWN RELAY CONNECTOR.** SEE GENERAL INFO 4.6
WITH A VOLTMETER, MEASURE THE ASD RELAY FUSED B(+) CIRCUIT. FIG. 1, 2 OR 3
NO
REPAIR THE OPEN FUSED B(+) CIRCUIT FROM BATTERY TO ASD RELAY.*
YES
TEST ASD RLY OUTPUT CKT FROM ASD RLY TO LOW PRESS SHUT-OFF SOLENOID. FIG. 1, 2 OR 3
YES
NO
REPAIR THE OPEN ASD RELAY OUTPUT CIRCUIT FROM LOW PRESSURE SHUT-OFF SOLENOID TO ASD RELAY.*
N TEST NS-12B O S T A R T T E S T S
AB BODY
BR BODY
AB BODY
FIG. 1
AN BODY BR BODY
FIG. 2
874
FIG. 3
N O S T A R T T E S T S
DISCONNECT THE HIGH PRESS FUEL SHUT-OFF SOLENOID CONN.** SEE GENERAL INFO 4.2
USING AN OHMMETER, MEASURE THE GND CIRCUIT IN THE SOLENOID CONN. FIG. 1, 2 OR 3
NO
REPAIR THE OPEN HIGH PRESSURE FUEL SHUT-OFF SOLENOID GROUND CIRCUIT.*
YES
USING A VOLTMETER, MEASURE THE HIGH PRESS SHUT-OFF RELAY OUTPUT CKT. FIG. 1, 2 OR 3
YES
NO
DISCONNECT THE FUEL HIGH PRESSURE SOLENOID RELAY CONNECTOR.** SEE GENERAL INFO 4.6
USING A VOLTMETER, MEASURE THE SHUT-OFF RELAY FUSED B(+) CIRCUIT. FIG. 1, 2 OR 3
NO
REPAIR THE OPEN FUSED B(+) CIRCUIT FROM BATTERY TO THE HIGH PRESSURE SHUT-OFF RELAY.*
YES
USING AN OHMMETER, MEASURE THE RESISTANCE OF THE HIGH PRESSURE SHUT-OFF RELAY...
YES
NO
REPAIR THE OPEN HIGH PRESS SHUT-OFF RELAY OUTPUT CIRCUIT FROM SHUT-OFF SOLENOID TO RELAY.*
N TEST NS-13A O S T A R T T E S T S
NOTES
876
N O S T A R T T E S T S
ARE THERE ANY INJECTOR TROUBLE CODES PRESENT? YES PERFORM THE INJECTOR TROUBLE CODE TEST LISTED IN DTC TEST.
NOTE: AN INJECTOR CONTROL CIRCUIT IS SHORTED TO GROUND CAUSING THE ENGINE TO FLOOD.
NO
USING AN OHMMETER...
CHECK EACH INJECTOR CONTROL CIRCUIT FOR A SHORT TO GROUND. SEE GENERAL INFO 4.0
YES
NO
N TEST NS-14A O S T A R T T E S T S
FIG. 1
FIG. 2
878
N O S T A R T
T E S T S
NOTE: TO HEAR CLICK IN THE NEXT STEP, IT MAY BE NECESSARY TO DISCONNECT THE RELAY MORE THAN ONCE. WHILE LISTENING FOR THE RELAY TO CLICK, DISCONNECT THE FUEL HEATER RELAY.** FIG. 1 DID THE RELAY CLICK? YES CONTINUE TEST NS-14A ON THE NEXT PAGE.
NO
USING A VOLTMETER, MEASURE THE FUSED IGN SWITCH OUTPUT CIRCUIT. FIG. 2
NO
YES
USING AN OHMMETER, MEASURE THE FUEL HEATER RELAY GROUND CIRCUIT. FIG. 2
YES
NO
N TEST NS-14A O S T A R T T E S T S
FIG. 1
FIG. 2
FIG. 3
FIG. 4
880
FIG. 5
N O S T A R T T E S T S
NO REPAIR THE OPEN FUEL HEATER GROUND CIRCUIT.*
USING A VOLTMETER, MEASURE THE FUSED B(+) IN THE HEATER RELAY CONN. FIG. 1
NO
YES
YES
USING AN OHMMETER, MEASURE THE RESISTANCE OF THE FUEL HEATER RELAY OUTPUT CIRCUIT...
YES
NO
DISCONNECT THE FUEL HEATER ELEMENT CONNECTOR.** INSPECT ALL TERMINALS. FIG. 2
YES
NO
NOTE: THE FUEL HEATER TEMPERATURE MUST BE BELOW 40F FOR THE NEXT STEP.
USING AN OHMMETER, MEASURE THE RESISTANCE OF THE FUEL HEATER. FIG. 2 AND 5
NO
THE NO START CONDITION IS DUE TO A MECHANICAL PROBLEM. SEE SERVICE MANUAL FOR REPAIRS.
YES
N TEST NS-15A O S T A R T T E S T S
FIG. 1
FIG. 2
882
TEST NS-15A CHECKING THE FUEL SHUTDOWN RELAY AND SOLENOID (DIESEL)
Perform TEST NS-SEL Before Proceeding
N O S T A R T T E S T S
NOTE: DO NOT TURN THE IGNITION OFF AFTER CRANKING THE ENGINE FOR 3 SECONDS IN THE NEXT STEP.
THE NO START YES CONDITION IS DUE TO A MECHANICAL PROBLEM. SEE SERVICE MANUAL FOR REPAIRS.
NO
MANUALLY RETRACT THE FUEL SHUTDOWN SOLENOID PLUNGER AND THEN RELEASE.
DOES THE PLUNGER REMAIN RETRACTED WHEN IT IS NO LONGER MANUALLY HELD IN? NO
YES
USING A VOLTMETER, MEASURE THE FUSED IGN SWITCH OUTPUT CIRCUIT. FIG. 2
NO
YES
NO
YES
N TEST NS-15A O S T A R T T E S T S
FIG. 1
FIG. 2
884
TEST NS-15A CONTINUED - CHECKING THE FUEL SHUTDOWN RELAY AND SOLENOID (DIESEL)
N O S T A R T T E S T S
USING A VOLTMETER, MEASURE THE FUEL SHUTDOWN RELAY OUTPUT CIRCUIT. FIG. 2
NO
YES
USING AN OHMMETER, MEASURE THE FUEL SHUTDOWN SOLENOID GROUND CIRCUIT. FIG. 2
NO
YES
N TEST NS-15A O S T A R T T E S T S
FIG. 1
FIG. 2
886
TEST NS-15A CONTINUED - CHECKING THE FUEL SHUTDOWN RELAY AND SOLENOID (DIESEL)
N O S T A R T T E S T S
MEASURE THE FUEL SHUTDOWN RELAY OUTPUT CIRCUIT FOR RESISTANCE. FIG. 2
NO
YES
USING A VOLTMETER, MEASURE THE FUSED B(+) CIRCUIT IN THE SHUTDOWN RELAY CONN. FIG. 2
NO
YES
USING AN OHMMETER, MEASURE THE SHUTDOWN RELAY GROUND CIRCUIT IN RELAY CONNECTOR. FIG. 2
YES
NO
USING AN OHMMETER, MEASURE THE RESISTANCE OF THE STARTER RELAY OUTPUT CIRCUIT...
YES
NO
V TEST VER-1A NO START VERIFICATION E R I Inspect the vehicle to ensure that all engine components are connected. Reassemble and reconnect F components as necessary. I C Inspect the engine for contamination. If it is contaminated, change the oil and filter. A T Attempt to start the engine. I If the engine is unable to start, look for any Technical Service Bulletins that may relate to this O condition. Return to DTC TEST if necessary. N
The repair is now complete.
T E S T S
888
V E R I F I C A T I O N T E S T S
889
V TEST VER-3A CHARGING VERIFICATION E R I Inspect the vehicle to ensure that all engine components are connected. Reassemble and reconnect F components as necessary. I C If the powertrain control module has been changed, do the following: A 1. If the vehicle is equipped with a factory theft alarm, start the vehicle at least 20 times so that the T alarm system may be activated when desired. I O Connect the DRB to the PCM data link connector and erase the codes. N
Ensure no other charging system problems remain by doing the following:
T E S T S
1. Start the engine. 2. Raise the engine speed to 2000 rpm for at least 30 seconds. 3. Allow the engine to idle. 4. Turn the engine off. 5. Turn the ignition key on. 6. With the DRB, read trouble code messages. If the repaired code has reset, or another one has set, check all pertinent Technical Service Bulletins and return to DTC TEST if necessary. If there are no codes, the repair is now complete.
890
V E R I F I C A T I O N T E S T S
891
V TEST VER-5A ROAD TEST FOR OBDII TROUBLE CODES E R I Inspect the vehicle to ensure that all engine components are connected. Reassemble and reconnect F components as necessary. I C If there are any existing diagnostic trouble codes that have not been repaired, perform DTC TEST A and follow the path specified. After all diagnostic trouble codes have been repaired, return to TEST T VER-5A and run the monitor for the previously repaired OBDII trouble code. I 1. Connect the DRB to the data link connector. O N 2. Ensure the fuel tank has at least a quarter tank of fuel. T E S T S
3. Turn the air conditioning off. 4. The proper way to verify that the trouble code has been repaired is to allow the powertrain control module to run the monitor. The technician can see the monitor using the DRBIII. The enabling conditions must be met before the powertrain control module will run the monitor. The enabling conditions for the covered OBDII codes can be found in each trouble code test. Read the enabling conditions for the trouble code that was repaired. The enabling conditions are different for each OBDII code. 5. With the DRBIII, monitor the pre-test enabling conditions until all conditions have been met. Once the enabling conditions have been met, monitor the appropriate OBDII monitor with the DRBIII. 6. If the repaired OBDII trouble code has reset or was seen in the OBDII monitor while on the road test, the repair is not complete. Check for any related Technical Service Bulletins and return to DTC TEST. If another trouble code has set, return to DTC TEST and follow the path specified for that trouble code. If there are no trouble codes, the repair was successful and is now complete.
892
8.0
There is no specific maintenance or service information in this manual. Refer to the appropriate service manual for information about repair and replacement procedures. When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected.
G E N E R A L I N F O R M A T I O N
9.0 9.1
1. 2. 3. 4. 5. 6.
9.2 9.2.1
1. 2. 3.
Fuel System Pressure Release Procedure (CNG) Fuel Line Pressure Release Procedure
Close the fuel control valves on all cylinder(s) by turning the valves completely clockwise. Ensure the manual shut-off valve is in the open position. The valve is open when the handle is parallel with the fuel tubes. Start or attempt to start the engine. If the engine runs, let it run until it runs out of fuel. Attempt to start the engine by cranking for 6 seconds.
893
G E N E R A L I N F O R M A T I O N
4. 5.
Pausing 10 seconds between attempts, repeat step 3 two more times. If the check valve or fuel fill receptacle is to be serviced, slowly loosen the inlet side of the fuel fill tube fitting at the check valve until fuel has purged.
9.2.2
1. 2. 3. 4. 5.
WARNING: THE FUEL CYLINDERS THAT ARE NOT BEING SERVICED STILL CONTAIN HIGH-PRESSURE FUEL.
894
10.0 10.1
G E N E R A L I N F O R M A T I O N
895
G E N E R A L I N F O R M A T I O N
10.2
896
10.3
G E N E R A L I N F O R M A T I O N
897
G E N E R A L I N F O R M A T I O N
10.4
898
10.5
G E N E R A L I N F O R M A T I O N
899
G E N E R A L I N F O R M A T I O N
10.6
900
10.7
G E N E R A L I N F O R M A T I O N
901
G E N E R A L I N F O R M A T I O N
10.8
902
10.9
G E N E R A L I N F O R M A T I O N
903
G E N E R A L I N F O R M A T I O N
10.10
904
10.11
G E N E R A L I N F O R M A T I O N
905
G E N E R A L I N F O R M A T I O N
10.12
906
11.0
G E N E R A L I N F O R M A T I O N
12.0
GLOSSARY OF TERMS
backfire, popback CKP CMP - Fuel ignites in either the intake or the exhaust system.
- crank position sensor - camshaft position sensor - a steady pulsation or the inability of the engine to maintain a consistent rpm
detonation, spark knock - a mild to severe ping, especially under loaded engine conditions ECT EGR - engine coolant temperature sensor - exhaust gas recirculation valve and system - previously callled alternator - The engine takes longer than usual to start, even though it is able to crank normally. - There is a momentary lack of response when the throttle is opened. This can occur at all vehicle speeds. If it is severe enough, the engine may stall.
- intake air temperature sensor - idle air control valve - Combined engine and transmission control module
lack of power, sluggish - The engine has less than expected power, with little or no increase in vehicle speed when the throttle is opened. MAP MTV - manifold absolute pressure sensor - manifold tuning valve
MVLPS - manual valve lever position switch (previously called park/neutral switch) O2S O2SR - oxygen sensor (left oxygen sensor when there are two sensors) - right oxygen sensor
907
G E N E R A L I N F O R M A T I O N
12.1
PCM PCV
poor fuel economy - There is significantly less fuel mileage than other vehicles of the same design and configuration. rough, unstable, or erratic idle stalling - The engine runs unevenly at idle and causes the engine to shake if it is severe enough. The engine idle rpm may vary (called hunting). This condition may cause stalling if it is severe enough. start & stall - The engine starts but immediately dies. surge TPS VSS - engine rpm fluctuation without corresponding change in throttle position sensor - throttle position sensor - vehicle speed sensor
CARS F24S FJ22 GS JA Eagle Talon Chrysler Sebring Dodge Avenger Chrysler Grand Voyager Chrysler Ram Van Chrysler Cirrus Plymouth Dodge Stratus Chrysler Sebring Convertible Chrysler Concorde Chrysler LHS Chrysler New Yorker Dodge Intrepid Eagle Vision
NS
PL SR27 SR29
Chrysler Town and Country Dodge Caravan / Grand Caravan Plymouth Voyager / Grand Voyager Dodge Neon Plymouth Neon Dodge Viper Roadster Dodge Viper Coupe
JX LH
TRUCKS AB AN BR BT Dodge Ram 150, 250, 350 (Van / Wagon) Dodge Dakota Dodge Ram 1500, 2500, 3500 (Pickup) Dodge Ram 1500, 2500, 3500 (Cab) TJ XJ ZJ Jeep Wrangler Jeep Cherokee Jeep Grand Cherokee
908
NOTES
G E N E R A L I N F O R M A T I O N
909