1996 dakota gas powertrain diagnostics

TABLE OF CONTENTS1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.1 SYSTEM COVERAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.2 SIX-STEP TROUBLESHOOTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . .1

2.0 IDENTIFICATION OF SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION . . . . . . . . . . . . . . . . . . . . . .1

3.1 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.2 JTEC CONTROLLER AND OPERATING MODES . . . . . . . . . . . . . . . . . . . . . . . .1

3.2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.2.2 Hardware Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23.2.3 Software Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23.2.4 Spark Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23.2.5 Fuel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23.2.6 On Board Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33.2.7 Transmission Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53.2.8 Other Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63.2.9 PCM Operating Modes (Gasoline & Eng.) . . . . . . . . . . . . . . . . . . . . . . . . .63.2.10 PCM Operating Modes (Diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83.2.11 Non-Monitored Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

3.3 DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113.3.1 Hard Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113.3.2 Intermittent Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113.3.3 Reset Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113.3.4 Handling No Trouble Code Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3.4 USING THE DRB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113.5 DRB ERROR MESSAGES AND BLANK SCREEN. . . . . . . . . . . . . . . . . . . . . . .12

3.5.1 DRB Does Not Power Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123.5.2 Display Is Not Visible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

4.0 SYSTEM COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

4.1 POWERTRAIN CONTROL MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134.2 CONTROLS & SOLENOIDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194.3 DATA LINK CONNECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294.4 SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304.5 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .484.6 RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .514.7 SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .584.8 LAMPS & INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

5.0 DISCLAIMERS, SAFETY, WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

5.1 DISCLAIMERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .665.2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

5.2.1 Technician Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .665.2.2 Vehicle Preparation for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .675.2.3 Servicing Sub-Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .675.2.4 DRBIII Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

5.3 WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .685.3.1 Vehicle Damage Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .685.3.2 Road Testing a Complaint Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

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TABLE OF CONTENTS - Continued

7.0 DIAGNOSTIC INFORMATION AND PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . .69

7.1 GENERAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

TROUBLE CODE TESTSDTC TEST CHECKING THE SYSTEM FOR DIAGNOSTIC TROUBLE CODES

(DTCs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

TROUBLE CODE TESTSTC-1A REPAIRING - NO CAM SIGNAL AT PCM . . . . . . . . . . . . . . . . . . . . . . .74TC-5A REPAIRING - CHARGING SYSTEM VOLTAGE TOO LOW . . . . . . . . .84TC-6A REPAIRING - CHARGING SYSTEM VOLTAGE TOO HIGH . . . . . . . . .88TC-10A REPAIRING - AUTO SHUTDOWN RELAY CONTROL CIRCUIT . . . . .96TC-11A REPAIRING - GENERATOR FIELD NOT SWITCHING PROPERLY. .100TC-12A REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANS

RELAY CKT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104TC-14A REPAIRING - RAD FAN CONTROL RELAY CIRCUIT . . . . . . . . . . . .122TC-15A REPAIRING - SPEED CONTROL SOLENOID CIRCUITS OR SPEED

CONTROL POWER RELAY CIRCUITS . . . . . . . . . . . . . . . . . . . . . . .126TC-16A REPAIRING - A/C CLUTCH RELAY CIRCUIT. . . . . . . . . . . . . . . . . . .136TC-17A REPAIRING - EGR SOLENOID CIRCUIT . . . . . . . . . . . . . . . . . . . . . .140TC-18A REPAIRING - EVAP PURGE SOLENOID CIRCUIT . . . . . . . . . . . . . .144TC-19A REPAIRING - INJECTOR #3 CONTROL CIRCUIT . . . . . . . . . . . . . . .150TC-20A REPAIRING - INJECTOR #2 CONTROL CIRCUIT . . . . . . . . . . . . . . .158TC-21A REPAIRING - INJECTOR CONTROL CIRCUITS . . . . . . . . . . . . . . . .166TC-25A REPAIRING - IDLE AIR CONTROL MOTOR CIRCUITS. . . . . . . . . . .178TC-26A REPAIRING - THROTTLE POSITION SENSOR VOLTAGE LOW. . . .194TC-27A REPAIRING - THROTTLE POSITION SENSOR VOLTAGE HIGH . . .200TC-30A REPAIRING - ECT SENSOR VOLTAGE TOO LOW . . . . . . . . . . . . . .206TC-31A REPAIRING - ECT SENSOR VOLTAGE TOO HIGH. . . . . . . . . . . . . .210TC-35A REPAIRING - NO VEHICLE SPEED SENSOR SIGNAL. . . . . . . . . . .214TC-36A REPAIRING - MAP SENSOR VOLTAGE TOO LOW - NO 5 VOLTS TO

MAP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226TC-37A REPAIRING - MAP SENSOR VOLTAGE TOO HIGH . . . . . . . . . . . . .232TC-39A REPAIRING - NO CHANGE IN MAP FROM START TO RUN . . . . . .238TC-40A REPAIRING - NO CRANK REFERENCE SIGNAL AT PCM . . . . . . . .242TC-41A REPAIRING - IGNITION COIL #3 PRIMARY CIRCUIT . . . . . . . . . . . .248TC-42A REPAIRING - IGNITION COIL #2 PRIMARY CIRCUIT . . . . . . . . . . . .252TC-43A REPAIRING - IGNITION COIL #1 PRIMARY CIRCUIT . . . . . . . . . . . .256TC-44A REPAIRING - NO ASD RELAY OUTPUT VOLTAGE AT PCM. . . . . . .264TC-48A REPAIRING - PCM FAILURE SRI MILE NOT STORED . . . . . . . . . . .272TC-49A REPAIRING - EEPROM WRITE DENIED . . . . . . . . . . . . . . . . . . . . . .273TC-50A REPAIRING - TRANS 3-4 SOLENOID/TRANS RELAY CKTS . . . . . .274TC-55A REPAIRING - INJECTOR #9 CONTROL CIRCUIT . . . . . . . . . . . . . . .290TC-56A REPAIRING - INJECTOR #10 CONTROL CIRCUIT . . . . . . . . . . . . . .292TC-57A REPAIRING - INTAKE AIR TEMP SENSOR VOLTAGE LOW . . . . . . .294TC-58A REPAIRING - INTAKE AIR TEMP SENSOR VOLTAGE HIGH . . . . . .298TC-61A REPAIRING - INJECTOR #4 CONTROL CIRCUIT . . . . . . . . . . . . . . .302TC-62A REPAIRING - 1/1 O2 SENSOR SHORTED TO VOLTAGE . . . . . . . . .310TC-66A REPAIRING - 2/1 O2 SENSOR SHORTED TO VOLTAGE . . . . . . . . .314TC-69A REPAIRING - INJECTOR #5 CONTROL CIRCUIT . . . . . . . . . . . . . . .318TC-70A REPAIRING - INJECTOR #6 CONTROL CIRCUIT . . . . . . . . . . . . . . .324TC-74A REPAIRING - TRANS TEMP SENSOR VOLTAGE TOO LOW . . . . . .330

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TC-75A REPAIRING - TRANS TEMP SENSOR VOLTAGE TOO HIGH . . . . . .334TC-76A REPAIRING - IGNITION COIL #4 PRIMARY CIRCUIT . . . . . . . . . . . .342TC-77A REPAIRING - IGNITION COIL #5 PRIMARY CIRCUIT . . . . . . . . . . . .346TC-79A REPAIRING - INJECTOR #7 CONTROL CIRCUIT . . . . . . . . . . . . . . .350TC-80A REPAIRING - INJECTOR #8 CONTROL CIRCUIT . . . . . . . . . . . . . . .360TC-87A REPAIRING - SPEED CONTROL SWITCH ALWAYS LOW . . . . . . . .366TC-94A REPAIRING - CNG TEMP SENSOR VOLTAGE TOO LOW . . . . . . . .370TC-95A REPAIRING - CNG TEMP SENSOR VOLTAGE TOO HIGH . . . . . . . .374TC-98A REPAIRING - CNG PRESSURE SENSOR VOLTAGE TOO HIGH . . .378TC-99A REPAIRING - CNG PRESSURE SENSOR VOLTAGE TOO LOW . . .384TC-101A REPAIRING - FUEL PUMP (SYSTEM) RELAY CONTROL CIRCUIT .390TC-102A REPAIRING - 1/1 O2 SENSOR SLOW RESPONSE . . . . . . . . . . . . .398TC-103A REPAIRING - 1/1 O2 SENSOR HEATER FAILURE . . . . . . . . . . . . . .400TC-104A REPAIRING - 1/2 O2 SENSOR SLOW RESPONSE . . . . . . . . . . . . .404TC-105A REPAIRING - 1/2 O2 SENSOR HEATER FAILURE . . . . . . . . . . . . . .406TC-106A REPAIRING - MULTIPLE CYLINDER MIS-FIRE . . . . . . . . . . . . . . . . .410TC-107A REPAIRING - CYLINDER #1, #2, #3, #4, #5, #6, #7, OR #8

MISFIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .418TC-112A REPAIRING - CATALIYTIC CONVERTER EFFICIENCY FAILURE. . .422TC-113A REPAIRING - EVAP PURGE FLOW MONITOR FAILURE . . . . . . . . .424TC-114A REPAIRING - P/N SWITCH STUCK IN PARK OR IN GEAR . . . . . . .432TC-115A REPAIRING - POWER STEERING SWITCH FAILURE . . . . . . . . . . .438TC-118A REPAIRING - FUEL SYSTEM 1/1 RICH . . . . . . . . . . . . . . . . . . . . . . .444TC-119A REPAIRING - FUEL SYSTEM 1/1 LEAN. . . . . . . . . . . . . . . . . . . . . . .448TC-120A REPAIRING - FUEL SYSTEM 2/1 RICH . . . . . . . . . . . . . . . . . . . . . . .452TC-121A REPAIRING - FUEL SYSTEM 2/1 LEAN. . . . . . . . . . . . . . . . . . . . . . .456TC-122A REPAIRING - 2/1 O2 SENSOR SLOW RESPONSE . . . . . . . . . . . . .460TC-124A REPAIRING - 2/1 O2 SENSOR HEATER FAILURE . . . . . . . . . . . . . .462TC-126A REPAIRING - 1/2 O2 SENSOR SHORTED TO VOLTAGE . . . . . . . . .466TC-128A REPAIRING - CLOSED LOOP TEMP NOT REACHED . . . . . . . . . . .470TC-132A REPAIRING - TPS VOLTAGE DOES NOT AGREE WITH MAP . . . . .472TC-138A REPAIRING - TARGET IDLE NOT REACHED . . . . . . . . . . . . . . . . . .478TC-140A REPAIRING - EGR SYSTEM FAILURE . . . . . . . . . . . . . . . . . . . . . . .484TC-141A REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET

15-20 PSI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .488TC-142A REPAIRING - GOVERNOR PRESSURE ABOVE 3 PSI IN GEAR WITH

0 MPH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .498TC-144A REPAIRING - 1/3 O2 SENSOR SHORTED TO GROUND . . . . . . . . .506TC-147A REPAIRING - 1/3 O2 SENSOR SHORTED TO VOLTAGE . . . . . . . . .510TC-148A REPAIRING - TORQ CONV CLU, NO RPM DROP AT LOCKUP . . . .514TC-149A REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO LOW . . . .524TC-150A REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO HIGH . . . .528TC-151A REPAIRING - FUEL LEVEL UNIT NO CHANGE OVER MILES . . . . .534TC-153A REPAIRING - BATTERY TEMP SENSOR VOLTAGE TOO LOW/TOO

HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .538TC-155A REPAIRING - 1/1 O2 SENSOR SHORTED TO GROUND . . . . . . . . .544TC-156A REPAIRING - 1/2 O2 SENSOR SHORTED TO GROUND . . . . . . . . .548TC-157A REPAIRING - INTERMITTENT LOSS OF CMP OR CKP . . . . . . . . . .552TC-160A REPAIRING - EVAP LEAK MONITOR SMALL LEAK DETECTED . . .566TC-161A REPAIRING - EVAP LEAK MONITOR LARGE LEAK DETECTED . . .570TC-162A REPAIRING - NO TEMP RISE SEEN FROM INTAKE HEATERS. . . .574TC-164A REPAIRNG - TRANS TEMP SENSOR, NO RISE AFTER START . . .582

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TC-165A REPAIRING - 3-4 SHIFT SOLENOID, NO RPM DROP 3-4 SHIFT. . .586TC-166A REPAIRING - LOW OUTPUT SPEED SENSOR RPM, ABOVE 15

MPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .592TC-167A REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO

LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .596TC-168A REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO

HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .600TC-169A REPAIRING - GOVERNOR PRESSURE SENSOR OFFSET VOLTS

TOO LOW OR HIGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .614TC-171A REPAIRING - GOVERNOR PRESSURE SOLENOID/TRANS RELAY

CKTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .620TC-173A REPAIRING - TRANS 12 VOLT SUPPLY RELAY CNTRL CIRCUIT . .636TC-181A REPAIRING - 2/1 O2 SENSOR SHORTED TO GROUND . . . . . . . . .640TC-183A REPAIRING - LEAK DETECTION PUMP SOLENOID CIRCUIT . . . . .644TC-184A REPAIRING - LEAK DETECTION PUMP SW OR MECHANICAL

FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .648TC-186A REPAIRING - MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT . . . . . . .652TC-187A REPAIRING - EVAP LEAK MONITOR PINCHED HOSE . . . . . . . . . .654TC-188A REPAIRING - O/D SWITCH PRESSED (LO) MORE THAN 5 MIN. . .658TC-189A REPAIRING - 1/3 O2 SENSOR HEATER FAILURE . . . . . . . . . . . . . .662

NO TROUBLE CODE TESTSNTC-1A NO TROUBLE CODE TEST MENU . . . . . . . . . . . . . . . . . . . . . . . . . .666NTC-2A CHECKING SECONDARY IGNITION AND TIMING . . . . . . . . . . . . . .668NTC-3A CHECKING FUEL PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .670NTC-4A CHECKING COOLANT SENSOR CALIBRATION . . . . . . . . . . . . . . . .676NTC-5A CHECKING THROTTLE POSITION SENSOR . . . . . . . . . . . . . . . . . .678NTC-6A CHECKING MAP SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .680NTC-7A CHECKING OXYGEN SENSOR SWITCHING . . . . . . . . . . . . . . . . . .682NTC-8A CHECKING THE OXYGEN SENSOR HEATER . . . . . . . . . . . . . . . . .688NTC-9A CHECKING IDLE AIR CONTROL MOTOR . . . . . . . . . . . . . . . . . . . . .690NTC-10A CHECKING THE PARK/NEUTRAL POSITION SWITCH. . . . . . . . . . .698NTC-11A CHECKING THE PCM POWER AND GROUND CIRCUITS . . . . . . . .702NTC-12A CHECKING THE EVAP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . .704NTC-13A CHECKING EGR SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .708NTC-14A CHECKING THE ENGINE VACUUM . . . . . . . . . . . . . . . . . . . . . . . . .714NTC-15A CHECKING THE INTAKE AIR TEMP SENSOR . . . . . . . . . . . . . . . . .716NTC-16A CHECKING MINIMUM AIR FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . .718NTC-17A CHECKING THE AIR INTAKE HEATER #1. . . . . . . . . . . . . . . . . . . . .720NTC-18A CHECKING THE AIR INTAKE HEATER #2. . . . . . . . . . . . . . . . . . . . .726NTC-19A CHECKING THE FUEL HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . .732NTC-20A CHECKING THE WAIT-TO-START LAMP. . . . . . . . . . . . . . . . . . . . . .736NTC-21A CHECKING THE WATER-IN-FUEL LAMP & SENSOR . . . . . . . . . . . .740NTC-22A CHECKING THE ENGINE MECHANICAL SYSTEMS. . . . . . . . . . . . .748

SPEED CONTROL TESTSSC-1A CHECKING THE SPEED CONTROL OPERATION . . . . . . . . . . . . . .750SC-2A CHECKING THE SPEED CONTROL OPERATION . . . . . . . . . . . . . .762SC-3A CHECKING THE SPEED CONTROL OPERATION . . . . . . . . . . . . . .764SC-4A CHECKING THE SPEED CONTROL OPERATION . . . . . . . . . . . . . .770SC-5A CHECKING THE SPEED CONTROL OPERATION . . . . . . . . . . . . . .772

CHARGING TESTS

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CH-1A CHARGING SYSTEM NO CODE TEST . . . . . . . . . . . . . . . . . . . . . . .774

NO START TESTSNS-SEL NO START SELECTION MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . .780NS-1A QUALIFYING A NO START CONDITION . . . . . . . . . . . . . . . . . . . . . .782NS-2A CHECKING FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .792NS-3A CHECKING THE MECHANICAL SYSTEM . . . . . . . . . . . . . . . . . . . . .794NS-4A REPAIRING LOW FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . .796NS-5A CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .798NS-6A REPAIRING A 9NO RESPONSE9 CONDITION . . . . . . . . . . . . . . . . . .802NS-7A CHECKING IDLE AIR CONTROL MOTOR . . . . . . . . . . . . . . . . . . . . .826NS-8A REPAIRING A START AND STALL CONDITION. . . . . . . . . . . . . . . . .840NS-9A REPAIRING A NO CRANK CONDITION. . . . . . . . . . . . . . . . . . . . . . .842NS-10A QUALIFYING A NO START CONDITION (8.0 L ONLY) . . . . . . . . . . .852NS-11A CHECKING THE FUEL SYSTEM (CNG) . . . . . . . . . . . . . . . . . . . . . .858NS-12A CHECKING THE FUEL RELAYS AND SOLENOIDS . . . . . . . . . . . . .872NS-13A CHECKING FUEL PRESSURE LOSS . . . . . . . . . . . . . . . . . . . . . . . .876NS-14A CHECKING THE FUEL HEATER RELAY . . . . . . . . . . . . . . . . . . . . . .878NS-15A CHECKING THE FUEL SHUTDOWN RELAY AND SOLENOID

(DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .882

VERIFICATION TESTSVER-1A NO START VERIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .888VER-2A ROAD TEST VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .889VER-3A CHARGING VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .890VER-4A SPEED CONTROL VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . .891VER-5A ROAD TEST FOR OBDII TROUBLE CODES . . . . . . . . . . . . . . . . . . .892

8.0 MAINTENANCE AND SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .893

9.0 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .893

9.1 FUEL SYSTEM RELEASE PROCEDURE (GASOLINE). . . . . . . . . . . . . . . . . .8939.2 FUEL SYSTEM PRESSURE RELEASE PROCEDURE (CNG) . . . . . . . . . . . .893

9.2.1 Fuel Line Pressure Release Procedure . . . . . . . . . . . . . . . . . . . . . . . . .8939.2.2 Fuel Cylinder Pressure Release Procedure. . . . . . . . . . . . . . . . . . . . . .894

10.0 SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .895

10.1 1996 DODGE 2.5L JTEC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89510.2 1996 JEEP XJ 2.5L JTEC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89610.3 1996 JEEP XJ 4.0L JTEC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89710.4 1996 JEEP ZJ 4.0L JTEC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89810.5 1996 DODGE 3.9L JTEC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89910.6 1996 DODGE 5.2/5.9L JTEC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90010.7 1996 JEEP ZJ 5.2L JTEC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90110.8 1996 DODGE 5.9L-HD JTEC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90210.9 1996 DODGE 5.9L CUMMINS DIESEL JTEC SYSTEM. . . . . . . . . . . . . . . . . .90310.10 1996 DODGE 8.0L V10-MD SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90410.11 1996 DODGE 8.0L V10-HD SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90510.12 1996 DODGE 5.2L CNG, AB, AN, AND BR SYSTEM . . . . . . . . . . . . . . . . . . .906

11.0 REQUIRED TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .907

v


12.0 GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .907

12.1 BODY CODES DEFINED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .908

vi

1.0 INTRODUCTION

The procedures contained in this manual include all the specifications, instructions, and graphicsneeded to diagnose powertrain control module (PCM) problems; they are no start, diagnostictrouble code, and no trouble code problems for the PCM. The diagnostics in this manual arebased 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 properremoval and repair procedure.

Diagnostic procedures change every year. New diagnostic systems may be added; carryoversystems may be enhanced. READ THE GENERAL INFORMATION SECTIONS IN THISMANUAL BEFORE TRYING TO DIAGNOSE A VEHICLE TROUBLE CODE. It is recommendedthat 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, ifyou have any comments or recommendations, please fill out the form at the back of the book andmail it back to us.

1.1 System Coverage

This diagnostic procedures manual covers all 1996 Jeep and Dodge Truck vehicles with a newPCM (JTEC Engine and 42RX Transmission Controller).

1.2 Six-Step Troubleshooting Procedure

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, ignitionsystem, and automatic transmission.

3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION

3.1 General Description

The Jeep and Dodge Truck engine and Auto Transmission systems have the latest in technicaladvances. The on-board OBDII diagnostics incorporated with the PCM controller are intended toassist the field technician in repairing vehicle problems by the quickest means.

3.2 JTEC Controller and Operating Modes

3.2.1 Overview

The Jeep-Truck PCM features a multi-processor environment (one 16 bit microcomputer, two 8 bitmicrocomputers) allowing parallel processing of time critical operations. Dedication of one 8 bitprocessor (K4) to spark control and the other 8 bit processor (D3) to fuel control allows increasesin throughput and reduced software complexity in the 16 bit microcomputer (Z2). The result is

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increased capability in the Z2 to handle overall strategy implementation, OBDII, and othercomputation-intensive processes. This approach allows control of ten cylinder engines in runningexcess of 6,500 RPM.

3.2.2 Hardware Architecture

The design of the PCM can be broken up into about eight major sections. The mainmicrocontroller, a Motorola MC68HC16Z2, is attached to a 256k byte memory device (flashmemory) which is programmed after manufacture of the module. (This memory can bereprogrammed at the factory or at a dealership. The MC68HC11D3 and MC68HC11K4 micro-computers have memories which are permanently programmed during their manufacture, andtherefore cannot be reprogrammed.)

The microcomputers communicate over a bus which allows for rapid transmission of high prioritymessages. The Z2 executes the primary powertrain control strategy; transmits fuel and sparkrequirements to the D3 and K4; communicates with outside devices; and processes 14 analoginputs and about half of the one bit inputs and outputs. The D3 microcomputer controls fuelinjector timing pulses and a small number of one bit inputs and outputs. The K4 controls sparktiming 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 ignitioncoil currents.

3.2.3 Software Architecture

The 68HC16Z2 microcontroller is the main computing unit of the PCM. The 68HC11D3 and K4microcontrollers control fuel and spark respectively. They handle the critical timing requirementsof 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 asupdating sensor inputs values and checking for the occurrence of a crank position pulse. If thispulse is observed, a program known as the decision maker is executed and performs high prioritytasks such as fuel and spark calculations, and RPM processing. Low priority tasks (i.e. OBDIIprocessing, 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 transmissionssupported by this PCM. Once installed, the information contained in this area is fixed for a givenengine and transmission. Changes to this data, if required, can be performed only by computerprogramming personnel. The calibration areas (engine, transmission and OBDII) contain infor-mation relating to emissions, fuel economy and driveability and can be altered directly bycalibration personnel.

3.2.4 Spark Control

The K4 microcomputer controls the generation and timing of spark pulses. The spark advanceand dwell characteristics are determined by: engine speed, throttle position, MAP, coolanttemperature, 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 iscalculated using the speed density method using engine speed, manifold absolute pressure, andair 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

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crank time strategy. Cold engine operation is determined via an open loop strategy until the O2sensors have reached operating temperature. At this point, the strategy enters a closed loopmode 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 atechnique 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 theZ2 microcomputer. Injector timing with respect to engine position is determined by the D3 and istransparent to the Z2.

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 PCMmemory. The criteria may be a range of: engine rpm, engine temperature, and/or input voltage tothe PCM. If a problem is sensed with a monitored circuit, and all of the criteria or arming conditionsare 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 memoryeven though a malfunction has occurred. This may happen because one of the trouble codecriteria (arming conditions) has not been met.

The PCM compares input signal voltages from each input device with specifications (theestablished high and low limits of the range) that are programmed into it for that device. If the inputvoltage is not within specifications and other trouble code criteria (arming conditions) are met, atrouble code will be stored in the PCM memory.

The On Board Diagnostics have evolved to the second Generation of Diagnostics referred to asOBDII. These OBDII Diagnostics control the functions necessary to meet the requirements ofCalifornia OBDII and Federal OBD regulations. These requirements specify the inclusion of amalfunction indicator light (MIL) located on the instrument panel for all 1994 and subsequentmodel-year passenger cars, light duty trucks, and medium-duty vehicles. The purpose of the MILis to inform the vehicle operator in the event of malfunction of any powertrain components whichcan affect emissions and which provide input to, or receive output from, the engine controllermodule.

Control of OBDII functions is separated into two areas: the Task Manager and the ComprehensiveComponent Manager.

Task ManagerThe Task Manager controls the execution of some component/systems tests, control of MILillumination, storage of fault codes, and storage of vehicle data at time of fault detection (freezeframe). This routine performs the following monitoring requirements:

Fuel System MonitoringMisfire DetectionEGR System MonitorOxygen Sensor Upstream Heater MonitorOxygen Sensor Upstream MonitorEvaporative System MonitorCatalyst Monitor

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Purge Flow Monitor02 Heater Downstream Monitor02 Sensor Downstream Monitor

Another function of the task manager is control of the Disable Tables. These tables are used todiscontinue testing when a condition specified in the tables are met. Testing of a component orsystem 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 ManagerThe Comprehensive Component Manager controls the testing of all powertrain components/systems which can affect emissions and were not otherwise tested by the Task Manager. Thisroutine is organized into three areas:

D3 and K4 CIRCUIT CHECKS − Performed on sensor inputs connected to the D3 and K4to determine out-of-range or high/flow input conditions. Performed on outputs to check foropen/short conditions. The components tested are:

IAC Open/Short CircuitGenerator FieldTCC SolenoidFan RelayA/C RelayAir Switch / Shift Lock SolenoidTransmission Relay OutputASD RelayFuel Pump RelayEVAP Purge SolenoidEGR SolenoidIgnition Coils (1 thru 5)Injector Failure (1-10)

Z2 CIRCUIT CHECKS − Performed on sensor inputs connected to the Z2 to determineout-of-range or high/low input conditions. Performed on outputs to check for open/shortconditions. 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 CheckCNG 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)

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FUNCTIONALITY/RATIONALITY CHECKS − These tests determine if a component isworking correctly through methods other than voltage limit tests and open/short tests.Solenoids in this section are checked for proper operation (functionality) and sensors arechecked for meaningful output values (rationality). The components/systems checked are:

Cam Sensor Pulses PresentCrank Sensor Pulses PresentMAP Sensor Output in RangeCoolant Temperature in RangeThrottle Position Sensor in RangeVehicle Speed Sensor Output CorrectPark/Neutral Switch WorkingFuel Level Sensor Output CorrectTransmission Temperature Sensor Output CorrectTransmission Governor Pressure in RangeOutput Shaft Speed Sensor Output CorrectAIS Motor WorkingLock-up Solenoid Working3/4 Shift Solenoid WorkingGovernor Pressure Solenoid WorkingO2 Sensor 1/1 Output Voltage LowO2 Sensor 1/2 Output Voltage LowO2 Sensor 2/1 Output Voltage LowO2 Sensor 2/2 Output Voltage LowCharging System WorkingPower Steering Switch WorkingThermostat WorkingO2 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)

3.2.7 Transmission Control

The PCM operation includes control of 3 and 4 speed automatic transmissions utilizing electronicgovernor pressure control, eliminating the need for a separate transmission controller. Transmis-sion control is achieved through regulation of governor pressure using a variable force solenoidvalve. (Valve position is controlled by pulse width modulation. Torque convertor lock-up andoverdrive solenoids are also controlled by the PCM, as are the transmission protection relay anddashboard overdrive lamp. PCM inputs affecting transmission operation include the throttleposition sensor, output shaft speed sensor, vehicle speed sensor, engine speed sensor, brakeswitch, cruise control switches, ignition, overdrive on/off switch and sump fluid temperaturethermistor.

Electronic Governor Pressure ControlRegulation of governor pressure by enables control of WOT shift points to within +/- 50 RPMresulting in improved shift quality (as opposed to control to within +/- 300 RPM in transmissionutilizing mechanical governors). The elimination of the mechanical governor resulted in aphysically smaller and lighter package. Torque calculation can be used to determine whenupshifting is advantageous.

Anti-Hunt Shift StrategyThis strategy was added in order to maintain fuel economy over a variety of load conditions. Thistechnique allows for relatively early upshift in mid-range throttle settings under light loadconditions, resulting in improved fuel economy. Under heavier loading, shifts are delayed toprevent upshifting into a condition where insufficient torque is available to maintain vehicle speed,resulting in downshift/upshift cycling.

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Sump Pump Temperature SensingA themistor is attached to the lock-up solenoid and submerged in the sump fluid. The sump fluidtemperature is a factor in the calculation of WOT shift strategy, low temperature shift compen-sation, sump temperature limiting strategy, overdrive strategy, torque converter clutch strategy,and governor pressure transducer calibration.

3.2.8 Other Controls

Cruise ControlThe PCM controls vehicle speed by operation of the speed control servo vacuum and ventsolenoids. Energizing the vacuum solenoid applies vacuum to the servo to increase throttleposition. Operation of the vent solenoid slowly releases the vacuum allowing throttle position todecrease. A special dump solenoid allows immediate release of throttle position caused bybraking, cruise control turn off, or ignition key off.

Exhaust Gas RecirculationThe 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 onlyafter 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 intothe throttle body for mixing with incoming air. Metering of the gases is performed by duty cyclingthe purge solenoid by the PCM.

The system is disabled during wide open throttle conditions and while the engine is below aspecified coolant temperature. When engine temperature becomes greater than a calibratedparameter, duty cycle purge is delayed for a calibrated time. Once purge delay is over, purge willbe 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 uponknown fuel flow through the injector at a given pulsewidth and RPM) and is adjusted tocompensate for changes in flow due to varying engine vacuum.

3.2.9 PCM Operating Modes (Gasoline & Eng.)

As Input signals to the PCM change, the PCM adjusts its response to output devices. Forexample, the PCM must calculate a different injector pulse width and ignition timing for idle thanit does for wide open throttle. There are several different modes of operation that determine howthe 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 presetprogramming. Inputs from the heated oxygen sensors are not monitored.

In closed loop operation, the PCM monitors the inputs from the heated oxygen sensors. This inputindicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuelratio of 14.7 parts air to 1 part fuel. By monitoring the exhaust oxygen content through the oxygensensor, the PCM can fine tune injector pulse width. Fine tuning injector pulse width allows thePCM to achieve optimum fuel economy combined with low emissions.

The engine start-up (crank), engine warm-up, and wide open throttle modes are open loopmodes. Under most operating conditions, the acceleration, deceleration, and cruise modes, withthe engine at operating temperature, are closed loop modes.

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Ignition Switch On (Engine Off) ModeWhen 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 determinebasic fuel strategy.

2. The PCM monitors the engine coolant temperature sensor and throttle position sensorinput. 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 autoshutdown relay and fuel pump relay are not energized. Therefore, voltage is not supplied to thefuel pump, ignition coil, and fuel injectors.

Engine Start-Up Mode – This is an open loop mode. The following actions occur when the startermotor is engaged:

1. The auto shutdown and fuel pump relays are energized. If the PCM does not receive thecamshaft and crankshaft signals within approximately one second, these relays arede-energized.

2. The PCM energizes all fuel injectors until it determines crankshaft position from thecamshaft and crankshaft signals. The PCM determines crankshaft position within oneengine revolution. After the crankshaft position has been determined, the PCMenergizes the fuel injectors in sequences. The PCM adjusts the injector pulse width andsynchronizes 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 fuelinjector pulse width based on the following:

–– engine coolant temperature– manifold absolute pressure– intake air temperature– engine revolutions– throttle position

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 andcontrols injector synchronization by controlling the fuel injectors’ ground paths. The PCM adjustsignition timing and engine idle speed. The PCM adjusts the idle speed by controlling the idle aircontrol motor.

Cruise or Idle Mode – When the engine is at normal operating temperature, this is a closed loopmode. During certain idle conditions, the PCM may enter into a variable idle speed strategy. At thistime, 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 throttleposition and a decrease in Manifold Vacuum as engine load increases. In response, the PCMincreases the injector pulse width to meet the increased load.

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Deceleration Mode – This is a closed loop mode. The PCM recognizes a decrease in throttleposition and an increase in Manifold Vacuum as engine load decreases. In response, the PCMdecreases the injector pulse width to meet the decreased load.

Wide Open Throttle Mode – This is an open loop mode. The throttle position sensor notifies thePCM of a wide open throttle condition. The PCM adjusts injector pulse width to supply apredetermined amount of additional fuel.

3.2.10 PCM Operating Modes (Diesel)

As input signals to the powertrain control module (PCM) change, the PCM adjusts its responseto output devices. There are several different modes of operation that determine how the PCMresponds to the various input signals. In all modes, the wait-to-start lamp will flash if an opencircuit is detected in the intake air temperature sensor circuit.

Ignition Switch On (Engine Off) ModeWhen 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 suppliedthrough 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 apredetermined temperature, the PCM will start the air intake heater preheat cycle. The PCMwill energize the intake heaters by grounding the air intake heater relays. The PCM will turnthe wait-to-start lamp on until the preheat cycle is over. If the PCM receives a crank signalbefore 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-fuelsensor. NOTE: If the water-in-fuel lamp remains illuminated after the 2-second bulb check, thevehicle should not be started until the fuel filter has been drained and primed.

Engine Start-Up ModeWhen 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 PCMdetermines that the engine is running.

4. If the PCM receives a crank signal before the preheat cycle is over, the heaters will bede-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 66°F or less when the ignition was turned on, the cycle isstarted.

2. If the transmission temperature sensor determines it is below 59°F, the automatic transmis-sion will not be allowed to enter overdrive.

3. If the transmission temperature sensor determines it is below 69°F, the transmission’s torqueconverter 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-fuelsensor.

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Cruise or Idle ModeDuring 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 thetransmission overdrive and torque converter clutch operation.

4. If the transmission temperature sensor determines it is below 59°F or above 275°F, theautomatic transmission will not be allowed to enter overdrive. If the transmission is inoverdrive when the transmission temperature is above 275°F, the transmission will downshiftand not upshift again until the transmission temperature drops to 240°F.

5. The water in-fuel sensor signal is used by the PCM to turn on the water-in-fuel lamp, if wateris sensed in the fuel.

Acceleration ModeWhen there is an abrupt demand for increased engine output and vehicle acceleration, thefollowing occurs:

1. The vehicle speed, crank position, and throttle position sensors are used to controltransmission overdrive and torque converter clutch operation.

2. If the transmission temperature sensor determines it is below 69°F, the transmission’s torqueconverter clutch will not be allowed to engage.

3. If the transmission temperature sensor determines it is below 59°F or above 275°F, theautomatic transmission will not be allowed to enter overdrive. If the transmission is inoverdrive when the transmission temperature is above 275°F, the transmission will downshiftand not upshift again until the transmission temperature drops to 240°F.

4. If the speed control system resume/accelerate function is being used, the PCM will only allowthe vehicle to accelerate at a predetermined rate. If a speed control has been set and theresume/accelerate button is momentarily pushed in, the PCM will increase vehicle speed bytwo 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 ModeDuring deceleration, the following inputs are received by the PCM:

1. The vehicle speed, crank position, and throttle position sensors are used to controltransmission 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 275°F, theautomatic transmission will not be allowed to enter overdrive. If the transmission is inoverdrive when the transmission temperature is above 275°F, the transmission will downshiftand not upshift again until the transmission temperature drops to 240°F.

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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 ModeWhen the ignition switch is turned to the ‘‘off’’ position, the PCM still receives battery voltagethrough the battery input. Battery voltage is needed to keep PCM memory alive. The Memorystores 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 couldhave malfunctions that result in driveability problems. A diagnostic code may not be displayed forthe following conditions. However, problems with these systems may cause a diagnostic code tobe displayed for other systems. For example, a fuel pressure problem will not register a diagnosticcode directly, but could cause a rich or lean condition. This could cause an oxygen sensor, fuelsystem, 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 fuelsupply.(*)

Fuel Injectors – The PCM cannot detect if the fuel injector is clogged, the pintle is sticking, or thewrong 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 ofthis book.)

PCM Grounds – The PCM cannot detect a poor system ground. However, a diagnostic troublecode 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 filterelement.(*)

Exhaust System – The PCM cannot detect a plugged, restricted, or leaking exhaust system.(*)

Cylinder Compression – The PCM cannot detect uneven, low, or high engine cylindercompression.(*)

Excessive Oil Consumption – Although the PCM monitors the exhaust stream oxygen contentthrough the oxygen sensor when the system is in a closed loop, it cannot determine excessive oilconsumption.

(*)NOTE: Any of these conditions could result in a rich or lean condition causing an oxygen sensortrouble code to be stored in the PCM, or the vehicle may exhibit one or more of the driveabilitysymptoms listed in TEST NTC-1A - No Trouble Code Test Menu.

GENERAL

INFORMATION

10

3.3 Diagnostic Trouble Codes

Each diagnostic trouble code is diagnosed by following a specific testing procedure. Thediagnostic test procedures contain step-by-step instructions for determining the cause of troublecodes as well as no trouble code problems. It is not necessary to perform all of the tests in thisbook to diagnose an individual code.

Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins inthe DTC TEST – Checking the System for Diagnostic Trouble Codes. This will direct you to thespecific test(s) that must be performed.

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 circuitor function. Procedures in this manual verify if the trouble code is a hard code at the beginningof 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 thecircuit is an ‘‘intermittent’’ code. Most intermittent codes are caused by wiring or connectorproblems. Defects that come and go like this are the most difficult to diagnose; they must belooked for under specific conditions that cause them. The following checks may assist you inidentifying a possible intermittent problem:

• Visually inspect related wire harness connectors. Look for broken, bent, pushed out, orcorroded 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 lastset, 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 recordedby 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 CODESFOUND’’ and the reset counter will show ‘‘RESET COUNT = XXX.’’

3.3.4 Handling No Trouble Code Problems

After reading Section 3.0 (System Description and Functional Operation), you should have abetter understanding of the theory and operation of the on-board diagnostics, and how this relatesto 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 Using the DRB

Refer to the DRB user’s guide for instructions and assistance with reading trouble codes, erasingtrouble codes, and other DRB functions.

GENERAL

INFORMATION

11

3.5 DRB Error Messages and Blank Screen

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 MDSHotline, or call for information and assistance at 1-800-825-8737. This is a sample of such anerror message display:

ver: 2.14date: 26 Jul93file: key_itf.ccdate: Jul 26 1993line: 548err: 0x1User-Requested COLD Boot

Press MORE to switch between this displayand the application screen.

Press F4 when done noting information.

3.5.1 DRB Does Not Power Up

If the LED’s do not light or no sound is emitted at start up, check for loose cable connections ora bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11volts is required to adequately power the DRB.

If all connections are proper between the DRB and the vehicle or other devices, and the vehiclebattery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring. Fora blank screen, refer to the appropriate body diagnostics manual.

3.5.2 Display Is Not Visible

Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for thiscondition.

GENERAL

INFORMATION

12

4.0 SYSTEM COMPONENT LOCATIONS

4.1 Powertrain Control ModuleAB BODY

CAV CIRCUIT FUNCTION

A2 F18 LG/BK Fused Ignition Switch Output

A4 K4 BK/LB Sensor Ground

A6 T41 BR/OR P/N Position Switch Sense

A7 K19 GY Ignition Coil Driver #1

A8 K24 GY/BK Crank Position Sensor Signal

A10 K60 YL/BK Idle Air Control #2 Driver

A11 K40 BR/WT Idle Air Control #3 Driver

A15 K21 BK/RD Intake Air Temp Sensor Signal

A16 K2 TN/BK ECT Sensor Signal

A17 K6 VT/WT 5-Volt Supply

A18 K44 TN/YL Camshaft Position SensorSignal

A19 K39 GY/RD Idle Air Control #1 Driver

A20 K59 VT/BK Idle Air Control #4 Driver

A22 A14 RD/WT Fused B(+)

A23 K22 OR/DB Throttle Position Sensor Signal

A24 K41 BK/LG Upstream O2 Sensor Signal

A25 K341 TN/WT Downstream O2 Sensor Signal

A27 K1 DG/RD MAP Sensor Signal

A31 Z1 BK/TN Ground

A32 Z1 BK/TN Ground

B1 T34 GY/BK Trans Temp Sensor Signal

B2 K26 VT Injector #7 Driver

B4 K11 WT/DB Injector #1 Driver

B5 K13 YL/WT Injector #3 Driver

B6 K38 GY Injector #5 Driver

B8 T59 PK Governor Pressure SolenoidControl

B10 K20 DG/WT Generator Field Driver

B11 K54 OR/BK TCC Solenoid Control

B12 K58 BR/DB Injector #6 Driver

B13 K28 GY/LB Injector #8 Driver

B15 K12 TN Injector #2 Driver


B16 K14 LB/BR Injector #4 Driver

B21 T60 OR/WT Solenoid Control 3-4 Shift

B22 G79 TN/PK Fuel Temp Sensor Signal

B25 T13 DB/BK Output Shaft Speed SensorGround

B27 G7 WT/OR Vehicle Speed Sensor Signal

B28 T14 LG/WT Output Shaft Speed SensorSignal

B29 T25 LG/RD Governor Pressure Signal

B30 T30 VT/LB Transmission Relay Control

B31 K7 OR 5-Volt Supply

C1 C13 DB/OR A/C Comp Clutch Relay Control

C3 K51 DB/YL Auto Shutdown Relay Control

C4 V36 TN/RD S/C Vacuum Solenoid Control

C5 V35 LG/RD S/C Vent Solenoid Control

C6 T18 LG/OR Overdrive Off Lamp Driver

C11 V32 YL/RD 12 Volt Supply

C12 A142 DG/OR Auto Shutdown Relay Output

C13 T6 OR/WT Overdrive Off Switch Sense

C15 K118 PK/YL Battery Temp Sensor Signal

C16 G12 TN/BK Generator Lamp Driver

C17 G3 BK/PK MIL (Check Engine) LampDriver

C19 K31 BR Fuel Pump Relay Control

C20 K52 PK/BK Evaporative Emission SolenoidCtrl

C22 C20 BR/WT A/C Request Signal

C23 C90 LG A/C Select Signal

C24 K29 WT/PK Brake Switch Sense

C26 G8 LB/BK Low Fuel Sense

C27 D21 PK SCI Transmit

C29 D20 LG/WT SCI Receive

C32 V33 WT/LG Speed Control Switch Signal

GENERAL

INFORMATION

13

4.1 Powertrain Control Module (Continued)AN BODY


A2 A21 DB Fused Ignition Switch Output


A6 T41 BR/YL P/N Position Switch Sense













A24 K141 TN/WT Upstream O2 Sensor Signal

A25 K341 TN/PK Downstream O2 Sensor Signal


A28 K242 DG/LB Fuel Pressure Sensor Signal

A31 Z12 BK/TN Ground


B1 T54 VT Trans Temp Sensor Signal

B2 K26 DB Injector #7 Driver





B10 K20 DG Generator Field Driver



B13 K28 GY/LB Injector #8 Driver



B21 T60 BR Solenoid Control 3-4 Shift


B22 K221 TN/PK Fuel Temperature Sensor Signal




B29 T25 LG/RD Governor Pressure Signal

B30 T30 VT/LB Transmission Relay Control

B31 T33 RD/YL 5-Volt Supply


C2 C27 DB/PK Radiator Fan Relay Control





C7 G14 PK/BK Trans Temp Lamp Driver





C16 G12 DG/YL Generator Lamp Driver




C22 C20 BR A/C Request Signal





C28 D2 WT/PK CCD Bus (-)

C29 D20 LG SCI Receive

C30 D1 VT/BR CCD Bus (+)

C31 G21 GY/LB Tachometer Signal


GENERAL

INFORMATION

14

BR BODY (Gasoline Engines)


A1 K32 YL/GY Ignition Coil Driver #4A2 F18 LG/BK Fused Ignition Switch OutputA3 K18 RD/BK Ignition Coil Driver #3A4 K4 BK/LB Sensor GroundA5 K43 DG/GY Ignition Coil Driver #5A6 T41 BK/WT P/N Position Switch SenseA7 K19 BK/GY Ignition Coil Driver #1A8 K24 GY/BK Crank Position Sensor SignalA9 K17 DB/WT Ignition Coil Driver #2A10 K60 YL/BK Idle Air Control #2 DriverA11 K40 BR/WT Idle Air Control #3 DriverA15 K21 BK/RD Intake Air Temp Sensor SignalA16 K2 TN/BK ECT Sensor SignalA17 K6 VT/WT 5-Volt SupplyA18 K44 TN/YL Camshaft Position Sensor SignalA19 K39 GY/RD Idle Air Control #1 DriverA20 K59 VT/BK Idle Air Control #4 DriverA22 A14 RD/WT Fused B(+)A23 K22 OR/DB Throttle Position Sensor SignalA24 K141 TN/WT Upstream O2 Sensor SignalA24 K41 BK/DG Upstream O2 Sensor SignalA25 K341 OR/BK Downstream O2 Sensor SignalA26 K41 BK/DG Right Upstream O2 Sensor SignalA26 K241 BK/DG Right Upstream O2 Sensor SignalA27 K1 DG/RD MAP Sensor SignalA28 K242 DG/LB Fuel Pressure Sensor SignalA29 K441 TN/RD Center O2 Sensor SignalA31 Z12 BK/TN GroundA32 Z12 BK/TN GroundB1 K54 VT Trans Temp Sensor SignalB2 K26 VT/TN Injector #7 DriverB3 K115 TN Injector #9 DriverB4 K11 WT/DB Injector #1 DriverB5 K13 YL/WT Injector #3 DriverB6 K38 GY Injector #5 DriverB8 K88 VT/WT Governor Pressure Solenoid

ControlB10 K20 DG Generator Field DriverB11 K54 OR/BK TCC Solenoid Control


B12 K58 BR/DB Injector #6 DriverB13 K28 GY/LB Injector #8 DriverB14 K116 WT/DB Injector #10 DriverB15 K12 TN Injector #2 DriverB16 K14 LB/BR Injector #4 DriverB21 T60 BR Solenoid Control 3-4 ShiftB22 K221 TN/PK Fuel Temp Sensor SignalB25 T13 DB/BK Output Shaft Speed Sensor

GroundB27 G7 WT/OR Vehicle Speed Sensor SignalB28 T14 LG/BK Output Shaft Speed Sensor SignalB29 T25 LG/WT Governor Pressure SignalB30 K30 PK Transmission Relay ControlB31 K7 OR 5-Volt SupplyB32 K35 GY/YL EGR Solenoid ControlC1 C13 DB/OR A/C Comp Clutch Relay ControlC3 K51 DB/YL Auto Shutdown Relay ControlC4 V36 TN/RD S/C Vacuum Solenoid ControlC5 V35 LG/RD S/C Vent Solenoid ControlC6 T18 LG/OR Overdrive Off Lamp DriverC7 G14 PK/BK Trans Temp Lamp DriverC11 V32 YL/RD 12 Volt SupplyC12 A142 DG/OR Auto Shutdown Relay OutputC13 T6 OR/WT Overdrive Off Switch SenseC15 K118 PK/YL Battery Temp Sensor SignalC16 G12 TN/YL Generator Lamp DriverC17 G3 BK/PK MIL (Check Engine) Lamp DriverC18 G24 GY/PK Service Reminder Indicator DriverC19 K31 BR/WT Fuel Pump Relay ControlC20 K52 PK Evaporative Emission Solenoid

CtrlC22 C20 BR A/C Request SignalC23 C90 LG A/C Select SignalC24 V40 WT/PK Brake Switch SenseC26 K226 DB/WT Low Fuel SenseC27 D21 PK/DB SCI TransmitC29 D20 DG SCI ReceiveC31 G21 GY/LB Tachometer SignalC32 V37 RD/LG Speed Control Switch Signal

The PCM is located in the rear enginecompartment, passenger side.

GENERAL

INFORMATION

15

4.1 Powertrain Control Module (Continued)

BR BODY 5.9L DIESEL


A2 F18 LG/BK Fused Ignition Switch Output


A6 T41 BK/WT P/N Position Switch Sense

A7 S21 YL/BK Air Intake Heater Relay #1 Con-

trol


A9 S22 OR/BK Air Intake Heater Relay #2 Con-

trol

A12 D28 LG/RD EGR Fault Monitor





A27 K1 DG/RD Water-In-Fuel Sensor Signal



B1 K54 VT Trans Temp Sensor Signal

B8 K88 VT/WT Governor Pressure SolenoidControl



B20 G85 OR/BK Wait to Start Lamp Driver




B28 T14 LG/BK Output Shaft Speed SensorSignal


B29 T25 LG/WT Governor Pressure Signal

B30 K30 PK Transmission Relay Control







C7 G14 PK/BK Trans Temp Lamp Driver

C9 D29 PK/DG EGR Test Mode





C16 G12 TN/YL Generator Lamp Driver


C18 G86 TN/OR Water-in-Fuel Lamp Driver

C22 C20 BR A/C Request Signal


C24 V40 WT/PK Brake Switch Sense

C27 D21 PK/DB SCI Transmit

C29 D20 DG SCI Receive


C32 V37 RD/LG Speed Control Switch Signal

GENERAL

INFORMATION

16

XJ BODY


A2 A21 DB Fused Ignition Switch Output


A6 T41 BR/YL P/N Position Switch Sense





A12 K10 DB/OR Power Steering Pressure SwitchSense







A22 A14 RD Fused B(+)


A24 K41 BK/LG Upstream O2 Sensor Signal

A25 K341 TN/WT Downstream O2 Sensor Signal
















C2 C27 DB/PK Radiator Fan Relay Control







C16 G14 PK/BK Generator Lamp Driver




C22 C21 DB/OR A/C Request Signal



C26 G4 DB Low Fuel Sense


C28 D2 WT/BK CCD Bus (-)

C29 D20 LG SCI Receive




GENERAL

INFORMATION

17

4.1 Powertrain Control Module (Continued)

ZJ BODY


A2 F99 RD/OR Fused Ignition Switch Output


A6 T41 BK/WT P/N Position Switch Sense

A7 K19 GY/WT Ignition Coil Driver #1

A8 K27 RD/LG Crank Position Sensor Signal





A17 K25 WT/BK 5-Volt Supply

A18 K24 GY/BK Camshaft Position SensorSignal



A22 F5 RD/YL Fused B(+)


A24 K41 BK/OR Upstream O2 Sensor Signal

A25 K141 BK/PK Downstream O2 Sensor Signal

A27 K70 RD/WT MAP Sensor Signal



B1 T54 VT Trans Temp Sensor Signal

B2 K17 DB/WT Injector #7 Driver






B11 T22 DG/LB TCC Solenoid Control

B12 K58 BR/YL Injector #6 Driver

B13 K18 DB/YL Injector #8 Driver





B23 G6 GY/WT Oil Pressure Switch Signal




B29 T25 LG Governor Pressure Signal

B30 T66 BR/OR Transmission Relay Control

B31 K6 VT/WT 5-Volt Supply

B32 K35 GY/YL EGR Solenoid Control

C1 C13 DB/RD A/C Comp Clutch Relay Control

C3 K900 PK/BK Auto Shutdown Relay Control



C6 G68 BR/YL Overdrive Off Lamp Driver

C10 J95 DG/RD Leak Detection Pump SolenoidCtrl



C13 T9 OR Overdrive Off Switch Sense

C14 J96 VT/RD Leak Detection Pump SwitchSense

C15 T222 YL/RD Battery Temp Sensor Signal

C19 K81 PK Fuel Pump Relay Control


C22 C3 DB/BK A/C Request Signal

C24 L53 BR Brake Switch Sense


C27 D83 BK/PK SCI Transmit

C28 D2 WT/BK CCD Bus (-)

C29 D84 BK/WT SCI Receive


C32 K95 PK Speed Control Switch Signal

GENERAL

INFORMATION

18

4.2 Controls & SolenoidsBR 5.9L HD GASOLINE BR DIESEL

BR BODY AB, AN, BR EXCEPT 8.0L

AN 2.5L BR 8.0L

GENERAL

INFORMATION

19

4.2 Controls & Solenoids (Continued)ZJ 4.0L ZJ 5.2L

XJ BODY AB BODY

AN XJ BODIES BR BODY

GENERAL

INFORMATION

20

ZJ BODY AB BODY

AN 2.5L AN EXCEPT 2.5L BR EXCEPT 8.0L

BR 8.0L XJ BODY

GENERAL

INFORMATION

21

4.2 Controls & Solenoids (Continued)BR DIESEL ZJ 4.0L

ZJ 5.2L

AB BODY AN BODY

GENERAL

INFORMATION

22

BR BODY ZJ BODY

2.5L AND 4.0L 3.9L, 5.2L, 5.9L EXCEPT 8.0L

BR 8.0L AB BODY

GENERAL

INFORMATION

23

4.2 Controls & Solenoids (Continued)AN BR BODIES XJ BODY

ZJ BODY 3.9L, 5.2L AND 5.9L

2.5L AND 4.0L BR 8.0L

GENERAL

INFORMATION

24

AB, AN AND XJ BODIES BR EXCEPT 8.0L

ZJ BR 8.0L

3.9L, 5.2L AND 5.9L EXCEPT CNG ANDDIESEL

AN XJ 2.5L

GENERAL

INFORMATION

25

4.2 Controls & Solenoids (Continued)BR 8.0L XJ, ZJ 4.0L

AB, AN, BR 5.2L CNG AB, AN, BR BODIES

XJ BODY ZJ BODY

GENERAL

INFORMATION

26

ZJ 4.0L ZJ 4.0L

AB, AN, BR AND ZJ BODIES AB BODY

AN BODY BR BODY

GENERAL

INFORMATION

27

4.2 Controls & Solenoids (Continued)ZJ BODY AB BODY

BR BODY XJ BODY

ZJ BODY ALL BODIES

GENERAL

INFORMATION

28

AB 3.9L AB BODY

4.3 Data Link ConnectorsAB BODY AB BODY

AN BODY AN BODY

GENERAL

INFORMATION

29

4.3 Data Link Connectors (Continued)BR BODY BR BODY

XJ BODY XJ BODY

4.4 SensorsZJ BODY ZJ BODY

GENERAL

INFORMATION

30

AB BODY AN BODY

BR BODY XJ BODY

ZJ BODY AB, AN , BR , XJ BODIES

GENERAL

INFORMATION

31

4.4 Sensors (Continued)ZJ BODY AB, AN, BR EXCEPT 2.5L, 8.0L AND DIESEL

2.5L AND 4.0L BR 8.0L

ZJ 5.2L BR 5.9L DIESEL

GENERAL

INFORMATION

32

AB, AN, BR BODIES XJ BODY

ZJ BODY 3.9L, 5.2L, 5.9L

2.5L AND 4.0L BR 8.0L

GENERAL

INFORMATION

33

4.4 Sensors (Continued)AB, AN, BR AND XJ BODIES ZJ BODY

3.9L, 5.2L 5.9L 2.5L AND 4.0L

BR 8.0L AB, AN, BR AND ZJ 5.2L

GENERAL

INFORMATION

34

XJ BODY ZJ 4.0L

5.2L CNG 5.2L CNG

ALL 4XRE TRANS. AB BODY

GENERAL

INFORMATION

35

4.4 Sensors (Continued)AN BODY BR BODY

ZJ BODY 3.9L, 5,2L, 5.9L

2.5L AND 4.0L BR 5.9L DIESEL

GENERAL

INFORMATION

36

BR 8.0L AB, AN, BR AND XJ BODIES

ZJ BODY 3.9L, 5.2L, 5.9L

2.5L AND 4.0L BR 8.0L

GENERAL

INFORMATION

37

4.4 Sensors (Continued)AB, AN, XJ AND BR EXCEPT 8.0L BR 8.0L

ZJ BODY

GENERAL

INFORMATION

38

AB 3.9L, 5.2L AND ZJ 5.2L 1/1 AB 5.9L 1/1

AN EXCEPT 2.5L, BR EXCEPT 5.9L HDAND 8.0L 1/1

BR 5.9L AND 8.0L HD 1/1 2/1

XJ BODY AND ZJ 4.0L 1/1 BR 8.0L CAL 1/1 1/2 1/3 2/1

GENERAL

INFORMATION

39

4.4 Sensors (Continued)AB BODY 1/1 AN BODY 1/1

BR 3.9L, 5.2L, 5.9L EXCEPT HD 1/1 BR 5.9L HD AND 8.0L 1/1

XJ 2.5L AND 4.0L 1/1 ZJ 5.2L AND 4.0L 1/1

GENERAL

INFORMATION

40

AB BODY 1/2 AN, BR EXCEPT 5.9L HD AND 8.0L ANDXJ 1/2

ZJ BODY 1/2 BR 8.0L CAL 1/1 1/2 1/3 2/1

AB BODY 1/2 AN BODY1/2

GENERAL

INFORMATION

41

4.4 Sensors (Continued)BR 3.9L, 5.2L, 5.9L 1/2 BR 8.0L 1/2

XJ 2.5L AND 4.0L 1/2 ZJ BODY 1/2

BR 8.0L 1/3 BR 5.9L AND 8.0L HD 2/1

GENERAL

INFORMATION

42

ZJ 4.0L ZJ 5.2L

ZJ BODY ALL 4XRE TRANS

ALL BODIES EXCEPT BR BR BODY

GENERAL

INFORMATION

43

4.4 Sensors (Continued)AB, AN EXCEPT 2.5L, BR 3.9L, 5.2L, 5.9L AN 2.5L XJ AND ZJ 4.0L

ZJ 5.2L BR 5.9L DIESEL

BR 8.0L AB, AN AND BR EXCEPT DIESEL

GENERAL

INFORMATION

44

BR 5.9L DIESEL XJ BODY

ZJ BODY AB, EX 3.9L, AN, EX 2.5L, BR

AB, EX 3.9L, AN, EX 2.5L, BR AB BODY

GENERAL

INFORMATION

45

4.4 Sensors (Continued)AN BODY BR BODY

ZJ BODY 3 SPEED AUTO TRANS

MANUAL TRANS AND 4X4 4 SPEED AUTO TRANS

GENERAL

INFORMATION

46

AB, BR AND XJ BODIES AN BODY

ZJ BODY BR 5.9L DIESEL

BR 5.9L DIESEL

GENERAL

INFORMATION

47

4.5 Fuel SystemAB BODY AB BODY

AN BODY AN BODY

BR BODY BR BODY

GENERAL

INFORMATION

48

XJ BODY XJ BODY

ZJ BODY ZJ BODY

BR 5.9L DIESEL BR 5.9L DIESEL

GENERAL

INFORMATION

49

4.5 Fuel System (Continued)BR 5.9L DIESEL BR 5.9L DIESEL

BR 5.9L DIESEL CNG FUEL TEMP & REG

AB 5.2L CNG AN, BR BODIES

GENERAL

INFORMATION

50

AB 5.2L CNG AN, BR 5.2L CNG

AB 5.2L CNG AN, BR 5.2L CNG

4.6 RelaysAB BODY AN BODY

GENERAL

INFORMATION

51

4.6 Relays (Continued)BR BODY XJ BODY

ZJ BODY AB BODY

AN BODY BR BODY

GENERAL

INFORMATION

52

XJ BODY ZJ BODY


AB BODY AN BODY

GENERAL

INFORMATION

53

4.6 Relays (Continued)BR BODY XJ BODY

ZJ BODY AB EXCEPT CNG

AN EXCEPT CNG BR EXCEPT CNG

GENERAL

INFORMATION

54

XJ BODY ZJ BODY

AB CNG AN CNG

BR CNG BR 5.9L DIESEL

GENERAL

INFORMATION

55

4.6 Relays (Continued)BR 5.9L DIESEL BR 5.9L DIESEL

AN 2.5L XJ 4.0L

AB BODY AN BODY

GENERAL

INFORMATION

56

BR BODY XJ BODY

ZJ BODY AB EXCEPT 3.9L

AB EXCEPT 3.9L AN EXCEPT DIESEL

GENERAL

INFORMATION

57

4.6 Relays (Continued)BR BODY ZJ BODY

4.7 SwitchesAB, AN AND BR BODIES XJ AND ZJ BODIES

AB BODY AN AND XJ BODIES

GENERAL

INFORMATION

58

BR BODY ZJ BODY

AB BODY AN BODY

BR BODY ZJ BODY

GENERAL

INFORMATION

59

4.7 Switches (Continued)AB, AN BODIES BR BODY

ZJ BODY AB, AN, BR AND ZJ BODIES

XJ BODY AB BODY

GENERAL

INFORMATION

60

AN BODY BR BODY

XJ BODY ZJ BODY

AB, AN AND BR BODIES ZJ BODY

GENERAL

INFORMATION

61

4.7 Switches (Continued)XJ BODY ALL EXCEPT ZJ

ZJ BODY

4.8 Lamps & IndicatorsAB BODY AN BODY

GENERAL

INFORMATION

62

BR BODY XJ BODY

AB BODY AN BODY

BR BODY XJ BODY

GENERAL

INFORMATION

63

4.8 Lamps & Indicators (Continued)AB BODY AN BODY

BR BODY ZJ BODY

AB, AN BODIES BR BODY

GENERAL

INFORMATION

64

ZJ BODY AN BODY

BR BODY XJ BODY

BR 5.9L & 8.0L AN BODY

GENERAL

INFORMATION

65

4.8 Lamps & Indicators (Continued)BR BODY XJ BODY


5.0 DISCLAIMERS, SAFETY, WARNINGS

5.1 Disclaimers

All information, illustrations, and specifications contained in this manual are based on the latestinformation available at the time of publication. The right is reserved to make changes at any timewithout notice.

5.2 Safety

5.2.1 Technician Safety Information

WARNING: Engines produce carbon monoxide that is odorless, causes slower reactiontime, and can lead to serious injury. When the engine is operating, keep service areasWELL VENTILATED or attach the vehicle exhaust system to the shop exhaust removalsystem.

GENERAL

INFORMATION

66

Set the parking brake and block the wheels before testing or repairing the vehicle. It is especiallyimportant to block the wheels on front-wheel drive vehicles; the parking brake does not hold thedrive wheels.

When servicing a vehicle, always wear eye protection, and remove any metal jewelry such aswatchbands or bracelets that might make an inadvertent electrical contact.

When diagnosing a body system problem, it is important to follow approved procedures whereapplicable. These procedures can be found in General Information Section 9.0 (Specifications) orin service manual procedures. Following these procedures is very important to the safety ofindividuals performing diagnostic tests.

5.2.2 Vehicle Preparation for Testing

Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnosticcodes 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 injuryand/or improper system operation. Only those components with approved repair and installationprocedures in the service manual should be serviced.

5.2.4 DRBIII Safety Information

WARNING: Exceeding the limits of the DRB multimeter is dangerous. It can expose you toserious or possibly fatal injury. Carefully read and understand the cautions and thespecification limits.

• Follow the vehicle manufacturer’s 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 currentmeasurements that may exceed the rated capacity.

• Do not exceed the limits shown in the table below:

FUNCTION INPUT LIMIT

Volts 0 - 500 peak volts AC0 - 500 volts DC

Ohms (resistance)* 0 - 1.12 megohms

Frequency MeasuredFrequency Generated

0 - 10 kHz

Temperature -58 - 1100°F-50 - 600°C

* Ohms cannot be measured if voltage ispresent. Ohms can be measured only in anon-powered circuit.

• Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC.

GENERAL

INFORMATION

67

• 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 tomeasure circuits exceeding 10A.

• When testing for the presence of voltage or current, make sure the meter is functioningcorrectly. 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 avoidmeasuring error from outside interference.

5.3 Warnings

5.3.1 Vehicle Damage Warnings

Before disconnecting any control module, make sure the ignition is ‘‘off.’’ Failure to do so coulddamage the module.

When testing voltage or continuity at the powertrain control module, use the terminal side (not thewire end) of the connector. Do not probe a wire through the insulation; this will damage it andeventually cause it to fail because of corrosion.

Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Suchmistakes can damage fuses or components. Also, a second code could be set, making diagnosisof the original problem more difficult.

5.3.2 Road Testing a Complaint Vehicle

Some complaints will require a test drive as part of the repair verification procedure. The purposeof 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 theDRB from the rear view mirror or operate it yourself. Have an assistant available to operatethe DRB.

GENERAL

INFORMATION

68

7.0 DIAGNOSTIC INFORMATION AND PROCEDURES

7.1GENERAL

TROUBLESHOOTING

69

DTC TEST CHECKING THE SYSTEM FOR DIAGNOSTIC TROUBLE CODES (DTCs)

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 aredisplayed.

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 inthis manual.

5. If trouble code messages are displayed, refer to the trouble code list below and on the nextpage for the appropriate test.

6. If there are no trouble codes displayed, refer to one of the following:For Driveability problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-1AFor No Start problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NS-SELFor Speed Control problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SC-1AFor Charging problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .CH-1A

NOTE: The decimal test numbers for these trouble codes were derived from the hexadecimal codesas set in the PCM. Therefore, some test numbers will be missing because all codes are notapplicable to the vehicles covered in this manual.

TROUBLE CODE Test # MIL DTC ScanTool

DESCRIPTION [SDD] Code HEX

3-4 SHIFT SOL, NO RPM DROP @ 3-4 SHIFT TC-165 45 A5 P 0783

A/C CLUTCH RELAY CIRCUIT TC-16 33 10 N/A

AUTO SHUTDOWN RELAY CONTROL CIRCUIT TC-10 42 0A N/A

BATTERY TEMP SENSOR VOLTAGE TOO HIGH TC-153 44 9A P 1492

BATTERY TEMP SENSOR VOLTAGE TOO LOW TC-153 44 99 P 1493

CATALYTIC CONVERTER EFFICIENCY FAILURE TC-112 72,64 70 P 0420

CHARGING SYSTEM VOLTAGE TOO HIGH TC-6 46 06 N/A

CHARGING SYSTEM VOLTAGE TOO LOW TC-5 47 05 N/A

CLOSED LOOP TEMP NOT REACHED TC-128 17 80 P 0125

CNG PRESSURE SENSOR VOLTAGE TOO HIGH TC-98 64 62 P 1292

CNG PRESSURE SENSOR VOLTAGE TOO LOW TC-99 64 63 P 1293

CNG TEMP SENSOR VOLTAGE TOO HIGH TC-95 64 5F P 0183

CNG TEMP SENSOR VOLTAGE TOO LOW TC-94 64 5E P 0182

CYLINDER #1 MIS-FIRE TC-107 43 6B P 0301

CYLINDER #2 MIS-FIRE TC-107 43 6C P 0302

CYLINDER #3 MIS-FIRE TC-107 43 6D P 0303

CYLINDER #4 MIS-FIRE TC-107 43 6E P 0304

CYLINDER #5 MIS-FIRE TC-107 43 AE P 0305

CYLINDER #6 MIS-FIRE TC-107 43 AF P 0306

CYLINDER #7 MIS-FIRE TC-107 43 B0 P 0307

CYLINDER #8 MIS-FIRE TC-107 43 B1 P 0308

TROUBLE

CODE

TESTS

70




(Pre-Cat) DOWNSTREAM O2 SENSOR HEATER FAILURE TC-105 21 69 P 0141

(Pre-Cat) DOWNSTREAM O2S VOLTS SHORTED TO GND TC-156 21 9C P 0137

(Pre-Cat) DOWNSTREAM O2S SHORTED TO VOLTAGE TC-126 21 7E P 0138

ECT SENSOR VOLTAGE TOO HIGH TC-31 22 1F P 0118

ECT SENSOR VOLTAGE TOO LOW TC-30 22 1E P 0117

EGR SOLENOID CIRCUIT TC-17 32 11 P 0403

EGR SYSTEM FAILURE TC-140 68 8C P 0400

ENGINE IS COLD TOO LONG ** 17 21 N/A

EVAP LEAK MONITOR LARGE LEAK DETECTED TC-161 31 A1 P 0455

EVAP LEAK MONITOR PINCHED HOSE FOUND TC-187 31 BB P 1486

EVAP LEAK MONITOR SMALL LEAK DETECTED TC-160 31 A0 P 0442

EVAP PURGE FLOW MONITOR FAILURE TC-113 31 71 P 0441

EVAP PURGE SOLENOID CIRCUIT TC-18 31 12 P 0443

FUEL LEVEL SENDING UNIT VOLTS TOO HIGH TC-150 42 96 N/A

FUEL LEVEL SENDING UNIT VOLTS TOO LOW TC-149 42 95 N/A

FUEL LEVEL UNIT NO CHANGE OVER MILES TC-151 42 97 N/A

FUEL PUMP RELAY CONTROL CIRCUIT TC-101 42 65 N/A

FUEL SYSTEM LEAN TC-119 51 77 P 0171

FUEL SYSTEM RICH TC-118 52 76 P 0172

GENERATOR FIELD NOT SWITCHING PROPERLY TC-11 41 0B N/A

GOV PRES ABOVE 3 PSI IN GEAR WITH 0 MPH TC-142 45 8E P 1757

GOV PRESS NOT EQUAL TO TARGET @ 15-20 PSI TC-141 45 8D P 1756

GOV PRESS SEN OFFSET VOLTS TOO LOW OR HIGH TC-169 45 A9 P 1762

GOVERNOR PRESSURE SENSOR VOLTS TOO HI TC-168 45 A8 P 1763

GOVERNOR PRESSURE SENSOR VOLTS TOO LOW TC-167 45 A7 P 1764

GOVERNOR PRESSURE SOLENOID/TRANS RELAY CKTS TC-171 45 AB P 0748

IDLE AIR CONTROL MOTOR CIRCUIT TC-25 25 19 P 0505

IGNITION COIL #1 PRIMARY CIRCUIT TC-43 43 2B P 0351

IGNITION COIL #2 PRIMARY CIRCUIT TC-42 43 2A P 0351

IGNITION COIL #3 PRIMARY CIRCUIT TC-41 43 29 P 0351

IGNITION COIL #4 PRIMARY CIRCUIT TC-76 43 4C P 0351

IGNITION COIL #5 PRIMARY CIRCUIT TC-77 43 4D P 0351

INJECTOR #1 CONTROL CIRCUIT TC-21 27 15 P 0201



INJECTOR #4 CONTROL CIRCUIT TC-21 27 3D P 0204



INJECTOR #7 CONTROL CIRCUIT TC-21 27 4F P 0207




INTAKE AIR TEMP SENSOR VOLTAGE HIGH TC-58 23 3A P 0113

INTAKE AIR TEMP SENSOR VOLTAGE LOW TC-57 23 39 P 0112

INTERMITTENT LOSS OF CMP OR CKP TC-157 11 9D P 1391

** = Trouble code information on last page of DTC test.

TROUBLE

CODE

TESTS

71




INTERNAL CONTROLLER FAILURE ** 53 02 P 0601

LEAK DETECT PUMP SW OR MECHANICAL FAULT TC-184 31 B8 P 1494

LEAK DETECTION PUMP SOLENOID CIRCUIT TC-183 31 B7 P 1495

LOW OUTPUT SPD SENSOR RPM, ABOVE 15 MPH TC-166 15 A6 P 0720

* MAP SENSOR VOLTAGE TOO HIGH TC-37 14 25 P 0108

* MAP SENSOR VOLTAGE TOO LOW TC-36 14 24 P 0107

MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT TC-186 11 BA P 1398

* MULTIPLE CYLINDER MIS-FIRE TC-106 43 6A P 0300

NO 5 VOLTS TO MAP SENSOR TC-135 14 87 P 1296

NO ASD RELAY OUTPUT VOLTAGE AT PCM TC-44 42 2C N/A

NO CAM SIGNAL AT PCM TC-1 54 01 P 0340

NO CHANGE IN MAP FROM START TO RUN TC-39 13 27 P 1297

NO CRANK REFERENCE SIGNAL AT PCM TC-40 11 28 N/A

NO TEMP RISE SEEN FROM INTAKE HEATERS TC-162 23 A2 P 1291

NO VEHICLE SPEED SENSOR SIGNAL TC-35 15 23 P 0500

O/D SWITCH PRESSED (LO) MORE THAN 5 MIN TC-188 45 BC N/A

P/N SWITCH STUCK IN PARK OR IN GEAR TC-114 37 72 P 1899

PCM FAILURE EEPROM WRITE DENIED TC-49 63 31 P 1698

PCM FAILURE SPI COMMUNICATIONS ** 53 44 P 0600

PCM FAILURE SRI MILE NOT STORED TC-48 62 30 P 1697

POST-CATALYST O2 SEN SHORTED TO GROUND TC-144 21 90 P 0143

POST-CATALYST O2 SEN SHORTED TO VOLTAGE TC-147 21 93 P 0144

POST-CATALYST O2S HEATER FAILURE TC-189 21 BD P 0147

POST-CATALYST O2 SLOW RESPONSE TC-159 21 9F P 0145

POWER STEERING SWITCH FAILURE TC-115 65 73 P 0551

PRE-CATALYST O2 SENSOR SLOW RESPONSE TC-104 21 68 P 0139

RAD FAN CONTROL RELAY CIRCUIT TC-14 35 0E P 1491

RIGHT BANK FUEL SYSTEM LEAN TC-121 51 79 P 0174

RIGHT BANK FUEL SYSTEM RICH TC-120 52 78 P 0175

RIGHT BANK UPSTRM O2S SHORTED TO GROUND TC-181 21 B5 P 0151

RIGHT O2 SENSOR SHORTED TO VOLTAGE TC-66 21 42 P 0152

RIGHT UPSTREAM O2 SENSOR HEATER FAILURE TC-124 21 7C P 0155

RIGHT UPSTREAM O2 SENSOR SLOW RESPONSE TC-122 21 7A P 0153

SPEED CONTROL POWER RELAY CIRCUIT TC-15 77 52 N/A

SPEED CONTROL SOLENOIDS CIRCUITS TC-15 34 0F N/A

SPEED CONTROL SWITCH ALWAYS LOW TC-87 34 57 N/A

TARGET IDLE NOT REACHED TC-138 25 8A P 1294

* THROTTLE POSITION SENSOR VOLTAGE HIGH TC-27 24 1B P 0123

* THROTTLE POSITION SENSOR VOLTAGE LOW TC-26 24 1A P 0122

TORQ CONV CLU, NO RPM DROP AT LOCKUP TC-148 37 94 P 0740

TORQUE CONVERTER CLUCTH SOLENOID/TRANS RELAY CKT TC-12 37 0C P 0743

* TPS VOLTAGE DOES NOT AGREE WITH MAP TC-132 24 84 P 0121

* = These DTC’s 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.

TROUBLE

CODE

TESTS

72




TRANS 12 VOLT SUPPLY RELAY CNTRL CIRCUIT TC-173 45 AD P 1765

TRANS 3-4 SOLENOID/TRANS RELAY CKTS TC-50 45 32 P 0753

TRANS TEMP SENSOR VOLTAGE TOO HIGH TC-75 37 4B P 0713

TRANS TEMP SENSOR VOLTAGE TOO LOW TC-74 37 4A P 0712

TRANS TEMP SENSOR, NO TEMP RISE AFTER START TC-164 37 A4 P 0711

(Left) UPSTREAM O2 SENSOR HEATER FAILURE TC-103 21 67 P 0135

(Left) UPSTREAM O2S VOLTAGE SHORTED TO GROUND TC-155 21 9B P 0131

(Left) UPSTREAM O2 SENSOR SLOW RESPONSE TC-102 21 66 P 0133

(Left) UPSTREAM O2 SENSOR SHORTED TO VOLTAGE TC-62 21 3E P 0132

For an ENGINE IS COLD TOO LONG trouble code, the engine does not warm to 176°F while drivingfor 20 minutes after start. See the service manual for cooling system repair (thermostat).

For an INTERNAL CONTROLLER FAILURE trouble code, replace the powertrain control moduleand go to Verification TEST VER-2A.

For a PCM FAILURE SPI COMMUNICATIONS trouble code, replace the powertrain control moduleand go to Verification TEST VER-2A.

* These DTC’s can be set by Low Fuel Level, add fuel to 14 tank and test for DTC to set again.

TROUBLE

CODE

TESTS

73

TEST TC-1A REPAIRING - NO CAM SIGNAL AT PCM

Perform DTC TEST Before Proceeding

ZJ BODY

FIG. 1

ALL OTHERS

FIG. 2

ALL EXCEPT 8.0L ENGINE 8.0L ENGINE

TROUBLE

CODE

TESTS

74

TEST TC-1A REPAIRING - NO CAM SIGNAL AT PCM


*Perform Verification TEST VER-2A. **Check connectors - Clean / repair as necessary.

START TEST USING THE DRB, TC-1A. ERASE TROUBLE

CODES.

ATTEMPT TO STARTTHE ENGINE. IF IT USING THE DRB, DID THE CODE "NO NO PERFORM TEST

DOES NOT START, READ ALL TROUBLE CAM SIGNAL AT PCM" TC-1C. CRANK FOR AT LEAST CODES. RETURN?

15 SECONDS.

YES

KEY OFF, DISCONNECT IS ANY TERMINAL THE CAMSHAFT CORRODED, DAMAGED, YES REPAIR AS

POSITION SENSOR PUSHED OUT OR NECESSARY.*CONNECTOR.** MISWIRED?

SEE GENERAL INFO 4.4

NO

USING AN OHMMETER, GROUND CIRCUIT FROM REPAIR THE OPEN MEASURE THE THE CMP SENSOR IS THE RESISTANCE NO CMP SENSOR GROUND

RESISTANCE OF THE CONNECTOR TO GROUND. BELOW 5.0 OHMS? CIRCUIT TO THECMP SENSOR... HARNESS SPLICE.*

FIG. 1 OR 2

YES

USING A VOLTMETER, MEASURE THE 5-VOLT IS THE VOLTAGE NO REPAIR THE OPEN

TURN IGNITION ON. SUPPLY CIRCUIT. ABOVE 4.0 VOLTS? 5-VOLT SUPPLY CIRCUIT.*

FIG. 1 OR 2

YES

CONNECT ONE END OF WITH THE DRB MONITORA JUMPER WIRE TO THE CMP COUNT WHILE DOES THE CURRENT YES PERFORM TEST

THE CMP SENSOR TAPPING THE OTHER CMP COUNT CHANGE? TC-1B. SIGNAL CIRCUIT. END OF THE JUMPER TO

FIG. 1 OR 2 SENSOR GROUND.

NO

CONTINUE TEST TC-1A ON THE

NEXT PAGE.

TROUBLE

CODE

TESTS

75

TEST TC-1A CONTINUED - REPAIRING - NO CAM SIGNAL AT PCM

ZJ BODY

FIG. 1

ALL OTHERS

FIG. 2

TROUBLE

CODE

TESTS

76

TEST TC-1A CONTINUED - REPAIRING - NO CAM SIGNAL AT PCM


TEST TC-1ACONTINUED FROM

THE PREVIOUS TURN IGNITION OFF. PAGE.

DISCONNECT THEPOWERTRAIN CONTROL

MODULE CONNECTORS.**


USE AN OHMMETER IN CIRCUIT FROM THE CMPTHE FOLLOWING STEPS, SENSOR CONNECTOR TO IS THE RESISTANCE NO REPAIR THE OPEN

MEASURE THE THE PCM. BELOW 5.0 OHMS? CMP SENSOR SIGNAL RESISTANCE OF THE CIRCUIT.*

CMP SENSOR SIGNAL... FIG. 1 OR 2

YES

MEASURE THE AND THE CMP SENSOR REPAIR THE CMPRESISTANCE BETWEEN GROUND CIRCUIT AT IS THE RESISTANCE YES SENSOR SIGNAL

THE CMP SENSOR THE CMP SENSOR BELOW 5.0 OHMS? CIRCUIT FOR ASIGNAL CIRCUIT... CONNECTOR. SHORT TO THE

FIG. 1 OR 2 SENSOR GROUND.*

NO

MEASURE THE AND GROUND AT THE REPAIR THE CMPRESISTANCE BETWEEN CMP SENSOR IS THE RESISTANCE YES SENSOR SIGNAL

THE CMP SENSOR CONNECTOR. BELOW 5.0 OHMS? CIRCUIT FOR ASIGNAL CIRCUIT... SHORT TO GROUND.*

FIG. 1 OR 2

NO

MEASURE THE 5-VOLT SUPPLY REPAIR THE CMPRESISTANCE BETWEEN CIRCUIT AT THE CMP IS THE RESISTANCE YES SENSOR SIGNAL

THE CMP SENSOR SENSOR CONNECTOR. BELOW 5.0 OHMS? CIRCUIT FOR A SHORTSIGNAL CIRCUIT AND TO THE 5-VOLT SUPPLY

THE... FIG. 1 OR 2 CIRCUIT.*

NO

REPLACE THEPOWERTRAIN CONTROL

MODULE.*

TROUBLE

CODE

TESTS

77

TEST TC-1B REPAIRING - NO CAM SIGNAL AT PCM

Perform TEST TC-1A Before Proceeding

FIG. 1

TROUBLE

CODE

TESTS

78

TEST TC-1B REPAIRING - NO CAM SIGNAL AT PCM



START TEST IS THE VEHICLE YES CONTINUE TEST TC-1B. TURN IGNITION OFF. EQUIPPED WITH A TC-1B ON THE

8.0 LITER ENGINE? NEXT PAGE.

NO

REMOVE DISTRIBUTOR REPAIR OR REPLACECAP AND ROTOR. INSPECT THE PULSE IS THE PULSE RING NO THE DISTRIBUTOR AND

RING FOR DAMAGE OR OKAY? OR THE PULSE RING AS MISALIGNMENT. NECESSARY.*

FIG. 1

YES

REPLACE THECAMSHAFT POSITION

SENSOR.*

TROUBLE

CODE

TESTS

79

TEST TC-1B CONTINUED - REPAIRING - NO CAM SIGNAL AT PCM

FIG. 1

TROUBLE

CODE

TESTS

80

TEST TC-1B CONTINUED - REPAIRING - NO CAM SIGNAL AT PCM


TEST TC-1B REMOVE THECONTINUED FROM CAMSHAFT POSITION

THE PREVIOUS SENSOR.PAGE.

FIG. 1

INSPECT THECAMSHAFT SPROCKET IS THE CAMSHAFT YES REPLACE THEPER SERVICE MANUAL SPROCKET OK? CAMSHAFT POSITION

INSTRUCTIONS. SENSOR.*

NO

REPAIR AS NECESSARY.*

TROUBLE

CODE

TESTS

81

TEST TC-1C REPAIRING - NO CAM SIGNAL AT PCM


FIG. 1

ZJ BODY ALL OTHERS

TROUBLE

CODE

TESTS

82

TEST TC-1C REPAIRING - NO CAM SIGNAL AT PCM



START TEST ATTEMPT TO START DOES THE ENGINE NO PERFORM NO TC-1C. THE ENGINE, IF NOT START? START TEST

ALREADY RUNNING. NS-SEL.

YES

AT THIS TIME, THE USING THECONDITION REQUIRED SCHEMATIC AS A WERE ANY PROBLEMS YES REPAIR AS TO SET THE CODE IS GUIDE, INSPECT THE FOUND? NECESSARY.*

NOT PRESENT. WIRING ANDFIG. 1 CONNECTORS.

NO

REFER TO GEN INFO 3.3.2 FOR

INFORMATION ON TEST COMPLETE.* INACTIVE TROUBLE

CODES.

TROUBLE

CODE

TESTS

83

TEST TC-5A REPAIRING - CHARGING SYSTEM VOLTAGE TOO LOW


AB, AN AND BR BODIES

FIG. 1

XJ BODY

FIG. 2

ZJ BODY

FIG. 3

TROUBLE

CODE

TESTS

84

TEST TC-5A REPAIRING - CHARGING SYSTEM VOLTAGE TOO LOW



START TEST NOTE: BATTERY MUST TC-5A. BE FULLY CHARGED.

NOTE: GENERATOR START ENGINE, WITH BELT TENSION AND DRB, READ THE IS THE TARGET NO CONTINUE TEST

CONDITION MUST BE TARGET CHARGING CHARGING VOLTAGE TC-5A ON THECHECKED BEFORE VOLTAGE. ABOVE 15.1 VOLTS? NEXT PAGE.

CONTINUING.

YES

WITH THE DRB READ USING A IS THE TEMPERATURETHE BATTERY TEMP THERMOMETER, WITHIN 10F DEG. OF YES CONTINUE TEST

SENSOR MEASURE UNDER HOOD BATTERY TC-5A ON THETEMPERATURE. TEMPERATURE. TEMPERATURE? NEXT PAGE.

NO

DISCONNECT THE CONNECT A JUMPER BATTERY TEMPERATURE ACROSS THE TERMINALSSENSOR CONNECTOR.** OF THE BATTERY

TEMPERATURE SENSOR.SEE GENERAL INFO 4.4 FIG. 1, 2 OR 3

WITH THE DRB, READ BATTERY IS THE VOLTAGE NO REPLACE THE

TEMPERATURE SENSOR READING EQUAL TO POWERTRAIN CONTROLVOLTAGE. ZERO? MODULE.*

YES

REPLACE THEBATTERY

TEMPERATURESENSOR.*

TROUBLE

CODE

TESTS

85

TEST TC-5A CONTINUED - REPAIRING - CHARGING SYSTEM VOLTAGE TOO LOW

FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

86

TEST TC-5A CONTINUED - REPAIRING - CHARGING SYSTEM VOLTAGE TOO LOW


TEST TC-5ACONTINUED FROM YES DOES THE ENGINE NO PERFORM TEST

THE PREVIOUS IS THIS A DIESEL? RUN? TC-40A.PAGE.

NO YES

CAUTION: IF THIS IS A DIESEL, DO NOT DO USE A VOLTMETER IN ANY CHARGING SYSTEM THE FOLLOWING

TEST WITH INTAKE STEP.HEATERS ON.

MEASURE VOLTAGE CAUTION: ENSURE REPAIR THE B (+)BETWEEN THE GEN B+ ALL WIRES ARE IS THE VOLTAGE YES CIRCUIT FOR HIGH

TERMINAL AND THE CLEAR OF THE ABOVE 0.4 VOLT? RESISTANCE BETWEENBATTERY (+) POST. ENGINE’S MOVING THE GENERATOR AND

FIG. 1 PARTS. THE BATTERY.*

NO

IGNITION KEY OFF. MEASURE VOLTAGE CAUTION: ENSURE USE A VOLTMETER IN BETWEEN THE ALL WIRES ARE

THE FOLLOWING GENERATOR CASE AND CLEAR OF THESTEP. BATTERY (-) POST. ENGINE’S MOVING

FIG. 2 PARTS.

REPAIR GENERATORWARM THE ENGINE TO IS THE VOLTAGE YES GROUND FOR HIGH

START THE ENGINE. OPERATING ABOVE 0.1 VOLT? RESISTANCE,TEMPERATURE. GENERATOR CASE TO

BATTERY (-) SIDE.*

NO

TURN ON ALL READ TARGET ACCESSORIES, CHARGING AND IS THERE MORE THAN YES REPAIR OR REPLACE

MANUALLY SET ENGINE CHARGING VOLTAGE. A 1.0 VOLT THE GENERATOR AS SPEED TO 1600 RPM. COMPARE THE TWO DIFFERENCE? NECESSARY.*

WITH THE DRB... READINGS.

NO

RECORD ALL DTC’S CHARGING SYSTEM ALLOW THE ENGINE TURN ENGINE OFF. AND FREEZE FRAME CHECKS OK AT THIS

TO RETURN TO IDLE (IGNITION KEY ON) DATA, NOW ERASE TIME.SPEED. CODES.

SEE GEN INFO 3.3.2

TROUBLE

CODE

TESTS

87

TEST TC-6A REPAIRING - CHARGING SYSTEM VOLTAGE TOO HIGH


FIG. 1

FIG. 2 FIG. 3

TROUBLE

CODE

TESTS

88

TEST TC-6A REPAIRING - CHARGING SYSTEM VOLTAGE TOO HIGH



READ FIGURE 1 TO START TEST DETERMINE WHICH

TC-6A. TERMINAL IS THEGENERATOR FIELDDRIVER CIRCUIT.

WITH THE DRB, PLEASE READ FIGURE ACTUATE THE 2 TO HAVE A CLEAR

GENERATOR FIELD UNDERSTANDING OF DRIVER. THIS TROUBLE CODE.

BACKPROBE THEUSE A VOLTMETER IN GENERATOR FIELD DOES THE VOLTAGE YES PERFORM TEST

THE FOLLOWING DRIVER CIRCUIT IN SHIFT LOW TO HIGH? TC-6B. STEP. BACK OF GENERATOR.

FIG. 3

NO

WITH THE DRB, STOP THE GENERATOR

FIELD DRIVER TURN IGNITION OFF. ACTUATION.

DISCONNECT THE DISCONNECT THEPOWERTRAIN CONTROL FIELD HARNESS CONTINUE TEST

MODULE.** CONNECTOR AT BACK TC-6A ON THEOF THE NEXT PAGE.

SEE GENERAL INFO 4.1 GENERATOR.**

TROUBLE

CODE

TESTS

89

TEST TC-6A CONTINUED - REPAIRING - CHARGING SYSTEM VOLTAGE TOO HIGH

FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

90

TEST TC-6A CONTINUED - REPAIRING - CHARGING SYSTEM VOLTAGE TOO HIGH


TEST TC-6ACONTINUED FROM USE AN OHMMETER IN

THE PREVIOUS THE FOLLOWINGPAGE. STEPS.

MEASURE THE REPAIR THEGENERATOR FIELD IS THE RESISTANCE YES GENERATOR FIELD

DRIVER CIRCUIT FROM BELOW 5.0 OHMS? DRIVER CIRCUITTHE PCM CONNECTOR TO SHORT TO GROUND.* GROUND. FIG. 1

NO

MEASURE RESISTANCE REPAIR OR REPLACEOF THE GENERATOR IS THE RESISTANCE YES THE SHORTED

FIELD TERMINALS AT BELOW 5.0 OHMS? GENERATOR AS THE GENERATOR. NECESSARY.*

FIG. 2

NO


MODULE.*

TROUBLE

CODE

TESTS

91

TEST TC-6B REPAIRING - CHARGING SYSTEM VOLTAGE TOO HIGH


AB BODY

AN AND BR BODIES

TROUBLE

CODE

TESTS

92

TEST TC-6B REPAIRING - CHARGING SYSTEM VOLTAGE TOO HIGH



WITH THE DRB, STOP START TEST THE GENERATOR FIELD IS THE TARGET YES CONTINUE TEST

TC-6B. DRIVER ACTUATION. CHARGING VOLTAGE TC-6B ON THEREAD THE TARGET ABOVE 13.0 VOLTS? NEXT PAGE.

CHARGING VOLTAGE.

NO

WITH THE DRB, READ USING A IS THE TEMPERATURETHE BATTERY TEMP THERMOMETER, WITHIN 10F DEG. OF YES PERFORM TEST

SENSOR MEASURE THE UNDER BATTERY TC-153A. TEMPERATURE. HOOD TEMPERATURE. TEMPERATURE?

NO

CONTINUE TEST TC-6B ON THE

NEXT PAGE.

TROUBLE

CODE

TESTS

93

TEST TC-6B CONTINUED - REPAIRING - CHARGING SYSTEM VOLTAGE TOO HIGH


NOTES

TROUBLE

CODE

TESTS

94

TEST TC-6B CONTINUED - REPAIRING - CHARGING SYSTEM VOLTAGE TOO HIGH



TEST TC-6BCONTINUED FROM

THE PREVIOUS START THE ENGINE.PAGE.

WITH THE DRB, READ MANUALLY SET THE BOTH THE BATTERYENGINE SPEED TO VOLTAGE AND THE

1600 RPM. TARGET CHARGING VOLTAGE.

COMPARE THE MONITOR VOLTAGE FOR"TARGET VOLTAGE" 5 MINUTES, IF WAS THERE MORE YES REPLACE THETO THE "BATTERY NECESSARY. LOOK FOR THAN A 1.0 VOLT POWERTRAIN CONTROL

VOLTAGE" READING. A 1.0 VOLT DIFFERENCE? MODULE.* DIFFERENCE OR MORE.

NO

RECORD ALL DTC’SALLOW THE ENGINE TURN ENGINE OFF. AND FREEZE FRAME NO TROUBLE FOUND

TO RETURN TO IDLE IGNITION KEY ON. DATA, NOW ERASE AT THIS TIME.SPEED. CODES.

SEE GEN INFO 3.3.2

TROUBLE

CODE

TESTS

95

TEST TC-10A REPAIRING - AUTO SHUTDOWN RELAY CONTROL CIRCUIT


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

96

TEST TC-10A REPAIRING - AUTO SHUTDOWN RELAY CONTROL CIRCUIT



WITH THE DRB, START TEST ACTUATE THE AUTO IS THE AUTO NO CONTINUE TEST

TC-10A. SHUTDOWN RELAY. SHUTDOWN RELAY TC-10A ON THECLICKING? NEXT PAGE.


YES

THE CONDITION USING THEREQUIRED TO SET SCHEMATIC AS A WERE ANY PROBLEMS YES REPAIR AS THE TROUBLE CODE GUIDE, INSPECT THE FOUND? NECESSARY.*IS NOT PRESENT. WIRING AND

FIG. 1 CONNECTORS.

NO

WIGGLE THE WIRING IS THE VEHICLE NO HARNESS FROM THE

START THE ENGINE. EQUIPPED WITH A RELAY TO THEDIESEL ENGINE? POWERTRAIN CONTROL

MODULE.

YES

DISCONNECT THE REPAIR CIRCUIT AS INTAKE AIR TEMP DID THE ENGINE DIE YES NECESSARY WHERE

HEATER RELAY CONTROL OUT WHEN WIGGLING WIGGLING CAUSED WIRES. WIRES? THE ENGINE TO DIE

SEE GENERAL INFO 4.6 OUT.*

NO

TURN THE HEADLAMPS REFER TO FIGURE 2ON & WIGGLE THE FOR INACTIVE

WIRING HARNESS TROUBLE CODE TEST COMPLETE.* FROM ASD RELAY TO CONDITION

THE PCM. INFORMATION.

NO

REPAIR AS DID WIGGLING CAUSE YES NECESSARY WHERE

THE HEADLAMPS TO WIGGLING CAUSED FLICKER? THE HEADLAMPS TO

FLICKER.*

TROUBLE

CODE

TESTS

97

TEST TC-10A CONTINUED - REPAIRING - AUTO SHUTDOWN RELAY CONTROL CIRCUIT

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5 FIG. 6

TROUBLE

CODE

TESTS

98

TEST TC-10A CONTINUED - REPAIRING - AUTO SHUTDOWN RELAY CONTROL CIRCUIT


TEST TC-10A DISCONNECT THE AUTO CONTINUED FROM SHUTDOWN RELAY.**

THE PREVIOUS PAGE.


USING A VOLTMETER, REPAIR THE OPEN MEASURE THE FUSED IS THE VOLTAGE NO FUSED IGNITION IGN SWITCH OUTPUT ABOVE 10.0 VOLTS? SWITCH OUTPUT

CKT AT RELAY. CIRCUIT.*FIG. 1, 2, 3, 4 OR 5

YES

MEASURE THEUSE AN OHMMETER IN RESISTANCE BETWEEN IS THE RESISTANCE NO REPLACE THE AUTO

THE FOLLOWING TERMINALS 85 AND BELOW 100.0 OHMS? SHUTDOWN RELAY.*STEP. 86 OF THE ASD

RELAY. FIG. 6

YES

KEY OFF. DISCONNECT USING AN OHMMETER, REPAIR THE AUTO THE POWERTRAIN MEASURE THE ASD RLY IS THE RESISTANCE YES SHUTDOWN RELAY

CONTROL MODULE GREY CONTROL CIRCUIT AT BELOW 5.0 OHMS? CONTROL CKT FOR ACONNECTOR.** PCM TO GROUND. SHORT TO GROUND.*

SEE GENERAL INFO 4.1 FIG. 1, 2, 3, 4 OR 5

NO

USING AN OHMMETER, FROM THE RELAY TO REPAIR THE OPEN MEASURE THE THE PCM. IS THE RESISTANCE NO AUTO SHUTDOWN

RESISTANCE OF THE BELOW 5.0 OHMS? RELAY CONTROLASD RELAY CONTROL CIRCUIT.*

CIRCUIT... FIG. 1, 2, 3, 4 OR 5

YES


MODULE.*

TROUBLE

CODE

TESTS

99

TEST TC-11A REPAIRING - GENERATOR FIELD NOT SWITCHING PROPERLY


FIG. 1

FIG. 2 FIG. 3

TROUBLE

CODE

TESTS

100

TEST TC-11A REPAIRING - GENERATOR FIELD NOT SWITCHING PROPERLY



RECORD ALL DTC’SSTART TEST AND FREEZE FRAME

TC-11A. DATA, NOW ERASECODES.

READ FIGURE 1 TO WITH THE DRB, DETERMINE WHICH ACTUATE THETERMINAL IS THE GENERATOR FIELDGENERATOR FIELD DRIVER CIRCUIT. DRIVER CIRCUIT.

BACKPROBE THE ASD REPAIR THE OPEN RELAY OUTPUT CIRCUIT IS THE VOLTAGE NO ASD RELAY OUTPUT

AT THE BACK OF THE ABOVE 10.0 VOLTS? CIRCUIT, GENERATORGENERATOR. TO HARNESS

FIG. 2 SPLICE.*

YES

BACKPROBE THE GENFIELD DRIVER CIRCUIT DOES THE VOLTAGE NO CONTINUE TEST

AT THE BACK OF THE SHIFT FROM LOW TO TC-11A ON THEGENERATOR. HIGH? NEXT PAGE.

FIG. 2

YES



NO

WITH THE DRB, READ DOES THE GENERATOR REPAIR AS CODES. NOTE: WIGGLE WIRING FIELD DRIVER YES NECESSARY WHERE

ACTUATOR TEST HARNESS FROM THE CIRCUIT CODE WIGGLING CAUSED SHOULD STILL BE GENERATOR TO PCM. RETURN? PROBLEM TO

RUNNING. APPEAR.*

NO

TEST COMPLETE.*

TROUBLE

CODE

TESTS

101

TEST TC-11A CONTINUED - REPAIRING - GENERATOR FIELD NOT SWITCHING PROPERLY

FIG. 1 FIG. 2

FIG. 3 FIG. 4

TROUBLE

CODE

TESTS

102

TEST TC-11A CONTINUED - REPAIRING - GENERATOR FIELD NOT SWITCHING PROPERLY


TEST TC-11A READ FIGURE 1 TO CONTINUED FROM DETERMINE WHICH

THE PREVIOUS TERMINAL IS THEPAGE. GENERATOR FIELD

DRIVER CIRCUIT.

WITH THE DRB, STOP TURN IGNITION OFF. DISCONNECT THE GENTHE GENERATOR DISCONNECT THE FIELD HARNESS

FIELD DRIVER POWERTRAIN CONTROL CONNECTOR AT BACK OF ACTUATION. MODULE.** THE GENERATOR.**

SEE GENERAL INFO 4.1 SEE GENERAL INFO 4.2

MEASURE RESISTANCE REPAIR THE OPEN USE AN OHMMETER IN OF THE GEN FIELD IS THE RESISTANCE NO GENERATOR FIELD

THE FOLLOWING DRIVER CKT, GEN BELOW 5.0 OHMS? DRIVER CIRCUIT, STEPS. CONN TO PCM CONN. GENERATOR TO PCM.*

FIG. 2

YES

MEASURE THERESISTANCE ACROSS IS THE RESISTANCE NO REPAIR THE

THE GENERATOR FIELD BELOW 5.0 OHMS? GENERATOR AS TERMINALS AT THE NECESSARY.*

GENERATOR. FIG. 3

YES

MEASURE THE GEN REPAIR THEFIELD DRIVER CIRCUIT IS THE RESISTANCE YES GENERATOR FIELDAT GENERATOR HARNESS BELOW 5.0 OHMS? DRIVER CIRCUIT,

CONN TO GROUND. SHORT TO GROUND.* FIG. 4

NO


MODULE.*

TROUBLE

CODE

TESTS

103

TEST TC-12A REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CKT


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

104

TEST TC-12A REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CKT



DOES THIS VEHICLESTART TEST HAVE A 4 SPEED NO PERFORM TEST

TC-12A. ELECTRONIC TC-12E.TRANSMISSION?

YES

IS THE TRANS12-VOLT SUPPLY YES PERFORM TEST RELAY CONTROL TC-173A.

CIRCUIT CODE SET?

NO

WITH THE DRB, DID THE ENGINE NO CONTINUE TEST PERFORM THE TCC STALL? TC-12A ON THE

SYSTEM TESTS. NEXT PAGE.

YES

AT THIS TIME, THE USING THECONDITION REQUIRED SCHEMATIC AS A WERE ANY PROBLEMS YES REPAIR AS

TO SET THIS CODE GUIDE, INSPECT THE FOUND? NECESSARY.*IS NOT PRESENT. WIRING AND

FIG. 1 CONNECTORS.

NO

WITH THE DRB, WHILE READING DTC’S DOES THE TCCCLEAR CODES. WITH THE DRB, WIGGLE SOLENOID CONTROL YES REPAIR THE WIRING

THE WIRING HARNESS CIRCUIT FAULT CODE AS NECESSARY.*START THE ENGINE. FROM THE SOLENOID TO APPEAR?

THE PCM.

NO

REFER TO FIGURE 2FOR ADDITIONAL TEST COMPLETE.

INFORMATION.

TROUBLE

CODE

TESTS

105

TEST TC-12A CONTINUED - REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANSRELAY CKT

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

106



TEST TC-12A DISCONNECT THE TRANSCONTINUED FROM SOLENOID PACK

THE PREVIOUS CONNECTOR.** PAGE.


KEY ON. WITH THE MEASURE THE DOES THE VOLTAGEDRB, ACTUATE THE VOLTAGE AT THE FLUCTUATE FROM 0 NO PERFORM TEST

TRANS CONTROL TRANS RELAY OUTPUT VOLT TO OVER 10.0 TC-12B.RELAY. CIRCUIT. VOLTS?

FIG. 1, 2, 3 OR 4

YES

KEY OFF. KEY ON. MEASUREDISCONNECT THE THE VOLTAGE AT THE IS THE VOLTAGE YES PERFORM TEST

POWERTRAIN CONTROL TCC SOLENOID ABOVE 10.0 VOLTS? TC-12D.MODULE WHITE CONTROL CIRCUIT. CONNECTOR.** FIG. 1, 2, 3 OR 4

NO


NEXT PAGE.

TROUBLE

CODE

TESTS

107


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

108



TEST TC-12A KEY OFF. MEASURECONTINUED FROM THE RESISTANCE

THE PREVIOUS BETWEEN THE TCCPAGE. SOLENOID CONTROL

CIRCUIT...

AT THE PCM REPAIR THE TCCCONNECTOR AND IS THE RESISTANCE YES SOLENOID CONTROL

GROUND. BELOW 5.0 OHMS? CIRCUIT SHORTED TO GROUND.*

FIG. 1, 2, 3 OR 4

NO

CONNECT THESOLENOID PACK

CONNECTOR.

MEASURE THE AT THE PCMRESISTANCE BETWEEN CONNECTOR AND IS THE RESISTANCE YES RELACE THE

THE TCC SOLENOID GROUND. BELOW 5.0 OHMS? SOLENOID ANDCONTROL CIRCUIT... HARNESS ASSEMBLY.*

FIG. 1, 2, 3 OR 4

NO


NEXT PAGE.

TROUBLE

CODE

TESTS

109


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

110



TEST TC-12A REMOVE THE TRANSCONTINUED FROM CONTROL RELAY.**

THE PREVIOUS PAGE.


MEASURE THE AND THE TCCRESISTANCE BETWEEN SOLENOID CONTROL IS THE RESISTANCE YES REPLACE THETHE TRANS CONTROL CIRCUIT AT THE PCM BETWEEN 26.0 AND POWERTRAIN CONTROL

RELAY OUTPUT CIRCUIT CONNECTOR. 40.0 OHMS? MODULE.* AT THE RELAY... FIG. 1, 2, 3 OR 4

NO

IS THE RESISTANCE NO PERFORM TEST ABOVE 40.0 OHMS? TC-12C.

YES


NEXT PAGE.

TROUBLE

CODE

TESTS

111


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

112






MEASURE THE FROM THE PCMRESISTANCE OF THE CONNECTOR TO THE IS THE RESISTANCE NO REPAIR THE OPEN

TCC SOLENOID SOLENOID BELOW 5.0 OHMS? TCC SOLENOID CONTROL CIRCUIT... CONNECTOR. CONTROL CIRCUIT.*

FIG. 1, 2, 3 OR 4

YES

REPLACE THESOLENOID AND

HARNESS ASSEMBLY.*

TROUBLE

CODE

TESTS

113

TEST TC-12B REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CKT


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

114

TEST TC-12B REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CKT



REMOVE THE TRANSSTART TEST CONTROL RELAY.**

TC-12B.


KEY OFF. MEASURE AT THE RELAY REPAIR THE TRANSTHE RESISTANCE CONNECTOR AND IS THE RESISTANCE YES CONTROL RELAY

BETWEEN THE TRANS GROUND. BELOW 5.0 OHMS? OUTPUT CIRCUITCONTROL RELAY SHORTED TO

OUTPUT CIRCUIT... FIG. 1, 2, 3 OR 4 GROUND.*

NO

MEASURE THE FROM THE RELAY REPAIR THE OPEN RESISTANCE OF THE CONNECTOR TO THE IS THE RESISTANCE YES TRANS CONTROL

TRANS CONTROL SOLENOID ABOVE 5.0 OHMS? RELAY OUTPUT RELAY OUTPUT CONNECTOR. CIRCUIT.*

CIRCUIT... FIG. 1, 2, 3 OR 4

NO

KEY ON, MEASURE THE REPAIR THE OPEN VOLTAGE AT THE FUSED IS THE VOLTAGE NO FUSED B(+) FEED TO B(+) CIRCUIT IN THE ABOVE 10.0 VOLTS? THE TRANS CONTROL

RELAY CONNECTOR. RELAY.*FIG. 1, 2, 3 OR 4

YES

REPLACE THE TRANSCONTROL RELAY.*

TROUBLE

CODE

TESTS

115

TEST TC-12C CONTINUED - REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANSRELAY CKT


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

116

TEST TC-12C CONTINUED - REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANSRELAY CKT



DISCONNECT THE TRANS DISCONNECT ALL PCMSTART TEST SOLENOID CONNECTORS.**

TC-12C. CONNECTOR.**


MEASURE AND RECORD AND ALL OTHER IS THE RESISTANCE REPAIR TCC SOLENOID THE RESISTANCES CIRCUITS IN THE BELOW 5.0 OHMS YES CONTROL CKT SHORTEDBETWEEN THE TCC SOLENOID BETWEEN ANY TWO TO CIRCUIT(S) THAT SOLENOID CONTROL CONNECTOR. CIRCUITS? MEASURED BELOW 5.0

CIRCUIT... FIG. 1, 2, 3 OR 4 OHMS.*

NO

REPLACE THE SOLENOID HARNESS INSIDE THE CONNECT ALL

TRANSMISSION AND THE DISCONNECTED SOLENOID PACK.* CONNECTORS.

WITH THE DRB, DID THE VEHICLE NO PERFORM TCC SYSTEM STALL? REPLACE THE PCM.*

TEST.

YES

TEST COMPLETE.

TROUBLE

CODE

TESTS

117

TEST TC-12D REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CKT


NOTES

TROUBLE

CODE

TESTS

118

TEST TC-12D REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CKT



REPAIR TCCSTART TEST SOLENOID CONTROL

TC-12D. CIRCUIT SHORTED TO VOLTAGE.*

CONNECT ALL WITH THE DRB, DID THE VEHICLE NO REPLACE THEDISCONNECTED PERFORM TCC SYSTEM STALL? POWERTRAIN CONTROLCONNECTORS. TEST. MODULE.*

YES

TEST COMPLETE.

TROUBLE

CODE

TESTS

119

TEST TC-12E REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CKT


AB AND XJ BODIES WITH 3 SPD RH TRANS

AB BODY WITH 3 SPD RH TRANS

FIG. 1

AB BODY WITH 3 SPD RH TRANS

FIG. 2

TROUBLE

CODE

TESTS

120

TEST TC-12E REPAIRING - TORQUE CONVERTER CLUTCH SOLENOID/TRANS RELAY CKT



DISCONNECT THESTART TEST TRANSMISSION

TC-12E. SOLENOID CONNECTOR.**


MEASURE THE VOLTAGEAT THE FUSED IS THE VOLTAGE YES REPAIR THE OPEN

IGNITION KEY ON. IGNITION SWITCH BELOW 10.0 VOLTS? FUSED IGNITONOUTPUT CIRCUIT. SWITCH OUTOUT.*

FIG. 1

NO

KEY OFF. DISCONNECT THE

POWERTRAIN CONTROLMODULE.**

MEASURE THE AND GROUND. REPAIR THE TCCRESISTANCE BETWEEN IS THE RESISTANCE YES SOLENOID CONTROL

THE TCC SOLENOID BELOW 5.0 OHMS? CIRCUIT SHORTED TO CONTROL CIRCUIT... GROUND.*

FIG. 1

NO

MEASURE THE THE POWERTRAIN RESISTANCE OF THE CONTROL MODULE TO IS THE RESISTANCE NO REPAIR THE OPEN

TCC SOLENOID THE TCC SOLENOID BELOW 5.0 OHMS? TCC SOLENOID CONTROL CIRCUIT CONNECTOR. CONTROL CIRCUIT.*

FROM... FIG. 2

YES

CONNECT THE TCC MEASURE THE VOLTAGESOLENOID AT THE TCC SOLENOID IS THE VOLTAGE NO REPLACE THE TCC

CONNECTOR. CONTROL CIRCUIT AT ABOVE 10.0 VOLTS? SOLENOID.* PCM CONNECTOR.

TURN KEY ON. FIG. 2

YES


MODULE.*

TROUBLE

CODE

TESTS

121

TEST TC-14A REPAIRING - RAD FAN CONTROL RELAY CIRCUIT


AN BODY XJ BODY

AN BODY

FIG. 1

XJ BODY

FIG. 2

FIG. 3 FIG. 4

TROUBLE

CODE

TESTS

122

TEST TC-14A REPAIRING - RAD FAN CONTROL RELAY CIRCUIT



WITH THE DRB, START TEST ACTUATE THE IS THE RADIATOR NO CONTINUE TEST

TC-14A. RADIATOR FAN FAN RELAY TC-14A ON THERELAY. CLICKING? NEXT PAGE.

FIG. 1 OR 2

YES


FIG. 3 CONNECTORS.

NO

WIGGLE THE WIRING NOTE: THE DRB MUST REPAIR AS HARNESS FROM THE STILL BE ACTUATING DID THE WIGGLING YES NECESSARY WHERE

RELAY TO THE THE RADIATOR FAN INTERRUPT THE WIGGLING CAUSED POWERTRAIN CONTROL RELAY. CLICKING? THE CLICKING TO BE

MODULE. INTERRUPTED.*

NO

REFER TO FIG. 4FOR INACTIVE TROUBLE CODE TEST COMPLETE.*

CONDITIONINFORMATION.

TROUBLE

CODE

TESTS

123

TEST TC-14A CONTINUED - REPAIRING - RAD FAN CONTROL RELAY CIRCUIT

AN BODY

FIG.1

XJ BODY

FIG. 2 FIG. 3

AN BODY

FIG. 4

XJ BODY

FIG. 5

TROUBLE

CODE

TESTS

124

TEST TC-14A CONTINUED - REPAIRING - RAD FAN CONTROL RELAY CIRCUIT


TEST TC-14A DISCONNECT THECONTINUED FROM RADIATOR FAN

THE PREVIOUS RELAY.** PAGE.

FIG. 1 OR 2


CIRCUIT. CIRCUIT.*FIG. 1 OR 2

YES

MEASURE THEUSE AN OHMMETER IN RESISTANCE BETWEEN IS THE RESISTANCE NO REPLACE THE

THE FOLLOWING TERMINALS 85 AND BELOW 100.0 OHMS? RADIATOR FANSTEP. 86 OF THE RAD FAN RELAY.*

RELAY. FIG. 3

YES

KEY OFF. DISCONNECT USING AN OHMMETER, REPAIR THETHE POWERTRAIN MEASURE THE RAD FAN IS THE RESISTANCE YES RADIATOR FAN RELAY

CONTROL MODULE GREY RELAY CONTROL CKT AT BELOW 5.0 OHMS? CONTROL CKT FOR ACONNECTOR.** PCM TO GROUND. SHORT TO GROUND.*

SEE GENERAL INFO 4.1 FIG. 4 OR 5

NO

USING AN OHMMETER, FROM THE RELAY TO MEASURE THE RAD THE PCM. IS THE RESISTANCE NO REPAIR THE OPEN

FAN RELAY CONTROL BELOW 5.0 OHMS? RADIATOR FAN RELAYCIRCUIT... CONTROL CKT.*

FIG. 4 OR 5

YES


MODULE.*

TROUBLE

CODE

TESTS

125

TEST TC-15A REPAIRING - SPEED CONTROL SOLENOID CIRCUITS OR SPEED CONTROL POWERRELAY CIRCUITS


FIG. 1

ALL OTHERS

FIG. 2

ZJ BODY

FIG. 3

TROUBLE

CODE

TESTS

126

TEST TC-15A REPAIRING - SPEED CONTROL SOLENOID CIRCUITS OR SPEED CONTROL POWERRELAY CIRCUITS



WITH DRB, READ,START TEST RECORD AND CLEAR NOT SUPPLY POWER

TC-15A. ALL FAULTS. IF S/C TO THE S/C SERVOS. START ENGINE.FAULTS EXISTS, THE

PCM WILL...

WITH THE DRB, PRESS THE S/C DID THE SPEEDMONITOR THE S/C ON/OFF SWITCH TO CONTROL ON/OFF YES PERFORM TEST

ON/OFF SWITCH ON AND OFF WHILE SWITCH STATE TC-15B.STATE. MONITORING CHANGE ON THE DRB

DISPLAY. DISPLAY?

NO

DISCONNECT THE S/C USING AN OHMMETER, DOES THE S/CSWITCH.** MEASURE RESISTANCE SWITCH RESISTANCE NO REPLACE THE S/C

OF THE S/C SWITCH. MATCH CHART IN SWITCH.* FIGURE 2 OR 3?


YES

WITH THE S/C SWITCH NOTE: ENSURE THEON, DISCONNECT THE BRAKE PEDAL IS NOT

SPEED CONTROL SERVO DEPRESSED DURING THE4-WAY CONNECTOR.** FOLLOWING STEPS.


MEASURE THE SWITCHED WITH THE DRB, SPEED CONTROL POWER IS THE VOLTAGE YES PERFORM TEST

ACTUATE THE S/C SUPPLY CIRCUIT AT ABOVE 10.0 VOLTS? TC-15B.VENT SOLENOID. S/C SERVO CONNECTOR.

FIG. 1

NO

PERFORM TEST TC-15C.

TROUBLE

CODE

TESTS

127

TEST TC-15B REPAIRING - SPEED CONTROL SOLENOID CIRCUITS OR SPEED CONTROL POWERRELAY CIRCUIT


FIG. 1

AB, AN AND XJ BODIES

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

128

TEST TC-15B REPAIRING - SPEED CONTROL SOLENOID CIRCUITS OR SPEED CONTROL POWERRELAY CIRCUIT



NOTE: ENSURE THESTART TEST BRAKE PEDAL IS NOT

TC-15B. DEPRESSED DURING THEFOLLOWING STEPS.

USING AN OHMMETER,MEASURE THE S/C IS THE RESISTANCE NO REPAIR THE OPEN GROUND CIRCUIT. BELOW 5.0 OHMS? GROUND CIRCUIT.*

FIG. 1

YES

KEY OFF. DISCONNECT RECONNNECT SPEEDTHE POWERTRAIN CONTROL SERVO 4-WAY

CONTROL MODULE.** CONNECTOR.


WITH AN OHMMETER, TO THE SPEEDMEASURE THE CONTROL VENT IS THE RESISTANCE YES REPLACE THE

RESISTANCE FROM SOLENOID CONTROL BETWEEN 35.0 OHMS POWERTRAIN CONTROLTHE 12-VOLT POWER FROM PCM CONN. AND 55.0 OHMS? MODULE.*

SUPPLY... FIG. 2, 3 OR 4

NO


NEXT PAGE.

TROUBLE

CODE

TESTS

129

TEST TC-15B CONTINUED - REPAIRING - SPEED CONTROL SOLENOID CIRCUITS OR SPEEDCONTROL POWER RELAY CIRCUIT


FIG. 1

BR BODY

FIG. 2

ZJ BODY

FIG. 3

TROUBLE

CODE

TESTS

130

TEST TC-15B CONTINUED - REPAIRING - SPEED CONTROL SOLENOID CIRCUITS OR SPEEDCONTROL POWER RELAY CIRCUIT


TEST TC-15B CONTINUED FROM WITH AN OHMMETER,

THE PREVIOUS MEASURE THEPAGE. RESISTANCE FROM...

12-VOLT POWERSUPPLY TO SPEED IS THE RESISTANCE YES REPLACE THECONTROL VACCUUM BETWEEN 35.0 OHMS POWERTRAIN CONTROL

SOLENOID CONTROL. AND 55.0 OHMS? MODULE.* FIG. 1, 2 OR 3

NO

WITH AN OHMMETER, REPAIR THE OPEN MEASURE THE S/C IS THE RESISTANCE NO SPEED CONTROLVACUUM SOLENOID BELOW 5.0 OHMS? VACUUM SOLENOID CONTROL CIRCUIT. CONTROL CIRCUIT.*

FIG. 1, 2 OR 3

YES

WITH AN OHMMETER, REPAIR THE OPEN MEASURE THE S/C IS THE RESISTANCE NO SPEED CONTROL VENT

VENT SOLENOID BELOW 5.0 OHMS? SOLENOID CONTROLCONTROL CIRCUIT. CIRCUIT.*

FIG. 1, 2 OR 3

YES

REPLACE THE SPEEDCONTROL SERVO.*

TROUBLE

CODE

TESTS

131

TEST TC-15C REPAIRING - SPEED CONTROL SOLENOID CIRCUITS OR SPEED CONTROL POWERRELAY CIRCUIT


FIG. 1

AB BODY

FIG. 2

AN AND XJ BODIES

FIG. 3

BR BODY

FIG. 4

ZJ BODY

FIG. 5

TROUBLE

CODE

TESTS

132

TEST TC-15C REPAIRING - SPEED CONTROL SOLENOID CIRCUITS OR SPEED CONTROL POWERRELAY CIRCUIT



DISCONNECT THE BRAKESTART TEST SWITCH CONNECTOR.

TC-15C.


CIRCUIT AT THEUSING A VOLTMETER, BRAKE SWITCH IS THE VOLTAGE NO PERFORM TEST MEASURE THE BRAKE CONNECTOR. ABOVE 10.0 VOLTS? TC-15D.

SWITCH OUTPUT...FIG. 2, 3, 4 OR 5

YES

WITH AN OHMMETER, FROM THE SPEEDMEASURE THE S/C CONTROL SERVO

BRAKE SWITCH 4-WAY CONNECTOROUTPUT CIRCUIT... SWITCHED S/C POWER

SUPPLY....

TO THE BRAKE SWITCH CONNECTOR SWITCHED IS THE RESISTANCE YES REPLACE THE BRAKE

S/C BRAKE SWITCH BELOW 5.0 OHMS? SWITCH.* OUTPUT CIRCUIT.

FIG. 1, 2, 3, 4 OR 5

NO

REPAIR THE OPEN S/CBRAKE SWITCH OUTPUT CIRCUIT.*

TROUBLE

CODE

TESTS

133

TEST TC-15D REPAIRING - SPEED CONTROL SOLENOID CIRCUITS OR SPEED CONTROL POWERRELAY CIRCUIT

Perform TEST TC-15C Before Proceeding

AB BODY

FIG. 1

AN AND XJ BODIES

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

134

TEST TC-15D REPAIRING - SPEED CONTROL SOLENOID CIRCUITS OR SPEED CONTROL POWERRELAY CIRCUIT

Perform TEST TC-15C Before Proceeding

DISCONNECT THESTART TEST POWERTRAIN CONTROL

TC-15D. MODULE.**


WITH AN OHMMETER, FROM THE PCM PINMEASURE THE SPEED C11 TO BRAKE IS THE RESISTANCE YES REPLACE THE

CONTROL POWER SWITCH CONNECTOR. BELOW 5.0 OHMS? POWERTRAIN CONTROLSUPPLY CIRCUIT... MODULE.*

FIG. 1, 2, 3 OR 4

NO

REPAIR THE OPEN SPEED CONTROL

POWER SUPPLY CIRCUIT.*

TROUBLE

CODE

TESTS

135

TEST TC-16A REPAIRING - A/C CLUTCH RELAY CIRCUIT


ALL BODIES

FIG. 1 FIG. 2

TROUBLE

CODE

TESTS

136

TEST TC-16A REPAIRING - A/C CLUTCH RELAY CIRCUIT



START TEST WITH THE DRB, IS THE A/C CLUTCH NO CONTINUE TEST TC-16A. ACTUATE THE A/C RELAY CLICKING? TC-16A ON THE

CLUTCH RELAY. NEXT PAGE.

YES


FIG. 1 CONNECTORS.

NO


RELAY TO THE THE A/C CLUTCH INTERRUPT THE WIGGLING CAUSED POWERTRAIN CONTROL RELAY. CLICKING? THE CLICKING TO BE


NO

REFER TO FIGURE 2FOR INACTIVE TROUBLE CODE TEST COMPLETE.*


TROUBLE

CODE

TESTS

137

TEST TC-16A CONTINUED - REPAIRING - A/C CLUTCH RELAY CIRCUIT

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5 FIG. 6

TROUBLE

CODE

TESTS

138

TEST TC-16A CONTINUED - REPAIRING - A/C CLUTCH RELAY CIRCUIT


TEST TC-16A DISCONNECT THE A/CCONTINUED FROM CLUTCH RELAY.**

THE PREVIOUS PAGE.



CIRCUIT. CIRCUIT.*FIG. 1, 2, 3, 4 OR 5

YES

MEASURE THEUSE AN OHMMETER IN RESISTANCE BETWEEN IS THE RESISTANCE NO REPLACE THE A/C

THE FOLLOWING TERMINALS 85 AND 86 BELOW 100.0 OHMS? CLUTCH RELAY.*STEP. OF THE A/C CLUTCH

RELAY. FIG. 6

YES

KEY OFF. DISCONNECT USING AN OHMMETER, REPAIR THE A/CTHE POWERTRAIN MEASURE THE A/C IS THE RESISTANCE YES CLUTCH RELAY

CONTROL MODULE GREY CLUTCH CONTROL CKT BELOW 5.0 OHMS? CONTROL CIRCUITCONNECTOR.** AT PCM TO GROUND. FOR A SHORT TO

SEE GENERAL INFO 4.1 FIG. 1, 2, 3, 4 OR 5 GROUND.*

NO

USING AN OHMMETER, FROM THE RELAY TO MEASURE THE A/C THE PCM. IS THE RESISTANCE NO REPAIR OPEN A/C

CLUTCH RELAY BELOW 5.0 OHMS? CLUTCH RELAYCONTROL CIRCUIT... CONTROL CIRCUIT.*

FIG. 1, 2, 3, 4 OR 5

YES


MODULE.*

TROUBLE

CODE

TESTS

139

TEST TC-17A REPAIRING - EGR SOLENOID CIRCUIT


5.9L HD

FIG. 1

5.9L DIESEL

FIG. 2

TROUBLE

CODE

TESTS

140

TEST TC-17A REPAIRING - EGR SOLENOID CIRCUIT



START TEST WITH THE DRB, TC-17A ERASE TROUBLE

CODES.

DID THE EGRWITH THE DRB, WITH THE DRB, SOLENOID CONTROL YES CONTINUE TEST

ACTUATE THE EGR READ ALL TROUBLE CIRCUIT CODE TC-17A ON THESOLENOID. CODES. RETURN? NEXT PAGE.

NO

DOES THE EGR REPAIR AS NOTE: ACTUATOR WIGGLE WIRING SOLENOID CONTROL YES NECESSARY WHERE

TEST MUST STILL BE HARNESS FROM THE CIRCUIT CODE WIGGLING CAUSED RUNNING. SOLENOID TO PCM. RETURN? THE PROBLEM TO

APPEAR.*

NO


NOT PRESENT. WIRING ANDFIG. 1 OR 2 CONNECTORS.

NO

REFER TO GENERALINFO 3.3.2 FORINFORMATION ON TEST COMPLETE.*

INACTIVE TROUBLECODES.

TROUBLE

CODE

TESTS

141

TEST TC-17A CONTINUED - REPAIRING - EGR SOLENOID CIRCUIT

FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

142

TEST TC-17A CONTINUED - REPAIRING - EGR SOLENOID CIRCUIT


TEST TC-17A KEY OFF, DISCONNECT CONTINUED FROM THE EGR SOLENOID



MEASURE THE FUSED REPAIR THE OPEN KEY ON, USE A IGNITION SWITCH IS THE VOLTAGE NO FUSED IGNITION

VOLTMETER IN THE OUTPUT CKT. AT THE ABOVE 10.0 VOLTS? SWITCH OUTPUT FOLLOWING STEP. SOLENOID CONNECTOR. CIRCUIT.*

FIG. 1

YES

KEY OFF, DISCONNECT MEASURE THETHE PCM RESISTANCE OF THE IS THE RESISTANCE NO REPAIR THE OPEN

CONNECTORS.** CONTROL CKT FROM PCM BELOW 5.0 OHMS? EGR SOLENOID TO EGR SOLENOID. CONTROL CIRCUIT.*

USING AN OHMMETER... FIG. 2

YES

OHMMETER, REPAIR THE EGRTHE EGR IS THE RESISTANCE YES SOLENOID CONTROL

SOLENOID CONTROL . BELOW 5.0 OHMS? CIRCUIT SHORT TO CIRCUIT. GROUND.*

NO

RECONNECT EGR MEASURE THE EGRSOLENOID SOLENOID CONTROL IS THE VOLTAGE NO REPLACE THE EGR

CONNECTOR. KEY ON, CIRCUIT AT THE PCM ABOVE 10.0 VOLTS? SOLENOID.* USING A CONNECTOR.

VOLTMETER... FIG. 2

YES


MODULE.*

USING AN FROM THE EGRMEASURE SOLENOID CONNECTOR

TO GROUND ..

FIG. 1

TROUBLE

CODE

TESTS

143

TEST TC-18A REPAIRING - EVAP PURGE SOLENOID CIRCUIT


AB BODY AN AND XJ BODIES

BR BODY ZJ BODY

FIG. 1 FIG. 2

TROUBLE

CODE

TESTS

144

TEST TC-18A REPAIRING - EVAP PURGE SOLENOID CIRCUIT



RECORD ALL DTC’SSTART TEST AND FREEZE FRAME

TC-18A DATA, NOW ERASECODES.

START ENGINE. ALLOWWITH THE DRB, ENGINE TO REACH

MONITOR STATE OF NORMAL OPERATINGPURGE SOLENOID. TEMPERATURE.

(ABOVE 170 DEG.).

DISCONNECT THE PURGE IS PURGE SOLENOID VACUUM HOSE AT THE ALLOWING VACUUM NO CONTINUE TEST SOLENOID THAT GOES THROUGH WHEN THE DRB TC-18A ON THE

TO THE CANISTER. SHOWS DUTY CYCLE NEXT PAGE.MORE THAN O PERCENT?

YES



NO

WITH THE DRB, READ DOES THE EVAP REPAIR AS CODES. NOTE: WIGGLE WIRING PURGE SOLENOID YES NECESSARY WHERE

ACTUATOR TEST HARNESS FROM THE CONTROL CIRCUIT WIGGLING CAUSED SHOULD STILL BE SOLENOID TO PCM. CODE RETURN? PROBLEM TO

RUNNING. APPEAR.*

NO

TEST COMPLETE.*


TROUBLE

CODE

TESTS

145

TEST TC-18A CONTINUED - REPAIRING - EVAP PURGE SOLENOID CIRCUIT

AB BODY

FIG. 1

AN AND XJ BODIES

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

146



TEST TC-18A KEY OFF, DISCONNECT CONTINUED FROM EVAP PURGE SOLENOID



KEY ON, USING A CIRCUIT AT THE REPAIR THE OPEN VOLTMETER, MEASURE SOLENOID IS THE VOLTAGE NO FUSED IGNITION THE VOLTAGE OF THE CONNECTOR. ABOVE 10.0 VOLTS? SWITCH OUTPUT

FUSED IGNITION CIRCUIT.*SWITCH OUTPUT... FIG. 1, 2, 3 OR 4

YES


NEXT PAGE.

TROUBLE

CODE

TESTS

147


AB BODY

FIG. 1

AN AND XJ BODIES

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

148



TEST TC-18A KEY OFF, DISCONNECT CONTINUED FROM THE POWERTRAIN

THE PREVIOUS CONTROL MODULE.**PAGE.


WITH AN OHMMETER, FROM THE REPAIR THE OPEN MEASURE THE EVAP POWERTRAIN CONTROL IS THE RESISTANCE NO EVAP PURGE

PURGE SOLENOID MODULE TO THE EVAP BELOW 5.0 OHMS? SOLENOID CONTROLCONTROL CIRCUIT... SOLENOID CIRCUIT.*FIG. 1, 2, 3 OR 4 CONNECTOR.

YES

OHMMETER REPAIR THE EVAP THE AP AT THE PCM IS THE RESISTANCE YES PURGE SOLENOID

PURGE SOLENOID CONNECTOR. BELOW 5.0 OHMS? CONTROL CIRCUITCONTROL CIRCUIT SHORT TO GROUND.*

FIG. 1, 2, 3 OR 4

NO

RECONNECT EVAP MEASURE THE EVAP PURGE SOLENOID PURGE SOLENOID IS THE VOLTAGE NO REPLACE THE EVAP

CONNECTOR. KEY ON, CONTROL CIRCUIT AT ABOVE 10.0 VOLTS? PURGE SOLENOID.* USING A THE PCM CONNECTOR.

VOLTMETER... FIG. 1, 2, 3 OR 4

YES


MODULE.*

USING AN ,MEASURE EV

TO GROUND...

TROUBLE

CODE

TESTS

149

TEST TC-19A REPAIRING - INJECTOR #3 CONTROL CIRCUIT


FIG. 1


FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

150




YESSTART TEST IS THIS A CNG PERFORM TEST

TC-19A VEHICLE? TC-19B.

NO

KEY OFF, DISCONNECT USING AN OHMMETER,THE INJECTOR #3 MEASURE THE IS THE RESISTANCE NO REPLACE THE FUEL

CONNECTOR.** RESISTANCE OF BETWEEN 10.0 AND INJECTOR.* INJECTOR #3. 16.0 OHMS?

SEE GENERAL INFO 4.2 FIG. 1

YES

KEY ON, WITH THE USING A VOLTMETER, DRB, ACTUATE THE MEASURE THE ASD DOES THE VOLTAGE NO REPAIR THE OPEN

AUTO SHUTDOWN RELAY OUTPUT CYCLE HIGH AND ASD RELAY OUTPUT RELAY. CIRCUIT. LOW? CIRCUIT.*

FIG. 2, 3 OR 4

YES

TEST TC-19A CONTINUED ON

THE NEXT PAGE.

TROUBLE

CODE

TESTS

151

TEST TC-19A CONTINUED - REPAIRING - INJECTOR #3 CONTROL CIRCUIT

FIG. 1


FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

152



KEY OFF, DISCONNECT TEST TC-19A THE POWERTRAIN

CONTINUED FROM CONTROL MODULE.**PREVIOUS PAGE.


USING AN OHMMETER, REPAIR THEMEASURE THE INJECTOR IS THE RESISTANCE YES INJECTOR #3 DRIVER #3 DRIVER CIRCUIT IN BELOW 5.0 OHMS? CIRCUIT FOR A

THE PCM TO GROUND. SHORT TO GROUND.* FIG. 1

NO

WITH AN OHMMETER, FROM THEMEASURE ACROSS THE POWERTRAIN CONTROL IS THE RESISTANCE NO REPAIR THE OPEN INJECTOR #3 DRIVER MODULE CONNECTOR BELOW 5.0 OHMS? INJECTOR #3 DRIVER

CIRCUIT... TO THE INJECTOR CIRCUIT.*FIG. 2, 3 OR 4 CONNECTOR.

YES


MODULE.*

TROUBLE

CODE

TESTS

153

TEST TC-19B REPAIRING - INJECTOR #3 CONTROL CIRCUIT


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

154




KEY OFF, DISCONNECT START TEST THE INJECTOR #3

TC-19B CONNECTOR.**


USING AN OHMMETER,MEASURE THE IS THE RESISTANCE NO REPLACE THE FUEL

RESISTANCE OF BETWEEN 3.0 AND INJECTOR.* INJECTOR #3. 6.0 OHMS?

FIG. 1

YES



FIG. 2

YES

TEST TC-19B CONTINUED ON

THE NEXT PAGE.

TROUBLE

CODE

TESTS

155

TEST TC-19B CONTINUED - REPAIRING - INJECTOR #3 CONTROL CIRCUIT

FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

156



KEY OFF, DISCONNECT TEST TC-19B THE POWERTRAIN





NO

WITH AN OHMMETER, FROM THEMEASURE THE POWERTRAIN CONTROL IS THE RESISTANCE NO REPAIR THE OPEN

INJECTOR #3 DRIVER MODULE TO THE BELOW 5.0 OHMS? INJECTOR #3 DRIVER CIRCUIT... INJECTOR CIRCUIT.*

FIG. 2 CONNECTOR.

YES


MODULE.*

TROUBLE

CODE

TESTS

157



FIG. 1


FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

158






NO




YES



FIG. 2, 3 OR 4

YES


THE NEXT PAGE.

TROUBLE

CODE

TESTS

159


FIG. 1


FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

160








NO

WITH AN OHMMETER, FROM THEMEASURE ACROSS THE POWERTRAIN CONTROL IS THE RESISTANCE NO REPAIR THE OPEN INJECTOR #2 DRIVER MODULE TO THE BELOW 5.0 OHMS? INJECTOR #2 DRIVER

CIRCUIT... INJECTOR CIRCUIT.*FIG. 2, 3 OR 4 CONNECTOR.

YES


MODULE.*

TROUBLE

CODE

TESTS

161



FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

162





TC-20B CONNECTOR.**




FIG. 1

YES



FIG. 2

YES


THE NEXT PAGE.

TROUBLE

CODE

TESTS

163


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

164








NO

WITH AN OHMMETER, FROM THEMEASURE ACROSS THE POWERTRAIN CONTROL IS THE RESISTANCE NO REPAIR THE OPEN INJECTOR #2 DRIVER MODULE TO THE BELOW 5.0 OHMS? INJECTOR #2 DRIVER

CIRCUIT... INJECTOR CIRCUIT.*FIG. 2 CONNECTOR.

YES


MODULE.*

TROUBLE

CODE

TESTS

165

TEST TC-21A REPAIRING - INJECTOR CONTROL CIRCUITS


ALL 4-CYLINDER ENGINES ALL 6-CYLINDER ENGINES

ALL 8-CYLINDER ENGINES ALL 10-CYLINDER ENGINES

FIG. 1 FIG. 2

TROUBLE

CODE

TESTS

166

TEST TC-21A REPAIRING - INJECTOR CONTROL CIRCUITS



START TEST START ENGINE, LETTC-21A IDLE FOR AT LEAST

20 SECONDS.

DOES THE DRB SHOW KEY ON, ENGINE WITH THE DRB, READ ANY "INJECTOR YES CONTINUE TEST

OFF. TROUBLE CODES. CONTROL CIRCUIT" TC-21A ON THECODE WITH A START NEXT PAGE.RUN COUNT OF ZERO?

NO



NO

WIGGLE WIRING REPAIR AS HARNESS FROM THE DOES THE ENGINE YES NECESSARY WHERE

START ENGINE. INJECTOR TO THE MISS OR STALL? WIGGLING CAUSED PCM. PROBLEM TO

APPEAR.*

NO

REFER TO FIGURE 2FOR ADDTIONAL TEST COMPLETE.*

INFORMATION.

TROUBLE

CODE

TESTS

167

TEST TC-21A CONTINUED - REPAIRING - INJECTOR CONTROL CIRCUITS

NOTES

TROUBLE

CODE

TESTS

168

TEST TC-21A CONTINUED − REPAIRING − INJECTOR CONTROL CIRCUITS

Refer to the chart below and perform the diagnostic test that corresponds to the trouble codedisplayed on the DRB.

TROUBLE CODE DIAGNOSTIC TEST

INJECTOR #1 CONTROL CIRCUIT TC-21B

INJECTOR #2 CONTROL CIRCUIT TC-20A









TROUBLE

CODE

TESTS

169



FIG. 1


FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

170





TC-21B VEHICLE? TC-21C

NO




YES

USING A VOLTMETER, KEY ON, WITH THE MEASURE THE ASD DOES THE VOLTAGE NO REPAIR THE OPEN

DRB, ACTUATE AUTO RELAY OUTPUT CYCLE HIGH AND ASD RELAY OUTPUT SHUTDOWN RELAY. CIRCUIT. LOW? CIRCUIT.*

FIG. 2, 3 OR 4

YES


NEXT PAGE.

TROUBLE

CODE

TESTS

171


FIG. 1


FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

172








NO

USING AN OHMMETER, FROM THEMEASURE ACROSS THE POWERTRAIN CONTROL IS THE RESISTANCE NO REPAIR THE OPEN INJECTOR #1 DRIVER MODULE TO THE BELOW 5.0 OHMS? INJECTOR #1 DRIVER


YES


MODULE.*

TROUBLE

CODE

TESTS

173

TEST TC-21C REPAIRING - INJECTOR #1 CONTROL CIRCUIT

Perform TEST TC-21B Before Proceeding

FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

174

TEST TC-21C REPAIRING - INJECTOR #1 CONTROL CIRCUIT

Perform TEST TC-21B Before Proceeding



TC-21C CONNECTOR.**




FIG. 1

YES



FIG. 2

YES

CONTINUE TEST TC-21C ON THE

NEXT PAGE.

TROUBLE

CODE

TESTS

175

TEST TC-21C CONTINUED - REPAIRING - INJECTOR #1 CONTROL CIRCUIT

FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

176

TEST TC-21C CONTINUED - REPAIRING - INJECTOR #1 CONTROL CIRCUIT


KEY OFF, DISCONNECT TEST TC-21C THE POWERTRAIN





NO



YES


MODULE.*

TROUBLE

CODE

TESTS

177

TEST TC-25A REPAIRING - IDLE AIR CONTROL MOTOR CIRCUITS


FIG. 1

AB, AN, BR AND XJ BODIES ZJ BODY

TROUBLE

CODE

TESTS

178

TEST TC-25A REPAIRING - IDLE AIR CONTROL MOTOR CIRCUITS



START TEST TURN IGNITION OFF START ENGINE,TC-25A FOR 10 SECONDS. ALLOW TO IDLE FOR

20 SECONDS.

NOTE: IF THE ENGINE WITH THE DRB NOTE: RELEASEWILL NOT IDLE, HOLD ACTUATE THE IDLE THROTTLE. NO CONTINUE TEST

THE THROTTLE OPEN AIR CONTROL MOTOR TC-25A ON THESLIGHTLY TO KEEP TO 1400 RPM. IS THE ENGINE SPEED NEXT PAGE.ENGINE RUNNING. 1400 +/- 100 RPM?

YES

WITH THE DRBACTUATE THE IDLE IS THE ENGINE NO CONTINUE TEST

AIR CONTROL MOTOR SPEED 900 +/- 100 TC-25A ON THETO 900 RPM. RPM? NEXT PAGE.

YES



NO

START ENGINE. WITH THE IDLE SPEEDTHE DRB IN SYSTEMS SHOULD RAISE AND DOES THE IDLE NO CONTINUE TEST TESTS, PERFORM THE LOWER WITH THE SPEED RAISE AND TC-25A ON THE

IAC WIGGLE TEST. DISPLAY. LOWER PROPERLY? NEXT PAGE.

YES

WIGGLE THE WIRING HARNESS FROM THE OBSERVE FOR THE DID THE IAC STOP YES REPAIR THE HARNESSIAC MOTOR TO THE IAC MOTOR TO STOP OPERATING AT ANY OR CONNECTORS AS

PCM. OPERATING. TIME? NECESSARY.*

NO

REFER TO GENERALWITH THE DRB, STOP INFO 3.3.2 FOR

THE IAC WIGGLE INFORMATION ON TEST COMPLETE.* TEST. INACTIVE TROUBLE

CODES.

TROUBLE

CODE

TESTS

179

TEST TC-25A CONTINUED - REPAIRING - IDLE AIR CONTROL MOTOR CIRCUITS

AB BODY

FIG. 1

AN AND BR BODIES

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

180



TEST TC-25A CONTINUED FROM USING THE DRB,

THE PREVIOUS STOP ALL TESTS. PAGE.

WITH THE ENGINE STILL RUNNING,

DISCONNECT THE IACMOTOR CONNECTOR.**

USING A VOLTMETER, MEASURE THE IAC WAS THE VOLTAGE NO PERFORM TEST

DRIVER #1 CIRCUIT. OVER 5.0 VOLTS AT TC-25B ANY TIME?

FIG. 1, 2, 3 OR 4

YES


DRIVER #2 CIRCUIT. OVER 5.0 VOLTS AT TC-25C ANY TIME?

FIG. 1, 2, 3 OR 4

YES


DRIVER #3 CIRCUIT. OVER 5.0 VOLTS AT TC-25D ANY TIME?

FIG. 1, 2, 3 OR 4

YES


DRIVER #4 CIRCUIT. OVER 5.0 VOLTS AT TC-25E ANY TIME?

FIG. 1, 2, 3 OR 4

YES


NEXT PAGE.

TROUBLE

CODE

TESTS

181


AB BODY

FIG. 1

AN AND BR BODIES

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

182



TEST TC-25A CONTINUED FROM

THE PREVIOUS TURN KEY OFF. PAGE.

THE IAC DRIVER #1 REPAIR THE IAC #1 USING AN OHMMETER, AND GROUND. IS THE RESISTANCE YES DRIVER CIRCUITMEASURE BETWEEN... BELOW 5.0 OHMS? SHORTED TO

GROUND.* FIG. 1, 2, 3 OR 4

NO



NO



NO



NO


NEXT PAGE.

TROUBLE

CODE

TESTS

183


AB BODY

FIG. 1

AN AND BR BODIES

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

184



TEST TC-25A KEY OFF, DISCONNECT IS ANY TERMINAL CONTINUED FROM THE POWERTRAIN CORRODED, DAMAGED, YES REPAIR AS

THE PREVIOUS CONTROL MODULE.** PUSHED OUT OR NECESSARY.*PAGE. MISWIRED?


NO

THE FOLLOWING USING AN OHMMETER,STEPS ARE CHECKING MEASURE THE

FOR A SHORT RESISTANCE BETWEENBETWEEN THE DRIVER THE...

CIRCUITS...

IAC #1 DRIVER AND IS THE RESISTANCE #2, #3, #4 DRIVERS. BELOW 5.0 OHMS ON YES REPAIR THE IAC

ANY OF THE DRIVER CIRCUITS,DRIVERS? SHORTED TOGETHER.*

FIG. 1, 2 3 OR 4

NO

USING AN OHMMETER, IAC #2 DRIVER AND IS THE RESISTANCE MEASURE THE #3,#4 DRIVERS. BELOW 5.0 OHMS ON YES REPAIR THE IAC

RESISTANCE BETWEEN ANY OF THE DRIVER CIRCUITS,THE... DRIVERS? SHORTED TOGETHER.*

FIG. 1, 2, 3 OR 4

NO

USING AN OHMMETER, IAC #3 DRIVER ANDMEASURE THE #4 DRIVER. IS THE RESISTANCE YES REPAIR THE IAC

RESISTANCE BETWEEN BELOW 5.0 OHMS? DRIVER CIRCUITS,THE... SHORTED TOGETHER.*

FIG. 1, 2, 3 OR 4

NO

REPLACE THE IDLE AIR CONTROL

MOTOR.*

TROUBLE

CODE

TESTS

185

TEST TC-25B REPAIRING - IDLE AIR CONTROL MOTOR CIRCUITS


AB BODY

FIG. 1

AN AND BR BODIES

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

186

TEST TC-25B REPAIRING - IDLE AIR CONTROL MOTOR CIRCUITS



KEY OFF, DISCONNECT IS ANY TERMINAL START TEST THE POWERTRAIN CORRODED, DAMAGED, YES REPAIR AS

TC-25B. CONTROL MODULE PUSHED OUT OR NECESSARY.*CONNECTOR.** MISWIRED?


NO

USING AN OHMMETER, FROM THEMEASURE THE POWERTRAIN CONTROL IS THE RESISTANCE YES REPLACE THE

RESISTANCE OF THE MODULE CONNECTOR BELOW 5.0 OHMS? POWERTRAIN CONTROLIAC #1 DRIVER CKT... TO THE IAC MODULE.*

FIG. 1, 2, 3 OR 4 CONNECTOR.

NO

REPAIR THE OPEN IDLE AIR CONTROL

MOTOR DRIVER CIRCUIT.*

TROUBLE

CODE

TESTS

187

TEST TC-25C REPAIRING - IDLE AIR CONTROL MOTOR CIRCUITS


AB BODY

FIG. 1

AN AND BR BODIES

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

188

TEST TC-25C REPAIRING - IDLE AIR CONTROL MOTOR CIRCUITS



KEY OFF, DISCONNECT START TEST THE POWERTRAIN IS ANY TERMINAL YES REPAIR AS

TC-25C. CONTROL MODULE DAMAGED, PUSHED NECESSARY.*CONNECTOR.** OUT OR MISWIRED?


NO




NO



TROUBLE

CODE

TESTS

189

TEST TC-25D REPAIRING - IDLE AIR CONTROL MOTOR CIRCUITS


AB BODY

FIG. 1

AN AND BR BODIES

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

190

TEST TC-25D REPAIRING - IDLE AIR CONTROL MOTOR CIRCUITS




TC-25D. CONTROL MODULE DAMAGED, PUSHED NECESSARY.*CONNECTOR.** OUT OR MISWIRED?


NO




NO



TROUBLE

CODE

TESTS

191

TEST TC-25E REPAIRING - IDLE AIR CONTROL MOTOR CIRCUITS


AB BODY

FIG. 1

AN AND BR BODIES

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

192

TEST TC-25E REPAIRING - IDLE AIR CONTROL MOTOR CIRCUITS




TC-25E. CONTROL MODULE DAMAGED, PUSHED NECESSARY.*CONNECTOR.** OUT OR MISWIRED?


NO




NO



TROUBLE

CODE

TESTS

193

TEST TC-26A REPAIRING - THROTTLE POSITION SENSOR VOLTAGE LOW


ZJ BODY ALL OTHERS

FIG. 1 FIG. 2

TROUBLE

CODE

TESTS

194

TEST TC-26A REPAIRING - THROTTLE POSITION SENSOR VOLTAGE LOW



WITH THE DRB, READ IS THE THROTTLE START TEST THE THROTTLE POSITION SENSOR YES CONTINUE TEST

TC-26A. POSITION SENSOR VOLTAGE BELOW TC-26A ON THE(TP SENSOR) 0.2 VOLT? NEXT PAGE.

VOLTAGE.

NO

WHILE MONITORING THE DRB, SLOWLY IS THE VOLTAGE NO REPLACE THE

OPEN AND CLOSE THE CHANGE SMOOTH? THROTTLE POSITION THROTTLE. SENSOR.*

YES

STOP MOVING WAS THERE ANY REPAIR THE HARNESSLINKAGE. WIGGLE MONITOR THE DRB CHANGE IN THROTTLE YES OR CONNECTOR THAT

THROTTLE POSITION DISPLAY. POSITION SENSOR CAUSED THE VOLTAGESENSOR CONNECTORS VOLTAGE WHEN CHANGE.*

AND HARNESS. WIGGLED?

NO



NO

THE PROBLEM DOES NOT EXSIST AT THIS

TIME. TEST COMPLETE.*

FIG. 2

TROUBLE

CODE

TESTS

195

TEST TC-26A CONTINUED - REPAIRING - THROTTLE POSITION SENSOR VOLTAGE LOW

AB, AN, BR AND XJ BODIES

FIG. 1

BR DIESEL

FIG. 2

ZJ BODY

FIG. 3

TROUBLE

CODE

TESTS

196



TEST TC-26A DISCONNECT THECONTINUED FROM THROTTLE POSITION

THE PREVIOUS (TP) SENSOR.**PAGE.


MEASURE THEUSE A VOLTMETER IN THROTTLE POSITION IS THE VOLTAGE YES REPAIR THE OPEN TP

THE FOLLOWING SENSOR 5-VOLT BELOW 4.0 VOLTS? SENSOR 5-VOLT STEP. SUPPLY CIRCUIT. SUPPLY CIRCUIT.*

FIG. 1, 2 OR 3

NO

WITH THE DRB, READ THE THROTTLE IS THE VOLTAGE YES REPLACE THE

POSITION SENSOR ABOVE 1.0 VOLT? THROTTLE POSITION VOLTAGE. SENSOR.*

NO

IS THIS A XJ WITH YES CONTINUE TEST A 4.OL ENGINE AND TC-26A ON THE

A AW4 TRANS? PAGE.

NO

KEY OFF. DISCONNECT USING AN OHMMETER, REPAIR THETHE POWERTRAIN MEASURE THE TP IS THE RESISTANCE YES THROTTLE POSITION

CONTROL MODULE.** SENSOR SIGNAL BELOW 5.0 OHMS? SENSOR SIGNAL CIRCUIT TO GROUND. CIRCUIT FOR A

SEE GENERAL INFO 4.0 FIG. 1, 2 OR 3 SHORT TO GROUND.*

NO

MEASURE BETWEEN REPAIR THE SENSOR USE AN OHMMETER IN THE SENSOR SIGNAL IS THE RESISTANCE YES SIGNAL CIRCUIT

THE FOLLOWING CKT AND THE SENSOR BELOW 5.0 OHMS? SHORTED TO SENSOR STEP. GROUND CKT. GROUND CIRCUIT.*

FIG. 1, 2 OR 3

NO


MODULE.*

TROUBLE

CODE

TESTS

197


FIG. 1

TROUBLE

CODE

TESTS

198



TEST TC-26A KEY OFF. CONTINUED FROM DISCONNECT THE

THE PREVIOUS TRANSMISSION PAGE. CONTROL MODULE.**

KEY ON. WITH THEDRB, READ THE IS THE VOLTAGE YES REPLACE THE

THROTTLE POSITION ABOVE 1.0 VOLT? TRANSMISSION SENSOR VOLTAGE. CONTROL MODULE.*

NO

KEY OFF. DISCONNECT USING AN OHMMETER, REPAIR THETHE POWERTRAIN MEASURE THE TP IS THE RESISTANCE YES THROTTLE POSITION

CONTROL MODULE.** SENSOR SIGNAL BELOW 5.0 OHMS? SENSOR SIGNAL CIRCUIT TO GROUND. CIRCUIT FOR A

SEE GENERAL INFO 4.1 FIG. 1 SHORT TO GROUND.*

NO

MEASURE BETWEEN REPAIR THE SENSOR USE AN OHMMETER IN THE SENSOR SIGNAL IS THE RESISTANCE YES SIGNAL CIRCUIT

THE FOLLOWING CIRCUIT AND THE BELOW 5.0 OHMS? SHORTED TO SENSOR STEP. SENSOR GROUND CKT. GROUND CIRCUIT.*

FIG. 1

NO


MODULE.*

TROUBLE

CODE

TESTS

199

TEST TC-27A REPAIRING - THROTTLE POSITION SENSOR VOLTAGE HIGH


ZJ BODY ALL OTHERS

FIG. 1 FIG. 2

TROUBLE

CODE

TESTS

200

TEST TC-27A REPAIRING - THROTTLE POSITION SENSOR VOLTAGE HIGH



WITH THE DRB, READ IS THE THROTTLE START TEST THE THROTTLE POSITION SENSOR YES CONTINUE TEST

TC-27A. POSITION SENSOR VOLTAGE ABOVE 4.5 TC-27A ON THEVOLTAGE. VOLTS? NEXT PAGE.

NO



YES

WIGGLE THROTTLE WAS THERE ANY REPAIR THE HARNESSPOSITON SENSOR MONITOR THE DRB CHANGE IN THROTTLE YES OR CONNECTOR THAT CONNECTORS AND DISPLAY. POSITION SENSOR CAUSED THE VOLTAGE

HARNESS. VOLTAGE WHEN CHANGE.* WIGGLED?

NO



NO

THE PROBLEM DOES NOT EXSIST AT THIS

TIME. TEST COMPLETE.*

FIG. 2

TROUBLE

CODE

TESTS

201

TEST TC-27A CONTINUED - REPAIRING - THROTTLE POSITION SENSOR VOLTAGE HIGH


FIG. 1

BR DIESEL

FIG. 2

ZJ BODY

FIG. 3

TROUBLE

CODE

TESTS

202



TEST TC-27A DISCONNECT THECONTINUED FROM THROTTLE POSITION

THE PREVIOUS SENSOR.**PAGE.


CONNECT A JUMPER USING THE DRB, WIRE BETWEEN THE READ THE THROTTLE IS THE VOLTAGE YES REPLACE THETP SENSOR SIGNAL POSITION SENSOR BELOW 1.0 VOLT? THROTTLE POSITION

CKT AND SENSOR GND VOLTAGE. SENSOR.* CKT.FIG. 1, 2 OR 3

NO

REPAIR THE 5-VOLT DOES THE DRB SHOW YES SUPPLY SHORTED TO

NO RESPONSE? TP SENSOR SIGNAL CIRCUIT.*

NO

MOVE THE JUMPER WIRE BETWEEN THE SENSOR READ THE THROTTLE IS THE VOLTAGE YES REPAIR THE OPEN TP

SIGNAL CIRCUIT AND A POSITION SENSOR BELOW 1.0 VOLT? SENSOR GROUND GOOD ENGINE GROUND. VOLTAGE. CIRCUIT.*

FIG. 1, 2 OR 3


NEXT PAGE.

TROUBLE

CODE

TESTS

203



FIG. 1

BR DIESEL

FIG. 2

ZJ BODY

FIG. 3

TROUBLE

CODE

TESTS

204



TEST TC-27A DISCONNECT THECONTINUED FROM POWERTRAIN CONTROL

THE PREVIOUS TURN IGNITION OFF. MODULE.**PAGE.


MEASURE THE THROTTLE USE AN OHMMETER IN POSITION SENSOR IS THE RESISTANCE YES REPLACE THE

THE FOLLOWING SIGNAL CIRCUIT FOR BELOW 5.0 OHMS? POWERTRAIN CONTROLSTEP. RESISTANCE. MODULE.*

FIG. 1, 2 OR 3

NO

REPAIR THE OPEN TP SENSOR SIGNAL

CIRCUIT.*

TROUBLE

CODE

TESTS

205

TEST TC-30A REPAIRING - ECT SENSOR VOLTAGE TOO LOW


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

206

TEST TC-30A REPAIRING - ECT SENSOR VOLTAGE TOO LOW



WITH THE DRB, READ IS THE ENGINE START TEST THE ENGINE COOLANT COOLANT YES CONTINUE TEST

TC-30A. TEMPERATURE SENSOR TEMPERATURE SENSOR TC-30A ON THE(ECT) VOLTAGE. VOLTAGE BELOW NEXT PAGE.

0.5 VOLT?

NO

WIGGLE THE ENGINE WAS THERE ANY REPAIR THE HARNESSCOOLANT MONITOR THE DRB ENGINE COOLANT YES OR CONNECTOR THAT

TEMPERATURE SENSOR DISPLAY. TEMPERATURE SENSOR CAUSED THE VOLTAGECONNECTOR & VOLTAGE CHANGE? CHANGE.*

HARNESS.

NO



NO

REFER TO FIGURE 2FOR ADDITIONAL TEST COMPLETE.*

INFORMATION.

TROUBLE

CODE

TESTS

207

TEST TC-30A CONTINUED - REPAIRING - ECT SENSOR VOLTAGE TOO LOW

AB, AN, BR AND ZJ 5.2L

FIG. 1

XJ BODY

FIG. 2

ZJ 4.0L

FIG. 3

TROUBLE

CODE

TESTS

208

TEST TC-30A CONTINUED - REPAIRING - ECT SENSOR VOLTAGE TOO LOW


TEST TC-30A DISCONNECT THECONTINUED FROM ENGINE COOLANT

THE PREVIOUS TEMPERATURE (ECT)PAGE. SENSOR CONNECTOR.**


WITH THE DRB, READ IS THE ECT SENSOR YES REPLACE THE ECTTHE ECT SENSOR VOLTAGE ABOVE 4.0 SENSOR.*

VOLTAGE. VOLTS?

NO

KEY OFF, DISCONNECT USING AN OHMMETER, REPAIR THE SENSOR THE POWERTRAIN MEASURE THE ECT IS THE RESISTANCE YES SIGNAL CIRCUIT FOR

CONTROL MODULE.** SENSOR SIGNAL BELOW 5.0 OHMS? A SHORT TO CIRCUIT TO GROUND. GROUND.*

SEE GENERAL INFO 4.1 FIG. 1, 2 OR 3

NO

ECT SENSOR SIGNAL REPAIR THE ECTWITH AN OHMMETER, CIRCUIT AND THE IS THE RESISTANCE YES SENSOR SIGNAL

MEASURE BETWEEN SENSOR GROUND BELOW 5.0 OHMS? CIRCUIT SHORTED TO THE... CIRCUIT. THE SENSOR GROUND

FIG. 1, 2 OR 3 CIRCUIT.*

NO


MODULE.*

TROUBLE

CODE

TESTS

209

TEST TC-31A REPAIRING - ECT SENSOR VOLTAGE TOO HIGH


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

210

TEST TC-31A REPAIRING - ECT SENSOR VOLTAGE TOO HIGH



WITH THE DRB, READ IS THE ENGINE START TEST THE ENGINE COOLANT COOLANT YES CONTINUE TEST

TC-31A. TEMPERATURE (ECT) TEMPERATURE SENSOR TC-31A ON THESENSOR VOLTAGE. VOLTAGE ABOVE 4.5 NEXT PAGE.

VOLTS?

NO

WIGGLE THE ENGINE WAS THERE ANY REPAIR THE HARNESSCOOLANT TEMP MONITOR THE DRB ENGINE COOLANT YES OR CONNECTOR THAT

SENSOR CONNECTOR & DISPLAY. TEMPERATURE SENSOR CAUSED THE VOLTAGEHARNESS. VOLTAGE CHANGE? CHANGE.*

NO



NO


INFORMATION.

TROUBLE

CODE

TESTS

211

TEST TC-31A CONTINUED - REPAIRING - ECT SENSOR VOLTAGE TOO HIGH


FIG. 1

XJ BODY

FIG. 2

ZJ 4.0L

FIG. 3


FIG. 4

XJ BODY

FIG. 5

ZJ 4.0L

FIG. 6

TROUBLE

CODE

TESTS

212

TEST TC-31A CONTINUED - REPAIRING - ECT SENSOR VOLTAGE TOO HIGH


TEST TC-31A DISCONNECT THECONTINUED FROM ENGINE COOLANT

THE PREVIOUS TEMPERATURE (ECT)PAGE. SENSOR.**


WITH A VOLTMETER, REPAIR THE ECTMEASURE THE ECT AT THE ECT SENSOR IS THE VOLTAGE YES SENSOR SIGNAL SENSOR SIGNAL... CONNECTOR. ABOVE 4.5 VOLTS? SHORTED TO

VOLTAGE.*FIG. 1, 2 OR 3

NO

CONNECT A JUMPER BETWEEN THE ECT WITH THE DRB, READ IS THE VOLTAGE YES REPLACE THE ECT

SENSOR SIGNAL AND THE ECT SENSOR BELOW 1.0 VOLT? SENSOR.* SENSOR GROUND CKT. VOLTAGE.

FIG. 1, 2 OR 3

NO

MOVE THE JUMPER WITH THE DRB, READ WIRE FROM THE THE ENGINE COOLANT IS THE VOLTAGE YES REPAIR THE OPEN

SENSOR GROUND TO TEMPERATURE SENSOR BELOW 1.0 VOLT? SENSOR GROUND AN ENGINE GROUND. VOLTAGE. CIRCUIT.*

FIG. 1, 2 OR 3

NO

KEY OFF, DISCONNECT THE POWERTRAIN USE AN OHMMETER IN

CONTROL MODULE.** THE FOLLOWINGSTEP.


MEASURE THE ECTSENSOR SIGNAL FROM THE PCM TO IS THE RESISTANCE YES REPLACE THE

CIRCUIT FOR THE ECT SENSOR BELOW 5.0 OHMS? POWERTRAIN CONTROLRESISTANCE... CONNECTOR. MODULE.* FIG. 4, 5 OR 6

NO

REPAIR THE OPEN ECT SENSOR SIGNAL

CIRCUIT.*

TROUBLE

CODE

TESTS

213

TEST TC-35A REPAIRING - NO VEHICLE SPEED SENSOR SIGNAL


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

214

TEST TC-35A REPAIRING - NO VEHICLE SPEED SENSOR SIGNAL



WARNING: BE SURE START TEST RAISE THE DRIVE TO KEEP HANDS AND

TC-35A. WHEELS OFF THE FEET CLEAR OF GROUND. ROTATING WHEELS.

START ENGINE, WITH THE DRB, READ THE PUT THE DOES THE DRB SHOW NO CONTINUE TEST

VEHICLE SPEED TRANSMISSION IN ABOVE ZERO MPH? TC-35A ON THESENSOR. ANY FORWARD GEAR. NEXT PAGE.

YES

AT THIS TIME, THE USING THECONDITION REQUIRED SCHEMATIC AS A WERE ANY PROBLEMS YES REPAIR AS TO SET THE CODE IS GUIDE, INSPECT THE FOUND? NECESSARY. *

NOT PRESENT. WIRING ANDCONNECTORS.

NO


INFORMATION.

FIG. 1

TROUBLE

CODE

TESTS

215

TEST TC-35A CONTINUED - REPAIRING - NO VEHICLE SPEED SENSOR SIGNAL

XJ BODY

FIG. 1

ALL OTHER BODIES

FIG. 2

TROUBLE

CODE

TESTS

216



WITH THE WHEELS DOES THETEST TC-35A STILL ROLLING, SPEEDOMETER YES PERFORM TEST

CONTINUED FROM OBSERVE THE DISPLAY SHOW ABOVE TC-35C PREVIOUS PAGE. SPEEDOMETER. ZERO MPH?

NO

HOIST VEHICLE, CHECKTHE VSS ADAPTER FOR WAS THE ADAPTER NO REPAIR AS

PROPER SEATING AND POSITIONED AND NECESSARY.*POSITIONING. SEATED PROPERLY?

SEE SERVICE MANUAL.

YES

KEY OFF, DISCONNECT KEY ON, MEASURETHE VEHICLE SPEED THE VOLTAGE AT THE IS THE VOLTAGE NO REPAIR THE OPEN

SENSOR(VSS) 5-VOLT SUPPLY ABOVE 4.0 VOLTS? 5-VOLT SUPPLY CONNECTOR.** CIRCUIT. CIRCUIT.*


YES

KEY OFF. KEY ON. MEASURE THEDISCONNECT THE VOLTAGE AT THE IS THE VOLTAGE NO CONTINUE TEST

INSTRUMENT CLUSTER VEHICLE SPEED SENSOR ABOVE 4.5 VOLTS? TC-35A ON THECONNECTOR.** SIGNAL CIRCUIT. NEXT PAGE.

FIG. 1 OR 2

YES

CONNECT ONE END OF A JUMPER WIRE TO WITH THE DRB, READ

THE VSS SENSOR THE VSS SIGNAL.SIGNAL CIRCUIT.

FIG. 1 OR 2

WHILE OBSERVINGDISPLAY, TAP THE DOES THE DISPLAY NO PERFORM TEST

OTHER END OF JUMPER SHOW MORE THAN TC-35B.TO THE SENSOR 0 MPH?

GROUND CIRCUIT.

YES

REMOVE THE VEHICLESPEED SENSOR. IS THE PINION GEAR NO REPAIR AS

INSPECT THE OK? NECESSARY.*SPEEDOMETER PINION

GEAR.

YES

REPLACE THEVEHICLE SPEED

SENSOR.*

TROUBLE

CODE

TESTS

217


AN BODY

FIG. 1

ALL OTHER BODIES

FIG. 2

AN BODY

FIG. 3

ALL OTHER BODIES

FIG. 4

TROUBLE

CODE

TESTS

218






MEASURE THE FROM THE PCM NO RESISTANCE OF THE CONNECTOR TO THE IS THE RESISTANCE REPAIR THE OPEN

VEHICLE SPEED VSS CONNECTOR. BELOW 5.0 OHMS? SPEED SENSOR SENSOR SIGNAL SIGNAL CIRCUIT.*

CIRCUIT... FIG. 1 OR 2

YES

MEASURE THERESISTANCE BETWEEN IS THE RESISTANCE YES CONTINUE TEST

THE VSS SIGNAL BELOW 5.0 OHMS? TC-35A ON THECIRCUIT AND GROUND. NEXT PAGE.

FIG. 3 OR 4

NO


MODULE.*

TROUBLE

CODE

TESTS

219


AN BODY

FIG. 1

ALL OTHER BODIES

FIG. 2

TROUBLE

CODE

TESTS

220



IS THE VEHICLE REPAIR THE VEHICLETEST TC-35A EQUIPPED WITH NO SPEED SENSOR

CONTINUED FROM DAYLIGHT RUNNING SIGNAL CIRCUIT FORPREVIOUS PAGE. LAMPS? A SHORT TO

GROUND.*

YES

MEASURE THE REPAIR THE VSSDISCONNECT THE RESISTANCE BETWEEN IS THE RESISTANCE YES SIGNAL CIRCUIT FOR

DAYLIGHT RUNNING THE VSS SIGNAL BELOW 5.0 OHMS? A SHORT TO LAMP MODULE.** CIRCUIT AND GROUND GROUND.*

FIG. 1 OR 2

NO

REPLACE THEDAYLIGHT RUNNING

LAMP MODULE.*

TROUBLE

CODE

TESTS

221

TEST TC-35B REPAIRING - NO VEHICLE SPEED SENSOR SIGNAL


AN BODY

FIG. 3

ALL OTHER BODIES

FIG. 2

TROUBLE

CODE

TESTS

222

TEST TC-35B REPAIRING - NO VEHICLE SPEED SENSOR SIGNAL



CONNECT ONE END OF START TEST A JUMPER WIRE TO WITH THE DRB, READ

TC-35B. THE VSS SENSOR THE VSS SIGNAL.SIGNAL CIRCUIT.

FIG. 1 OR 2

WHILE OBSERVINGDISPLAY, TAP OTHER DOES THE DISPLAY YES REPAIR THE OPEN

END OF JUMPER TO SHOW MORE THAN SENSOR GROUND GROUND. 0 MPH? CIRCUIT.*

FIG. 1 OR 2

NO


MODULE.*

TROUBLE

CODE

TESTS

223

TEST TC-35C REPAIRING - NO VEHICLE SPEED SENSOR SIGNAL


AN BODY

FIG. 1

ALL OTHER BODIES

FIG. 2

TROUBLE

CODE

TESTS

224

TEST TC-35C REPAIRING - NO VEHICLE SPEED SENSOR SIGNAL




START TEST 35C. WHITE PCMCONNECTOR.**

MEASURE THEVOLTAGE AT THE VSS IS THE VOLTAGE YES REPLACE THE

SIGNAL CIRCUIT. ABOVE 4.5 VOLTS? POWERTRAIN CONTROLMODULE.*

FIG. 1 OR 2

NO

REPAIR THE OPEN VSS SIGNAL CIRCUIT

BETWEEN THE VSSAND THE PCM.*

TROUBLE

CODE

TESTS

225

TEST TC-36A REPAIRING - MAP SENSOR VOLTAGE TOO LOW - NO 5 VOLTS TO MAP SENSOR


ZJ BODY ALL OTHERS

FIG. 1 FIG. 2

FIG. 3

TROUBLE

CODE

TESTS

226

TEST TC-36A REPAIRING - MAP SENSOR VOLTAGE TOO LOW - NO 5 VOLTS TO MAP SENSOR



START TEST START ENGINE ANDTC-36A. LET IDLE.

WITH THE DRB, READ IS THE MAP SENSOR YES CONTINUE TEST THE MAP SENSOR VOLTAGE BELOW 1.2 TC-36A ON THE

VOLTAGE. VOLTS? NEXT PAGE.

NO

TURN IGNITION ON. WITH THE DRB, READ IS THE MAP SENSOR YES CONTINUE TEST (ENGINE OFF) THE MAP SENSOR VOLTAGE BELOW 2.35 TC-36A ON THE


NO

WIGGLE THE MAP REPAIR THE HARNESSSENSOR CONNECTOR & MONITOR THE DRB WAS THERE ANY MAP YES OR CONNECTOR THAT

HARNESS. DISPLAY. SENSOR VOLTAGE CAUSED THE VOLTAGECHANGE? TO CHANGE.*


NO



NO


INFORMATION.

TROUBLE

CODE

TESTS

227

TEST TC-36A CONTINUED - REPAIRING - MAP SENSOR VOLTAGE TOO LOW - NO 5 VOLTS TOMAP SENSOR


FIG. 1

BR 8.0L

FIG. 2

ZJ BODY

FIG. 3

TROUBLE

CODE

TESTS

228



TEST TC-36A TURN ENGINE OFF DISCONNECT THE MAPCONTINUED FROM AND IGNITION ON SENSOR ELECTRICAL

THE PREVIOUS (IF ENGINE IS CONNECTOR.** PAGE. RUNNING).


USING A VOLTMETER, MEASURE THE VOLTAGE MAP SENSOR IS THE VOLTAGE NO CONTINUE TEST

OF THE MAP SENSOR CONNECTOR. ABOVE 4.5 VOLTS? TC-36A ON THE5-VOLT SUPPLY NEXT PAGE.

CIRCUIT AT THE... FIG. 1, 2 OR 3

YES

USE THE DRB TO IS THE MAP SENSOR YES REPLACE THE MAPREAD MAP SENSOR VOLTAGE ABOVE 4.5 SENSOR.*

VOLTAGE. VOLTS?

NO

KEY OFF. DISCONNECT THE POWERTRAIN USE AN OHMMETER IN



MEASURE THE THE MAP SENSOR REPAIR MAP SENSOR RESISTANCE BETWEEN GROUND CIRCUIT AT IS THE RESISTANCE YES SIGNAL CIRCUIT

THE MAP SENSOR MAP SENSOR BELOW 5.0 OHMS? SHORTED TO MAPSIGNAL CIRCUIT CONNECTOR. SENSOR GROUND

AND... FIG. 1, 2 OR 3 CIRCUIT.*

NO

USING AN OHMMETER, AT MAP SENSOR REPAIR THE MAPMEASURE THE CONNECTOR TO IS THE RESISTANCE YES SENSOR SIGNAL

RESISTANCE OF THE GROUND. BELOW 5.0 OHMS? CIRCUIT FOR AMAP SENSOR SIGNAL SHORT TO GROUND.*

CIRCUIT... FIG. 1, 2 OR 3

NO


MODULE.*

TROUBLE

CODE

TESTS

229



FIG. 1

BR 8.0L

FIG. 2

ZJ BODY

FIG. 3

TROUBLE

CODE

TESTS

230



TEST TC-36A CONTINUED FROM


DISCONNECT THEPOWERTRAIN CONTROL USE AN OHMMETER IN

MODULE.** THE FOLLOWINGSTEP.


MEASURE THE FROM THE MAP SENSOR RESISTANCE OF THE CONNECTOR TO THE PCM IS THE RESISTANCE NO REPAIR THE OPEN MAP SENSOR 5-VOLT CONNECTOR. BELOW 5.0 OHMS? 5-VOLT SUPPLY SUPPLY CIRCUIT... CIRCUIT.*

FIG. 1, 2 OR 3

YES

MEASURE THE MAP REPAIR THE 5-VOLT SENSOR 5-VOLT SUPPLY IS THE RESISTANCE YES SUPPLY CIRCUIT FOR

WITH AN OHMMETER. CKT FOR RESISTANCE BELOW 5.0 OHMS? A SHORT TO TO GROUND. GROUND.*

FIG. 1, 2 OR 3

NO


MODULE.*

TROUBLE

CODE

TESTS

231

TEST TC-37A REPAIRING - MAP SENSOR VOLTAGE TOO HIGH


ZJ BODY ALL OTHERS

FIG. 1 FIG. 2

TROUBLE

CODE

TESTS

232

TEST TC-37A REPAIRING - MAP SENSOR VOLTAGE TOO HIGH



START TEST TC-37A. START THE ENGINE.

WITH THE DRB, READ IS THE MAP SENSOR YES CONTINUE TEST THE MAP SENSOR VOLTAGE ABOVE 4.6 TC-37A ON THE


NO

WIGGLE MAP SENSOR WAS THERE ANY MAP REPAIR THE HARNESSCONNECTOR & HARNESS. MONITOR THE DRB SENSOR VOLTAGE YES OR CONNECTOR THAT

DISPLAY. CHANGE WHEN CAUSED THE VOLTAGEWIGGLED? CHANGE.*


NO


NOT PRESENT. HARNESS ANDFIG. 1 CONNECTORS.

NO


INFORMATION.

TROUBLE

CODE

TESTS

233

TEST TC-37A CONTINUED - REPAIRING - MAP SENSOR VOLTAGE TOO HIGH


FIG. 1

BR 8.0L

FIG. 2

ZJ BODY

FIG. 3

TROUBLE

CODE

TESTS

234



TEST TC-37A DISCONNECT THE MAPCONTINUED FROM TURN ENGINE OFF SENSOR ELECTRICAL

THE PREVIOUS (IGNITION ON) CONNECTOR.** PAGE.

USING A VOLTMETERIN THE FOLLOWING CIRCUIT AT THE MAP IS THE VOLTAGE YES REPAIR MAP SENSOR

STEP, MEASURE THE SENSOR CONNECTOR. ABOVE 5.5 VOLTS? SIGNAL SHORTED TO VOLTAGE OF THE MAP BATTERY VOLTAGE.

SENSOR SIGNAL... FIG. 1, 2 OR 3

NO

KEY OFF, USING AN REPAIR SHORTED MAPOHMMETER, MEASURE CIRCUIT TO 5-VOLT IS THE RESISTANCE YES SENSOR SIGNAL THE RESISTANCE OF SUPPLY CIRCUIT. BELOW 5.0 OHMS? CIRCUIT SHORTED TO

THE MAP SENSOR 5-VOLTS.*SIGNAL...

NO

CONNECT A JUMPER WIRE BETWEEN THE READ THE MAP IS THE VOLTAGE YES REPLACE THE MAP

SENSOR SIGNAL AND SENSOR VOLTAGE. BELOW 1.0 VOLT? SENSOR.* SENSOR GROUND CKTS.

FIG. 1, 2 OR 3

NO

MOVE THE JUMPER WIRE FROM THE SENSOR READ THE MAP IS THE MAP SENSOR YES REPAIR THE OPEN

GROUND CIRCUIT TO SENSOR VOLTAGE. VOLTAGE BELOW 1.0 MAP SENSOR GROUND ENGINE GROUND. VOLT? CIRCUIT.*FIG. 1, 2 OR 3


NEXT PAGE.


TROUBLE

CODE

TESTS

235



FIG. 1

BR 8.0L

FIG. 2

ZJ BODY

FIG. 3

TROUBLE

CODE

TESTS

236



TEST TC-37A KEY OFF, DISCONNECT CONTINUED FROM THE POWERTRAIN USE AN OHMMETER IN

THE PREVIOUS CONTROL MODULE.** THE FOLLOWINGPAGE. STEP.


MEASURE THE MAP AND THE MAP SENSOR SENSOR SIGNAL CONNECTOR. IS THE RESISTANCE YES REPLACE THE

CIRCUIT BETWEEN BELOW 5.0 OHMS? POWERTRAIN CONTROLTHE PCM MODULE.*

CONNECTOR... FIG. 1, 2 OR 3

NO

REPAIR THE OPEN MAP SENSOR SIGNAL

CIRCUIT.*

TROUBLE

CODE

TESTS

237

TEST TC-39A REPAIRING - NO CHANGE IN MAP FROM START TO RUN


ZJ BODY

ALL OTHERS

FIG. 1

TROUBLE

CODE

TESTS

238

TEST TC-39A REPAIRING - NO CHANGE IN MAP FROM START TO RUN



WITH THE DRB, READ START TEST TURN IGNITION ON. CODES. IS "MAP YES PERFORM TEST

TC-39A. (ENGINE OFF) SENSOR VOLTAGE TOO TC-36A.LOW" CODE SET?

NO

WITH THE DRB, DOES THE DRB SHOW ERASE CODES, START WITH THE DRB, READ "NO CHANGE IN MAP YES CONTINUE TEST ENGINE, AND ALLOW CODES. FROM START TO TC-39A ON NEXT ENGINE TO IDLE FOR RUN"? PAGE.

30 SECONDS.

NO

NOTE: THE ENGINE WITH THE DRB, SETIS STILL RUNNING. THE ENGINE SPEED

TO 1500 RPM.

WITH THE ENGINE WHILE MONITORING REPAIR THE WIRING RPM AT 1500, READ THE VOLTAGE, DID THE ENGINE YES OR CONNECTOR

MAP SENSOR WIGGLE THE WIRING STALL OR VOLTAGE DEFECT BETWEEN THEVOLTAGE. FROM THE MAP BECOME ERRATIC? MAP SENSOR AND THE

SENSOR TO THE PCM. PCM.*

NO

WHILE MONITORING AT THIS TIME, THETHE DRB DISPLAY, DID THE VACUUM YES CONDITION REQUIRED

STOP ACTUATION. SNAP THE THROTTLE DROP RAPIDLY BELOW TO SET THE CODE IS OPEN AND CLOSED. 1.0"? NOT PRESENT.TEST

COMPLETE.* FIG. 1

NO

REMOVE MAP SENSOR ALSO INSPECT IS THERE A REPAIR THEAND INSPECT CONDITON CONDITION OF RESTRICTION OR YES RESTRICTED OR

OF VACUUM PORT. INTAKE MANIFOLD OR DEFECT IN THE DEFECTIVE VACUUM THROTTLE BODY VACUUM PORTS? PORTS.*

SEE GENERAL INFO 4.4 VACUUM PORT.

NO

REPLACE MAPSENSOR.*

TROUBLE

CODE

TESTS

239

TEST TC-39A CONTINUED - REPAIRING - NO CHANGE IN MAP FROM START TO RUN


FIG. 1

BR 8.0L

FIG. 2

ZJ BODY

FIG. 3

TROUBLE

CODE

TESTS

240

TEST TC-39A CONTINUED - REPAIRING - NO CHANGE IN MAP FROM START TO RUN


TEST TC-39A IGNITION KEY ON.CONTINUED FROM (ENGINE OFF) PREVIOUS PAGE.

REMOVE MAP SENSOR ALSO INSPECT REMOVE THEAND INSPECT CONDITON CONDITON OF INTAKE WAS THERE A YES RESTRICTION AND

OF VACUUM PORT. MANIFOLD OR RESTRICTION? REINSTALL THE MAPTHROTTLE BODY SENSOR.*

SEE GENERAL INFO 4.4 VACUUM PORT.

NO

MEASURE THE MAPUSE A VOLTMETER IN SENSOR 5-VOLT IS THE VOLTAGE NO REPAIR THE OPEN

THE FOLLOWING SUPPLY CIRCUIT. ABOVE 4.5 VOLTS? MAP SENSOR 5-VOLT STEP. SUPPLY CIRCUIT.*

FIG. 1, 2 0R 3

YES

REPLACE THE MAPSENSOR.*

TROUBLE

CODE

TESTS

241

TEST TC-40A REPAIRING - NO CRANK REFERENCE SIGNAL AT PCM


5.9L DIESEL

FIG. 1

ALL OTHERS

FIG. 2

TROUBLE

CODE

TESTS

242

TEST TC-40A REPAIRING - NO CRANK REFERENCE SIGNAL AT PCM



WITH THE DRB, READ DOES THE CURRENTSTART TEST THE CURRENT CKP CKP COUNT CHANGE NO CONTINUE TEST

TC-40A COUNT AND ATTEMPT WHILE ATTEMPTING TC-40A ON THETO START THE TO START THE NEXT PAGE.

ENGINE. ENGINE?

YES

AT THIS TIME, THE USING THECONDITION REQUIRED SCHEMATIC AS A WERE ANY PROBLEMS YES REPAIR AS TO SET THE TROUBLE GUIDE, INSPECT THE FOUND? NECESSARY.*

CODE IS NOT PRESENT. WIRING ANDFIG. 1 OR 2 CONNECTORS.

NO

WIGGLE THE WIRING REPAIR CIRCUIT AS HARNESS FROM CKP DID THE ENGINE DIE YES NECESSARY WHERE

SENSOR TO THE OUT WHEN WIGGLING WIGGLING CAUSED POWERTRAIN CONTROL WIRES? THE ENGINE TO DIE

MODULE. OUT.*

NO

REFER TO GENERALINFO 3.3.2 FOR

INACTIVE TROUBLE TEST COMPLETE.* CODE INFORMATION.

TROUBLE

CODE

TESTS

243

TEST TC-40A CONTINUED - REPAIRING - NO CRANK REFERENCE SIGNAL AT PCM


FIG. 1

XJ BODY

FIG. 2

ZJ BODY

FIG. 3


FIG. 4

XJ BODY

FIG. 5

ZJ BODY

FIG. 6

TROUBLE

CODE

TESTS

244



TEST TC-40A KEY OFF, DISCONNECT IS ANY TERMINAL CONTINUED FROM THE CRANKSHAFT CORRODED, DAMAGED, YES REPAIR AS

THE PREVIOUS POSITION SENSOR PUSHED OUT, OR NECESSARY.*PAGE. CONNECTOR.** MISWIRED?


NO

USING A VOLTMETER, MEASURE THE 5-VOLT IS THE VOLTAGE NO CONTINUE TEST

TURN IGNITION ON. SUPPLY CIRCUIT. ABOVE 4.5 VOLTS? TC-40A ON THENEXT PAGE.

FIG. 1, 2 0R 3

YES

TURN IGNITION OFF. FROM THE CKPUSING AN OHMMETER, SENSOR CONNECTOR IS THE RESISTANCE NO REPAIR THE OPEN MEASURE THE SENSOR TO GROUND. BELOW 5.0 OHMS? SENSOR GROUND GROUND CIRCUIT... CIRCUIT.*

FIG. 1, 2 OR 3

YES

DISCONNECT THE PCM IS ANY TERMINAL BLACK CONNECTOR. CORRODED, DAMAGED, YES REPAIR AS

INSPECT ALL PUSHED OUT, OR NECESSARY.*TERMINALS.** MISWIRED?


NO

USING AN OHMMETER, FROM THE PCM TO MEASURE THE THE CKP CONNECTOR. IS THE RESISTANCE NO REPAIR THE OPEN

RESISTANCE OF THE BELOW 5.0 OHMS? CKP SIGNAL CKP SIGNAL CIRCUIT.*CIRCUIT... FIG. 4, 5 OR 6

YES

USING AN OHMMETER, AND GROUND AT THEMEASURE THE PCM CONNECTOR. IS THE RESISTANCE NO REPLACE THE

RESISTANCE BETWEEN BELOW 5.0 OHMS? CRANKSHAFT THE CKP SIGNAL POSITION SENSOR.*


YES

REPAIR THE CKPSIGNAL CIRCUIT FOR

A SHORT TO GROUND.*

TROUBLE

CODE

TESTS

245



FIG. 1

XJ BODY

FIG. 2

ZJ BODY

FIG. 3

TROUBLE

CODE

TESTS

246



TEST TC-40A KEY OFF. DISCONNECT IS ANY TERMINAL CONTINUED FROM THE PCM BLACK CORRODED, DAMAGED, YES REPAIR AS

THE PREVIOUS CONNECTOR. INSPECT PUSHED OUT OR NECESSARY.*PAGE. ALL TERMINALS.** MISWIRED?


NO

USING AN OHMMETER, FROM THE PCM TO MEASURE THE THE CKP SENSOR IS THE RESISTANCE NO REPAIR THE OPEN

RESISTANCE OF THE CONNECTOR. BELOW 5.0 OHMS? 5-VOLT SUPPLY 5-VOLT SUPPLY CIRCUIT.*


YES

FROM THE CKP REPAIR THE 5-VOLT USING AN OHMMETER, SENSOR CONNECTOR IS THE RESISTANCE YES SUPPLY CIRCUIT FORMEASURE THE 5-VOLT TO GROUND. BELOW 5.0 OHMS? A SHORT TO SUPPLY CIRCUIT... GROUND.*

FIG. 1, 2 OR 3

NO


MODULE.*

TROUBLE

CODE

TESTS

247

TEST TC-41A REPAIRING - IGNITION COIL #3 PRIMARY CIRCUIT


FIG. 1 FIG. 2

FIG. 3 FIG. 4

TROUBLE

CODE

TESTS

248




START TEST TC-41A TURN IGNITION OFF.

DISCONNECT THE CONNECT CABLE TO ASPARK PLUG CABLE SPARK PLUG TESTER.

AT SPARK PLUG #8.

FIG. 1 FIG. 2

CONNECT THE SPARKPLUG TESTER TO A

GOOD GROUND.

TURN IGNITION ON. WITH THE DRB, IS THERE GOOD NO CONTINUE TEST (ENGINE OFF) ACTUATE IGNITION SPARK? TC-41A ON THE

COIL #3. NEXT PAGE.

YES



NO

WIGGLE WIRING REPAIR AS HARNESS FROM THE DOES THE SPARK YES NECESSARY WHERE

REAR COIL PACK TO BECOME ERRATIC OR WIGGLING CAUSED THE POWERTRAIN STOP? PROBLEM TO

CONTROL MODULE. APPEAR.*

NO


INFORMATION.

TROUBLE

CODE

TESTS

249

TEST TC-41A CONTINUED - REPAIRING - IGNITION COIL #3 PRIMARY CIRCUIT

FIG. 1

FIG. 2

FIG. 3

TROUBLE

CODE

TESTS

250



TEST TC-41A KEY OFF, DISCONNECT IS ANY TERMINAL CONTINUED FROM THE REAR IGNITION DAMAGED, PUSHED YES REPAIR AS

THE PREVIOUS COIL CONNECTOR.** OUT OR MISWIRED? NECESSARY.*PAGE.

SEE GENERAL INF0 4.0 FIG. 1

NO

USING A VOLTMETER, KEY ON, WITH THE MEASURE THE ASD IS THE VOLTAGE NO REPAIR THE OPEN

DRB, ACTUATE RELAY OUTPUT. ABOVE 10.0 VOLTS? ASD RELAY OUTPUT IGNITION COIL #3. CIRCUIT.*

FIG. 1

YES

KEY OFF, DISCONNECT USING AN OHMMETER, REPAIR THETHE POWERTRAIN MEASURE THE IGNITION IS THE RESISTANCE YES IGNITION COIL #3

CONTROL MODULE.** COIL #3 PRIMARY BELOW 5.0 OHMS? DRIVER CIRCUIT FORCIRCUIT TO GROUND. A SHORT TO

SEE GENERAL INFO 4.1 FIG. 2 GROUND.*

NO

MEASURE THEUSE AN OHMMETER IN IGNITION COIL #3

THE FOLLOWING DRIVER CIRCUITSTEP. FROM THE PCM

CONNECTOR...

TO THE REAR IGNITION COIL CONNECTOR. IS THE RESISTANCE NO REPAIR THE OPEN

BELOW 5.0 OHMS? IGNITION COIL #3 DRIVER CIRCUIT.*

FIG. 2

YES

MEASURE THEUSE AN OHMMETER IN IGNITION COIL #3 IS THE RESISTANCE NO REPLACE THE REAR

THE FOLLOWING PRIMARY CIRCUIT BELOW 2.0 OHMS? IGNITION COIL.* STEP. FOR RESISTANCE.

FIG. 3

YES


MODULE.*

TROUBLE

CODE

TESTS

251



FIG. 1 FIG. 2

FIG. 3 FIG. 4

TROUBLE

CODE

TESTS

252





DISCONNECT THE CONNECT CABLE TO ASPARK PLUG CABLE SPARK TESTER. CONNECT SPARK

AT SPARK PLUG #5. TESTER TO A GOOD GROUND.

FIG. 1 FIG. 2


COIL #2. NEXT PAGE.

YES



NO


REAR COIL PACK TO BECOME ERRATIC OR WIGGLING CAUSED THE POWERTRAIN STOP? PROBLEM TO


NO


INFORMATION.

TROUBLE

CODE

TESTS

253


FIG. 1

FIG. 2

FIG. 3

TROUBLE

CODE

TESTS

254



TEST TC-42A KEY OFF, DISCONNECT IS ANY TERMINAL CONTINUED FROM THE REAR IGNITION DAMAGED, PUSHED YES REPAIR AS



NO



FIG. 1

YES




NO



CONNECTOR...

TO THE REAR IGNITION COIL CONNECTOR. IS THE RESISTANCE NO REPAIR THE OPEN

BELOW 5.0 OHMS? IGNITION COIL #2 DRIVER CIRCUIT.*

FIG. 2

YES

MEASURE THEUSE AN OHMMETER IN IGNITION COIL #2 IS THE RESISTANCE NO REPLACE THE REAR


FIG. 3

YES


MODULE.*

TROUBLE

CODE

TESTS

255



FIG.1 FIG. 2

FIG. 3 FIG. 4

TROUBLE

CODE

TESTS

256




START TEST DOES THE VEHICLE NO PREFORM TEST TC-43A HAVE A V-10 TC-43B.

ENGINE?

YES

KEY OFF. DISCONNECT CONNECT CABLE TO THE SPARK PLUG CABLE SPARK TESTER. CONNECT SPARK


FIG. 1 FIG. 2

TURN IGNITION ON. WITH THE DRB IS THERE GOOD NO CONTINUE TEST (ENGINE OFF) ACTUATE IGNITION SPARK? TC-43A ON THE

COIL #1. NEXT PAGE.

YES



NO


FRONT COIL PACK TO BECOME ERRATIC OR WIGGLING CAUSED THE POWERTRAIN STOP? PROBLEM TO


NO


INFORMATION.

TROUBLE

CODE

TESTS

257


FIG. 1

FIG. 2

FIG. 3

TROUBLE

CODE

TESTS

258



TEST TC-43A KEY OFF, DISCONNECT IS ANY TERMINAL CONTINUED FROM THE FRONT IGNITION DAMAGED, PUSHED YES REPAIR AS



NO



FIG. 1

YES




NO



CONNECTOR...

TO THE FRONTIGNITION COIL IS THE RESISTANCE NO REPAIR THE OPEN

CONNECTOR. BELOW 5.0 OHMS? IGNITION COIL #1 DRIVER CIRCUIT.*

FIG. 2

YES

MEASURE THEUSE AN OHMMETER IN IGNITION COIL #1 IS THE RESISTANCE NO REPLACE THE FRONT


FIG. 3

YES


MODULE.*

TROUBLE

CODE

TESTS

259

TEST TC-43B REPAIRING - IGNITION COIL #1 PRIMARY CIRCUIT


BR BODY

FIG. 1


FIG. 2

ZJ BODY

FIG. 3 FIG. 4

TROUBLE

CODE

TESTS

260

TEST TC-43B REPAIRING - IGNITION COIL #1 PRIMARY CIRCUIT



KEY OFF, DISCONNECT START TEST THE IGNITION COIL IS ANY TERMINAL YES REPAIR AS

TC-43B. CONNECTOR.** DAMAGED, PUSHED NECESSARY.*OUT OR MISWIRED?


NO

WITH A VOLTMETER, KEY ON, WITH THE MEASURE THE ASD IS THE VOLTAGE NO REPAIR THE OPEN

DRB, ACTUATE OUTPUT CIRCUIT. ABOVE 10.0 VOLTS? ASD OUTPUT IGNITION COIL #1. CIRCUIT.*

FIG. 1, 2 OR 3

YES

TEST THE IGNITION USE AN OHMMETER IN COIL PRIMARY IS THE RESISTANCE NO REPLACE THE

THE FOLLOWING CIRCUIT FOR BELOW 2.0 OHMS? IGNITION COIL.* STEPS. RESISTANCE.

FIG. 4

YES

KEY OFF, DISCONNECT MEASURE THE REPAIR THETHE POWERTRAIN RESISTANCE OF THE IS THE RESISTANCE YES IGNITION COIL

CONTROL MODULE.** IGNITION COIL BELOW 5.0 OHMS?DRIVER CKT TO GND.


NO


NEXT PAGE.

#1 DRIVER CIRCUIT FOR

A SHORT TO GROUND.*

TROUBLE

CODE

TESTS

261

TEST TC-43B CONTINUED - REPAIRING - IGNITION COIL #1 PRIMARY CIRCUIT

AB AND AN BODIES

FIG. 1

BR BODY

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

262

TEST TC-43B CONTINUED - REPAIRING - IGNITION COIL #1 PRIMARY CIRCUIT


TEST TC-43B CONTINUED FROM USE AN OHMMETER IN

THE PREVIOUS THE FOLLOWINGPAGE. STEP.

TEST THE IGNITION COIL #1 DRIVER IS THE RESISTANCE NO REPAIR THE OPEN

CIRCUIT FOR BELOW 5.0 OHMS? IGNITION COIL #1 RESISTANCE. DRIVER CIRCUIT.*

FIG. 1, 2, 3 OR 4.

YES


MODULE.*

TROUBLE

CODE

TESTS

263

TEST TC-44A REPAIRING - NO ASD RELAY OUTPUT VOLTAGE AT PCM


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

264

TEST TC-44A REPAIRING - NO ASD RELAY OUTPUT VOLTAGE AT PCM



IS A TROUBLE CODE START TEST ALSO SET FOR "AUTO YES PERFORM TEST

TC-44A. SHUTDOWN RELAY TC-10A.CONTROL CIRCUIT"?

NO

START ENGINE, DOES THE DRB SHOW WITH THE DRB, ALLOW ENGINE TO "NO ASD RELAY OUTPUT YES CONTINUE TEST

ERASE CODES. IDLE FOR AT LEAST VOLTAGE AT PCM" WITH TC-44A ON THE10 SECONDS. A START/RUN COUNT OF NEXT PAGE.

RE-READ CODES. ZERO?

NO


FIG. 1 CONNECTORS.

NO

WIGGLE WIRING REPAIR AS NECESSARYERASE FAULT CODES. HARNESS FROM ASD DID WIGGLING CAUSE YES WHERE WIGGLING

START ENGINE AND RELAY TO THE PCM. THE FAULT CODE TO CAUSED THE FAULTLET IDLE. RE-CHECK FAULT APPEAR? CODE TO APPEAR.*

CODES.

NO



TROUBLE

CODE

TESTS

265

TEST TC-44A CONTINUED - REPAIRING - NO ASD RELAY OUTPUT VOLTAGE AT PCM

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5

TROUBLE

CODE

TESTS

266



TEST TC-44A CONTINUED FROM IS THE VEHICLE YES PERFORM TEST

THE PREVIOUS EQUIPPED WITH A TC-44B PAGE. DIESEL ENGINE?

NO

ATTEMPT TO START DID THE ENGINE YES CONTINUE TEST THE VEHICLE. START? TC-44A ON THE

NEXT PAGE.

NO

DISCONNECT THE AUTO USING A VOLTMETER, SHUTDOWN RELAY.** MEASURE THE FUSED IS THE VOLTAGE NO REPAIR THE OPEN

B(+) CIRCUIT. ABOVE 10.0 VOLTS? FUSED B(+) CIRCUIT.*


YES

INSTALL ASUBSTITUTE RELAY ATTEMPT TO START DID THE ENGINE YES REPLACE THE

FOR THE AUTO THE VEHICLE. START? ORIGINAL AUTO SHUTDOWN RELAY. SHUTDOWN RELAY.*

NO

IGNITION OFF. USING AN OHMMETER,DISCONNECT THE MEASURE THE

POWERTRAIN CONTROL RESISTANCE OF THEMODULE GREY CONN.** ASD RELAY OUTPUT SEE GENERAL INFO 4.1 CIRCUIT...

FROM THE RELAY TO THE PCM. IS THE RESISTANCE YES REPAIR OPEN ASD

ABOVE 5.0 OHMS? RELAY OUTPUT CIRCUIT.*

FIG. 1, 2, 3, 4 OR 5

NO


MODULE.*

TROUBLE

CODE

TESTS

267


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5

TROUBLE

CODE

TESTS

268



TEST TC-44A IGNITION OFF. CONTINUED FROM DISCONNECT THE

THE PREVIOUS POWERTRAIN CONTROLPAGE. MODULE GREY CONN.**


DISCONNECT THE AUTO USING AN OHMMETER,SHUTDOWN RELAY.** MEASURE THE ASD

RELAY OUTPUT CIRCUIT...


FROM THE RELAY TO THE PCM. IS THE RESISTANCE YES REPAIR OPEN ASD


FIG. 1, 2, 3, 4 OR 5

NO


MODULE.*

TROUBLE

CODE

TESTS

269

TEST TC-44B REPAIRING - NO ASD RELAY OUTPUT VOLTAGE AT PCM


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

270

TEST TC-44B REPAIRING - NO ASD RELAY OUTPUT VOLTAGE AT PCM



DISCONNECT THE AUTO START TEST SHUTDOWN RELAY.**

TC-44B.

FIG.1

USING A VOLTMETER, MEASURE THE FUSED IS THE VOLTAGE NO REPAIR THE OPEN

B(+) CIRCUIT. ABOVE 10.0 VOLTS? FUSED B(+) CIRCUIT.*

FIG. 1

YES

ERASE FAULT CODES. DID THE FAULT CODE INSTALL A START ENGINE. LET "NO ASD RELAY NO REPLACE THE

SUBSTITUTE RELAY IDLE FOR AT LEAST OUTPUT VOLTAGE AT ORIGINAL AUTO FOR THE AUTO 10 SECONDS. PCM" RETURN? SHUTDOWN RELAY.*

SHUTDOWN RELAY.

YES

IGNITION OFF. USING AN OHMMETER,DISCONNECT THE MEASURE THE ASD

POWERTRAIN CONTROL RELAY OUTPUT MODULE GREY CONN.** CIRCUIT... SEE GENERAL INFO 4.1

FROM THE PCM TO THE RELAY. IS THE RESISTANCE YES REPAIR OPEN ASD


FIG. 2

NO


MODULE.*

TROUBLE

CODE

TESTS

271

TEST TC-48A REPAIRING - PCM FAILURE SRI MILE NOT STORED



START TEST WITH THE DRB DOES THE DRB YES REPLACE THETC-48A. PERFORM THE SRI DISPLAY "WRITE POWERTRAIN CONTROL

MEMORY TEST. FAILURE"? MODULE.*

NO

WITH THE DRB, NO DOES THE DRB YES PERFORM THE SRI

DISPLAY "WRITE MEMORY TEST AREFUSED"? SECOND TIME.

DOES THE DRB YES REPLACE THEDISPLAY "WRITE POWERTRAIN CONTROL

REFUSED" AGAIN? MODULE.*

NO

DOES THE DRB YES UPDATE THE MILEAGEDISPLAY "SRI AND RETEST THE SRI

MILEAGE INVALID"? MEMORY.*

NO

COMPARE SRIMILEAGE STORED IS THE MILEAGE YES RETEST THE SRI

VALUE TO THE WITHIN THE DRB MEMORY.* INSTRUMENT PANEL SPECIFED RANGE?

ODOMETER MILEAGE.

NO

UPDATE THE MILEAGEAND RETEST THE SRI

MEMORY.*

TROUBLE

CODE

TESTS

272

TEST TC-49A REPAIRING - EEPROM WRITE DENIED



START TEST WITH THE DRB, DOES THE DRB NO TC-49A. PERFORM THE SRI DISPLAY "WRITE TEST COMPLETE.*

MEMORY TEST. REFUSED"?

YES

WITH THE DRB, PERFORM THE SRI DOES THE DRB YES REPLACE THE

MEMORY TEST A DISPLAY "WRITE POWERTRAIN CONTROLSECOND TIME. REFUSED" AGAIN? MODULE.*

NO

TEST COMPLETE.*

TROUBLE

CODE

TESTS

273

TEST TC-50A REPAIRING - TRANS 3-4 SOLENOID/TRANS RELAY CKTS


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

274

TEST TC-50A REPAIRING - TRANS 3-4 SOLENOID/TRANS RELAY CKTS



IS THE TRANSSTART TEST 12-VOLT SUPPLY YES PERFORM TEST

TC-50A. RELAY CONTROL TC-173.CIRCUIT CODE SET?

NO

ROAD TEST VEHICLE. PUSH OD SWITCH 4ATTAIN VEHICLE TIMES SUCH THAT DID THE VEHICLE NO CONTINUE TEST

SPEED OF AT LEAST VEHICLE ATTEMPTS SHIFT BETWEEN 3RD TC-50A ON THE50 MPH. TO SHIFT FROM 4TH AND 4TH? NEXT PAGE.

TO 3RD AND BACK.

YES

AT THIS TIME THE USING THECONDITION REQUIRED SCHEMATIC AS A WERE ANY PROBLEMS YES REPAIR AS


FIG. 1 CONNECTORS.

NO

WITH DRB, CLEAR WHILE READING DTC’S DOES THE 3-4CODES. WITH THE DRB, WIGGLE SOLENOID CONTROL YES REPAIR WIRING AS

THE WIRING HARNESS CIRCUIT FAULT CODE NECESSARY.*START THE ENGINE. FROM THE SOLENOID TO APPEAR?

THE PCM.

NO


INFORMATION.

TROUBLE

CODE

TESTS

275

TEST TC-50A CONTINUED - TRANS 3-4 SOLENOID/TRANS RELAY CKTS

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

276






MEASURE THE DOES THE VOLTAGEKEY ON, WITH THE VOLTAGE AT THE FLUCTUATE FROM 0 NO PERFORM TEST

DRB, ACTUATE TRANS TRANS RELAY OUTPUT VOLTS TO OVER 10.0 TC-50B.CONTROL RELAY. CIRCUIT. VOLTS?

FIG. 1, 2, 3 OR 4

YES

KEY OFF. KEY ON. MEASUREDISCONNECT THE THE VOLTAGE AT THE IS THE VOLTAGE YES PERFORM TEST

POWERTRAIN CONTROL 3-4 SHIFT SOLENOID ABOVE 10.0 VOLTS? TC-50D.MODULE WHITE CONTROL CIRCUIT. CONNECTOR.** FIG. 1, 2, 3 OR 4

NO


NEXT PAGE.

TROUBLE

CODE

TESTS

277


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

278



TEST TC-50A KEY OFF. MEASURECONTINUED FROM THE RESISTANCE

THE PREVIOUS BETWEEN THE 3-4PAGE. SHIFT SOLENOID

CONTROL CIRCUIT...

AT THE PCM REPAIR THE 3-4CONNECTOR AND IS THE RESISTANCE YES SHIFT SOLENOID

GROUND. BELOW 5.0 OHMS? CONTROL CIRCUITSHORTED TO

FIG. 1,2,3 OR 4 GROUND.*

NO

RECONNECT THESOLENOID PACK

CONNECTOR.

MEASURE THE AT THE PCMRESISTANCE BETWEEN CONNECTOR AND IS THE RESISTANCE YES RELACE THE

THE 3-4 SHIFT GROUND. BELOW 5.0 OHMS? SOLENOID ANDSOLENOID CONTROL HARNESS ASSEMBLY.*

CIRCUIT... FIG. 1,2,3 OR 4

NO


NEXT PAGE.

TROUBLE

CODE

TESTS

279


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

280




THE PREVIOUS PAGE.


MEASURE THE AND THE 3-4RESISTANCE BETWEEN SOLENOID CONTROL IS THE RESISTANCE YESTHE TRANS CONTROL CIRCUIT AT THE PCM BETWEEN 26.0 AND REPLACE THE PCM.*

RELAY OUTPUT CIRCUIT CONNECTOR. 40.0 OHMS?AT THE RELAY... FIG. 1,2,3 OR 4

NO


YES


NEXT PAGE.

TROUBLE

CODE

TESTS

281


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

282






MEASURE THE FROM THE PCMRESISTANCE OF THE CONNECTOR TO THE IS THE RESISTANCE NO REPAIR THE OPEN

3-4 SOLENOID SOLENOID BELOW 5.0 OHMS? 3-4 SOLENOID CONTROL CIRCUIT... CONNECTOR. CONTROL CIRCUIT.*

FIG. 1, 2, 3 OR 4

YES

REPLACE THESOLENOID AND

HARNESS ASSEMBLY.*

TROUBLE

CODE

TESTS

283

TEST TC-50B REPAIRING - TRANS 3-4 SOLENOID/TRANS RELAY CKTS


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

284

TEST TC-50B REPAIRING - TRANS 3-4 SOLENOID/TRANS RELAY CKTS




TC-50B.


TRANS CONTROL RELAY REPAIR THE TRANSKEY OFF. MEASURE OUTPUT CIRCUIT AND IS THE RESISTANCE YES RELAY OUTPUT

THE RESISTANCE GROUND. BELOW 5.0 OHMS? CIRCUIT SHORTED TO BETWEEN THE... GROUND.*

FIG. 1, 2, 3 OR 4

NO

MEASURE THE FROM THE RELAYRESISTANCE OF THE CONNECTOR TO THE IS THE RESISTANCE YES REPAIR THE OPEN

TRANS CONTROL SOLENOID ABOVE 5.0 OHMS? TRANS RELAY OUTPUT RELAY OUTPUT CONNECTOR. CIRCUIT.*


NO

KEY ON, MEASURE THE REPAIR THE OPEN VOLTAGE AT THE FUSED IS VOLTAGE ABOVE NO FUSED B(+) FEED TO B(+) CIRCUIT IN THE 10.0 VOLTS? THE TRANS CONTROL

RELAY CONNECTOR. RELAY.*FIG. 1, 2, 3 OR 4

YES


TROUBLE

CODE

TESTS

285

TEST TC-50C CONTINUED - TRANS 3-4 SOLENOID/TRANS RELAY CKTS


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

286

TEST TC-50C CONTINUED - TRANS 3-4 SOLENOID/TRANS RELAY CKTS



DISCONNECT THE TRANS DISCONNECT ALL PCMSTART TEST SOLENOID CONNECTORS.**



MEASURE AND RECORD AND ALL OTHER IS THE RESISTANCE REPAIR 3-4 SOLENOID THE RESISTANCES CIRCUITS IN THE BELOW 5.0 OHMS YES CONTROL CKT SHORTEDBETWEEN THE 3-4 SOLENOID BETWEEN ANY TWO TO CIRCUIT(S) THAT

SHIFT SOLENOID CONNECTOR. CIRCUITS? MEASURED BELOW 5.0CONTROL CIRCUIT... FIG. 1, 2, 3 OR 4 OHMS.

NO

REPLACE THE SOLENOID HARNESS INSIDE THE CONNECT ALL

TRANSMISSION AND THE DISCONNECTED SOLENOID PACK.* CONNECTORS.

ROAD TEST VEHICLE. PUSH OD SWITCH 4ATTAIN VEHICLE TIMES SUCH THAT DID THE VEHICLE NO

SPEED OF AT LEAST VEHICLE ATTEMPTS SHIFT BETWEEN 3RD REPLACE THE PCM.*50 MPH. TO SHIFT FROM 4TH AND 4TH?

TO THIRD AND BACK.

YES

TEST COMPLETE.

TROUBLE

CODE

TESTS

287

TEST TC-50D REPAIRING - TRANS 3-4 SOLENOID/TRANS RELAY CKTS


NOTES

TROUBLE

CODE

TESTS

288

TEST TC-50D REPAIRING - TRANS 3-4 SOLENOID/TRANS RELAY CKTS



REPAIR 3-4START TEST SOLENOID CONTROL

TC-50D. CIRCUIT SHORTED TO VOLTAGE.*

CONNECT ALLDISCONNECTED CONNECTORS.

ROAD TEST VEHICLE. PUSH OD SWITCH 4ATTAIN VEHICLE TIMES SUCH THAT DID THE VEHICLE NO

SPEED OF AT LEAST VEHICLE ATTEMPTS SHIFT BETWEEN 3RD REPLACE THE PCM.*50 MPH. TO SHIFT FROM 4TH AND 4TH?

TO 3RD AND BACK.

YES

TEST COMPLETE.

TROUBLE

CODE

TESTS

289



FIG. 1

BR BODY

FIG. 2

BR BODY

FIG. 3

BR BODY

FIG. 4

TROUBLE

CODE

TESTS

290





TC-55A CONNECTOR.**




FIG. 1

YES



FIG. 2

YES

KEY OFF, DISCONNECT USING AN OHMMETER, REPAIR THETHE POWERTRAIN MEASURE THE INJECTOR IS THE RESISTANCE YES INJECTOR #9 DRIVER

CONTROL MODULE.** #9 DRIVER CIRCUIT IN BELOW 5.0 OHMS? CIRCUIT FOR ATHE PCM TO GROUND. SHORT TO GROUND.*


NO

USING AN OHMMETER, FROM THEMEASURE ACROSS THE POWERTRAIN CONTROL IS THE RESISTANCE NO REPAIR THE OPEN INJECTOR #9 DRIVER MODULE CONNECTOR BELOW 5.0 OHMS? INJECTOR #9 DRIVER

CIRCUIT... TO THE INJECTOR CIRCUIT.*FIG. 4 CONNECTOR.

YES


MODULE.*

TROUBLE

CODE

TESTS

291



FIG. 1

BR BODY

FIG. 2

BR BODY

FIG. 3

BR BODY

FIG. 4

TROUBLE

CODE

TESTS

292




NOTE: ON SOME START TEST ENGINES, IT MAY BE

TC-56A NECESSARY TO REMOVE THE INTAKE PLENUM.

SEE SERVICE MANUAL.




YES



FIG. 2

YES

KEY OFF, DISCONNECT USING AN OHMMETER, REPAIR THETHE POWERTRAIN MEASURE THE INJECTOR IS THE RESISTANCE YES INJECTOR #10

CONTROL MODULE.** #10 DRIVER CKT IN BELOW 5.0 OHMS? DRIVER CIRCUIT FORTHE PCM TO GROUND. A SHORT TO


NO

USING AN OHMMETER, FROM THEMEASURE ACROSS THE POWERTRAIN CONTROL IS THE RESISTANCE NO REPAIR THE OPEN

INJECTOR #10 MODULE CONNECTOR BELOW 5.0 OHMS? INJECTOR #10DRIVER CIRCUIT. TO THE INJECTOR DRIVER CIRCUIT.*

FIG. 4 CONNECTOR.

YES


MODULE.*

TROUBLE

CODE

TESTS

293

TEST TC-57A REPAIRING - INTAKE AIR TEMP SENSOR VOLTAGE LOW


CNG AND GAS ENGINES

FIG. 1

DIESEL ENGINES

FIG. 2 FIG. 3

TROUBLE

CODE

TESTS

294

TEST TC-57A REPAIRING - INTAKE AIR TEMP SENSOR VOLTAGE LOW



WITH THE DRB, READ IS THE INTAKE AIRSTART TEST THE INTAKE AIR TEMPERATURE SENSOR YES CONTINUE TEST

TC-57A. TEMPERATURE SENSOR VOLTAGE BELOW 0.5 TC-57A ON THEVOLTAGE. VOLT? NEXT PAGE.

NO

WIGGLE THE INTAKE WAS THERE ANY REPAIR THE HARNESSAIR TEMP SENSOR MONITOR THE DRB INTAKE AIR YES OR CONNECTOR THAT

CONNECTOR & DISPLAY. TEMPERATURE SENSOR CAUSED THE VOLTAGEHARNESS. VOLTAGE CHANGE? CHANGE.*

NO



NO


INFORMATION.

TROUBLE

CODE

TESTS

295

TEST TC-57A CONTINUED - REPAIRING - INTAKE AIR TEMP SENSOR VOLTAGE LOW


FIG. 1

XJ BODY

FIG. 2

ZJ BODY

FIG. 3

TROUBLE

CODE

TESTS

296

TEST TC-57A CONTINUED - REPAIRING - INTAKE AIR TEMP SENSOR VOLTAGE LOW


TEST TC-57A DISCONNECT THECONTINUED FROM INTAKE AIR

THE PREVIOUS TEMPERATUREPAGE. SENSOR.**


WITH THE DRB, READ IS THE INTAKE AIRTHE INTAKE AIR TEMPERATURE SENSOR YES REPLACE THE INTAKE

TEMPERATURE SENSOR VOLTAGE ABOVE 4.0 AIR TEMPERATUREVOLTAGE. VOLTS? SENSOR.*

NO




MEASURE THE REPAIR THE SENSOR RESISTANCE BETWEEN IS THE RESISTANCE YES SIGNAL CIRCUIT FORTHE SENSOR SIGNAL BELOW 5.0 OHMS? A SHORT TO SENSOR

AND SENSOR GND CKT. GROUND.* FIG. 1, 2 OR 3

NO

USING AN OHMMETER, REPAIR THE SENSOR MEASURE THE SIGNAL CIRCUIT TO IS THE RESISTANCE YES SIGNAL CIRCUIT FOR

RESISTANCE OF THE GROUND. BELOW 5.0 OHMS? A SHORT TO IAT SENSOR... GROUND.*

FIG. 1,2 OR 3

NO


MODULE.*

TROUBLE

CODE

TESTS

297

TEST TC-58A REPAIRING - INTAKE AIR TEMP SENSOR VOLTAGE HIGH


CNG AND GAS ENGINES

FIG. 1

DIESEL ENGINES

FIG. 2 FIG. 3

TROUBLE

CODE

TESTS

298

TEST TC-58A REPAIRING - INTAKE AIR TEMP SENSOR VOLTAGE HIGH



WITH THE DRB, READ IS THE INTAKE AIRSTART TEST THE INTAKE AIR TEMPERATURE SENSOR YES CONTINUE TEST

TC-58A. TEMPERATURE SENSOR VOLTAGE ABOVE 4.5 TC-58A ON THEVOLTAGE. VOLTS? NEXT PAGE.

NO

WIGGLE THE INTAKE WAS THERE ANY REPAIR THE HARNESSAIR TEMP SENSOR MONITOR DRB INTAKE AIR YES OR CONNECTOR THAT

CONNECTOR & DISPLAY. TEMPERATURE SENSOR CAUSED THE VOLTAGEHARNESS. VOLTAGE CHANGE? CHANGE.*

NO



NO


INFORMATION.

TROUBLE

CODE

TESTS

299

TEST TC-58A CONTINUED - REPAIRING - INTAKE AIR TEMP SENSOR VOLTAGE HIGH


FIG. 1

XJ BODY

FIG. 2

ZJ BODY

FIG. 3


FIG. 4

XJ BODY

FIG. 5

ZJ BODY

FIG. 6

TROUBLE

CODE

TESTS

300

TEST TC-58A CONTINUED - REPAIRING - INTAKE AIR TEMP SENSOR VOLTAGE HIGH


TEST TC-58A DISCONNECT THECONTINUED FROM INTAKE AIR

THE PREVIOUS TEMPERATURE (IAT)PAGE. SENSOR.**


USING A VOLTMETER, MEASURE THE IS THE VOLTAGE YES REPAIR IAT SIGNAL

VOLTAGE OF THE IAT ABOVE 6.0 VOLT? CIRCUIT SHORTED TO SIGNAL CIRCUIT. VOLTAGE.*

FIG. 1, 2 OR 3

NO

CONNECT A JUMPER WITH THE DRB, READ WIRE ACROSS THE IAT THE INTAKE AIR IS THE VOLTAGE YES REPLACE THE INTAKE

SIGNAL AND SENSOR TEMPERATURE SENSOR BELOW 1.0 VOLT? AIR TEMPERATUREGROUND CIRCUITS. VOLTAGE. SENSOR.*

FIG. 1, 2 OR 3

NO

MOVE THE JUMPER WIRE FROM THE READ THE INTAKE IS THE VOLTAGE YES REPAIR THE OPEN

SENSOR GROUND TO AIR TEMPERATURE BELOW 1.0 VOLT? SENSOR GROUND AN ENGINE GROUND. SENSOR VOLTAGE. CIRCUIT.*

FIG. 1, 2 OR 3

NO

KEY OFF. DISCONNECT THE POWERTRAIN

CONTROL MODULE.**


USING AN OHMMETER, FROM THE PCM TO MEASURE THE IAT THE INTAKE AIR IS THE RESISTANCE YES REPLACE THE

SENSOR SIGNAL FOR TEMPERATURE SENSOR BELOW 5.O OHMS? POWERTRAIN CONTROLRESISTANCE... CONNECTOR. MODULE.*

FIG. 4, 5 OR 6

NO

REPAIR THE OPEN INTAKE AIR

TEMPERATURE SENSOR SIGNAL CIRCUIT.*

TROUBLE

CODE

TESTS

301



FIG. 1


FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

302






NO

NOTE: ON SOME KEY OFF, DISCONNECT ENGINES, IT MAY BE THE INJECTOR #4

NECESSARY TO REMOVE CONNECTOR.** THE INTAKE PLENUM.

SEE SERVICE MANUAL. SEE GENERAL INFO 4.2

USING AN OHMMETER,MEASURE RESISTANCE IS THE RESISTANCE NO REPLACE THE FUEL

OF INJECTOR #4. BETWEEN 10.0 AND INJECTOR.* 16.0 OHMS?

FIG. 1

YES



FIG. 2, 3 OR 4

YES


NEXT PAGE.

TROUBLE

CODE

TESTS

303


FIG. 1


FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

304








NO



YES


MODULE.*

TROUBLE

CODE

TESTS

305



FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

306





TC-61B CONNECTOR.**




FIG. 1

YES



FIG. 2

YES


NEXT PAGE.

TROUBLE

CODE

TESTS

307


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

308








NO



YES


MODULE.*

TROUBLE

CODE

TESTS

309

TEST TC-62A REPAIRING - 1/1 O2 SENSOR SHORTED TO VOLTAGE


FIG. 1

5.9L HD AND 8.0L BR ALL OTHERS

TROUBLE

CODE

TESTS

310




WARM UP ENGINE TO START TEST ABOVE 180F, WAIT

TC-62A. 4 MINUTES, LEAVEENGINE RUNNING.

WITH THE DRB, READ IS THE 1/1 O2 YES CONTINUE TEST THE 1/1 O2 SENSOR SENSOR VOLTAGE TC-62A ON THE

VOLTAGE. ABOVE 1.5 VOLTS? NEXT PAGE.

NO

WIGGLE THE 1/1 O2 DID THE 1/1 O2 REPAIR THE HARNESSSENSOR CONNECTOR AND WHILE WIGGLING THE SENSOR VOLTAGE GO YES OR CONNECTOR THAT

HARNESS. HARNESS, WATCH THE ABOVE 1.5 VOLTS AT HAS THE INTERMITTENT DRB DISPLAY. ANY TIME? SHORT TO VOLTAGE.*


NO

AT THIS TIME, THE USING THE SCHEMATICCONDITION REQUIRED AS A GUIDE, INSPECT WERE THERE ANY YES REPAIR AS TO SET THE TROUBLE THE WIRING AND PROBLEMS FOUND? NECESSARY.*

CODE IS NOT PRESENT. CONNECTORS.FIG. 1

NO

TEST COMPLETE.*

TROUBLE

CODE

TESTS

311

TEST TC-62A CONTINUED - REPAIRING - 1/1 O2 SENSOR SHORTED TO VOLTAGE

AB BODY

FIG. 1

AN BODY

FIG. 2

5.9L HD AND 8.0L

FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5

ALL OTHERS

FIG. 6

TROUBLE

CODE

TESTS

312



TEST TC-62A DISCONNECT THE 1/1 IS THE TERMINAL CONTINUED FROM O2 SENSOR.** CORRODED, DAMAGED, YES REPAIR OR REPLACE

THE PREVIOUS PUSHED OUT OR AS NECESSARY.*PAGE. MISWIRED?


NO

WITH THE DRB, READ IS THE VOLTAGE NO REPLACE THE 1/1 O2 THE 1/1 O2 SENSOR ABOVE 4.97 VOLTS? SENSOR.*

VOLTAGE.

YES

KEY OFF. DISCONNECT IS ANY TERMINAL THE POWERTRAIN CORRODED, DAMAGED, YES REPAIR OR REPLACECONTROL MODULE PUSHED OUT OR AS NECESSARY.*CONNECTORS.** MISWIRED?


NO

TURN IGNITION ON. MEASURE THE 1/1 02 REPAIR THE 1/1 O2 USE A VOLTMETER IN SENSOR SIGNAL IS THE VOLTAGE YES SENSOR SIGNAL

THE FOLLOWING CIRCUIT AT THE PCM ABOVE 5.0 VOLTS? CIRCUIT FOR ASTEP. CONNECTOR. SHORT TO VOLTAGE.*

FIG. 1,2,3,4,5 OR 6

NO

WIGGLE THE O2 SENSOR DID THE VOLTAGEHARNESS WHILE CHANGE WHILE NO REPLACE THE

CHECKING FOR VOLTAGE WIGGLING THE POWERTRAIN CONTROLIN THE O2 SENSOR HARNESS? MODULE.* SIGNAL CIRCUIT.

YES

REPAIR THE 1/1 O2 SENSOR SIGNAL CIRCUIT FOR A

SHORT TO VOLTAGE.*

TROUBLE

CODE

TESTS

313



FIG. 1

8.0L MD CAL ALL OTHERS

TROUBLE

CODE

TESTS

314








NO


HARNESS. HARNESS, WATCH THE ABOVE 1.5 VOLTS AT HAS THE INTERMITTENT DRB DISPLAY. ANY TIME? SHORT TO VOLTAGE.*


NO

AT THIS TIME, THE USING THE SCHEMATICCONDITION REQUIRED AS A GUIDE, INSPECT WERE THERE ANY YES REPAIR AS TO SET THE TROUBLE THE WIRING AND PROBLEMS FOUND? NECESSARY.*

CODE IS NOT PRESENT. CONNECTORS.FIG. 1

NO

TEST COMPLETE.*

TROUBLE

CODE

TESTS

315


FIG. 1

TROUBLE

CODE

TESTS

316






NO


VOLTAGE.

YES



NO

TURN IGNITION ON. MEASURE THE 2/1 02 REPAIR THE 2/1 O2 USE A VOLTMETER IN SENSOR SIGNAL IS THE VOLTAGE YES SENSOR SIGNAL

THE FOLLOWING CIRCUIT AT THE PCM ABOVE 5.0 VOLTS? CIRCUIT FOR ASTEP. CONNECTOR. SHORT TO VOLTAGE.*

FIG. 1

NO



YES


SHORT TO VOLTAGE.*

TROUBLE

CODE

TESTS

317



FIG. 1


FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

318




START TEST IS THIS A CNG YES PERFORM TEST TC-69A VEHICLE? TC-69B.

NO




YES



FIG. 2, 3 OR 4

YES


THE NEXT PAGE.

TROUBLE

CODE

TESTS

319


FIG. 1


FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

320








NO



YES


MODULE.*

TROUBLE

CODE

TESTS

321



FIG. 1 FIG. 2

FIG. 3 FIG. 4

TROUBLE

CODE

TESTS

322





TC-69B CONNECTOR.**




FIG. 1

YES



FIG. 2

YES




NO



YES


MODULE.*

TROUBLE

CODE

TESTS

323



FIG. 1


FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

324





NO






FIG. 1

YES



FIG. 2, 3 OR 4

YES


THE NEXT PAGE.

TROUBLE

CODE

TESTS

325



FIG. 1

ZJ BODY

FIG. 2


FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5

TROUBLE

CODE

TESTS

326







THE PCM TO GROUND. SHORT TO GROUND.* FIG. 1 OR 2

NO



YES


MODULE.*

TROUBLE

CODE

TESTS

327



FIG. 1 FIG. 2

FIG. 3 FIG. 4

TROUBLE

CODE

TESTS

328





TC-70B CONNECTOR.**




FIG. 1

YES



FIG. 2

YES




NO



YES


MODULE.*

TROUBLE

CODE

TESTS

329

TEST TC-74A REPAIRING - TRANS TEMP SENSOR VOLTAGE TOO LOW


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4 FIG. 5

TROUBLE

CODE

TESTS

330

TEST TC-74A REPAIRING - TRANS TEMP SENSOR VOLTAGE TOO LOW



START TEST KEY OFF. TC-74A. DISCONNECT ALL PCM

CONNECTORS.**

MEASURE THE SENSOR GROUND CONTINUE TEST RESISTANCE BETWEEN CIRCUIT. IS THE RESISTANCE YES TC-74A ON THE

THE TRANS TEMP BELOW 550.0 OHMS? FOLLOWING PAGE.SIGNAL CIRCUIT AND

THE... FIG. 1, 2, 3 OR 4

NO

IS THE RESISTANCE YES PERFORM TEST ABOVE 2300.0 OHMS? TC-75A.

NO

MEASURE THE AND GROUND. CONTINUE TEST RESISTANCE BETWEEN IS THE RESISTANCE NO TC-74A ON THE

THE TRANS TEMP ABOVE 5.0 OHMS? FOLLOWING PAGE.SIGNAL CIRCUIT...

FIG. 1, 2, 3 OR 4

YES

RECONNECT ALL WITH THE DRB, READ IS THE VOLTAGE YESCONNECTORS. TRANS TEMP BELOW 1.5 VOLTS. REPLACE THE PCM.*

VOLTAGE.

NO



NO

TEST COMPLETE.*

TROUBLE

CODE

TESTS

331

TEST TC-74A CONTINUED - REPAIRING - TRANS TEMP SENSOR VOLTAGE TOO LOW

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

332

TEST TC-74A CONTINUED - REPAIRING - TRANS TEMP SENSOR VOLTAGE TOO LOW


TEST TC-74A DISCONNECT THECONTINUED FROM TRANSMISSION

THE PREVIOUS SOLENOID PAGE. CONNECTOR.**


USE AN OHMMETER IN SIGNAL CIRCUIT AND REPAIR THE TRANSTHE FOLLOWING THE SENSOR GROUND IS THE RESISTANCE YES TEMP SIGNAL

STEPS. MEASURE THE CIRCUIT AT PCM BELOW 5.0 OHMS? CIRCUIT SHORTED TO RESISTANCE BETWEEN CONNECTOR. SENSOR GROUND THE TRANS TEMP... FIG. 1, 2, 3 OR 4 CIRCUIT.*

NO

MEASURE THE AT PCM CONNECTOR REPAIR THE TRANSRESISTANCE BETWEEN AND GROUND. IS THE RESISTANCE YES TEMP SIGNAL

THE TRANS TEMP BELOW 5.0 OHMS? CIRCUIT FOR ASIGNAL CIRCUIT... SHORT TO GROUND.*

FIG. 1, 2, 3 OR 4

NO

RECONNECT THE DISCONNECT THE TRANSTRANSMISSION REMOVE THE TRANS PRESSURE/TEMP

SOLENOID OIL PAN. SENSOR.**CONNECTOR.


MEASURE THE THE SENSOR GROUND REPLACE THERESISTANCE BETWEEN CIRCUIT AT PCM IS THE RESISTANCE YES TRANSMISSION

THE TRANS TEMP CONNECTOR. BELOW 5.0 OHMS? SOLENOID ANDSIGNAL CIRCUIT HARNESS ASSEMBLY.*

AND... FIG. 1, 2, 3 OR 4

NO

MEASURE THE AT PCM CONNECTOR REPLACE THERESISTANCE BETWEEN AND GROUND. IS THE RESISTANCE YES TRANSMISSION

THE TRANS TEMP BELOW 5.0 OHMS? SOLENOID ANDSIGNAL CIRCUIT... HARNESS ASSEMBLY.*

FIG. 1, 2, 3 OR 4

NO

REPLACE THEPRESSURE/TEMPERATURE

SENSOR.*

TROUBLE

CODE

TESTS

333

TEST TC-75A REPAIRING - TRANS TEMP SENSOR VOLTAGE TOO HIGH


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4 FIG. 5

TROUBLE

CODE

TESTS

334

TEST TC-75A REPAIRING - TRANS TEMP SENSOR VOLTAGE TOO HIGH



KEY OFF. DISCONNECT START TEST ALL PCM

TC-75A. CONNECTORS.**


KEY ON. MEASURETHE VOLTAGE AT THE IS THE VOLTAGE YES CONTINUE TEST TRANS TEMP SIGNAL ABOVE 1.0 VOLT? TC-75A ON THE

CIRCUIT. NEXT PAGE.FIG. 1, 2, 3 OR 4

NO

KEY OFF. MEASURE AND THE SENSOR THE RESISTANCE GROUND CIRCUIT. IS THE RESISTANCE YES PERFORM TEST

BETWEEN THE TRANS BELOW 550.0 OHMS? TC-74A.TEMP SIGNAL


NO

IS THE RESISTANCE YES PERFORM TEST ABOVE 2300.0 OHMS? TC-75B.

NO

RECONNECT ALL WITH THE DRB, READ IS THE VOLTAGE YESCONNECTORS. TRANS TEMP ABOVE 3.76 VOLTS? REPLACE THE PCM.*

VOLTAGE.

NO



NO

TEST COMPLETE.*

TROUBLE

CODE

TESTS

335

TEST TC-75A CONTINUED - REPAIRING - TRANS TEMP SENSOR VOLTAGE TOO HIGH

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

FIG. 5

TROUBLE

CODE

TESTS

336

TEST TC-75A CONTINUED - REPAIRING - TRANS TEMP SENSOR VOLTAGE TOO HIGH


TEST TC-75A DISCONNECT THECONTINUED FROM TRANSMISSION



MEASURE THE VOLTAGE REPAIR THE TRANSAT THE TRANS TEMP IS THE VOLTAGE YES TEMP SIGNAL

SIGNAL CIRCUIT. ABOVE 1.0 VOLT? CIRCUIT FOR ASHORT TO VOLTAGE.*

FIG. 1, 2, 3 OR 4

NO

RECONNECT THE REMOVE THE TRANS OILTRANSMISSION PAN AND DISCONNECT

SOLENOID THE TRANS PRESSURE CONNECTOR. /TEMP SENSOR.**


MEASURE THE VOLTAGE REPLACE THEAT THE TRANS TEMP IS THE VOLTAGE YES TRANSMISSION

SIGNAL CIRCUIT. ABOVE 1.0 VOLT? SOLENOID ANDHARNESS ASSEMBLY.*

FIG. 5

NO

REPLACE THEPRESSURE/TEMPERATURE

SENSOR.*

TROUBLE

CODE

TESTS

337

TEST TC-75B REPAIRING - TRANS TEMP SENSOR VOLTAGE TOO HIGH


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

338




KEY OFF. START TEST DISCONNECT THE

TC-75B. TRANS SOLENOID PACK CONNECTOR.**

MEASURE THE FROM THE SOLENOID RESISTANCE OF THE PACK CONNECTOR TO IS THE RESISTANCE NO REPAIR THE OPEN TRANS TEMP SENSOR THE PCM CONNECTOR. BELOW 5.O OHMS TRANS TEMP SENSOR SIGNAL CIRCUIT... SIGNAL CIRCUIT.*

FIG. 1, 2, 3 OR 4

YES

MEASURE THE FROM THE SOLENOID RESISTANCE OF THE PACK CONNECTOR TO IS THE RESISTANCE NO REPAIR THE OPEN

SENSOR GROUND THE PCM CONNECTOR. BELOW 5.O OHMS SENSOR GROUND CIRCUIT... CIRCUIT.*

FIG. 1, 2, 3 OR 4

YES


NEXT PAGE.

TROUBLE

CODE

TESTS

339


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

340



TC-75B CONTINUED FROM REMOVE THE TRANS

THE PREVIOUS OIL PAN. PAGE.

DISCONNECT THE TRANSPRESSURE/TEMP CONNECT THE TRANS

SENSOR.** SOLENOID CONNECTOR.


MEASURE THE TO THE GOVERNOR RESISTANCE OF TRANS PRESSURE/TEMP IS THE RESISTANCE YES REPLACE THE TRANS

TEMP SENSOR SIGNAL SENSOR CONNECTOR. ABOVE 5.0 OHMS? SOLENOID/HARNESS CIRCUIT FROM THE PCM ASSEMBLY.*

CONNECTOR... FIG. 1, 2, 3 OR 4

NO

MEASURE THE TO THE GOVERNOR RESISTANCE OF PRESSURE/TEMP IS THE RESISTANCE YES REPLACE THE TRANSSENSOR GROUND SENSOR CONNECTOR. ABOVE 5.0 OHMS? SOLENOID/HARNESS

CIRCUIT FROM THE ASSEMBLY.* PCM CONNECTOR... FIG. 1, 2, 3 OR 4

NO

REPLACE THE TRANSPRESSURE/TEMP

SENSOR.*

TROUBLE

CODE

TESTS

341



FIG. 1 FIG. 2

FIG. 3 FIG. 4

TROUBLE

CODE

TESTS

342





DISCONNECT THE CONNECT CABLE TO SPARK PLUG CABLE SPARK TESTER. CONNECT SPARK


FIG. 1 FIG. 2

TURN IGNITION ON. WITH THE DRB IS THERE GOOD NO CONTINUE TEST (ENGINE OFF) ACTUATE IGNITION SPARK? TC-76A ON THE

COIL #4. NEXT PAGE.

YES



NO




NO


INFORMATION.

TROUBLE

CODE

TESTS

343


FIG. 1

FIG. 2

FIG. 3

TROUBLE

CODE

TESTS

344





SEE GENERAL INFO 4.0 FIG.1

NO



FIG. 1

YES

KEY OFF, DISCONNECT USING AN OHMMETER, REPAIR THEPOWERTRAIN CONTROL MEASURE THE IGNITION IS THE RESISTANCE YES IGNITION COIL #4

MODULE.** COIL #4 PRIMARY BELOW 5.0 OHMS? DRIVER CIRCUIT FORCIRCUIT TO GROUND. A SHORT TO


NO



CONNECTOR...



FIG. 2

YES



FIG. 3

YES


MODULE.*

TROUBLE

CODE

TESTS

345



FIG. 1 FIG. 2

FIG. 3 FIG. 4

TROUBLE

CODE

TESTS

346





DISCONNECT THE CONNECT CABLE TO ASPARK PLUG CABLE SPARK PLUG TESTER. CONNECT SPARK PLUG


FIG. 1 FIG. 2


COIL #5. NEXT PAGE.

YES



NO




NO


INFORMATION.

TROUBLE

CODE

TESTS

347


FIG. 1

FIG. 2

FIG. 3

TROUBLE

CODE

TESTS

348






NO



FIG. 1

YES

KEY OFF, DISCONNECT USING AN OHMMETER, REPAIR THEPOWERTRAIN CONTROL MEASURE THE IGNITION IS THE RESISTANCE YES IGNITION COIL #5

MODULE.** COIL #5 DRIVER BELOW 5.0 OHMS? DRIVER CIRCUIT FORCIRCUIT TO GROUND. A SHORT TO


NO



CONNECTOR...



FIG. 2

YES



FIG. 3

YES


MODULE.*

TROUBLE

CODE

TESTS

349



FIG. 1

AB BODY

FIG. 2

AN BODY

FIG. 3

BR BODY

FIG. 4

ZJ BODY

FIG. 5

TROUBLE

CODE

TESTS

350





NO

KEY OFF, DISCONNECT USING AN OHMMETER,THE INJECTOR #7 MEASURE RESISTANCE IS THE RESISTANCE NO REPLACE THE FUEL

CONNECTOR.** OF INJECTOR #7. BETWEEN 10.0 AND INJECTOR.* 16.0 OHMS?


YES



FIG. 2, 3, 4 OR 5

YES


NEXT PAGE.

TROUBLE

CODE

TESTS

351


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

352







THE PCM TO GROUND. SHORT TO GROUND.* FIG. 1, 2, 3 OR 4

NO


NEXT PAGE.

TROUBLE

CODE

TESTS

353


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

354



USING AN OHMMETER,TEST TC-79A MEASURE ACROSS THE

CONTINUED FROM INJECTOR #7 DRIVER PREVIOUS PAGE. CIRCUIT...

FIG. 1, 2, 3 OR 4

FROM THE PCM TO IS THE RESISTANCE NO REPAIR THE OPEN THE INJECTOR BELOW 5.0 OHMS? INJECTOR #7 DRIVER

CONNECTOR. CIRCUIT.*

YES


MODULE.*

TROUBLE

CODE

TESTS

355



FIG. 1

AB BODY

FIG. 2

AN BODY

FIG. 3

BR BODY

FIG. 4

TROUBLE

CODE

TESTS

356





TC-79B CONNECTOR.**




FIG. 1

YES



FIG. 2, 3 OR 4

YES


THE NEXT PAGE.

TROUBLE

CODE

TESTS

357

TEST TC-79B CONTINUED - INJECTOR #7 CONTROL CIRCUIT

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

TROUBLE

CODE

TESTS

358

TEST TC-79B CONTINUED - INJECTOR #7 CONTROL CIRCUIT






THE PCM TO GROUND. SHORT TO GROUND.* FIG. 1, 2 OR 3

NO



YES


MODULE.*

TROUBLE

CODE

TESTS

359



FIG. 1


FIG. 2

ZJ BODY

FIG. 3

TROUBLE

CODE

TESTS

360




START TEST IS THIS A CNG YES PERFORM TEST TC-80A FUELED VEHICLE? TC-80B.

NO






FIG. 1

YES



FIG. 2 OR 3

YES


NEXT PAGE.

TROUBLE

CODE

TESTS

361



FIG. 1

ZJ BODY

FIG. 2


FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

362







THE PCM TO GROUND. SHORT TO GROUND.* FIG. 1 OR 2

NO

USING AN OHMMETER,MEASURE ACROSS THE FROM THE PCM TO IS THE RESISTANCE NO REPAIR THE OPEN INJECTOR #8 DRIVER THE INJECTOR BELOW 5.0 OHMS? INJECTOR #8 DRIVER

CIRCUIT... CONNECTOR. CIRCUIT.*FIG. 3 OR 4

YES


MODULE.*

TROUBLE

CODE

TESTS

363



FIG. 1 FIG. 2

FIG. 3 FIG. 4

TROUBLE

CODE

TESTS

364





TC-80B. CONNECTOR.**




FIG. 1

YES



FIG. 2

YES




NO



YES


MODULE.*

TROUBLE

CODE

TESTS

365

TEST TC-87A REPAIRING - SPEED CONTROL SWITCH ALWAYS LOW



BR BODY

FIG. 1


FIG. 2

BR BODY

FIG. 3

TROUBLE

CODE

TESTS

366

TEST TC-87A REPAIRING - SPEED CONTROL SWITCH ALWAYS LOW



RECORD ALL DTC’SSTART TEST AND FREEZE FRAME IS THIS VEHICLE A YES PERFORM TEST

TC-87A. DATA, NOW ERASE "ZJ" BODY? TC-87B CODES BEFORE PROCEEDING.

NO

AT THIS TIME THEWITH THE DRB, READ IS THE S/C SWITCH NO CONDITION REQUIRED

THE S/C SWITCH VOLTAGE BELOW 1.0 TO SET THE TROUBLEVOLTS IN SENSORS. VOLTS? CODE IS NOT PRESENT.

SEE GEN INFO 3.3.2

YES

DISCONNECT THE S/CSWITCH.** DID THE S/C SWITCH YES REPLACE THE S/C

VOLTS CHANGE TO SWITCH.* 5.0 VOLTS?


NO

USING AN OHMMETER,MEASURE THE AND THE SENSOR IS THE RESISTANCE YES REPAIR S/C SIGNAL

RESISTANCE BETWEEN GROUND CIRCUIT. BELOW 5.0 OHMS? CIRCUIT SHORTED TO THE S/C SIGNAL SENSOR GROUND.*

CIRCUIT... FIG. 1

NO

DISCONNECT THE WITH AN OHMMETER,POWERTRAIN CONTROL MEASURE RESISTANCE IS THE RESISTANCE NO REPLACE THE

MODULE.** OF S/C SWITCH SIGNAL BELOW 5.0 OHMS? POWERTRAIN CONTROLCKT TO GND AT THE MODULE.*

SEE GENERAL INFO 4.1 PCM. FIG. 1 OR 2

YES

REPAIR S/C SWITCH SIGNAL CIRCUIT FOR

A SHORT TO GROUND.*

TROUBLE

CODE

TESTS

367

TEST TC-87B REPAIRING - SPEED CONTROL SWITCH ALWAYS LOW


ZJ BODY

ZJ BODY

FIG. 1

TROUBLE

CODE

TESTS

368

TEST TC-87B REPAIRING - SPEED CONTROL SWITCH ALWAYS LOW



AT THIS TIME THESTART TEST WITH THE DRB, READ IS THE S/C SWITCH NO CONDITION REQUIRED

TC-87B. THE S/C SWITCH VOLTAGE BELOW 1.0 TO SET THE TROUBLEVOLTS IN SENSORS. VOLTS? CODE IS NOT PRESENT

SEE GEN INFO 3.3.2

YES

DISCONNECT THE S/CON/OFF SWITCH.** DID THE S/C SWITCH YES REPLACE THE S/C

VOLTS CHANGE TO ON/OFF SWITCH.* 5.0 VOLTS?


NO

DISCONNECT THE S/CCANCEL SWITCH.** DID THE S/C SWITCH YES REPLACE THE S/C

VOLTS CHANGE TO CANCEL SWITCH.* 5.0 VOLTS?


NO

USING AN OHMMETER,MEASURE THE AND THE SENSOR IS THE RESISTANCE YES REPAIR S/C SIGNAL

RESISTANCE BETWEEN GROUND CIRCUIT. BELOW 5.0 OHMS? CIRCUIT SHORTED TO THE S/C SIGNAL SENSOR GROUND.*

CIRCUIT... FIG. 1

NO

DISCONNECT THE WITH AN OHMMETER, TO GROUND AT THEPOWERTRAIN CONTROL MEASURE RESISTANCE PCM. IS THE NO REPLACE THE POWER

MODULE.** OF THE S/C SWITCH RESISTANCE BELOW TRAIN CONTROLSIGNAL CIRCUIT... 5.0 OHMS? MODULE.*


YES

REPAIR S/C SWITCH SIGNAL CIRCUIT FOR

A SHORT TO GROUND.*

TROUBLE

CODE

TESTS

369

TEST TC-94A REPAIRING - CNG TEMP SENSOR VOLTAGE TOO LOW


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

370

TEST TC-94A REPAIRING - CNG TEMP SENSOR VOLTAGE TOO LOW



WITH THE DRB, READ YESSTART TEST THE FUEL IS THE FUEL TEMP CONTINUE TEST

TC-94A. TEMPERATURE SENSOR SENSOR VOLTAGE TC-94A ON THEVOLTAGE. BELOW 0.29 VOLTS? NEXT PAGE.

NO

WIGGLE THE FUEL YES REPAIR THETEMP SENSOR MONITOR THE DRB WAS THERE ANY FUEL CONNECTOR OR

CONNECTOR AND DISPLAY. TEMP SENSOR HARNESS WIRES THAT HARNESS WIRES. VOLTAGE CHANGE? CAUSED THE VOLTAGE

CHANGE.*

NO

AT THIS TIME THE USING THE YESCONDITION REQUIRED SCHEMATIC AS A WERE ANY PROBLEMS REPAIR AS


CONNECTORS.

NO


INFORMATION.

FIG. 1

TROUBLE

CODE

TESTS

371

TEST TC-94A CONTINUED - REPAIRING - CNG TEMP SENSOR VOLTAGE TOO LOW

FIG. 1

TROUBLE

CODE

TESTS

372

TEST TC-94A CONTINUED - REPAIRING - CNG TEMP SENSOR VOLTAGE TOO LOW


TEST TC-94A DISCONNECT THE FUEL CONTINUED FROM TEMP SENSOR



WITH THE DRB, YES RELEASE THE FUEL MONITOR THE FUEL IS THE FUEL TEMP PRESSURE.

TEMPERATURE SENSOR SENSOR VOLTAGE SEE GENERAL INFO 9.1VOLTAGE. ABOVE 4.0 VOLTS? REPLACE THE FUEL

TEMP SENSOR.*

NO

USING AN OHMMETER, YES REPAIR THE FUEL MEASURE THE FUEL IS THE RESISTANCE TEMP SENSOR SIGNAL

TEMP SENSOR SIGNAL BELOW 5.0 OHMS? CIRCUIT FOR ACIRCUIT TO GROUND. SHORT TO GROUND.*

FIG. 1

NO

USING AN OHMMETER, CIRCUIT TO THEMEASURE THE SENSOR GROUND IS THE RESISTANCE NO REPLACE THE

RESISTANCE OF THE CIRCUIT. BELOW 5.0 OHMS? POWERTRAIN CONTROLSENSOR SIGNAL.. MODULE.*

FIG. 1

YES

REPAIR THE FUEL TEMP SENSOR SHORTTO SENSOR GROUND.*


CONTROL MODULE.**


TROUBLE

CODE

TESTS

373

TEST TC-95A REPAIRING - CNG TEMP SENSOR VOLTAGE TOO HIGH


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

374

TEST TC-95A REPAIRING - CNG TEMP SENSOR VOLTAGE TOO HIGH



WITH THE DRB, READ YESSTART TEST THE FUEL IS THE FUEL TEMP CONTINUE TEST

TC-95A. TEMPERATURE SENSOR SENSOR VOLTAGE TC-95A ON THEVOLTAGE. ABOVE 4.6 VOLTS? NEXT PAGE.

NO

WIGGLE THE FUEL YES REPAIR THETEMP SENSOR MONITOR THE DRB WAS THERE ANY FUEL CONNECTOR OR

CONNECTOR AND DISPLAY. TEMP SENSOR HARNESS WIRES THAT HARNESS WIRES. VOLTAGE CHANGE? CAUSED THE VOLTAGE

CHANGE.*

NO

AT THIS TIME THE USING THE YESCONDITION REQUIRED SCHEMATIC AS A WERE ANY PROBLEMS REPAIR AS


CONNECTORS.

NO


INFORMATION.

FIG. 1

TROUBLE

CODE

TESTS

375

TEST TC-95A CONTINUED - REPAIRING - CNG TEMP SENSOR VOLTAGE TOO HIGH

FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

376

TEST TC-95A CONTINUED - REPAIRING - CNG TEMP SENSOR VOLTAGE TOO HIGH


TEST TC-95A DISCONNECT THE FUEL CONTINUED FROM TEMP SENSOR



WITH A VOLTMETER, REPAIR THE FUEL MEASURE THE FUEL AT THE FUEL TEMP IS THE VOLTAGE YES TEMP SENSOR

TEMP SENSOR SENSOR CONNECTOR. ABOVE 6.0 VOLTS? CIRCUIT SHORTED TO CIRCUIT... VOLTAGE.*

FIG. 1

NO

CONNECT A JUMPER WITH THE DRB , RELEASE THE FUEL WIRE ACROSS THE MONITOR THE FUEL IS THE FUEL TEMP YES PRESSURE.

SENSOR SIGNAL AND TEMP SENSOR SENSOR VOLTAGE SEE GENERAL INFO 9.1SENSOR GROUND CKTS. VOLTAGE. BELOW 1.0 VOLT? REPLACE THE FUEL

FIG. 1 TEMP SENSOR.*

NO

MOVE THE JUMPER WITH THE DRB, WIRE FROM THE MONITOR THE FUEL IS THE FUEL TEMP YES REPAIR THE OPEN

SENSOR GROUND TO TEMP SENSOR SENSOR VOLTAGE SENSOR GROUND AN ENGINE GROUND. VOLTAGE. BELOW 1.0 VOLT? CIRCUIT.*

FIG. 1

NO

WITH AN OHMMETER, NO MEASURE THE FUEL IS THE RESISTANCE REPAIR THE OPEN

TEMP SENSOR SIGNAL BELOW 5.0 OHMS? FUEL TEMP SENSOR CIRCUIT FROM PCM SIGNAL CIRCUIT.*TO CONN. FIG. 2

YES


MODULE.*


POWERTRAIN CONTROLMODULE.**


TROUBLE

CODE

TESTS

377

TEST TC-98A REPAIRING - CNG PRESSURE SENSOR VOLTAGE TOO HIGH


AN AND BR BODIES AB BODY

FIG. 1 FIG. 2

TROUBLE

CODE

TESTS

378

TEST TC-98A REPAIRING - CNG PRESSURE SENSOR VOLTAGE TOO HIGH



START TEST WITH THE DRB, IGNITION KEY OFFTC-98A. ERASE CODES. FOR TEN SECOUNDS.

DID THE "CNG ATTEMPT TO START WITH THE DRB, READ PRESSURE SENSOR YES CONTINUE TEST

THE ENGINE AND LET CODES. VOLTAGE TOO HIGH" TC-98A ON THEIDLE. CODE RETURN? NEXT PAGE.

NO

WIGGLE THE FUEL WITH THE DRB, WAS THERE ANY REPAIR THE HARNESSPRESSURE SENSOR MONITOR THE FUEL CHANGE IN FUEL YES OR CONNECTOR THAT

CONNECTORS AND PRESSURE SENSOR PRESSURE SENSOR CAUSED THE VOLTAGEHARNESS. VOLTAGE WHILE VOLTAGE WHEN CHANGE.*

SEE GENERAL INFO 4.0 WIGGLING. WIGGLED?

NO

DID THE "CNG REPAIR THE HARNESSWITH THE DRB, READ PRESSURE SENSOR YES OR CONNECTOR THAT

CODES. VOLTAGE TOO HIGH" CAUSED THE CODE TO CODE RETURN? RETURN.*

NO



NO


INFORMATION.

TROUBLE

CODE

TESTS

379

TEST TC-98A CONTINUED - REPAIRING - CNG PRESSURE SENSOR VOLTAGE TOO HIGH

AN AND BR BODIES

FIG. 1

AB BODY

FIG. 2

AN AND BR BODIES

FIG. 3

AB BODY

FIG. 4

TROUBLE

CODE

TESTS

380



TEST TC-98A DISCONNECT THE CNGCONTINUED FROM FUEL PRESSURE SENSOR



MEASURE THE CNG REPAIR THE FUEL USE A VOLTMETER IN FUEL PRESSURE IS THE VOLTAGE YES PRESSURE SENSOR

THE FOLLOWING SENSOR SIGNAL ABOVE 4.0 VOLTS? SIGNAL CIRCUITSTEP. CIRCUIT. SHORTED TO

FIG. 1 OR 2 VOLTAGE.*

NO

KEY OFF, MEASUREUSE AN OHMMETER IN THE CNG FUEL IS THE RESISTANCE NO REPAIR THE OPEN

THE FOLLOWING PRESSURE SENSOR BELOW 5.0 OHMS? SENSOR GROUND STEP. GROUND CIRCUIT. CIRCUIT.*

FIG. 1 OR 2

YES


TURN IGNITION OFF. MODULE.**


MEASURE THE CNG FUEL USE AN OHMMETER IN PRESSURE SENSOR IS THE RESISTANCE NO REPAIR THE OPEN

THE FOLLOWING SIGNAL CIRCUIT FOR BELOW 5.0 OHMS? FUEL PRESSURE STEP. RESISTANCE. SIGNAL CIRCUIT.*

FIG. 3 OR 4

YES


NEXT PAGE.

TROUBLE

CODE

TESTS

381


AN AND BR BODIES

FIG. 1

AB BODY

FIG. 2

TROUBLE

CODE

TESTS

382



TEST TC-98A RECONNECT ALLCONTINUED FROM PREVIOUSLY TURN IGNITION KEY

THE PREVIOUS DISCONNECTED ON.PAGE. CONNNECTORS.

DISCONNECT THE FUEL WITH THE DRB, READ PRESSURE SENSOR.** THE CNG FUEL

PRESSURE SENSOR PRESSURE AND NOTE

SEE GENERAL INFO 4.4 PRESSURE READING.

JUMPER THE CNG FUEL WITH THE DRB, READ DID THE CNG FUEL PRESSURE SIGNAL THE CNG FUEL PRESSURE SENSOR YESNOTE: SEE GENERAL

CIRCUIT TO THE PRESSURE SENSOR PRESSURE DROP TO 0 INFO 9.0 FOR FUEL SENSOR GROUND PRESSURE. WHEN JUMPERED? RELEASE PROCEDURE.

CIRCUIT. FIG. 1 OR 2

NO

REPLACE THE FUEL PRESSURE SENSOR.*


MODULE.*

TROUBLE

CODE

TESTS

383

TEST TC-99A REPAIRING - CNG PRESSURE SENSOR VOLTAGE TOO LOW


AN AND BR BODIES AB BODY

FIG. 1 FIG. 2

TROUBLE

CODE

TESTS

384

TEST TC-99A REPAIRING - CNG PRESSURE SENSOR VOLTAGE TOO LOW



START TEST WITH THE DRB, IGNITION KEY OFFTC-99A. ERASE CODES. FOR TEN SECOUNDS.

DID THE "CNG ATTEMPT TO START WITH THE DRB, READ PRESSURE SENSOR YES CONTINUE TEST

THE ENGINE AND LET CODES. VOLTAGE TOO LOW" TC-99A ON THEIDLE. CODE RETURN? NEXT PAGE.

NO

WIGGLE THE FUEL WITH THE DRB, DID WIGGLING CAUSE REPAIR THE HARNESSPRESSURE SENSOR MONITOR THE FUEL THE FUEL PRESSURE YES OR CONNECTOR THAT

CONNECTORS AND PRESSURE SENSOR SENSOR VOLTAGE TO CAUSED THE VOLTAGEHARNESS. VOLTAGE WHILE CHANGE? CHANGE.*

SEE GENERAL INFO 4.0 WIGGLING HARNESS.

NO

DID THE "CNG REPAIR THE HARNESSWITH THE DRB, READ PRESSURE SENSOR YES OR CONNECTOR THAT

CODES. VOLTAGE TOO LOW" CAUSED THE CODE TO CODE RETURN? RETURN.*

NO



NO


INFORMATION.

TROUBLE

CODE

TESTS

385

TEST TC-99A CONTINUED - REPAIRING - CNG PRESSURE SENSOR VOLTAGE TOO LOW

AN AND BR BODIES

FIG. 1

AB BODY

FIG. 2

TROUBLE

CODE

TESTS

386



TEST TC-99A DISCONNECT THE FUEL CONTINUED FROM PRESSURE SENSOR

THE PREVIOUS CONNNECTOR.**PAGE.


MEASURE THE CNG REPAIR THE OPEN USE A VOLTMETER IN PRESSURE SENSOR IS THE VOLTAGE NO FUEL PRESSURE

THE FOLLOWING 5-VOLT SUPPLY ABOVE 4.0 VOLTS? SENSOR 5-VOLT STEP. CIRCUIT. SUPPLY CIRCUIT.*

FIG. 1 OR 2

YES


CONTROL MODULE.**


MEASURE BETWEEN THE REPAIR THE FUEL USE AN OHMMETER IN FUEL PRESSURE SENSOR IS THE RESISTANCE YES PRESSURE SENSOR

THE FOLLOWING SIGNAL CIRCUIT AND BELOW 5.0 OHMS? SIGNAL CIRCUITSTEP. THE GROUND CIRCUIT. SHORTED TO SENSOR

FIG. 1 OR 2 GROUND CIRCUIT.*

NO

MEASURE THE FUEL REPAIR THE FUEL USE AN OHMMETER IN PRESSURE SENSOR IS THE RESISTANCE YES PRESSURE SENSOR

THE FOLLOWING SIGNAL CIRCUIT TO BELOW 5.0 OHMS? SIGNAL CIRCUIT FORSTEP. GROUND. A SHORT TO

FIG. 1 OR 2 GROUND.*

NO


NEXT PAGE.

TROUBLE

CODE

TESTS

387


AN AND BR BODIES

FIG. 1

AB BODY

FIG. 2

TROUBLE

CODE

TESTS

388



TEST TC-99A RECONNECT ALLCONTINUED FROM PREVIOUSLY

THE PREVIOUS DISCONNECTED PAGE. CONNNECTORS.

TURN IGNITION KEYON.

DISCONNECT THE FUEL IS THE FUEL PRESSURE SENSOR.** WITH THE DRB, READ PRESSURE SENSOR YES NOTE: SEE GENERAL

THE FUEL PRESSURE VOLTAGE ABOVE 4.0 INFO 9.0 FOR FUEL SENSOR VOLTAGE. VOLTS? RELEASE PROCEDURE.


NO

REPLACE THE FUEL PRESSURE SENSOR.*

REPLACE POWERTRAIN CONTROL MODULE.*

TROUBLE

CODE

TESTS

389

TEST TC-101A REPAIRING - FUEL PUMP (SYSTEM) RELAY CONTROL CIRCUIT


AB BODY AN AND BR BODIES

XJ BODY ZJ BODY

FIG. 1 FIG. 2

TROUBLE

CODE

TESTS

390

TEST TC-101A REPAIRING - FUEL PUMP (SYSTEM) RELAY CONTROL CIRCUIT



START TEST IS THE VEHICLE YES PERFORM TEST TC-101A. EQUIPPED WITH CNG? TC-101B.

NO

WITH THE DRB, ACTUATE THE FUEL IS THE FUEL PUMP NO CONTINUE TEST

PUMP RELAY. RELAY CLICKING? TC-101A ON THENEXT PAGE.


YES


FIG. 1 CONNECTORS.

NO

WITH THE DRB, WIGGLE THE WIRING DID THE RELAY REPAIR CIRCUIT AS ACTUATE THE FUEL HARNESS FROM THE CLICKING STOP OR YES NECESSARY WHERE

PUMP RELAY. RELAY TO THE BECOME IRREGULAR WIGGLING CAUSED THEPOWERTRAIN CONTROL WHEN WIGGLING THE CLICKING TO STOP OR

SEE GENERAL INFO 4.6 MODULE. WIRES? BECOME IRREGULAR.*

NO



TROUBLE

CODE

TESTS

391

TEST TC-101A CONTINUED - REPAIRING - FUEL PUMP (SYSTEM) RELAY CONTROL CIRCUIT

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5 FIG. 6

TROUBLE

CODE

TESTS

392

TEST TC-101A CONTINUED - REPAIRING - FUEL PUMP (SYSTEM) RELAY CONTROL CIRCUIT


TEST TC-101A DISCONNECT THE FUEL CONTINUED FROM PUMP RELAY.**

THE PREVIOUS PAGE.


USING A VOLTMETER, MEASURE THE FUSED IS THE VOLTAGE NO REPAIR THE OPEN IGN SWITCH OUTPUT ABOVE 10.0 VOLTS? FUSED IGN SWITCH

CKT AT RELAY. OUTPUT CIRCUIT.*FIG. 1, 2, 3, 4 OR 5

YES

MEASURE THEUSE AN OHMMETER IN RESISTANCE BETWEEN IS THE RESISTANCE NO REPLACE FUEL PUMP

THE FOLLOWING TERMINALS 85 AND 86 BELOW 100.0 OHMS? RELAY.*STEP. OF THE FUEL SYSTEM

RELAY. FIG. 6

YES

KEY OFF. DISCONNECT USING AN OHMMETER, REPAIR THE FUEL THE POWERTRAIN MEASURE THE FUEL IS THE RESISTANCE YES PUMP RELAY CONTROL

CONTROL MODULE GREY PUMP RELAY CONTROL BELOW 5.0 OHMS? CIRCUIT FOR ACONNECTOR.** CKT AT PCM TO GND. SHORT TO GROUND.*


NO

USING AN OHMMETER, FROM THE PCM TO THEMEASURE THE RELAY. IS THE RESISTANCE NO REPAIR OPEN FUEL

RESISTANCE OF THE BELOW 5.0 OHMS? PUMP RELAY CONTROLFUEL SYSTEM RELAY CIRCUIT.*CONTROL CIRCUIT... FIG. 1, 2, 3, 4 OR 5

YES


MODULE.*

TROUBLE

CODE

TESTS

393

TEST TC-101B REPAIRING - FUEL PUMP (SYSTEM) RELAY CONTROL CIRCUIT


AB BODY

AN BODY BR BODY

FIG. 1 FIG. 2

TROUBLE

CODE

TESTS

394

TEST TC-101B REPAIRING - FUEL PUMP (SYSTEM) RELAY CONTROL CIRCUIT



WITH THE DRB, START TEST ACTUATE THE HI IS THE RELAY NO CONTINUE TEST

TC-101B. PRESSURE FUEL CLICKING? TC-101B ON THESHUTOFF RELAY. NEXT PAGE.


YES


FIG. 1 CONNECTORS.

NO

WITH THE DRB, WIGGLE THE WIRING DID THE RELAY REPAIR CIRCUIT AS ACTUATE THE HI HARNESS FROM THE CLICKING STOP OR YES NECESSARY WHEREPRESSURE FUEL RELAY TO THE BECOME IRREGULAR WIGGLING CAUSED THESHUTOFF RELAY. POWERTRAIN CONTROL WHILE WIGGLING THE CLICKING TO STOP OR

SEE GENERAL INFO 4.6 MODULE. WIRES? BECOME IRREGULAR.

NO



TROUBLE

CODE

TESTS

395

TEST TC-101B CONTINUED - REPAIRING - FUEL PUMP (SYSTEM) RELAY CONTROL CIRCUIT

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3 FIG. 4

TROUBLE

CODE

TESTS

396

TEST TC-101B CONTINUED - REPAIRING - FUEL PUMP (SYSTEM) RELAY CONTROL CIRCUIT


TEST TC-101B DISCONNECT THE FUEL CONTINUED FROM SYSTEM RELAY.**

THE PREVIOUS PAGE.


USING A VOLTMETER, MEASURE THE FUSED IS THE VOLTAGE NO REPAIR THE OPEN IGN SWITCH OUTPUT ABOVE 10.0 VOLTS? FUSED IGN SWITCH

CKT AT RELAY. OUTPUT CIRCUIT.*FIG. 1, 2 OR 3

YES

MEASURE THEUSE AN OHMMETER IN RESISTANCE BETWEEN IS THE RESISTANCE NO REPLACE FUEL

THE FOLLOWING TERMINALS 85 & 86 OF BELOW 100.0 OHMS? SYSTEM RELAY.*STEP. THE FUEL SYSTEM RLY.

FIG. 4

YES

KEY OFF. DISCONNECT USING AN OHMMETER, REPAIR THE FUEL THE POWERTRAIN MEASURE FUEL SYSTEM IS THE RESISTANCE YES SYSTEM RELAY

CONTROL MODULE GREY RELAY CONTROL CKT AT BELOW 5.0 OHMS? CONTROL CKT FOR ACONNECTOR.** PCM TO GROUND. SHORT TO GROUND.*


NO

USING AN OHMMETER, FROM THE PCM TO MEASURE THE THE RELAY. IS THE RESISTANCE NO REPAIR OPEN FUEL

RESISTANCE OF THE BELOW 5.0 OHMS? SYSTEM RELAYFUEL SYSTEM RELAY CONTROL CKT.*CONTROL CIRCUIT... FIG. 1, 2 OR 3

YES


MODULE.*

TROUBLE

CODE

TESTS

397

TEST TC-102A REPAIRING - 1/1 O2 SENSOR SLOW RESPONSE


FIG. 1

TYPICAL CONNECTOR

FIG. 2

TROUBLE

CODE

TESTS

398




REFER TO FIGURE 1START TEST FOR POSSIBLE

TC-102A. TROUBLE CODE CAUSES.

CHECK THE EXHAUST REPAIR OR REPLACESYSTEM FOR LEAKS IS THERE ANY YES LEAKING EXHAUST

START THE ENGINE. BETWEEN THE ENGINE EXHAUST LEAK? PARTS AS AND THE CATALYST. NECESSARY.*

NO

NOTE: CHECK THE IS THERE AN OIL OR REPAIR ENGINE EXHAUST FOR COOLANT YES MECHANICAL AS

EXCESSIVE SMOKE CONSUMPTION NECESSARY ANDCAUSED BY OIL OR CONDITION PRESENT? REPLACE THE 1/1 O2

COOLANT CONSUMPTION. SENSOR.*

NO

TURN IGNITION OFF. IS ANY TERMINAL DISCONNECT THE 1/1 INSPECT THE CORRODED, DAMAGED, YES REPAIR OR REPLACE

O2 SENSOR.** CONNECTORS AND PUSHED OUT OR AS NECESSARY.*TERMINALS. MISWIRED?


NO

USING AN OHMMETER, THE 1/1 O2 SENSOR MEASURE THE 1/1 O2 CONNECTOR TO IS THE RESISTANCE NO REPAIR THE OPEN

SENSOR GROUND GROUND. BELOW 5.0 OHMS? 1/1 O2 SENSOR CIRCUIT FROM... GROUND CIRCUIT.*

FIG. 2

YES

DISCONNECT THE IS ANY TERMINAL POWERTRAIN CONTROL INSPECT THE CORRODED, DAMAGED, YES REPAIR AS

MODULE.** CONNECTORS AND PUSHED OUT OR NECESSARY.*TERMINALS. MISWIRED?


NO

REPLACE THE 1/1 O2 SENSOR.*

TROUBLE

CODE

TESTS

399

TEST TC-103A REPAIRING - 1/1 O2 SENSOR HEATER FAILURE


FIG. 1

TROUBLE

CODE

TESTS

400




ARE THERE ANY REFER TO "DTC START TEST WITH THE DRB, READ OTHER "1/1 O2 YES TEST" TO PERFORM

TC-103A. ALL TROUBLE CODES. SENSOR" RELATED THE APPROPRIATETROUBLE CODES? OXYGEN SENSOR

TEST.

NO

TURN IGNITION ON (ENGINE OFF). WAIT 3 MINUTES.

WITH THE DRB IN WAIT FOR THESENSORS, MONITOR VOLTAGE READING TO

THE 1/1 O2 SENSOR STABILIZE ABOVEVOLTAGE. 4.5 VOLTS.

WITH THE DRB IN IS THE 1/1ACTUATOR TESTS, MONITOR THE 1/1 O2 O2 SENSOR YES CONTINUE TEST

PERFORM THE O2 SENSOR VOLTAGE FOR VOLTAGE STILL TC-103A ON THESENSOR HEATER THREE MINUTES. ABOVE 1.0 VOLT? NEXT PAGE.

TEST.

NO

DID YOU COME FROM YES CONTINUE TEST TEST TC-118A? TC-118A.

NO

AT THIS TIME, THECONDITION REQUIRED STOP ALL ACTUATOR TO SET THE TROUBLE TESTS.

CODE IS NOT PRESENT. TEST COMPLETE.* FIG. 1

TROUBLE

CODE

TESTS

401

TEST TC-103A CONTINUED - REPAIRING - 1/1 O2 SENSOR HEATER FAILURE

TYPICAL CONNECTOR

FIG. 1

TYPICAL CONNECTOR

FIG. 2

TROUBLE

CODE

TESTS

402



TEST TC-103A DISCONNECT THE 1/1 IS ANY TERMINAL CONTINUED FROM O2 SENSOR CORRODED, DAMAGED, YES REPAIR OR REPLACE

THE PREVIOUS CONNECTOR.** PUSHED OUT OR AS NECESSARY.*PAGE MISWIRED?


NO

NOTE: THE DRB IS USING A VOLTMETER, STILL ACTUATING MEASURE THE ASD IS THE VOLTAGE NO REPAIR THE OPEN

THE O2 SENSOR RELAY OUTPUT ABOVE 10.0 VOLTS? ASD RELAY OUTPUT HEATER TEST. CIRCUIT. CIRCUIT.*

FIG. 1

YES

USING AN OHMMETER,STOP ALL ACTUATOR MEASURE THE O2 IS THE RESISTANCE NO REPLACE THE 1/1 O2

TESTS. SENSOR HEATER BETWEEN 4.0 AND SENSOR.* ELEMENT. 7.0 OHMS?

FIG. 2

YES

USING AN OHMMETER, CIRCUIT TO GROUND. IS THE RESISTANCE NO REPAIR THE OPEN MEASURE FROM THE BELOW 5.0 OHMS? 1/1 O2 SENSOR HEATER GROUND... GROUND CIRCUIT.*

FIG. 1

YES


TROUBLE

CODE

TESTS

403



FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

404








NO


EXCESSIVE SMOKE CONSUMPTION NECESSARY ANDCAUSED BY OIL OR CONDITION PRESENT? REPLACE THE 1/2 O2

COOLANT CONSUMPTION. SENSOR.*

NO

TURN IGNITION OFF. IS ANY TERMINAL DISCONNECT THE 1/2 INSPECT THE CORRODED, DAMAGED, YES REPAIR OR REPLACE

O2 SENSOR.** CONNECTORS AND PUSHED OUT OR AS NECESSARY.*TERMINALS. MISWIRED?


NO

USING AN OHMMETER, THE 1/2 O2 SENSOR MEASURE THE 1/2 O2 CONNECTOR TO IS THE RESISTEANCE NO REPAIR THE OPEN

SENSOR GROUND GROUND. BELOW 5.0 OHMS? 1/2 O2 SENSOR CIRCUIT FROM... GROUND CIRCUIT.*

FIG. 2

YES

DISCONNECT THE IS ANY TERMINAL POWERTRAIN CONTROL INSPECT THE CORRODED, DAMAGED, YES REPAIR AS

MODULE.** CONNECTORS AND PUSHED OUT OR NECESSARY.*TERMINALS. MISWIRED?


NO


TROUBLE

CODE

TESTS

405



FIG. 1

8.0L CAL/MD ALL OTHERS

TROUBLE

CODE

TESTS

406






TEST.

NO


WITH THE DRB IN SENSORS, MONITOR WAIT FOR THE

THE 1/2 O2 SENSOR VOLTAGE READING TO VOLTAGE. STABILIZE ABOVE

4.5 VOLTS.

WITH THE DRB IN ACTUATOR TESTS, MONITOR THE 1/2 O2 IS THE 1/2 O2 YES CONTINUE TEST

PERFORM THE O2 SENSOR VOLTAGE FOR SENSOR VOLTAGE TC-105A ON THESENSOR HEATER THREE MINUTES. ABOVE 1.0 VOLT? NEXT PAGE.

TEST.

NO



TROUBLE

CODE

TESTS

407


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

408




THE PREVIOUS CONNECTOR.** PUSHED OUT OR AS NECESSARY.*PAGE. MISWIRED?


NO



FIG. 1

YES



FIG. 2

YES


FIG. 1

YES


TROUBLE

CODE

TESTS

409

TEST TC-106A REPAIRING - MULTIPLE CYLINDER MIS-FIRE


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

410

TEST TC-106A REPAIRING - MULTIPLE CYLINDER MIS-FIRE



NOTE: YOU MUST THIS CODE WILL START TEST REPAIR ANY ONLY SET IF THE WITH THE DRB,

TC-106A. NON-MISFIRE CONDITION OCCURS ERASE TROUBLETROUBLE CODES DURING THE ROAD CODES.

BEFORE CONTINUING. TEST.

NOTE: IN THE NEXT THE ENGINE MUST BE DRIVE VEHICLE AT ASTEP, YOU MUST STOP AT OPERATING STEADY RATE AT

IN THE MIDDLE OF TEMPERATURE AND VARIOUS MAP ANDYOUR ROAD TEST, KEY ADAPTIVE NUMERATOR RPM RANGES...OFF, THEN BACK ON... UPDATED.

DID THE "MULTIPLETEST DRIVE WITH THE DRB, READ CYLINDER MISFIRE" YES CONTINUE TEST

VEHICLE. TROUBLE CODES. TROUBLE CODE TC-106A ON THERETURN? NEXT PAGE.

NO

IS ANY SINGLE CYLINDER MISFIRE YES PERFORM TEST

TROUBLE CODE TC-107A. PRESENT?

NO

CONNECT A SUITABLE FOLLOW THE EQUIPMENT REPAIR OR REPLACEENGINE ANALYZER TO MANUFACTURER’S IS THE SECONDARY NO THE FAILED

THE ENGINE AND PROCEDURE FOR IGNITION PATTERN COMPONENT IN THESTART ENGINE. PATTERN ANALYSIS. OK? SECONDARY IGNITION

FIG. 1 SYSTEM.*

YES

WITH A SPRAY BOTTLE REPAIR THENOTE: DO NOT SPRAY SPRAY IGNITION DID IGNITION YES INDICATEDINDUCTIVE PICKUP. CABLES WITH WATER PATTERN CHANGE? COMPONENT IN THE

AND MONITOR IGNITION SECONDARY IGNITION PATTERN. SYSTEM.*

NO

NOTE: AN INACURRATE AT THIS TIME, THE REFER TO GEN INFO SPEED SENSOR READING CONDITIONS REQUIRED 3.3.2 FOR ADDITIONAL (TOO HIGH) MAY CAUSE TO SET THE TROUBLE INFORMATION ON TEST COMPLETE.*

THIS CODE TO SET CODE IS NOT PRESENT. INACTIVE TROUBLEINTERMITTENTLY. FIG. 2 CODES.*

NOTE: SHARPMANEUVERS MAY

TEMPORARILYDISABLE MISFIRE

DETECTION.

TROUBLE

CODE

TESTS

411

TEST TC-106A CONTINUED - REPAIRING - MULTIPLE CYLINDER MIS-FIRE

2.5L ENGINES

FIG. 1

4.0L ENGINES

FIG. 2

3.9L ENGINES

FIG. 3

5.2L AND 5.9L ENGINES

FIG. 4

TROUBLE

CODE

TESTS

412



TEST TC-106A INSPECT IGNITION CONTINUED FROM CABLES FOR PROPER ARE THE IGNITION NO REPAIR AS

THE PREVIOUS LOCATION. CABLES INSTALLED NECESSARY.*PAGE. CORRECTLY?

FIG. 1, 2, 3 OR 4

YES

TURN IGNITION OFF. FOLLOW THE REPAIR THE FAULTY CONNECT A SUITABLE EQUIPMENT IS THE SECONDARY NO COMPONENT(S) IN

ENGINE ANALYZER,THEN MANUFACTURER’S IGNITION PATTERN THE SECONDARYSTART ENGINE AND LET PROCEDURE FOR OK? IGNITION SYSTEM.* IDLE FOR 2 MINUTES. PATTERN ANALYSIS.

YES

REMOVE WHILE IS THE OPEN PLUG DISCONNECTING CIRCUIT SECONDARY NO REPLACE THE

WIRES FROM EACH WIRE, OBSERVE VOLTAGE AT LEAST IGNITION COIL.* COIL THE SECONDARY KV 25KV FOR EACH

. PEAK LINE. WIRE?

YES

USING APPROPRIATE DO ALL CYLINDERSTURN ENGINE OFF. PRESSURE GAUGE, HAVE A MINIMUM NO REPAIR ENGINE REMOVE ALL SPARK TEST ALL CYLINDERS COMPRESSION OF 100 MECHANICAL PROBLEM

PLUGS & ASD RELAY. FOR PROPER PSI AND WITHIN 25% AS NECESSARY.*COMPRESSION. OF EACH OTHER?

YES

REINSTALL ALL CONTINUE TEST SPARK PLUGS, WIRES TC-106A ON THE

AND ASD RELAY. NEXT PAGE.

MOMENTARILY &REINSTALL SPARK

IGNITION OR DISTRIBUTOR

ONE AT A TIME

TROUBLE

CODE

TESTS

413


FIG. 1

TROUBLE

CODE

TESTS

414



TEST TC-106ACONTINUED FROM CONNECT A VACUUM

THE PREVIOUS TURN IGNITION OFF. GAUGE TO ENGINE PAGE. VACUUM.

RUN ENGINE UNTIL DEPRESS PARKING DOES THE VACUUM NORMAL OPERATING BRAKE AND PUT GAUGE READ AT NO PERFORM TEST

TEMPERATURE IS SHIFT LEVER IN THE LEAST 13 INCHES. NTC-22A. REACHED. NEUTRAL POSITION. OF VACUUM?

(180 DEGREES F) READ VACUUM GAUGE. FIG. 1

YES

WHILE MONITORING THE VACUUM GAUGE, DID THE VACUUM NO REPAIR RESTRICTED SNAP THE THROTTLE DROP RAPIDLY TO EXHAUST SYSTEM.*

OPEN AND CLOSED. ZERO?

YES

WARNING: THE FUEL CONNECT A FUEL TURN IGNITION ON.SYSTEM MUST BE PRESSURE GAUGE TO WITH THE DRB,

TURN IGNITION OFF. OPENED AND MAY BE THE FUEL RAIL. ACTUATE THE FUEL UNDER PRESSURE. SEE APPROPRIATE SYSTEM TEST.

SEE GENERAL INFO 9.1 SERVICE MANUAL.

ALLOW TIME FOR WITH THE DRB, STOP FUEL PRESSURE FUEL SYSTEM TEST. IS THE FUEL YES PERFORM TEST

GAUGE TO STABILIZE MONITOR THE FUEL PRESSURE BELOW 45 NTC-3A.TO NORMAL FUEL PRESSURE GAUGE FOR PSI?

PRESSURE. 1 MINUTE.

NO

INSPECT THE AIR CLEAN THEFILTER AND INLET WERE THERE ANY YES RESTRICTED AIR

DUCTS FOR RESTRICTIONS? INLET SYSTEM AS RESTRICTIONS. NECESSARY.*

NO

NOTE: AN INACCURATE SPEED SENSOR READING CONTINUE TEST (TOO HIGH) MAY CAUSE TC-106A ON THE

THIS CODE TO SET NEXT PAGE.INTERMITTENTLY.

TROUBLE

CODE

TESTS

415


NOTES

TROUBLE

CODE

TESTS

416

TEST TC-106A CONTINUED − REPAIRING − MULTIPLE CYLINDER MIS-FIRE

Make sure all the wiring and connectors are ok.

Perform each of the following tests in the order listed below. If a test passes, continue to the next testuntil the problem is found:

Secondary Ignition Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-2A

Fuel Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-3A

PCM Grounds and Power Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-11A

EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-13A

Engine Mechanical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-22A


TROUBLE

CODE

TESTS

417

TEST TC-107A REPAIRING - CYLINDER #1, #2, #3, #4, #5, #6, #7, OR #8 MISFIRE


FIG. 1

2.5L ENGINES

FIG. 2

4.0L ENGINES

FIG. 3

3.9L ENGINES

FIG. 4

5.2L 5.9L ENGINES

FIG. 5

TROUBLE

CODE

TESTS

418

TEST TC-107A REPAIRING - CYLINDER #1, #2, #3, #4, #5, #6, #7, OR #8 MISFIRE



NOTE: YOU MUST START TEST REPAIR MULTIPLE

TC-107A. MISFIRE OR ANYNON-MISFIRE TROUBLE

CODES FIRST.

NOTE: READ FIGURE 1 INSPECT IGNITION TO GET A CLEAR CABLES FOR PROPER ARE THE IGNITION NO REPAIR AS

UNDERSTANDING OF LOCATION. CABLES INSTALLED NECESSARY.*THIS CODE BEFORE CORRECTLY?

PROCEEDING. FIG. 2, 3, 4 OR 5

YES

TURN IGNITION OFF. FOLLOW THE REPAIR THE FAULTY CONNECT A SUITABLE EQUIPMENT IS THE SECONDARY NO COMPONENT(S) IN

ENGINE ANALYZER,THEN MANUFACTURER’S IGNITION PATTERN THE SECONDARYSTART ENGINE AND LET PROCEDURE FOR OK? IGNITION SYSTEM.* IDLE FOR 2 MINUTES. PATTERN ANALYSIS.

YES

REMOVE ONE AT A TIME, IS THE OPEN WHILE OBSERVING CIRCUIT SECONDARY NO REPLACE THE

PLUG WIRE FROM THE SECONDARY KV VOLTAGE AT LEAST IGNITION COIL.* COIL PEAK LINE. 25KV FOR EACH

WIRE?

YES

WITH A SPRAY BOTTLE NOTE: IN THE NEXT SPRAY THE IGNITION DID IGNITION YES REPLACE IGNITION STEP DO NOT SPRAY CABLES WITH WATER PATTERN CHANGE? CABLES AS INDUCTIVE PICKUP. AND MONITOR IGNITION NECESSARY.*

PATTERN.

NO

USING APPROPRIATE DO ALL CYLINDERSTURN ENGINE OFF. PRESSURE GAUGE, HAVE A MINIMUM NO REPAIR ENGINE REMOVE ALL SPARK TEST ALL CYLINDERS COMPRESSION OF 100 MECHANICAL PROBLEM

PLUGS & ASD RELAY. FOR PROPER PSI AND WITHIN 25% AS NECESSARY.*COMPRESSION. OF EACH OTHER?

YES


NEXT PAGE.

MOMENTARILY& REINSTALL EACH

THEIGNITION OR

DISTRIBUTOR...

TROUBLE

CODE

TESTS

419

TEST TC-107A CONTINUED - REPAIRING - CYLINDER #1, #2, #3, #4, #5, #6, #7, OR #8 MISFIRETROUBLE

CODE

TESTS

420

TEST TC-107A CONTINUED - REPAIRING - CYLINDER #1, #2, #3, #4, #5, #6, #7, OR #8 MISFIRE


TEST TC-107ACONTINUED FROM REINSTALL SPARK

THE PREVIOUS PLUGS, PLUG WIRESPAGE. AND ASD RELAY.

START ENGINE, LETIDLE UNTIL NORMAL WITH THE DRB,

OPERATING PERFORM INJECTOR TEMPERATURE IS KILL TEST.

REACHED.

MONITOR SCOPE DID INJECTOR KILL INSPECT LOW CYLINDER PATTERN AND ENGINE TEST SHOW A WEAK YES FOR MECHANICAL RPM WHEN INJECTOR CYLINDER? PROBLEMS, IF OK.KILL IS ACTUATED. REPLACE APPROPRIATE

INJECTOR.*

NO

TURN ENGINE OFF, PARKING BRAKE ON DOES THE VACUUM CONNECT A VACUUM GEAR SHIFT IN THE GAUGE READ AT NO PERFORM TEST

GAUGE TO MANIFOLD NEUTRAL POSITION. LEAST 13 INCHES OF TEST NTC-22A. VACUUM. START VACUUM?

ENGINE, LET IDLE. READ VACUUM GAUGE.

YES

INSPECT VALVETRAIN AND TIMING IS THE VALVE NO REPAIR OR REPLACEOF THE CYLINDER TIMING OK? ENGINE COMPONENTS WITH THE TROUBLE AS NECESSARY.*

CODE.

YES

NOTE: AN INACCURATE NOTE: CHECK TSB’SSPEED SENSOR READING AND FLASH UPDATES REPLACE THE(TOO HIGH) MAY CAUSE THAT MAY APPLY TO POWERTRAIN CONTROL

THIS CODE TO SET THIS CODE BEFORE MODULE.* INTERMITTENTLY. NEXT REPAIR.

TROUBLE

CODE

TESTS

421

TEST TC-112A REPAIRING - CATALIYTIC CONVERTER EFFICIENCY FAILURE


FIG. 1

TROUBLE

CODE

TESTS

422

TEST TC-112A REPAIRING - CATALIYTIC CONVERTER EFFICIENCY FAILURE



NOTE: ANY OTHER O2 ARE THERE ANY PERFORM THESTART TEST SENSOR TROUBLE OTHER TROUBLE YES DTC TEST OR

TC-112A. CODES OR T.S.B.’S CODES OR T.S.B.’S T.S.B.’S THAT SHOULD BE REPAIRED THAT APPLY? APPLY. BEFORE PROCEEDING.

NO

REFER TO FIGURE 1FOR POSSIBLE TROUBLE CODE

CAUSES.

CHECK THE EXHAUST REPAIR OR REPLACESTART ENGINE AND SYSTEM FOR LEAKS IS THERE ANY YES LEAKING EXHAUST

LET IDLE. BETWEEN THE ENGINE EXHAUST LEAK? PARTS AS AND THE 1/2 O2 NECESSARY.*

SENSOR.

NO


EXCESSIVE SMOKE CONSUMPTION NECESSARY, ANDFROM INTERNAL OIL CONDITION PRESENT? REPLACE CATALYTICOR COOLANT LEAKS. CONVERTER.*

NO

NOTE: A NEW HAS THE DOWNSTREAM DOWNSTREAM O2 SENSOR MAY CAUSE OXYGEN SENSOR BEEN NO REPLACE THE

SENSOR ALONG THIS TROUBLE CODE REPLACED WITHIN CATALYTICWITH AN AGING TO SET. THE LAST 5000 CONVERTER.*UPSTREAM O2... MILES?

YES

HAS THE UPSTREAM OXYGEN SENSOR BEEN YES REPLACE THE

REPLACED WITHIN CATALYTICTHE LAST 5000 CONVERTER.*

MILES?

NO

REPLACE THEUPSTREAM OXYGEN

SENSOR.*

TROUBLE

CODE

TESTS

423

TEST TC-113A REPAIRING - EVAP PURGE FLOW MONITOR FAILURE

Perform TEST DTC Before Proceeding

FIG. 1

1996 2.5/4.0/5.2/5.9/8.0L Jeep and Truck EnginePublication No. 81-699-96103TSB 26-06-97 June, 1997

WITHOUT LDP

WITH LDP

TROUBLE

CODE

TESTS

424

TEST TC-113A REPAIRING - EVAP PURGE FLOW MONITOR FAILURE



NOTE: REPLACING NOTE: CAREFULLYSTART TEST THE POWERTRAIN WITH THE DRB, INSPECT ALL VACUUM

TC-113A. CONTROL MODULE ERASE CODES. HOSES FOR PROPER WILL NOT CORRECT ROUTING AND FOR

THIS PROBLEM. PINCHED OR...

PLUGGED HOSES FROM ENGINE TO EVAP ARE ALL VACUUM NO REPAIR THE VACUUM

SOLENOID TO GAS HOSES OK? HOSES AS TANK. NECESSARY.*

YES

START ENGINE. ALLOWENGINE TO REACH TURN THE ENGINE NORMAL OPERATING OFF (IGN. OFF).

TEMPERATURE (ABOVE 170 DEG.).

DISCONNECT THE START THE ENGINE. IS THE PURGEPURGE VACUUM HOSE THERE SHOULD BE NO SOLENOID ALLOWING YES PERFORM TEST

AT THE SOLENOID FLOW THROUGH THE VACUUM THROUGH THE TC-113C. THAT GOES TO THE SOLENOID FROM 1 TO SOLENOID WITHIN 1

CANISTER. 2 MINUTES. MINUTE?

NO

AFTER 90 SECONDS, IS PURGE SOLENOID THE PURGE CYCLE ALLOWING VACUUM TO NO CONTINUE TEST

SOLENOID WILL INTERMITTENTLY AT CYCLE THROUGH TC-113A ON THEALLOW VACUUM TO... A STEADY RATE. INTERMITTENTLY AT NEXT PAGE.

A STEADY RATE?

YES

NOTE: IN THE NEXT KEY OFF, ATTEMPT SOLENOID AND HOSESSTEPS, DO NOT USE TO BLOW AIR DOES THE CANISTER YES ARE OK.MORE THAN FIVE (5) THROUGH VACUUM AND VACUUM LINE

PSI. LINE THAT GOES TO ALLOW AIR TO PASS?CANISTER. FIG. 1

NO

PERFORM TEST TC-113B.


TROUBLE

CODE

TESTS

425

TEST TC-113A CONTINUED - REPAIRING - EVAP PURGE FLOW MONITOR FAILURE


AB BODY

FIG. 1

AN BODY

FIG. 2


BR BODY

FIG. 3

XJ BODY

FIG. 4

ZJ 4.0L

FIG. 5

ZJ 5.2L

FIG. 6

TROUBLE

CODE

TESTS

426

TEST TC-113A CONTINUED - REPAIRING - EVAP PURGE FLOW MONITOR FAILURE



TEST TC-113A REMOVE THE HOSE’S AT CONTINUED FROM THE EVAP SOLENOID.

THE PREVIOUS PAGE.

FIG. 1,2,3,4,5 OR 6

CONNECT A VACUUM GAUGE TO THE VACUUM DOES THE GAUGE NO REPAIR THE VACUUM

HOSE THAT GOES TO READ MANIFOLD HOSE OR THROTTLE THE THROTTLE BODY. VACUUM? BODY.* FIG.1,2,3,4,5 OR 6

YES

RECONNECT THE VACUUM CONNECT A VACUUM LINE FROM THE GAUGE TO THE DOES THE VACUUM NO REPLACE THE EVAP

THROTTLE BODY TO THE CANISTER SIDE OF GAUGE READ 5" OF SOLENOID.* EVAP SOLENOID. THE EVAP SOLENOID. VACUUM +/- 2"?

FIG.1,2,3,4,5 OR 6 FIG.1,2,3,4,5 OR 6

YES

CONNECT AN AUXILIARYVACUUM SUPPLY TO THE DOES CANISTER HOLD NO REPLACE THE EVAP

HOSE GOING TO THE MORE THAN 2" OF SOLENOID.* CANISTER. ACHIEVE > VACUUM?

2" OF VACUUM.

YES

CHECK FOR A IS THE HOSE YES REPAIR AS PLUGGED HOSE OR PLUGGED? NECESSARY.*

PLUGGED VENT PORT.

NO

IS THE VENT PORT YES CLEAN THE PLUGGEDPLUGGED? VENT AND RETEST.*

NO

REPLACE THE EVAP CANISTER.*


TROUBLE

CODE

TESTS

427

TEST TC-113B CONTINUED - REPAIRING - EVAP PURGE FLOW MONITOR FAILURE


AB BODY

FIG. 1

AN BODY

FIG. 2


BR BODY

FIG. 3

XJ BODY

FIG. 4

ZJ 4.0L

FIG. 5

ZJ 5.2L

FIG. 6

TROUBLE

CODE

TESTS

428

TEST TC-113B CONTINUED - REPAIRING - EVAP PURGE FLOW MONITOR FAILURE



DISCONNECT THESTART TEST PURGE VACUUM LINE

TC-113B. AT THE CANISTER.

FIG.1,2,3,4,5 OR 6

ATTEMPT TO BLOW AIR THROUGH THE DOES THE VACUUM NO REPAIR OR REPLACEVACUUM LINE THAT LINE ALLOW AIR TO THE VACUUM LINE.*

GOES TO THE PASS?CANISTER.

YES

CHECK FOR A IS THE VENT PORT NO REPLACE THEPLUGGED VENT PORT PLUGGED? EVAPORATIVE

ON CANISTER. CANISTER.*

YES

REPAIR THE PLUGGEDVENT PORT AND

RETEST.*


TROUBLE

CODE

TESTS

429

TEST TC-113C REPAIRING - EVAP PURGE FLOW MONITOR FAILURE


NOTES

TROUBLE

CODE

TESTS

430

TEST TC-113C REPAIRING - EVAP PURGE FLOW MONITOR FAILURE



REMOVE THE PURGESTART TEST SOLENOID AND TAP DID ANY FOREIGN NO REPLACE THE EVAP

TC-113C. THE PORTS AGAINST MATERIAL FALL OUT? PURGE SOLENOID.* A CLEAN SOLID

SURFACE.

YES

INSPECT THE LINE CLEAN OUT LINE ANDFROM THE PURGE IS THE LINE NO REPLACE THE EVAP

SOLENOID TO THE DISCONNECTED, PURGE SOLENOID ANDCANISTER. RIPPED OR CUT? CANISTER.*

YES

REPAIR THE LINE AND REPLACE THEPURGE SOLENOID.*


TROUBLE

CODE

TESTS

431

TEST TC-114A REPAIRING - P/N SWITCH STUCK IN PARK OR IN GEAR


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

432

TEST TC-114A REPAIRING - P/N SWITCH STUCK IN PARK OR IN GEAR



WITH THE DRB, READ START TEST THE PARK/NEUTRAL

TC-114A. SWITCH INPUTSTATE.

WHILE MOVING GEAR SELECTOR IN & OUT DID THE DISPLAY NO CONTINUE TEST OF PARK & REVERSE, SHOW "P/N" AND TC-114A ON THE

WATCH THE DRB "D/R"? NEXT PAGE.DISPLAY.

YES

AT THIS TIME, THE INSPECT THE WIRING CONDITION REQUIRED AND CONNECTORS WERE ANY PROBLEMS YES REPAIR AS TO SET THE CODE IS RELATING TO PARK FOUND? NECESSARY.*

NOT PRESENT. NEUTRAL POSITION FIG. 1 SWITCH.

NO


INFORMATION.

TROUBLE

CODE

TESTS

433

TEST TC-114A CONTINUED - REPAIRING - P/N SWITCH STUCK IN PARK OR IN GEAR

AB BODY

FIG. 1

AN AND XJ BODIES

FIG. 2

BR AND ZJ BODIES

FIG. 3

TROUBLE

CODE

TESTS

434



TEST TC-114A KEY OFF. PUT THECONTINUED FROM GEAR SELECTOR IN PREVIOUS PAGE. PARK.


MODULE.**


MEASURE THE OBSERVE OHMMETER DID THE DISPLAYRESISTANCE BETWEEN DISPLAY WHILE MOVING SWITCH FROM BELOW YES REPLACE THE

THE P/N SWITCH SENSE GEAR SELECTOR FROM 10.0 OHMS TO ABOVE POWERTRAIN CONTROLCIRCUIT AND GROUND. PARK TO REVERSE AND 10.0 OHMS? MODULE.*

FIG. 1, 2 OR 3. BACK TO PARK.

NO

DID THE DISPLAY NO CONTINUE TEST STAY BELOW 10.0 TC-114A ON THE

OHMS AT ALL TIMES? NEXT PAGE.

YES

DISCONNECT THE PARK NEUTRAL SWITCH.**


MEASURE THERESISTANCE BETWEEN IS THE RESISTANCE YES REPAIR P/N SWITCH

THE P/N SWITCH SENSE BELOW 5.0 OHMS? SENSE CKT FOR ACIRCUIT AND GROUND. SHORT TO GROUND.*

FIG. 1, 2 OR 3.

NO

REPAIR OR REPLACESTUCK PARK NEUTRAL

SWITCH.*

TROUBLE

CODE

TESTS

435


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

XJ BODY 4.0L AUTO

FIG. 4

XJ BODY ALL OTHERS

FIG. 5

ZJ BODY

FIG. 6

TROUBLE

CODE

TESTS

436



DISCONNECT THETEST TC-114A PARK/NEUTRAL

CONTINUED FROM POSITION SWITCH PREVIOUS PAGE. CONNECTOR.**

MEASURE THE FROM THE PCMRESISTANCE OF THE CONNECTOR TO THE P/N IS THE RESISTANCE YES REPLACE THE

P/N SWITCH SENSE SWITCH CONNECTOR. BELOW 5.0 OHMS? PARK/NEUTRAL CIRCUIT... POSITION SWITCH.*

FIG. 1,2,3,4,5 OR 6

NO

REPAIR OPEN P/NSWITCH SENSE CKT.*


TROUBLE

CODE

TESTS

437

TEST TC-115A REPAIRING - POWER STEERING SWITCH FAILURE


XJ BODY

FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

438

TEST TC-115A REPAIRING - POWER STEERING SWITCH FAILURE


START ENGINE. WITH DID THE POWERSTART TEST THE DRB, MONITOR STEERING PRESSURE NO CONTINUE TEST

TC-115A THE P/S SW. TURN SWITCH CHANGE TC-115A ON THETHE STEERING WHEEL STATE? NEXT PAGE.TO BOTH EXTREMES.

YES

USING THESCHEMATIC, INSPECT WERE ANY PROBLEMS YES REPAIR AS

THE WIRING AND FOUND? NECESSARY.*HARNESSES.

NO

WITH THE DRBMONITOR THE PS DID THE POWER YES REPAIR THE HARNESSSWITCH STATE, STEERING SWITCH AS NECESSARY.*

WHILE WIGGLING THE CHANGE STATE? HARNESS

NO

REFER TO FIGURE 1AND FIGURE 2 FOR

ADDITIONAL TEST COMPLETE.* INFORMATION.

TROUBLE

CODE

TESTS

439

TEST TC-115A CONTINUED - REPAIRING - POWER STEERING SWITCH FAILURE

XJ BODY

FIG. 1

XJ BODY

FIG. 2

TROUBLE

CODE

TESTS

440



TEST TC-115A KEY OFF. DISCONNECT CONNECT A JUMPER CONTINUED FROM THE POWER STEERING WIRE TO THE POWER

THE PREVIOUS PRESSURE SWITCH.** STEERING PRESSURE PAGE. SWITCH CIRCUIT.


WITH THE DRB, DID THE POWER YESMONITOR THE POWER TOUCH THE OTHER STEERING PRESSURE CONTINUE TEST STEERING PRESSURE END OF THE JUMPER SWITCH CHANGE TC-115A ON THE

SWITCH. TO GROUND 5 TIMES. STATE? NEXT PAGE.

NO

DISCONNECT THE WITH AN OHMMETER, REPAIR THE OPEN POWERTRAIN CONTROL MEASURE THE P/S WAS THE RESISTANCE NO POWER STEERING

MODULE.** PRESSURE SW CKT FROM BELOW 5.0 OHMS? PRESSURE SWITCH THE PCM TO THE CIRCUIT.*

SEE GENERAL INFO 4.1 CONN. FIG. 2

YES

USING AN OHMMETER, REPAIR THE POWERMEASURE THE P/S WAS THE RESISTANCE YES STEERING PRESSURE

PRESSURE SWITCH CKT BELOW 5.0 OHMS? SWITCH CIRCUIT FORAT THE P/S SW TO A SHORT TO

GROUND. FIG. 1 GROUND.*

NO


MODULE.*

TROUBLE

CODE

TESTS

441


XJ BODY

FIG. 1

TROUBLE

CODE

TESTS

442



TEST TC-115A USING AN OHMMETER,CONTINUED FROM MEASURE THE GROUND IS THE RESISTANCE NO REPAIR THE OPEN

THE PREVIOUS CIRCUIT AT P/S BELOW 5.0 OHMS? GROUND CIRCUIT.*PAGE. PRESSURE SW CONN.

FIG. 1

YES

REPLACE THE POWERSTEERING PRESSURE

SWITCH.*

TROUBLE

CODE

TESTS

443

TEST TC-118A REPAIRING - FUEL SYSTEM 1/1 RICH


FIG. 1

TROUBLE

CODE

TESTS

444





TC-118A. CODES OR T.S.B.’S CODES OR T.S.B.’S T.S.B.’S THAT SHOULD BE REPAIRED THAT APPLY? APPLY. BEFORE PRODEEDING.

NO


CAUSES.

PERFORM O2 HEATER DID TEST TC-103A NO TEST TC-103A. PASS? TEST COMPLETE. *

YES

WITH THE DRB, READ IS THE LONG TERM THE CONDITIONTURN ENGINE OFF THE LONG TERM ADAPTIVE MEMORY NO REQUIRED TO SET THIS

AND KEY ON. ADAPTIVE MEMORY BETWEEN TROUBLE CODE IS NO VALUE. -20% TO -38%? LONGER PRESENT.

TEST COMPLETE.*

YES


TROUBLE

CODE

TESTS

445

TEST TC-118B REPAIRING - FUEL SYSTEM 1/1 RICH


5.9L HD, 8.0L HD AND 8.0L CAL/MD

ALL CNG

ALL OTHERS

TROUBLE

CODE

TESTS

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 testuntil the problem is found.


Coolant Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-4A

Throttle Position Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST-NTC5A

MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-6A

Evaporative Emission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-12A



TROUBLE

CODE

TESTS

447

TEST TC-119A REPAIRING - FUEL SYSTEM 1/1 LEAN


FIG. 1

TROUBLE

CODE

TESTS

448




NOTE: VERY LOW FUEL DID THE VEHICLE ERASE TROUBLESTART TEST LEVEL COULD CAUSE RUN OUT OF FUEL YES CODES.

TC-119A. THIS TROUBLE CODE TO SHORTLY BEFORE SET. MAKE SURE TANK COMING IN? TEST COMPLETE.* IS AT LEAST 1/4 FULL

NO

REFER TO FIGURE 1 ARE THERE ANY PERFORM THEFOR POSSIBLE WITH THE DRB, READ OTHER TROUBLE YES DTC TEST OR TROUBLE CODE ALL TROUBLE CODES. CODES OR T.S.B.’S THE T.S.B.’S

CAUSES. THAT APPLY? THAT APPLY..

NO

START THE ENGINE CHECK EXHAUSTAND ALLOW IT TO SYSTEM FOR LEAKS ARE THERE ANY YES REPAIR OR REPLACE

REACH NORMAL BETWEEN ENGINE AND EXHAUST LEAKS? EXHAUST COMPONENTS OPERATING THE O2 SENSORS. AS NECESSARY.*

TEMPERATURE.

NO

IS THE 1/1 O2S STATE THE CONTITIONWITH THE DRB, FOR 20 SECONDS OR SWITCHING BETWEEN YES REQUIRED TO SET THIS

MONITOR THE 1/1 O2 MORE. "LEAN-CENTER-RICH" TROUBLE CODE IS NO SENSOR STATE... TWICE OR MORE IN 20 LONGER PRESENT.

SECONDS? TEST COMPLETE.*

NO

WITH THE DRB, READ ARE ANY OF THE THE CONDITIONTHE LONG TERM LONG TERM ADAPTIVE NO REQUIRED TO SET THIS

ADAPTIVE MEMORY MEMORY BETWEEN TROUBLE CODE IS NO VALUES. +18% AND +25% ? LONGER PRESENT.

TEST COMPLETE.*

YES


TROUBLE

CODE

TESTS

449

TEST TC-119B REPAIRING - FUEL SYSTEM 1/1 LEAN



ALL CNG

ALL OTHERS

TROUBLE

CODE

TESTS

450







Throttle Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-5A


Evaporative Emission System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-13A

Engine Mechanical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST-NTC22A


TROUBLE

CODE

TESTS

451



FIG. 1

TROUBLE

CODE

TESTS

452





TC-120A. CODES OR T.S.B.’S CODES OR T.S.B.’S T.S.B.’S THAT MUST BE REPAIRED THAT APPLY? APPLY.

BEFORE PROCEEDING.

NO


CAUSES.

PERFORM O2 HEATER DID TEST TC-124A NO TEST TC-124A. PASS? TEST COMPLETE. *

YES

WITH THE DRB, READ IS THE LONG TERM THE CONDITIONTURN ENGINE OFF THE LONG TERM ADAPTIVE MEMORY NO REQUIRED TO SET THIS

AND KEY ON. ADAPTIVE MEMORY BETWEEN TROUBLE CODE IS NO VALUE. -20% TO -38%? LONGER PRESENT.

TEST COMPLETE.*

YES


TROUBLE

CODE

TESTS

453




TROUBLE

CODE

TESTS

454






Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-2A





TROUBLE

CODE

TESTS

455



FIG. 1

TROUBLE

CODE

TESTS

456




NOTE: VERY LOW FUEL DID THE VEHICLE ERASE TROUBLESTART TEST LEVEL COULD CAUSE RUN OUT OF FUEL YES CODES.

TC-121A. THIS TROUBLE CODE TO SHORTLY BEFORE SET. MAKE SURE TANK COMING IN? TEST COMPLETE.* IS AT LEAST 1/4 FULL

NO

REFER TO FIGURE 1 ARE THERE ANY PERFORM THEFOR POSSIBLE WITH THE DRB, READ OTHER TROUBLE YES DTC TEST OR TROUBLE CODE ALL TROUBLE CODES. CODES OR T.S.B.’S THE T.S.B.’S

CAUSES. THAT APPLY? THAT APPLY..

NO

START THE ENGINE CHECK EXHAUSTAND ALLOW IT TO SYSTEM FOR LEAKS ARE THERE ANY YES REPAIR OR REPLACE

REACH NORMAL BETWEEN ENGINE AND EXHAUST LEAKS? EXHAUST COMPONENTS OPERATING THE O2 SENSORS. AS NECESSARY.*

TEMPERATURE.

NO

IS THE 2/1 O2S STATE THE CONTITIONWITH THE DRB, FOR 20 SECONDS OR SWITCHING BETWEEN YES REQUIRED TO SET THIS

MONITOR THE 2/1 O2 MORE. "LEAN-CENTER-RICH" TROUBLE CODE IS NO SENSOR STATE... TWICE OR MORE IN 20 LONGER PRESENT.

SECONDS? TEST COMPLETE.*

NO

WITH THE DRB, READ ARE ANY OF THE THE CONDITIONTHE LONG TERM LONG TERM ADAPTIVE NO REQUIRED TO SET THIS

ADAPTIVE MEMORY MEMORY BETWEEN TROUBLE CODE IS NO VALUES. +20% AND +32% ? LONGER PRESENT.

TEST COMPLETE.*

YES


TROUBLE

CODE

TESTS

457




TROUBLE

CODE

TESTS

458






Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TEST NTC-2A





TROUBLE

CODE

TESTS

459



FIG. 1

TYPICAL CONNECTOR

FIG. 2

TROUBLE

CODE

TESTS

460




REFER TO THE FIGURE START TEST FOR POSSIBLE TROUBLE

TC-122A. CODE CAUSES.

FIG. 1



NO

NOTE: CHECK THE IS THERE AN OIL OR REPAIR ENGINE EXHAUST FOR COOLANT YES MECHANICAL,

EXCESSIVE SMOKE CONSUMPTION REPLACE THE 2/1 O2 CAUSED BY OIL OR CONDITION PRESENT? SENSOR.*

COOLANT CONSUMPTION.

NO

KEY OFF. DISCONNECT IS ANY TERMINAL THE 2/1 OXYGEN INSPECT THE CORRODED, DAMAGED, YES REPAIR OR REPLACE

SENSOR.** CONNECTORS AND PUSHED OUT OR AS NECESSARY.*TERMINALS. MISWIRED?


NO

USING AN OHMMETER, GROUND CIRCUIT TO MEASURE THE A GOOD GROUND. IS THE RESISTEANCE NO REPAIR THE OPEN

RESISTANCE FROM BELOW 5.0 OHMS? 2/1 O2 SENSOR THE O2 SENSOR... GROUND CIRCUIT.*

FIG. 2

YES

DISCONNECT THEPOWERTRAIN CONTROL INSPECT THE IS THE CONNECTOR NO REPAIR AS

MODULE.** CONNECTOR. CONDITION OK? NECESSARY.*


YES

REPLACE THE 2/1OXYGEN SENSOR.*

TROUBLE

CODE

TESTS

461



FIG. 1

TROUBLE

CODE

TESTS

462




START TEST TURN IGNITION ON TC-124A. (ENGINE OFF).

WITH THE DRB, MONITOR THE 2/1 O2 WAIT FOR THESENSOR VOLTAGE FOR VOLTAGE READING TO

A FEW MINUTES. STABILIZE ABOVE4.5 VOLTS.

WITH THE DRB, ACTUATE THE O2 MONITOR THE 2/1 O2 IS THE 2/1 O2 YES CONTINUE TEST SENSOR HEATER SENSOR VOLTAGE FOR SENSOR VOLTAGE TC-124A ON THE

TEST. UP TO TWO MINUTES. ABOVE 1.0 VOLT? NEXT PAGE.

NO

AT THIS TIME, THE REFER TO GENERALCONDITION REQUIRED INFO 3.3.2 FOR STOP ALL ACTUATOR TO SET THE TROUBLE INFORMATION ON TESTS.

CODE IS NOT PRESENT. INACTIVE TROUBLE TEST COMPLETE.* FIG. 1 CODES.

TROUBLE

CODE

TESTS

463


TYPICAL CONNECTOR

FIG. 1

TYPICAL CONNECTOR

FIG. 2

TROUBLE

CODE

TESTS

464



TEST TC-124A DISCONNECT THE 2/1 ARE ANY TERMINALSCONTINUED FROM O2 SENSOR CONNECTOR CORRODED, DAMAGED, YES REPAIR AS

THE PREVIOUS AND INSPECT ALL PUSHED OUT OR NECESSARY.*PAGE. TERMINALS.** MISWIRED.


NO

WITH THE O2 HEATER OF THE ASD RELAYTEST STILL OUTPUT AT THE O2 IS THE VOLTAGE YES REPAIR THE OPEN

RUNNING. MEASURE SENSOR CONNECTOR. BELOW 10.0 VOLTS? ASD RELAY OUTPUT THE VOLTAGE... CIRCUIT.*

FIG. 1

NO

USING AN OHMMETER, OUTPUT TO THEMEASURE THE 2/1 O2 HEATER GROUND AT IS THE RESISTANCE NO REPLACE THE 2/1

SENSOR HEATER THE O2 SENSOR BETWEEN 4.0 AND OXYGEN SENSOR.* ELEMENT FROM THE CONNECTOR. 7.0 OHMS?

ASD RELAY... FIG. 2

YES

USING AN OHMMETER, O2 SENSOR REPAIR THE OPEN MEASURE THE HEATER CONNECTOR TO IS THE RESISTANCE NO GROUND CIRCUIT TO

GROUND CIRCUIT GROUND. BELOW 5.0 OHMS? THE 2/1 O2 FROM THE... SENSOR.*

FIG. 1

YES

REPLACE THE 2/1OXYGEN SENSOR.*

TROUBLE

CODE

TESTS

465



TROUBLE

CODE

TESTS

466




START TEST START ENGINE, LETTC-126A. IDLE FOR AT LEAST

5 MINUTES.

WITH THE DRB, READ IS THE 1/2 O2 NO CONTINUE TEST THE 1/2 O2 SENSOR SENSOR VOLTAGE TC-126A ON THE


YES

DISCONNECT THE 1/2O2 SENSOR IS THE 1/2 O2 NO REPLACE THE 1/2

CONNECTOR.** SENSOR VOLTAGE OXYGEN SENSOR.* ABOVE 4.97 VOLTS?


YES


SHORT TO VOLTAGE.*

TROUBLE

CODE

TESTS

467

TEST TC-126A CONTINUED - REPAIRING - 1/2 O2 SENSOR SHORTED TO VOLTAGETROUBLE

CODE

TESTS

468



TEST TC-126ACONTINUED FROM WITH THE ENGINE

THE PREVIOUS STILL IDLING.PAGE.

DID THE 1/2 O2 REPAIR THE HARNESSWIGGLE THE 1/2 O2 WHILE WIGGLING THE SENSOR VOLTAGE GO YES OR CONNECTOR THAT

SENSOR CONNECTOR HARNESS, WATCH THE ABOVE 1.2 VOLTS AT HAS THEAND HARNESS. DRB DISPLAY. ANY TIME? INTERMITTENT SHORT

TO VOLTAGE.*

NO

AT THIS TIME, THECONDITION REQUIRED TO SET THE TROUBLE

CODE IS NOTPRESENT.

TURN KEY OFF. DISCONNECT THE PCM INSPECT ALL WERE THERE ANY YES REPAIR AS

AND THE 1/2 O2 TERMINALS. PROBLEMS FOUND? NECESSARY.*SENSOR

CONNECTOR.**

NO

USING A SCHEMATICAS A GUIDE, WERE THERE ANY YES REPAIR AS INSPECT THE PROBLEMS FOUND? NECESSARY.*

WIRING.

NO

TEST COMPLETE.*

TROUBLE

CODE

TESTS

469

TEST TC-128A REPAIRING - CLOSED LOOP TEMP NOT REACHED


FIG. 1

TROUBLE

CODE

TESTS

470

TEST TC-128A REPAIRING - CLOSED LOOP TEMP NOT REACHED



THIS TEST START TEST PROCEDURE WILL BE IS THE THERMOSTAT NO REPLACE THE

TC-128A. INVALID IF THE OPERATING THERMOSTAT.* THERMOSTAT IS CORRECTLY?

STUCK OPEN.

YES

TO HAVE A CLEAR RUN ENGINE UNTILUNDERSTANDING OF ENGINE TEMPERATURETHIS CODE PLEASE IS ABOVE

READ FIGURE 1. 80 DEGREES F.

KEY OFF, DISCONNECT THE ENGINE COOLANT IS ANY TERMINAL YES CLEAN OR REPAIR TEMPERATURE SENSOR DAMAGED, PUSHED CONNECTOR AS

CONNECTOR.** OUT OR MISWIRED? NECESSARY.*SEE GENERAL INFO 4.4

NO

USING AN OHMMETER, REPLACE ENGINE MEASURE THE IS THE RESISTANCE NO COOLANT

RESISTANCE OF THE BELOW 11.00 K OHM? TEMPERATUREENGINE COOLANT SENSOR.*

SENSOR.

YES

KEY OFF. DISCONNECT THE POWERTRAIN IS ANY TERMINAL YES CLEAN OR REPAIR

CONTROL MODULE.** DAMAGED, PUSHED CONNECTOR AS OUT OR MISWIRED? NECESSARY.*


NO


MODULE.*

TROUBLE

CODE

TESTS

471

TEST TC-132A REPAIRING - TPS VOLTAGE DOES NOT AGREE WITH MAP


ZJ BODY

ALL OTHERS

FIG. 1

TROUBLE

CODE

TESTS

472

TEST TC-132A REPAIRING - TPS VOLTAGE DOES NOT AGREE WITH MAP



START TEST USING THE DRB, IS ANY OTHER MAP YES PERFORM "DTC TC-132A. READ THE TROUBLE SENSOR TROUBLE TEST".

CODES. CODE PRESENT?

NO

WITH THE DRB, READ IS THE MAP SENSOR YES PERFORM TEST THE MAP SENSOR VOLTAGE BELOW 3.5 NTC-6A.

VOLTAGE. VOLTS?

NO

DID THE MAP SENSOR WITH THE DRB, READ VOLTAGE DROP FROM NO PERFORM TEST

START ENGINE. THE MAP SENSOR ABOVE 3.5 VOLTS TO NTC-6A.VOLTAGE. BELOW 2.0 VOLTS?

YES

NOTE: TO HAVE ACLEAR CONTINUE TEST

UNDERSTANDING OF TC-132A ON THETHIS TROUBLE CODE NEXT PAGE.

READ FIGURE 1.

TROUBLE

CODE

TESTS

473

TEST TC-132A CONTINUED - REPAIRING - TPS VOLTAGE DOES NOT AGREE WITH MAP


FIG.1

BR DIESEL

FIG. 2

ZJ BODY

FIG. 3

TROUBLE

CODE

TESTS

474



TEST TC-132A CHECK THROTTLE ENSURE THECONTINUED FROM PLATE AND LINKAGE THROTTLE LINKAGE

THE PREVIOUS FOR A BINDING IS AT THE IDLE PAGE. CONDITION. POSITION.

NOTE: TP SENSOR GND DISCONNECT THE TP CIRCUIT AND THE SENSOR.**

5-VOLT SUPPLY CKTSWITCHED WILL CAUSETHIS CODE TO APPEAR. SEE GENERAL INFO 4.4

INSPECT TP SENSOR WIRE COLORS FOR IS ANY TERMINAL YES CLEAN OR REPAIR

THE CORRECT DAMAGED PUSHED OUT CONNECTOR AS CAVITIES.** OR CORRODED? NECESSARY.*

FIG. 1, 2 OR 3

NO

USING A VOLTMETER, REPAIR THE OPEN MEASURE THE 5-VOLT IS THE VOLTAGE YES 5-VOLT SUPPLY

SUPPLY CIRCUIT. BELOW 5.0 VOLTS? CIRCUIT TO TP SENSOR.*

FIG. 1, 2 OR 3

NO

RECONNECT THROTTLE WITH THE DRB, READ IS THE THROTTLE POSITION SENSOR THE THROTTLE POSITION SENSOR YES REPLACE THE

CONNECTOR. POSITION SENSOR VOLTAGE ABOVE 1.0 THROTTLE POSITION TURN IGNITION ON VOLTAGE. VOLTS? SENSOR.*

(ENGINE OFF)

NO


NEXT PAGE.

TROUBLE

CODE

TESTS

475


ZJ BODY

ALL OTHERS

FIG.1

TROUBLE

CODE

TESTS

476



TEST TC-132A WHILE MONITORING CONTINUED FROM THE DRB, SLOWLY

THE PREVIOUS OPEN AND CLOSE THEPAGE. THROTTLE PLATE.

NOTE: YOU MUST MOVE THE LINKAGE IS THE VOLTAGE NO REPLACE THE

VERY SLOWLY WHILE CHANGE SMOOTH? THROTTLE POSITION LOOKING FOR A JUMP SENSOR.*

IN VOLTAGE.

YES

WHILE MONITORING IS THE THROTTLE THE DRB, OPEN THE POSITION SENSOR NO REPLACE THETHROTTLE PLATE TO VOLTAGE ABOVE 3.5 THROTTLE POSITION

WIDE OPEN VOLTS? SENSOR.* THROTTLE.

YES

USING THE SCHEMATIC WHILE MONITORING AS A GUIDE, WIGGLE THE DRB, OBSERVE DID THE TP SENSOR YES REPAIR THE HARNESS

THE TP SENSOR FOR THE TP SENSOR VOLTAGE CHANGE AT OR CONNECTORS AS HARNESS AND VOLTAGE TO CHANGE. ANY TIME? NECESSARY.*

CONNECTORS TO PCM.

NO


INFORMATION.

TROUBLE

CODE

TESTS

477

TEST TC-138A REPAIRING - TARGET IDLE NOT REACHED


FIG.1


ZJ BODY

TROUBLE

CODE

TESTS

478

TEST TC-138A REPAIRING - TARGET IDLE NOT REACHED



CHECK THROTTLE START TEST TURN ENGINE OFF, PLATE AND LINKAGE

TC-138A. IGNITION ON. FOR A BINDINGCONDITION.

ENSURE THETHE THROTTLE THROTTLE PLATE IS IS THE THROTTLE NO REPAIR AS

LINKAGE MUST BE AT FULLY CLOSED AND PLATE AND LINKAGE NECESSARY.*THE IDLE POSITION. AGAINST ITS STOP. OK?

YES

START ENGINE, ALLOW IS THE ENGINE RPMTO IDLE FOR 60 WITH THE DRB READ WITHIN +200 OR YES CONTINUE TEST

SECONDS, IF THIS IS TARGET IDLE AND -100 RPM OF TARGET TC-138A ON THEAN AUTO TRANS, PUT ENGINE RPM. IDLE? NEXT PAGE.

IN DRIVE.

NO

FOR THIS TEST TO CHECK ENGINE,BE VALID THE BRAKE BOOSTER AND

ENGINE MUST NOT VACUUM HOSES FORHAVE ANY VACUUM LEAKS.

LEAKS.

ENSURE PCV VALVEIS THE CORRECT ONE WERE ANY PROBLEMS YES REPAIR AS

AND IS OPERATING FOUND? NECESSARY.*CORRECTLY.

NO

WITH THE DRB IN THE IDLE SPEEDSYSTEM TESTS, SHOULD RAISE AND DOES THE IDLE NO PERFORM TEST

PERFORM THE IAC LOWER WITH THE RAISE AND LOWER TC-25A.WIGGLE TEST. DISPLAY. WITH THE DISPLAY?

YES


TROUBLE

CODE

TESTS

479

TEST TC-138A CONTINUED - REPAIRING - TARGET IDLE NOT REACHED

FIG.1


ZJ BODY

TROUBLE

CODE

TESTS

480

TEST TC-138A CONTINUED - REPAIRING - TARGET IDLE NOT REACHED


TEST TC-138A AT THIS TIME, THECONTINUED FROM CONDITION REQUIRED

THE PREVIOUS TO SET THE CODE IS PAGE. NOT PRESENT.

FIG.1

USING THESCHEMATIC AS A WERE ANY PROBLEMS YES REPAIR AS

GUIDE, INSPECT THE FOUND? NECESSARY.*WIRING AND

CONNECTORS.

NO

START ENGINE. WITH THE IDLE SPEEDTHE DRB IN SYSTEM SHOULD RAISE AND DOES THE IDLE NO PERFORM TEST TESTS, PERFORM THE LOWER WITH THE RAISE AND LOWER TC-25A.

IAC WIGGLE TEST. DISPLAY. WITH THE DISPLAY?

YES

WIGGLE THE WIRING HARNESS FROM THE MONITOR THE ENGINE DID THE IAC STOP YES REPAIR THE HARNESSIAC MOTOR TO THE RPM. OPERATING AT ANY OR CONNECTORS AS

POWERTRAIN CONTROL TIME? NECESSARY.*MODULE.

NO

REFER TO GENERALSTOP THE IAC INFO 3.3.2 FORWIGGLE TEST. INFORMATION ON TEST COMPLETE.*


TROUBLE

CODE

TESTS

481

TEST TC-138B REPAIRING - TARGET IDLE NOT REACHED


ZJ BODY

TROUBLE

CODE

TESTS

482

TEST TC-138B REPAIRING - TARGET IDLE NOT REACHED


DISCONNECT THE PCVSTART TEST VALVE HOSE FROM THE

TC-138B TURN IGNITION OFF. INTAKE MANIFOLD ANDCAP PORT AT INTAKE

MANIFOLD.

DISCONNECT THE INSTALL MILLER IDLE PURGE HOSE TOOL #6714 TO THE

FROM THE THROTTLE PURGE HOSE PORT OF BODY.** THE THROTTLE BODY.

START ENGINE.ALLOW ENGINE TO ACTUATE THE MIN. IS THE ENGINE RPM NO REPLACE THROTTLE REACH OPERATING AIR FLOW. BELOW 550? BODY.*

TEMPERATURE. (ABOVE 180 DEG.)

YES

WARNING: CLEAN THEREMOVE THROTTLE THROTTLE BODY IN ABODY PER SERVICE WELL VENTILATED

MANUAL PROCEDURE. AREA AND WEAR RUBBER GLOVES.

WHILE HOLDING THE USING A SOFT SCUFFTHROTTLE OPEN, SPRAY PAD, CLEAN THEENTIRE THROTTLE BODY THROTTLE BODY BORE

BORE WITH MOPAR AND THROTTLE PARTS CLEANER. PLATE.

USING COMPRESSED START ENGINE ANDAIR, DRY THE LET IDLE. IS THE ENGINE RPM YES REPLACE THROTTLE

THROTTLE BODY AND WITH THE DRB, BELOW 550? BODY.* INSTALL THROTTLE ACTUATE THE MIN.

BODY ON MANIFOLD. AIR FLOW.

NO

TEST COMPLETE.*

TROUBLE

CODE

TESTS

483

TEST TC-140A REPAIRING - EGR SYSTEM FAILURE


TROUBLE

CODE

TESTS

484

TEST TC-140A REPAIRING - EGR SYSTEM FAILURE



START TEST START ENGINE ANDTC-140A. LET IDLE.

DISCONNECT THE EGRUSE A VACUUM GAUGE SOLENOID VACUUM IS THERE 20" OF NO REPAIR THE VACUUM

IN THE FOLLOWING SUPPLY AT THE EGR VACUUM PRESENT AT SUPPLY TO THE EGRSTEPS. SOLENOID. THE SOLENOID? SOLENOID.*

FIG. 1

YES

RECONNECT THE EGRSOLENOID VACUUM DISCONNECT THE

SUPPLY AT THE EGR VACUUM LINE TO THESOLENOID. EGR VALVE.

FIG. 1

USING THE DRB SELECT EGR SYSTEMS TEST. IS THERE 20" OF NO CONTINUE TEST

VACUUM PRESENT AT TC-40A ON THETHE EGR VALVE. NEXT PAGE.

SELECT #3 (FLOW).

YES

AFTER 40 SECONDSOF FLOW OPERATION. PRESS #1 (NORMAL) DID THE VACUUM NO REPLACE THE EGRRECORD THE VACUUM ON THE DRB. DROP TO ZERO QUICK RELEASE

READING TO THE RAPIDLY? VALVE.*EGR VALVE.

YES

RESELECT #3 (FLOW) VACUUM SUPPLY LINE MONITOR VACUUM FOR ISOLATE VACUUM FOR 40 SECONDS. TO THE EGR VALVE ONE MINUTE. YES LEAK AND REPAIR OR CONNECT A VACUUM VACUUM REGULATOR REPLACE AS

PUMP TO THE VACUUM SOLENOID AND APPLY DOES VACUUM DROP NECESSARY.*PUMP SIDE OF THE... 20" OF VACUUM. BELOW 8" OF VACUUM?

NO

NOTE: ENSURE THERE INTAKE AIR TEMP REPAIR OR REPLACETURN IGNITION OFF. IS NO CARBON BUILD SENSOR, EGR TUBE, AS NECESSARY.*

LET ENGINE COOL. UP ON OR IN ANY OF INTAKE AND EXHAUSTTHE FOLLOWING MANIFOLDS. RETEST EGR SYSTEM.

ITEMS.

TROUBLE

CODE

TESTS

485

TEST TC-140A CONTINUED - REPAIRING - EGR SYSTEM FAILURE

FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

486

TEST TC-140A CONTINUED - REPAIRING - EGR SYSTEM FAILURE


TEST TC-140A TURN IGNITION OFF. DOES THE INTAKE CONTINUED FROM REMOVE THE INTAKE AIR TEMPERATURE YES REPLACE INTAKE AIR

THE REVIOUSE AIR TEMP SENSOR SENSOR HAVE A TEMPERATUREPAGE. AND INSPECT SENSOR HEAVY SOOT SENSOR.*

FOR HEAVY SOOTING. ACCUMULATION?

NO

REINSTALL INTAKE DISCONNECT THE EGRAIR TEMP SENSOR. SOLENOID

CONNECTOR.**

USING A VOLTMETER, MEASURE THE IS THE VOLTAGE NO REPLACE THE EGR

URN IGNITION ON. VOLTAGE TO THE EGR GREATER THAN 11.0 VALVE.*SOLENOID AT THE VOLTS?

CONNECTOR.

YES


MODULE.*

TROUBLE

CODE

TESTS

487

TEST TC-141A REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20 PSI


TROUBLE

CODE

TESTS

488

TEST TC-141A REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20 PSI



CHECK FOR ANDSTART TEST RECORD OTHER ARE THERE OTHER YES PERFORM

TC-141A. TRANSMISSION TRANSMISSION APPROPRIATE DTCCODES. CODES? TEST.

NO

NOTE: YOU MAY BE THIS WILL SETREMOVING THE TRANS OTHER CODES. THEY

CONTROL RELAY CAN BE START ENGINE.DURING THIS DISREGARDED.

TEST...

WARM ENGINE TO APPLY THE PARKINGNORMAL OPERATING BRAKE.

TEMPERATURE.

APPLY BRAKES.WITH THE DRB, READ IS THE GOVERNOR YES PERFORM TEST

THE GOVERNOR PLACE GEAR SELECT PRESSURE ABOVE TC-141B. PRESSURE SENSOR. LEVER IN DRIVE. 3 PSI?

NO

PUT GEAR SELECT APPLY BRAKES.LEVER IN PARK. WITH IS THE GOVERNOR NO PERFORM TEST

ENGINE STILL PLACE GEAR SELECT PRESSURE BETWEEN TC-141C. RUNNING, REMOVE THE LEVER IN DRIVE. 40 AND 55 PSI? TRANS CONTROL RELAY.

YES

CONTINUE TEST 141A ON THENEXT PAGE.

TROUBLE

CODE

TESTS

489

TEST TC-141A CONTINUED - REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20PSI

FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

490

TEST TC-141A CONTINUED - REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20PSI


TEST TC-141A WHILE MONITORING CONTINUED FROM TURN ENGINE OFF. TARGET GOVERNOR

THE PREVIOUS INSTALL THE TRANS PRESSURE AND ACTUAL PAGE. CONTROL RELAY. GOVERNOR PRESSURE

WITH THE DRB...

DRIVE VEHICLE NOTE: ACTUAL IS ACTUAL GOVERNOR THE CONDITIONS AT A CONSTANT GOVERNOR PRESSURE PRESSURE WITHIN 5 YES REQUIRED TO SET THIS

SPEED BETWEEN 25 SHOULD BE WITHIN 5 PSI OF TARGET CODE ARE NOT PRESENTAND 30 MPH. PSI OF TARGET GOVERNOR PRESSURE? AT THIS TIME.

WITHIN 3 SECONDS. FIG. 1 AND 2

NO

TEST COMPLETE.

WHILE MONITORING REPLACE THE TARGET GOVERNOR

GOVERNOR PRESSURE PRESSURE ANDSOLENOID. ACTUAL GOVERNOR

PRESSURE...

DRIVE VEHICLE NOTE: ACTUAL IS ACTUAL GOVERNOR AT A CONSTANT GOVERNOR PRESSURE PRESSURE WITHIN 5 NO REPAIR INTERNAL

SPEED BETWEEN 25 SHOULD BE WITHIN 5 PSI OF TARGET TRANSMISSION AND 30 MPH. PSI OF TARGET GOVERNOR PRESSURE? LEAKAGE PROBLEM.*

WITHIN 3 SECONDS.

YES

TEST COMPLETE.

TROUBLE

CODE

TESTS

491

TEST TC-141B REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20 PSI


FIG. 1

TROUBLE

CODE

TESTS

492




KEY OFF. INSTALL ASTART TEST PRESSURE GAUGE AT

TC-141B. THE GOVERNOR TEST PORT.

FIG. 1

START ENGINE. READ THE GAUGE PRESSURE IS THE GAUGE YES PERFORM TEST

IN DRIVE. PRESSURE BELOW TC-141D5 PSI?

NO

DRAIN AND REMOVE TURN ENGINE OFF. THE TRANS OIL PAN.

CHECK FOR BURNT WAS FLUID BURNT YES OVERHAUL THETRANSMISSION FLUID AND/OR DEBRIS IN TRANSMISSION AS

OR DEBRIS. PAN? NECESSARY.*

NO

REPLACE GOVERNOR START ENGINE. READ PRESSURE SOLENOID THE GAUGE PRESSURE IS GAUGE PRESSURE YES

PER SERVICE IN DRIVE. BELOW 5 PSI? TEST COMPLETE.* MANUAL.

NO

REPLACE THE VALVEBODY.*

TROUBLE

CODE

TESTS

493

TEST TC-141C REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20 PSI


FIG. 1

TROUBLE

CODE

TESTS

494

TEST TC-141C REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20 PSI



START TEST TURN IGNITION OFF. TC-141C. INSTALL THE TRANS

RELAY.

INSTALL A PRESSURE START ENGINE.GAUGE AT GOVERNOR

TEST PORT.REMOVE THE TRANS

FIG. 1 CONTROL RELAY.

READ THE GAUGE IS THE GAUGE YES PERFORM TEST PRESSURE IN DRIVE. PRESSURE BETWEEN TC-141D.

40 AND 55 PSI?

NO

TURN ENGINE OFF. DRAIN AND REMOVE

INSTALL THE TRANS THE TRANS OIL PAN. RELAY.

CHECK FOR BURNT WAS FLUID BURNT YES OVERHAUL THETRANSMISSION FLUID AND/OR DEBRIS IN TRANSMISSION AS

OR DEBRIS. PAN? NECESSARY.*

NO

REPLACE THE START ENGINE. REMOVE GOVERNOR PRESSURE THE TRANS RELAY. IS THE GAUGE YES

SOLENOID PER PRESSURE BETWEEN TEST COMPLETE.* SERVICE MANUAL. READ THE GAUGE 40 AND 55 PSI?

PRESSURE IN DRIVE.

NO


TROUBLE

CODE

TESTS

495

TEST TC-141D REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20 PSI


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

496

TEST TC-141D REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20 PSI



DISCONNECT THESTART TEST SOLENOID PACK

TC-141D. CONNECTOR.**


KEY ON. MEASURE REPAIR OPEN 5-VOLT THE VOLTAGE AT THE IS THE VOLTAGE NO SUPPLY CIRCUIT TO

5-VOLT SUPPLY ABOVE 4.5 VOLTS? SOLENOID PACK CIRCUIT. CONNECTOR.*

FIG. 1, 2, 3 OR 4

YES

REPLACE THEGOVERNOR PRESSURE

SENSOR.*

TROUBLE

CODE

TESTS

497

TEST TC-142A REPAIRING - GOVERNOR PRESSURE ABOVE 3 PSI IN GEAR WITH 0 MPH


TROUBLE

CODE

TESTS

498

TEST TC-142A REPAIRING - GOVERNOR PRESSURE ABOVE 3 PSI IN GEAR WITH 0 MPH



START TEST CHECK FOR OTHER ARE THERE OTHER YES PERFORMTC-142A. TRANSMISSION TRANSMISSION APPROPRIATE "DTC

CODES. CODES? TEST".

NO

ERASE ALL TROUBLECODES. START ENGINE.

WARM THE ENGINE TO NORMAL OPERATING

TEMPERATURE.

WITH THE DRB, READ PLACE GEAR SELECT IS THE GOVERNOR YES PERFORM TEST THE GOVERNOR LEVER IN DRIVE. PRESSURE ABOVE TC-142B.

PRESSURE SENSOR. 3 PSI?

NO


NEXT PAGE.

TROUBLE

CODE

TESTS

499

TEST TC-142A CONTINUED - REPAIRING - GOVERNOR PRESSURE ABOVE 3 PSI IN GEAR WITH 0MPH

FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

500

TEST TC-142A CONTINUED - REPAIRING - GOVERNOR PRESSURE ABOVE 3 PSI IN GEAR WITH 0MPH


TEST TC-142A WHILE MONITORING CONTINUED FROM TARGET GOVERNOR

THE PREVIOUS PRESSURE ANDPAGE. ACTUAL GOVERNOR

PRESSURE...

DRIVE VEHICLE NOTE: ACTUAL IS ACTUAL GOVERNOR THE CONDITIONS AT A CONSTANT GOVERNOR PRESSURE PRESSURE WITHIN 5 YES REQUIRED TO SET THIS

SPEED BETWEEN 25 SHOULD BE WITHIN 5 PSI OF TARGET CODE ARE NOT PRESENTAND 30 MPH. PSI OF TARGET GOVERNOR PRESSURE? AT THIS TIME.

WITHIN 3 SECONDS. FIG. 1 AND 2

NO

TEST COMPLETE.

WHILE MONITORING REPLACE GOVERNOR TARGET GOVERNOR

PRESSURE SOLENOID. PRESSURE ANDACTUAL GOVERNOR

PRESSURE...

DRIVE VEHICLE NOTE: ACTUAL IS ACTUAL GOVERNOR REPAIR THEAT A CONSTANT GOVERNOR PRESSURE PRESSURE WITHIN 5 NO INTERNAL

SPEED BETWEEN 25 SHOULD BE WITHIN 5 PSI OF TARGET TRANSMISSION AND 30 MPH. PSI OF TARGET GOVERNOR PRESSURE? LEAKAGE PROBLEM.*

WITHIN 3 SECONDS.

YES

TEST COMPLETE.

TROUBLE

CODE

TESTS

501



FIG. 1

TROUBLE

CODE

TESTS

502




KEY OFF. START TEST INSTALL A PRESSURE

TC-142B. GAUGE AT GOVERNOR TEST PORT.

FIG. 1

START ENGINE. READ THE GAUGE PRESSURE IS THE GAUGE YES CONTINUE TEST

IN DRIVE. PRESSURE BELOW 142B ON THE3 PSI? NEXT PAGE.

NO

TURN ENGINE OFF. CHECK FOR BURNT WAS FLUID BURNT YES OVERHAUL THEDRAIN AND REMOVE TRANSMISSION FLUID AND/OR DEBRIS IN TRANSMISSION AS

THE TRANS OIL. OR DEBRIS. PAN? NECESSARY.*

NO

REPLACE THE START ENGINE. READ GOVERNOR PRESSURE THE GAUGE PRESSURE IS GAUGE PRESSURE YES

SOLENOID PER IN DRIVE. BELOW 3 PSI? TEST COMPLETE.* SERVICE MANUAL.

NO


TROUBLE

CODE

TESTS

503

TEST TC-142B CONTINUED - REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20PSI

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

504

TEST TC-142B CONTINUED - REPAIRING - GOVERNOR PRESSURE NOT EQUAL TO TARGET 15-20PSI


TEST TC-142BCONTINUED FROM DISCONNECT THE

THE PREVIOUS SOLENOID PACK PAGE. CONNECTOR.**

KEY ON. MEASURE REPAIR THE OPEN THE VOLTAGE AT THE IS THE VOLTAGE NO 5-VOLT SUPPLY

5-VOLT SUPPLY ABOVE 4.5 VOLTS? CIRCUIT TO CIRCUIT. SOLENOID PACK

FIG. 1, 2, 3 OR 4 CONNECTOR.*

YES


SENSOR.*

TROUBLE

CODE

TESTS

505

TEST TC-144A REPAIRING - 1/3 O2 SENSOR SHORTED TO GROUND


FIG. 1

8.0L CAL/MD

TROUBLE

CODE

TESTS

506






FIG. 1

IF ENGINE IS WARM,TURN ENGINE OFF TURN IGNITION ON.

FOR 15 MINUTES TO (ENGINE OFF) ALLOW O2 SENSOR TO

COOL DOWN.

WITH THE DRB, IS THE 1/3 O2 YES CONTINUE TEST MONITOR THE 1/3 O2 SENSOR VOLTAGE TC-144A ON THE

SENSOR VOLTAGE. BELOW 0.16V? NEXT PAGE.

NO

NOTE: WIGGLE THE 1/3 O2 DID THE 1/3 O2 THE CONDITIONSENSOR HARNESS AND SENSOR VOLTAGE NO REQUIRED TO SET

MONITOR THE CHANGE WHILE THIS TROUBLE CODE VOLTAGE. WIGGLING THE IS NOT PRESENT AT

HARNESS? THIS TIME.*

YES

REPAIR THE HARNESSOR WIRING THAT HAS

THE INTERMITTENT SHORT TO GROUND.*

A SHORTEDLOW CONDITION DUE

TO WATER IN THESENSOR CONNECTOR, MAY BE TEMPORARY.

TROUBLE

CODE

TESTS

507

TEST TC-144A CONTINUED - REPAIRING - 1/3 O2 SENSOR SHORTED TO GROUND

FIG. 1

TROUBLE

CODE

TESTS

508



CONTINUE TEST DISCONNECT THE 1/3 IS THE TERMINAL TC-144A FROM O2 SENSOR.** CORRODED, DAMAGED, YES REPAIR OR REPLACETHE PREVIOUS PUSHED OUT OR AS NECESSARY.*

PAGE. MISWIRED?SEE GENERAL INFO 4.4

NO

WITH THE DRB, READ IS THE VOLTAGE NO REPLACE THE 1/3 O2 THE 1/3 O2 SENSOR BELOW 0.16 VOLTS? SENSOR.*

VOLTAGE.

YES



NO

MEASURE THE 1/3 02 REPAIR THE 1/3 O2 USING AN OHMMETER SENSOR SIGNAL IS THE RESISTANCE YES SENSOR SIGNAL

IN THE FOLLOWING CIRCUIT FROM THE PCM BELOW 5.0 OHMS? CIRCUIT FOR ASTEP. CONNECTOR TO GROUND. SHORT TO GROUND.*

FIG. 1

NO

WIGGLE THE O2 SENSOR DID THE RESISTANCE HARNESS WHILE CHANGE WHILE NO REPLACE THE

CHECKING RESISTANCE WIGGLING THE POWERTRAIN CONTROLOF O2 SENSOR SIGNAL HARNESS? MODULE.*

CIRCUIT.

YES


SHORT TO GROUND.*

TROUBLE

CODE

TESTS

509



FIG. 1

TROUBLE

CODE

TESTS

510








NO


HARNESS. HARNESS, WATCH THE ABOVE 1.5 VOLTS AT HAS THE INTERMITTENT DRB DISPLAY. ANY TIME? OPEN CIRCUIT OR

SEE GENERAL INFO 4.4 SHORT TO VOLTAGE.*

NO

AT THIS TIME, THE USING THECONDITION REQUIRED SCHEMATIC AS A WERE THERE ANY YES REPAIR AS TO SET THE TROUBLE GUIDE, INSPECT THE PROBLEMS FOUND? NECESSARY.*

CODE IS NOT PRESENT. WIRING ANDFIG. 1 CONNECTORS.

NO

TEST COMPLETE.*

TROUBLE

CODE

TESTS

511


FIG. 1

TROUBLE

CODE

TESTS

512






NO


VOLTAGE.

YES



NO

TURN IGNITION ON. MEASURE THE 1/3 02 REPAIR THE 1/3 O2 USING A VOLTMETER SENSOR SIGNAL IS THE VOLTAGE YES SENSOR SIGNAL

IN THE FOLLOWING CIRCUIT AT THE PCM ABOVE 5.0 VOLTS? CIRCUIT FOR ASTEP. CONNECTOR. SHORT TO VOLTAGE.*

FIG. 1

NO



YES


SHORT TO VOLTAGE.*

TROUBLE

CODE

TESTS

513

TEST TC-148A REPAIRING - TORQ CONV CLU, NO RPM DROP AT LOCKUP


ALL BODIES WITH 3SPD RH TRANS ALL OTHERS

TROUBLE

CODE

TESTS

514

TEST TC-148A REPAIRING - TORQ CONV CLU, NO RPM DROP AT LOCKUP



IS THE "THROTTLESTART TEST WITH THE DRB, READ POSITION SENSOR YES PERFORM TEST

TC-148A. THE TROUBLE CODES. VOLTAGE TOO LOW" TC-26A.CODE SET?

NO

IS THE "THROTTLEPOSITION SENSOR YES PERFORM TEST

VOLTAGE TOO HIGH" TC-27A.CODE SET?

NO

IS THE "PCM FAILURE EEPROM YES PERFORM TEST

WRITE DENIED" CODE TC-49A.SET?

NO

IS THE "TORQUECONVERTER CLUTCH YES PERFORM TEST

SOLENOID TROUBLE" TC-12A.CODE PRESENT?

NO

PERFORMARE ANY "MISFIRE YES APPROPRIATE

TROUBLE" CODES MISFIRE DTCSET? TEST.

NO

IS THE "NO CRANKREFERENCE SIGNAL YES PERFORM TEST AT PCM" TROUBLE TC-40A.

CODE PRESENT?

NO


NEXT PAGE.

TROUBLE

CODE

TESTS

515

TEST TC-148A CONTINUED - REPAIRING - TORQ CONV CLU, NO RPM DROP AT LOCKUP

FIG. 1

ALL BODIES WITH 3 SPD RH TRANS ALL OTHERS

TROUBLE

CODE

TESTS

516



TEST TC-148ACONTINUED FROM CHECK TRANSMISSION IS FLUID LEVEL OK NO REPAIR AS

THE PREVIOUS FLUID LEVEL AND AND CLEAR FROM NECESSARY.*PAGE. FOR ANY DEBRIS. CONTAMINATION?

YES

IS THIS AN AB BODY YES PERFORM TEST WITH A 3 SPEED RH TC-148C.

TRANSMISSION?

NO

WITH THE DRB, DID THE VEHICLE NO CONTINUE TEST PERFORM THE TCC STALL? TC-148A ON THE

SYSTEM TEST. NEXT PAGE.

YES

PERFORM THE GOVAND 3-4 SHIFT DID THE VEHICLE YES PERFORM TEST

START VEHICLE. VALVE SYSTEM TEST. STALL? TC-148B.

SELECT 4TH GEAR.

NO

REPAIR THEREMOVE THE OIL PAN DOES PAN CONTAIN YES INTERNAL

AND INSPECT FOR EXCESSIVE DEBRIS? TRANSMISSION EXCESSIVE DEBRIS. PROBLEM.*

NO



NO

TEST COMPLETE.*

TROUBLE

CODE

TESTS

517


NOTES

TROUBLE

CODE

TESTS

518



TEST TC-148A KEY OFF. CONNECT ACONTINUED FROM PRESSURE GAUGE TO

THE PREVIOUS THE TRANSMISSION PAGE. COOLER OUT PORT WITH

A "T" CONNECTOR.

DID THE COOLER OUTWITH THE DRB, PRESSURE INCREASE YES REPLACE THE TORQUE

START ENGINE. PERFORM THE TCC WHEN THE TCC WAS CONVERTER.*SYSTEM TEST. ACTUATED?

NO

REPAIR VALVE BODY PER SERVICE MANUAL.

CHECK FOR BLOCKAGE OR LEAKS IN THE TCCHYDRAULIC CIRCUIT.*

TROUBLE

CODE

TESTS

519

TEST TC-148B REPAIRING - TORQ CONV CLU, NO RPM DROP AT LOCKUP


START TEST REPLACE THE TCCTC-148B. SOLENOID.

PERFORM THE GOVAND 3-4 SHIFT DID THE VEHICLE NO

VALVE SYSTEM TEST. STALL? TEST COMPLETE.*

SELECT 4TH GEAR.

YES

REPAIR THEINTERNAL PROBLEM. CHECK FOR BLOCKED

PASSAGE(S).*

TROUBLE

CODE

TESTS

520

TEST TC-148C REPAIRING - TORQ CONV CLU, NO RPM DROP AT LOCKUP



ROAD TEST VEHICLE DOES THE ENGINE AT THIS TIME, THESTART TEST WHILE MONITORING RPM DROP WHEN THE YES CONDITIONS

TC-148C. TCC STATE AND TCC STATE REQUIRED TO SETENGINE RPM WITH GOES TO ON? THIS CODE ARE NOT

THE DRB. PRESENT.

NO

TEST COMPLETE.

DOES THE PAN REPAIR THEREMOVE OIL PAN AND CONTAIN EXCESSIVE YES INTERNAL

CHECK FOR DEBRIS DEBRIS AND/OR IS TRANSMISSION OR BURNT OIL. THE FLUID BURNT? PROBLEM.*

NO

ROAD TEST VEHICLEREPLACE THE TCC WITH THE DRB, WHILE MONITORING

SOLENOID. CLEAR CODES. THROTTLE ANGLEWITH THE DRB.

ACCELERATE VEHICLETO 60 MPH REPEAT PRECEEDING

MAINTAINING A TEST 4 TIMES. CONSTANT 20 DEGREE

THROTTLE ANGLE.

WITH THE DRB, READ DID THE CODE NO DTC’S. RETURN DURING THE TEST COMPLETE.*

ROAD TEST?

YES

REPLACE THE TORQUE CONVERTER.*

TROUBLE

CODE

TESTS

521

TEST TC-148C CONTINUED - REPAIRING - TORQ CONV CLU, NO RPM DROP AT LOCKUP

NOTES

TROUBLE

CODE

TESTS

522

TEST TC-148C CONTINUED - REPAIRING - TORQ CONV CLU, NO RPM DROP AT LOCKUP


TEST TC-148C REMOVE THE OIL PAN IS THE OIL BURNT REPAIR THECONTINUED FROM AND INSPECT FOR OR DOES THE PAN YES INTERNAL

THE PREVIOUS EXCESSIVE DEBRIS CONTAIN EXCESSIVE TRANSMISSION PAGE. AND BURNT OIL. DEBRIS? PROBLEM.*

NO

AT THIS TIME, THECONDITIONS

REQUIRED TO SET TEST COMPLETE.* THIS CODE ARE NOT

PRESENT.

TROUBLE

CODE

TESTS

523

TEST TC-149A REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO LOW


AB BODY XJ BODY

ZJ BODY

FIG. 1

TROUBLE

CODE

TESTS

524

TEST TC-149A REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO LOW



WITH THE DRB, READ IS THE FUEL LEVELSTART TEST THE FUEL LEVEL SENDING UNIT YES CONTINUE TEST

TC-149A. SENDING UNIT VOLTAGE BELOW TC-149A ON THEVOLTAGE. 0.2 VOLT? NEXT PAGE.

NO

USING THE WAS THERE ANY FUEL REPAIR THE HARNESSSCHEMATIC, WIGGLE MONITOR THE DRB LEVEL SENDING UNIT YES OR CONNECTOR THAT

THE FUEL PUMP DISPLAY. SENSOR VOLTAGE CAUSED THE VOLTAGEMODULE CONNECTOR & CHANGE? CHANGE.*

HARNESS.

NO



NO

TEST COMPLETE.*

TROUBLE

CODE

TESTS

525

TEST TC-149A CONTINUED - REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO LOW

AB BODY

FIG. 1

XJ BODY

FIG. 2

ZJ BODY

FIG. 3

TROUBLE

CODE

TESTS

526

TEST TC-149A CONTINUED - REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO LOW


TEST TC-149A DISCONNECT THE FUEL CONTINUED FROM PUMP MODULE



WITH THE DRB, READ IS THE FUEL LEVELTHE FUEL LEVEL SENDING UNIT YES REPLACE THE FUEL

SENDING UNIT VOLTAGE ABOVE 4.5 PUMP MODULE.* VOLTAGE. VOLTS?

NO




MEASURE THE FUEL REPAIR THE SENSOR LEVEL SENSOR IS THE RESISTANCE YES SIGNAL CIRCUIT FOR

SIGNAL CIRCUIT BELOW 5.0 OHMS? A SHORT TO (OBDII) TO GROUND. GROUND.*

FIG. 1, 2 OR 3

NO

WITH AN OHMMETER, FUEL LEVEL SENSOR REPAIR THE FUEL MEASURE THE SIGNAL CIRCUIT IS THE RESISTANCE YES LEVEL SENSOR SIGNAL

RESISTANCE BETWEEN (OBDII) AND THE BELOW 5.0 OHMS? CIRCUIT SHORTED TO THE... SENSOR GROUND CKT. THE SENSOR GROUND

FIG. 1, 2 OR 3 CIRCUIT.*

NO


MODULE.*

TROUBLE

CODE

TESTS

527

TEST TC-150A REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO HIGH


AB BODY XJ BODY

ZJ BODY

FIG. 1

TROUBLE

CODE

TESTS

528

TEST TC-150A REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO HIGH



WITH THE DRB, READ IS THE FUEL LEVELSTART TEST THE FUEL LEVEL SENDING UNIT YES CONTINUE TEST

TC-150A. SENDING UNIT VOLTAGE ABOVE 4.7 TC-150A ON THEVOLTAGE. VOLTS? NEXT PAGE.

NO

USE THE SCHEMATIC AS REPAIR THE HARNESSA GUIDE AND WIGGLE MONITOR THE DRB WAS THERE ANY FUEL YES OR CONNECTOR THAT

THE FUEL PUMP MODULE DISPLAY. LEVEL SENDING UNIT CAUSED THE VOLTAGECONNECTOR & HARNESS. VOLTAGE CHANGE? CHANGE.*

NO



NO

TEST COMPLETE.*

TROUBLE

CODE

TESTS

529

TEST TC-150A CONTINUED - REPAIRING - FUEL LEVEL SENDING UNIT VOLTS TOO HIGH

AB BODY

FIG. 1

XJ BODY

FIG. 2

ZJ BODY

FIG. 3

TROUBLE

CODE

TESTS

530



TEST TC-150A DISCONNECT THE FUEL CONTINUED FROM PUMP MODULE



WITH A VOLTMETER, REPAIR THE FUEL MEASURE THE FUEL IS THE VOLTAGE YES LEVEL SIGNAL

LEVEL SIGNAL CIRCUIT AVOVE 5.5 VOLTS? CIRCUIT SHORTED TO FOR VOLTAGE. VOLTAGE.*

FIG. 1, 2 OR 3

NO

CONNECT A JUMPER WITH THE DRB, READ BETWEEN FUEL LEVEL THE FUEL LEVEL IS THE VOLTAGE YES REPLACE THE FUEL SIGNAL (OBDII) AND SENDING UNIT BELOW 1.0 VOLT? PUMP MODULE.*

SENSOR GND CKT. VOLTAGE. FIG. 1, 2 OR 3

NO

MOVE THE JUMPER WITH THE DRB, READ WIRE FROM THE THE FUEL LEVEL IS THE VOLTAGE YES REPAIR THE OPEN

SENSOR GROUND TO A SENDING UNIT BELOW 1.0 VOLT? SENSOR GROUND KNOWN GOOD GROUND. VOLTAGE. CIRCUIT.*

FIG. 1, 2 OR 3

NO


NEXT PAGE.

TROUBLE

CODE

TESTS

531


AB BODY

FIG. 1

XJ BODY

FIG. 2

ZJ BODY

FIG. 3

TROUBLE

CODE

TESTS

532



TEST TC-150A KEY OFF, DISCONNECT CONTINUED FROM THE POWERTRAIN



USING AN OHMMETER,MEASURE THE FUEL FROM THE PCM TO IS THE RESISTANCE YES REPLACE THE

LEVEL SENSOR SIGNAL THE FUEL PUMP BELOW 5.0 OHMS? POWERTRAIN CONTROLCIRCUIT (OBD II)... MODULE CONNECTOR. MODULE.*

FIG. 1, 2 OR 3

NO

REPAIR THE OPEN FUEL LEVEL SENSOR

SIGNAL CIRCUIT(OBDII).*

TROUBLE

CODE

TESTS

533

TEST TC-151A REPAIRING - FUEL LEVEL UNIT NO CHANGE OVER MILES


AB BODY XJ BODY

ZJ BODY

FIG. 1

TROUBLE

CODE

TESTS

534

TEST TC-151A REPAIRING - FUEL LEVEL UNIT NO CHANGE OVER MILES



WITH THE DRB, READ IS THE FUEL LEVELSTART TEST THE FUEL LEVEL SENDING UNIT YES PERFORM TEST

TC-151A. SENDING UNIT VOLTAGE BELOW TC-149A. VOLTAGE AND MAKE A 0.2 VOLT?

NOTE OF VOLTAGE.

NO

IS THE FUEL LEVELSENDING UNIT YES PERFORM TEST

VOLTAGE ABOVE TC-150A. 4.7 VOLTS?

NO

IS THE FUEL LEVELSENDING UNIT NO CONTINUE TEST

VOLTAGE BETWEEN TC-151A ON THE2.5 AND 4.7 VOLTS? NEXT PAGE.

YES

WITH THE DRB, READ DID THE FUEL LEVELADD FIVE GALLONS THE FUEL LEVEL SENDING UNIT NO REPLACE FUEL PUMP OF FUEL TO FUEL SENDING UNIT VOLTAGE DECREASE MODULE.*

TANK. VOLTAGE. BY AT LEAST 0.2VOLTS?

YES



NO

TEST COMPLETE.*

TROUBLE

CODE

TESTS

535

TEST TC-151A CONTINUED - REPAIRING - FUEL LEVEL UNIT NO CHANGE OVER MILES

AB BODY ZJ BODY

XJ BODY

FIG. 1

TROUBLE

CODE

TESTS

536

TEST TC-151A CONTINUED - REPAIRING - FUEL LEVEL UNIT NO CHANGE OVER MILES


IS THE VEHICLE ATEST TC-151A "ZJ" BODY WITH A NO

CONTINUED FROM CALIFORNIA PREVIOUS PAGE. EMISSION PACKAGE?

YES

IS THE FUEL LEVEL AT THIS TIME THESENDING UNIT NO CONDITION REQUIRED

VOLTAGE BETWEEN TO SET THE CODE IS 0.2 AND 1.0 VOLTS? NOT PRESENT.

TEST COMPLETE.

YES

WITH THE DRB, READ DID THE FUEL LEVELREMOVE AT LEAST THE FUEL LEVEL SENDING UNIT NO REPLACE THE FUEL FIVE GALLONS OF SENDING UNIT VOLTAGE INCREASE PUMP MODULE.* FUEL FROM TANK. VOLTAGE. BY AT LEAST O.2

VOLTS?

YES

AT THIS TIME, THE USING THECONDITION REQUIRED SCHEMATIC AS A WERE ANY PROBLEMS NO TO SET THE CODE IS GUIDE, INSPECT THE FOUND? TEST COMPLETE.*


YES


TROUBLE

CODE

TESTS

537

TEST TC-153A REPAIRING - BATTERY TEMP SENSOR VOLTAGE TOO LOW/TOO HIGH


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

538

TEST TC-153A REPAIRING - BATTERY TEMP SENSOR VOLTAGE TOO LOW/TOO HIGH



WITH THE DRB, READ START TEST THE BATTERY IS THE BTS VOLTAGE YES CONTINUE TEST

TC-153A. TEMPERATURE SENSOR BELOW 0.4 VOLT? TC-153A ON THE(BTS) VOLTAGE. NEXT PAGE.

NO

IS THE BTS VOLTAGE YES PERFORM TEST ABOVE 4.9 VOLTS? TC-153B.

NO

USE THE SCHEMATIC REPAIR THEAS A GUIDE AND MONITOR THE DRB WAS THERE ANY BTS YES CONNECTOR OR WIGGLE THE BTS DISPLAY. VOLTAGE CHANGE? HARNESS THAT CONNECTOR AND CAUSED THE VOLTAGE

HARNESS. CHANGE.*

NO


NOT PRESENT. CONNECTORS ANDFIG. 1 HARNESS WIRING.

NO


INFORMATION.

TROUBLE

CODE

TESTS

539

TEST TC-153A CONTINUED - REPAIRING - BATTERY TEMP SENSOR VOLTAGE TOO LOW


FIG. 1

XJ BODY

FIG. 2

ZJ BODY

FIG. 3

TROUBLE

CODE

TESTS

540

TEST TC-153A CONTINUED - REPAIRING - BATTERY TEMP SENSOR VOLTAGE TOO LOW


DISCONNECT THETEST TC-153A BATTERY TEMPERATURE

CONTINUED FROM SENSOR (BTS). PREVIOUS PAGE.


WITH THE DRB, READ IS THE BTS VOLTAGE YESTHE BTS VOLTAGE. ABOVE 4.0 VOLTS? REPLACE THE BTS.*

NO

KEY OFF, DISCONNECT USING AN OHMMETER, REPAIR THE BTSTHE POWERTRAIN MEASURE THE BTS IS THE RESISTANCE YES SIGNAL CIRCUIT FOR

CONTROL MODULE.** SIGNAL CIRCUIT TO BELOW 5.0 OHMS? A SHORT TO GROUND. GROUND.*


NO

WITH AN OHMMETER,MEASURE THE BTS IS THE RESISTANCE NO REPLACE THE

SIGNAL CIRCUIT TO BELOW 5.0 OHMS? POWERTRAIN CONTROLSENSOR GROUND. MODULE.* FIG. 1, 2 OR 3

YES

REPAIR THE SENSOR SIGNAL SHORTED TO

SENSOR GROUND.*

TROUBLE

CODE

TESTS

541

TEST TC-153B REPAIRING - BATTERY TEMP SENSOR VOLTAGE TOO HIGH



FIG. 1

XJ BODY

FIG. 2

ZJ BODY

FIG. 3


FIG. 4

XJ BODY

FIG. 5

ZJ BODY

FIG. 6

TROUBLE

CODE

TESTS

542

TEST TC-153B REPAIRING - BATTERY TEMP SENSOR VOLTAGE TOO HIGH



DISCONNECT THESTART TEST BATTERY TEMPERATURE

TC-153B. SENSOR (BTS).**


USING A VOLTMETER, REPAIR THE SENSOR MEASURE THE VOLTAGE IS THE VOLTAGE YES GROUND CIRCUITOF THE SENSOR GROUND BELOW 0.2 VOLT? SHORTED TO

CIRCUIT. VOLTAGE.*FIG. 1, 2 OR 3

NO

CONNECT A JUMPER ACROSS THE SENSOR WITH THE DRB, READ IS THE BTS VOLTAGE YES

SIGNAL AND THE THE BTS VOLTAGE. BELOW 1.0 VOLT? REPLACE THE BTS.*SENSOR GROUND.FIG. 1, 2 OR 3

NO

MOVE THE JUMPER WIRE FROM THE WITH THE DRB, READ IS THE VOLTAGE YES REPAIR THE OPEN

SENSOR GROUND TO THE BTS VOLTAGE. BELOW 1.0 VOLT? SENSOR GROUND AN ENGINE GROUND. CIRCUIT.*

FIG. 1, 2 OR 3

NO

KEY OFF, DISCONNECT THE POWERTRAIN

CONTROL MODULE.**


WITH AN OHMMETER, THE PCM TO THE BTSMEASURE THE BTS CONNECTOR. IS THE RESISTANCE YES REPLACE THE

SIGNAL CIRCUIT BELOW 5.0 OHMS? POWERTRAIN CONTROLFROM... MODULE.*

FIG. 4, 5 OR 6

NO

REPAIR THE OPEN BATTERY TEMP

SENSOR SIGNAL CIRCUIT.*

TROUBLE

CODE

TESTS

543



FIG. 1

TROUBLE

CODE

TESTS

544






IF ENGINE IS WARM,TURN ENGINE OFF TURN INGITION ON.


COOL DOWN.


SENSOR VOLTAGE. BELOW 0.16 VOLT? NEXT PAGE.

NO


MONITOR THE CHANGE WHILE THIS TROUBLE CODE VOLTAGE. WIGGLING WIRE? IS NOT PRESENT AT

THIS TIME.*

YES





TROUBLE

CODE

TESTS

545


FIG. 1

TROUBLE

CODE

TESTS

546



CONTINUE TEST DISCONNECT THE 1/1 IS ANY TERMINAL TC-155A FROM O2 SENSOR.** CORRODED, DAMAGED, YES REPAIR OR REPLACETHE PREVIOUS PUSHED OUT OR AS NECESSARY.*


NO


VOLTAGE.

YES



NO

MEASURE THE 1/1 02 REPAIR THE 1/1 O2 USING AN OHMMETER SENSOR SIGNAL IS THE RESISTANCE YES SENSOR SIGNAL


FIG. 1

NO



CIRCUIT.

YES


SHORT TO GROUND.*

TROUBLE

CODE

TESTS

547



FIG. 1

TROUBLE

CODE

TESTS

548






FIG. 1

IF ENGINE IS WARM,TURN ENGINE OFF TURN INGITION ON.


COOL DOWN.



NO

NOTE: DID THE 1/2 O2 THE CONDITIONWIGGLE THE 1/2 O2 SENSOR VOLTAGE NO REQUIRED TO SETSENSOR HARNESS AND CHANGE WHILE THIS TROUBLE CODE

MONITOR VOLTAGE. WIGGLING THE IS NOT PRESENT AT HARNESS? THIS TIME.*

YES





TROUBLE

CODE

TESTS

549


FIG. 1

TROUBLE

CODE

TESTS

550





NO


VOLTAGE.

YES



NO

MEASURE THE 1/2 02 REPAIR THE 1/2 O2 USE AN OHMMETER IN SENSOR SIGNAL IS THE RESISTANCE YES SENSOR SIGNAL

THE FOLLOWING CIRCUIT FROM THE PCM BELOW 5.0 OHMS? CIRCUIT FOR ASTEP. CONNECTOR TO GROUND. SHORT TO GROUND.*

FIG. 1

NO



CIRCUIT.

YES


SHORT TO GROUND.*

TROUBLE

CODE

TESTS

551

TEST TC-157A REPAIRING - INTERMITTENT LOSS OF CMP OR CKP


FIG. 1

TROUBLE

CODE

TESTS

552

TEST TC-157A REPAIRING - INTERMITTENT LOSS OF CMP OR CKP



START TEST SEE FIGURE 1 FOR IS THIS VEHICLE YES CONTINUE TEST TC-157A. TROUBLE CODE EQUIPPED WITH AN TC-157A ON THE

INFORMATION. 8.0L ENGINE? NEXT PAGE.

NO

WITH DRB, CHECK SET DISTRIBUTORTHE DISTRIBUTOR IS THE DISTRIBUTOR NO POSITION WITH DRB

POSITION WITH SET POSITION IN RANGE? USING STEPS GIVENSYNC SIGNAL UNDER IN TEST NS-8A.*

MISC. FUNCTIONS.

YES


NEXT PAGE.

TROUBLE

CODE

TESTS

553

TEST TC-157A CONTINUED - REPAIRING - INTERMITTENT LOSS OF CMP OR CKP

AB, AN, BR, AND XJ BODIES

FIG. 1

ZJ BODY

FIG. 2

TROUBLE

CODE

TESTS

554



TEST TC-157A NOTE: CMP OR CKPCONTINUED FROM SIGNAL LOSS CAN BE

THE PREVIOUS DETECTED BY A RPMPAGE. CHANGE, TROUBLE

CODE, OR...

DO YOU WANT TO A PATTERN ON THE DIAGNOSE CMP OR NO PERFORM TEST

OSCILLOSCOPE. CKP SIGNAL LOSS TC-157B. WITH AN

OSCILLOSCOPE?

YES

AT THE CMP SENSOR, START THE ENGINE ARE THERE ANYBACKPROBE THE SENSOR AND OBSERVE THE CAMSHAFT POSITION NO CONTINUE TEST SIGNAL CKT WITH THE CMP SENSOR VOLTAGE SENSOR SIGNALS TC-157A ON THE

VOLTAGE LEAD. PATTERN ON THE MISSING? NEXT PAGE.FIG. 1 OR 2 SCOPE.

YES

DISCONNECT THE CMP IS ANY TERMINAL TURN THE IGNITION SENSOR CONNECTOR. CORRODED, DAMAGED, YES REPAIR AS

OFF. INSPECT ALL PUSHED OUT, OR NECESSARY.*TERMINALS.** MISWIRED?


NO

DISCONNECT THE PCM IS ANY TERMINAL BLACK CONNECTOR. CORRODED, DAMAGED, YES REPAIR AS

INSPECT ALL PUSHED OUT, OR NECESSARY.*TERMINALS.** MISWIRED?


NO

PERFORM TEST TC-157C.

TROUBLE

CODE

TESTS

555



FIG. 1

ZJ BODY

FIG. 2


FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5

TROUBLE

CODE

TESTS

556



TEST TC-157A AT THE PCM, CONTINUED FROM BACKPROBE THE CMP

THE PREVIOUS SENSOR SIGNAL CKTPAGE. WITH THE VOLTAGE

LEAD. FIG. 1 OR 2

WHILE OBSERVING THE WERE ANY SIGNALS REPAIR WIRING SCOPE PATTERN, MISSING WHEN THE YES WHERE WIGGLING WIGGLE THE CMP WIGGLE TEST WAS CAUSED A MISSING

SENSOR CIRCUIT FROM CONDUCTED? CMP SENSOR THE SENSOR TO PCM. SIGNAL.*

NO

AT THE CRANKSHAFT POSITION SENSOR,

TURN IGNITION OFF. BACKPROBE THE CKPSENSOR SIGNAL

CIRCUIT...

WITH THE SCOPE’S START THE ENGINE VOLTAGE AND OBSERVE THE ARE ANY CRANKSHAFT NO CONTINUE TEST

MEASUREMENT LEAD. CKP SENSOR VOLTAGE POSITION SENSOR TC-157A ON THEPATTERN ON THE SIGNALS MISSING? NEXT PAGE.

FIG. 3, 4 OR 5 SCOPE.

YES

DISCONNECT THE CKP IS ANY TERMINAL SENSOR. CORRODED, DAMAGED, YES REPAIR AS

TURN IGNITION OFF. INSPECT ALL PUSHED OUT, OR NECESSARY.*TERMINALS.** MISWIRED?


NO

DISCONNECT THE PCM IS ANY TERMINAL BLACK CONNECTOR.** CORRODED, DAMAGED, YES REPAIR AS

INSPECT ALL PUSHED OUT, OR NECESSARY.*TERMINALS. MISWIRED?


NO

PERFORM TEST TC-157D.

TROUBLE

CODE

TESTS

557



FIG. 1

ZJ BODY

FIG. 2

TROUBLE

CODE

TESTS

558



TEST TC-157A AT PCM, BACKPROBECONTINUED FROM CKP SENSOR SIGNAL

THE PREVIOUS CKT WITH SCOPE’SPAGE. VOLTAGE LEAD.

FIG. 1 OR 2

WHILE OBSERVING WERE ANY CKP NOTE WHERETHE SCOPE PATTERN, SENSOR SIGNALS YES WIGGLING THE WIRESWIGGLE CKP SENSOR MISSING WHEN THE CAUSED A MISSING

CIRCUIT FROM WIGGLE TEST WAS CKP SENSOR SIGNAL.SENSOR TO PCM. CONDUCTED?

NO

THE CONDITION REPAIR THEREQUIRED TO SET CAMSHAFT ANDTHE TROUBLE CODE CRANKSHAFT WIRE IS NOT PRESENT. HARNESS AS

NECESSARY.*

REFER TO GENERALINFO 3.3.2 FORINFORMATION ON TEST COMPLETE.


TROUBLE

CODE

TESTS

559

TEST TC-157B REPAIRING - INTERMITTENT LOSS OF CMP OR CKP


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

560

TEST TC-157B REPAIRING - INTERMITTENT LOSS OF CMP OR CKP



KEY OFF. DISCONNECT IS ANY TERMINAL START TEST THE PCM BLACK CORRODED, DAMAGED, YES REPAIR AS

TC-157B. CONNECTOR.** INSPECT PUSHED OUT, OR NECESSARY.*ALL TERMINALS. MISWIRED?


NO

DISCONNECT THE CMP IS ANY TERMINAL SENSOR CONNECTOR.** CORRODED, DAMAGED, YES REPAIR AS



NO

DISCONNECT THE CKP IS ANY TERMINAL SENSOR CONNECTOR.** CORRODED, DAMAGED, YES REPAIR AS



NO

RECONNECT THE PCM, START THE ENGINE CKP AND CMP AND LET IT IDLE.CONNECTORS.

WITH THE DRB, DOES THE ENGINE NOTE WHERE WIGGLING MONITOR THE RPM SPEED CHANGE WHEN YES WIRES CAUSED A ENG

WHILE WIGGLING CMP WIGGLING THE WIRE SPEED CHANGE && CKP HARNESS HARNESS? REPAIR WIRE HARNESS

WIRING. AS NECESSARY.*

NO

NO PROBLEM HASYES BEEN FOUND. DO YOU

WANT TO WIGGLE ANOTHER WIRE

HARNESS SECTION?

NO

THE CONDITION REFER TO FIGURE 2REQUIRED TO SET FOR INACTIVE THE TROUBLE CODE TROUBLE CODE TEST COMPLETE.*

IS NOT PRESENT INFORMATION. FIG.1

TROUBLE

CODE

TESTS

561

TEST TC-157C REPAIRING - INTERMITTENT LOSS OF CMP OR CKP


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

562

TEST TC-157C REPAIRING - INTERMITTENT LOSS OF CMP OR CKP



REMOVE THE CAMSHAFT START TEST IS THE VEHICLE YES POSITION SENSOR AND

TC-157C. EQUIPPED WITH AN INSPECT THE CAMSHAFT 8.0L ENGINE? SPROCKET.

FIG. 1

NO

REMOVE THEDISTRIBUTOR CAP.

FIG. 2

INSPECT THE ROTORAND ROTOR DRIVE IS THE CAMSHAFT YES REPLACE THE

SYSTEM FOR LOOSENESS SPROCKET OK? CAMSHAFT POSITION PER SERVICE MANUAL SENSOR.*

INSTRUCTIONS.

NO


REPAIR THE LOOSEIS THE ROTOR AND NO DISTRIBUTOR ROTOR

ROTOR DRIVE SYSTEM OR ROTOR DRIVEOK? SYSTEM AS

NECESSARY.*

YES

REPLACE THECAMSHAFT POSITION

SENSOR.*

TROUBLE

CODE

TESTS

563

TEST TC-157D REPAIRING - INTERMITTENT LOSS OF CMP OR CKP


2.5L AND 4.0L ENGINES

FIG. 1

3.9L, 5.2L AND 5.9L ENGINES

FIG. 2

8.0L ENGINES

FIG. 3

TROUBLE

CODE

TESTS

564

TEST TC-157D REPAIRING - INTERMITTENT LOSS OF CMP OR CKP



REMOVE THE WAS THE CRANKSHAFT START TEST CRANKSHAFT POSITION SENSOR NO REPAIR AS

TC-157D. POSITION SENSOR. PROPERLY NECESSARY.*INSTALLED?

FIG. 1, 2 OR 3

YES

NO IS THE VEHICLEEQUIPPED WITH AN

8.0L ENGINE?

YES

INSPECT THECRANKSHAFT NOTCHES IS THE CRANKSHAFT NO REPAIR AS

FOR DAMAGE OR OKAY? NECESSARY.*MISALIGNMENT.

YES

REPLACE THECRANKSHAFT

POSITION SENSOR.*

INSPECT THEFLYWHEEL FOR IS THE FLYWHEEL YES REPAIR AS

DAMAGE OR DAMAGED? NECESSARY.*MISALIGNMENT.

NO


POSITION SENSOR.*

TROUBLE

CODE

TESTS

565

TEST TC-160A REPAIRING - EVAP LEAK MONITOR SMALL LEAK DETECTED


FIG. 1 FIG. 2

FIG. 3 FIG. 4

TROUBLE

CODE

TESTS

566

TEST TC-160A REPAIRING - EVAP LEAK MONITOR SMALL LEAK DETECTED



NOTE: A LOOSE GAS NOTE: THE FUEL START TEST CAP COULD CAUSE TANK MUST HAVE AT WARNING: READ

TC-160A. THIS TROUBLE CODE LEAST THREE FIGURE 1 BEFORE TO SET. GALLONS OF FUEL TO CONTINUING.

PERFORM THIS TEST.

CONNECT A HAND WITH HAND PUMP, ENSURE VACUUM LINESVACUUM PUMP TO LDP APPLY 18 INCHES OF DOES THE PUMP HOLD NO ARE OK BEFORE

VACUUM TEE VACUUM TO LEAK VACUUM? REPLACING LDP. (SVST PORT). DETECTION PUMP PERFORM TC-160A TO

(LDP). VERIFY.

YES

REPLACE LDP. WITH THE DRB, GO DID VACUUM DROP NO

IGNITION KEY ON. TO ACTUATIONS, WHEN SOLENOID WAS PERFORM TEST ACTUATE LDP. ACTUATED? TC-160A TO VERIFY.

YES

TO CONTINUE PERFORM EVAPORATIVE CONNECT THE EVAP USING AN AUXILIARYTESTING YOU WILL SYSTEM PRESSURE PUMP PRESSURE PUMP SUPPLY CONSTANT VACUUM NEED MILLER TOOL SELF TEST THAT IS HOSE TO VEHICLE SUPPLY, DRB IN LDP

KIT #6872A. SPECIFIED ON THE PRESSURE TEST PORT. SYSTEM TEST, PRESSFIG. 2 TESTER COVER. SEE GENERAL INFO 4.2 3 TO HOLD,...

DISCONNECT PURGE TURN PUMP TIMER DID PRESSURE DROP SOLENOID. SET ON. PERFORM IM240 MORE THEN 8 IN. YES CONTINUE TEST

PRESSURE HOLD TO SIMULATION THAT IS (H20) IN TWO TC-160A ON THEOPEN, AND SET VENT DESCRIBED ON COVER MINUTES? NEXT PAGE.

TO CLOSED. OF TOOL #6872.

NO


NOT PRESENT. WIRING, CONNECTORS FIG. 3 AND HOSES.

NO


INFORMATION.

TROUBLE

CODE

TESTS

567

TEST TC-160A CONTINUED - REPAIRING - EVAP LEAK MONITOR SMALL LEAK DETECTED

FIG. 1

TROUBLE

CODE

TESTS

568

TEST TC-160A CONTINUED - REPAIRING - EVAP LEAK MONITOR SMALL LEAK DETECTED


TEST TC-160A TO CONTINUE TESTING, CONTINUED FROM YOU WILL NEED MILLER

THE PREVIOUS TOOL ULTRASONIC LEAK PAGE. DETECTOR

(PARADISE 300).

SET PRESSURE HOLD TO TO PREVENT NOISE USING THE ULTRASONIC NOTE: LDP SYSTEM OPEN AND SET VENT TO FROM INTERFERING LEAK DETECTOR, START

TEST STILL GOING. CLOSED. WITH TEST MOVE LISTENING FOR LEAKSTOOL #6872A AWAY AT GAS CAP...

TURN PUMP TIMER ON. FROM VEHICLE.

CANISTER, LEAK WERE ANY LEAKSTHEN PROCEED TO DETECTION PUMP AND HEARD WITH THE YES REPAIR OR REPLACE

FUEL TANK ROLLOVER EVAPORTIVE PURGE ULTRASONIC LEAK LEAKINGVALVE... SOLENOID. DETECTOR? COMPONENT.*

NO

REPLACE THE LEAK DETECTION PUMP.*

TROUBLE

CODE

TESTS

569

TEST TC-161A REPAIRING - EVAP LEAK MONITOR LARGE LEAK DETECTED


FIG. 1 FIG. 2

FIG. 3 FIG. 4

TROUBLE

CODE

TESTS

570

TEST TC-161A REPAIRING - EVAP LEAK MONITOR LARGE LEAK DETECTED



NOTE: A LOOSE GAS NOTE: THE FUEL START TEST CAP COULD CAUSE TANK MUST HAVE AT WARNING: READ

TC-161A. THIS TROUBLE CODE LEAST THREE FIGURE 1 BEFORE TO SET. GALLONS OF FUEL TO CONTINUING.

PERFORM THIS THIS.

CONNECT A HAND WITH HAND PUMP, ENSURE VACUUM LINESVACUUM PUMP TO LDP APPLY 18 INCHES OF DOES THE PUMP HOLD NO ARE OK BEFORE

VACUUM TEE VACUUM TO LEAK VACUUM? REPLACING LDP. (SVST PORT). DETECTION PUMP PERFORM TC-161A TO

(LDP). VERIFY.

YES

REPLACE LDP. WITH THE DRB, GO DID VACUUM DROP NO

IGNITION KEY ON. TO ACTUATIONS, WHEN SOLENOID WAS PERFORM TEST ACTUATE LDP. ACTUATED? TC-161A TO VERIFY.

YES

TO CONTINUE PERFORM EVAPORATIVE CONNECT THE EVAP USING AN AUXILARY TESTING YOU WILL SYSTEM PRESSURE PUMP PRESSURE PUMP SUPPLY CONTANT VACUUM NEED MILLER TOOL SELF TEST THAT IS HOSE TO VEHICLE SUPPLY, DRB IN LDP

KIT #6872A. SPECIFIED ON THE PRESSURE TEST PORT. SYSTEM TEST PRESSFIG. 2 TESTER COVER. SEE GEN INFO 4.2 3 TO HOLD,...

DISCONNECT PURGE TURN PUMP TIMER DID PRESSURE DROP SOLENOID. SET ON. PERFORM IM240 MORE THEN 8 IN. YES CONTINUE TEST

PRESSURE HOLD TO SIMULATION THAT IS (H20) IN TWO TC-161A ON THEOPEN, AND SET VENT DESCRIBED ON COVER MINUTES? NEXT PAGE.

TO CLOSED. OF TOOL #6872.

NO


NOT PRESENT. WIRING, CONNECTORS FIG. 3 AND HOSES.

NO


INFORMATION.

TROUBLE

CODE

TESTS

571

TEST TC-161A CONTINUED - REPAIRING - EVAP LEAK MONITOR LARGE LEAK DETECTED

FIG. 1

TROUBLE

CODE

TESTS

572

TEST TC-161A CONTINUED - REPAIRING - EVAP LEAK MONITOR LARGE LEAK DETECTED


TEST TC-161A TO CONTINUE TESTINGCONTINUED FROM YOU WILL NEED MILLER

THE PREVIOUS TOOL ULTRASONIC LEAK PAGE. DETECTOR

(PARADISE 300).

SET PRESSURE HOLD TO TO PREVENT NOISE IF PUMP NOISE STILLOPEN, AND SET VENT FROM INTERFERING INTERFERES WITH

TO CLOSED. WITH TEST MOVE ULTRSASONIC LEAK TOOL #6872A (ESPP) TESTER TURN PRESSURE

TURN PUMP TIMER ON. AWAY FROM VEHICLE. HOLD TO CLOSED...

NOTE: SYSTEM MUST AND TURN PUMP HAVE PRESSURE TO TIMER TO OFF. DETECT A LEAK, IF

THE EVAP SYSTEM CANNOT MAINTAIN...

PRESSURE, LEAVE USING MILLER TOOL PUMP TIMER ON AND #6904 ULTRASONIC

PRESSURE HOLD TO LEAK DETECTOR, STARTOPEN. LISTENING FOR LEAKS

AT GAS CAP...

CANISTER, LEAK WERE ANY LEAKSTHEN PROCEED TO DETECTION PUMP AND HEARD WITH THE YES REPAIR OR REPLACE

FUEL TANK ROLLOVER EVAPORTIVE PURGE ULTRASONIC LEAK COMPONENT.*VALVE,... SOLENOID. DETECTOR?

NO

REPLACE LEAK DETECTION PUMP AND

FILTER.*

TROUBLE

CODE

TESTS

573

TEST TC-162A REPAIRING - NO TEMP RISE SEEN FROM INTAKE HEATERS



FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

574

TEST TC-162A REPAIRING - NO TEMP RISE SEEN FROM INTAKE HEATERS



START TEST WITH THE DRB DOES THE RELAY NO PERFORM TEST TC-162A. ACTUATE #1 AIR CLICK ON AND OFF? TC-162C.

INTAKE HEATER.

YES

WITH THE DRB, DOES THE RELAY NO PERFORM TEST ACTUATE #2 AIR CLICK ON AND OFF? TC-162D. INTAKE HEATER.

YES

NOTE: BECAUSE NOTE: IGNORE STOP HEATERS DRAW A LARGE ACTUATIONS IF

AMOUNT OF CURRENT, STEPS IN TEST CANENSURE ACTUATION BE PERFORMED

TIME IS BRIEF. QUICKLY.

USING A VOLTMETER, STOP ACTUATION. WITH THE DRB, MEASURE THE #1 NO CONTINUE TEST ACTUATE #1 AIR HEATER RELAY OUTPUT DID THE VOLTAGE TEST 162A ON INTAKE HEATER. CKT AT THE INTAKE TOGGLE ABOVE 9.6 THE NEXT PAGE.

MANIFOLD. FIG. 1 VOLTS?

YES

USING A VOLTMETER, STOP ACTUATION. WITH THE DRB, MEASURE THE #2 NO PERFORM TEST ACTUATE #2 AIR HEATER RELAY OUTPUT DID THE VOLTAGE TC-162B. INTAKE HEATER. CKT AT THE INTAKE TOGGLE ABOVE 9.6

MANIFOLD. FIG. 1 VOLTS?

YES

REMOVE THE AIR INSPECT THE HEATER IS THE HEATER YES REPLACE THEINTAKE HEATER PER FOR AN OPEN DEFECTIVE? DEFECTIVE HEATER.* SERVICE MANUAL.** CIRCUIT.

NO

INSPECT THE INTAKE AT THIS TIME THEAIR TEMP SENSOR CONDITIONS REQUIRED FOR HEAVY SOOT. TO SET THE CODE ARE TEST COMPLETE.*

REPLACE IF NOT PRESENT. NECESSARY. FIG. 2


TROUBLE

CODE

TESTS

575

TEST TC-162A CONTINUED - REPAIRING - NO TEMP RISE SEEN FROM INTAKE HEATERS


FIG. 1

TROUBLE

CODE

TESTS

576

TEST TC-162A CONTINUED - REPAIRING - NO TEMP RISE SEEN FROM INTAKE HEATERS


START TEST WITH THE DRB, TC-162B. ACTUATE #2 AIR

INTAKE HEATER.

USING A VOLTMETER, STOP ACTUATION. REPAIR THE OPEN #2 MEASURE THE #2 YES HEATER RELAY OUTPUT

HEATER RELAY DID THE VOLTAGE CIRCUIT.*OUTPUT CKT AT THE TOGGLE ABOVE 9.6 NOTE: CHECK CIRCUIT

RELAY. FIG. 1 VOLTS? FOR HIGH RESISTANCE

NO

USING A VOLTMETER, MEASURE FUSED B(+) IS THE VOLTAGE YES REPAIR THE OPEN

CIRCUIT AT #2 BELOW 9.6 VOLTS? FUSED B(+) HEATER RELAY. CIRCUIT.*

FIG. 1

NO

REPLACE THE AIRINTAKE HEATER #2

RELAY.*


TROUBLE

CODE

TESTS

577

TEST TC-162B REPAIRING - NO TEMP RISE SEEN FROM INTAKE HEATERS



FIG. 1

TROUBLE

CODE

TESTS

578

TEST TC-162B REPAIRING - NO TEMP RISE SEEN FROM INTAKE HEATERS



START TEST WITH THE DRB, TC-162B. ACTUATE #2 AIR

INTAKE HEATER.

USING A VOLTMETER, STOP ACTUATION. REPAIR THE OPEN #2 MEASURE THE #2 YES HEATER RELAY OUTPUT

HEATER RELAY DID THE VOLTAGE CIRCUIT.*OUTPUT CKT AT THE TOGGLE ABOVE 9.6 NOTE: CHECK CIRCUIT

RELAY. FIG. 1 VOLTS? FOR HIGH RESISTANCE

NO

USING A VOLTMETER, MEASURE FUSED B(+) IS THE VOLTAGE YES REPAIR THE OPEN

CIRCUIT AT #2 BELOW 9.6 VOLTS? FUSED B(+) HEATER RELAY. CIRCUIT.*

FIG. 1

NO

REPLACE THE AIRINTAKE HEATER #2

RELAY.*


TROUBLE

CODE

TESTS

579

TEST TC-162C REPAIRING - NO TEMP RISE SEEN FROM INTAKE HEATERS

Perform TEST TC-162A Before Proceeding1996 2.5/4.0/5.2/5.9/8.0L Jeep and Truck EnginePublication No. 81-699-96103TSB 26-06-97 June, 1997

FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

580

TEST TC-162C REPAIRING - NO TEMP RISE SEEN FROM INTAKE HEATERS



START TEST WITH THE DRB, STOP TC-162C. ALL ACTUATION

TESTS.

DISCONNECT THE FUSED USING A VOLTMETER, REPAIR THE OPEN IGN SWITCH OUTPUT MEASURE FUSED IS THE VOLTAGE NO FUSED IGNITION CKT CONNECTOR FROM IGNITION SWITCH ABOVE 10.0 VOLTS? SWITCH OUTPUT

#1 HEATER RLY.** OUTPUT CKT AT RLY CIRCUIT.*FIG. 1 CONN. FIG. 1

YES

RECONNECT THE DISCONNECT THE AITFUSED IGNITION HEATER RELAY #1 SWITCH OUTPUT CONTROL CIRCUIT AT

CIRCUIT CONNECTOR. THE RELAY.** FIG. 1 FIG. 1

USING A VOLTMETER, MEASURE THE IS THE VOLTAGE NO REPLACE THE #1

TERMINAL AT THE ABOVE 10.0 VOLTS? HEATER RELAY.*RELAY CONNECTOR.

FIG. 1

YES

TURN IGNITION OFF. USING AN OHMMETER, REPAIR THE #1 DISCONNECT THE PCM MEASURE THE #1 IS THE RESISTANCE YES HEATER RELAYBLACK CONNECTOR.** HEATER CONTROL BELOW 5.0 OHMS? CONTROL CIRCUIT

CIRCUIT AT PCM TO FOR A SHORT TO SEE GENERAL INFO 4.1 GROUND. FIG. 2 GROUND.*

NO

USING AN OHMMETER, FROM THE RELAY TO MEASURE THE THE PCM. IS THE RESISTANCE YES REPAIR THE OPEN #1

RESISTANCE OF THE ABOVE 5.0 OHMS? HEATER RELAY#1 HEATER CONTROL CONTROL CIRCUIT.*

CIRCUIT... FIG.2

NO


MODULE.*


TROUBLE

CODE

TESTS

581

TEST TC-162D REPAIRING - NO TEMP RISE SEEN FROM INTAKE HEATERS

Perform TEST TC-162A Before Proceeding1996 2.5/4.0/5.2/5.9/8.0L Jeep and Truck EnginePublication No. 81-699-96103TSB 26-06-97 June, 1997

FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

581A

TEST TC-162D REPAIRING - NO TEMP RISE SEEN FROM INTAKE HEATERS



START TEST WITH THE DRB, STOP TC-162C. ALL ACTUATION

TESTS.

DISCONNECT THE FUSED USING A VOLTMETER, REPAIR THE OPEN IGN SWITCH OUTPUT MEASURE FUSED IS THE VOLTAGE NO FUSED IGNITION CKT CONNECTOR FROM IGNITION SWITCH ABOVE 10.0 VOLTS? SWITCH OUTPUT

#1 HEATER RLY.** OUTPUT CKT AT RLY CIRCUIT.*FIG. 1 CONN. FIG. 1

YES

RECONNECT THE DISCONNECT THE AITFUSED IGNITION HEATER RELAY #1 SWITCH OUTPUT CONTROL CIRCUIT AT

CIRCUIT CONNECTOR. THE RELAY.** FIG. 1 FIG. 1

USING A VOLTMETER, MEASURE THE IS THE VOLTAGE NO REPLACE THE #1

TERMINAL AT THE ABOVE 10.0 VOLTS? HEATER RELAY.*RELAY CONNECTOR.

FIG. 1

YES

TURN IGNITION OFF. USING AN OHMMETER, REPAIR THE #1 DISCONNECT THE PCM MEASURE THE #1 IS THE RESISTANCE YES HEATER RELAYBLACK CONNECTOR.** HEATER CONTROL BELOW 5.0 OHMS? CONTROL CIRCUIT

CIRCUIT AT PCM TO FOR A SHORT TO SEE GENERAL INFO 4.1 GROUND. FIG. 2 GROUND.*

NO

USING AN OHMMETER, FROM THE RELAY TO MEASURE THE THE PCM. IS THE RESISTANCE YES REPAIR THE OPEN #1

RESISTANCE OF THE ABOVE 5.0 OHMS? HEATER RELAY#1 HEATER CONTROL CONTROL CIRCUIT.*

CIRCUIT... FIG.2

NO


MODULE.*


TROUBLE

CODE

TESTS

581B

TEST TC-164A REPAIRNG - TRANS TEMP SENSOR, NO RISE AFTER START


FIG. 1

TROUBLE

CODE

TESTS

582

TEST TC-164A REPAIRNG - TRANS TEMP SENSOR, NO RISE AFTER START



CHECK FOR A P/NSTART TEST SWITCH, TRANS TEMP WERE ANY OF THE YES REPAIR FAULT

TC-164A. SENSOR VOLTAGE TOO FAULT CODES CODE(S) FIRST. LOW OR TOO HIGH PRESENT?

FAULT CODE.

NO

T0 TEST THE TRANS LET ENGINE ANDTEMP SENSOR, THE IS THE ENGINE AND NO TRANS COOL DOWN TO ENGINE AND TRANS TRANS LESS THAN 85 LESS THAN

TEMPERATURE MUST BE DEGREES F? 85 DEG. F. LESS THAN 85 DEG F.

YES

READ ENGINE READ TRANSMISSION IS THE TRANSMISSION COOLANT TEMPERATURE SENSOR TEMERATURE WITHIN 9 NO CONTINUE TEST

TEMPERATURE SENSOR TEMPERATURE AND DEGREES OF ENGINE TC-164A ON THEAND RECORD. RECORD. COOLANT TEMPERATURE? NEXT PAGE.

YES

START ENGINE AND LET LOOK FOR THE DID TRANS TEMP IDLE IN DRIVE WITH TEMPERATURE TO INCREASE AT A STEADY NO CONTINUE TEST PARKING BRAKE ON, RAISE 15 DEGREES F RATE AND INCREASE 15 TC-164A ON THE

WHILE MONITORING THE OVER A TEN MINUTE DEGREES F OVER A TEN NEXT PAGE.TRANS TEMP SENSOR. PERIOD. MINUTE PERIOD?

YES



NO

TEST COMPLETE.*

TROUBLE

CODE

TESTS

583

TEST TC-164A CONTINUED - REPAIRNG - TRANS TEMP SENSOR, NO RISE AFTER START

NOTES

TROUBLE

CODE

TESTS

584

TEST TC-164A CONTINUED - REPAIRNG - TRANS TEMP SENSOR, NO RISE AFTER START


TEST TC-164A DISCONNECT THECONTINUED FROM TRANSMISSION WERE ALL OF THE NO CLEAN OR REPAIR AS

THE PREVIOUS SOLENOID EIGHT WAY CONNECTORS CLEAN NECESSARY.*PAGE. CONNECTOR.** AND UNDAMAGED?


YES

REPLACE TRANSMISSION TEMPERATURE/GOVERNOR

PRESSURE SENSOR.*

TROUBLE

CODE

TESTS

585

TEST TC-165A REPAIRING - 3-4 SHIFT SOLENOID, NO RPM DROP 3-4 SHIFT


TROUBLE

CODE

TESTS

586

TEST TC-165A REPAIRING - 3-4 SHIFT SOLENOID, NO RPM DROP 3-4 SHIFT



IS THE "TRANS 12 START TEST WITH THE DRB READ VOLT SUPPLY RELAY YES PERFORM TEST

TC-165A. TROUBLE CODES. CONTROL CIRCUIT" TC-173A. TROUBLE CODE

PRESENT?

NO

IS THE "TORQUECONVERTER CLUTCH YES PERFORM TEST

SOLENOID" TROUBLE TC-12A.CODE PRESENT?

NO

IS THE "TRANS 3-4SHIFT SOLENOID/TRANS YES PERFORM TEST

RELAY CIRCUIT" TC-50A.TROUBLE CODE

PRESENT?

NO

IS THE "NO CAMSIGNAL AT PCM" YES PERFORM TEST

TROUBLE CODE TC-01A.PRESENT?

NO

ARE ANY THROTTLE YES PERFORMPOSITION SENSOR APPROPRIATE

CODES SET? TEST FOR CODE.

NO

IS THE "P/N SWITCH STUCK IN PARK OR YES PERFORM TEST IN GEAR" TROUBLE TC-114A.

CODE SET?

NO


NEXT PAGE.

TROUBLE

CODE

TESTS

587

TEST TC-165A CONTINUED - REPAIRING - 3-4 SHIFT SOLENOID, NO RPM DROP 3-4 SHIFT

FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

588



TEST TC-165ACONTINUED FROM CHECK TRANSMISSION IS FLUID LEVEL OK NO REPAIR AS

THE PREVIOUS FLUID LEVEL AND AND CLEAR OF NECESSARY.*PAGE. FOR ANY DEBRIS. CONTAMINATION?

YES

CONNECT A ZERO TO CONNECT ANOTHER ZERO START ENGINE AND300 PSI PRESSURE TO 300 PSI GAUGE TO ALLOW TRANS TEMP

GAUGE TO THE THE GOVERNOR TO RISE TO NORMAL OVERDRIVE CLUTCH TEST PORT. OPERATING TEMP.

TEST PORT... FIG. 1

WHILE OBSERVING THE GOVERNOR THE PRESSURE PRESSURE SHOULD RISE

GAUGES, SELECT 4TH TO ABOVE 20 PSI. GEAR FROM GOV AND SHORTLY

3-4 SYSTEM TEST. AFTER THIS,...

CONTINUE TEST THE OD PRESSURE DID THE PRESSURE YES TC-165A ON THE

SHOULD RISE TO ACT AS DESCRIBED? FOLLOWING PAGE.ABOVE 40 PSI.

NO

START ENGINE AND WHILE OBSERVING THEREPLACE 3-4 SHIFT ALLOW THE TRANS PRESSURE GAUGES,

SOLENOID. LEAVE TEMP TO RISE TO ACTUATE THE 3-4GAUGES ATTACHED. NORMAL OPERATING SHIFT SOLENOID WITH

TEMP. THE DRB.

THE GOVERNOR PRESSURE SHOULD RISE THE OD PRESSURE DID THE PRESSURE YES

TO ABOVE 20 PSI. SHOULD RISE TO ACT AS DESCRIBED? TEST COMPLETE.* SHORTLY ABOVE 40 PSI.

AFTER THIS,...

NO

OVERHAUL THE PAY EXTRATRANSMISSION PER ATTENTION TO SEALS

SERVICE MANUAL AND CLUTCHES PROCEDURES. RELATED TO THE OD

CLUTCH.*

TROUBLE

CODE

TESTS

589


NOTES

TROUBLE

CODE

TESTS

590



TEST TC-165A REMOVE THE OIL PAN IS THE OIL BURNT REPAIR THECONTINUED FROM AND CHECK FOR OR DOES THE PAN YES INTERNAL

THE PREVIOUS EXCESSIVE DEBRIS CONTAIN EXCESSIVE TRANSMISSION PAGE. AND/OR BURNT OIL. DEBRIS? PROBLEM.*

NO

AT THIS TIME, THECONDITIONS

REQUIRED TO SET TEST COMPLETE.* THIS CODE ARE NOT

PRESENT.

TROUBLE

CODE

TESTS

591

TEST TC-166A REPAIRING - LOW OUTPUT SPEED SENSOR RPM, ABOVE 15 MPH


FIG. 1

TROUBLE

CODE

TESTS

592

TEST TC-166A REPAIRING - LOW OUTPUT SPEED SENSOR RPM, ABOVE 15 MPH



START TEST WITH THE DRB, WAS THERE A P/N YES REPAIR THIS FAULTTC-166A. CHECK FOR A P/N SWITCH FAULT CODE? CODE FIRST.

SWITCH FAULT CODE.

NO

RAISE THE DRIVE WARNING: BE SURE WHEELS OFF THE TO KEEP HANDS AND

GROUND AND FEET CLEAR OF PROPERLY SUPPORT ROTATING WHEELS.

VEHICLE.

START ENGINE, WITH PUT TRANSMISSION THE DRB, READ THE IN ANY FORWARD DOES THE DRB SHOW NO CONTINUE TEST

OUTPUT SPEED GEAR. RELEASE ABOVE 60 RPM? TC-166A ON THESENSOR. BRAKES TO LET NEXT PAGE.

WHEELS ROLL.

YES

WHILE STILL DID THE READING REPAIR INTERMITTENT MONITORING THE THE OSS TO THE DROP TOWARD ZERO YES SHORT OR OPEN

OUTPUT SPEED PCM. WHILE WIGGLING THE CIRCUIT AREA WHERESENSOR, WIGGLE THE WIRES? FLUCTUATION

WIRES FROM ... OCCURRED.*

NO

ROAD TEST VEHICLE. THE CONDITIONS WITH THE DRB, DID THE CODE NO REQUIRED TO SET THIS CLEAR TROUBLE WITH THE DRB, READ RETURN? CODE ARE NOT PRESENT

CODES. TROUBLE CODES. AT THIS TIME.FIG. 1

YES

REPLACE OUTPUT ROAD TEST VEHICLE. SPEED SENSOR. DID THE CODE NO

WITH THE DRB, READ RETURN? TEST COMPLETE.* ERASE TROUBLE TROUBLE CODES.

CODES.

YES

REPLACE THE PCM.*

TROUBLE

CODE

TESTS

593

TEST TC-166A CONTINUED - REPAIRING - LOW OUTPUT SPEED SENSOR RPM, ABOVE 15 MPH

AB AND AN BODIES

FIG. 1

BR AND ZJ BODIES

FIG. 2

AB, AN AND ZJ BODIES

FIG. 3

BR BODY

FIG. 4

TROUBLE

CODE

TESTS

594

TEST TC-166A CONTINUED - REPAIRING - LOW OUTPUT SPEED SENSOR RPM, ABOVE 15 MPH





MEASURE THE REPAIR THE OSSRESISTANCE BETWEEN IS THE RESISTANCE YES SIGNAL CIRCUIT

THE OSS SIGNAL BELOW 5.0 OHMS? SHORTED TO CIRCUIT AND GROUND. GROUND.*

FIG. 1 OR 2

NO

MEASURE THE REPAIR THE OSSRESISTANCE BETWEEN IS THE RESISTANCE NO GROUND CIRCUIT

THE OSS GROUND ABOVE 5.0 OHMS? SHORTED TO CIRCUIT AND GROUND. GROUND.*

FIG. 1 OR 2

YES

MEASURE THE THE OSS GROUND RESISTANCE BETWEEN CIRCUIT AT THE PCM IS THE RESISTANCE YES

THE OSS SIGNAL CONNECTOR. BETWEEN 300.0 AND REPLACE THE PCM.*CIRCUIT AND... 1200.0 OHMS?

FIG. 1 OR 2

NO

DISCONNECT THE MEASURE THEOUTPUT SPEED RESISTANCE ACROSS IS THE RESISTANCE NO REPLACE THE OUTPUT

SENSOR.** BOTH TERMINALS OF BETWEEN 300.0 AND SPEED SENSOR.* THE OUTPUT SPEED 1200.0 OHMS?

SEE GENERAL INFO 4.4 SENSOR.

YES

MEASURE THE TO THE PCMRESISTANCE OF THE CONNECTOR. IS THE RESISTANCE YES REPAIR THE OPEN OSS SIGNAL CIRCUIT ABOVE 5.0 OHMS? OSS SIGNAL

FROM THE OSS CIRCUIT.*CONNECTOR... FIG. 3 OR 4

NO

REPAIR THE OPEN OSS GROUND CIRCUIT.*

TROUBLE

CODE

TESTS

595

TEST TC-167A REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO LOW


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4 FIG. 5

TROUBLE

CODE

TESTS

596

TEST TC-167A REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO LOW



KEY OFF. DISCONNECT START TEST THE TRANS SOLENOID

TC-167A. CONNECTOR.**


KEY ON, MEASURETHE VOLTAGE AT THE IS THE VOLTAGE NO REPAIR THE OPEN

5-VOLT SUPPLY BETWEEN 4.5 AND 5-VOLT SUPPLY CIRCUIT. 5.5 VOLTS? CIRCUIT.

FIG. 1, 2, 3 OR 4

YES

KEY ON, WITH THECONNECT SOLENOID DRB, MONITOR THE IS VOLTAGE ABOVE YES PERFORM TEST

CONNECTOR. GOVERNOR PRESSURE 4.65 VOLTS? TC-168A. VOLTAGE.

NO

IS THE VOLTAGE YES CONTINUE TEST BELOW 0.12 VOLTS? TC-167A ON THE

NEXT PAGE.

NO

IS THE VOLTAGE NO PERFORM TEST BETWEEN 0.12 AND 168B.

0.80 VOLTS?

YES

WHILE MONITORING BETWEEN THE DID THE VOLTAGE REPAIR WIRING GOVERNOR PRESSURE GOVERNOR PRESSURE FLUCTUATE WHILE YES WHERE WIGGLING VOLTAGE WITH DRB, SENSOR AND THE WIGGLING THE CAUSED THEWIGGLE THE WIRING PCM. HARNESS? FLUCTUATION.*AND CONNECTORS...

NO

AT THIS TIME, THECONDITION REQUIRED TO SET THE TROUBLE TEST COMPLETE.*

CODE IS NOT PRESENT. FIG. 5

TROUBLE

CODE

TESTS

597

TEST TC-167A CONTINUED - REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO LOW

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

598

TEST TC-167A CONTINUED - REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO LOW


DISCONNECT THE KEY OFF. TEST TC-167A TRANSMISSION DISCONNECT ALL OF

CONTINUED FROM SOLENOID THE PCMPREVIOUS PAGE. CONNECTOR.** CONNECTORS.**


MEASURE THE AND THE SENSOR REPAIR THE GOVERNOR RESISTANCE BETWEEN GROUND CIRCUIT. IS THE RESISTANCE YES PRESSURE SENSOR

THE GOVERNOR BELOW 5.0 OHMS? SIGNAL CIRCUITPRESSURE SENSOR SHORTED TO SENSOR

SIGNAL CIRCUIT... FIG. 1, 2, 3 OR 4 GROUND CIRCUIT.*

NO

MEASURE THE AND GROUND. REPAIR THERESISTANCE BETWEEN IS THE RESISTANCE YES GOVERNOR PRESSURE

THE GOVERNOR BELOW 5.0 OHMS? SENSOR SIGNAL PRESSURE SENSOR CIRCUIT SHORTED TO

SIGNAL CIRCUIT... FIG. 1, 2, 3 OR 4 GROUND.*

NO

REMOVE THE TRANS OILPAN. DISCONNECT THE CONNECT THE TRANSPRESSURE/TEMP SENSOR SOLENOID

CONNECTOR.** CONNECTOR. SEE GENERAL INFO 4.4

MEASURE THE AND THE SENSOR REPLACE THERESISTANCE BETWEEN GROUND CIRCUIT. IS THE RESISTANCE YES TRANSMISSION

THE GOVERNOR BELOW 5.0 OHMS? HARNESS/SOLENOID PRESSURE SENSOR ASSEMBLY.*

SIGNAL CIRCUIT... FIG. 1, 2, 3 OR 4

NO

MEASURE THE AND GROUND. REPLACE THERESISTANCE BETWEEN IS THE RESISTANCE YES TRANSMISSION

THE GOVERNOR BELOW 5.0 OHMS? HARNESS/SOLENOID PRESSURE SENSOR ASSEMBLY.*

SIGNAL CIRCUIT... FIG. 1, 2, 3 OR 4

NO

RECONNECT ALL KEY ON. WITH ACOMPONENTS EXCEPT DRB, MONITOR IS THE VOLTAGE NO THE PRESSURE/TEMP GOVERNOR PRESSURE ABOVE 4.8 VOLTS? REPLACE THE PCM.*

SENSOR. SENSOR VOLTAGE.

YES

REPLACE THEPRESSURE/TEMP

SENSOR.*

TROUBLE

CODE

TESTS

599

TEST TC-168A REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO HIGH


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4 FIG. 5

TROUBLE

CODE

TESTS

600

TEST TC-168A REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO HIGH



KEY OFF. DISCONNECT START TEST THE TRANS SOLENOID

TC-168A. CONNECTOR.**


KEY ON, MEASURETHE VOLTAGE AT THE IS THE VOLTAGE NO REPAIR THE OPEN

5-VOLT SUPPLY BETWEEN 4.5 AND 5-VOLT SUPPLY CIRCUIT. 5.5 VOLTS? CIRCUIT.*

FIG. 1, 2, 3 OR 4

YES

KEY ON, WITH THECONNECT SOLENOID DRB, MONITOR THE IS THE VOLTAGE YES CONTINUE TEST

CONNECTOR. GOVERNOR PRESSURE ABOVE 4.65 VOLTS? TC-168A ON THEVOLTAGE. NEXT PAGE.

NO

IS THE VOLTAGE YES PERFORM TEST BELOW 0.12 VOLTS? TC-167A.

NO

IS THE VOLTAGE NO PERFORM TEST BETWEEN 0.12 AND 168B.

0.80 VOLTS?

YES


NO



TROUBLE

CODE

TESTS

601

TEST TC-168A CONTINUED - REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO HIGH

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

602



KEY OFF. DISCONNECT DISCONNECT ALL OF TEST TC-168A THE TRANSMISSION THE PCM

CONTINUED FROM SOLENOID CONNECTORS.**PREVIOUS PAGE. CONNECTOR.**


MEASURE THE THE PCM CONNECTOR REPAIR THE OPEN RESISTANCE OF THE TO THE SOLENOID IS THE RESISTANCE YES GOVERNOR PRESSURE GOVERNOR PRESSURE CONNECTOR. ABOVE 5.0 OHMS? SENSOR SIGNAL

SENSOR SIGNAL CIRCUIT.*CIRCUIT FROM... FIG. 1, 2, 3 OR 4

NO

MEASURE THE THE PCM CONNECTORRESISTANCE OF THE TO THE SOLENOID IS THE RESISTANCE YES REPAIR THE OPEN

SENSOR GROUND CONNECTOR. ABOVE 5.0 OHMS? SENSOR GROUND CIRCUIT FROM... CIRCUIT.*

FIG. 1, 2, 3 OR 4

NO


NEXT PAGE.

TROUBLE

CODE

TESTS

603


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

604



CONNECT A JUMPER RELAY OUTPUT TEST TC-168A WIRE FROM THE CIRCUIT IN THE

CONTINUED FROM FUSED B(+) CIRCUIT RELAY CONNECTOR. PREVIOUS PAGE. TO THE TRANS

CONTROL... FIG. 1, 2, 3 OR 4

KEY ON. MEASURE AT THE PCM REPAIR THETHE VOLTAGE AT THE CONNECTOR. IS THE VOLTAGE YES GOVERNOR PRESSURE GOVERNOR PRESSURE ABOVE 1.0 VOLT? SIGNAL CIRCUIT FORSIGNAL CIRCUIT... FIG. 1, 2, 3 OR 4 ON A SHORT TO

THE PRECEEDING PAGE VOLTAGE.*

NO

REMOVE THE TRANS OILPAN. DISCONNECT THE CONTINUE TEST PRESSURE/TEMP SENSOR TC-168A ON THE

CONNECTOR.** NEXT PAGE.SEE GENERAL INFO 4.4

TROUBLE

CODE

TESTS

605


ALL BODIES

FIG. 1

AB BODY

FIG. 2

AN BODY

FIG. 3

BR BODY

FIG. 4

ZJ BODY

FIG. 5

TROUBLE

CODE

TESTS

606



TEST TC-168ACONTINUED FROM CONNECT THE

THE PREVIOUS SOLENOID PAGE. CONNECTOR.

KEY ON. MEASURE REPLACE THETHE VOLTAGE AT THE IS THE VOLTAGE YES TRANSMISSION GOVERNOR PRESSURE ABOVE 1.0 VOLT? HARNESS/SOLENOID

SIGNAL CIRCUIT. ASSEMBLY.* FIG. 1

NO

KEY OFF. MEASURE THE PCM CONNECTOR TO THE REPLACE THERESISTANCE OF THE GOVERNOR PRESSURE IS THE RESISTANCE YES TRANSMISSION GOVERNOR PRESSURE SENSOR CONNECTOR. ABOVE 5.0 OHMS? HARNESS/SOLENOID

SENSOR SIGNAL ASSEMBLY.* CIRCUIT FROM THE... FIG. 2, 3, 4 OR 5

NO

MEASURE THE CONNECTOR TO THE REPLACE THERESISTANCE OF THE GOVERNOR PRESSURE IS THE RESISTANCE YES TRANSMISSION

SENSOR GROUND SENSOR CONNECTOR. ABOVE 5.0 OHMS? HARNESS/SOLENOID CIRCUIT FROM THE ASSEMBLY.*

PCM... FIG. 2, 3, 4 OR 5

NO

RECONNECT ALL CAREFULLY INSERT ACONNECTORS EXCEPT JUMPER WIRE BETWEEN

THE GOVERNOR THE GOVERNOR PRESSURE SENSOR PRESSURE SENSOR

CONNECTOR. SIGNAL CIRCUIT...

AND THE SENSOR KEY ON. MONITORGROUND CIRCUIT IN THE GOVERNOR IS THE VOLTAGE NO REPLACE THE

THE SENSOR PRESSURE SENSOR ABOVE 0.1 VOLTS? PRESSURE/TEMPCONNECTOR. VOLTAGE WITH THE SENSOR.*

FIG. 1 DRB.

YES

REPLACE THE PCM.*

TROUBLE

CODE

TESTS

607

TEST TC-168B REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO HIGH


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

608

TEST TC-168B REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO HIGH



DISCONNECT THE WHITESTART TEST PCM CONNECTOR.**

TC-168B.


WITH THE DRB, MONITOR GOVERNOR IS VOLTAGE ABOVE NO

START ENGINE. PRESSURE SENSOR 4.65 VOLTS? REPLACE THE PCM.*VOLTAGE.

YES

KEY OFF. DISCONNECT THE TRANSDISCONNECT THE SOLENOID REMAINING PCM CONNECTOR.** CONNECTORS.**


MEASURE THE THE PCM CONNECTOR REPAIR THE OPEN RESISTANCE OF THE TO THE SOLENOID IS THE RESISTANCE YES GOVERNOR PRESSURE GOVERNOR PRESSURE CONNECTOR. ABOVE 5.0 OHMS? SENSOR SIGNAL

SENSOR SIGNAL CIRCUIT.*CIRCUIT FROM... FIG. 1, 2, 3 OR 4

NO

MEASURE THE THE PCM CONNECTORRESISTANCE OF THE TO THE SOLENOID IS THE RESISTANCE YES REPAIR THE OPEN

SENSOR GROUND CONNECTOR. ABOVE 5.0 OHMS? SENSOR GROUND CIRCUIT FROM... CIRCUIT.*

FIG. 1, 2, 3 OR 4

NO

KEY ON. MEASURE AT THE PCM REPAIR THETHE VOLTAGE AT THE CONNECTOR. IS THE VOLTAGE YES GOVERNOR PRESSURE GOVERNOR PRESSURE ABOVE 1.0 VOLT? SENSOR SIGNAL SIGNAL CIRCUIT... CIRCUIT FOR A

FIG. 1, 2, 3 OR 4 SHORT TO VOLTAGE.*

NO


NEXT PAGE.

TROUBLE

CODE

TESTS

609

TEST TC-168B CONTINUED - REPAIRING - GOVERNOR PRESSURE SENSOR VOLTS TOO HIGH

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

610



REMOVE THE TRANS OILTEST TC-168B PAN. DISCONNECT THE

CONTINUED FROM PRESSURE/TEMP SENSOR PREVIOUS PAGE. CONNECTOR.**


KEY ON. MEASURE REPLACE THERECONNECT THE THE VOLTAGE AT THE IS THE VOLTAGE YES TRANSMISSION

SOLENOID GOVERNOR PRESSURE ABOVE 1.0 VOLT? HARNESS/SOLENOID CONNECTOR. SIGNAL CIRCUIT. ASSEMBLY.*

FIG. 1, 2, 3 OR 4

NO

CONTINUE TEST TC-168B ON THEFOLLOWING PAGE.

TROUBLE

CODE

TESTS

611


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

612



REMOVE THE TRANS OILTEST TC-168B PAN. DISCONNECT THE

CONTINUED FROM PRESSURE/TEMP SENSOR PREVIOUS PAGE. CONNECTOR.**


MEASURE THE PCM CONNECTOR TO THE REPLACE THERESISTANCE OF THE GOVERNOR PRESSURE IS THE RESISTANCE YES TRANSMISSION GOVERNOR PRESSURE SENSOR CONNECTOR. ABOVE 5.0 OHMS? HARNESS/SOLENOID

SENSOR SIGNAL ASSEMBLY.* CIRCUIT FROM THE... FIG. 1, 2, 3 OR 4

NO

MEASURE THE CONNECTOR TO THE REPLACE THERESISTANCE OF THE GOVERNOR PRESSURE IS THE RESISTANCE YES TRANSMISSION

SENSOR GROUND SENSOR CONNECTOR. ABOVE 5.0 OHMS? HARNESS/SOLENOID CIRCUIT FROM ASSEMBLY.*

THE PCM... FIG. 1, 2, 3 OR 4

NO

REPLACE THEPRESSURE/TEMP

SENSOR.*

TROUBLE

CODE

TESTS

613

TEST TC-169A REPAIRING - GOVERNOR PRESSURE SENSOR OFFSET VOLTS TOO LOW OR HIGH


FIG. 1

TROUBLE

CODE

TESTS

614

TEST TC-169A REPAIRING - GOVERNOR PRESSURE SENSOR OFFSET VOLTS TOO LOW OR HIGH



START ENGINE, ALLOW REPAIR FLUID LEVELSTART TEST TO WARM UP AND CHECK WAS FLUID NO AND/OR CONDITION

TC-169A FLUID LEVEL AND CONDITION AND OF BAD FLUID ANDCONDITION OF FLUID. LEVEL OK? RETEST.*

YES

WAS THE REPAIR CHECK PARK/NEUTRAL PARK/NEUTRAL NO PARK/NEUTRAL SWITCH FOR PROPER SWITCH OPERATION SWITCH AS

OPERATION. OK? NECESSARY.*

YES

PLACE VEHICLE IN NEUTRAL, WITH THE WAS THE VOLTAGE NO CONTINUE TEST

DRB, READ THE BETWEEN 0.3 AND TC-169A ON NEXT GOVERNOR PRESSURE 0.76 VOLTS? PAGE.

SENSOR VOLTAGE.

YES


NO



TROUBLE

CODE

TESTS

615

TEST TC-169A CONTINUED - REPAIRING GOVERNOR PRESSURE SENSOR OFFSET VOLTS TOOLOW OR HIGH

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

616



KEY ON, ENGINE OFF. TEST TC-169A DISCONNECT THE TRANS

CONTINUED FROM SOLENOID PREVIOUS PAGE CONNECTOR.**


MEASURE VOLTAGE AT THE 5-VOLT SUPPLY WAS THE VOLTAGE NO REPAIR THE OPEN

CIRCUIT IN TRANS ABOVE 4.5 VOLTS? 5-VOLT SUPPLY SOLENOID CONNECTOR. CIRCUIT.*

FIG. 1, 2, 3 OR 4

YES

TURN KEY OFF. DISCONNECT THE PCM

CONNECTOR.**


MEASURE THE TO THE SOLENOID RESISTANCE OF THE CONNECTOR. WAS THE RESISTANCE NO REPAIR THE OPEN

SENSOR GROUND BELOW 5.0 OHMS? SENSOR GROUND CIRCUIT FROM THE FIG. 1, 2, 3 OR 4 ON CIRCUIT.*PCM CONNECTOR... THE FOLLOWING PAGE.

YES

WHILE STILLRECONNECT ALL MONITORING

CONNECTORS. START GOVERNOR PRESSURE ENGINE. SENSOR VOLTAGE,...

WIGGLE THE WIRES DID THE GOVERNOR REPAIR WIRING BETWEEN THE PCM PRESSURE SENSOR YES WHERE WIGGLING AND THE SOLENOID VOLTAGE FLUCTUATE CAUSED THE

CONNECTOR. WHILE WIGGLING THE FLUCTUATION.*WIRES?

NO

CONTINUE TEST 169A ON

FOLLOWING PAGE.

TROUBLE

CODE

TESTS

617


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

618



TEST 169A CONTINUED FROM WITH THE DRB,

THE PREVIOUS CLEAR TROUBLEPAGE. CODES.

START ENGINE. LET THE CONDITIONS ENGINE IDLE IN DID CODE COME BACK NO REQUIRED TO SET THIS

PARK OR NEUTRAL AFTER 3 MINUTES OF CODE ARE NOT PRESENTFOR 3 MINUTES. ENGINE IDLING? AT THIS TIME.

FIG. 1 AND 2

YES

CHECK PAN AND/OR DOES THE PANREPLACE THE FILTER FOR AND/OR FILTER YES REPAIR CAUSE OF

GOVERNOR PRESSURE EXCESSIVE DEBRIS CONTAIN EXCESSIVE EXCESSIVE DEBRIS.* SENSOR.* WHILE CHANGING DEBRIS?

SENSOR.

NO

TEST COMPLETE.

TROUBLE

CODE

TESTS

619

TEST TC-171A REPAIRING - GOVERNOR PRESSURE SOLENOID/TRANS RELAY CKTS


FIG. 1

TROUBLE

CODE

TESTS

620

TEST TC-171A REPAIRING - GOVERNOR PRESSURE SOLENOID/TRANS RELAY CKTS



IS THE TRANSSTART TEST 12-VOLT SUPPLY YES PERFORM TEST

TC-171A RELAY CONTROL TC-173.CIRCUIT CODE SET?

NO

WITH THE DRB, SELECT 1ST GEAR.PERFORM A GOV AND IS THE GOVERNOR NO CONTINUE TEST

3-4 SHIFT VALVE READ GOVERNOR PRESSURE VOLTAGE TC-171A ON THESYSTEM TEST. PRESSURE VOLTAGE. BELOW 1.0 VOLTS? NEXT PAGE.

YES

AT THIS TIME, THE USING THECONDITION REQUIRED SCHEMATIC AS A WERE ANY PROBLEMS YES REPAIR AS


FIG. 1 CONNECTORS.

NO

WITH THE DRB, WHILE READING DTC’S DOES THE GOVERNOR CLEAR CODES. WITH THE DRB, WIGGLE PRESSURE SOLENOID YES REPAIR WIRING AS

THE WIRING HARNESS CONTROL CIRCUIT NECESSARY.*START THE ENGINE. FROM THE SOLENOID TO FAULT CODE APPEAR?

THE PCM.

NO

TEST COMPLETE.*

TROUBLE

CODE

TESTS

621

TEST TC-171A CONTINUED - REPAIRING - GOVERNOR PRESSURE SOLENOID/TRANS RELAY CKTS

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

622






KEY ON. WITH THE MEASURE THE DOES THE VOLTAGEDRB, ACTUATE THE VOLTAGE AT THE FLUCTUATE FROM 0 NO PERFORM TEST

TRANS CONTROL TRANS RELAY OUTPUT VOLTS TO OVER 10.0 TC-171B. RELAY. CIRCUIT. VOLTS?

FIG. 1, 2, 3 OR 4

YES


NEXT PAGE.

TROUBLE

CODE

TESTS

623


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

624



TEST TC-171A KEY OFF. DISCONNECT CONTINUED FROM THE POWERTRAIN

THE PREVIOUS CONTROL MODULE WHITEPAGE. CONNECTOR.**


KEY ON. MEASURE THEVOLTAGE AT THE GOV. IS THE VOLTAGE YES PERFORM TEST

PRESSURE SOLENOID ABOVE 10.0 VOLTS? TC-171D. CONTROL CIRCUIT.

FIG. 1, 2, 3 OR 4

NO

RECONNECT THESOLENOID PACK

CONNECTOR.

KEY OFF. MEASURE THE AT THE PCM REPAIR THERESISTANCE BETWEEN CONNECTOR AND IS THE RESISTANCE NO GOVERNOR PRESSURE

THE GOVERNOR GROUND. ABOVE 5.0 OHMS? SOLENOID CONTROLPRESSURE SOLENOID CIRCUIT SHORTED TO CONTROL CIRCUIT... FIG. 1, 2, 3 OR 4 GROUND.*

YES


NEXT PAGE.

TROUBLE

CODE

TESTS

625


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

626




THE PREVIOUS PAGE.


MEASURE THE AND THE GOVERNOR RESISTANCE BETWEEN PRESSURE SOLENOID IS THE RESISTANCE YESTHE TRANS CONTROL CONTROL CIRCUIT AT BETWEEN 2.5 AND REPLACE THE PCM.*

RELAY OUTPUT CIRCUIT THE PCM CONNECTOR. 5.0 OHMS?AT THE RELAY... FIG. 1, 2, 3 OR 4

NO


YES

CONTINUE TEST TC-171A ON THEFOLLOWING PAGE.

TROUBLE

CODE

TESTS

627


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

628






MEASURE THE FROM THE PCM REPAIR THE OPEN RESISTANCE OF THE CONNECTOR TO THE IS THE RESISTANCE YES GOVERNOR PRESSURE GOVERNOR PRESSURE SOLENOID ABOVE 5.0 OHMS? SOLENOID CONTROL

SOLENOID CONTROL CONNECTOR. CIRCUIT.*CIRCUIT... FIG. 1, 2, 3 OR 4

NO

DRAIN AND REMOVE OIL MEASURE THEPAN. DISCONNECT THE RESISTANCE ACROSS IS THE RESISTANCE NO REPLACE THE

GOVERNOR PRESSURE THE GOVERNOR ABOVE 5.0 OHMS? SOLENOID ANDSOLENOID.** PRESSURE SOLENOID. HARNESS ASSEMBLY.*


YES


SOLENOID.*

TROUBLE

CODE

TESTS

629

TEST TC-171B REPAIRING - GOVERNOR PRESSURE SOLENOID/TRANS RELAY CKTS


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

630

TEST TC-171B REPAIRING - GOVERNOR PRESSURE SOLENOID/TRANS RELAY CKTS




TC-171B.


KEY OFF. MEASURE AND GROUND AT THE REPAIR THE TRANSTHE RESISTANCE RELAY CONNECTOR. IS THE RESISTANCE YES RELAY OUTPUT

BETWEEN THE TRANS BELOW 5.0 OHMS? CIRCUIT SHORTED TO RELAY OUTPUT GROUND.*


NO

MEASURE THE FROM THE RELAYRESISTANCE OF THE CONNECTOR TO THE IS THE RESISTANCE YES REPAIR THE OPEN TRANS RELAY OUTPUT SOLENOID ABOVE 5.0 OHMS? TRANS RELAY OUTPUT

CIRCUIT... CONNECTOR. CIRCUIT.*FIG. 1, 2, 3 OR 4

NO

KEY ON, MEASURE THE REPAIR THE OPEN VOLTAGE AT THE FUSED IS THE VOLTAGE NO FUSED B(+) FEED TO B(+) CIRCUIT IN THE ABOVE 10.0 VOLTS ? THE TRANS CONTROL

RELAY CONNECTOR. RELAY. FIG. 1, 2, 3 OR 4

YES


TROUBLE

CODE

TESTS

631

TEST TC-171C REPAIRING - GOVERNOR PRESSURE SOLENOID/TRANS RELAY CKTS


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

TROUBLE

CODE

TESTS

632

TEST TC-171C REPAIRING - GOVERNOR PRESSURE SOLENOID/TRANS RELAY CKTS



DISCONNECT THE TRANSSTART TEST SOLENOID



MEASURE AND RECORD AND ALL OTHER IS THE RESISTANCE REPAIR GOVERNOR THE RESISTANCES CIRCUITS IN THE BELOW 2.5 OHMS YES PRESSURE SOLENOID

BETWEEN THE GOVERNOR SOLENOID BETWEEN ANY TWO CONTROL CKT SHORTEDPRESSURE SOLENOID CONNECTOR. CIRCUITS? TO CIRCUIT(S) THAT CONTROL CIRCUIT... FIG. 1, 2, 3 OR 4 WERE BELOW 2.5 OHMS.

NO

REMOVE THE TRANS MEASURE THEOIL PAN. RESISTANCE ACROSS

DISCONNECT THE BOTH TERMINALS OF GOVERNOR PRESSURE THE GOVERNOR

SOLENOID.** PRESSURE SOLENOID.

IS THE RESISTANCE YES REPLACE THEBELOW 2.5 OHMS? GOVERNOR PRESSURE

SOLENOID.*

NO

REPLACE THE TRANS RECONNECT ALLHARNESS/SOLENOID DISCONNECTED

ASSEMBLY.* CONNECTORS.

WITH THE DRB, SELECT 1ST GEAR.PERFORM THE GOV IS THE GOVERNOR NO

AND 3-4 SHIFT READ THE GOVERNOR PRESSURE VOLTAGE REPLACE THE PCM.*VALVE SYSTEM TEST. PRESSURE VOLTAGE. BELOW 1.0 VOLT?

YES

TEST COMPLETE.

TROUBLE

CODE

TESTS

633

TEST TC-171D REPAIRING - TRANS 3-4 SOLENOID/TRANS RELAY CKT


NOTES

TROUBLE

CODE

TESTS

634

TEST TC-171D REPAIRING - TRANS 3-4 SOLENOID/TRANS RELAY CKT



REPAIR GOVERNOR START TEST PRESSURE SOLENOID

TC-171D. CONTROL CIRCUITSHORTED TO VOLTAGE.*

RECONNECT ALLDISCONNECTED CONNECTORS.

WITH THE DRB, SELECT 1ST GEAR.PERFORM THE GOV IS THE GOVERNOR NO

AND 3-4 SHIFT READ THE GOVERNOR PRESSURE VOLTAGE REPLACE THE PCM.*VALVE SYSTEM TEST. PRESSURE VOLTAGE. BELOW 1.0 VOLT?

YES

TEST COMPLETE.

TROUBLE

CODE

TESTS

635

TEST TC-173A REPAIRING - TRANS 12 VOLT SUPPLY RELAY CNTRL CIRCUIT


AB BODY AN BODY

BR BODY ZJ BODY

FIG. 1 FIG. 2

TROUBLE

CODE

TESTS

636

TEST TC-173A REPAIRING - TRANS 12 VOLT SUPPLY RELAY CNTRL CIRCUIT



WITH THE DRB, IS THESTART TEST ACTUATE THE TRANSMISSION NO CONTINUE TEST

TC-173A. TRANSMISSION CONTROL RELAY TC-173A ON THECONTROL RELAY. CLICKING? NEXT PAGE.

YES

THE CONDITIONREQUIRED TO SETTHE TROUBLE CODE IS NOT PRESENT.

FIG. 1



CONNECTORS.

NO


RELAY TO THE THE TRANS CONTROL INTERRUPT THE WIGGLING CAUSED POWERTRAIN CONTROL RELAY. CLICKING? THE CLICKING TO BE


NO

REFER TO FIG. 2FOR INACTIVE TROUBLE CODE TEST COMPLETE.*


TROUBLE

CODE

TESTS

637

TEST TC-173A CONTINUED - REPAIRING - TRANS 12 VOLT SUPPLY RELAY CNTRL CIRCUIT

BR BODY

FIG. 3

AB BODY

FIG. 1

AN BODY

FIG. 2

ZJ BODY

FIG. 4

FIG. 5 FIG. 6

TROUBLE

CODE

TESTS

638

TEST TC-173A CONTINUED - REPAIRING - TRANS 12 VOLT SUPPLY RELAY CNTRL CIRCUIT


TEST TC-173A DISCONNECT THECONTINUED FROM TRANSMISSION CONTROL

THE PREVIOUS RELAY.** PAGE.


MEASURE THE VOLTAGE REPAIR THE OPEN AT THE FUSED IGN SW IS THE VOLTAGE NO FUSED IGNITION

OUTPUT CIRCUIT IN ABOVE 10.0 VOLTS? SWITCH OUTPUT THE RELAY CONNECTOR. CIRCUIT.*

FIG. 1, 2, 3 OR 4

YES

MEASURE THE OF THE TRANSRESISTANCE BETWEEN CONTROL RELAY. IS THE RESISTANCE NO REPLACE THE

TERMINALS 85 AND BELOW 100.0 OHMS? TRANSMISSION 86... CONTROL RELAY.*

FIG. 5 OR 6

YES


CONTROL MODULE WHITECONNECTOR.**


MEASURE THE AND GROUND. REPAIR THERESISTANCE BETWEEN IS THE RESISTANCE YES TRANSMISSION RELAY

THE TRANS RELAY BELOW 5.0 OHMS? CONTROL CIRCUITCONTROL CIRCUIT... FOR A SHORT TO

FIG. 1, 2, 3 OR 4 GROUND.*

NO

MEASURE THE FROM THE RELAY TO RESISTANCE OF THE THE PCM. IS THE RESISTANCE NO REPAIR OPEN

TRANS RELAY BELOW 5.0 OHMS? TRANSMISSION RELAYCONTROL CIRCUIT... CONTROL CIRCUIT.*

FIG. 1, 2, 3 OR 4

YES


MODULE.*

TROUBLE

CODE

TESTS

639



FIG. 1

TROUBLE

CODE

TESTS

640






FIG. 1

IF ENGINE IS WARM,TURN THE ENGINE TURN INGITION ON.

OFF FOR 15 MINUTES (ENGINE OFF) TO ALLOW O2 SENSOR

TO COOL DOWN.



NO


MONITOR THE CHANGE WHILE THIS TROUBLE CODE VOLTAGE. WIGGLING THE IS NOT PRESENT AT

HARNESS? THIS TIME.*

YES





TROUBLE

CODE

TESTS

641


FIG. 1

TROUBLE

CODE

TESTS

642





NO


VOLTAGE.

YES



NO

MEASURE THE 2/1 02 REPAIR THE 2/1 O2 USING AN OHMMETER, SENSOR SIGNAL IS THE RESISTANCE YES SENSOR SIGNAL


FIG. 1

NO



CIRCUIT.

YES


SHORT TO GROUND.*

TROUBLE

CODE

TESTS

643

TEST TC-183A REPAIRING - LEAK DETECTION PUMP SOLENOID CIRCUIT


FIG.1

FIG. 2

TROUBLE

CODE

TESTS

644

TEST TC-183A REPAIRING - LEAK DETECTION PUMP SOLENOID CIRCUIT



WITH THE DRB, READ START TEST START ENGINE AND THE LDP PRESSURE

TC-183A. LET IDLE. SWITCH STATE ANDNOTE POSITION.

DID THE DRB SHOW WITH THE DRB, WITH THE DRB, READ THE LEAK DETECTION NO CONTINUE TEST

ACTUATE THE LDP THE LDP PRESSURE PRESSURE SWITCH TC-183A ON THEPUMP SOLENOID. SWITCH STATE. CHANGE FROM DOWN NEXT PAGE.

TO UP?

YES

DID THE DRB SHOW WITH THE DRB, STOP WITH THE DRB, READ THE LEAK DETECTION NO CONTINUE TEST

ACTUATION OF THE THE LDP PRESSURE PRESSURE SWITCH TC-183A ON THELDP PUMP SOLENOID. SWITCH STATE. CHANGE FROM UP TO NEXT PAGE.

DOWN?

YES



NO

WHILE MONITORING THE DID THE LDP SWITCH REPAIR AS WITH THE DRB, LDP SWITCH STATE, STATE EVER CHANGE YES NECESSARY WHERE

ACTUATE THE LDP WIGGLE WIRING FROM UP TO DOWN WIGGLING CAUSED SOLENOID. HARNESS FROM THE LDP WHEN WIGGLED? PROBLEM TO

SOLENOID TO PCM. APPEAR.*

NO


INFORMATION.

TROUBLE

CODE

TESTS

645

TEST TC-183A CONTINUED - REPAIRING - LEAK DETECTION PUMP SOLENOID CIRCUIT

FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

646

TEST TC-183A CONTINUED - REPAIRING - LEAK DETECTION PUMP SOLENOID CIRCUIT


TEST TC-183A KEY OFF, DISCONNECT CONTINUED FROM THE LEAK DETECTION

THE PREVIOUS PUMP SOLENOID.**PAGE.


MEASURE THE FUSED REPAIR THE OPEN KEY ON, USE A IGNITION SWITCH IS THE VOLTAGE NO FUSED IGNITION

VOLTMETER IN THE OUTPUT CKT AT ABOVE 10.0 VOLTS? SWITCH OUTPUT FOLLOWING STEP. SOLENOID CONN. CKT.*

FIG. 1

YES

KEY OFF, DISCONNECT USING AN OHMMETER,THE POWERTRAIN MEASURE THE LDP

CONTROL MODULE.** SOLENOID CONTROLCIRCUIT...


FROM THE PCM REPAIR THE OPEN CONNECTOR TO THE IS THE RESISTANCE NO LEAK DETECTION

LDP CONNECTOR. BELOW 5.0 OHMS? PUMP SOLENOID CONTROL CIRCUIT.*

FIG. 2

YES

OHMMETER AT THE POWERTRAIN REPAIR THE LEAK CONTROL MODULE. IS THE RESISTANCE YES DETECTION PUMP

BELOW 5.0 OHMS? SOLENOID CIRCUITSOLENOID CONTROL FOR A SHORT TO

C FIG. 2 GROUND.*

NO

RECONNECT THE LEAK THE LEAK DETECTIONDETECTION PUMP PUMP SOLENOID IS THE VOLTAGE NO REPLACE THE LEAK

CONNECTOR. KEY ON, CONTROL CIRCUIT AT ABOVE 10.0 VOLTS? DETECTION PUMP.* WITH A VOLTMETER, THE PCM CONNECTOR.

MEASURE... FIG. 2

YES


MODULE.*

USING AN ,MEASURE THE LEAK

DETECTION PUMP

IRCUIT...

TROUBLE

CODE

TESTS

647

TEST TC-184A REPAIRING - LEAK DETECTION PUMP SW OR MECHANICAL FAULT


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

648

TEST TC-184A REPAIRING - LEAK DETECTION PUMP SW OR MECHANICAL FAULT



START TEST START ENGINE AND WITH THE DRB, READ TC-184A. LET IDLE. THE LDP PRESSURE

SWITCH STATE.

DID THE DRB SHOW WITH THE DRB, WITH THE DRB, READ THE LEAK DETECTION NO CONTINUE TEST

ACTUATE THE LDP THE LDP PRESSURE PRESSURE SWITCH TC-184A ON THEPUMP SOLENOID. SWITCH STATE. CHANGE FROM UP TO NEXT PAGE.

DOWN?

YES

DID THE DRB SHOW WITH THE DRB, STOP WITH THE DRB, READ THE LEAK DETECTION NO CONTINUE TEST

ACTUATION OF THE THE LDP PRESSURE PRESSURE SWITCH TC-184A ON THELDP PUMP SOLENOID. SWITCH STATE. CHANGE FROM DOWN NEXT PAGE.

TO UP?

YES



NO

WHILE MONITORING THE DID THE LDP SWITCH REPAIR AS WITH THE DRB, LDP SWITCH STATE, STATE EVER CHANGE YES NECESSARY WHERE

ACTUATE THE LDP WIGGLE WIRING FROM UP TO DOWN WIGGLING CAUSED SOLENOID. HARNESS FROM THE LDP WHEN WIGGLED? PROBLEM TO

SOLENOID TO PCM. APPEAR.*

NO


INFORMATION.

TROUBLE

CODE

TESTS

649

TEST TC-184A CONTINUED - REPAIRING - LEAK DETECTION PUMP SW OR MECHANICAL FAULT

FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

650

TEST TC-184A CONTINUED - REPAIRING - LEAK DETECTION PUMP SW OR MECHANICAL FAULT


TEST TC-184A CONNECT A VACUUM CONTINUED FROM GAUGE INTO THE

THE PREVIOUS VACUUM TEE TO THEPAGE. LDP.


DOES THE VACUUM START THE ENGINE GAUGE READ WITHIN NO REPAIR THE LEAK OR

AND READ THE 1 INCH OF ENGINE OBSTRUCTION IN THEVACUUM GAUGE. VACUUM. VACUUM HOSE.*

YES

KEY OFF. DISCONNECT KEY ON. USING ATHE POWERTRAIN VOLTMETER, MEASURE IS THE VOLTAGE YES REPLACE THE LEAK

CONTROL MODULE.** THE LDP PRESSURE ABOVE 10.0 VOLTS? DETECTION PUMP.* SWITCH CIRCUIT.


NO

DISCONNECT THE LEAK MEASURE THE FUSED REPAIR THE OPEN DETECTION PUMP IGNITION SWITCH IS THE VOLTAGE NO FUSED IGNITION

CONNECTOR.** OUTPUT CIRCUIT. ABOVE 10.0 VOLTS? SWITCH OUTPUT CKT.*


YES

USING AN OHMMETER, FROM THE PCM REPAIR OPEN LEAK MEASURE THE LDP CONNECTOR TO THE IS THE RESISTANCE NO DETECTION PUMP PRESSURE SWITCH LDP CONNECTOR. BELOW 5.0 OHMS? SWITCH SENSE

CIRCUIT... CIRCUIT.*FIG. 2

YES

REPLACE THE LEAK DETECTION PUMP.*

TROUBLE

CODE

TESTS

651

TEST TC-186A REPAIRING - MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT


AB, AN, BR, AND XJ BODIES ZJ BODY

TROUBLE

CODE

TESTS

652

TEST TC-186A REPAIRING - MIS-FIRE ADAPTIVE NUMERATOR AT LIMIT



DISCONNECT THE IS ANY TERMINAL START TEST CRANKSHAFT POSITION CORRODED, DAMAGED, YES REPAIR AS

TC-186A. CONNECTOR.** INSPECT PUSHED OUT OR NECESSARY.*ALL TERMINALS. MISWIRED?


NO

INSPECT THE IS THE CRANKSHAFT CRANKSHAFT POSITION POSITION SENSOR NO PROPERLY INSTALL

SENSOR FOR PROPER PROPERLY CRANKSHAFT INSTALLATION. INSTALLED? POSITION SENSOR.*


YES

NO IS THE VEHICLEEQUIPPED WITH AN

8.0L ENGINE?

YES

INSPECT THECRANKSHAFT NOTCHES IS THE CRANKSHAFT NO REPAIR AS

FOR DAMAGE OR OKAY? NECESSARY.*MISALIGNMENT.

YES


POSITION SENSOR.*

INSPECT THEFLYWHEEL FOR IS THE FLYWHEEL YES REPAIR AS

DAMAGE OR DAMAGED? NECESSARY.*MISALIGNMENT.

NO


POSITION SENSOR.*

TROUBLE

CODE

TESTS

653

TEST TC-187A REPAIRING - EVAP LEAK MONITOR PINCHED HOSE


FIG. 1 FIG. 2

TROUBLE

CODE

TESTS

654

TEST TC-187A REPAIRING - EVAP LEAK MONITOR PINCHED HOSE



TO PERFORM THIS START TEST TEST YOU WILL NEED

TC-187A. MILLER TOOL KIT#6872A.

FIG. 1

CAUTION: REFER TO PERFORM EVAPORATIVEFIGURE 2 FOR SYSTEM PRESSURE PUMP

SAFETY SELF TEST THAT IS INFORMATION. SPECIFIED ON THE

TESTER COVER.

CONNECT THE EVAP USING AN AUXIILIARY PRESSURE PUMP SUPPLY CONSTANT VACUUM

HOSE TO VEHICLE SUPPLY, WITH THEPRESSURE TEST PORT. DRB, GO TO LDPSEE GENERAL INFO 4.2 SYSTEM TEST,...

USING PRESSURE TOOL FOLLOW THE #6872A SET PRESSURE DISCONNECT THE

INSTRUCTIONS ON HOLD TO OPEN, AND PURGE SOLENOID THE SCREEN. SET VENT CLOSED. CONNECTOR.**

TURN PUMP TIMER ON.

ALLOW PRESSURE PUMP TO BUILD DID PRESSURE DROP NO CONTINUE TEST

PRESSURE UP TO AT REMOVE GAS CAP. WHEN GAS CAP WAS TC-187A ON THELEAST 14IN H20. REMOVED? NEXT PAGE.

YES

REINSTALL GAS CAP, BUILD PRESSURE DISCONNECT LDP DID PRESSURE DROP YESBACK UP TO AT PRESSURE HOSE FROM WHEN HOSE WAS REPLACE LDP.*

LEAST 14IN H20. THE LDP. DISCONNECTED?

NO

REPLACEEVAPORATIVE

CANISTER.*

TROUBLE

CODE

TESTS

655

TEST TC-187A CONTINUED REPAIRING EVAP LEAK MONITOR PINCHED HOSE

FIG. 1

TROUBLE

CODE

TESTS

656

TEST TC-187A CONTINUED - REPAIRING - EVAP LEAK MONITOR PINCHED HOSE


TEST TC-187ACONTINUED FROM REINSTALL THE GAS

THE PREVIOUS CAP. PAGE.

REMOVE THE GAS REPAIR THE PINCHEDMAKE SURE THE TANK ROLLOVER HOSE DID THE PRESSURE YES HOSE FROM THE GAS

PRESSURE IS STILL FROM THE EVAP DROP WHEN THE HOSE TANK TO THE EVAP AT LEAST 14IN H20. CANISTER. WAS DISCONNECTED? CANISTER.*

NO

DISCONNECT THE DID THE PRESSURE YES REPLACE THEEVAP PURGE LINE AT DROP WHEN THE HOSE EVAPORATIVE

THE CANISTER. WAS DISCONNECTED? CANISTER.*

NO

REPAIR THEOBSTRUCTION IN THEEVAP PURGE LINE TO

THE CANISTER.*

TROUBLE

CODE

TESTS

657

TEST TC-188A REPAIRING - O/D SWITCH PRESSED (LO) MORE THAN 5 MIN.


AB, AN, AND BR BODIES ZJ BODY

ZJ BODY

FIG. 1

ALL OTHER BODIES

FIG. 2

FIG. 3 FIG. 4

TROUBLE

CODE

TESTS

658

TEST TC-188A REPAIRING - O/D SWITCH PRESSED (LO) MORE THAN 5 MIN.



KEY OFF. DISCONNECT START TEST THE PCM.**

TC-188A


MEASURE THE CIRCUIT ANDRESISTANCE BETWEEN GROUND. IS THE RESISTANCE YES CONTINUE TEST THE OVERDRIVE OFF BELOW 5.O OHMS? TC-188A ON THE

SWITCH SENSE.. FOLLOWING PAGE FIG. 1 OR 2

NO

AT THIS TIME, THE USING THECONDITION REQUIRED SCHEMATIC AS A WERE ANY PROBLEMS YES REPAIR AS TO SET THE CODE IS GUIDE, INSPECT THE FOUND? NECESSARY. *

NOT PRESENT. WIRING ANDCONNECTORS.

NO


INFORMATION.

FIG. 3

TROUBLE

CODE

TESTS

659

TEST TC-188A CONTINUED - REPAIRING - O/D SWITCH PRESSED (LO) MORE THAN 5 MIN.

AB, AN, AND BR BODIES

FIG. 1

ZJ BODY

FIG. 2

TROUBLE

CODE

TESTS

660

TEST TC-188A CONTINUED - REPAIRING - O/D SWITCH PRESSED (LO) MORE THAN 5 MIN.


TEST TC-188ACONTINUED FROM DISCONNECT THE

THE PREVIOUS OVERDRIVE OFFPAGE. SWITCH.*

MEASURE THE CIRCUIT AND REPAIR THERESISTANCE BETWEEN GROUND. IS THE RESISTANCE YES OVERDRIVE OFFTHE OVERDRIVE OFF BELOW 5.O OHMS? SWITCH SENSE

SWITCH SENSE... CIRCUIT SHORTED TO FIG. 1 OR 2 GROUND.*

NO

REPLACE THEOVERDRIVE OFF

SWITCH.*

TROUBLE

CODE

TESTS

661



FIG. 1

TROUBLE

CODE

TESTS

662






TEST.

NO


WITH THE DRB IN SENSORS, MONITOR WAIT FOR THE

THE 1/3 O2 SENSOR VOLTAGE READING TO VOLTAGE. STABILIZE ABOVE

4.5 VOLTS.

WITH THE DRB IN IS THE 1/3ACTUATOR TESTS, MONITOR THE 1/3 O2 O2 SENSOR YES CONTINUE TEST

PERFORM THE O2 SENSOR VOLTAGE FOR VOLTAGE STILL TC-189A ON THESENSOR HEATER THREE MINUTES. ABOVE 1.0 VOLT? NEXT PAGE.

TEST.

NO



TROUBLE

CODE

TESTS

663


FIG. 1

FIG. 2

TROUBLE

CODE

TESTS

664




THE PREVIOUS CONNECTOR.** PUSHED OUT OR AS NECESSARY.*PAGE. MISWIRED?


NO



FIG. 1

YES



FIG. 2

YES


FIG. 1

YES


TROUBLE

CODE

TESTS

665

TEST NTC-1A NO TROUBLE CODE TEST MENU

Perform DTC Test Before Proceeding. For Diesel Vehicles Perform NTC-1B.

First, check all Technical Service Bulletins and Hotline Newsletters that relate to this driveabilityproblem. 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 MENUCHECKING SECONDARY IGNITION AND TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-2ACHECKING THE FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-3ACHECKING COOLANT SENSOR CALIBRATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-4ACHECKING THROTTLE POSITION SENSOR CALIBRATION. . . . . . . . . . . . . . . . . . . . . . . .NTC-5ACHECKING MAP SENSOR CALIBRATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-6ACHECKING FOR OXYGEN SENSOR SWITCHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-7ACHECKING THE OXYGEN SENSOR HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-8ACHECKING THE IDLE AIR CONTROL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-9ACHECKING THE PARK/NEUTRAL SWITCH (AUTO ONLY) . . . . . . . . . . . . . . . . . . . . . . . .NTC-10ACHECKING THE PCM POWER AND GROUND CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . .NTC-11ACHECKING THE EVAP SYSTEM (GASOLINE ENGINE). . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-12ACHECKING THE EGR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-13ACHECKING THE ENGINE VACUUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-14ACHECKING THE INTAKE AIR TEMP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-15ACHECKING THE MINIMUM IDLE AIR FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-16ACHECKING 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 vehicle’s driveability problem, performthe associated test(s) individually. Return No Trouble Code Menu if driveability problem stillexists, 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 actuallyhappens while the vehicle is being tested. To reduce diagnostic time, ensure that the DTC-Test andappropriate General Information sections have been reviewed before attempting to diagnose asymptom.

Select the symptom that most accurately describes the vehicle’s driveability problem and thenperform the test routine that pertains to this symptom. Perform each routine test in sequence until theproblem is found. For definitions, see Section 12.0 in the General Information section in this manual.

SYMPTOM DIAGNOSTIC TEST ROUTINE

HARD START NTC-2A, 3A, 4A, 5A, 6A, 7A, 9A, 11A, 16A, 22A

START AND STALL NTC-2A, 3A, 4A, 5A, 6A, 9A, 11A, 22A

HESITATION/SAG/STUMBLE NO TROUBLE CODE COMPLETE TEST (STEP 1)

SURGE NTC-2A, 3A, 4A, 5A, 6A, 7A, 9A, 11A, 12A, 13A, 22A

LACK OF POWER/SLUGGISH NTC-2A, 3A, 4A, 5A, 6A, 7A, 9A, 11A, 12A, 14A, 22A

SPARK KNOCK/DETONATION NTC-2A, 3A, 4A, 5A, 6A, 7A, 9A, 11A, 13A, 22A

CUTS OUT/MISSES NTC-2A, 3A, 7A, 11A, 14A, 22A

BACKFIRE/POPBACK NTC-2A, 3A, 6A, 7A, 11A, 14A, 22A

RUNS ROUGH/UNSTABLE/ERRATIC IDLE NO TROUBLE CODE COMPLETE TEST (STEP 1)

POOR FUEL ECONOMY NO TROUBLE CODE COMPLETE TEST (STEP 1)

NO

TROUBLE

CODE

TESTS

666

TEST NTC-1B NO TROUBLE CODE TEST MENU (DIESEL)

Perform DTC-Test Before Proceeding

First, check all Technical Service Bulletins and Hotline Newsletters that relate to thisdriveability 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 MENUCHECKING AIR INTAKE HEATER #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-17ACHECKING AIR INTAKE HEATER #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-18ACHECKING FUEL HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-19ACHECKING THE WAIT-TO-START LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-20ACHECKING THE WATER-IN-FUEL LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NTC-21ACHECKING 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 vehicle’s driveability problem, performthe associated test(s) individually. Return No Trouble Code Menu if driveability problem stillexists, or perform No Trouble Code Complete Test.

NO

TROUBLE

CODE

TESTS

667

TEST NTC-2A CHECKING SECONDARY IGNITION AND TIMING

Perform TEST NTC-1A Before Proceeding

FIG. 1 FIG. 2

FIG. 3 FIG. 4

NO

TROUBLE

CODE

TESTS

668

TEST NTC-2A CHECKING SECONDARY IGNITION AND TIMING



START TEST NTC-2A. ENGINE OFF.

NOTE: IF ENGINE NOTE: SET THECONNECT A SUITABLE ALLOW THE ENGINE WILL NOT IDLE, SCOPE TO READ ENGINE ANALYZER TO TO IDLE. MAINTAIN A DISPLAY OR PARADE

THE ENGINE. CONSTANT RPM ABOVE PATTERN. IDLE.

FOLLOW THE EQUIPMENT REPAIR THEMANUFACTURER’S IS THE SECONDARY NO INDICATEDPROCEDURE FOR IGNITION PATTERN COMPONENT IN THE

PATTERN ANALYSIS. OK? SECONDARY IGNITION FIG. 1, 2, 3 OR 4 SYSTEM.*

YES

IS THE OPEN REMOVE SPARK OBSERVE THE CIRCUIT SECONDARY NO REPLACE THE

PLUG WIRE SECONDARY KV LINE. VOLTAGE AT LEAST ELECTRONIC 25KV? IGNITION COIL.*

YES

NOTE: THE ENGINE REINSTALL THE TEMPERATURE MUST

SPARK PLUG WIRE. BE ABOVE 180F FORTHE FOLLOWING

TEST.

WITH THE DRB, READ RAISE THE ENGINE DID THE TIMING NO REPLACE THETHE TOTAL TIMING SPEED TO 2000 RPM. ADVANCE CHANGE POWERTRAIN CONTROL

ADVANCE. WITH RPM? MODULE.*

YES

SECONDARYIGNITION AND

TIMING ADVNORMAL.

TEST PASSED.

ANY.

NO

TROUBLE

CODE

TESTS

669

TEST NTC-3A CHECKING FUEL PRESSURE


FIG.1

NO

TROUBLE

CODE

TESTS

670

TEST NTC-3A CHECKING FUEL PRESSURE



INSPECT ALL OF THE WARNING: THE FUEL START TEST FUEL LINES FOR ARE THERE ANY YES SYSTEM MUST BE

NTC-3A. LEAKS, KINKS OR LEAKS, KINKS OR OPENED AND MAY BE RESTRICTIONS. RESTRICTED LINES? UNDER HIGH

PRESSURE.

NO

WARNING: THE FUEL RELIEVE FUEL RELIEVE FUEL SYSTEM MUST BE PRESSURE. PRESSURE AND REPAIR

OPENED AND MAY BE AS NECESSARY.*UNDER HIGH PRESSURE. SEE GENERAL INFO 9.0 SEE GENERAL INFO 9.0

RECONNECT FUEL PRESSURE GAUGE TO WITH THE DRB, IS THE FUEL YES WITH THE DRB, STOP

THE FUEL SYSTEM. ACTUATE THE FUEL PRESSURE BETWEEN THE FUEL SYSTEM SYSTEM TEST. 44.2 AND 54.2 PSI? ACTUATION TEST.

TURN IGNITION ON.

NO

STOP ACTUATIONTEST.

FUEL PRESSURE IS OK AT THIS TIME.

TEST PASSED.

RELIEVE FUEL WITH THE DRB, STOP PRESSURE AND REPLACE

THE FUEL SYSTEM FUEL PUMP MODULE.* ACTUATION TEST.


NO

TROUBLE

CODE

TESTS

671

TEST NTC-3B CHECKING THE FUEL PRESSURE (CNG)


FIG. 1

FIG. 2

NO

TROUBLE

CODE

TESTS

672

TEST NTC-3B CHECKING THE FUEL PRESSURE (CNG)



NOTE: THE FUEL TANK START TEST MUST BE AT LEAST 1/4

NTC-3B. FULL TO PERFORM THEFOLLOWING TEST.

TURN IGNITION OFF. IS THE PRESSURE INSTALL A PRESSURE GAUGE READING YES CONTINUE TEST GAUGE (0-300 PSI) START THE ENGINE. BETWEEN 90 PSI AND NTC-3B ON THE

AT SERVICE PORT. 140 PSI? NEXT PAGE.FIG. 1

NO

FOLLOW STEPS IN IS THE FUEL YES THE SERVICE MANUAL

PRESSURE ABOVE 140 TO REPLACE DAMAGEDPSI? FUEL PRESSURE

REGULATOR.*

NO

REFER TO FIGURE 2 WERE ANY FUEL FOR POSSIBLE FUEL DELIVERY YES REPAIR FUEL

DELIVERY MECHANICAL MECHANICAL DELIVERY SYSTEM AS PROBLEMS. PROBLEMS FOUND? NECESSARY.*

NO

UNABLE TO LOCATE FUEL

PROBLEM AT THIS TIME, RETURN TO NTC-1A.

NO

TROUBLE

CODE

TESTS

673

TEST NTC-3B CONTINUED - CHECKING THE FUEL PRESSURE (CNG)

NOTES

NO

TROUBLE

CODE

TESTS

674

TEST NTC-3B CONTINUED - CHECKING THE FUEL PRESSURE (CNG)


TEST NTC-3B WITH THE DRB, READ IS THE CNG FUEL FUEL PRESSURE CONTINUED FROM THE FUEL PRESSURE, PRESSURE WITHIN 5 YES IS NORMAL.

THE PREVIOUS AND COMPARE THE PSI OF THEPAGE. READING TO THE MECHANICAL FUEL

MECHANICAL GAUGE. PRESSURE GAUGE? TEST PASSED.

NO

RELEASE FUEL PRESSURE. REPLACE THE CNG

LOW FUEL PRESSURE SENSOR.*


NO

TROUBLE

CODE

TESTS

675

TEST NTC-4A CHECKING COOLANT SENSOR CALIBRATION


NO

TROUBLE

CODE

TESTS

676

TEST NTC-4A CHECKING COOLANT SENSOR CALIBRATION



WITH THE DRB, READ NOTE:START TEST THE ENGINE COOLANT

NTC-4A. TURN IGNITION ON. TEMPERATURE SENSOR VALUE.

WHILE MONITORING WAS THE COOLANTDRB, ALLOW ENGINE TO TEMPERATURE VALUE NO REPLACE THE

START THE ENGINE. REACH NORMAL INCREASE A SMOOTH COOLANT SENSOR.* OPERATING TEMP TRANSITION?

YES

NOTE: INSPECT FORA MECHANICAL

COOLING PROBLEMBEFORE REPLACING

SENSOR.

DID THE COOLANT NO REPLACE THETEMPERATURE REACH COOLANT SENSOR.*

180F OR ABOVE?

YES

NOTE: INSPECT FORA MECHANICAL

COOLING PROBLEMBEFORE REPLACING

SENSOR.

COOLANT SENSOR OPERATING NORMALLY

TEST PASSED.

IF VEHICLETEMP IS ABOVE

180F, ALLOW ENGINE TO COOL UNTIL 150F

IS REACHED.

THE

.(ABOVE 180F)

NO

TROUBLE

CODE

TESTS

677

TEST NTC-5A CHECKING THROTTLE POSITION SENSOR


ALL OTHER BODIES

ZJ BODY

NO

TROUBLE

CODE

TESTS

678

TEST NTC-5A CHECKING THROTTLE POSITION SENSOR



KEY ON. WITH THE IS THE VOLTAGE 1.5 IF A DIESEL CHECKSTART TEST DRB, READ THE TP VOLT OR GREATER YES ADJUSTMENT OF IDLE

NTC-5A. SENSOR VOLTAGE. WITH THE THROTTLE SPEED AND THROTTLE THROTTLE MUST BE CLOSED? LINKAGE ROD PER...

AGAINST STOP.

NO

SERVICE MANUAL SECTION 14 BEFORE

REPLACING THETHROTTLE POSITION

SENSOR.*



YES

STOP MOVING LINKAGE. WAS THERE ANY REPAIR THE HARNESSWIGGLE THE THROTTLE MONITOR THE DRB CHANGE IN THROTTLE YES OR CONNECTOR THAT

POSITION SENSOR DISPLAY. POSITION SENSOR CAUSED THE VOLTAGECONNECTORS AND VOLTAGE WHEN CHANGE.*

HARNESS. WIGGLED?

NO

START THE ENGINE. REPAIR THE HARNESSWIGGLE THE MONITOR THE ENGINE WAS THERE ANY YES OR CONNECTOR THAT

THROTTLE POSITION RPM. CHANGE IN ENGINE CAUSED THE ENGINE SENSOR CONNECTORS RPM WHEN WIGGLED? RPM TO CHANGE.*

AND HARNESS.

NO



CONNECTORS.

NO

TP SENSOR OPERATING

NORMALLY.

TEST PASSED.

NO

TROUBLE

CODE

TESTS

679

TEST NTC-6A CHECKING MAP SENSOR


ZJ BODY

ALL OTHERS

NO

TROUBLE

CODE

TESTS

680

TEST NTC-6A CHECKING MAP SENSOR



START TEST TURN THE ENGINE NTC-6A. OFF.

TEE IN A VACUUM GAUGE TO A

MANIFOLD VACUUM START THE ENGINE.SOURCE.

NOTE: IF THEALLOW THE ENGINE ENGINE WILL NOT

TO IDLE. IDLE, MAINTAIN ACONSTANT RPM ABOVE

IDLE.

IS THE READING MAP SENSOR USING THE DRB, WITHIN 1" OF THE YES OPERATING

READ THE MAP TEED-IN VACUUM NORMALLY.SENSOR VACUUM. GAUGE?

TEST PASSED.

NO

REPLACE THE MAPSENSOR.*

NO

TROUBLE

CODE

TESTS

681

TEST NTC-7A CHECKING OXYGEN SENSOR SWITCHING



ALL CNG

ALL OTHERS

NO

TROUBLE

CODE

TESTS

682

TEST NTC-7A CHECKING OXYGEN SENSOR SWITCHING



NOTE: ENGINE MUST START TEST BE RUNNING AND AT

NTC-7A. NORMAL OPERATINGTEMPERATURE.

NOTE: THE 1/2 AND1/3 O2 SENSORS WITH THE DRB, READ ARE THE O2 SENSOR YES

SHOULD SWITCH SLOWER THE O2 SENSOR VOLTAGES SWITCHING TEST PASSED.THAN THE 1/1 OR 2/1 VOLTAGES. NORMALLY?

O2 SENSORS.

NO

ARE ANY OF THE O2 YES PERFORM TEST SENSORS LOCKED NTC-7B.

"LEAN"?

NO

INSTALL A FUEL TURN THE ENGINE PRESSURE GAUGE TO WITH THE DRB

OFF. THE FUEL LINE. USE TURN IGNITION ON. ACTUATE THE ASDSPECIAL TOOLS IF FUEL SYSTEM TEST.

NECESSARY.

WITH THE DRB, STOP IF FUEL PUMP ANDALLOW FUEL FUEL SYSTEM TEST. IS THE FUEL YES LINES ARE OK,

PRESSURE TO MONITOR THE PRESSURE BELOW REPLACE LEAKINGSTABILIZE. PRESSURE GAUGE FOR 10 PSI? INJECTOR(S) AS

1 MINUTE. NECESSARY.*

NO

INSPECT THE AIR REPAIR OR REPLACEFILTER AND INLET WERE THERE ANY YES THE AIR INLET

DUCTS FOR RESTRICTIONS? SYSTEM AS RESTRICTION(S). NECESSARY.*


NO

PERFORM TEST NTC-22A.

NO

TROUBLE

CODE

TESTS

683

TEST NTC-7B CHECKING OXYGEN SENSOR SWITCHING


FIG. 1

FIG. 2

NO

TROUBLE

CODE

TESTS

684

TEST NTC-7B CHECKING OXYGEN SENSOR SWITCHING



START TEST ALLOW THE ENGINE NTC-7B. TO IDLE.

NOTE: REFER TO REPAIR ABNORMAL INSPECT THE ENGINE FIGURE 1 FOR ARE THERE ANY YES ENGINE VACUUM

FOR ANY ABNORMAL INDICATORS OF ABNORMAL VACUUM CONDITION AS VACUUM CONDITIONS. POSSIBLE ENGINE CONDITIONS? REQUIRED.*

MECHANICAL PROBLEMS.

NO

IS THE VOLTAGEWITH THE DRB, READ BELOW 0.10 VOLTS NO CONTINUE TEST

THE O2 SENSOR FOR ANY OF THE NTC-7B ON THEVOLTAGES. 02 SENSORS? NEXT PAGE.

YES

DISCONNECT THE O2 SENSOR CONNECTOR

TURN IGNITION OFF. THAT THE VOLTAGEIS BELOW 0.10

VOLT.


MODULE.**


USING AN OHMMETER, SIGNAL CIRCUIT AND REPAIR THE O2 MEASURE THE A GOOD GROUND. IS THE RESISTANCE YES SENSOR SIGNAL CKT

RESISTANCE BETWEEN BELOW 5.0 OHMS? FOR A SHORT TO THE O2 SENSOR... GROUND.*

FIG. 2

NO

REPLACE THE O2 SENSOR THAT WAS

BELOW 0.10 VOLTS.*

NO

TROUBLE

CODE

TESTS

685

TEST NTC-7B CONTINUED - CHECKING OXYGEN SENSOR SWITCHING

NOTES

NO

TROUBLE

CODE

TESTS

686

TEST NTC-7B CONTINUED - CHECKING OXYGEN SENSOR SWITCHING


TEST NTC-7B CONTINUED FROM TURN ENGINE OFF,

THE PREVIOUS IGNITION ON.PAGE.

WITH THE DRB IN START ENGINE AND NOTE: ENGINE MUST MISCELLANEOUS, LET IDLE FOR AT BE RUNNING AND AT

RESET THE ADAPTIVE LEAST THREE NORMAL OPERATINGFUEL MEMORY. MINUTES. TEMPERATURE.

NOTE: THE 1/2 AND1/3 O2 SENSOR SHOULD WITH THE DRB, READ ARE THE O2 SENSOR YES

SWITCH SLOWER THAN THE O2 SENSOR VOLTAGES SWITCHING TEST PASSED.THE 1/1 OR 2/1 O2 VOLTAGES. NORMALLY?

SENSOR.

NO

PERFORM TEST NTC-22A.

NO

TROUBLE

CODE

TESTS

687

TEST NTC-8A CHECKING THE OXYGEN SENSOR HEATER


TYPICAL CONNECTOR

FIG. 1

5.9L HD,8.0L HD AND 8.0L CAL/MD ALL OTHERS

NO

TROUBLE

CODE

TESTS

688

TEST NTC-8A CHECKING THE OXYGEN SENSOR HEATER



TURN IGNITION ON. NOTE:USE APPROPRIATESTART TEST WITH THE DRB, O2 SENSOR CONNECTOR

NTC-8A. ACTUATE THE O2 WHEN PERFORMING SENSOR HEATER THIS TEST.

TEST. FIG. 1

WAIT TWO MINUTES ARE ANY OF THE WITH THE DRB, FOR THE O2 SENSOR WITH THE DRB, READ VOLTAGES FOR THE NO STOP THE

VOLTAGES TO THE O2 SENSOR O2 SENSORS ABOVE ACTUATION TEST.STABILIZE. VOLTAGES. 1.0 VOLT?

TEST PASSED.

YES

NOTE: THE O2 SENSOR NOTE: THE DRB IS VOLTAGE STAYING STILL ACTUATING

ABOVE 1.0 VOLT THE O2 SENSOR INDICATES A PROBLEM HEATER TEST.

WITH THAT SENSOR.

DISCONNECT THE O2 USING A VOLTMETER, REPAIR THE OPEN SENSOR CONNECTOR MEASURE THE ASD IS THE VOLTAGE NO ASD RELAY OUTPUT THAT HAS VOLTAGE RELAY OUTPUT CIRCUIT ABOVE 10.0 VOLTS? CIRCUIT TO THE O2

ABOVE 1.0 VOLT.** AT SENSOR CONNECTOR. SENSOR CONNECTOR.*SEE GENERAL INFO 4.4 FIG. 1

YES

WITH THE DRB, STOP THE ACTUATOR TEST.

USING AN OHMMETER, CIRCUIT AND A GOOD REPAIR THE OPEN MEASURE THE GROUND. IS THE RESISTANCE NO HEATER GROUND

RESISTANCE BETWEEN BELOW 5.0 OHMS? CIRCUIT TO THE O2 THE HEATER SENSOR.* GROUND... FIG. 1

YES

REPLACE THE O2 SENSOR.*

NO

TROUBLE

CODE

TESTS

689

TEST NTC-9A CHECKING IDLE AIR CONTROL MOTOR


AB, AN, BR, AND XJ BODIES

ZJ BODY

NO

TROUBLE

CODE

TESTS

690

TEST NTC-9A CHECKING IDLE AIR CONTROL MOTOR



WITH THE ENGINE START TEST RUNNING AND AT

NTC-9A. NORMAL OPERATINGTEMPERATURE,...

USING THE DRB IN WITH THE DRB, ACTUATOR TESTS, IS THE ENGINE YES STOP ALL TESTS. SET ENGINE SPEED SPEED 1400 RPM IAC MOTOR IS

TO 1400 RPM. 100 RPM? OPERATING OK.TEST PASSED.

NO

WITH THE DRB, STOP INSPECT THE ENGINE IS THERE ANY YES REPAIR VACUUM ALL TESTS. FOR ANY VACUUM VACUUM LEAKS? LEAK(S) AS

LEAK(S). NECESSARY.*

NO

TURN ENGINE OFF.

DISCONNECT THE IDLE ARE ANY TERMINALSAIR CONTROL MOTOR INSPECT ALL CORRODED, DAMAGED, YES REPAIR AS

CONNECTOR.** TERMINALS. PUSHED OUT OR NECESSARY.*MISWIRED?


NO

CONTINUE TEST NTC-9A ON THE

NEXT PAGE.

NO

TROUBLE

CODE

TESTS

691

TEST NTC-9A CONTINUED - CHECKING IDLE AIR CONTROL MOTOR

AB BODY

FIG. 1

AN AND BR BODIES

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

NO

TROUBLE

CODE

TESTS

692



TEST NTC-9A KEY OFF, DISCONNECT IS ANY TERMINAL CONTINUED FROM THE IAC MOTOR CORRODED, DAMAGED, YES REPAIR AS

THE PREVIOUS CONNECTOR.** PUSHED OUT OR NECESSARY.*PAGE. MISWIRED?


NO

IAC DRIVER #1 AND REPAIR THE IAC #1 USING AN OHMMETER, GROUND. IS THE RESISTANCE YES DRIVER CIRCUITMEASURE BETWEEN... BELOW 5.0 OHMS? SHORTED TO


NO



NO



NO



NO


NEXT PAGE.

NO

TROUBLE

CODE

TESTS

693


AB BODY

FIG. 1

AN AND BR BODIES

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

NO

TROUBLE

CODE

TESTS

694



TURN IGNITION ON.TEST NTC-9A WITH THE DRB IN

CONTINUED FROM ACTUATOR TESTS, PREVIOUS PAGE. ACTUATE THE IAC

STEPPER MOTOR.

NOTE: THE VOLTAGEMAY SWITCH OR

REMAIN CONSTANT DURING THIS TEST.


DRIVER #1 CIRCUIT. OVER 5.0 VOLTS AT TC-25B.ANY TIME?

FIG. 1, 2, 3 OR 4

YES


DRIVER #2 CIRCUIT. OVER 5.0 VOLTS AT TC-25C.ANY TIME?

FIG. 1, 2, 3 OR 4

YES


DRIVER #3 CIRCUIT. OVER 5.0 VOLTS AT TC-25D.ANY TIME?

FIG. 1, 2, 3 OR 4

YES


DRIVER #4 CIRCUIT. OVER 5.0 VOLTS AT TC-25E.ANY TIME?

FIG. 1, 2, 3 OR 4

YES

PERFORM TEST NTC-9B.

NO

TROUBLE

CODE

TESTS

695

TEST NTC-9B CHECKING IDLE AIR CONTROL MOTOR


AB BODY

FIG. 1

AN AND BR BODIES

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

NO

TROUBLE

CODE

TESTS

696

TEST NTC-9B CHECKING IDLE AIR CONTROL MOTOR



KEY OFF, DISCONNECT IS ANY TERMINAL START TEST THE POWERTRAIN CORRODED, DAMAGED, YES REPAIR AS

NTC-9B. CONTROL MODULE.** PUSHED OUT OR NECESSARY.*MISWIRED?


NO

THE FOLLOWING USING AN OHMMETER,STEPS ARE CHECKING MEASURE THE

FOR A SHORT RESISTANCE BETWEENBETWEEN THE DRIVER THE ...

CIRCUITS.

IAC #1 DRIVER AND IS THE RESISTANCE #2, #3, #4 DRIVERS. BELOW 5.0 OHMS ON YES REPAIR THE IAC

ANY OF THE DRIVER CIRCUITS,DRIVERS? SHORTED TOGETHER.*

FIG. 1, 2, 3 OR 4

NO

USING AN OHMMETER, IAC #2 DRIVER AND IS THE RESISTANCE MEASURE THE #3, #4 DRIVERS. BELOW 5.0 OHMS ON YES REPAIR THE IAC

RESISTANCE BETWEEN ANY OF THE DRIVER CIRCUITS,THE ... DRIVERS? SHORTED TOGETHER.*

FIG. 1, 2, 3 OR 4

NO

USING AN OHMMETER, IAC #3 DRIVER ANDMEASURE THE #4 DRIVER. IS THE RESISTANCE YES REPAIR THE IAC

RESISTANCE BETWEEN BELOW 5.0 OHMS? DRIVER CIRCUITS,THE ... SHORTED TOGETHER.*

FIG. 1, 2, 3 OR 4

NO

REPLACE THE IACMOTOR.*

NO

TROUBLE

CODE

TESTS

697

TEST NTC-10A CHECKING THE PARK/NEUTRAL POSITION SWITCH


AB BODY

FIG. 1

AN AND XJ BODIES

FIG. 2

BR AND ZJ BODIES

FIG. 3

NO

TROUBLE

CODE

TESTS

698

TEST NTC-10A CHECKING THE PARK/NEUTRAL POSITION SWITCH



WITH THE DRB, READ START TEST THE PARK/NEUTRAL

NTC-10A. SWITCH INPUTSTATE.

WHILE MOVING GEAR DID THE DISPLAY PARK/NEUTRAL SELECTOR FROM PARK SHOW "P/N" AND YES POSITION

TO 1 AND BACK TO "D/R" IN THE SWITCH NORMAL.PARK, WATCH DRB CORRECT POSITIONS?

DISPLAY. TEST PASSED.

NO

DISCONNECT THEPUT THE GEAR TURN IGNITION KEY POWERTRAIN CONTROL

SELECTOR IN PARK. OFF. MODULE.**


MEASURE THE OBSERVE THE OHMMETER DID THE DISPLAYRESISTANCE BETWEEN DISPLAY WHILE MOVING SWITCH FROM BELOW YES REPLACE THE

THE P/N SWITCH SENSE GEAR SELECTOR FROM 10.0 OHMS TO ABOVE POWERTRAIN CONTROLCKT AND GROUND. PARK TO 1 AND BACK 10.0 OHMS? MODULE.*

FIG. 1, 2 OR 3 TO PARK.

NO

REPAIR THE P/NDID THE DISPLAY YES SWITCH SENSE CKTSTAY BELOW 10.0 FOR A SHORT TO

OHMS AT ALL TIMES? GROUND.*

NO


NEXT PAGE.

NO

TROUBLE

CODE

TESTS

699

TEST NTC-10A CONTINUED - CHECKING THE PARK/NEUTRAL POSITION SWITCH


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5

NO

TROUBLE

CODE

TESTS

700

TEST NTC-10A CONTINUED - CHECKING THE PARK/NEUTRAL POSITION SWITCH



TEST NTC-10A DISCONNECT THECONTINUED FROM PARK/NEUTRAL

THE PREVIOUS POSITION SWITCH PAGE. CONNECTOR.**


MEASURE THE FROM THE PCMRESISTANCE OF THE CONNECTOR TO THE IS THE RESISTANCE YES REPLACE THE

PARK/NEUTRAL P/N SWITCH CONN. BELOW 5.0 OHMS? PARK/NEUTRAL SWITCH SENSE POSITION SWITCH.*


NO

REPAIR THE OPEN P/N SWITCH SENSE

CIRCUIT.*

NO

TROUBLE

CODE

TESTS

701

TEST NTC-11A CHECKING THE PCM POWER AND GROUND CIRCUITS


AN BODY

FIG. 1

AB AND BR BODIES

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

NO

TROUBLE

CODE

TESTS

702

TEST NTC-11A CHECKING THE PCM POWER AND GROUND CIRCUITS



KEY OFF. DISCONNECT START TEST THE BLACK POWERTRAIN

NTC-11A. CONTROL MODULE CONNECTOR.**


USING AN OHMMETER,MEASURE CAVITY A31 IS THE RESISTANCE NO

IN THE BLACK PCM BELOW 5.0 OHMS?CONNECTOR.

FIG. 1, 2, 3 OR 4

YES

USING AN OHMMETER,MEASURE CAVITY A32 IS THE RESISTANCE NO REPAIR THE OPEN

IN THE BLACK PCM BELOW 5.0 OHMS? GROUND CIRCUIT.*CONNECTOR.

FIG. 1, 2, 3 OR 4

YES

USING A VOLTMETER, MEASURE CAVITY A22 IS THE VOLTAGE NO REPAIR THE OPEN

IN THE BLACK PCM ABOVE 10.0 VOLTS? FUSED B(+) CONNECTOR. CIRCUIT.*

FIG. 1, 2, 3 OR 4

YES

USING A VOLTMETER, REPAIR THE OPEN TURN THE IGNITION MEASURE CAVITY A2 IS THE VOLTAGE NO FUSED IGNITION

SWITCH ON. IN THE BLACK PCM ABOVE 10.0 VOLTS? SWITCH OUTPUT CONNECTOR. CIRCUIT.*

FIG. 1, 2, 3 OR 4

YES

RECONNECT THE PCM POWER ANDBLACK POWERTRAIN GROUND CIRCUITS

CONTROL MODULE ARE NORMAL.CONNECTOR.

TEST PASSED.

NO

TROUBLE

CODE

TESTS

703

TEST NTC-12A CHECKING THE EVAP SYSTEM


AB BODY AN BODY 1996 2.5/4.0/5.2/5.9/8.0L Jeep and Truck EnginePublication No. 81-699-96103TSB 26-06-97 June,1997

BR BODY XJ BODY

ZJ 4.0L ZJ 5.2L

NO

TROUBLE

CODE

TESTS

704

TEST NTC-12A CHECKING THE EVAP SYSTEM



NOTE: CAREFULLYSTART TEST INSPECT ALL VACUUM

NTC-12A. HOSES FOR PROPER ROUTING AND FOR

PINCHED OR...

PLUGGED HOSES FROM THE ENGINE TO THE ARE ALL THE VACUUM NO REPAIR THE VACUUM

EVAP SOLENOID TO HOSES OK? HOSES AS THE GAS TANK. NECESSARY.*

YES

START THE ENGINE ANDALLOW IT TO REACH TURN ENGINE OFF

NORMAL OPERATING (IGN. OFF).TEMPERATURE(170 DEG F).

DISCONNECT THE START THE ENGINE. IS THE PURGEPURGE VACUUM HOSE THERE SHOULD BE NO SOLENOID ALLOWING YES CONTINUE TEST

AT THE SOLENOID FLOW THE THROUGH VACUUM THROUGH THE NTC-12A ON THETHAT GOES TO THE SOLENOID FROM 1 TO SOLENOID WITHIN 1 NEXT PAGE.

CANISTER. 2 MINUTES. MINUTE?

NO

AFTER 90 SECONDS, IS THE EVAP SOLENOID THE PURGE CYCLE ALLOWING VACUUM TO NO REPLACE THE PURGE

SOLENOID WILL INTERMITTENTLY AT CYCLE THROUGH SOLENOID.* ALLOW VACUUM TO... A STEADY RATE. INTERMITTENTLY AT A

STEADY RATE?

YES

NOTE: IN THE NEXT KEY OFF, ATTEMPTSTEPS, DO NOT USE TO BLOW AIR DOES THE CANISTER YES PURGE SOLENOID

MORE THAN FIVE THROUGH THE VACUUM AND VACUUM LINE AND HOSES AREPSI. LINE THAT GOES TO ALLOW AIR TO PASS? OK. TEST

THE CANISTER. PASSED.

NO

PERFORM TEST NTC-12B.


NO

TROUBLE

CODE

TESTS

705

TEST NTC-12A CONTINUED - CHECKING THE EVAP SYSTEM


TEST NTC-12A REMOVE THE PURGECONTINUED FROM SOLENOID AND TAP DID ANY FOREIGN NO REPLACE THE EVAP

THE PREVIOUS THE PORTS AGAINST MATERIAL FALL OUT? PURGE SOLENOID.* PAGE. A CLEAN, SOLID

SURFACE.

YES

CLEAN OUT THE LINE INSPECT LINE FROM IS THE LINE NO AND REPLACE THETHE PURGE SOLENOID DISCONNECTED, EVAP PURGE

TO THE CANISTER. RIPPED OR CUT? SOLENOID ANDCANISTER.*

YES

REPAIR THE LINE AND REPLACE THEPURGE SOLENOID.*


NO

TROUBLE

CODE

TESTS

706

TEST NTC-12B CONTINUED - CHECKING THE EVAP SYSTEM


DISCONNECT THESTART TEST VACUUM LINE AT THE

NTC-12B. CANISTER THAT GOES TO THE EVAP

SOLENOID.

ATTEMPT TO BLOW AIR THROUGH THE DOES THE VACUUM YES REPLACE THEVACUUM LINE THAT LINE ALLOW AIR TO EVAPORATIVE

GOES TO THE PASS? CANISTER.* CANISTER.

NO

REPAIR OR REPLACETHE VACUUM LINE.*


NO

TROUBLE

CODE

TESTS

707

TEST NTC-13A CHECKING EGR SYSTEM

Perform TEST NTC-1B Before Proceeding

TYPICAL CONFIGURATION

FIG. 1

NO

TROUBLE

CODE

TESTS

708

TEST NTC-13A CHECKING EGR SYSTEM



INSPECT THESTART TEST CONDITION OF ALL EGR ARE THERE ANY YES REPAIR HOSES AS

NTC-13A. HOSES AND ROUTING. MISROUTED OR NECESSARY.*DAMAGED HOSES?

FIG. 1

NO

IS THIS VEHICLE NO PERFORM TEST EQUIPPED WITH A NTC-13B.

DIESEL ENGINE?

YES

WITH THE DRB IN START ENGINE AND EGR SYSTEM TEST

LET IDLE. PRESS #2 TO BLOCKEGR FLOW.

MONITOR IAT ACTUATE THE EGR DID THE INTAKE AIRTEMPERATURE UNTIL SOLENOID AND ALLOW TEMPERATURE RISE NO CONTINUE TEST

TEMPERATURE EGR TO FLOW. AFTER THE EGR WAS NTC-13A ON THESTABILIZES. MONITOR INTAKE AIR ACTUATED? NEXT PAGE.

TEMPERATURE.

YES



CONNECTORS.

NO

TEST COMPLETE.*

NO

TROUBLE

CODE

TESTS

709

TEST NTC-13A CONTINUED - CHECKING EGR SYSTEM


FIG. 1

NO

TROUBLE

CODE

TESTS

710

TEST NTC-13A CONTINUED - CHECKING EGR SYSTEM


TEST NTC-13A DISCONNECT THE EGRCONTINUED FROM SOLENOID VACUUM IS VACUUM PRESENT NO REPAIR THE VACUUM

THE PREVIOUS SUPPLY AT THE EGR AT THE SOLENOID? SUPPLY TO THE EGRPAGE. SOLENOID. SOLENOID.*

FIG. 1

YES

RECONNECT THE EGR DISCONNECT THE EGRSOLENOID VACUUM VACUUM LINE AT THE

SUPPLY AT THE EGR EGR SOLENOID THAT SOLENOID. GOES TO THE EGR.

FIG. 1

IS THE EGREGR STATUS SHOULD SOLENOID ALLOWING NO REPLACE THE EGR

STILL DISPLAY VACUUM TO PASS SOLENOID.* FLOW. THROUGH?

YES

RECONNECT THE EGR DISCONNECT THEVACUUM LINE AT THE VACUUM LINE AT THE IS VACUUM PRESENT NO REPAIR VACUUM HOSE EGR SOLENOID THAT EGR. AT THE EGR? OR CHECK VALVE AS

GOES TO THE EGR. NECESSARY.*FIG. 1

YES

STOP EGR SYSTEMSTESTS AND TURN

ENGINE OFF.

REMOVE EGR VALVE SLOWLY APPLY 10 DID POPPET VALVEAND CONNECT A HAND INCHES OF VACUUM START TO OPEN AT NO REPLACE THE EGR

OPERATED VACUUM TO EGR VALVE AND 10 INCHES OF VALVE.*PUMP TO FITTING. MONITOR POPPET VACUUM?

FIG. 1 VALVE.

YES

ENSURE THERE IS NO CARBON BUILD UP IN

EGR TUBE, INTAKE ANDEXHAUST MANIFOLDS

AND RETEST EGR.

NO

TROUBLE

CODE

TESTS

711

TEST NTC-13B CONTINUED - CHECKING EGR SYSTEM



FIG. 1

NO

TROUBLE

CODE

TESTS

712

TEST NTC-13B CONTINUED - CHECKING EGR SYSTEM



DISCONNECT THESTART TEST VACUUM LINE TO THE

NTC-13B. EGR VALVE.

FIG. 1

CONNECT A HAND HELD VACUUM SUPPLY TO THE EGR VALVE.

WHILE SLOWLY INSPECT PASSAGES,START ENGINE AND APPLYING VACUUM TO DID THE ENGINE YES IF OK, REPLACE THE

LET IDLE. THE EGR VALVE, SPEED STAY THE EGR VALVELISTEN FOR AN ENGINE SAME? ASSEMBLY.*

SPEED CHANGE.

NO

APPLY 10" OF DID THE VACUUM NO REPLACE THE EGRIGNITION KEY OFF. VACUUM AND HOLD HOLD FOR 30 VALVE ASSEMBLY.*

FOR 30 SECONDS. SECONDS?

YES

EGR SYSTEM NORMAL.

TEST PASSED.

NO

TROUBLE

CODE

TESTS

713

TEST NTC-14A CHECKING THE ENGINE VACUUM


FIG. 1

FIG. 2

NO

TROUBLE

CODE

TESTS

714

TEST NTC-14A CHECKING THE ENGINE VACUUM



START TEST CONNECT A VACUUM NTC-14A. GAUGE TO THE

ENGINE.

NOTE: A NORMAL ALLOW THE ENGINE VACUUM READING WILL

TO IDLE. VARY ACCORDING TO THE ALTITUDE.

FIG. 1

WHILE MONITORING OBSERVE THE VACUUM THE VACUUM GAUGE, GAUGE READINGS. ARE THE VACUUM NO PERFORM TEST SNAP THE THROTTLE GAUGE READINGS NTC-22A. OPEN A FEW TIMES. NORMAL?

FIG. 2

YES

ENGINE VACUUM NORMAL.

TEST PASSED.

NO

TROUBLE

CODE

TESTS

715

TEST NTC-15A CHECKING THE INTAKE AIR TEMP SENSOR

Perform TEST TC-118A, NTC-1A OR NTC-14A Before Proceeding

AB AND AN 3.9L, BR 5.2L AND 5.9L

FIG. 1

AN 2.5L, XJ, AND 4.0L ZJ

FIG. 2

AN 5.2L

FIG. 3

BR 8.0L

FIG. 4

ZJ 5.2L

FIG. 5

NO

TROUBLE

CODE

TESTS

716

TEST NTC-15A CHECKING THE INTAKE AIR TEMP SENSOR

Perform TEST TC-118A, NTC-1A OR NTC-14A Before Proceeding


NOTE: MAKE SURE CAUTION: DO NOT WITH THE DRB, READ START TEST THE IGNITION KEY ALLOW MORE THAN 5 THE INTAKE AIR

NTC-15A IS ON AT THIS TIME MINUTES DELAY TEMPERATURE (IAT)(ENGINE OFF). BETWEEN NEXT SENSOR AND RECORD

STEPS. THE READING.

KEY OFF. REMOVE THE USING A TEMP PROBE, IS THE IATMAP SENSOR. MEASURE THE IAT RECORDING WITHIN NO REPLACE THE IAT

INSIDE MAP SENSOR 10 DEGREES OF THE SENSOR.* OPENING. PROBE READING?

FIG. 1, 2, 3, 4 OR 5 FIG. 1, 2, 3, 4 OR 5

YES

RECONNECT THE MAPSENSOR. IAT SENSOR

TEST PASSED.

NO

TROUBLE

CODE

TESTS

717

TEST NTC-16A CHECKING MINIMUM AIR FLOW


FIG. 1

NO

TROUBLE

CODE

TESTS

718

TEST NTC-16A CHECKING MINIMUM AIR FLOW



2.5L AND 4.0L START TEST IS THIS VEHICLE A YES ENGINES DO NOT

NTC-16A. 2.5L OR 4.0L HAVE A MINIMUMENGINE? IDLE AIR FLOW

TEST.

NO

REMOVE THE AIR REMOVE THE VACUUM CLEANER. LINE FROM THE PCV

VALVE...

AND INSTALL THE DISCONNECT THE0.185 ORIFICE INTO 3/16" EVAPORATIVE

THE VACUUM LINE. EMISSION HOSE ON THE SIDE OF THE

FIG. 1 THROTTLE BODY...

ALLOWAND CAP THE ENGINE TO REACH

THROTTLE BODY NORMAL OPERATINGNIPPLE. TEMPERATURE.

(ABOVE 180 )

MINIMUM IDLE WITH THE DRB, WAIT FOR THE IS THE ENGINE RPM YES AIR FLOW

ACTUATE MINIMUM SYSTEM TO BETWEEN 500 AND NORMAL.IDLE AIR FLOW. STABILIZE. 900 RPM?

TEST PASSED.

NO

STOP ACTUATION TEST. START THE ENGINE.TURN ENGINE OFF. WITH THE DRB, IS THE ENGINE RPM YES

USING AN APPROVED ACTUATE THE BETWEEN 500 AND REPAIR COMPLETE.* CLEANER, CLEAN THE MINIMUM AIR FLOW. 900?

THROTTLE BODY.

NO

NOTE: A VACUUM LEAK MAY CAUSE THE REPLACE THE

IAC MOTOR NOT TO THROTTLE BODY.* PERFORM CORRECTLY.

START ENGINE.

F

NO

TROUBLE

CODE

TESTS

719

TEST NTC-17A CHECKING THE AIR INTAKE HEATER #1


FIG. 1

NO

TROUBLE

CODE

TESTS

720




CAUTION: AIR INTAKE USING A VOLTMETER, START TEST HEATER ACTUATION MEASURE THE WITH THE DRB,

NTC-17A. TIME MUST BE KEPT AT BATTERY B(+) ACTUATE #1 AIRA MINIMUM DUE TO TERMINAL AND INTAKE HEATER.

HIGH CURRENT DRAW. RECORD THE RESULT.

WHILE ACTUATING, DID THE BATTERY AIR INTAKE USE A VOLTMETER STOP ACTUATION VOLTAGE DROP 0.5 YES HEATER #1 AND MEASURE THE TEST. VOLT OR MORE OPERATION IS

BATTERY B(+) DURING ACTUATION NORMAL.TERMINAL. TEST? TEST PASSED.

NO

DID THE AIR INTAKE YES PERFORM TEST HEATER RELAY CLICK NTC-17B.

WHEN ACTUATED?

NO

DISCONNECT THE FUSED USING A VOLTMETER, REPAIR THE OPEN IGNITION SWITCH MEASURE THE FUSED IS THE VOLTAGE NO FUSED IGNITION

OUTPUT CIRCUIT AT IGN SWITCH OUTPUT ABOVE 10.0 VOLTS? SWITCH OUTPUT HEATER RLY #1 CAV.2 CIRCUIT. CIRCUIT TO RELAY.*

FIG. 1 FIG. 1

YES

RECONNECT THE DISCONNECT THE AIRFUSED IGNITION INTAKE HEATER SWITCH OUTPUT RELAY #1 CONTROL

CIRCUIT. CIRCUIT, CAVITY 1FIG. 1

CONNECT ONE END OF A JUMPER WIRE TO THE OTHER END OF DID THE AIR INTAKE NO REPLACE THE AIR

THE OPEN RELAY THE JUMPER WIRE TO HEATER RELAY INTAKE HEATER TERMINAL AND GROUND. CLICK? RELAY #1.*

BRIEFLY TAP...

YES


NEXT PAGE.

NO

TROUBLE

CODE

TESTS

721

TEST NTC-17A CONTINUED - CHECKING THE AIR INTAKE HEATER #1

FIG. 1

NO

TROUBLE

CODE

TESTS

722



TEST NTC-17A KEY OFF. DISCONNECT CONTINUED FROM THE POWERTRAIN

THE PREVIOUS CONTROL MODULE BLACKPAGE. CONNECTOR.**


USING AN OHMMETER, CONTROL CIRCUIT REPAIR THE OPEN MEASURE THE FROM THE PCM TO IS THE RESISTANCE NO AIR INTAKE HEATER

RESISTANCE OF THE THE RELAY. BELOW 5.0 OHMS? RELAY #1 CONTROLAIR INTAKE HEATER CIRCUIT.*

RELAY #1... FIG. 1

YES

USING AN OHMMETER, REPAIR THE AIRMEASURE AIR INTAKE IS THE RESISTANCE YES INTAKE HEATER

HEATER RLY #1 BELOW 5.0 OHMS? RELAY #1 CONTROLCONTROL CKT AT PCM CIRCUIT FOR A

TO GROUND. FIG. 1 SHORT TO GROUND.*

NO


MODULE.*

NO

TROUBLE

CODE

TESTS

723

TEST NTC-17B CHECKING THE AIR INTAKE HEATER #1


FIG. 1

FIG. 2

NO

TROUBLE

CODE

TESTS

724




USING A VOLTMETER, REPAIR THE OPEN START TEST MEASURE THE B(+) IS THE VOLTAGE NO B(+) CIRCUIT

NTC-17B. CIRCUIT FOR AIR ABOVE 10.0 VOLTS? BETWEEN THEINTAKE HEATER #1. BATTERY AND INTAKE

FIG. 1 HEATER RELAY #1.*

YES

WITH THE DRB, USING A VOLTMETER, REPAIR THE OPEN ACTUATE THE AIR MEASURE THE AIR IS THE VOLTAGE NO AIR INTAKE HEATER

INTAKE HEATER INTAKE HEATER RELAY ABOVE 9.0 VOLTS? RELAY #1 OUTPUT RELAY #1. #1 OUTPUT CIRCUIT. CIRCUIT.*

FIG. 2

YES

REPLACE THE AIRINTAKE HEATER

ELEMENT.*

NO

TROUBLE

CODE

TESTS

725



FIG. 1

NO

TROUBLE

CODE

TESTS

726




CAUTION: AIR INTAKE USING A VOLTMETER, START TEST HEATER ACTUATION MEASURE THE WITH THE DRB,

NTC-18A. TIME MUST BE KEPT AT BATTERY B(+) ACTUATE #2 AIRA MINIMUM DUE TO TERMINAL AND INTAKE HEATER.

HIGH CURRENT DRAW. RECORD THE RESULT.

WHILE ACTUATING, DID THE BATTERY AIR INTAKE MEASURE THE STOP ACTUATION VOLTAGE DROP 0.5 YES HEATER #2 BATTERY B(+) TEST. VOLT OR MORE OPERATION IS

TERMINAL. DURING ACTUATION NORMAL.TEST? TEST PASSED.

NO

DID THE AIR INTAKE YES PERFORM TEST HEATER RELAY CLICK NTC-18B.

WHEN ACTUATED?

NO

DISCONNECT THE FUSED USING A VOLTMETER, REPAIR THE OPEN IGNITION SWITCH MEASURE THE FUSED IS THE VOLTAGE NO FUSED IGNITION

OUTPUT CIRCUIT AT IGN SWITCH OUTPUT ABOVE 10.0 VOLTS? SWITCH OUTPUT HEATER RLY #2 CAV.4 CIRCUIT. CIRCUIT TO RELAY.*

FIG.1 FIG. 1

YES

RECONNECT THE DISCONNECT THE AIRFUSED IGNITION INTAKE HEATER SWITCH OUTPUT RELAY #2 CONTROL

CIRCUIT. CIRCUIT, CAVITY 3. FIG. 1

CONNECT ONE END OF A JUMPER WIRE TO THE OTHER END OF DID THE AIR INTAKE NO REPLACE THE AIR

THE OPEN RELAY THE JUMPER WIRE TO HEATER RELAY INTAKE HEATER TERMINAL AND GROUND. CLICK? RELAY #2.*

BRIEFLY TAP...

YES


NEXT PAGE.

NO

TROUBLE

CODE

TESTS

727


FIG. 1

NO

TROUBLE

CODE

TESTS

728



TEST NTC-18A KEY OFF. DISCONNECT CONTINUED FROM THE POWERTRAIN

THE PREVIOUS CONTROL MODULE BLACKPAGE. CONNECTOR.**


USING AN OHMMETER, CONTROL CIRCUIT REPAIR THE OPEN MEASURE THE FROM THE PCM TO IS THE RESISTANCE NO AIR INTAKE HEATER

RESISTANCE OF THE THE RELAY. BELOW 5.0 OHMS? RELAY #2 CONTROLAIR INTAKE HEATER CIRCUIT.*

RELAY #2... FIG. 1

YES

USING AN OHMMETER, REPAIR THE AIRMEASURE AIR INTAKE IS THE RESISTANCE YES INTAKE HEATER

HEATER RLY #2 BELOW 5.0 OHMS? RELAY #2 CONTROLCONTROL CKT AT PCM CIRCUIT FOR A

TO GROUND. FIG. 1 SHORT TO GROUND.*

NO


MODULE.*

NO

TROUBLE

CODE

TESTS

729



FIG. 1

FIG. 2

NO

TROUBLE

CODE

TESTS

730




USING A VOLTMETER, REPAIR THE OPEN START TEST MEASURE THE B(+) IS THE VOLTAGE NO B(+) CIRCUIT

NTC-18B. CIRCUIT FOR AIR ABOVE 10.0 VOLTS? BETWEEN THEINTAKE HEATER #2. BATTERY AND INTAKE

FIG. 1 HEATER RELAY #2.*

YES

WITH THE DRB, USING A VOLTMETER, REPAIR THE OPEN ACTUATE THE AIR MEASURE THE AIR WAS THE VOLTAGE NO AIR INTAKE HEATER

INTAKE HEATER INTAKE HEATER RELAY ABOVE 9.0 VOLTS? RELAY #2 OUTPUT RELAY #2. #2 OUTPUT CIRCUIT. CIRCUIT.*

FIG. 2

YES

REPLACE THE AIRINTAKE HEATER

ELEMENT.*

NO

TROUBLE

CODE

TESTS

731

TEST NTC-19A CHECKING THE FUEL HEATER


FIG. 1

FIG. 2

NO

TROUBLE

CODE

TESTS

732

TEST NTC-19A CHECKING THE FUEL HEATER



START TEST NTC-19A. TURN IGNITION ON.

NOTE: TO HEAR CLICK WHILE LISTENING FORIN THE NEXT STEP. IT THE RELAY TO CLICK, DID THE RELAY YES CONTINUE TEST MAY BE NECESSARY TO DISCONNECT THE FUEL CLICK? NTC-19A ON THEDISCONNECT THE RELAY HEATER RLY.** NEXT PAGE.

MORE THAN ONCE. FIG. 1

NO

WITH A VOLTMETER, MEASURE THE FUSED IS THE VOLTAGE NO REPAIR THE OPEN IGN SWITCH OUTPUT ABOVE 10.0 VOLTS? FUSED IGNITION

CIRCUIT. SWITCH OUTPUT.* FIG. 2

YES

WITH AN OHMMETER,MEASURE THE FUEL IS THE RESISTANCE YES REPAIR THE OPEN

TURN IGNITION OFF. HEATER RELAY ABOVE 5.0 OHMS? FUEL HEATER RELAYGROUND CIRCUIT. GROUND CIRCUIT.*

FIG. 2

NO

REPLACE THE FUEL HEATER RELAY.*

NO

TROUBLE

CODE

TESTS

733

TEST NTC-19A CONTINUED - CHECKING THE FUEL HEATER RELAY

FIG. 1

FIG. 2 FIG. 3

FIG. 4 FIG. 5

NO

TROUBLE

CODE

TESTS

734

TEST NTC-19A CONTINUED - CHECKING THE FUEL HEATER RELAY


TEST NTC-19A WITH A VOLTMETER, CONTINUED FROM MEASURE THE FUSED IS THE VOLTAGE NO REPAIR THE OPEN

THE PREVIOUS B(+) IN HEATER ABOVE 10.0 VOLTS? FUSED B(+) PAGE. RELAY CONNECTOR. CIRCUIT.*

FIG. 1

YES

IGNITION OFF. WITH AN OHMMETER,DISCONNECT THE FUEL MEASURE THE FUEL IS THE RESISTANCE NO REPAIR THE OPEN

HEATER ELECTRICAL HEATER GROUND BELOW 5.0 OHMS? FUEL HEATER GROUND CONNECTOR.** CIRCUIT. CIRCUIT.*

FIG. 2 FIG. 3

YES

USING AN OHMMETER, FROM THE RELAY TO MEASURE THE THE HEATER IS THE RESISTANCE YES REPAIR THE OPEN

RESISTANCE OF THE CONNECTOR. ABOVE 5.0 OHMS? FUEL HEATER RELAYFUEL HEATER RELAY OUTPUT CIRCUIT.*OUTPUT CIRCUIT... FIG. 4

NO

DISCONNECT FUEL REPAIR THEHEATER ELEMENT IS ANY TERMINAL YES TERMINAL(S) FOR

CONNECTOR.** DAMAGED, PUSHED DAMAGE, PUSHOUT, INSPECT ALL OUT, OR MISWIRED? OR MISWIRING.*

TERMINALS. FIG. 2

NO

NOTE: THE FUEL USING AN OHMMETER, THE NO STARTHEATER TEMPERATURE MEASURE THE IS THE RESISTANCE NO CONDITION IS DUE TO MUST BE BELOW 40F RESISTANCE OF THE ABOVE 10.0 OHMS? A MECHANICAL FOR THE NEXT STEP. FUEL HEATER. PROBLEM. SEE SERVICE

FIG. 2 AND 5 MANUAL FOR REPAIRS.

YES

REPLACE THE FUEL HEATER.*

NO

TROUBLE

CODE

TESTS

735

TEST NTC-20A CHECKING THE WAIT-TO-START LAMP


NO

TROUBLE

CODE

TESTS

736

TEST NTC-20A CHECKING THE WAIT-TO-START LAMP



IS THE VEHICLESTART TEST SYMPTOM PROBLEM NO

NTC-20A. WITH WAIT-TO-START TEST PASSED.LAMP?

YES

WHILE WATCHING THEWAIT-TO-START LAMP DID THE NO CONTINUE TEST

TURN IGNITION WAIT-TO-START LAMP NTC-20A ON THEKEY ON. LIGHT? NEXT PAGE.

YES

DID THE WAIT-TO-STARTWAIT-TO-START LAMP NO LAMP OPERATING

STAY ON ALL THE NORMALLY.TIME?

TEST PASSED.

YES

KEY OFF, DISCONNECT WHILE WATCHING THE REPAIR DIESEL POWERTRAIN CONTROL WAIT-TO-START DID WAIT-TO-START YES WAIT-TO-START LAMP

MODULE CONNECTOR.** LAMP, TURN LAMP LIGHT? DRIVER CIRCUIT FORIGNITION KEY ON. A SHORT TO

SEE GENERAL INFO 4.1 GROUND.*

NO


MODULE.*

NO

TROUBLE

CODE

TESTS

737

TEST NTC-20A CONTINUED - CHECKING THE WAIT-TO-START LAMP

FIG. 1

FIG. 2

NO

TROUBLE

CODE

TESTS

738

TEST NTC-20A CONTINUED - CHECKING THE WAIT-TO-START LAMP


TEST NTC-20A DISCONNECT THECONTINUED FROM POWERTRAIN CONTROL

THE PREVIOUS TURN IGNITION OFF. MODULE CONNECTOR.** TURN IGNITION ON.PAGE.


MEASURE THEUSE A VOLTMETER IN WAIT-TO-START LAMP IS THE VOLTAGE YES REPLACE THE

THE FOLLOWING DRIVER AT THE PCM. ABOVE 10.0 VOLTS? POWERTRAIN CONTROLSTEP. MODULE.*

FIG. 1

NO

DISCONNECT THEWAIT-TO-START LAMP VERIFY THE LAMP NO REPLACE THE

CONNECTOR.** CONDITION. IS THE LAMP OK? WAIT-TO-STARTLAMP.*


YES

BACKPROBE THE FUSED REPAIR THE OPEN REINSTALL THE IGNITION SWITCH IS THE VOLTAGE NO FUSED IGNITION WAIT-TO-START OUTPUT CKT AT THE ABOVE 10.0 VOLTS? SWITCH OUTPUT LAMP. KEY ON. MESSAGE CENTER CONN. CIRCUIT.*

FIG. 2 TO MESSAGE CENTER.

YES

CONNECT A JUMPER REPAIR THE OPEN BETWEEN MESSAGE DID THE YES WAIT-TO-START LAMP CENTER CONNECTOR WAIT-TO-START LAMP DRIVER CIRCUIT.*

AND A GOOD GROUND. ILLUMINATE? PCM TO MESSAGEFIG. 2 CENTER.

NO

REPLACE THEMESSAGE CENTER

PRINTED CIRCUITASSEMBLY.*

NO

TROUBLE

CODE

TESTS

739

TEST NTC-21A CHECKING THE WATER-IN-FUEL LAMP & SENSOR


FIG. 1

NO

TROUBLE

CODE

TESTS

740

TEST NTC-21A CHECKING THE WATER-IN-FUEL LAMP & SENSOR



IS THE VEHICLESTART TEST SYMPTOM PROBLEM NO

NTC-21A. WITH WATER-IN-FUEL TEST PASSED.LAMP?

YES

DISCONNECT THE GROUND THEWATER-IN-FUEL SENSOR WATER-IN-FUEL SENSOR

CONNECTOR.** SIGNAL CIRCUIT.


IGNITION KEY OFF, THEN IGNITION KEY IS THE YES PERFORM TEST

ON TO RECYCLE WATER-IN-FUEL LAMP NTC-21B. LAMP. ILLUMINATED?

NO

DISCONNECT THEPOWERTRAIN CONTROL CONTINUE TEST

IGNITION KEY OFF. MODULE CONNECTOR.** NTC-21A ON THENEXT PAGE.


,

NO

TROUBLE

CODE

TESTS

741

TEST NTC-21A CONTINUED - CHECKING THE WATER-IN-FUEL LAMP & SENSOR

FIG. 1

FIG. 2

NO

TROUBLE

CODE

TESTS

742



TEST NTC-21ACONTINUED FROM USE AN OHMMETER IN

THE PREVIOUS THE FOLLOWINGPAGE. STEP.

MEASURE ACROSS THEWATER-IN-FUEL SENSE IS THE RESISTANCE NO REPAIR THE OPEN CKT FROM THE PCM TO BELOW 5.0 OHMS? WATER-IN-FUEL

THE WIF CONNECTOR. SENSE CIRCUIT.*FIG. 1

YES

USE A VOLTMETER IN TURN IGNITION ON. THE FOLLOWING

STEP.

MEASURE THEWATER-IN-FUEL LAMP IS THE VOLTAGE YES REPLACE THEDRIVER CIRCUIT, AT ABOVE 10.0 VOLTS? POWERTRAIN CONTROL

THE PCM. MODULE.* FIG. 2

NO


NEXT PAGE.

NO

TROUBLE

CODE

TESTS

743


FIG. 1

NO

TROUBLE

CODE

TESTS

744



TEST NTC-21A DISCONNECT THECONTINUED FROM WATER-IN-FUEL

THE PREVIOUS LAMP.**PAGE.


VERIFY LAMP NO REPLACE THECONDITION. IS THE LAMP OK? WATER-IN-FUEL

LAMP.*

YES

BACKPROBE THE REPAIR THE OPEN RE-INSTALL THE FUSED IGN. SWITCH IS THE VOLTAGE NO FUSED IGNITION

LAMP. OUTPUT CKT. AT ABOVE 10.0 VOLTS? SWITCH OUTPUT MESSAGE CTR CONN. CIRCUIT.*

FIG. 1

YES

CONNECT A JUMPER WIRE FROM THE LAMP DID THE NO REPAIR THE OPEN DRIVER TO GROUND. WATER-IN-FUEL LAMP WATER-IN-FUEL

ILLUMINATE? DRIVER CIRCUIT.*FIG. 1

YES

REPLACE THEMESSAGE CENTER

PRINTED CIRCUITASSEMBLY.*

NO

TROUBLE

CODE

TESTS

745

TEST NTC-21B CHECKING THE WATER-IN-FUEL LAMP & SENSOR


FIG. 1

NO

TROUBLE

CODE

TESTS

746

TEST NTC-21B CHECKING THE WATER-IN-FUEL LAMP & SENSOR



START TEST TURN IGNITION OFF. NTC-21B. DISCONNECT THE

JUMPER WIRE.

MEASURE THE SENSOR USE AN OHMMETER IN GROUND CIRCUIT AT IS THE RESISTANCE YES REPAIR THE OPEN

THE FOLLOWING WATER-IN-FUEL ABOVE 5.0 OHMS? SENSOR GROUND STEP. CONNECTOR. CIRCUIT.*

FIG. 1

NO

REPLACE THEWATER-IN-FUEL

SENSOR.*

NO

TROUBLE

CODE

TESTS

747

TEST NTC-22A CHECKING THE ENGINE MECHANICAL SYSTEMS

Perform TEST NTC-1A or NTC-21A Before Proceeding

The components and systems that you have checked before this are operating properly. Here areadditional non-monitored components or systems to check, that could cause a driveability problem.

1. DISTRIBUTOR POSITION − must be within specifications2. ENGINE VACUUM − must be at least 13 inches in neutral (see below) †3. ENGINE VALVE TIMING − must be within specifications4. ENGINE COMPRESSION − must be within specifications5. ENGINE EXHAUST SYSTEM − must be free of any restrictions6. ENGINE PCV SYSTEM − must flow freely7. ENGINE DRIVE SPROCKET − must be properly positioned8. TORQUE CONVERTER STALL SPEED − must be within specifications (auto only)9. POWER BRAKE BOOSTER − no internal vacuum leaks10. FUEL − must be free of contamination11. 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 causedby one of the first items above, replace the powertrain control module and perform TESTVER-2A (Road Test Verification).

Checking Distributor Position With DRBConnect the DRB to the data link connector and select SET SYNC from the menu. WARNING: Thefollowing 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 INRANGE message should appear along with 0°. If the distributor needs to be adjusted, loosen thedistributor hold-down clamp bolt. Rotate the distributor until reading is as close as to 0° as possibleand the IN RANGE message displayed. Tighten the clamp bolt to 22.5 Nzm (200 in. lbs.) torque.

NOTE: Setting the distributor position does not adjust the ignition timing. Ignition timing values aredetermined by the powertrain control module.

† The readings below are only indicators of possible mechanical engine problems.

NO

TROUBLE

CODE

TESTS

748

TEST NTC-22B CHECKING THE ENGINE MECHANICAL SYSTEMS (Diesel)


The components and systems that you have checked before this are operating properly. Here areadditional 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

NO

TROUBLE

CODE

TESTS

749

TEST SC-1A CHECKING THE SPEED CONTROL OPERATION



BR BODY

ZJ BODY

SPEED

CONTROL

TESTS

750




START TEST SC-1A. START ENGINE.

KEY ON, WITH THE WHILE OBSERVINGDRB, MONITOR THE DISPLAY, PRESS THE DOES THE DRB SHOW NO PERFORM TEST

SPEED CONTROL SPEED CONTROL "ON" SPEED CONTROL SC-2A. SWITCH INPUTS. SWITCH. SWITCH "ON"?

YES

WHILE OBSERVING DOES THE DRB SHOW THE DISPLAY, PRESS BRAKE SWITCH NO PERFORM TEST

THE BRAKE PEDAL "PRESSED" AND SC-3A. SEVERAL TIMES. "RELEASED"?

YES

WHILE OBSERVING DOES THE DRB SHOW THE DISPLAY, MOVE THE PARK/NEUTRAL NO PERFORM TEST THE GEAR SELECTOR SWITCH IN SC-4A.

TO DRIVE. "DRIVE/REVERSE"?

YES

CONTINUE TEST SC-1A ON THE

NEXT PAGE.

SPEED

CONTROL

TESTS

751

TEST SC-1A CONTINUED - CHECKING THE SPEED CONTROL OPERATION

NOTES

SPEED

CONTROL

TESTS

752



TEST SC-1A WHILE OBSERVING DOES THE DRB SHOW CONTINUED FROM THE DISPLAY, PRESS THE SET SWITCH NO REPLACE THE SPEED

THE PREVIOUS THE SET SWITCH "PRESSED" AND CONTROL SWITCH.* PAGE. SEVERAL TIMES. "RELEASED"?

YES

WHILE OBSERVING DOES THE DRB SHOW THE DISPLAY, PRESS THE RESUME SWITCH NO REPLACE THE SPEEDTHE RESUME SWITCH "PRESSED" AND CONTROL SWITCH.*

SEVERAL TIMES. "RELEASED"?

YES

WHILE OBSERVING DOES THE DRB SHOW THE DISPLAY, PRESS THE CANCEL SWITCH NO REPLACE THE SPEEDTHE CANCEL SWITCH "PRESSED" AND CONTROL SWITCH.*

SEVERAL TIMES. "RELEASED"?(ZJ BODY ONLY)

YES


NEXT PAGE.

SPEED

CONTROL

TESTS

753


FIG. 1

SPEED

CONTROL

TESTS

754



TEST SC-1A KEY OFF, DISCONNECT CONTINUED FROM THE SPEED CONTROL IS ANY TERMINAL YES REPAIR AS

THE PREVIOUS SERVO CONNECTOR.** DAMAGED, PUSHED NECESSARY.*PAGE. OUT OR MISWIRED?


NO

WITH AN OHMMETER,MEASURE THE GROUND IS THE RESISTANCE NO REPAIR THE OPEN

CIRCUIT FOR BELOW 5.0 OHMS? GROUND CIRCUIT.*RESISTANCE.

FIG. 1

YES

KEY ON. WITH THE WITH A VOLTMETER, DRB, ACTUATE THE MEASURE THE IS THE VOLTAGE NO PERFORM TEST

SPEED CONTROL VENT SWITCHED SC POWER ABOVE 10.0 VOLTS? SC-1BSOLENOID. SUPPLY CIRCUIT.

FIG. 1

YES

RECONNECT THE SPEED TURN ENGINE OFF, CONTROL SERVO (IGNITION ON) WITH DOES THE THROTTLE YES PERFORM TEST

CONNECTOR. START THE DRB, ACTUATE OPEN AND CLOSE? SC-5A. ENGINE, ALLOW TO THE SPEED CONTROL

IDLE 1 MINUTE. SERVO SOLENOIDS.

NO

KEY OFF, ATTACH A VACUUM DISCONNECT THE GAUGE TO THE DOES THE VACUUM NO REPAIR THE VACUUM

VACUUM SUPPLY TO DISCONNECTED HOSE. GAUGE READ SUPPLY FOR A LEAK THE SPEED CONTROL START ENGINE. MANIFOLD VACUUM? OR RESTRICTION.*

SERVO.

YES

TURN ENGINE OFF, OBSERVE VACUUM DOES THE VACUUM NO REPLACE THE VACUUM

GAUGE FOR 10 HOLD FOR AT LEAST RESERVOIR.*SECONDS. 10 SECONDS?

YES


NEXT PAGE.

SPEED

CONTROL

TESTS

755


AB, AN AND XJ BODIES BR BODY

ZJ BODY AB, AN AND XJ BODIES

FIG. 1

BR BODY

FIG. 2

ZJ BODY

FIG. 3

SPEED

CONTROL

TESTS

756



TEST SC-1ACONTINUED FROM INSPECT THE IS THE CABLE YES REPAIR AS

THE PREVIOUS THROTTLE CABLE. DISCONNECTED OR NECESSARY.*PAGE. DAMAGED?

NO

KEY OFF. DISCONNECT DISCONNECT THETHE SPEED CONTROL POWERTRAIN CONTROL

SERVO 4 WAY MODULE.**CONNECTOR.**


WITH AN OHMMETER, SPEED CONTROL REPAIR THE OPEN MEASURE THE VACUUM SOLENOID IS THE RESISTANCE NO SPEED CONTROL

RESISTANCE OF CONTROL CIRCUIT TO BELOW 5.0 OHMS? VACUUM SOLENOID THE... THE PCM CONNECTOR. CONTROL CIRCUIT.*

FIG. 1, 2 OR 3

YES

WITH AN OHMMETER, SPEED CONTROL VENT REPAIR THE OPEN MEASURE THE SOLENOID CONTROL IS THE RESISTANCE NO SPEED CONTROL VENT

RESISTANCE OF CIRCUIT TO THE PCM BELOW 5.0 OHMS? SOLENOID CONTROLTHE... CONNECTOR. CIRCUIT.*

FIG. 1, 2 OR 3

YES

REPLACE THE SPEEDCONTROL SERVO.*

SPEED

CONTROL

TESTS

757

TEST SC-1B CHECKING THE SPEED CONTROL OPERATION

Perform TEST SC-1A Before Proceeding

FIG. 1

AB BODY

FIG. 2

AN AND XJ BODIES

FIG. 3

BR BODY

FIG. 4

ZJ BODY

FIG. 5

SPEED

CONTROL

TESTS

758

TEST SC-1B CHECKING THE SPEED CONTROL OPERATION



USING AN OHMMETER, REPAIR THESTART TEST MEASURE THE SWITCHED IS THE RESISTANCE YES SWITCHED S/C POWER

SC-1B. S/C POWER SUPPLY CKT BELOW 5.0 OHMS? SUPPLY OUTPUT AT S/C SERVO TO GND. CICUIT SHORTED TO

FIG. 1 GROUND.*

NO

DISCONNECT THE BRAKESWITCH CONNECTOR.** IS ANY TERMINAL YES REPAIR AS

DAMAGED, PUSHED NECESSARY.*OUT OR MISWIRED?


NO

MEASURE THE S/CWITH THE VENT BRAKE SWITCH IS THE VOLTAGE NO CONTINUE TEST

SOLENOID STILL IN OUTPUT CIRCUIT. ABOVE 10.0 VOLTS? SC-1B ON THEACTUATION MODE. NEXT PAGE.

FIG. 2, 3, 4 OR 5

YES

MEASURE THEKEY OFF, USE AN SWITCHED S/C BRAKEOHMMETER IN THE SWITCH OUTPUT FOLLOWING STEP. CIRCUIT FOR

RESISTANCE....

FROM BRAKE SWITCH CONNECTOR TO SPEED IS THE RESISTANCE NO REPAIR THE OPEN

CONTROL SERVO. BELOW 5.0 OHMS? SWITCHED S/C POWERSUPPLY CIRCUIT.*

FIG. 1 AND 2 THRU 5

YES

REPLACE THE BRAKESWITCH.*

SPEED

CONTROL

TESTS

759

TEST SC-1B CONTINUED CHECKING THE SPEED CONTROL OPERATION

AB BODY

FIG. 1

AN AND XJ BODIES

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

SPEED

CONTROL

TESTS

760

TEST SC-1B CONTINUED - CHECKING THE SPEED CONTROL OPERATION


TEST SC-1B KEY OFF, DISCONNECT CONTINUED FROM THE PCM.**

THE PREVIOUS PAGE.


USE AN OHMMETER IN S/C POWER SUPPLY REPAIR THE OPEN THE FOLLOWING OUTPUT CKT, PCM TO IS THE RESISTANCE NO S/C POWER SUPPLY STEP. MEASURE BRAKE SWITCH. BELOW 5.O OHMS? CIRCUIT, PCM TO

RESISTANCE OF THE BRAKE SWITCH.* SWITCHED... FIG. 1, 2, 3 OR 4

YES


MODULE.*

SPEED

CONTROL

TESTS

761




FIG. 1

1996 2.5/3.9/4.0/5.2/5.9/8.0L AB/AN/BR/XJ/ZJPublication No. 81-699-96103TSB 26-03-98 March, 1998

ZJ BODY

FIG. 2


FIG. 3

BR BODY

FIG. 4

ZJ BODY

FIG. 5

SPEED

CONTROL

TESTS

762




KEY OFF, DISCONNECT START TEST THE SPEED CONTROL IS ANY TERMINAL YES REPAIR AS

SC-2A. SWITCH(S).** DAMAGED, PUSHED NECESSARY.*OUT OR MISWIRED?


NO

WITH AN OHMMETER, REPAIR THE SPEEDMEASURE THE SPEED IS THE RESISTANCE YES CONTROL SWITCH

CONTROL SWITCH BELOW 5.0 OHMS? SIGNAL CIRCUIT, SIGNAL TO GROUND. FOR A SHORT TO

FIG. 1 OR 2 GROUND.*

NO

THE SPEED CONTROL REPAIR THE OPEN WITH AN OHMMETER, SENSOR GROUND IS THE RESISTANCE NO SENSOR GROUND

MEASURE... CIRCUIT AT THE BELOW 5.0 OHMS? CIRCUIT TO SWITCH TO GROUND. SWITCH.*

FIG. 1 OR 2

YES

CONNECT A JUMPER ACROSS SIGNAL CKT WITH THE DRB, READ DOES THE DRB SHOW YES REPLACE THE SPEEDAND GROUND CKT AT THE SPEED CONTROL "0.00V"? CONTROL SWITCH.* SWITCH CONNECTOR. SWITCH VOLTAGE.

FIG. 1 OR 2

NO

KEY OFF, DISCONNECT USING AN OHMMETER,THE POWERTRAIN MEASURE THE S/C IS THE RESISTANCE YES REPLACE THE

CONTROL MODULE.** SWITCH SIGNAL CKT, BELOW 5.0 OHMS? POWERTRAIN CONTROLSWITCH TO PCM. MODULE.*


NO

DISCONNECT THE USING AN OHMMETER,CLOCKSPRING 4-WAY TO MEASURE THE S/C IS THE RESISTANCE YES REPLACE THE

I/P HARNESS.** SWITCH SIGNAL CKT BELOW 5.0 OHMS? CLOCKSPRING.*CLOCKSPRING TO PCM.


NO

REPAIR THE OPEN SPEED CONTROLSWITCH SIGNAL

CIRCUIT.*

SPEED

CONTROL

TESTS

763



AB BODY

FIG. 1

AN AND XJ BODY

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

SPEED

CONTROL

TESTS

764




DISCONNECT THE BRAKESTART TEST SWITCH CONNECTOR.**

SC-3A.


KEY ON, WITH AVOLTMETER, MEASURE IS THE VOLTAGE NO CONTINUE TEST

THE BRAKE SWITCH ABOVE 10.0 VOLTS? SC-3A ON THESENSE CIRCUIT. NEXT PAGE.

FIG. 1, 2, 3 OR 4

YES

CONNECT A JUMPER BETWEEN THE BRAKE WITH THE DRB, READ DOES THE DRB SHOW YES REPLACE THE BRAKE

SWITCH SENSE AND THE BRAKE SWITCH BRAKE SW SWITCH.* GROUND. INPUT STATUS. "RELEASED"?

FIG. 1, 2, 3 OR 4

NO

REPAIR THE OPEN GROUND CIRCUIT.*

SPEED

CONTROL

TESTS

765



FIG. 1

BR BODY

FIG. 2

ZJ BODY

FIG. 3

SPEED

CONTROL

TESTS

766



TEST SC-3A KEY OFF, DISCONNECT CONTINUED FROM THE POWERTRAIN IS ANY TERMINAL YES REPAIR AS

THE PREVIOUS CONTROL MODULE.** DAMAGED, PUSHED NECESSARY.*PAGE. OUT OR MISWIRED?


NO

USING AN OHMMETER REPAIR THE BRAKEIN THE FOLLOWING SENSE CIRCUIT AT IS THE RESISTANCE YES SWITCH SENSE

STEPS, MEASURE THE PCM TO GROUND. BELOW 5.0 OHMS? CIRCUIT, SHORTEDBRAKE SWITCH... TO GROUND.*

FIG. 1, 2 OR 3

NO


NEXT PAGE.

SPEED

CONTROL

TESTS

767


AB BODY

FIG. 1

AB AND XJ BODIES

FIG. 2

BR BODY

FIG. 3

ZJ BODY

FIG. 4

SPEED

CONTROL

TESTS

768



TEST SC-3A MEASURE THE BRAKECONTINUED FROM SWITCH SENSE CKT IS THE RESISTANCE YES REPLACE THE

THE PREVIOUS FROM PCM TO BRAKE BELOW 5.0 OHMS? POWERTRAIN CONTROLPAGE. SWITCH CONNECTOR. MODULE.*

FIG. 1, 2, 3 OR 4

NO

REPAIR THE OPEN BRAKE SWITCH SENSE

CIRCUIT.*

SPEED

CONTROL

TESTS

769



AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5

SPEED

CONTROL

TESTS

770




KEY OFF, DISCONNECT START TEST THE POWERTRAIN NOTE: THE GEAR

SC-4A. CONTROL MODULE.** SELECTOR SHOULD STILL BE IN DRIVE.


WITH AN OHMMETER,MEASURE THE P/N IS THE RESISTANCE NO REPLACE THEPOSITION SWITCH BELOW 5.0 OHMS? POWERTRAIN CONTROL

SENSE CIRCUIT. MODULE.* FIG. 1, 2, 3, 4 OR 5

YES

DISCONNECT THE WITH AN OHMMETER,PARK/NEUTRAL MEASURE THE P/N IS THE RESISTANCE NO REPLACE THE

SWITCH.** POSITION SWITCH BELOW 5.0 OHMS? PARK/NEUTRAL SENSE CKT AT PCM. SWITCH.*


YES

REPAIR THEPARK/NEUTRAL

POSITION SENSECIRCUIT, SHORTED

TO GROUND.*

SPEED

CONTROL

TESTS

771



NOTES

SPEED

CONTROL

TESTS

772




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 attemptto set the speed control. The following items will not allow the speed control to set. The last or mostrecent cause for speed control not to set is indicated by the ‘‘Denied’’ status.

Denied Message

ON/OFF The powertrain control module does not see an ‘‘ON’’ signal from the switch.

SPEED The vehicle speed as seen by the powertrain control module is not greaterthan 36 mph.

RPM The engine rpm is excessively high.

BRAKE The brake switch sense circuit is open indicating to the powertrain controlmodule that the brakes are applied. The sense circuit is grounded throughthe brake pedal switch when the brakes are released.

P/N The park/neutral switch sense circuit is grounded indicating to the powertraincontrol module that the transmission is not in gear. The sense circuit isgrounded through the park/neutral switch when the transmission is in park orneutral.

RPM/SPD The PCM senses excessive engine rpm for a given vehicle speed.

SOL FLT The powertrain control module senses a servo solenoid circuit trouble codethat is maturing or set in memory.

SPEED

CONTROL

TESTS

773

TEST CH-1A CHARGING SYSTEM NO CODE TEST



ZJ BODY XJ BODY

FIG. 1

CHARGING

TESTS

774

TEST CH-1A CHARGING SYSTEM NO CODE TEST



BATTERY CONDITIONSTART TEST MUST BE VERIFIED

CH-1A. PRIOR TO THIS TEST.

INSPECT THEGENERATOR BELT IS THE GENERATOR NO REPAIR AS

TENSION AND BELT OK? NECESSARY.*CONDITION.

YES

START ENGINE, TURN ON ALL ACCESSORIES RETURN THE ENGINE ARE THERE ANY YES PERFORM DTC

AND RAISE THE ENGINE TO IDLE SPEED AND CHARGING SYSTEM TEST.SPEED TO 2000 RPM READ CODES. TROUBLE CODES?

FOR 30 SECONDS.

NO

DRIVER TERMINAL AT TURN ENGINE OFF WITH THE DRB, USING A VOLTMETER THE BACK OF THE

(IGNITION ON). ACTUATE THE BACKPROBE THE GENERATOR. GENERATOR FIELD. GENERATOR FIELD...

FIG. 1

NOTE: THE VOLTAGE WHILE MONITORING THE WAS THERE ANY REPAIR THE WIRE SHOULD CYCLE FROM VOLTMETER, WIGGLE INTERRUPTION IN YES WHERE WIGGLING

0 TO BATTERY THE FIELD TERMINALS THE NORMAL CYCLE INTERRUPTED THEVOLTAGE EVERY 1.4 BACK TO THE PCM AND BETWEEN 0 AND VOLTAGE CYCLE.*

SECONDS. ASD RELAY. BATTERY VOLTAGE?

NO

WITH THE DRB, READ ARE THERE ANY YES PERFORM DTCSTOP ACTUATION. TROUBLE CODES. CHARGING SYSTEM TEST.

TROUBLE CODES?

NO

CONTINUE TEST CH-1A ON THE

NEXT PAGE.

CHARGING

TESTS

775

TEST CH-1A CONTINUED - CHARGING SYSTEM NO CODE TEST


ZJ BODY XJ BODY

FIG. 1

CHARGING

TESTS

776



TEST CH-1A TEST BETWEEN THECONTINUED FROM USE A VOLTMETER IN GENERATOR (12V) B(+)

THE PREVIOUS THE FOLLOWING TERMINAL AND THEPAGE. STEP. BATTERY (+) SIDE.

FIG. 1

CAUTION: ENSURE ALL REPAIR THE B(+) WIRES ARE CLEAR OF IS THE VOLTAGE YES CIRCUIT FOR HIGH

THE ENGINE’S MOVING START THE ENGINE. ABOVE 0.4 VOLT? RESISTANCE BETWEENPARTS. THE GENERATOR AND

THE BATTERY.*

NO

IGNITION KEY OFF. MEASURE BETWEENUSE A VOLTMETER IN THE GENERATOR CASE

THE FOLLOWING AND BATTERY (-)STEP. SIDE.

CAUTION: ENSURE ALL REPAIR GENERATORWIRES ARE CLEAR OF IS THE VOLTAGE YES GROUND HIGH

THE ENGINE’S MOVING START THE ENGINE. ABOVE 0.1 VOLT? RESISTANCE PARTS. GENERATOR CASE TO

BATTERY (-) SIDE.*

NO

WITH THE DRB, READ USING A VOLTMETER, THE BATTERY READ BATTERYVOLTAGE AND VOLTAGE B(+) TO

RECORD. B(-) TERMINAL.

RECORD SECOND VOLTAGE READING. IS THE VOLTAGE YESCOMPARE THE TWO DIFFERENCE LESS TEST COMPLETE.*

VOLTAGE READINGS. THAN ONE VOLT?

NO

CONTINUE TEST CH-1A ON THE

NEXT PAGE.

CHARGING

TESTS

777


FIG. 1

CHARGING

TESTS

778



TEST CH-1ACONTINUED FROM


DISCONNECT THE TURN IGNITION ON, IS THE VOLTAGEPOWERTRAIN CONTROL USING A VOLTMETER, WITHIN ONE VOLT OF NO REPLACE THE

MODULE.** MEASURE THE FUSED THE DRB RECORDED POWERTRAIN CONTROLB(+) AT THE PCM. READING? MODULE.*


YES

REPAIR THE B(+) CIRCUIT FOR HIGH

RESISTANCE BETWEENTHE PCM FUSED B(+) AND THE BATTERY.*

CHARGING

TESTS

779

TEST NS-SEL NO START SELECTION MENU


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 40°F or below . . . . . . . . . . . . . . . . . . . . . . .NS-14

Diesel engine no-start independent of temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .NS-15

NO

START

TESTS

780

TEST NS-SEL NO START SELECTION MENU


NOTES

NO

START

TESTS

781

TEST NS-1A QUALIFYING A NO START CONDITION

Perform TEST NS-SEL Before Proceeding

FIG. 1

NO

START

TESTS

782

TEST NS-1A QUALIFYING A NO START CONDITION



KEY OFF. START TEST DISCONNECT THE SPARK

NS-1A. PLUG CABLE AT SPARKPLUG #1.


CONNECT THE SPARK WHILE CRANKING THECONNECT THE CABLE TESTER TO A GOOD ENGINE FOR 10 TO A SPARK TESTER. GROUND. SECONDS, WATCH FOR

SPARK. FIG. 1

NO IS THERE GOOD SPARK?

YES

DOES THE VEHICLE YES PERFORM TEST START AND STALL? NS-7A.

NO

REMOVE THE COIL SECONDARY CABLE PERFORM TEST

TURN IGNITION OFF. FROM THE NS-2A. DISTRIBUTOR.

CONNECT THE CABLE CONNECT THE SPARK WHILE CRANKING THETO A SPARK TESTER. TESTER TO A GOOD ENGINE FOR 10 CONTINUE TEST

GROUND. SECONDS, WATCH FOR NS-1A ON THESPARK. NEXT PAGE.

FIG. 1 FIG. 1

NO

START

TESTS

783

TEST NS-1A CONTINUED - QUALIFYING A NO START CONDITION

FIG. 1

FIG. 2

NO

START

TESTS

784



TEST NS-1A REPAIR THECONTINUED FROM IS THERE GOOD YES SECONDARY

THE PREVIOUS SPARK? IGNITION:PAGE. DISTRIBUTOR CAP,

ROTOR, CABLES.*

NO

REMOVE THE COIL TURN IGNITION OFF. SECONDARY CABLE.

MEASURE THEUSE AN OHMMETER IN RESISTANCE OF THE IS THE RESISTANCE YES REPLACE THE COIL

THE FOLLOWING COIL SECONDARY ABOVE 15K OHMS? SECONDARY CABLE.*STEP. CABLE.

FIG. 1

NO

REMOVE THEDISTRIBUTOR CAP. WHILE CRANKING THE DID THE ROTOR TURN NO REPAIR THE

ENGINE, WATCH FOR WHEN THE ENGINE DISTRIBUTOR DRIVETHE ROTOR TO TURN. WAS CRANKED? SYSTEM.*

FIG. 2

YES

REINSTALL THE REPAIR TERMINAL(S)DISTRIBUTOR CAP DISCONNECT THE IS ANY TERMINAL YES FOR DAMAGE,

AND IGNITION COIL IGNITION COIL DAMAGED, PUSHED PUSHOUT, OR CABLE. CONNECTOR.** OUT, OR MISWIRED? MISWIRING.*

NO

WITH GENERATORWITH THE DRB, FIELD STILL CONTINUE TEST

TURN IGNITION ON. ACTUATE THE ACTUATING, USE A NS-1A ON THEGENERATOR FIELD. VOLTMETER IN THE NEXT PAGE.

NEXT STEP.

NO

START

TESTS

785



FIG. 1

BR BODY

FIG. 2

ZJ BODY

FIG. 3

NO

START

TESTS

786



TEST NS-1A MEASURE THE ASD REPAIR THE OPEN CONTINUED FROM RELAY OUTPUT IS THE VOLTAGE NO ASD RELAY OUTPUT

THE PREVIOUS CIRCUI IN THE COIL ABOVE 10.0 VOLTS? CKT FROM COIL PAGE. CONNECTOR. CONNECTOR TO

FIG. 1, 2, OR 3 SPLICE.*

YES

CONTINUE TEST NS-1A ON THE

NEXT PAGE

NO

START

TESTS

787


FIG. 1

FIG. 2

NO

START

TESTS

788



TURN IGNITION OFF. TEST NS-1A

CONTINUED FROM USE AN OHMMETER IN PREVIOUS PAGE THE FOLLOWING

STEPS.

MEASURE THE IS THE PRIMARYRESISTANCE BETWEEN RESISTANCE BETWEEN NO REPLACE THE

THE PRIMARY 0.60 AND 1.40 IGNITION COIL.* TERMINALS OF THE OHMS?

IGNITION COIL.FIG. 1

YES

MEASURE THE IS THE SECONDARYRESISTANCE BETWEEN RESISTANCE BETWEEN NO REPLACE THE

THE PRIMARY AND 11,300 - 15,300 IGNITION COIL.* SECONDARY TERMINALS OHMS?OF THE COIL. FIG. 2

YES


NEXT PAGE

NO

START

TESTS

789



FIG. 1

BR BODY

FIG. 2

ZJ BODY

FIG. 3

NO

START

TESTS

790



TEST NS-1A DISCONNECT THECONTINUED FROM POWERTRAIN CONTROL

THE PREVIOUS MODULE BLACKPAGE. CONNECTOR.**


USING AN OHMMETER, FOR RESISTANCE TO REPAIR THEMEASURE THE GROUND. IS THE RESISTANCE YES IGNITION COIL

IGNITION COIL BELOW 5.0 OHMS? DRIVER CIRCUIT FORDRIVER CKT AT SHORT TO GROUND.*

THE PCM... FIG. 1, 2, OR 3

NO

USING AN OHMMETER, FROM THE IGNITION REPAIR OPEN MEASURE THE COIL TO THE PCM IS THE RESISTANCE YES IGNITION COIL

RESISTANCE OF THE CONNECTOR. ABOVE 5.0 OHMS? DRIVER FROM PCM TO COIL DRIVER COIL CONNECTOR.*

CIRCUIT... FIG. 1, 2, OR 3

NO

CHECK VALVE TIMING IS VALVE TIMING NO REPAIR THE ENGINE PER SERVICE MANUAL WITHIN VALVE TIMING AS

INSTRUCTIONS. SPECIFICATIONS? NECESSARY.*

YES


MODULE.*

NO

START

TESTS

791

TEST NS-2A CHECKING FUEL SYSTEM



ENSURE THE THROTTLE REPAIR THESTART TEST CABLE IS NOT HOLDING IS THE THROTTLE YES CONDITION THAT IS

NS-2A. THE THROTTLE OPEN. BEING HELD OPEN BY HOLDING THETHE CABLE? THROTTLE BODIES

SEE GENERAL INFO 4.0 OPEN.*

NO

WITH THE DRB, GO INTO THEFT ALARM DOES THE DRB SHOW YES CONTINUE TEST

AND SELECT "ENGINE CONTROLLER NS-2A ON THEMONITORED DISPLAY. OK TO RUN ENGINE"? NEXT PAGE.

NO

PERFORM THE THEFTALARM TEST IN THE

BODY DIAGNOSTIC PROCEDURES

MANUAL.*

NO

START

TESTS

792

TEST NS-2A CONTINUED - CHECKING FUEL SYSTEM



TEST NS-2ACONTINUED FROM WITH THE DRB,

THE PREVIOUS ACTUATE THE FUEL PAGE. SYSTEM.

NOTE: IT MAY BE NECESSARY TO USE A LISTEN FOR FUEL CAN THE FUEL PUMP NO PERFORM TEST

MECHANICS PUMP OPERATION AT OPERTION BE HEARD? NS-5A. STETHOSCOPE IN THE THE FUEL TANK.

NEXT STEP.

YES

WARNING: THE FUEL KEY OFF. INSTALL A NOTE: THE FUEL SYSTEM MUST BE FUEL PRESSURE TANK MUST BE AT

OPENED AND MAY BE GAUGE TO FUEL LEAST 1/4 FULL FORUNDER HIGH PRESSURE. SYSTEM. THE FOLLOWINGSEE GENERAL INFO 9.0 TESTS.

TURN IGNITION ON. REPLACE THE FUEL READ THE FUEL IS THE FUEL YES FILTER/REGULATOR

WITH THE DRB, PRESSURE GAUGE. PRESSURE ABOVE AND PRIMARYACTUATE THE FUEL 54.2 PSI? FILTER.*

SYSTEM.

NO

IS THE FUEL YES PERFORM TEST PRESSURE BELOW NS-4A.

44.2 PSI?

NO

DID THE VEHICLE YES PERFORM TEST INITIALLY START & NS-7A. STALL REPEATEDLY?

NO

PERFORM TEST NS-3A.

NO

START

TESTS

793

TEST NS-3A CHECKING THE MECHANICAL SYSTEM

8.0L

FIG. 1

AB, AN AND BR 3.9L

FIG. 2

AB, AN, BR AND ZJ 5.2L AND 5.9L

FIG. 3

XJ 2.5L

FIG. 4

XJ AND ZJ 4.0L

FIG. 5

NO

START

TESTS

794

TEST NS-3A CHECKING THE MECHANICAL SYSTEM


REMOVE ALL SPARKSTART TEST PLUGS & INSPECT

NS-3A. THE TIPS FOR WETFUEL.

ARE THE SPARK PLUG YES CLEAN THE SPARKTIPS WET? PLUGS.

NO

INSPECT SPARK PLUG REINSTALL THE CABLES FOR CORRECT ARE ALL SPARK PLUG NO REINSTALL SPARK

SPARK PLUGS. PLACEMENT. CABLES POSITIONED PLUG CABLES AS CORRECTLY? NECESSARY.*

FIG. 1, 2, 3, 4 OR 5

YES

USING SERVICEMANUAL PROCEDURES, IS VALVE TIMING NO REPAIR THE ENGINE

TURN IGNITION OFF. CHECK VALVE WITHIN VALVE TIMING AS TIMING. SPECIFICATIONS? NECESSARY.*

YES

CHECK EXHAUST IS THE EXHAUST NO REPAIR AS SYSTEM FOR ANY FREE OF NECESSARY.*RESTRICTIONS. RESTRICTIONS?

YES

USING SERVICEMANUAL PROCEDURES, IS ENGINE NO REPAIR AS

CHECK ENGINE COMPRESSION WITHIN NECESSARY.*COMPRESSION. SPECIFICATIONS?

YES

REPLACE POWERTRAIN CONTROL MODULE.*

NO

START

TESTS

795

TEST NS-4A REPAIRING LOW FUEL PRESSURE


NOTES

NO

START

TESTS

796

TEST NS-4A REPAIRING LOW FUEL PRESSURE



INSPECT FUEL LINESSTART TEST FROM TANK TO FUEL IS THERE ANY YES REPAIR RESTRICTED

NS-4A. RAIL FOR RESTRICTION? FUEL LINES.*RESTRICTION.


NO

REPLACE THE FUEL PUMP MODULE.*

NO

START

TESTS

797

TEST NS-5A CHECKING THE FUEL PUMP

Perform TEST NS-2A Before Proceeding

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5

NO

START

TESTS

798

TEST NS-5A CHECKING THE FUEL PUMP



START TEST WITH THE DRB, STOP NS-5A. THE ACTUATION

TEST.

TOUCH THE FUEL PUMP WITH THE DRB, RELAY. DOES THE FUEL PUMP NO PERFORM TEST

ACTUATE THE FUEL RELAY PULSATE WITH TC-101A. PUMP RELAY. ACTUATION?

FIG. 1, 2, 3, 4 OR 5

YES

DISCONNECT THE FUEL PUMP RELAY.**

IGNITION KEY OFF.

FIG. 1, 2, 3, 4 OR 5

USING A VOLTMETER, REPAIR THE FUEL MEASURE THE FUEL IS THE VOLTAGE NO PUMP RELAY B(+)

PUMP RLY FUSED B(+) ABOVE 10.0 VOLTS? CIRCUIT FOR AN CIRCUIT. OPEN TO SPLICE.*

FIG. 1, 2, 3, 4 OR 5

YES


NEXT PAGE.

NO

START

TESTS

799

TEST NS-5A CONTINUED - CHECKING THE FUEL PUMP

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5

NO

START

TESTS

800

TEST NS-5A CONTINUED - CHECKING THE FUEL PUMP


TEST NS-5A INSTALL A SUBSTITUTE CONTINUED FROM RELAY OF THE SAME

THE PREVIOUS PART NUMBER FOR THEPAGE. FUEL PUMP RELAY.

ATTEMPT TO START DOES THE ENGINE YES REPLACE THE FUEL THE ENGINE START? PUMP RELAY.*

NO

DISCONNECT THE FUEL REINSTALL THE PUMP HARNESS

ORIGINAL FUEL PUMP CONNECTOR.** RELAY.


CAUTION: IT IS IGNITION ON.CRITICAL THAT THE

FUEL PUMP CONNECTOR WITH THE DRB, HAS A CLEAN AND ACTUATE THE FUEL

TIGHT CONNECTION.** SYSTEM.

USING A VOLTMETER, MEASURE THE FUEL IS THE VOLTAGE NO REPAIR THE OPEN PUMP RLY OUTPUT ABOVE 10.0 VOLTS? FUEL PUMP RELAY

CIRCUIT. OUTPUT CIRCUIT.*FIG. 1, 2, 3, 4 OR 5

YES

USING AN OHMMETER,WITH THE DRB, STOP MEASURE THE FUEL IS THE RESISTANCE NO REPAIR THE OPEN

THE ACTUATION PUMP GROUND CKT IN BELOW 5.0 OHMS? FUEL PUMP GROUND TEST. THE FUEL PUMP CONN. CIRCUIT.*

FIG. 1, 2, 3, 4 OR 5

YES

REPLACE THE FUEL PUMP.*

NO

START

TESTS

801

TEST NS-6A REPAIRING A (NO RESPONSE( CONDITION

Perform DTC TEST OR NS-SEL Before Proceeding

AB AND BR BODIES

FIG. 1

AN BODY

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

NO

START

TESTS

802

TEST NS-6A REPAIRING A (NO RESPONSE( CONDITION

Perform DTC TEST OR NS-SEL Before Proceeding


KEY OFF, DISCONNECT START TEST THE POWERTRAIN

NS-6A. CONTROL MODULE BLACKCONNECTOR.**


USING AN OHMMETER, REPAIR THE OPEN MEASURE BOTH IS THE RESISTANCE NO GROUND(S) AT THE

GROUND CIRCUITS AT BELOW 5.0 OHMS AT POWERTRAIN CONTROLPCM CONNECTOR. BOTH TERMINALS? MODULE.*

FIG. 1, 2, 3 OR 4

YES

USING A VOLTMETER, REPAIR THE OPEN MEASURE THE FUSED IS THE VOLTAGE NO FUSED IGN SWITCH

TURN IGNITION ON. IGN SWITCH OUTPUT ABOVE 10.0 VOLTS? OUTPUT CIRCUITCIRCUIT. BETWEEN PCM &

FIG. 1, 2, 3 OR 4 IGNITION SWITCH.*

YES


NEXT PAGE.

NO

START

TESTS

803

TEST NS-6A CONTINUED - REPAIRING A (NO RESPONSE( CONDITION

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5

NO

START

TESTS

804



TEST NS-6A MEASURE THE FUSEDCONTINUED FROM B(+) CKT IN THE PCM IS THE VOLTAGE YES PERFORM TEST

THE PREVIOUS CONNECTOR. ABOVE 10.0 VOLTS? NS-6D. PAGE. SEE FIG. 1, 2, 3 OR

4 ON PREVIOUS PAGE

NO

REMOVE THE FUSE IN THE PDC THAT NO CONTINUE TEST

SUPPLIES FUSED B(+) INSPECT THE FUSE. IS THE FUSE OK? NS-6A ON THETO PCM CAVITY A22. NEXT PAGE.

FIG. 1, 2, 3, 4 OR 5

YES

USING A VOLTMETER, REPAIR THE OPEN MEASURE THE B(+) IS THE VOLTAGE NO B(+) CIRCUIT FROM SIDE OF THE FUSE ABOVE 10.0 VOLTS? FUSE TO THE

SOCKET. BATTERY .* FIG. 1, 2, 3, 4 OR 5

YES

REPAIR THE OPEN FUSED B(+) CIRCUITFROM FUSE TO PCM.*

NO

START

TESTS

805


AB AND BR BODIES

FIG. 1

AN BODY

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

NO

START

TESTS

806



TEST NS-6A TURN IGNITION OFF. CONTINUED FROM DISCONNECT THE AUTO

THE PREVIOUS SHUTDOWN RELAY.** PAGE.


NOTE: THE WITH AN OHMMETER, REPAIR THE FUSEDPREVIOUSLY MEASURE THE FUSED IS THE RESISTANCE YES B(+) CIRCUIT FOR A

INSPECTED FUSE B(+) CIRCUIT IN PCM BELOW 5.0 OHMS? SHORT TO GROUND.SHOULD STILL BE CONNECTOR TO GND.

REMOVED. FIG. 1, 2, 3, 4 OR 5 REPLACE FUSE.*

NO

MEASURE THE ASDRELAY OUTPUT CKT FIG. 1, 2, 3, 4 OR IS THE RESISTANCE YES CONTINUE TEST IN THE ASD RELAY 5 ON FOLLOWING BELOW 5.0 OHMS? NS-6A ON THE

CONNECTOR... PAGE. NEXT PAGE.

NO

IS THE VEHICLE NO PERFORM TEST EQUIPPED WITH A NS-6C.

DIESEL ENGINE?

YES

NOTE: AN INTERMITTENT ASDRELAY OUTPUT CKT REPLACE FUSE.* SHORT TO GROUND

MAY EXIST.

NO

START

TESTS

807


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5

NO

START

TESTS

808



TEST NS-6ACONTINUED FROM IS THE VEHICLE YES CONTINUE TEST

THE PREVIOUS EQUIPPED WITH A NS-6A ON THEPAGE. DIESEL ENGINE? NEXT PAGE.

NO

DISCONNECT THE WITH AN OHMMETER, MEASURE THE ASDCONNECTORS FOR EACH MEASURE THE ASD RLY IS THE RESISTANCE YES RELAY OUTPUT CKT IN

OXYGEN SENSOR.** OUTPUT CIRCUIT FOR ABOVE 5.0 OHMS? EACH O2 SENSOR FORRESISTANCE TO GND. RESISTANCE TO GND.

SEE GENERAL INFO 4.4 FIG. 1, 2, 3, 4 OR 5 SEE GENERAL INFO 4.4

NO

NOTE: THE OXYGEN REPLACE THE OXYGEN SENSORS MUST REMAIN SENSOR THAT HASDISCONNECTED FOR THE CONTINUITY TO

REMAINDER OF THE GROUND.TEST. REPLACE FUSE.*

DISCONNECT THE WITH AN OHMMETER, REPLACE THEIGNITION COIL MEASURE THE ASD RLY IS THE RESISTANCE YES IGNITION COIL.

CONNECTOR.** OUTPUT CIRCUIT FOR ABOVE 5.0 OHMS?RESISTANCE TO GND.

SEE GENERAL INFO 4.2 FIG. 1, 2, 3, 4 OR 5 REPLACE FUSE.*

NO

DISCONNECT THE WITH AN OHMMETER, REPAIR GENERATORGENERATOR FIELD MEASURE THE ASD RLY IS THE RESISTANCE YES FOR SHORT TO

CONNECTOR.** OUTPUT CIRCUIT FOR ABOVE 5.0 OHMS? GROUND.RESISTANCE TO GND.


NO

CONTINUE TO MONITOR IS THE RESISTANCE REPLACE THE FUEL OHMMETER DISPLAY ABOVE 5.0 OHMS YES INJECTOR THAT

WHILE DISCONNECTING WHEN ANY OF THE CAUSED A CHANGE IN EACH FUEL INJECTOR. INJECTORS ARE RESISTANCE.SEE GENERAL INFO 4.2 DISCONNECTED? REPLACE FUSE.*

NO

REPAIR ASD RELAYOUTPUT CIRCUIT FOR

HARNESS SHORT TO GROUND.

REPLACE FUSE.*

NO

START

TESTS

809

TEST NS-6B REPAIRING A (NO RESPONSE( CONDITION

Perform DTC TEST OR NS SEL Before Proceeding

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5

NO

START

TESTS

810

TEST NS-6B REPAIRING A (NO RESPONSE( CONDITION

Perform DTC TEST OR NS SEL Before Proceeding


1996 Powertrain 2.5L/3.9L/4.0L/5.2L/5.9L/8.0L SFI/MPI/CNG/DIESELAB/AN/BR/XJ/ZJ

Publication No. 81-699-96103TSB 26-10-99 October, 1999

NO

START

TESTS

811

TEST NS-6B CONTINUED - REPAIRING A (NO RESPONSE( CONDITION

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5

NO

START

TESTS

812

TEST NS-6B CONTINUED - REPAIRING A (NO RESPONSE( CONDITION


TEST NS-6B MEASURE THECONTINUED FROM RESISTANCE OF THE IS THE RESISTANCE NO REPAIR THE OPEN

THE PREVIOUS SCI RECEIVE CKT FROM BELOW 5.0 OHMS? SCI RECEIVEPAGE. THE PCM TO THE DLC. CIRCUIT.*

FIG. 1, 2, 3, 4 OR 5

YES

CONNECT THE DRB TO A FUNCTIONAL DATA

LINK ON ANOTHER TURN IGNITION ON.VEHICLE.

REPLACE THEWITH THE DRB, DID THE DRB NO INITIAL VEHICLE’S

ATTEMPT TO READ DISPLAY "NO POWERTRAIN CONTROLTROUBLE CODES. RESPONSE"? MODULE.*

YES

SUBSTITUTE ANOTHER WITH THE DRB, DID THE DRB NO REPLACE THE DRBDRB ADAPTER CABLE. ATTEMPT TO READ DISPLAY "NO ADAPTER CABLE.

TROUBLE CODES. RESPONSE"?

YES

HAVE THE DRBREPAIRED OR

REPLACED.

NO

START

TESTS

813

TEST NS-6C REPAIRING A (NO RESPONSE( CONDITION


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5

NO

START

TESTS

814

TEST NS-6C REPAIRING A (NO RESPONSE( CONDITION



START TEST IS THE VEHICLE YES CONTINUE NS-6CNS-6C. EQUIPPED WITH A ON THE NEXT

CNG FUEL SYSTEM? PAGE.

NO

DISCONNECT THE FUEL WITH AN OHMMETER, REPAIR THE FUEL PUMP ELECTRICAL MEASURE THE FUEL IS THE RESISTANCE YES PUMP RELAY OUTPUT

CONNECTOR.** PUMP RLY OUTPUT CKT BELOW 5.0 OHMS? CIRCUIT FOR AIN THE RELAY CONN. SHORT TO GROUND.


NO

NOTE: AN REPLACE THE FUEL INTERMITTENT FUEL PUMP.PUMP RELAY OUTPUT

CIRCUIT SHORT TO GROUND MAY EXIST. REPLACE FUSE.*

NO

START

TESTS

815

TEST NS-6C CONTINUED REPAIRING A (NO RESPONSE( CONDITION


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

NO

START

TESTS

816

TEST NS-6C CONTINUED REPAIRING A (NO RESPONSE( CONDITION



TEST NS-6C DISCONNECT THE HIGH CONTINUED FROM PRESSURE SHUT-OFF



USING AN OHMMETER, REPAIR THE FUEL MEASURE THE FUEL IS THE RESISTANCE YES SYSTEM RELAY

SYSTEM RELAY OUTPUT BELOW 5.0 OHMS? OUTPUT CIRCUIT FORCKT IN THE RELAY A SHORT TO GROUND.

CONN. FIG. 1, 2 OR 3 REPLACE FUSE.*

NO

REPLACE THE HIGH PRESSURE FUEL

SHUT-OFF SOLENOID.

REPLACE FUSE.*

NO

START

TESTS

817

TEST NS-6D CHECKING A (NO RESPONSE( CONDITION


FIG. 1



FIG. 2

BR DIESEL

FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5

NO

START

TESTS

818

TEST NS-6D CHECKING A (NO RESPONSE( CONDITION



RECONNECT ALLSTART TEST DISCONNECTED

NS-6D. CONNECTORS.


USE A VOLTMETER IN THE FOLLOWING

STEPS.

NOTE: IF THE BACKPROBE THE CKPVEHICLE IS A BR SENSOR 5-VOLT DIESEL, EQUIPPED SUPPLY AND SKIP

WITH A MANUAL THE TPS DISCONNECT TRANS,... STEP. FIG. 1

ALL OTHER VEH’S, IGNITION KEY ON.BACKPROBE THE TP IS THE VOLTAGE NO PERFORM TEST

SENSOR 5-VOLT RECORD VOLTMETER BELOW 4.0 VOLTS? NS-6E. SUPPLY CIRCUIT. READING.

FIG. 2, 3, 4 OR 5

YES

DISCONNECT THE TP TP SENSOR 5-VOLT SENSOR CONNECTOR.** SUPPLY CIRCUIT AND IS THE VOLTAGE NO REPLACE THE

READ VOLTMETER. BELOW 4.0 VOLTS? THROTTLE POSITION CONNECT A VOLTMETER SENSOR.*

TO THE... FIG. 2, 3, 4 OR 5

YES

DISCONNECT THECRANKSHAFT SENSOR.** IS THE VOLTAGE NO REPLACE THE

READ VOLTMETER. BELOW 4.0 VOLTS? CRANKSHAFT SENSOR.*


YES

CONTINUE TEST NS-6D ON THE

NEXT PAGE.


NO

START

TESTS

819

TEST NS-6D CONTINUED CHECKING A (NO RESPONSE( CONDITION


NO

START

TESTS

820




TEST NS-6DCONTINUED FROM DOES THE VEHICLE YES CONTINUE TEST

THE PREVIOUS HAVE A DIESEL NS-6D ON THEPAGE. ENGINE? NEXT PAGE.

NO

DISCONNECT THECAMSHAFT SENSOR.** IS THE VOLTAGE NO REPLACE THE

READ VOLTMETER. BELOW 4.0 VOLTS? CAMSHAFT SENSOR.*


YES

DISCONNECT THE MAPSENSOR.** IS THE VOLTAGE NO REPLACE THE MAP

READ VOLTMETER. BELOW 4.0 VOLTS? SENSOR.*


YES

CONTINUE TEST NS-6D ON THE

NEXT PAGE.

NO

START

TESTS

821



FIG. 1

NO

START

TESTS

822




TEST NS-6D DISCONNECT THECONTINUED FROM VEHICLE SPEED IS THE VOLTAGE NO REPLACE THE

THE PREVIOUS SENSOR.** READ THE BELOW 4.0 VOLTS? VEHICLE SPEEDPAGE. VOLTMETER. SENSOR.*


YES

DISCONNECT THETRANSMISSION IS THE VOLTAGE NO REPLACE THE

SOLENOID CONNECTOR READ VOLTMETER. BELOW 4.0 VOLTS? GOVERNOR/TEMPIF EQUIPPED.** PRESSURE SENSOR.*


YES

MEASURE THE REPAIR THE SENSOR DISCONNECT THE VOLTAGE OF THE IS THE VOLTAGE YES GROUND CIRCUIT

VOLTMETER. SENSOR GROUND ABOVE 1.0 VOLT? SHORTED TO CIRCUIT. VOLTAGE.*

NO

KEY OFF. DISCONNECT THE POWERTRAIN DISCONNECT THE

CONTROL MODULE.** VOLTMETER.


WITH AN OHMMETER, TO GROUND AT THE REPAIR THE SHORTEDMEASURE THE POWERTRAIN CONTROL IS THE RESISTANCE YES 5-VOLT PRIMARY

RESISTANCE OF THE MODULE CONNECTOR. BELOW 5.0 OHMS? SUPPLY SHORTED TO 5-VOLT PRIMARY GROUND.*

SUPPLY CIRCUIT... FIG. 1

NO

MEASURE THE TO GROUND AT THE REPAIR THE SHORTEDRESISTANCE OF THE POWERTRAIN CONTROL IS THE RESISTANCE YES 5-VOLT SECONDARY

5-VOLT SECONDARY MODULE. BELOW 5.0 OHMS? SUPPLY SHORTED TO SUPPLY CIRCUIT... GROUND.*

FIG. 1

NO

PERFORM TEST NS-6B.

NO

START

TESTS

823

TEST NS-6E CHECKING A (NO RESPONSE( CONDITION



FIG. 1

BR DIESEL

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

NO

START

TESTS

824

TEST NS-6E CHECKING A (NO RESPONSE( CONDITION



DISCONNECT THE TP START TEST SENSOR CONNECTOR.**

NS-6E. CONNECT A VOLTMETER

TO THE...

TP SENSOR 5 VOLT SUPPLY CIRCUIT AND IS THE VOLTAGE NO REPLACE THE

READ VOLTMETER. ABOVE 5.5 VOLTS? POWERTRAIN CONTROLMODULE.*

FIG. 1, 2, 3 OR 4

YES

REPAIR THE 5-VOLT SUPPLY CIRCUIT

SHORTED TO VOLTAGE.*

NO

START

TESTS

825

TEST NS-7A CHECKING IDLE AIR CONTROL MOTOR


AB BODY

FIG. 1

AN AND BR BODIES

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

NO

START

TESTS

826

TEST NS-7A CHECKING IDLE AIR CONTROL MOTOR



HOLD THE ENGINE DOES THE ENGINE START TEST THROTTLE 1/4 OF START AND STAY NO PERFORM TEST

NS-7A. THE WAY DOWN AND RUNNING AND THEN NS-8A. ATTEMPT TO START STALL WHEN THROTTLE

ENGINE. IS RELEASED?

YES

DISCONNECT THE IDLE AIR CONTROL MOTOR WITH THE DRB,

CONNECTOR.** ACTUATE THE IDLE AIR CONTROL MOTOR.


MEASURE THE IDLE USE A VOLTMETER IN AIR CONTROL #3 DID THE VOLTAGE YES PERFORM TEST

THE FOLLOWING DRIVER CKT. STAY BELOW 1.0 NS-7B. STEP. VOLT?

FIG. 1, 2, 3 OR 4

NO

MEASURE THE IDLE AIR CONTROL #1 DID THE VOLTAGE YES PERFORM TEST

DRIVER CKT. STAY BELOW 1.0 NS-7C. VOLT?

FIG. 1, 2, 3 OR 4

NO


DRIVER CKT. STAY BELOW 1.0 NS-7D. VOLT?

FIG. 1, 2, 3 OR 4

NO


DRIVER CKT. STAY BELOW 1.0 NS-7E. VOLT?

FIG. 1, 2, 3 OR 4

NO


NEXT PAGE.

NO

START

TESTS

827

TEST NS-7A CONTINUED CHECKING IDLE AIR CONTROL MOTOR

FIG. 1

NO

START

TESTS

828

TEST NS-7A CONTINUED CHECKING IDLE AIR CONTROL MOTOR


TEST NS-7ACONTINUED FROM


REMOVE THE IDLE AIR RECONNECT IDLE AIRCONTROL MOTOR FROM CONTROL MOTORTHE THROTTLE BODY. ELECTRICAL

CONNECTOR. SEE GENERAL INFO 4.0

WITH THE DRB, ACTUATE THE IDLE IS THE IDLE AIR NO CONTINUE TEST

AIR CONTROL MOTOR. CONTROL MOTOR TIP NS-7A ON THEMOVING IN AND OUT? NEXT PAGE.

FIG. 1

YES

INSPECT THROTTLE BODY FOR A IS THE THROTTLE NO CLEAN OR REPLACE

RESTRICTION OR BODY FREE OF THROTTLE BODY.* CARBON BUILD UP. RESTRICTIONS?

YES

PERFORM TEST NS-8A.

NO

START

TESTS

829

TEST NS-7A CONTINUED - CHECKING IDLE AIR CONTROL MOTOR

AB BODY

FIG. 1

AN AND BR BODIES

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

NO

START

TESTS

830

TEST NS-7A CONTINUED - CHECKING IDLE AIR CONTROL MOTOR


TEST NS-7A KEY OFF, DISCONNECT CONTINUED FROM THE POWERTRAIN



THE FOLLOWINGSTEPS ARE CHECKING

FOR A SHORTBETWEEN THE DRIVER

CIRCUITS.

USING AN OHMMETER, IAC #1 DRIVER AND IS THE RESISTANCE MEASURE THE #2, #3, #4 DRIVERS. BELOW 5.0 OHMS ON YES REPAIR THE IAC


FIG. 1, 2, 3 OR 4

NO

IAC #2 DRIVER AND IS THE RESISTANCE MEASURE THE #3, #4 DRIVERS. BELOW 5.0 OHMS ON YES REPAIR THE IAC


FIG. 1, 2, 3 OR 4

NO

IAC #3 DRIVER ANDMEASURE THE #4 DRIVER. IS THE RESISTANCE YES REPAIR THE IAC

RESISTANCE BETWEEN BELOW 5.0 OHMS? DRIVER CIRCUITS,THE ... SHORTED TOGETHER.*

FIG. 1, 2, 3 OR 4

NO

REPLACE THE IDLE AIR CONTROL

MOTOR.*

NO

START

TESTS

831

TEST NS-7B CHECKING IDLE AIR CONTROL MOTOR


AB BODY

FIG. 1

AN AND BR BODIES

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

NO

START

TESTS

832

TEST NS-7B CHECKING IDLE AIR CONTROL MOTOR



KEY OFF. DISCONNECT REPAIR TERMINAL(S)START TEST POWERTRAIN CONTROL IS ANY TERMINAL YES FOR DAMAGE,

NS-7B. MODULE.** DAMAGED, PUSHED PUSHOUT, OR OUT, OR MISWIRED? MISWIRING.*


NO

TEST THE IDLE AIRUSE AN OHMMETER IN CONTROL MOTOR #3 IS THE RESISTANCE YES REPLACE THE

THE FOLLOWING DRIVER CKT FOR BELOW 5.0 OHMS? POWERTRAIN CONTROLSTEP. RESISTANCE. MODULE.*

FIG. 1, 2, 3 OR 4

NO

REPAIR THE OPEN IDLE AIR CONTROLMOTOR #3 DRIVER

CIRCUIT.*

NO

START

TESTS

833

TEST NS-7C CHECKING IDLE AIR CONTROL MOTOR


AB BODY

FIG. 1

AN AND BR BODIES

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

NO

START

TESTS

834

TEST NS-7C CHECKING IDLE AIR CONTROL MOTOR



KEY OFF. DISCONNECT REPAIR TERMINAL(S)START TEST THE POWERTRAIN IS ANY TERMINAL YES FOR DAMAGE,

NS-7C. CONTROL MODULE DAMAGED, PUSHED PUSHOUT, OR CONNECTOR.** OUT, OR MISWIRED? MISWIRING.*


NO



FIG. 1, 2, 3 OR 4

NO


CIRCUIT.*

NO

START

TESTS

835

TEST NS-7D CHECKING IDLE AIR CONTROL MOTOR


AB BODY

FIG. 1

AN AND BR BODIES

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

NO

START

TESTS

836

TEST NS-7D CHECKING IDLE AIR CONTROL MOTOR




NS-7D. CONTROL MODULE DAMAGED, PUSHED PUSHOUT, OR CONNECTOR.** OUT, OR MISWIRED? MISWIRING.*

SEE GENERAL ONFO 4.0

NO



FIG. 1, 2, 3 OR 4

NO


CIRCUIT.*

NO

START

TESTS

837

TEST NS-7E CHECKING IDLE AIR CONTROL MOTOR


AB BODY

FIG. 1

AN AND BR BODIES

FIG. 2

XJ BODY

FIG. 3

ZJ BODY

FIG. 4

NO

START

TESTS

838

TEST NS-7E CHECKING IDLE AIR CONTROL MOTOR




NS-7E. CONTROL MODULE DAMAGED, PUSHED PUSHOUT, OR CONNECTOR.** OUT, OR MISWIRED? MISWIRING.*


NO



FIG. 1, 2, 3 OR 4

NO


CIRCUIT.*

NO

START

TESTS

839

TEST NS-8A REPAIRING A START AND STALL CONDITION



NOTES

NO

START

TESTS

840

TEST NS-8A REPAIRING A START AND STALL CONDITION


At this point in the diagnostic test procedure, you have determined that all of the engine electricalsystems are operating as designed; therefore, they are not the cause of the start and stallproblem. The following additional items should be checked as possible mechanical causes of the nostart condition. Any one or more of these items can produce a no start condition; none can beoverlooked 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 withrotating components.

Start the engine and observe the DRB display. When the distributor is correctly positioned, the INRANGE message should appear along with 0°. If the distributor needs to be adjusted, loosen thedistributor hold-down clamp bolt. Rotate the distributor until reading is as close to 0° as possible andthe IN RANGE message is displayed. Tighten the clamp bolt to 22.5 Nzm (200 in. lbs.) torque.

NOTE: Setting the distributor position does not adjust the ignition timing. Ignition timing values aredetermined by the powertrain control module.

NO

START

TESTS

841

TEST NS-9A REPAIRING A NO CRANK CONDITION

Perform TEST NS SEL Before Proceeding

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5

NO

START

TESTS

842

TEST NS-9A REPAIRING A NO CRANK CONDITION



IS THE VEHICLESTART TEST EQUIPPED WITH A YES PERFORM TEST

NS-9A. MANUAL NS-9B. TRANSMISSION?

NO

WITH THE DRB, SELECT NOTE: THEENSURE THE INPUTS/OUTPUTS AND DOES THE DRB READ NO PARK/NEUTRAL

TRANSMISSION IS IN READ THE P/N? SWITCH SENSEPARK. PARK/NEUTRAL CIRCUIT IS OPEN.

POSITION.

YES

PERFORM TEST TC-114A.

DISCONNECT THE WITH A VOLTMETER, STARTER RELAY MEASURE THE FUSED IS THE VOLTAGE NO REPAIR THE OPEN

CONNECTOR.** B(+) CIRCUIT AT THE ABOVE 10.0 VOLTS? FUSED B(+) RELAY CONN. CIRCUIT.*


YES

WITH A VOLTMETER, WHILE OBSERVINGMESURE THE IGNITION VOLTMETER, HOLD IS THE VOLTAGE NO REPAIR THE OPEN SWITCH OUTPUT CKT AT IGNITION KEY IN ABOVE 10.0 VOLTS? IGNITION SWITCH

RELAY CONN. THE START OUTPUT CKT.*FIG. 1, 2, 3, 4 OR 5 POSITION.

YES

WARNING: THE TRANS WARNING: THE ENGINE BRIEFLY CONNECT AMUST BE IN PARK MAY BE CRANKED IN JUMPER WIRE BETWEEN PERFORM TEST AND THE PARKING THE NEXT STEP. KEEP STARTER RLY FUSED NS-9C. BRAKE MUST BE ON AWAY FROM MOVING (B+) & OUTPUT CKTS.

FOR THE NEXT STEP. ENGINE PARTS. FIG. 1, 2, 3, 4 OR 5

NO

START

TESTS

843

TEST NS-9B REPAIRING A NO CRANK CONDITION


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5

NO

START

TESTS

844

TEST NS-9B REPAIRING A NO CRANK CONDITION



DISCONNECT THESTART TEST STARTER RELAY.**

NS-9B.


WITH AN OHMMETER,MEASURE THE GROUND IS THE RESISTANCE YES REPAIR THE OPEN

CIRCUIT. ABOVE 5.0 OHMS? STARTER RELAYGROUND CIRCUIT.*

FIG. 1, 2, 3, 4 OR 5

NO

WITH A VOLTMETER, MEASURE THE FUSED IS THE VOLTAGE YES REPAIR THE OPEN

B(+) CIRCUIT. BELOW 10.0 VOLTS? FUSED B(+) CIRCUIT.*

FIG. 1, 2, 3, 4 OR 5

NO

WITH A VOLTMETER, WHILE OBSERVINGMEASURE THE IGNITION VOLTMETER, HOLD IS THE VOLTAGE YES PERFORM TEST

SWITCH OUTPUT IGNITION KEY IN THE ABOVE 10.0 VOLTS? NS-9C. CIRCUIT. START POSITION AND

FIG. 1, 2, 3, 4 OR 5 DEPRESS CLUTCH PEDAL

NO

DISCONNECT THE JUMPER ACROSS THECLUTCH PEDAL CLUTCH PEDAL

POSITION SWITCH POSITION SWITCH LOCATED ON CLUTCH WITH A JUMPER

MASTER CYLINDER. WIRE.

HOLD THE IGNITION IS THE VOLTAGE YES REPLACE THE CLUTCH KEY IN THE START ABOVE 10.0 VOLTS? MASTER CYLINDER.*

POSITION.

NO

CONTINUE TEST NS-9B ON THE

NEXT PAGE.

NO

START

TESTS

845

TEST NS-9B CONTINUED REPAIRING A NO CRANK CONDITION


NOTES

NO

START

TESTS

846

TEST NS-9B CONTINUED REPAIRING A NO CRANK CONDITION



TEST NS-9BCONTINUED FROM DISCONNECT THE

THE PREVIOUS JUMPER WIRE.PAGE.

WITH A VOLTMETER, CHECK FOR VOLTAGE IS THE VOLTAGE AT MEASURE THE IGNITION AT THE CONNECTOR, THE CLUTCH SWITCH NO REPAIR THE OPEN SWITCH OUTPUT AT THE WITH THE IGNITION CONNECTOR ABOVE IGNITION SWITCH

CLUTCH PEDAL SWITCH IN THE 10.0 VOLTS? OUTPUT.* POSITION SWITCH. START POSITION.

YES

REPAIR THE OPEN IGNITION SWITCH

OUTPUT CIRCUITBETWEEN THE CLUTCH SWITCH AND RELAY.*

NO

START

TESTS

847

TEST NS-9C REPAIRING A NO CRANK CONDITION

Perform TEST NS-9A OR NS-9B Before Proceeding

AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5

NO

START

TESTS

848

TEST NS-9C REPAIRING A NO CRANK CONDITION



START TEST DID THE STARTER YES CONTINUE TEST NS-9C. MOTOR CRANK THE NS-9C ON THE

ENGINE? NEXT PAGE.

NO

NOTE IF THESTARTER SOLENOID DISCONNECT THECLICKED WHEN THE JUMPER WIRE.JUMPER WIRE WAS

CONNECTED.

DISCONNECT STARTERRELAY OUTPUT WIRE USE AN OHMMETER IN

FROM THE STARTER THE FOLLOWINGSOLENOID.** STEP.


MEASURE THE FROM THE RELAY TO RESISTANCE OF THE THE SOLENOID IS THE RESISTANCE NO REPAIR THE OPEN

STARTER RELAY CONNECTOR. BELOW 5.O OHMS? STARTER RELAYOUTPUT CIRCUIT... OUTPUT CKT.*

FIG. 1, 2, 3, 4 OR 5

YES

CHECK THE BATTERY DID EITHER BATTERYREINSTALL THE CABLES FOR HIGH CIRCUIT HAVE A YES REPAIR THE BATTERYSTARTER RELAY. RESISTANCE.(USE VOLTAGE DROP CIRCUIT FOR HIGH

SERVICE MANUAL GREATER THAT 0.2 RESISTANCE.* PROCECURE) VOLT?

NO

DID THE STARTERSOLENOID CLICK WHEN NO REPLACE THETHE JUMPER WIRE WAS STARTER SOLENOID.*

PREVIOUSLY CONNECTED?

YES

REPAIR MECHANICAL CONDITION

PREVENTING THESTARTER MOTOR FROM

CRANKING.*

NO

START

TESTS

849

TEST NS-9C CONTINUED - REPAIRING A NO CRANK CONDITION


AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

XJ BODY

FIG. 4

ZJ BODY

FIG. 5

NO

START

TESTS

850

TEST NS-9C CONTINUED - REPAIRING A NO CRANK CONDITION



TEST NS-9C IS THE VEHICLECONTINUED FROM EQUIPPED WITH A YES

THE PREVIOUS MANUAL PAGE. TRANSMISSION?

NO

WITH AN OHMMETER, IN THE STARTER RELAYMEASURE THE P/N CONNECTOR. IS THE RESISTANCE YES REPLACE THEPOSITION SWITCH BELOW 5.0 OHMS? STARTER RELAY.*SENSE CIRCUIT...

FIG. 1, 2, 3, 4 OR 5

NO

REPAIR THE OPEN PARK/NEUTRAL SWITCH

SENSE CIRCUITBETWEEN STARTER

RELAY AND SPLICE.*

NO

START

TESTS

851

TEST NS-10A QUALIFYING A NO START CONDITION (8.0 L ONLY)


FIG. 1

FIG. 2

NO

START

TESTS

852

TEST NS-10A QUALIFYING A NO START CONDITION (8.0 L ONLY)



NOTE: REPAIR ANYSTART TEST DIAGNOSTIC TROUBLE

NS-10A. CODES BEFORE PROCEEDING.

DISCONNECT THESPARK PLUG CABLE

TURN IGNITION OFF. AT SPARK PLUG #1.

FIG. 1

INSERT A SPARK WHILE CRANKING THETESTER IN THE ENGINE FOR 10

CABLE TERMINAL. SECONDS, WATCH FORSPARK.

FIG. 2

NOTE: CONSIDER 1OR 2 SPARKS AS A IS THERE GOOD YES RECONNECT SPARK

NO SPARK SPARK? PLUG CABLE. CONDITION.

NO

PERFORM TEST NS-2A.

INSERT A SPARKRECONNECT SPARK DISCONNECT THE TESTER IN THE CONTINUE TEST

PLUG CABLE. SPARK PLUG CABLE CABLE TERMINAL. NS-1A ON THEAT SPARK PLUG #2. NEXT PAGE.

FIG. 2

NO

START

TESTS

853

TEST NS-10A CONTINUED - QUALIFYING A NO START CONDITION (8.0 L ONLY)

FIG. 1

NO

START

TESTS

854



TEST NS-10A WHILE CRANKING THECONTINUED FROM ENGINE FOR 10

THE PREVIOUS SECONDS, WATCH FORPAGE. SPARK.

NOTE: CONSIDER 1OR 2 SPARKS AS A IS THERE GOOD YES REPLACE SPARK PLUG

NO SPARK SPARK? CABLE #1.CONDITION.

NO

PERFORM TEST NS-2A.

DISCONNECT THE FRONT REPAIR TERMINAL(S)IGNITION COIL IS ANY TERMINAL YES FOR DAMAGE

CONNECTOR.** INSPECT DAMAGED, PUSHED PUSHOUT, OR ALL TERMINALS. OUT, OR MISWIRED? MISWIRING.*

FIG. 1

NO


NEXT PAGE.

NO

START

TESTS

855


FIG. 1

NO

START

TESTS

856



TEST NS-10A ENSURE KEY IS ON.CONTINUED FROM WITH THE DRB,

THE PREVIOUS ACTUATE IGNITION PAGE. COIL #1.

USING A VOLTMETER, REPAIR THE OPEN MEASURE THE ASD IS THE VOLTAGE NO ASD RELAY OUTPUT

RELAY OUTPUT CKT IN ABOVE 10.0 VOLTS? CKT FROM COIL THE IGNITION COIL CONNECTOR TO CONNECTOR. FIG. 1 SPLICE.*

YES

USING SERVICEWITH THE DRB, STOP MANUAL PROCEDURES, IS VALVE TIMING NO REPAIR THE ENGINE

ALL ACTUATIONS. CHECK VALVE WITHIN VALVE TIMING AS TIMING. SPECIFICATIONS? NECESSARY.*

YES


MODULE.*

NO

START

TESTS

857

TEST NS-11A CHECKING THE FUEL SYSTEM (CNG)


AB BODY

FIG. 1

AN AND BR BODIES

FIG. 2

AB BODY

FIG. 3

AN AND BR BODIES

FIG. 4

NO

START

TESTS

858

TEST NS-11A CHECKING THE FUEL SYSTEM (CNG)



START TEST ATTEMPT TO CRANK WAS THE ENGINE NO PERFORM TEST NS-11A. THE ENGINE. ABLE TO CRANK? NS-9A.

YES

TURN IGNITION OFF.

WARNING: READ NOTE: FUEL WARNINGS, CYLINDERS MUST BE

DISCLAIMERS,AND AT LEAST 1/4 FULL SAFETY SECTION IN FOR THE FOLLOWING

INTRODUCTION. TEST.

CHECK THE MANUAL FUEL SHUT-OFF IS THE MANUAL FUEL NO OPEN THE MANUAL

VALVE POSITION. SHUT-OFF VALVE IN FUEL SHUT-OFF THE OPEN POSITION? VALVE.*

FIG. 1 OR 2

YES

CHECK THE FUEL THE VALVE(S) IS THE FUEL CYLINDER MANUAL SHOULD BE FULLY CYLINDER MANUAL NO OPEN FUEL CYLINDER

CONTROL VALVE(S). COUNTERCLOCKWISE CONTROL VALVE(S) MANUAL CONTROLWHEN OPEN. OPEN? VALVES.*

FIG. 3 OR 4

YES

TURN IGNITION ON.CONTINUE TEST

ACTUATE THE ASD NS-11A ON THERELAY. NEXT PAGE.

NO

START

TESTS

859

TEST NS-11A CONTINUED - CHECKING THE FUEL SYSTEM (CNG)

FIG. 1

AN AND BR BODIES

FIG. 2

AB BODY

FIG. 3

NO

START

TESTS

860



TEST NS-11A TOUCH THE LOW DOES THE LOWCONTINUED FROM PRESSURE FUEL PRESSURE FUEL NO PERFORM TEST

THE PREVIOUS SHUT-OFF SOLENOID. SHUT-OFF SOLENOID NS-12A.PAGE. PULSATE WITH

FIG. 1 ACTUATION?

YES

TOUCH THE HIGH IS THE HIGH PRESSURE FUEL PRESSURE FUEL NO PERFORM TEST

SHUT-OFF SOLENOID. SHUT-OFF SOLENOID NS-12B.PULSATING WITH

FIG. 2 OR 3 ACTUATION?

YES

NOTE: THE FUEL GAUGEMUST INDICATE FUEL WITH THE DRB, READ IS THE FUEL YES PERFORM TEST IS PRESENT BEFORE FUEL PRESSURE. PRESSURE BELOW NS-11B.

PERFORMING NEST 90 PSI? STEP.

NO

IS THE FUEL NO CONTINUE TEST PRESSURE ABOVE NS-11A ON THE

134 PSI? NEXT PAGE.

YES

CONNECT A 0 TO 300 TURN IGNITION OFF. PSI PRESSURE GAUGE WITH THE DRB, IS THE FUEL GAUGE YES

TO FUEL SERVICE ACTUATE THE FUEL PRESSURE ABOVE REPLACE THE FUEL PORT. SYSTEM. 140 PSI? PRESSURE FIG. 1 REGULATOR.*

NO


NEXT PAGE.

NO

START

TESTS

861


FIG. 1

FIG. 2

NO

START

TESTS

862



TEST NS-11A DOES THE VEHICLE PURGE NATURAL GASCONTINUED FROM WITH THE DRB, STOP HAVE A FUEL PRESSURE NO FROM THE FUEL RAIL.

THE PREVIOUS ACTUATOR TEST. SERVICE PORT ON THEPAGE. FUEL RAIL?

FIG. 1 SEE GENERAL INFO 9.0

YES

ENSURE THE REINSTALL THE FUEL THROTTLE IS NOT PRESSURE SENSOR.BEING HELD OPEN.

REPAIR CONDITIONIS THE THROTTLE YES THAT HOLDS THE

HELD OPEN? THROTTLE BODY OPEN.*

NO

WITH THE DRB, READ IS THE VOLTAGE NO CONTINUE TEST THROTTLE POSITION ABOVE 1.5 VOLTS? NS-11A ON THE

SENSOR VOLTAGE. NEXT PAGE.

YES

DISCONNECT THE INSPECT THE REPAIR TERMINAL(S)THROTTLE POSITION CONNECTOR FOR IS ANY TERMINAL YES FOR DAMAGE,

SENSOR CONNECTOR.** PROPER WIRING AND DAMAGED, PUSHED PUSHOUT, OR IS FREE OF DIRT. OUT, OR MISWIRED? MISWIRING.*


NO

REPLACE THETHROTTLE POSITION

SENSOR.*

NO

START

TESTS

863



FIG. 1

NO

START

TESTS

864



TEST NS-11A DISCONNECT THECONTINUED FROM INJECTOR #1

THE PREVIOUS CONNECTOR. PAGE.


WITH THE DRB, ACTUATE ALL WITH THE DRB STILL

SOLENOIDS AND ACTUATING, USE ARELAYS. VOLTMETER TO...

MEASURE THE AUTO REPAIR THE OPEN AUTO SHUTDOWN RELAY IS THE VOLTAGE NO SHUTDOWN RELAY

OUTPUT CIRCUIT. ABOVE 10.0 VOLTS? OUTPUT CIRCUIT FROM INJECTOR TO SPLICE.*

FIG. 1

YES

NOTE: THE FUEL DISCONNECT THE LOWPRESSURE MUST BE PRESSURE FUEL READ IMMEDIATELY SHUT-OFF SOLENOID.**

AFTER THE NEXT STEP. SEE GENERAL INFO 4.0

WITH THE DRB, READ IS THE FUEL NO CONTINUE TEST THE FUEL PRESSURE. PRESSURE ABOVE NS-11A ON THE

10 PSI? NEXT PAGE.

YES

RECONNECT THE LOWPRESSURE FUEL PERFORM TEST

SHUT-OFF SOLENOID NS-4A. CONNECTOR.

NO

START

TESTS

865


FIG. 1

NO

START

TESTS

866



TEST NS-11A WITH THE DRB, CONTINUED FROM WITH THE DRB, STOP RECONNECT THE LOW ACTUATE ALL

THE PREVIOUS ACTUATOR TEST. PRESSURE FUEL SOLENOIDS ANDPAGE. SHUT-OFF SOLENOID. RELAYS.

WITH THE DRB, STOP ACTUATOR TEST AND IS THE FUEL YES PERFORM TEST

IMMEDIATELY READ PRESSURE ABOVE NS-13A.THE FUEL PRESSURE. 10 PSI?

NO

REMOVE THE AIRCLEANER ASSEMBLY.

HOLD THE THROTTLE TURN IGNITION OFF. WITH THE DRB, OPEN AND LISTEN IS ESCAPING GAS YES

ACTUATE THE FUEL FOR ESCAPING GAS. HEARD FROM THE ONE OF THE FUEL SYSTEM. THROTTLE AREA? INJECTORS IS

FIG. 1 LEAKING.

NO

REPLACE THETURN IGNITION OFF. LEAKING FUEL

INJECTOR.*

NOTE: THE FUEL LEAK HAS BEEN REPAIR THE GAS

ISOLATED TO THE LEAK AT THE FUEL FUEL RAIL AREA. RAIL.*

NO

START

TESTS

867

TEST NS-11B CHECKING THE FUEL SYSTEM (CNG)


AN AND BR BODIES

FIG. 1

AB BODY

FIG. 2

AN AND BR BODIES

FIG. 3

BR BODY

FIG. 4

NO

START

TESTS

868

TEST NS-11B CHECKING THE FUEL SYSTEM (CNG)



DISCONNECT THE FUEL CONNECT JUMPER WIRE START TEST WITH THE DRB, STOP LOW PRESSURE SENSOR FROM FUEL PRESSURE

NS-11B. ACTUATION TEST. CONNECTOR.** SENSOR SIGNAL TO 5-VOLT SUPPLY CKT.


WITH THE DRB, READ IS THE FUEL NO CONTINUE TEST CNG FUEL PRESSURE. PRESSURE ABOVE NS-11B ON THE

130 PSI? NEXT PAGE.

YES

REPAIR KINKED OR INSPECT ALL FUEL IS THERE ANY KINK YES RESTRICTED FUEL

LINES FOR KINK OR OR RESTRICTION? LINE AS RESTRICTION. NECESSARY.*

NO

PURGE NATURAL GAS DOES THE VEHICLE CONNECT A FUEL FROM THE FUEL RAIL. HAVE A FUEL YES PRESSURE GAUGE TO

TURN IGNITION OFF. PRESSURE SERVICE THE FUEL SERVICEPORT ON THE FUEL PORT. THEN WITH DRB,

SEE GENERAL INFO 9.0 RAIL? ACTUATE FUEL SYSTEM.

NO

REMOVE FUEL PRESSSENSOR & CONNECT A WITH THE DRB, IS THE FUEL YES REPLACE THE FUEL

0-300 PSI PRESS ACTUATE THE FUEL PRESSURE ABOVE 90 PRESSURE SENSOR.* GAUGE TO FUEL RAIL SYSTEM. PSI?


NO

USING SERVICE MANUAL PROCEDURES, REPLACE ATTEMPT TO START DID THE ENGINE YES

THE FUEL FILTER. THE ENGINE. START? TEST COMPLETE.

FIG. 3 OR 4

NO

REPLACE THE FUEL PRESSURE

REGULATOR.*

NO

START

TESTS

869

TEST NS-11B CONTINUED - CHECKING THE FUEL SYSTEM (CNG)

AN AND BR BODIES

FIG. 1

AB BODY

FIG. 2

NO

START

TESTS

870

TEST NS-11B CONTINUED - CHECKING THE FUEL SYSTEM (CNG)


TEST NS-11B CONTINUED FROM REMOVE JUMPER

THE PREVIOUS WIRE.PAGE.

USING A VOLTMETER, REPAIR THE OPEN MEASURE THE 5-VOLT IS THE VOLTAGE NO 5-VOLT SUPPLY CKT

SUPPLY CIRCUIT. ABOVE 4.5 VOLTS? FROM FUEL PRESSURE SENSOR TO SPLICE.*

FIG. 1 OR 2

YES


TURN IGNITION OFF. MODULE.**


USING AN OHMMETER, REPAIR THE FUEL MEASURE THE FUEL IS THE RESISTANCE NO PRESSURE SENSOR PRESSURE SENSOR ABOVE 5.0 OHMS? SIGNAL CKT SHORT

SIGNAL CKT TO GROUND TO GROUND.* FIG. 1 OR 2

YES


MODULE.*

NO

START

TESTS

871

TEST NS-12A CHECKING THE FUEL RELAYS AND SOLENOIDS


AB BODY AN BODY

BR BODY AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

NO

START

TESTS

872

TEST NS-12A CHECKING THE FUEL RELAYS AND SOLENOIDS



START TEST NS-12A. TURN IGNITION OFF.

DISCONNECT THE LOW WITH AN OHMMETER, REPAIR THE OPEN PRESS FUEL SHUT-OFF MEASURE THE GND IS THE RESISTANCE NO GROUND FROM LOW

SOLENOID CONN.** CIRCUIT IN LOW PRESS BELOW 5.0 OHMS? PRESSURE SHUT-OFF SHUT-OFF SOL CONN. SOLENOID TO

SEE GENERAL INFO 4.2 FIG. 1, 2 OR 3 SPLICE.*

YES

WITH A VOLTMETER, WITH THE DRB, MEASURE THE AUTO IS THE VOLTAGE YES REPLACE THE LOW

ACTUATE GENERATOR SHUTDOWN RELAY ABOVE 10.0 VOLTS? PRESSURE SHUT-OFF FIELD. OUTPUT CIRCUIT. SOLENOID.*

FIG. 1, 2 OR 3

NO

DISCONNECT THE AUTO SHUTDOWN RELAY

TURN IGNITION OFF. CONNECTOR.**


WITH A VOLTMETER, REPAIR THE OPEN MEASURE THE ASD IS THE VOLTAGE NO FUSED B(+) CIRCUITRELAY FUSED B(+) ABOVE 10.0 VOLTS? FROM BATTERY TO

CIRCUIT. ASD RELAY.*FIG. 1, 2 OR 3

YES

TEST ASD RLY OUTPUT USE AN OHMMETER IN CKT FROM ASD RLY TO IS THE RESISTANCE YES REPLACE THE AUTO

THE FOLLOWING LOW PRESS SHUT-OFF BELOW 5.0 OHMS? SHUTDOWN RELAY.*STEP. SOLENOID.

FIG. 1, 2 OR 3

NO

REPAIR THE OPEN ASDRELAY OUTPUT CIRCUIT

FROM LOW PRESSURE SHUT-OFF SOLENOID TO

ASD RELAY.*

NO

START

TESTS

873

TEST NS-12B CHECKING THE FUEL RELAYS AND SOLENOIDS


AB BODY AN BODY

BR BODY AB BODY

FIG. 1

AN BODY

FIG. 2

BR BODY

FIG. 3

NO

START

TESTS

874

TEST NS-12B CHECKING THE FUEL RELAYS AND SOLENOIDS



START TEST NS-12B. TURN IGNITION OFF.

DISCONNECT THE HIGH USING AN OHMMETER, REPAIR THE OPEN PRESS FUEL SHUT-OFF MEASURE THE GND IS THE RESISTANCE NO HIGH PRESSURE FUEL

SOLENOID CONN.** CIRCUIT IN THE BELOW 5.0 OHMS? SHUT-OFF SOLENOID SOLENOID CONN. GROUND CIRCUIT.*


YES

USING A VOLTMETER, REPLACE THE FUEL WITH THE DRB, MEASURE THE HIGH IS THE VOLTAGE YES HIGH PRESSURE

ACTUATE FUEL PRESS SHUT-OFF ABOVE 10.0 VOLTS? SHUT-OFF SYSTEM. RELAY OUTPUT CKT. SOLENOID.*

FIG. 1, 2 OR 3

NO

DISCONNECT THE FUEL HIGH PRESSURE

TURN IGNITION OFF. SOLENOID RELAYCONNECTOR.**


USING A VOLTMETER, REPAIR THE OPEN MEASURE THE SHUT-OFF IS THE VOLTAGE NO FUSED B(+) CIRCUIT

RELAY FUSED B(+) ABOVE 10.0 VOLTS? FROM BATTERY TO CIRCUIT. THE HIGH PRESSURE

FIG. 1, 2 OR 3 SHUT-OFF RELAY.*

YES

USING AN OHMMETER, OUTPUT CIRCUIT REPLACE THE HIGH MEASURE THE FROM THE RELAY TO IS THE RESISTANCE YES PRESSURE FUEL

RESISTANCE OF THE THE SHUT-OFF BELOW 5.0 OHMS? SHUT-OFF SOLENOID HIGH PRESSURE SOLENOID. RELAY.*

SHUT-OFF RELAY... FIG. 1, 2 OR 3

NO

REPAIR THE OPEN HIGH PRESS SHUT-OFF RELAYOUTPUT CIRCUIT FROM SHUT-OFF SOLENOID TO

RELAY.*

NO

START

TESTS

875

TEST NS-13A CHECKING FUEL PRESSURE LOSS


NOTES

NO

START

TESTS

876

TEST NS-13A CHECKING FUEL PRESSURE LOSS



NOTE: AN INJECTOR START TEST CONTROL CIRCUIT IS

NS-13A. SHORTED TO GROUND CAUSING THE ENGINE

TO FLOOD.

PERFORM THEWITH THE DRB, READ ARE THERE ANY YES INJECTOR DIAGNOSTIC TROUBLE INJECTOR TROUBLE TROUBLE CODE

CODES. CODES PRESENT? TEST LISTED IN DTC TEST.

NO

DISCONNECT THE DISCONNECT ALL THEPOWERTRAIN CONTROL INJECTOR CONNECTORS

MODULE.**


CHECK EACH INJECTOR REPAIR THEUSING AN CONTROL CIRCUIT FOR WAS ANY INJECTOR YES INJECTOR CONTROL

OHMMETER... A SHORT TO GROUND. CONTROL CIRCUIT CIRCUIT SHORTED TO SHORTED TO GROUND? GROUND.*


NO


MODULE.*

NO

START

TESTS

877

TEST NS-14A CHECKING THE FUEL HEATER RELAY


FIG. 1

FIG. 2

NO

START

TESTS

878

TEST NS-14A CHECKING THE FUEL HEATER RELAY



START TEST NS-14A. TURN IGNITION ON.

NOTE: TO HEAR CLICK WHILE LISTENING FORIN THE NEXT STEP, IT THE RELAY TO CLICK, DID THE RELAY YES CONTINUE TEST MAY BE NECESSARY TO DISCONNECT THE FUEL CLICK? NS-14A ON THEDISCONNECT THE RELAY HEATER RELAY.** NEXT PAGE.

MORE THAN ONCE. FIG. 1

NO

USING A VOLTMETER, MEASURE THE FUSED IS THE VOLTAGE NO REPAIR THE OPEN IGN SWITCH OUTPUT ABOVE 10.0 VOLTS? FUSED IGNITION

CIRCUIT. SWITCH OUTPUT.* FIG. 2

YES

USING AN OHMMETER,MEASURE THE FUEL IS THE RESISTANCE YES REPAIR THE OPEN

TURN IGNITION OFF. HEATER RELAY ABOVE 5.0 OHMS? FUEL HEATER RELAYGROUND CIRCUIT. GROUND CIRCUIT.*

FIG. 2

NO

REPLACE THE FUEL HEATER RELAY.*

NO

START

TESTS

879

TEST NS-14A CONTINUED - CHECKING THE FUEL HEATER RELAY

FIG. 1

FIG. 2 FIG. 3

FIG. 4 FIG. 5

NO

START

TESTS

880

TEST NS-14A CONTINUED - CHECKING THE FUEL HEATER RELAY


TEST NS-14A USING A VOLTMETER, CONTINUED FROM MEASURE THE FUSED IS THE VOLTAGE NO REPAIR THE OPEN

THE PREVIOUS B(+) IN THE HEATER ABOVE 10.0 VOLTS? FUSED B(+) PAGE. RELAY CONN. CIRCUIT.*

FIG. 1

YES

IGNITION OFF. USING AN OHMMETER,DISCONNECT THE FUEL MEASURE THE FUEL IS THE RESISTANCE NO REPAIR THE OPEN

HEATER ELECTRICAL HEATER GROUND BELOW 5.0 OHMS? FUEL HEATER GROUND CONNECTOR.** CIRCUIT. CIRCUIT.*

FIG. 2 FIG. 3

YES

USING AN OHMMETER, FROM THE RELAY TO MEASURE THE THE HEATER IS THE RESISTANCE YES REPAIR THE OPEN

RESISTANCE OF THE CONNECTOR. ABOVE 5.0 OHMS? FUEL HEATER RELAYFUEL HEATER RELAY OUTPUT CIRCUIT.*OUTPUT CIRCUIT... FIG. 4

NO

DISCONNECT THE FUEL REPAIR ANYHEATER ELEMENT IS ANY TERMINAL YES TERMINAL(S) FOR

CONNECTOR.** DAMAGED, PUSHED DAMAGE, PUSHOUT, INSPECT ALL OUT, OR MISWIRED? OR MISWIRING.*

TERMINALS. FIG. 2

NO

NOTE: THE FUEL USING AN OHMMETER, THE NO STARTHEATER TEMPERATURE MEASURE THE IS THE RESISTANCE NO CONDITION IS DUE TO MUST BE BELOW 40F RESISTANCE OF THE ABOVE 10.0 OHMS? A MECHANICAL FOR THE NEXT STEP. FUEL HEATER. PROBLEM. SEE SERVICE

FIG. 2 AND 5 MANUAL FOR REPAIRS.

YES

REPLACE THE FUEL HEATER.*

NO

START

TESTS

881

TEST NS-15A CHECKING THE FUEL SHUTDOWN RELAY AND SOLENOID (DIESEL)


FIG. 1

FIG. 2

NO

START

TESTS

882

TEST NS-15A CHECKING THE FUEL SHUTDOWN RELAY AND SOLENOID (DIESEL)



OBSERVE THESTART TEST EXTENSION OF THE

NS-15A. FUEL SHUTDOWN SOLENOID PLUNGER.

FIG. 1

NOTE: DO NOT TURN THE IGNITION OFF

AFTER CRANKING THE CRANK THE ENGINE.ENGINE FOR 3 SECONDS

IN THE NEXT STEP.

INSPECT THE FUEL THE NO STARTSHUTDOWN SOLENOID IS THE PLUNGER YES CONDITION IS DUE TO

PLUNGER. RETRACTED? A MECHANICAL PROBLEM. SEE SERVICE

FIG. 1 MANUAL FOR REPAIRS.

NO

MANUALLY RETRACT DOES THE PLUNGERTHE FUEL SHUTDOWN REMAIN RETRACTED YES TEST NS-15A

TURN IGNITION ON. SOLENOID PLUNGER WHEN IT IS NO CONTINUED ON AND THEN RELEASE. LONGER MANUALLY THE NEXT PAGE.

HELD IN?

NO

DISCONNECT THE FUEL USING A VOLTMETER, SHUTDOWN SOLENOID.** MEASURE THE FUSED IS THE VOLTAGE NO REPAIR THE OPEN

IGN SWITCH OUTPUT ABOVE 10.0 VOLTS? FUSED IGN. SWITCH CIRCUIT. OUTPUT CKT.*


YES

USING AN OHMMETER,MEASURE THE FUEL IS THE RESISTANCE NO REPAIR THE OPEN

TURN IGNITION OFF. SHUTDOWN SOLENOID BELOW 5.0 OHMS? GROUND CIRCUIT.*GROUND CKT.

YES

REPLACE THE FUEL SHUTDOWN

SOLENOID.*

NO

START

TESTS

883

TEST NS-15A CONTINUED - CHECKING THE FUEL SHUTDOWN RELAY AND SOLENOID (DIESEL)

FIG. 1

FIG. 2

NO

START

TESTS

884



TEST NS-15A DISCONNECT THE FUEL CONTINUED FROM SHUTDOWN SOLENOID

THE PREVIOUS ELECTRICAL PAGE. CONNECTOR.**

FIG. 1

USING A VOLTMETER, MEASURE THE FUEL WHILE CRANKING THE WAS THE VOLTAGE NO CONTINUE TEST

SHUTDOWN RELAY ENGINE, READ ABOVE 10.0 VOLTS? NS-15A ON THEOUTPUT CIRCUIT. VOLTAGE. NEXT PAGE.

FIG. 2

YES

USING AN OHMMETER,MEASURE THE FUEL IS THE RESISTANCE NO REPAIR THE OPEN

TURN IGNITION OFF. SHUTDOWN SOLENOID BELOW 5.0 OHMS? GROUND CIRCUIT.*GROUND CIRCUIT.

FIG. 2

YES

REPLACE THE FUEL SHUTDOWN

SOLENOID.*

NO

START

TESTS

885


FIG. 1

FIG. 2

NO

START

TESTS

886



TEST NS-15A IGNITION OFF. CONTINUED FROM

THE PREVIOUS DISCONNECT THE FUEL PAGE. SHUTDOWN RELAY.**

FIG. 1

MEASURE THE FUEL REPAIR THE OPEN USE AN OHMMETER IN SHUTDOWN RELAY IS THE RESISTANCE NO FUEL SHUTDOWN

THE FOLLOWING OUTPUT CIRCUIT FOR BELOW 5.0 OHMS? RELAY OUTPUT STEP. RESISTANCE. CIRCUIT.*

FIG. 2

YES

USING A VOLTMETER, MEASURE THE FUSED IS THE VOLTAGE NO REPAIR THE OPEN

B(+) CIRCUIT IN THE ABOVE 10.0 VOLTS? FUSED B(+).* SHUTDOWN RELAY CONN.

FIG. 2

YES

USING AN OHMMETER,MEASURE THE SHUTDOWN IS THE RESISTANCE YES REPAIR THE OPEN RELAY GROUND CIRCUIT ABOVE 5.0 OHMS? RELAY GROUND IN RELAY CONNECTOR. CIRCUIT.*

FIG. 2

NO

DISCONNECT THE USING AN OHMMETER,STARTER RELAY.** MEASURE THE

RESISTANCE OF THESTARTER RELAY

FIG. 3 OUTPUT CIRCUIT...

FROM THE FUEL SHUTDOWN RELAY TO IS THE RESISTANCE YES REPAIR THE OPEN THE STARTER RELAY. ABOVE 5.0 OHMS? STARTER RELAY

OUTPUT CIRCUIT.*FIG. 3

NO

REPLACE THE FUEL SHUTDOWN RELAY.*

NO

START

TESTS

887

TEST VER-1A NO START VERIFICATION

Inspect the vehicle to ensure that all engine components are connected. Reassemble and reconnectcomponents as necessary.

Inspect the engine for contamination. If it is contaminated, change the oil and filter.

Attempt to start the engine.

If the engine is unable to start, look for any Technical Service Bulletins that may relate to thiscondition. Return to DTC TEST if necessary.

The repair is now complete.

VERIFICATION

TESTS

888

TEST VER-2A ROAD TEST VERIFICATION

Inspect the vehicle to ensure that all engine components are connected. Reassemble and reconnectall components as necessary.

If this verification procedure is being performed after a NO TROUBLE CODE test, do thefollowing:

1. Check to see if the initial symptom still exists.

2. If the initial or another symptom exists, the repair is not complete. Check all pertinent TechnicalService Bulletins and return to DTC TEST, if necessary.

If this verification procedure is being performed after an OBDII trouble code test, performVER-5. For all other trouble codes, continue with this verification.

For previously read trouble codes that have not been dealt with, return to DTC TEST and follow thepath specified; otherwise continue.

If the powertrain control module has not been changed:

1. Connect the DRB to the PCM data link connector and erase trouble codes.

2. With the DRB, reset all values in the adaptive memory.

3. Disconnect the DRB.

Ensure no trouble code remains by doing the following:

1. If this test is for an A/C Relay Control Circuit Code, drive the vehicle for at least five minuteswith the A/C on. For some of the drive, go at least 40 mph; at some point stop the car and turnthe engine off for 10 seconds or more; then restart and continue. Ensure the transmission shiftsthrough all gears. Upon completion of the road test, turn the engine off, and read trouble codeswith the DRB.

2. If the repaired code has reset, the repair is not complete. Check all related Technical ServiceBulletins and return to DTC TEST if necessary. If another trouble code has set, return to DTCTEST and follow the path specified for that trouble code. If there are no trouble codes, the repairwas successful and is now complete.

VERIFICATION

TESTS

889

TEST VER-3A CHARGING VERIFICATION


If the powertrain control module has been changed, do the following:

1. If the vehicle is equipped with a factory theft alarm, start the vehicle at least 20 times so that thealarm system may be activated when desired.

Connect the DRB to the PCM data link connector and erase the codes.

Ensure no other charging system problems remain by doing the following:

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 Bulletinsand return to DTC TEST if necessary.

If there are no codes, the repair is now complete.

VERIFICATION

TESTS

890

TEST VER-4A SPEED CONTROL VERIFICATION


If the powertrain control module has been changed, do the following:

1. If the vehicle is equipped with a factory theft alarm, start the vehicle at least 20 times so that thealarm system may be activated when desired.

Connect the DRB to the PCM data link connector and erase the codes.

Ensure no other speed control problems remain by doing the following:

1. Road test the vehicle at a speed above 35 mph.

2. Turn the speed control ON/OFF switch to the ON position.

3. Depress and release the SET switch. If the speed control did not engage, the repair is notcomplete.*

4. Quickly depress and release the RESUME/ACCEL switch. If the vehicle speed did not increaseby 2 mph, the repair is not complete.*

5. Using caution, depress and release the brake pedal. If the speed control did not disengage. Therepair is not complete.*

6. Bring the vehicle speed back up to 35 mph.

7. Depress the RESUME/ACCEL switch. If the speed control did not resume the previously setspeed, the repair is not complete.*

8. Hold down the SET switch. If the vehicle did not decelerate, the repair is not complete.*

9. Ensure the vehicle speed is greater than 35 mph and release the SET switch. If the vehicle didnot adjust and set a new vehicle speed, the repair is not complete.*

10. Turn on the ON/OFF switch to the OFF position. If the speed control did not disengage, therepair is not complete.*

If the vehicle successfully passed all of the previous tests, the speed control system is nowfunctioning as designed. The repair is now complete.

*Check for Technical Service Bulletins that pertain to this speed control problem and then, ifnecessary, return to DTC TEST.

VERIFICATION

TESTS

891

TEST VER-5A ROAD TEST FOR OBDII TROUBLE CODES


If there are any existing diagnostic trouble codes that have not been repaired, perform DTC TESTand follow the path specified. After all diagnostic trouble codes have been repaired, return to TESTVER-5A and run the monitor for the previously repaired OBDII trouble code.

1. Connect the DRB to the data link connector.

2. Ensure the fuel tank has at least a quarter tank of fuel.

3. Turn the air conditioning off.

4. The proper way to verify that the trouble code has been repaired is to allow the powertraincontrol module to run the monitor. The technician can see the monitor using the DRBIII. Theenabling conditions must be met before the powertrain control module will run the monitor. Theenabling conditions for the covered OBDII codes can be found in each trouble code test. Readthe enabling conditions for the trouble code that was repaired. The enabling conditions aredifferent 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 theDRBIII.

6. If the repaired OBDII trouble code has reset or was seen in the OBDII monitor while on the roadtest, the repair is not complete. Check for any related Technical Service Bulletins and return toDTC TEST.

— If another trouble code has set, return to DTC TEST and follow the path specified for thattrouble code.

— If there are no trouble codes, the repair was successful and is now complete.

VERIFICATION

TESTS

892

8.0 MAINTENANCE AND SERVICE INFORMATION

There is no specific maintenance or service information in this manual. Refer to the appropriateservice 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 systemoverload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that mustbe corrected.

9.0 SPECIFICATIONS

9.1 Fuel System Release Procedure (Gasoline)

1. Loosen the fuel filler cap.

2. Remove the fuel pump relay.

3. Start and run engine until it stalls.

4. Attempt to restart the engine until it will no longer run.

5. Ensure the ignition key is off.

6. If the vehicle is equipped with a fuel pressure test port perform the following steps. Forall others go to number 7 below.

a. Remove the protective cap from the fuel pressure test port.b. Use the hose with fitting, from pressure tool set 5069. Place the open end of the

fuel pressure release hose, with gauge removed, into an approved gasolinecontainer.

c. Place a shop towel under the fuel pressure test port.d. Connect the fitting end of the fuel hose to the fuel pressure test port.e. After all fuel pressure is relieved, remove hose and reinstall test port cap.

7. This step is for engines without a fuel pressure test port.

a. Unplug the connector from any injector.b. Attach jumper wires to both pins on the injector.c. Attach the other end of one jumper wire to a good ground.d. Touch the loose end of the remaining jumper wire to B+ for no more than 4

seconds. Repeat this twice.

8. With fuel pressure relieved the fuel system can now be opened for required work.Continue to use caution, fuel leakage is still possible.

9.2 Fuel System Pressure Release Procedure (CNG)

9.2.1 Fuel Line Pressure Release Procedure

1. Close the fuel control valves on all cylinder(s) by turning the valves completelyclockwise.

2. Ensure the manual shut-off valve is in the open position. The valve is open when thehandle is parallel with the fuel tubes.

3. 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.

GENERAL

INFORMATION

893

4. Pausing 10 seconds between attempts, repeat step 3 two more times.

5. If the check valve or fuel fill receptacle is to be serviced, slowly loosen the inlet side ofthe fuel fill tube fitting at the check valve until fuel has purged.

WARNING: THE FUEL CYLINDERS STILL CONTAIN HIGH-PRESSURE FUEL.

9.2.2 Fuel Cylinder Pressure Release Procedure

1. Close the fuel control valves on the cylinders not being serviced by turning the valvescompletely clockwise.

2. Ensure the manual shut-off valve is in the open position. The valve is open when thehandle is parallel with the fuel tubes.

3. Start the engine and let it run until the fuel is depleted.

4. Attempt to start the engine by cranking for 6 seconds.

5. Pausing 10 seconds between attempts, repeat steps 3 and 4 two more times.

WARNING: THE FUEL CYLINDERS THAT ARE NOT BEING SERVICED STILL CONTAINHIGH-PRESSURE FUEL.

GENERAL

INFORMATION

894

10.0 SCHEMATIC DIAGRAMS

10.1 1996 Dodge 2.5L JTEC System

GENERAL

INFORMATION

895

10.2 1996 Jeep XJ 2.5L JTEC SystemGENERAL

INFORMATION

896

10.3 1996 Jeep XJ 4.0L JTEC System GENERAL

INFORMATION

897

10.4 1996 Jeep ZJ 4.0L JTEC SystemGENERAL

INFORMATION

898

10.5 1996 Dodge 3.9L JTEC System GENERAL

INFORMATION

899

10.6 1996 Dodge 5.2/5.9L JTEC SystemGENERAL

INFORMATION

900

10.7 1996 Jeep ZJ 5.2L JTEC System GENERAL

INFORMATION

901

10.8 1996 Dodge 5.9L-HD JTEC SystemGENERAL

INFORMATION

902

10.9 1996 Dodge 5.9L Cummins Diesel JTEC System GENERAL

INFORMATION

903

10.10 1996 Dodge 8.0L V10-MD SystemGENERAL

INFORMATION

904

10.11 1996 Dodge 8.0L V10-HD System GENERAL

INFORMATION

905

10.12 1996 Dodge 5.2L CNG, AB, AN, and BR SystemGENERAL

INFORMATION

906

11.0 REQUIRED TOOLS AND EQUIPMENT

DRB (diagnostic read-out box)fuel line adapters 6541, 6539, 6631 or 6923fuel pressure test kit 5069fuel pressure test kit C-4799-BDiesel only: fuel pressure test kit 6977jumper wiresohmmeteroscilloscopevacuum gaugevoltmeterpressure gauge (0-300 psi)

12.0 GLOSSARY OF TERMS

backfire, popback - Fuel ignites in either the intake or the exhaust system.

CKP - crank position sensor

CMP - camshaft position sensor

cuts out, misses - a steady pulsation or the inability of the engine to maintain aconsistent rpm

DLC - data link connector (previously called ‘‘engine diagnostic connector’’)

detonation, spark knock - a mild to severe ping, especially under loaded engineconditions

ECT - engine coolant temperature sensor

EGR - exhaust gas recirculation valve and system

generator - previously callled ‘‘alternator’’

hard start - The engine takes longer than usual to start, even though it is able tocrank normally.

hesitation, sag, stuble - There is a momentary lack of response when the throttle isopened. This can occur at all vehicle speeds. If it is severeenough, the engine may stall.

IAT - intake air temperature sensor

IAC - idle air control valve

JTEC - Combined engine and transmission control module

lack of power, sluggish - The engine has less than expected power, with little or noincrease in vehicle speed when the throttle is opened.

MAP - manifold absolute pressure sensor

MTV - manifold tuning valve

MVLPS - manual valve lever position switch (previously called ‘‘park/neutral switch’’)

O2S - oxygen sensor (left oxygen sensor when there are two sensors)

O2SR - right oxygen sensor

GENERAL

INFORMATION

907

PCM - powertrain control module

PCV - positive crankcase ventilation

poor fuel economy - There is significantly less fuel mileage than other vehicles of thesame design and configuration.

rough, unstable, orerratic 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 severeenough.

start & stall - The engine starts but immediately dies.

surge - engine rpm fluctuation without corresponding change in throttle positionsensor

TPS - throttle position sensor

VSS - vehicle speed sensor

12.1 Body Codes Defined

CARS

F24S Eagle TalonFJ22 Chrysler Sebring

Dodge AvengerGS Chrysler Grand Voyager

Chrysler Ram VanJA Chrysler Cirrus

PlymouthDodge Stratus

JX Chrysler Sebring ConvertibleLH Chrysler Concorde

Chrysler LHSChrysler New YorkerDodge IntrepidEagle Vision

NS Chrysler Town and CountryDodge Caravan /Grand CaravanPlymouth Voyager /Grand Voyager

PL Dodge NeonPlymouth Neon

SR27 Dodge Viper RoadsterSR29 Dodge Viper Coupe

TRUCKS

AB Dodge Ram 150, 250, 350(Van / Wagon)

AN Dodge DakotaBR Dodge Ram 1500, 2500,

3500 (Pickup)BT Dodge Ram 1500, 2500,

3500 (Cab)

TJ Jeep WranglerXJ Jeep CherokeeZJ Jeep Grand Cherokee

GENERAL

INFORMATION

908

NOTES GENERAL

INFORMATION

909

1996 dakota gas powertrain diagnostics

Documents

repairing trans

repairing eeprom

repairing map sensor

repairing ect sensor

repairing ignition coil

repairing generator

fuel control

spark control