International CV-Series Models Repair Service Manual 2018-2020
Complete service repair manual with Electrical Wiring Diagrams for 2018-2020 International CV-Series Trucks, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
2018-2020 International CV-Series Trucks workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 5,407 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
0001111853 - 2018-2020 International CV Technician Manual (Service and Diagnostics).pdf
MAIN SECTIONS
toc...3
Table of Contents...3
Safety Terminology...6
Safety Instructions...6
Work Area...6
Safety Equipment...6
Protective Measures...6
Vehicle...6
Engine...7
Fire Prevention...7
Batteries...7
Compressed Air...7
Tools...7
Fluids Under Pressure...8
Fuel...8
Removal of Tools, Parts, and Equipment...8
General Information...9
1. General Information...11
Introduction...11
Graphic Colors and Graphic Symbols...11
Vehicle, Engine and Transmission ID and VIN Location, Derivative and Usage...12
Vehicle Certification Label...14
Feature Code List...15
Vehicle Symptom Diagnostics...27
1. Noise, Vibrations, and Harshness (NVH)...29
Cab...29
Noise in Steering Column...29
Looseness in Steering Column...32
Air Pressure Test...34
Overview...34
Special Tools...34
Equipment Condition...34
Test Setup...34
Test Procedure...34
Follow-On Procedure...34
Soap Suds or Bubble Test...35
Overview...35
Special Tools...35
Equipment Condition...35
Test Setup...35
Test Procedure...35
Follow-On Procedure...35
Tracing Powder or Chalk Test...36
Overview...36
Special Tools...36
Equipment Condition...36
Test Setup...36
Test Procedure...36
Follow-On Procedure...36
Interior Wind Noise Inspection...37
Overview...37
Special Tools...37
Equipment Condition...37
Inspection Procedure...37
Follow-On Procedure...37
Exterior Wind Noise Inspection...38
Overview...38
Special Tools...38
Equipment Condition...38
Inspection Procedure...38
Follow-On Procedure...39
Chassis...40
Brake System Noise...40
Power Steering System Rattle, Clunk, Pop or Shudder Noise...43
Power Steering System Whine or Growl Noise...46
Engine...47
Exhaust Noise Diagnostics...47
Overview...47
Repair Instructions...47
Generator Noise Diagnostics...48
Diagnostic Aids...48
Circuit / System Testing...48
Repair Instructions...48
Starter Noise Diagnostics...49
Diagnostic Instructions...49
Circuit / System Description...49
Reference Information...49
Description and Operation...49
Circuit / System Verification...49
Circuit / System Testing...49
Repair Instructions...49
Collision...51
1. Inspections...53
Overview...53
Repairs and Inspections Required After a Collision...53
Accident With or Without Air Bag Deployment Inspection...54
Overview...54
Special Tools...54
Equipment Condition...54
Inspection Procedure...54
Follow-On Procedure...54
Accident With Frontal Air Bag Deployment Inspection...55
Overview...55
Special Tools...55
Equipment Condition...55
Replacement Procedures...55
Inspection Procedure...55
Follow-On Procedure...55
Accident With Side Seat Air Bag Deployment Inspection...56
Overview...56
Special Tools...56
Equipment Condition...56
Replacement Procedures...56
Inspection Procedure...56
Follow-On Procedure...56
Accident With Seat Belt Pretensioner Deployment Only Inspection...57
Overview...57
Special Tools...57
Equipment Condition...57
Replacement Procedures...57
Inspection Procedure...57
Follow-On Procedure...57
Steering Column Accident Damage Inspection...58
Overview...58
Special Tools...58
Equipment Condition...58
Inspection Procedure...58
Follow-On Procedure...60
Frame and Bumper...61
1. Frame...63
Back Up Alarm...63
Removal...63
Overview...63
Special Tools...63
Equipment Condition...63
Procedure...64
Follow-On Procedure...64
Installation...65
Overview...65
Special Tools...65
Equipment Condition...65
Procedure...66
Follow-On Procedure...66
Cross Members...67
Transmission Support Cross Member Four-Wheel Drive (4WD)...67
Removal...67
Overview...67
Special Tools...67
Equipment Condition...67
Procedure...67
Follow-On Procedure...69
Installation...70
Overview...70
Special Tools...70
Equipment Condition...70
Procedure...70
Follow-On Procedure...72
Transmission Support Cross Member Two-Wheel Drive (2WD)...73
Removal...73
Overview...73
Special Tools...73
Equipment Condition...73
Procedure...73
Follow-On Procedure...75
Installation...76
Overview...76
Special Tools...76
Equipment Condition...76
Procedure...76
Follow-On Procedure...78
Frame Rails...79
Lifting and Jacking the Vehicle...79
Overview...79
Special Tools...79
Equipment Conditions...79
Procedure...80
Follow-On Procedure...80
Shields...81
Overview...81
Front Compartment Splash Shield Replacement (Hood)...82
Removal...82
Overview...82
Special Tools...82
Equipment Conditions...82
Procedure...83
Follow-On Procedure...83
Installation...84
Overview...84
Special Tools...84
Equipment Conditions...84
Procedure...84
Follow-On Procedure...85
Front Compartment Splash Shield Replacement (Frame)...86
Removal...86
Overview...86
Special Tools...86
Equipment Conditions...86
Procedure...87
Follow-On Procedure...87
Installation...88
Overview...88
Special Tools...88
Equipment Conditions...88
Procedure...88
Follow-On Procedure...89
Transfer Case Skid Shield Four-Wheel Drive (4WD)...90
Removal...90
Overview...90
Special Tools...90
Equipment Condition...90
Procedure...90
Follow-On Procedure...91
Installation...92
Overview...92
Special Tools...92
Equipment Condition...92
Procedure...92
Follow-On Procedure...92
2. Bumper...93
Overview...93
Front License Plate Bracket...94
Removal...94
Overview...94
Special Tools...94
Equipment Condition...94
Procedure...95
Follow-On Procedure...95
Installation...96
Overview...96
Special Tools...96
Equipment Condition...96
Procedure...97
Follow-On Procedure...97
Horn...98
Removal...98
Overview...98
Special Tools...98
Equipment Condition...98
Procedure...99
Follow-On Procedure...99
Installation...100
Overview...100
Special Tools...100
Equipment Condition...100
Procedure...100
Follow-On Procedure...101
Front Axle...103
1. Front Driving Axle...105
Dana Spicer®...105
Differential Drive Pinion Gear Seal...105
Removal...105
Overview...105
Special Tools...105
Equipment Condition...105
Procedure...106
Follow-On Procedure...113
Installation...114
Overview...114
Special Tools...114
Equipment Condition...114
Procedure...115
Follow-On Procedure...121
Drive Pinion and Ring Gear...122
Removal...122
Overview...122
Special Tools...122
Equipment Condition...122
Procedure...123
Follow-On Procedure...133
Installation...134
Overview...134
Special Tools...134
Equipment Condition...134
Procedure...135
Follow-On Procedure...143
Front Axle Shaft...144
Removal...144
Overview...144
Special Tools...144
Equipment Condition...144
Procedure...145
Follow-On Procedure...145
Installation...146
Overview...146
Special Tools...146
Torque Specifications...146
Equipment Condition...146
Procedure...146
Follow-On Procedure...147
Front Differential...148
Removal...148
Overview...148
Special Tools...148
Equipment Condition...148
Procedure...149
Follow-On Procedure...152
Installation...153
Overview...153
Special Tools...153
Equipment Condition...153
Procedure...153
Follow-On Procedure...157
Disassembly...158
Overview...158
Special Tools...158
Equipment Condition...158
Procedure...159
Follow-On Procedure...163
Assembly...164
Overview...164
Special Tools...164
Torque Specifications...164
Equipment Condition...164
Procedure...164
Follow-On Procedure...173
Front Differential Carrier Cover and Gasket...174
Removal...174
Overview...174
Special Tools...174
Equipment Condition...174
Procedure...175
Follow-On Procedure...175
Installation...176
Overview...176
Special Tools...176
Equipment Condition...176
Procedure...176
Follow-On Procedure...177
Front Wheel Hub...178
Removal...178
Overview...178
Special Tools...178
Equipment Condition...178
Procedure...179
Follow-On Procedure...181
Installation...182
Overview...182
Equipment Condition...182
Procedure...182
Follow-On Procedure...187
Steering Knuckle...188
Removal...188
Overview...188
Special Tools...188
Equipment Conditions...188
Procedure...189
Follow-On Procedure...190
Installation...191
Overview...191
Special Tools...191
Equipment Conditions...191
Procedure...192
Follow-On Procedure...193
Differential Carrier Bearing Preload Adjustment...195
Overview...195
Special Tools...195
Equipment Condition...195
Procedure...195
Follow-On Procedure...213
Backlash Inspection and Adjustment...214
Overview...214
Special Tools...214
Equipment Condition...214
Procedure...214
Follow-On Procedure...215
2. Front Non-Driving Axle...216
Dana Spicer®...216
Overview...216
Front Axle (Non-Driving Axle)...217
Removal...217
Overview...217
Special Tools...217
Equipment Condition...217
Procedure...218
Follow-On Procedure...219
Installation...220
Overview...220
Special Tools...220
Equipment Condition...220
Procedure...220
Follow-On Procedure...221
Front Wheel Bearing and Hub...222
Removal...222
Overview...222
Special Tools...222
Equipment Condition...222
Procedure...223
Follow-On Procedure...226
Installation...227
Overview...227
Special Tools...227
Equipment Condition...227
Procedure...227
Follow-On Procedure...230
Steering Knuckle...231
Removal...231
Overview...231
Special Tools...231
Equipment Condition...231
Procedure...232
Follow-On Procedure...233
Installation...234
Overview...234
Special Tools...234
Equipment Condition...234
Procedure...234
Follow-On Procedure...236
Steering Knuckle King Pin Bushing...237
Removal...237
Overview...237
Special Tools...237
Equipment Condition...237
Procedure...238
Follow-On Procedure...238
Installation...239
Overview...239
Special Tools...239
Equipment Condition...239
Procedure...239
Follow-On Procedure...240
Wheel Stud...241
Removal...241
Overview...241
Special Tools...241
Equipment Condition...241
Procedure...242
Follow-On Procedure...242
Installation...243
Overview...243
Special Tools...243
Torque Specifications...243
Equipment Condition...243
Procedure...243
Follow-On Procedure...244
Front Wheel Spindle Replacement...245
Removal...245
Overview...245
Special Tools...245
Equipment Conditions...245
Procedure...246
Follow-On Procedure...248
Installation...249
Overview...249
Special Tools...249
Equipment Conditions...249
Procedure...249
Follow-On Procedure...251
Front Suspension...253
1. Suspension Systems...255
Parabolic Taper Leaf Spring...255
Overview...255
Leaf Springs...255
Stabilizer Bar...255
Front Spring Replacement (Left Driving Axle)...256
Removal...256
Overview...256
Special Tools...256
Equipment Condition...256
Procedure...257
Follow-On Procedure...259
Installation...260
Overview...260
Special Tools...260
Equipment Condition...260
Procedure...260
Follow-On Procedure...262
Front Spring Replacement (Right Driving Axle)...263
Removal...263
Overview...263
Special Tools...263
Equipment Condition...263
Procedure...264
Follow-On Procedure...266
Installation...267
Overview...267
Special Tools...267
Equipment Condition...267
Procedure...267
Follow-On Procedure...269
Front Spring Replacement (Non-Driving Axle)...270
Removal...270
Overview...270
Special Tools...270
Equipment Condition...270
Procedure...271
Follow-On Procedure...273
Installation...274
Overview...274
Special Tools...274
Equipment Condition...274
Procedure...274
Follow-On Procedure...276
Front Spring Shackle Replacement (Driving Axle)...278
Removal...278
Overview...278
Special Tools...278
Equipment Condition...278
Procedure...279
Follow-On Procedure...279
Installation...280
Overview...280
Special Tools...280
Equipment Condition...280
Procedure...280
Follow-On Procedure...281
Front Spring Shackle Replacement (Non-Driving Axle)...282
Removal...282
Overview...282
Special Tools...282
Equipment Condition...282
Procedure...283
Follow-On Procedure...283
Installation...284
Overview...284
Special Tools...284
Equipment Condition...284
Procedure...284
Follow-On Procedure...284
Shock Absorber (Driving Axle)...286
Removal...286
Overview...286
Special Tools...286
Equipment Condition...286
Procedure...286
Follow-On Procedure...287
Installation...288
Overview...288
Special Tools...288
Equipment Condition...288
Procedure...288
Follow-On Procedure...289
Shock Absorber Replacement (Non-Driving Axle)...290
Removal...290
Overview...290
Special Tools...290
Equipment Condition...290
Procedure...290
Follow-On Procedure...291
Installation...292
Overview...292
Special Tools...292
Equipment Condition...292
Procedure...292
Follow-On Procedure...293
Spring Bumper Replacement (Left Driving Axle)...294
Removal...294
Overview...294
Special Tools...294
Equipment Condition...294
Procedure...295
Follow-On Procedure...296
Installation...297
Overview...297
Special Tools...297
Equipment Condition...297
Procedure...297
Follow-On Procedure...298
Spring Bumper Replacement (Right Driving Axle)...299
Removal...299
Overview...299
Special Tools...299
Equipment Condition...299
Procedure...300
Follow-On Procedure...301
Installation...302
Overview...302
Special Tools...302
Equipment Condition...302
Procedure...302
Follow-On Procedure...303
Spring Bumper Replacement (Non-Driving Axle)...304
Removal...304
Overview...304
Special Tools...304
Equipment Condition...304
Procedure...305
Follow-On Procedure...306
Installation...307
Overview...307
Special Tools...307
Equipment Condition...307
Procedure...307
Follow-On Procedure...308
Stabilizer Shaft...310
Removal...310
Overview...310
Special Tools...310
Equipment Condition...310
Procedure...310
Follow-On Procedure...312
Installation...313
Overview...313
Special Tools...313
Equipment Condition...313
Procedure...313
Follow-On Procedure...316
Stabilizer Shaft Bushing...317
Removal...317
Overview...317
Special Tools...317
Equipment Condition...317
Procedure...317
Follow-On Procedure...319
Installation...320
Overview...320
Special Tools...320
Equipment Condition...320
Procedure...320
Follow-On Procedure...322
Stabilizer Shaft Link...323
Removal...323
Overview...323
Special Tools...323
Equipment Condition...323
Procedure...323
Follow-On Procedure...324
Installation...325
Overview...325
Special Tools...325
Equipment Condition...325
Procedure...325
Follow-On Procedure...325
Brakes...327
1. Air Systems...331
Air Compressors...331
Yoosung Air Compressor...331
Removal...331
Overview...331
Special Tools...331
Equipment Condition...331
Procedure...332
Follow-On Procedure...341
Installation...342
Overview...342
Special Tools...342
Equipment Condition...342
Procedure...343
Follow-On Procedure...352
Unloader Valve...353
Removal...353
Overview...353
Special Tools...353
Equipment Condition...353
Procedure...354
Follow-On Procedure...355
Installation...356
Overview...356
Special Tools...356
Equipment Condition...356
Procedure...356
Follow-On Procedure...357
Unloader Valve Pressure Switch...358
Removal...358
Overview...358
Special Tools...358
Equipment Condition...358
Procedure...359
Follow-On Procedure...359
Installation...360
Overview...360
Special Tools...360
Torque Specifications...360
Equipment Condition...360
Procedure...360
Follow-On Procedure...361
Air Lines...362
Air Compressor Discharge Line...362
Removal...362
Overview...362
Special Tools...362
Equipment Condition...362
Procedure...363
Follow-On Procedure...363
Installation...364
Overview...364
Special Tools...364
Equipment Condition...364
Procedure...365
Follow-On Procedure...365
Air Compressor Discharge Hose...366
Removal...366
Overview...366
Special Tools...366
Equipment Condition...366
Procedure...367
Follow-On Procedures...367
Installation...368
Overview...368
Special Tools...368
Equipment Condition...368
Procedure...369
Follow-On Procedure...369
Air Compressor Fresh Air Inlet Line...370
Removal ...370
Overview...370
Special Tools...370
Equipment Condition...370
Procedure...371
Follow-On Procedure...371
Installation...372
Overview...372
Special Tools...372
Torque Specifications...372
Equipment Condition...372
Procedure...372
Follow-On Procedure...373
Air Compressor Oil Return Line...374
Removal...374
Overview...374
Special Tools...374
Equipment Condition...374
Procedure...375
Follow-On Procedure...375
Installation...376
Overview...376
Special Tools...376
Equipment Condition...376
Procedure...376
Follow-On Procedure...377
Air Compressor Oil Supply Line...378
Removal...378
Overview...378
Special Tools...378
Equipment Condition...378
Procedure...379
Follow-On Procedure...379
Installation...380
Overview...380
Special Tools...380
Equipment Condition...380
Procedure...380
Follow-On Procedure...381
Air Supply Line (Air Filter Dryer to Air Pressure Tank)...382
Removal...382
Overview...382
Special Tools...382
Equipment Condition...382
Procedure...383
Follow-On Procedure...384
Installation...385
Overview...385
Special Tools...385
Torque Specifications...385
Equipment Condition...385
Procedure...385
Follow-On Procedure...386
Air Unloader Line (Air Compressor to Dryer)...387
Removal...387
Overview...387
Special Tools...387
Equipment Condition...387
Procedure...388
Follow-On Procedure...388
Installation...389
Overview...389
Special Tools...389
Torque Specifications...389
Equipment Condition...389
Procedure...389
Follow-On Procedure...390
Air Unloader Line (Unloader Valve to Air Pressure Tank)...391
Removal...391
Overview...391
Special Tools...391
Equipment Condition...391
Procedure...392
Follow-On Procedure...393
Installation...394
Overview...394
Special Tools...394
Torque Specifications...394
Equipment Condition...394
Procedure...394
Follow-On Procedure...395
Air Tanks...396
Removal...396
Overview...396
Special Tools...396
Equipment Condition...396
Procedure...396
Follow-On Procedure...396
Installation...397
Overview...397
Special Tools...397
Equipment Condition...397
Procedure...397
Follow-On Procedure...397
Automatic Level Control Air Supply Reservoir...398
Removal...398
Overview...398
Special Tools...398
Equipment Condition...398
Procedure...399
Follow-On Procedure...400
Installation...401
Overview...401
Special Tools...401
Equipment Condition...401
Procedure...402
Follow-On Procedure...403
Air Dryer...404
WABCO Air Filter Dryer Assembly...404
Removal...404
Overview...404
Special Tools...404
Equipment Condition...404
Procedure...405
Follow-On Procedure...406
Installation...407
Overview...407
Special Tools...407
Equipment Condition...407
Procedure...408
Follow-On Procedure...409
WABCO Air Filter Dryer Cartridge...410
Removal...410
Overview...410
Special Tools...410
Equipment Condition...410
Procedure...411
Follow-On Procedure...411
Installation...412
Overview...412
Torque Specifications...412
Equipment Condition...412
Procedure...412
Follow-On Procedure...413
2. Hydraulic Brakes – Foundation...414
Disc Brakes...414
Front Brake Caliper Two-Wheel (2WD) Replacement...414
Removal...414
Overview...414
Special Tools...414
Equipment Conditions...414
Procedure...415
Follow-On Procedure...418
Installation...419
Overview...419
Special Tools...419
Equipment Conditions...419
Procedure...420
Follow-On Procedure...423
Front Brake Caliper Replacement (4WD)...424
Removal...424
Overview...424
Special Tools...424
Equipment Conditions...424
Procedure...425
Follow-On Procedure...428
Installation...429
Overview...429
Special Tools...429
Equipment Conditions...429
Procedure...430
Follow-On Procedure...433
Rear Brake Caliper Replacement...434
Removal...434
Overview...434
Special Tools...434
Equipment Conditions...434
Procedure...435
Follow-On Procedure...437
Installation...437
Overview...437
Special Tools...437
Equipment Conditions...438
Procedure...439
Follow-On Procedure...441
Front Brake Caliper Overhaul...442
Disassembly...442
Overview...442
Special Tools...442
Equipment Condition...442
Procedure...443
Follow-On Procedure...444
Reassembly...445
Overview...445
Special Tools...445
Torque Specifications...445
Equipment Condition...445
Procedure...445
Follow-On Procedure...447
Front Brake Caliper Bracket...448
Removal...448
Overview...448
Special Tools...448
Equipment Condition...448
Procedure...449
Follow-On Procedure...450
Installation...451
Overview...451
Special Tools...451
Equipment Condition...451
Procedure...452
Follow-On Procedure...454
Front Brake Caliper Hardware...455
Removal...455
Overview...455
Special Tools...455
Equipment Condition...455
Procedure...455
Follow-On Procedure...457
Installation...458
Overview...458
Special Tools...458
Equipment Condition...458
Procedure...458
Follow-On Procedure...459
Front Brake Rotor Two-wheel Drive (2WD) Replacement...461
Removal...461
Overview...461
Special Tools...461
Equipment Condition...461
Procedure...462
Follow-On Procedure...462
Installation...463
Overview...463
Special Tools...463
Equipment Condition...463
Procedure...463
Follow-On Procedure...464
Front Brake Rotor, Four-Wheel Drive (4WD) Replacement...465
Removal...465
Overview...465
Special Tools...465
Equipment Condition...465
Procedure...466
Follow-On Procedure...466
Installation...467
Overview...467
Special Tools...467
Equipment Condition...467
Procedure...467
Follow-On Procedure...468
Front Brake Shield Two-Wheel Drive (2WD) Replacement...469
Removal...469
Overview...469
Special Tools...469
Equipment Condition...469
Procedure...470
Follow-On Procedure...470
Installation...471
Overflow...471
Special Tools...471
Equipment Condition...471
Procedure...471
Follow-On Procedure...472
Front Brake Shield Four-Wheel Drive (4WD) Replacement...473
Removal...473
Overview...473
Special Tools...473
Equipment Condition...473
Procedure...474
Follow-On Procedure...475
Installation...476
Overview...476
Special Tools...476
Equipment Condition...476
Procedure...476
Follow-On Procedure...477
Front Disc Brake Pad Replacement...478
Removal...478
Overview...478
Special Tools...478
Equipment Condition...478
Procedure...478
Follow-On Procedure...479
Installation...480
Overview...480
Special Tools...480
Equipment Condition...480
Procedure...480
Follow-On Procedure...481
Rear Brake Caliper...483
Removal...483
Overview...483
Special Tools...483
Equipment Condition...483
Procedure...484
Follow-On Procedure...486
Installation...487
Overview...487
Special Tools...487
Equipment Condition...487
Procedure...487
Follow-On Procedure...490
Rear Brake Caliper Bracket...491
Removal...491
Overview...491
Special Tools...491
Equipment Condition...491
Procedure...492
Follow-On Procedure...494
Installation...495
Overview...495
Special Tools...495
Equipment Condition...495
Procedure...495
Follow-On Procedure...497
Rear Brake Caliper Hardware...498
Removal...498
Overview...498
Special Tools...498
Equipment Condition...498
Procedure...498
Follow-On Procedure...500
Installation...501
Overview...501
Special Tools...501
Equipment Condition...501
Procedure...501
Follow-On Procedure...502
Rear Brake Rotor...504
Removal...504
Overview...504
Special Tools...504
Equipment Condition...504
Procedure...505
Follow-On Procedure...505
Installation...506
Overview...506
Special Tools...506
Equipment Condition...506
Procedure...506
Follow-On Procedures...507
Rear Disc Brake Pads...508
Removal...508
Overview...508
Special Tools...508
Equipment Condition...508
Procedure...508
Follow-On Procedure...509
Installation...510
Overview...510
Special Tools...510
Equipment Condition...510
Procedure...510
Follow-On Procedure...511
Brake Rotor Assembled Lateral Runout Measurement...513
Overview...513
Special Tools...513
Equipment Condition...513
Measurement Procedure...513
Follow-On Procedure...515
Brake Rotor Thickness Variation Measurement...516
Overview...516
Special Tools...516
Equipment Condition...516
Measurement Procedure...516
Follow-On Procedure...517
Brake Pad and Rotor Burnishing...518
Overview...518
Special Tools...518
Equipment Conditions...518
Procedure...518
Follow-On Procedure...518
Service Brake System...519
Overview...519
Brake Assist System Component Description...519
Brake Assist System Operation...520
Hydraulic Brake System Components...520
Hydraulic Brake System Operation...520
Brake and Accelerator Pedal Assembly...522
Removal...522
Overview...522
Special Tools...522
Equipment Condition...522
Procedure...523
Follow-On Procedure...524
Installation...525
Overview...525
Special Tools...525
Equipment Condition...525
Procedure...525
Follow-On Procedure...526
Brake Pedal Assembly...527
Removal...527
Overview...527
Special Tools...527
Equipment Condition...527
Procedure...528
Follow-On Procedure...528
Installation...529
Overview...529
Special Tools...529
Equipment Condition...529
Procedure...529
Follow-On Procedure...530
Brake Master Cylinder (Feature Code: 004198)...531
Removal...531
Overview...531
Special tools...531
Equipment Condition...531
Procedure...532
Follow-On Procedure...534
Installation...535
Overview...535
Special Tools...535
Equipment Condition...535
Procedure...535
Follow-On Procedure...537
Brake Master Cylinder Pressure Sensor Replacement...538
Removal...538
Overview...538
Special Tools...538
Equipment Condition...538
Procedure...539
Follow-On Procedure...539
Installation...540
Overview...540
Special Tools...540
Equipment Condition...540
Procedure...541
Follow-On Procedure...541
Front Brake Hose Two-Wheel Drive (2WD) Replacement...542
Removal...542
Overview...542
Special Tools...542
Equipment Condition...542
Procedure...543
Follow-On Procedure...545
Installation...546
Overview...546
Special Tools...546
Equipment Condition...546
Procedure...546
Follow-On Procedure...549
Front Brake Hose Four-Wheel Drive (4WD) Replacement...550
Removal...550
Overview...550
Special Tools...550
Equipment Condition...550
Procedure...551
Follow-On Procedure...553
Installation...554
Overview...554
Special Tools...554
Equipment Condition...554
Procedure...555
Follow-On Procedure...557
Power Brake Booster...558
Removal...558
Overview...558
Special Tools...558
Equipment Condition...558
Procedure...559
Follow-On Procedure...562
Installation...563
Overview...563
Special Tools...563
Equipment Condition...563
Procedure...563
Follow-On Procedure...567
Power Brake Booster Pump...568
Removal...568
Overview...568
Special Tools...568
Equipment Condition...568
Procedure...569
Follow-On Procedure...573
Installation...574
Overview...574
Special Tools...574
Equipment Condition...574
Procedure...574
Follow-On Procedure...580
Brake Master Cylinder Reservoir Filling...581
Overview...581
Special Tools...581
Equipment Condition...581
Filling Procedure...581
Follow-On Procedure...582
Brake Master Cylinder Bench Bleeding...583
Overview...583
Special Tools...583
Equipment Condition...583
Bleeding Procedure...584
Follow-On Procedure...585
Brake Pipe Replacement...586
Overview...586
Special Tools...586
Equipment Condition...586
Replacement Procedure...587
Follow-On Procedure...593
Hydraulic Brake Fluid Replacement...594
Overview...594
Special Tools...594
Equipment Condition...594
Replacement Procedure...594
Follow-On Procedure...595
Hydraulic Brake System Bleeding...596
Overview...596
Special Tools...596
Equipment Condition...596
Bleeding Procedure...596
Follow-On Procedure...598
Hydraulic Brake System Flushing...599
Overview...599
Special Tools...599
Equipment Condition...599
Flushing Procedure...599
Follow-On Procedure...601
Brake System External Leak Inspection...602
Overview...602
Special Tools...602
Equipment Conditions...602
Procedure...602
Follow-On Procedure...603
Brake System Internal Leak Test...604
Overview...604
Special Tools...604
Torque Specifications...604
Equipment Conditions...604
Procedure...604
Follow-On Procedure...606
Park Brake System...607
Overview...607
System Operation...607
Parking Brake Drum...608
Removal...608
Overview...608
Special Tools...608
Equipment Condition...608
Procedure...609
Follow-On Procedure...610
Installation...611
Overview...611
Special Tools...611
Equipment Condition...611
Procedure...611
Follow-On Procedure...612
Parking Brake Lever Pedal Assembly...613
Removal...613
Overview...613
Special Tools...613
Equipment Condition...613
Procedure...614
Follow-On Procedure...616
Installation...617
Overview...617
Special Tools...617
Equipment Condition...617
Procedure...617
Follow-On Procedure...619
Parking Brake Shoes...620
Removal...620
Overview...620
Special Tools...620
Equipment Condition...620
Procedure...621
Follow-On Procedure...625
Installation...626
Overview...626
Special Tools...626
Equipment Condition...626
Procedure...627
Follow-On Procedure...631
Parking Brake Shoe Adjuster...632
Removal...632
Overview...632
Special Tools...632
Equipment Conditions...632
Procedure...633
Follow-On Procedure...636
Installation...637
Overview...637
Special Tools...637
Equipment Conditions...637
Procedure...637
Follow-On Procedure...640
Parking Brake Adjustment (Drum Off)...641
Overview...641
Special Tools...641
Equipment Condition...641
Procedure...641
Follow-On Procedure...642
Parking Brake Adjustment (Drum On)...643
Overview...643
Special Tools...643
Equipment Condition...643
Procedure...643
Follow-On Procedure...644
Parking Brake Cable Adjustment...645
Overview...645
Special Tools...645
Equipment Condition...645
Procedure...646
Follow-On Procedure...649
3. Hydraulic Brakes - Bosch...650
Antilock Brake System (ABS)...650
Brake Pedal Position Sensor...650
Removal...650
Overview...650
Special Tools...650
Equipment Condition...650
Procedure...651
Follow-On Procedure...651
Installation...652
Overview...652
Special Tools...652
Equipment Condition...652
Procedure...652
Follow-On Procedure...652
Calibration...653
Overview...653
Special Tools...653
Equipment Condition...653
Calibration Procedure...653
Follow-On Procedure...654
Electronic Brake Control Module (EBCM)...655
Removal...655
Overview...655
Special Tools...655
Equipment Condition...655
Procedure...656
Follow-On Procedure...658
Installation...659
Overview...659
Special Tools...659
Equipment Condition...659
Procedure...659
Follow-On Procedure...661
Front Wheel Speed Sensor Replacement...662
Removal...662
Overview...662
Special Tools...662
Equipment Condition...662
Procedure...663
Follow-On Procedure...664
Installation...665
Overview...665
Special Tools...665
Torque Specifications...665
Equipment Condition...665
Procedure...665
Follow-On Procedure...666
Steering Angle Sensor...668
Removal...668
Overview...668
Special Tools...668
Equipment Condition...668
Procedure...668
Follow-On Procedure...670
Installation...671
Overview...671
Special Tools...671
Equipment Condition...671
Procedure...671
Follow-On Procedure...673
Vehicle Yaw Sensor Learn...675
Yaw Rate Sensor...675
4. Trailer...676
Trailer Brake Controls...676
Overview...676
The Trailer Brake Control System is compatible with two types of Trailer Brake Systems as listed below:...676
Trailer Brake Output Versus Trailer Brake Type...676
The vehicle is equipped with the following trailer braking components:...677
CCM – Auxiliary...677
Trailer Brake Power Control Module...677
Trailer Brake Control Panel...677
Manual Trailer Brake Apply...677
Trailer Gain Adjustment...678
Trailer Gain Adjustment Procedure...678
Hill Start Assist...678
Trailer Sway Control...678
Driver Information Center Indicators and Messages...678
Trailer Connected...678
Check Trailer Wiring...679
Service Trailer Brake System...679
Trailer Gain and Output Display...679
Auxiliary Chassis Control Module – Trailer Brake...679
Removal...679
Overview...679
Special Tools...680
Warnings and Cautions...680
Equipment Conditions...680
Procedure...681
Follow-On Procedures...682
Installation...682
Overview...682
Special Tools...682
Warnings and Cautions...682
Equipment Conditions...682
Procedure...683
Follow-On Procedures...684
Steering...685
1. Power Steering...689
Hydraulic With Hydro-Max® Brakes...689
Overview...689
Operation...689
Power Steering Fluid Flow...689
Power Steering Fluid Cooler...691
Removal...691
Overview...691
Special Tools...691
Equipment Condition...691
Procedure...692
Follow-On Procedure...692
Installation...693
Overview...693
Special Tools...693
Equipment Condition...693
Procedure...693
Follow-On Procedure...694
Power Steering Fluid Cooler Pipe / Hose...695
Removal...695
Overview...695
Special Tools...695
Equipment Condition...695
Procedure...696
Follow-On Procedure...698
Installation...699
Overview...699
Special Tools...699
Equipment Condition...699
Procedure...699
Follow-On Procedure...702
Power Steering Fluid Reservoir...703
Removal...703
Overview...703
Special Tools...703
Equipment Condition...703
Procedure...704
Follow-On Procedure...704
Installation...705
Overview...705
Special Tools...705
Equipment Condition...705
Procedure...705
Follow-On Procedure...706
Power Steering Fluid Reservoir Inlet Hose...707
Removal...707
Overview...707
Special Tools...707
Equipment Condition...707
Procedure...707
Follow-On Procedure...709
Installation...710
Overview...710
Special Tools...710
Equipment Condition...710
Procedure...710
Follow-On Procedure...711
Power Steering Fluid Reservoir Outlet Hose...712
Removal...712
Overview...712
Special Tools...712
Equipment Condition...712
Procedure...712
Follow-On Procedure...713
Installation...714
Overview...714
Special Tools...714
Equipment Condition...714
Procedure...714
Follow-On Procedure...715
Power Steering Gear...716
Removal...716
Overview...716
Special Tools...716
Equipment Condition...716
Procedure...717
Follow-On Procedure...718
Installation...719
Overview...719
Special Tools...719
Equipment Condition...719
Procedure...719
Follow-On Procedure...720
Hydraulic Steering Limitation Valve Screw...722
Removal...722
Overview...722
Special Tools...722
Equipment Condition...722
Procedure...723
Follow-On Procedure...723
Installation...724
Overview...724
Special Tools...724
Equipment Condition...724
Procedure...725
Follow-On Procedure...725
Hydraulic Steering Limitation Valve Setup...726
Overview...726
Special Tools...726
Torque Specifications...726
Equipment Condition...726
Procedure...726
Follow-On Procedure...726
Power Steering Gear Inlet Pipe / Hose...727
Removal...727
Overview...727
Special Tools...727
Equipment Condition...727
Procedure...727
Follow-On Procedure...728
Installation...729
Overview...729
Special Tools...729
Equipment Condition...729
Procedure...729
Follow-On Procedure...730
Power Steering Gear Outlet Pipe / Hose...731
Removal...731
Overview...731
Special Tools...731
Equipment Condition...731
Procedure...731
Follow-On Procedure...733
Installation...734
Overview...734
Special Tools...734
Equipment Condition...734
Procedure...734
Follow-On Procedure...736
Power Steering Pump...737
Removal...737
Overview...737
Special Tools...737
Equipment Condition...737
Procedure...738
Follow-On Procedure...738
Installation...739
Overview...739
Special Tools...739
Equipment Condition...739
Procedure...739
Follow-On Procedure...740
Power Steering Pump Pulley...741
Removal...741
Overview...741
Special Tools...741
Equipment Condition...741
Procedure...741
Follow-On Procedure...742
Installation...743
Overview...743
Special Tools...743
Torque Specifications...743
Equipment Condition...743
Procedure...743
Follow-On Procedure...744
Checking and Adding Power Steering Fluid...745
Overview...745
Special Tools...745
Equipment Condition...745
Procedure...745
Follow-On Procedure...746
Power Steering System Bleeding...747
Overview...747
Special Tools...747
Procedure...747
Follow-On Procedure...748
Power Steering System Flushing...749
Overview...749
Special Tools...749
Equipment Conditions...749
Procedure...749
Follow-On Procedure...750
2. Steering Linkage...751
Two-Wheel Drive (2WD)...751
Overview...751
Front Axle Tie Rod Two-Wheel Drive (2WD) Replacement...752
Removal...752
Overview...752
Special Tools...752
Equipment Condition...752
Procedure...753
Follow-On Procedure...753
Installation...754
Overview...754
Special Tools...754
Equipment Condition...754
Procedure...754
Follow-On Procedure...754
Pitman Arm Two-Wheel Drive (2WD) Replacement...756
Removal...756
Overview...756
Special Tools...756
Equipment Condition...756
Procedure...757
Follow-On Procedure...757
Installation...758
Overview...758
Special Tools...758
Equipment Condition...758
Procedure...758
Follow-On Procedure...759
Relay Rod Two-Wheel Drive (2WD) Replacement...760
Removal...760
Overview...760
Special Tools...760
Equipment Condition...760
Procedure...761
Follow-On Procedure...762
Installation...763
Overview...763
Special Tools...763
Equipment Condition...763
Procedure...763
Follow-On Procedure...766
Steering Arm Two-Wheel Drive (2WD) Replacement...767
Removal...767
Overview...767
Special Tools...767
Equipment Condition...767
Procedure...768
Follow-On Procedure...769
Installation...770
Overview...770
Special Tools...770
Equipment Condition...770
Procedure...770
Follow-On Procedure...771
Steering Linkage Outer Tie Rod Two-Wheel Drive (2WD) Replacement...773
Removal...773
Overview...773
Special Tools...773
Equipment Condition...773
Procedure...774
Follow-On Procedure...775
Installation...776
Overview...776
Special Tools...776
Equipment Condition...776
Procedure...776
Follow-On Procedure...778
Tie Rod Arm Two-Wheel Drive (2WD) Replacement...779
Removal...779
Overview...779
Special Tools...779
Equipment Condition...779
Procedure...780
Follow-On Procedure...781
Installation...782
Overview...782
Special Tools...782
Equipment Condition...782
Procedure...782
Follow-On Procedure...784
Steering Linkage Two-Wheel Drive (2WD) Inspection...785
Overview...785
Special Tools...785
Equipment Condition...785
Procedure...785
Steering Linkage Outer Tie Rod...785
Steering Linkage Relay Rod...786
Follow-On Procedure...787
Four-Wheel Drive (4WD)...788
Overview...788
Front Axle Tie Rod Four-Wheel Drive (4WD) Replacement...789
Removal...789
Overview...789
Special Tools...789
Equipment Condition...789
Procedure...790
Follow-On Procedure...790
Installation...791
Overview...791
Special Tools...791
Equipment Condition...791
Procedure...791
Follow-On Procedure...791
Pitman Arm Four-Wheel Drive (4WD) Replacement...792
Removal...792
Overview...792
Special Tools...792
Equipment Condition...792
Procedure...793
Follow-On Procedure...793
Installation...794
Overview...794
Special Tools...794
Equipment Condition...794
Procedure...794
Follow-On Procedure...795
Relay Rod Four-Wheel Drive (4WD) Replacement...796
Removal...796
Overview...796
Special Tools...796
Equipment Condition...796
Procedure...797
Follow-On Procedure...799
Installation...800
Overview...800
Special Tools...800
Equipment Condition...800
Procedure...800
Follow-On Procedure...803
Steering Arm Four-Wheel Drive (4WD) Replacement...804
Removal...804
Overview...804
Special Tools...804
Equipment Condition...804
Procedure...805
Follow-On Procedure...805
Installation...806
Overview...806
Special Tools...806
Equipment Condition...806
Procedure...806
Follow-On Procedure...807
Steering Linkage Outer Tie Rod Four-Wheel Drive (4WD) Replacement...808
Removal...808
Overview...808
Special Tools...808
Equipment Condition...808
Procedure...808
Follow-On Procedure...810
Installation...811
Overview...811
Special Tools...811
Equipment Condition...811
Procedure...811
Follow-On Procedure...813
Tie Rod Arm Four-Wheel Drive (4WD) Replacement...814
Removal...814
Overview...814
Special Tools...814
Equipment Condition...814
Procedure...815
Follow-On Procedure...816
Installation...817
Overview...817
Special Tools...817
Equipment Condition...817
Procedure...817
Follow-On Procedure...819
Steering Linkage Four-Wheel Drive (4WD) Inspection...820
Overview...820
Special Tools...820
Equipment Condition...820
Procedure...820
Steering Linkage Outer Tie Rod...820
Steering Linkage Relay Rod...821
Follow-On Procedure...822
3. Steering Wheel and Column...823
Diagnostic Information and Procedures...823
Steering Wheel and Column Description and Operation...823
Vehicle Steering...823
Vehicle Security, Found on Some Vehicle Models...823
Driver Convenience...823
Driver Safety...823
NO TITLE...824
Symptoms – Steering Wheel and Column...825
Visual / Physical Inspection...825
Symptoms List...825
Steering Column Tilt Function Inoperative...826
High Shift Effort...828
Steering Column...830
Fastener Specifications...830
Single Use Non-Threaded Fasteners / Components...830
Reusable Threaded Fastener Tightening Specifications...830
Turn Signal Switch Cancel Cam Replacement...831
Removal...831
Overview...831
Special Tools...831
Equipment Conditions...831
Procedure...832
Follow-On Procedure...833
Installation...834
Overview...834
Special Tools...834
Torque Specifications...834
Equipment Conditions...834
Procedure...834
Follow-On Procedure...835
Theft Deterrent Module Replacement...836
Removal...836
Overview...836
Special Tools...836
Equipment Conditions...836
Procedure...837
Follow-On Procedure...837
Installation...838
Overview...838
Special Tools...838
Equipment Conditions...838
Procedure...839
Follow-On Procedure...839
Transmission Control Replacement...840
Removal...840
Overview...840
Special Tools...840
Equipment Conditions...840
Procedure...841
Follow-On Procedure...842
Installation...843
Overview...843
Special Tools...843
Equipment Conditions...843
Procedure...844
Follow-On Procedure...845
Shift Lever Replacement...847
Removal...847
Overview...847
Special Tools...847
Equipment Conditions...847
Procedure...847
Follow-On Procedure...848
Installation...849
Overview...849
Special Tools...849
Equipment Conditions...849
Procedure...849
Follow-On Procedure...849
Intermediate Steering Shaft Seal...850
Removal...850
Overview...850
Special Tools...850
Equipment Condition...850
Procedure...850
Follow-On Procedure...851
Installation...852
Overview...852
Special Tools...852
Equipment Condition...852
Procedure...852
Follow-On Procedure...853
Upper Intermediate Steering Shaft Replacement...854
Removal...854
Overview...854
Special Tools...854
Equipment Conditions...854
Procedure...855
Follow-On Procedure...857
Installation...857
Overview...857
Special Tools...858
Equipment Conditions...858
Procedure...859
Follow-On Procedure...861
Lower Intermediate Steering Shaft Replacement...862
Removal...862
Overview...862
Special Tools...862
Equipment Conditions...862
Procedure...863
Follow-On Procedure...867
Installation...867
Overview...867
Special Tools...868
Equipment Conditions...868
Procedure...869
Follow-On Procedure...873
Steering Shaft Upper Bearing Replacement...874
Removal...874
Overview...874
Special Tools...874
Equipment Conditions...874
Procedure...875
Follow-On Procedure...877
Installation...878
Overview...878
Special Tools...878
Torque Specifications...878
Equipment Conditions...878
Procedure...879
Follow-On Procedure...881
Steering Shaft Lower Bearing Adapter...882
Removal...882
Overview...882
Special Tools...882
Equipment Conditions...882
Procedure...882
Follow-On Procedure...883
Installation...884
Overview...884
Special Tools...884
Equipment Conditions...884
Procedure...884
Follow-On Procedure...885
Steering Shaft Lock Plate Replacement...886
Removal...886
Overview...886
Special Tools...886
Torque Specifications...886
Equipment Conditions...886
Procedure...887
Follow-On Procedure...890
Installation...891
Overview...891
Special Tools...891
Torque Specifications...891
Equipment Conditions...891
Procedure...891
Follow-On Procedure...893
Steering Column Upper Trim Cover Replacement...894
Removal...894
Overview...894
Special Tools...894
Equipment Conditions...894
Procedure...894
Follow-On Procedure...895
Installation...896
Overview...896
Special Tools...896
Torque Specifications...896
Equipment Conditions...896
Procedure...896
Follow-On Procedure...897
Steering Column Replacement...898
Removal...898
Overview...898
Special Tools...898
Equipment Conditions...898
Procedure...899
Follow-On Procedure...902
Installation...903
Overview...903
Special Tools...903
Equipment Conditions...903
Procedure...903
Follow-On Procedure...906
Clockspring Replacement...908
Removal...908
Overview...908
Special Tools...908
Equipment Condition...908
Procedure...909
Follow-On Procedure...909
Installation...910
Overview...910
Special Tools...910
Torque Specifications...910
Equipment Condition...910
Procedure...911
Follow-On Procedure...911
Clockspring Centering...912
Overview...912
Special Tools...912
Equipment Condition...912
Procedure...913
Follow-On Procedure...914
Ignition and Start Switch Replacement...915
Removal...915
Overview...915
Special Tools...915
Equipment Conditions...915
Procedure...916
Follow-On Procedure...917
Installation...918
Overview...918
Special Tools...918
Torque Specifications...918
Equipment Conditions...918
Procedure...918
Follow-On Procedure...923
Ignition Lock Cylinder...924
Removal...924
Overview...924
Special Tools...924
Equipment Condition...924
Procedure...925
Follow-On Procedure...926
Installation...927
Overview...927
Special Tools...927
Torque Specifications...927
Equipment Condition...927
Procedure...927
Follow-On Procedure...928
Ignition Lock Cylinder Case Replacement...929
Removal...929
Overview...929
Special Tools...929
Equipment Conditions...929
Procedure...929
Follow-On Procedure...930
Installation...931
Overview...931
Special Tools...931
Equipment Conditions...931
Procedure...932
Follow-On Procedure...932
Steering Column Tilt Spring Replacement...934
Removal...934
Overview...934
Special Tools...934
Equipment Conditions...934
Procedure...934
Follow-On Procedure...935
Installation...936
Overview...936
Special Tools...936
Torque Specifications...936
Equipment Conditions...936
Procedure...937
Follow-On Procedure...938
Steering Wheel...939
Cruise Control Switch...939
Removal...939
Overview...939
Special Tools...939
Equipment Condition...939
Procedure...940
Follow-On Procedure...940
Installation...941
Overview...941
Special Tools...941
Equipment Condition...941
Procedure...941
Follow-On Procedure...941
Left Steering Wheel Spoke Cover...942
Removal...942
Overview...942
Special Tools...942
Equipment Condition...942
Procedure...942
Follow-On Procedure...943
Installation...944
Overview...944
Special Tools...944
Torque Specifications...944
Equipment Condition...944
Procedure...944
Follow-On Procedure...944
Radio Rear Control Switch...945
Removal...945
Overview...945
Special Tools...945
Equipment Conditions...945
Procedure...946
Follow-On Procedure...946
Installation...947
Overview...947
Special Tools...947
Torque Specifications...947
Equipment Conditions...947
Procedure...947
Follow-On Procedure...948
Right Steering Wheel Spoke Cover...949
Removal...949
Overview...949
Special Tools...949
Equipment Condition...949
Procedure...949
Follow-On Procedure...950
Installation...951
Overview...951
Special Tools...951
Torque Specifications...951
Equipment Condition...951
Procedure...951
Follow-On Procedure...951
4. Wheel Alignment...952
Steering Wheel Angle and / or Front Toe Alignment (4WD and 2WD)...952
Overview...952
Special Tools...952
Equipment Condition...952
Alignment Procedure...953
Follow-On Procedure...954
Drivelines...955
1. Drive Shaft...957
Overview...957
Drive Shaft Phasing...958
Prop Shaft Ordering Guide...959
Overview...959
Special Tools...959
Equipment Condition...959
Ordering Guidelines...960
Follow-On Procedure...963
Phasing Measurement...964
Special Tools...964
Torque Specifications...964
Equipment Conditions...964
Procedure...965
Follow-On Procedue...965
Phasing Adjustment...966
Special Tools...966
Torque Specifications...966
Equipment Conditions...966
Procedure...966
Follow-On Procedures...975
Spicer®...976
Front Axle Drive Shaft...976
Removal...976
Overview...976
Special Tools...976
Equipment Condition...976
Procedure...976
Follow-On Procedures...979
Installation...980
Overview...980
Special Tools...980
Equipment Condition...980
Procedure...980
Follow-On Procedure...983
Two-Piece Drive Shaft...984
Removal...984
Overview...984
Special Tools...984
Equipment Conditions...984
Procedure...984
Follow-On Procedure...988
Installation...989
Overview...989
Special Tools...989
Equipment Condition...989
Procedure...989
Follow-On Procedure...993
Universal Joint...993
Overview...993
Removal...995
Overview...995
Special Tools...995
Equipment Condition...995
Procedure...995
Follow-On Procedure...998
Installation...999
Overview...999
Special Tools...999
Torque Specifications...999
Equipment Condition...999
Procedure...1000
Follow-On Procedure...1004
Exhaust...1005
1. Exhaust Systems...1007
Aftertreatment...1007
Diesel Particulate Filter...1007
Removal...1007
Overview...1007
Special Tool...1007
Equipment Condition...1007
Procedure...1008
Follow-On Procedure...1013
Installation...1014
Overview...1014
Special Tools...1014
Equipment Condition...1014
Procedure...1015
Follow-On Procedure...1021
DEF Head Unit (Emission Reduction Fluid Supply Pump Module)...1022
Removal...1022
Overview...1022
Special Tools...1022
Equipment Condition...1022
Procedure...1023
Follow-On Procedure...1025
Installation...1026
Overview...1026
Special Tools...1026
Equipment Condition...1026
Procedure...1027
Follow-On Procedure...1030
Particulate Matter Sensor...1032
Removal...1032
Overview...1032
Special Tools...1032
Equipment Condition...1032
Procedure...1033
Follow-On Procedure...1034
Installation...1035
Overview...1035
Special Tools...1035
Equipment Condition...1035
Procedure...1036
Follow-On Procedure...1037
DPF Differential Pressure Sensor...1039
Removal...1039
Overview...1039
Special Tools...1039
Equipment Condition...1039
Procedure...1040
Follow-On Procedure...1042
Installation...1043
Overview...1043
Special Tools...1043
Equipment Condition...1043
Procedure...1044
Follow-On Procedure...1047
DPF Intake Temperature Sensor (Exhaust Temperature Sensor 3)...1048
Removal...1048
Overview...1048
Special Tools...1048
Equipment Condition...1048
Procedure...1049
Follow-On Procedure...1050
Installation...1051
Overview...1051
Special Tools...1051
Equipment Condition...1051
Procedure...1052
Follow-On Procedure...1053
DPF Outlet Temperature Sensor (Exhaust Temperature Sensor 4)...1054
Removal...1054
Overview...1054
Special Tools...1054
Equipment Condition...1054
Procedure...1055
Follow-On Procedure...1056
Installation...1057
Overview...1057
Special Tools...1057
Equipment Condition...1057
Procedure...1058
Follow-On Procedure...1059
SCR Temperature Exhaust Sensor (Exhaust Temperature Sensor 5)...1060
Removal...1060
Overview...1060
Special Tools...1060
Equipment Condition...1060
Procedure...1061
Follow-On Procedure...1062
Installation...1063
Overview...1063
Special Tools...1063
Equipment Condition...1063
Procedure...1063
Follow-On Procedure...1064
Selective Catalytic Reduction (SCR) Assembly...1066
Removal...1066
Overview...1066
Special Tools...1066
Equipment Condition...1066
Procedure...1067
Follow-On Procedure...1072
Installation...1073
Overview...1073
Special Tools...1073
Equipment Condition...1073
Procedure...1074
Follow-On Procedure...1079
Piping and Mounting...1080
Exhaust Front Bracket...1080
Removal...1080
Overview...1080
Special Tools...1080
Equipment Condition...1080
Procedure...1081
Follow-On Procedure...1081
Installation...1082
Overview...1082
Special Tools...1082
Equipment Condition...1082
Procedure...1082
Follow-On Procedure...1083
Exhaust Front Bracket – Lower...1084
Removal...1084
Overview...1084
Special Tools...1084
Equipment Condition...1084
Procedure...1085
Follow-On...1086
Installation...1087
Overview...1087
Equipment Condition...1087
Procedure...1087
Follow-On Procedure...1088
Exhaust Front Bracket – Upper...1089
Removal...1089
Overview...1089
Special Tools...1089
Equipment Condition...1089
Procedure...1090
Follow-On Procedure...1090
Installation...1091
Overview...1091
Special Tools...1091
Equipment Condition...1091
Procedure...1091
Follow-On Procedure...1092
Exhaust Front Pipe...1093
Removal...1093
Overview...1093
Special Tools...1093
Equipment Condition...1093
Procedure...1094
Follow-On Procedure...1101
Installation...1102
Overview...1102
Special Tools...1102
Equipment Condition...1102
Procedure...1103
Follow-On Procedure...1110
Electrical...1111
1. Diagnostic Trouble Code (DTC) List...1119
Diagnostic Trouble Codes Decoded...1147
System Code...1147
Code Type...1147
Sub-system or Component...1147
2. Electronic Service Tools (EST)...1148
Global Diagnostic System 2 (GDS2)...1148
Engine Control Module: Scan Tool Information (0012GAC)...1148
Fuel Pump Power Control Module Scan Tool Information...1220
Glow Plug Control Module: Scan Tool Information...1221
Transfer Case Control Module: Scan Tool Information...1227
Service Programming System (SPS)...1239
Overview...1239
Body Control Module: Programming and Setup...1241
Overview...1241
Special Tools...1241
Equipment Condition...1241
Replace and Program Control Module...1241
Reprogram Control Module...1242
Unsuccessful Programming Recovery...1243
Follow-On Procedure...1243
Chassis Control Module – Auxiliary: Programming and Setup...1244
Overview...1244
Special Tools...1244
Equipment Condition...1244
Replace and Program Control Module or Reprogram Control Module...1244
Unsuccessful Programming Recovery...1244
Follow-On Procedure...1245
Electronic Brake Control Module: Programming and Setup...1246
Overview...1246
Special Tools...1246
Equipment Condition...1246
Replace and Program Control Module or Reprogram Control Module...1246
Unsuccessful Programming Recovery...1246
Follow-On Procedure...1247
Human Machine Interface Module: Programming and Setup...1248
Overview...1248
Special Tools...1248
Equipment Condition...1248
Replace and Program Control Module...1248
Reprogram Control Module...1249
Unsuccessful Programming Recovery...1250
Follow-On Procedure...1250
Human Machine Interface Module Bypass Module: Programming and Setup...1251
Overview...1251
HVAC Controls: Programming and Setup...1252
Overview...1252
HVAC Control Module: Programming and Setup...1253
Overview...1253
Special Tools...1253
Equipment Condition...1253
Programming an Existing or New Control Module ...1253
Unsuccessful Programming Recovery ...1253
Follow-On Procedure...1254
Immobilizer Control Module: Programming and Setup...1255
Overview...1255
Immobilizer System Module Flashing (Component Programming)...1256
Overview...1256
Special Tools...1256
Equipment Condition...1257
Programming Procedure...1257
Follow-On Procedure...1257
Inflatable Restraint Sensing and Diagnostic Module: Programming and Setup...1258
Overview...1258
Special Tools...1258
Equipment Condition...1258
Programming and Setup Procedure...1258
Follow-On Procedure...1258
Gauge Cluster (Instrument Cluster): Programming and Setup...1259
Overview...1259
Special Tools...1259
Equipment Condition...1259
Replace and Program ECU...1259
Reprogram ECU...1259
Unsuccessful Programming Recovery...1260
Follow-On Procedure...1260
Radio (0008RNM): Programming and Setup...1261
Overview...1261
Special Tools...1261
Equipment Condition...1261
Replace and Program Control Module or Reprogram Control Module...1262
XM Activation (If Equipped)...1262
Unsuccessful Programming Recovery...1262
Valet Mode Reset...1263
Follow-On Procedure...1263
Radio (0008RNN / 0008RNR / 0008RNX): Programming and Setup...1264
Overview...1264
Special Tools...1264
Equipment Condition...1264
Replace and Program Control Module or Reprogram Control Module...1264
XM Activation (If Equipped)...1264
Unsuccessful Programming Recovery...1265
Valet Mode Reset...1265
Follow-On Procedure...1265
Radio Controls: Programming and Setup...1266
Overview...1266
Special Tools...1266
Equipment Condition...1266
Replace Control Module...1266
Reprogram Control Module...1266
Unsuccessful Programming Recovery...1266
Follow-On Procedure...1267
Seat Heating Control Module – Front: Programming and Setup...1268
Overview...1268
Serial Data Gateway Module: Programming and Setup...1269
Overview...1269
Special Tools...1269
Equipment Condition...1269
Replace and Program Control Module or Reprogram Control Module...1269
Unsuccessful Programming Recovery...1269
Follow-On Procedure...1270
Trailer Brake Power Control Module: Programming and Setup...1271
Overview...1271
Trailer Lighting Control Module: Programming and Setup...1272
Overview...1272
Special Tools...1272
Equipment Condition...1272
Trailer Lighting Control Module Programming...1272
Trailer Lighting Control Module Configuration / Reconfiguration and Setup...1272
Follow-On Procedure...1273
Transfer Case Control Module: Programming and Setup...1274
Overview...1274
Special Tools...1274
Equipment Condition...1274
Programming an Existing or New Control Module...1274
Unsuccessful Programming Recovery ...1274
Follow-On Procedure...1275
3. General Electrical Repair...1276
Diagnostic Information and Procedures...1276
Strategy Based Diagnosis...1276
Overview...1276
Additional Information...1277
Diagnostic System Check Instructions...1278
Diagnostic Instructions...1278
Circuit Testing...1280
Use Connector Test Adapters...1281
Probing Electrical Connectors...1282
Troubleshooting with a Digital Multimeter...1283
Digital Multimeter (DMM) Basic Requirements...1283
Display and Settings...1283
Voltage...1283
Current...1283
Resistance...1283
Frequency...1283
Diode Test...1283
MIN MAX Readings...1283
Troubleshooting with a Test Lamp...1285
Use Fused Jumper Wire(s)...1286
Measuring Voltage...1287
Measuring Voltage Drop...1288
Measuring Frequency...1289
Testing Ground and Low Reference Circuits...1290
Testing for Continuity...1291
With a Digital Multimeter (DMM)...1291
With a Test Lamp...1291
Testing for short to ground...1292
With a Digital Multimeter (DMM)...1292
With a Test Lamp...1292
Fuse Powering Several Loads...1292
Testing for a short to voltage...1293
Testing for Intermittent Conditions and Poor Connections...1294
Testing for Terminal Fretting...1294
Testing for Proper Terminal Contact...1294
Testing for Proper Terminal Contact in Bussed Electrical Centers...1295
Flat Wire Connectors...1295
Control Module/Component Voltage and Grounds...1295
Temperature Sensitivity...1296
Electromagnetic Interference and Electrical Noise...1296
Incorrect Control Module...1297
Inducing Intermittent Fault Conditions...1298
High Temperature Conditions...1298
Low Temperature Conditions...1298
Duplicating Failure Conditions...1299
Testing for Electrical Intermittent...1300
Diagnostic Starting Point – Vehicle...1301
Overview...1301
Diagnostic System Check – Vehicle...1302
Diagnostic Instructions...1302
Diagnostic System Check...1302
Diagnostic Repair Verification...1305
Overview...1305
Procedure...1305
Power Mode Description and Operation...1306
Serial Data Power Mode Master...1306
Relay Controlled Power Mode...1306
Battery Saver Mode (Transport Mode)...1306
BCM Awake / Sleep States...1307
Retained Accessory Power Description and Operation...1308
Retained Accessory Power...1308
Relay Controlled Retained Accessory Power...1308
Serial Data Controlled Retained Accessory Power (RAP)...1308
Radio...1308
Vehicle Communication Interface Module (VCIM) (If Equipped)...1309
Retained Accessory Power Malfunction...1310
Diagnostic Instructions...1310
Circuit / System Description...1310
Circuit / System Verification...1310
Circuit / System Testing...1310
Component Testing...1314
Relay Test...1314
Repair Instructions...1315
Vehicle Will Not Change Power Mode...1316
Diagnostic Instructions...1316
DTC Descriptions...1316
Circuit / System Description...1316
Conditions for Running the DTC...1316
B1370 01, B1370 04...1316
B1380 01, B1380 04...1316
B1441 01, B1441 04...1317
Conditions for Setting the DTC...1317
B1370 01...1317
B1370 04...1317
B1380 01...1317
B1380 04...1317
B1441 01...1317
B1441 04...1317
Actions Taken When the DTC Sets...1317
Conditions for Clearing the DTC...1317
Circuit / System Verification...1317
Circuit / System Testing...1318
Component Testing...1320
Repair Instructions...1321
Repair Procedures...1322
Symptoms – Wiring Systems...1322
Visual / Physical Inspection...1322
Intermittent...1322
Symptom List...1322
Power Mode Mismatch...1323
Diagnostic Instructions...1323
Circuit / System Description...1323
Diagnostic Aids...1323
Circuit / System Verification...1323
Circuit / System Testing...1324
Diagnostic A...1324
Diagnostic B...1326
Diagnostic C...1327
Diagnostic D...1329
Component Testing...1331
Relay Test...1331
Repair Instructions...1332
Wire-to-Wire Repair...1333
Overview...1333
Special Tools...1333
Equipment Condition...1334
Splice Sleeve Repair Procedure...1334
Weatherpack™ Wiring Repair Procedure...1337
High Temperature Wiring Repair...1338
Follow-On Procedure...1338
4. 12 Volt System...1339
Charging System...1339
Charging System Description and Operation...1339
Electrical Power Management Overview...1339
Charging System Components...1339
Generator...1339
Generator Pulley...1339
Body Control Module (BCM)...1340
Battery Current Sensor (if applicable)...1340
Battery Sensor Module (if applicable)...1340
Engine Control Module (ECM)...1340
Instrument Cluster...1340
Charging System Operation...1340
Charging System Modes...1341
Battery Sulfation Mode...1341
Charge Mode...1342
Fuel Economy Mode...1342
Headlamp Mode...1342
Start Up Mode...1342
Tow / Haul Mode (if applicable)...1342
Instrument Cluster Operation...1342
Charge Indicator Operation...1342
Driver Information Center (DIC) Message: BATTERY NOT CHARGING SERVICE CHARGING SYSTEM or SERVICE BATTERY CHARGING SYSTEM...1343
Voltmeter Gauge and/or System Voltage Display (if equipped)...1343
Electrical Power Management Description and Operation (Diesel)...1344
Operational Checkout Procedure...1346
Overview...1346
Visual / Physical Inspection...1346
Intermittent...1346
Symptom List...1346
Battery...1347
Overview...1347
Battery Low Start Vehicle Message...1347
Battery Ratings...1347
Amperage Hours...1348
Cold Cranking Amperage (CCA)...1348
Battery Electrical Drain / Parasitic Load Test...1349
12 Volt Battery...1349
Circuit / System Description...1349
Diagnostic Aids...1349
Circuit / System Verification...1350
Using an Inductive Pickup Probe...1351
Circuit / System Testing...1351
Repair Instructions...1351
Battery Inspection / Test...1352
Description and Operation...1352
Circuit / System Testing...1352
Repair Instructions...1353
DTC B1517...1354
DTC Description...1354
Circuit / System Description...1354
Conditions for Running the DTC...1354
Conditions for Setting the DTC ...1354
Actions Taken When the DTC Sets ...1354
Conditions for Clearing the DTC ...1354
Diagnostic Aids ...1354
Circuit / System Verification ...1354
Circuit / System Testing...1355
Repair Instructions ...1356
DTC B151A...1357
DTC Description...1357
Circuit / System Description...1357
Conditions for Running the DTC...1357
Conditions for Setting the DTC...1357
Action Taken When the DTC Sets...1357
Conditions for Clearing the DTC...1357
Description and Operation...1357
Circuit / System Verification...1357
DTC B1527...1358
DTC Description...1358
Circuit / System Description...1358
Conditions for Running the DTC...1358
Conditions for Setting the DTC...1358
Action Taken When the DTC Sets...1358
Conditions for Clearing the DTC...1358
Description and Operation...1358
Circuit / System Verification...1358
DTC P0560 - P0563...1359
DTC Description ...1359
Circuit / System Description ...1359
Conditions for Running the DTC ...1359
Conditions for Setting the DTC ...1359
Actions Taken When the DTC Sets ...1359
Conditions for Clearing the DTC ...1359
Diagnostic Aids...1359
Circuit / System Verification ...1359
Circuit / System Testing ...1360
Repair Instructions ...1361
Auxiliary Battery...1362
Removal...1362
Overview...1362
Special Tools...1362
Equipment Condition...1362
Procedure...1363
Follow-On Procedure...1364
Installation...1365
Overview...1365
Special Tools...1365
Equipment Condition...1365
Procedure...1365
Follow-On Procedure...1366
Battery...1367
Removal...1367
Overview...1367
Special Tools...1367
Equipment Condition...1367
Procedure...1368
Follow-On Procedure...1369
Installation...1370
Overview...1370
Special Tools...1370
Equipment Condition...1370
Procedure...1370
Follow-On Procedure...1371
Battery Negative Cable (Crankcase (Engine Block) to Frame)...1372
Removal...1372
Overview...1372
Special Tools...1372
Equipment Condition...1372
Procedure...1373
Follow-On Procedure...1373
Installation...1374
Overview...1374
Special Tools...1374
Equipment Condition...1374
Procedure...1374
Follow-On Procedure...1375
Disconnection...1376
Overview...1376
Special Tools...1376
Equipment Condition...1376
Procedure...1376
Follow-On Procedure...1380
Connection...1381
Overview...1381
Special Tools...1381
Equipment Condition...1381
Procedure...1381
Follow-On Procedure...1385
Battery Positive Cable...1386
Removal...1386
Overview...1386
Special Tools...1386
Equipment Condition...1386
Procedure...1387
Follow-On Procedure...1391
Installation...1392
Overview...1392
Special Tools...1392
Equipment Condition...1392
Procedure...1393
Follow-On Procedure...1397
Battery Charging...1398
Battery State of Charge...1398
Charging Time Required...1399
Charging Procedure...1400
Body Control Module...1401
Overview...1401
Power Mode Master...1401
Gateway...1401
Charging System...1402
Overview...1402
Electrical Power Management Overview...1402
Charging System Components...1402
Alternator (Generator)...1402
Alternator (Generator) Pulley...1402
Body Control Module (BCM)...1403
Battery Current Sensor (if equipped)...1403
Battery Sensor Module (if equipped)...1403
Engine Control Module (ECM)...1403
Gauge Cluster (Instrument Cluster)...1403
Charging System Operation...1403
Charging System Modes...1404
Battery Sulfation Mode...1404
Charge Mode...1404
Fuel Economy Mode...1405
Headlight (Headlamp) Mode...1405
Start Up Mode...1405
Tow / Haul Mode (if equipped)...1405
Gauge Cluster (Instrument Cluster) Operation...1405
Charge Indicator Operation (If Equipped)...1405
DIC Message: BATTERY NOT CHARGING SERVICE CHARGING SYSTEM or SERVICE BATTERY CHARGING SYSTEM...1406
Voltmeter Gauge and / or System Voltage Display (if equipped)...1406
Charging System Test...1407
Circuit / System Description...1407
Diagnostic Aids...1407
Circuit / System Verification...1408
Circuit / System Testing...1409
Repair Instructions...1411
DTC C1575 or C1576...1412
Diagnostic Instructions...1412
DTC Description...1412
Circuit / System Description ...1412
Conditions for Running the DTC ...1412
Conditions for Setting the DTC...1412
Actions Taken When the DTC Sets...1412
Diagnostic Aids...1412
Circuit / System Verification...1412
Circuit / System Testing ...1413
Repair Instructions...1414
DTC P0621 (Diesel)...1415
DTC Description...1415
Circuit / System Description...1415
Conditions for Running the DTC...1415
Conditions for Setting the DTC...1415
Action Taken When the DTC Sets...1415
Conditions for Clearing the DTC...1415
Diagnostic Aids...1415
Circuit / System Testing – Single Generator...1415
Circuit / System Testing – Dual Generators...1416
Repair Instructions...1418
DTC P0622 (Diesel)...1419
DTC Description...1419
Circuit / System Description...1419
Conditions for Running the DTC...1419
Conditions for Setting the DTC...1419
Action Taken When the DTC Sets...1419
Conditions for Clearing the DTC...1419
Description and Operation...1419
Circuit / System Verification...1419
Circuit / System Testing...1420
Repair Instructions...1421
DTC P062B, P0630, P064D - P064E, P134C, P160A - P160E, P161C, P163A - P163B, P16F3, P2610, P262B, P264F, or P27B5...1422
Diagnostic Instructions...1422
DTC Description...1422
Circuit / System Description...1422
Conditions for Running the DTC...1422
P0630, P160A, P160D, P160E, P161C, P264F...1422
P062B...1422
P064D, P064E, P134C, P27B5...1422
P163A, P163B...1423
P16F3...1423
P2610, P262B...1423
Conditions for Setting the DTC...1423
Actions Taken When the DTC Sets...1423
Diagnostic Aids...1423
Circuit / System Verification...1423
Repair Instructions...1424
DTC P2670 or P2671...1425
Diagnostic Instructions...1425
DTC Description...1425
Circuit / System Description...1425
Conditions for Running the DTC ...1425
Conditions for Setting the DTC...1426
Actions Taken When the DTC Sets...1426
Circuit / System Verification...1426
Circuit / System Testing...1427
Repair Instructions...1427
Electrical Power Management...1428
Overview...1428
DTC B097C...1431
Diagnostic Instructions...1431
DTC Description...1431
Conditions for Running the DTC...1431
Conditions for Setting the DTC...1432
B097C 02...1432
Actions Taken When the DTC Sets...1432
Circuit / System Verification...1432
Circuit / System Testing...1432
Repair Instructions...1433
DTC B1325, C0800, or C1512...1434
DTC Description...1434
Circuit / System Description...1434
Conditions for Running the DTC ...1434
Conditions for Setting the DTC...1434
Actions Taken When the DTC Sets...1434
Diagnostic Aids...1434
Circuit / System Verification...1434
Circuit / System Testing ...1435
Repair Instructions ...1436
DTC B1370 (Instrument Cluster)...1437
Diagnostic Instructions...1437
DTC Description...1437
Circuit / System Description...1437
Conditions for Running the DTC...1437
B1370 01...1437
B1370 06...1437
Conditions for Setting the DTC...1437
B1370 01...1437
B1370 06...1437
Action Taken When the DTC Sets...1437
Circuit / System Verification...1437
Circuit / System Testing...1438
Repair Instructions...1438
DTC B1370, B1380, or B1441...1439
Diagnostic Instructions...1439
DTC Descriptions...1439
Circuit / System Description...1439
Conditions for Running the DTC...1439
B1370 01 or B1370 04...1439
B1380 01 or B1380 04...1440
B1441 01 or B1441 04...1440
Conditions for Setting the DTC...1440
B1370 01...1440
B1370 04...1440
B1380 01...1440
B1380 04...1440
B1441 01...1440
B1441 04...1440
Actions Taken When the DTC Sets...1440
Circuit / System Verification...1440
Circuit / System Testing...1441
Component Testing...1443
Repair Instructions...1444
DTC B1445...1445
Diagnostic Instructions...1445
DTC Description...1445
Circuit / System Description...1445
Conditions for Running the DTC...1445
Conditions for Setting the DTC...1445
B1445 02...1445
B1445 04...1445
Action Taken When the DTC Sets...1445
B1445 02...1445
B1445 04...1445
Circuit / System Verification...1446
Circuit / System Testing...1446
Repair Instructions...1447
DTC B144A...1448
Diagnostic Instructions...1448
DTC Description...1448
Circuit / System Description...1448
Conditions for Running the DTC...1448
Conditions for Setting the DTC...1448
B144A 01...1448
B144A 02...1448
B144A 04...1448
Action Taken When the DTC Sets...1448
B144A 01, B144A 04...1448
B144A 02...1448
Circuit / System Testing...1449
Repair Instructions...1449
DTC B144B...1450
Diagnostic Instructions...1450
DTC Description...1450
Circuit / System Description...1450
Conditions for Running the DTC...1450
Conditions for Setting the DTC...1450
B144B 01...1450
B144B 02...1450
B144B 04...1450
Action Taken When the DTC Sets...1450
B144B 01, B144B 04...1450
B144B 02...1450
Diagnostic Aids...1451
Circuit / System Verification...1451
Circuit / System Testing...1451
Repair Instructions...1452
DTC P0611, P1002, P129B, P129C, P15AE, or P15AF...1453
DTC Description...1453
Circuit / System Description...1453
Conditions for Running the DTC ...1453
Conditions for Setting the DTC...1453
Actions Taken When the DTC Sets...1453
Diagnostic Aids...1453
Circuit / System Verification...1453
Circuit / System Testing ...1454
Repair Instructions ...1455
Starting System...1456
Overview...1456
Circuit Description (Key Start)...1456
Engine Cranks Slowly...1457
Description and Operation...1457
Circuit / System Testing...1457
Repair Instructions...1458
Starter Malfunction...1459
Circuit / System Description...1459
Circuit / System Verification...1459
Circuit / System Testing...1460
Component Testing...1463
Relay Test...1463
Repair Instructions ...1463
DTC P0615, P0616, or P0617...1464
DTC Descriptions...1464
Circuit / System Description...1464
Conditions for Running the DTC...1464
Conditions for Setting the DTC...1464
Action Taken When the DTC Sets...1464
Description and Operation...1464
Circuit / System Testing...1464
Component Testing...1466
Relay Test...1466
Repair Instructions...1467
DTC P2534 or P2535...1468
Diagnostic Instructions...1468
DTC Descriptions...1468
Circuit / System Description...1468
Conditions for Running the DTC...1468
P2534...1468
P2535...1468
Conditions for Setting the DTC...1468
P2534...1468
P2535...1468
Action Taken When the DTC Sets...1468
Diagnostic Aids...1468
Circuit / System Verification...1468
Circuit / System Testing...1469
Repair Instructions...1470
DTC P2537...1471
Diagnostic Instructions...1471
DTC Description...1471
Circuit / System Description...1471
Conditions for Running the DTC...1471
Conditions for Setting the DTC...1471
Action Taken When the DTC Sets...1471
Circuit / System Verification...1471
Circuit / System Testing...1471
Repair Instructions...1472
5. Accessories...1473
Auxiliary Power Outlets...1473
12 Volt DC Power Receptacle...1473
Overview...1473
Power Outlet Receptacle Malfunction (12 Volt)...1473
Circuit / System Description...1473
Diagnostic Aids...1473
Circuit / System Verification...1473
X80D, X80E, or X80L...1473
X80G, X80J or X80K...1473
Circuit / System Testing...1474
Diagnostic A...1474
Diagnostic B...1475
Repair Instructions...1475
110 Volt AC Power Receptacle...1476
Overview...1476
System Description...1476
System Operation...1476
Isolation Fault Protection...1476
Overload Shutdown...1476
Internal Shutdown...1476
Power Outlet Receptacle Malfunction (110 Volt)...1477
Circuit / System Description...1477
Circuit / System Verification...1477
Circuit / System Testing...1477
Component Testing...1480
Accessory Power Outlet – 110 volts AC...1480
Repair Instructions...1481
Cruise Control...1482
Overview...1482
Speed Control System...1482
Cruise Control Engaged...1482
Cruise Control Disengaged...1483
Cruise Control Inhibited...1484
Cruise Control Inhibit Reasons...1484
Operational Checkout Procedure...1489
Visual / Physical Inspection...1489
Intermittent...1489
Symptom List...1489
Cruise Control Malfunction...1490
DTC Descriptions...1490
Circuit / System Description...1491
Conditions for Running the DTC...1491
Conditions for Setting the DTC...1491
B3623...1491
B3794, P0564, P0565, P0567, P0568, P056C, P0580, P0581 ...1491
P0589, P0592, P0593, P155B, P155C ...1491
P155A ...1492
P162C ...1492
Actions Taken When the DTC Sets...1492
Circuit / System Verification ...1492
Circuit / System Testing...1492
Cruise Control Set / Coast / Resume / Accelerate Switch Signal...1492
Adaptive Cruise Control Gap Up / Down Switch Signal...1494
Repair Instructions...1495
Cruise Control Indicator Malfunction...1496
Circuit / System Description...1496
Circuit / System Verification...1496
Repair Instructions...1496
DTC B3623, B3794, P0564, P0565, P0567, P0568, P056C, P0580, P0581, P0589, P0592, P0593, P155A - P155C, or P162C...1497
DTC Descriptions...1497
Circuit / System Description...1497
Conditions for Running the DTC ...1497
Actions Taken When the DTC Sets ...1498
Circuit / System Verification...1498
Circuit / System Testing ...1498
Cruise Control Set / Coast / Resume / Accelerate Switch Signal...1498
Adaptive Cruise Control Gap Up / Down Switch Signal...1500
Repair Instructions...1501
DTC P0571...1502
DTC Description...1502
Circuit / System Description...1502
Conditions for Running the DTC...1502
Actions Taken When the DTC Sets...1502
Circuit / System Verification...1502
Repair Instructions...1502
DTC P0572 or P0573...1503
DTC Description...1503
Circuit / System Description...1503
Conditions for Running the DTC...1503
Conditions for Setting the DTC...1503
Actions Taken When the DTC Sets...1503
Circuit / System Verification...1503
Circuit / System Testing...1504
Repair Instructions ...1505
DTC P0575...1506
DTC Description...1506
Circuit / System Description...1506
Conditions for Running the DTC ...1506
Conditions for Setting the DTC ...1506
Actions Taken When the DTC Sets ...1506
Circuit / System Verification...1506
Repair Instructions...1507
DTC P0703...1508
DTC Description...1508
Circuit / System Description...1508
Conditions for Running the DTC ...1508
Conditions for Setting the DTC...1508
Actions Taken When the DTC Sets ...1508
Circuit / System Verification...1508
Repair Instructions...1509
DTC P1553...1510
DTC Description...1510
Circuit / System Description...1510
Conditions for Running the DTC...1510
Conditions for Setting the DTC...1510
Actions Taken When the DTC Sets...1510
Circuit / System Verification...1510
Repair Instructions...1510
DTC P158A...1511
DTC Description...1511
Circuit / System Description...1511
Conditions for Running the DTC...1511
Conditions for Setting the DTC...1511
Actions Taken When the DTC Sets...1511
Circuit / System Verification...1511
Repair Instructions...1512
Horns...1513
Overview...1513
System Description...1513
System Operation...1513
Circuit Operation...1513
Operational Checkout Procedure...1514
Visual / Physical Inspection...1514
Intermittent...1514
Symptom List...1514
Fastener Specifications...1515
Horns Malfunction...1516
Circuit / System Description...1516
Diagnostic Aids...1516
Circuit / System Verification...1516
Circuit / System Testing...1517
Test 1...1517
Test 2...1517
Test 3 ...1519
Component Testing...1520
Horn...1520
Repair Instructions...1520
DTC B2750...1521
DTC Description...1521
Circuit / System Description...1521
Conditions for Running the DTC...1521
Conditions for Setting the DTC...1521
Actions Taken When the DTC Sets...1521
Circuit / System Verification...1521
Circuit / System Testing...1521
Repair Instructions...1522
Immobilizer...1523
Immobilizer Description and Operation...1523
Body Control Module (BCM)...1523
Engine Control Module (ECM)...1524
Immobilizer Control Module...1524
Ignition Key...1524
Environment Identifier...1524
Security Indicator...1525
Programming Additional Keys...1526
Adding Keys (Without SPS)...1526
Adding Keys (With SPS)...1527
Replacing Keys...1528
With SPS...1528
Without SPS (United States and Mexico only)...1529
Operational Checkout Procedure...1530
Set Up...1530
Visual / Physical Inspection...1530
Intermittent...1530
DTC B3055...1531
DTC Description...1531
Circuit / System Description...1531
Conditions for Running the DTC...1531
Conditions for Setting the DTC...1531
Action Taken When the DTC Sets...1531
Diagnostic Aids...1531
Circuit / System Verification...1531
Repair Instructions...1532
DTC B3060...1533
DTC Description...1533
Circuit / System Description...1533
Conditions for Running the DTC...1533
Conditions for Setting the DTC...1533
Action Taken When the DTC Sets...1533
Circuit / System Verification...1533
Repair Instructions...1533
DTC B389A...1534
DTC Description...1534
Circuit / System Description...1534
Conditions for Running the DTC...1534
Conditions for Setting the DTC...1534
Action Taken When the DTC Sets...1534
Diagnostic Aids...1534
Circuit / System Verification...1534
Repair Instructions...1535
DTC B3902...1536
DTC Description...1536
Circuit / System Description...1536
Conditions for Running the DTC...1536
Conditions for Setting the DTC...1536
Action Taken When the DTC Sets...1536
Circuit / System Verification...1536
Repair Instructions...1536
DTC B3924 - B3928...1537
DTC Descriptions...1537
Circuit / System Description...1537
Conditions for Running the DTC...1537
Conditions for Setting the DTC...1537
Action Taken When the DTC Sets...1537
Circuit / System Verification...1537
Repair Instructions...1537
DTC B3935...1538
DTC Description...1538
Circuit / System Description...1538
Conditions for Running the DTC...1538
Conditions for Setting the DTC...1538
Action Taken When the DTC Sets...1538
Circuit / System Verification...1538
Repair Instructions...1539
DTC B3976...1540
DTC Description...1540
Circuit / System Description...1540
Conditions for Running the DTC...1540
Conditions for Setting the DTC...1540
Action Taken When the DTC Sets...1540
Circuit / System Verification...1540
Repair Instructions...1540
DTC B3978 - B3982...1541
DTC Descriptions...1541
Circuit / System Description...1541
Conditions for Running the DTC...1541
Conditions for Setting the DTC...1541
Action Taken When the DTC Sets...1541
Circuit / System Verification...1541
Repair Instructions...1541
DTC B3984...1542
DTC Description...1542
Circuit / System Description...1542
Conditions for Running the DTC...1542
Conditions for Setting the DTC...1542
Action Taken When the DTC Sets...1542
Circuit / System Verification...1542
Repair Instructions...1542
DTC P0513...1543
DTC Description...1543
Circuit / System Description...1543
Conditions for Running the DTC...1543
Conditions for Setting the DTC...1543
Action Taken When the DTC Sets...1543
Diagnostic Aids...1543
Circuit / System Verification...1543
Repair Instructions...1543
DTC P0633...1544
DTC Description...1544
Circuit / System Description...1544
Conditions for Running the DTC...1544
Conditions for Setting the DTC...1544
Action Taken When the DTC Sets...1544
Circuit / System Verification...1544
Repair Instructions...1544
DTC P1631...1545
DTC Description...1545
Circuit / System Description...1545
Conditions for Running the DTC...1545
Conditions for Setting the DTC...1545
Action Taken When the DTC Sets...1545
Circuit / System Verification...1545
Repair Instructions...1545
DTC P1649...1546
DTC Description...1546
Circuit / System Description...1546
Conditions for Running the DTC...1546
Conditions for Setting the DTC...1546
Action Taken When the DTC Sets...1546
Circuit / System Verification...1546
Repair Instructions...1546
Power Door Locks / Mirrors / Windows...1547
Remote Control Door Lock Transmitter Learn...1547
Erase / Program All Key Fobs...1547
Next Available Slot...1547
Slot Programming...1548
Keyless Entry Remote...1549
Operational Checkout Procedure...1549
Visual / Physical Inspection...1549
Intermittent...1549
Symptom List...1549
Keyless Entry System Malfunction...1550
Circuit / System Description...1550
Diagnostic Aids...1550
Special Tools...1550
Circuit / System Verification...1550
Circuit / System Testing...1551
Repair Instructions...1552
Remote Vehicle Start Malfunction...1553
Circuit / System Description...1553
Diagnostic Aids...1553
Circuit / System Verification...1553
Repair Instructions...1554
DTC B3101...1555
DTC Description...1555
Circuit / System Description...1555
Conditions for Running the DTC...1555
Conditions for Setting the DTC...1555
Action Taken When the DTC Sets...1555
Circuit / System Testing...1555
Repair Instructions...1557
DTC B3105...1558
DTC Description...1558
Circuit / System Description...1558
Conditions for Running the DTC...1558
Conditions for Setting the DTC...1558
Action Taken When the DTC Sets...1558
Circuit / System Verification...1558
Repair Instructions...1558
DTC B3106...1559
DTC Description...1559
Circuit / System Description...1559
Conditions for Running the DTC...1559
Conditions for Setting the DTC...1559
Action Taken When the DTC Sets...1559
Circuit / System Verification...1559
Repair Instructions...1559
DTC B3109 - B3113...1560
DTC Descriptions...1560
Circuit / System Description...1560
Conditions for Running the DTC...1560
Conditions for Setting the DTC...1560
Action Taken When the DTC Sets...1560
Circuit / System Verification...1560
Repair Instructions...1561
DTC B310D - B310F...1562
DTC Descriptions...1562
Circuit / System Description...1562
Conditions for Running the DTC...1562
Conditions for Setting the DTC...1562
Action Taken When the DTC Sets...1562
Circuit / System Verification...1562
Repair Instructions...1562
Power Door Locks...1563
Overview...1563
Door Lock System Components...1563
Door Lock System Controls...1563
Door Lock Operation...1563
Child Security Lockout System Operation...1563
Operational Checkout Procedure...1565
Visual / Physical Inspection...1565
Intermittent...1565
Symptom List...1565
Power Door Child Lock Malfunction...1566
Circuit / System Description...1566
Diagnostic Aids...1566
Circuit / System Verification...1567
Circuit / System Testing...1567
Lockout Switch Inoperative...1567
Lockout Indicator Malfunction...1568
Security Lockout Status Malfunction...1569
Security Lockout Malfunction...1570
Component Testing...1572
Door Latch Test...1572
Repair Instructions...1573
Power Door Lock Key Cylinder Switches Malfunction...1574
Circuit / System Description ...1574
Circuit / System Verification...1574
Circuit / System Testing...1574
Component Testing ...1576
Repair Instructions...1576
Power Door Locks Malfunction (Standard Cab)...1577
Circuit / System Description...1577
Diagnostic Aids...1578
Circuit / System Verification...1578
Circuit / System Testing...1578
Door Lock Switch Malfunction...1578
Driver Door Lock Malfunction...1580
Passenger Door Lock Malfunction...1581
Both Door Locks Inoperative...1581
Component Testing...1584
Door Lock Switch...1584
Door Latch Test...1584
Repair Instructions...1584
Power Door Locks Malfunction (Crew Cab)...1585
Circuit / System Description...1585
Diagnostic Aids...1586
Circuit / System Verification...1586
Circuit / System Testing...1586
Door Lock Switch Malfunction...1586
Driver Door Lock Malfunction...1588
Passenger Door Lock Malfunction...1589
All Door Locks Inoperative...1590
Component Testing...1592
Door Lock Switch...1592
Door Latch Test...1593
Repair Instructions...1593
DTC B252C...1594
DTC Description...1594
Circuit / System Description...1594
Conditions for Running the DTC...1594
Conditions for Setting the DTC...1594
Action Taken When the DTC Sets...1594
Circuit / System Verification...1594
Circuit / System Testing...1594
Repair Instructions...1595
DTC B252E...1596
DTC Description...1596
Circuit / System Description...1596
Conditions for Running the DTC...1596
Conditions for Setting the DTC...1596
Actions Taken When the DTC Sets ...1596
Circuit / System Verification...1596
Circuit / System Testing...1597
Repair Instructions...1598
DTC B3125, B3130, or B3135 (Standard Cab)...1599
DTC Descriptions...1599
Circuit / System Description...1599
Conditions for Running the DTC...1599
Conditions for Setting the DTC...1599
B3125 01, B3130 01, B3135 01...1599
B3125 02, B3130 02, B3135 02 Condition 1...1599
B3125 02, B3130 02, B3135 02 Condition 2 ...1599
B3125 02, B3130 02, B3135 02 Condition 3 ...1600
Actions Taken When the DTC Sets...1600
Circuit / System Verification...1600
Circuit / System Testing...1601
Test 1 ...1601
Test 2 ...1601
Test 3 ...1602
Component Testing ...1604
Repair Instructions...1605
DTC B3125, B3130, or B3135 (Crew Cab)...1606
DTC Descriptions...1606
Circuit / System Description...1606
Conditions for Running the DTC...1606
Conditions for Setting the DTC ...1606
B3125 01, B3130 01, B3135 01...1606
B3125 02, B3130 02, B3135 02 Condition 1...1607
B3125 02, B3130 02, B3135 02 Condition 2...1607
B3125 02, B3130 02, B3135 02 Condition 3...1607
Actions Taken When the DTC Sets...1607
Circuit / System Verification...1607
Circuit / System Testing...1608
Test 1...1608
Test 2 ...1608
Test 3 ...1609
Component Testing...1611
Repair Instructions...1612
DTC B3140, B3145, B3150, or B3155 (Manual Windows)...1613
DTC Descriptions...1613
Circuit / System Description...1613
Conditions for Running the DTC...1613
Conditions for Setting the DTC...1613
B3140 00...1613
B3145 00...1613
B3150 00...1614
B3155 00...1614
Actions Taken When the DTC Sets...1614
B3140 00...1614
B3145 00...1614
B3150 00...1614
B3155 00...1614
Circuit / System Verification...1614
Circuit / System Testing...1615
Component Testing ...1617
Door Lock Switch Test...1617
Repair Instructions...1617
DTC B3140, B3145, B3150, or B3155 (Power Windows)...1618
DTC Descriptions...1618
Circuit / System Description...1618
Conditions for Running the DTC...1618
Conditions for Setting the DTC...1618
B3140 00...1618
B3145 00...1618
B3150 00...1619
B3155 00...1619
Actions Taken When the DTC Sets...1619
B3140 00...1619
B3145 00...1619
B3150 00...1619
B3155 00...1619
Circuit / System Verification...1619
Circuit / System Testing...1620
Test 1...1620
Test 2...1621
Component Testing...1623
Door Lock Switch Test...1623
Repair Instructions...1624
DTC B3930...1625
DTC Description...1625
Circuit / System Description...1625
Conditions for Running the DTC...1625
Conditions for Setting the DTC...1625
B3930 01...1625
B3930 02...1625
B3930 04...1625
Actions Taken When the DTC Sets...1625
Circuit / System Verification...1625
Circuit / System Testing...1626
Repair Instructions...1627
Power Mirrors...1628
Overview...1628
Power Mirror System Components...1628
Power Mirror System Controls...1628
Power Mirror System Operation...1628
Heated Mirrors...1628
Rearview Mirror with Automatic Day-Night System Operation (If Equipped)...1629
Automatic Day-Night Mirror Description and Operation...1630
Inside Rearview Mirror with the Automatic Day-Night Feature System Operation...1630
Driver Outside Rearview Mirror with Automatic Day-Night System Operation (If Equipped)...1630
Outside Mirror Description and Operation...1631
Power Mirror System Components...1631
Power Mirror System Controls...1631
Power Mirror System Operation...1631
Heated Mirrors...1631
Operational Checkout Procedure...1632
Visual / Physical Inspection...1632
Intermittent...1632
Symptom List...1632
Automatic Day-Night Mirrors Malfunction...1633
Circuit / System Description...1633
Circuit / System Verification...1633
Circuit / System Testing...1634
Inside Review Mirror Dimming Inoperative...1634
Day-Night Disable Malfunction...1635
Exterior Mirrors (Outside Rearview Mirror) Dimming Malfunction...1635
Repair Instructions...1636
Heated Mirrors Malfunction...1637
Circuit / System Description...1637
Circuit / System Verification...1637
Circuit / System Testing...1637
Repair Instructions...1638
Power Mirror Malfunction...1639
Circuit / System Description...1639
Circuit / System Verification...1639
Circuit / System Testing...1640
Both Exterior (Outside Rearview Mirrors) Inoperative...1640
Driver Exterior (Outside Rearview Mirror) Movement Malfunction...1641
Passenger Exterior (Outside Rearview Mirror) Mirror Movement Malfunction...1642
Repair Instructions...1643
DTC B154A or B154B...1644
DTC Descriptions...1644
Circuit / System Description...1644
Conditions for Running the DTC...1644
Conditions for Setting the DTC...1644
B154A 39...1644
B154B 39...1644
Action Taken When the DTC Sets...1644
Circuit / System Verification...1644
Repair Instructions...1645
Power Windows Description and Operation...1646
Power Windows System Components...1646
Driver Express Up and Express Down Power Window Motor...1646
Passenger, Left Rear and Right Rear Express Down Window Motors...1646
Lockout Switch Feature...1646
DTC B0283...1647
Diagnostic Instructions ...1647
DTC Description...1647
Circuit / System Description...1647
Conditions for Running the DTC ...1647
Conditions for Setting the DTC...1647
Actions Taken When the DTC Sets...1648
Circuit / System Verification...1648
Circuit / System Testing...1648
Component Testing...1649
Relay Test ...1649
Repair Instructions...1650
DTC B316B, B317A, B318A, or B319A...1651
Diagnostic Instructions...1651
DTC Description...1651
Circuit / System Description ...1651
Conditions for Running the DTC...1652
Conditions for Setting the DTC...1653
B316B 00...1653
B316B 02...1653
B316B 39...1653
B317A 02...1653
B318A 02...1653
B319A 02...1653
Actions Taken When the DTC Sets...1653
Circuit / System Verification...1653
Circuit / System Testing...1656
Repair Instructions...1659
DTC B3205...1660
Diagnostic Instructions...1660
DTC Description...1660
Circuit / System Description...1660
Conditions for Running the DTC...1660
Conditions for Setting the DTC...1660
B3205 00...1660
B3205 39...1660
B3205 42...1660
B3205 4B...1660
Actions Taken When the DTC Sets...1661
B3205 00, B3205 39, B3205 42...1661
B3205 4B...1661
Circuit / System Verification...1661
Repair Instructions...1661
Window Motor Programming – Express Function...1662
Window Motor Normalized Procedure...1662
Procedure...1662
Window Motor Relearn Procedure...1662
Procedure...1663
Rearview Camera (Rear Vision Camera)...1664
Rearview Camera (Rear Vision Camera) (0008RNY / 0008RNM / 0008RNN)...1664
Overview...1664
Rearview Camera (Rear Vision Camera) (0008RNY / 0008RNR / 0008RNX)...1665
Overview...1665
Rearview Camera (Rear Vision Camera) System Malfunction...1666
DTC Description...1666
Circuit / System Description...1666
Conditions for Running the DTC...1666
Conditions for Setting the DTC...1666
Actions Taken When the DTC Sets ...1666
Diagnostic Aids...1667
Circuit / System Verification...1667
Circuit / System Testing...1667
Repair Instructions...1669
DTC B127B...1670
DTC Description...1670
Circuit / System Description...1670
Conditions for Running the DTC...1670
Conditions for Setting the DTC...1670
Actions Taken When the DTC Sets...1670
Diagnostic Aids...1670
Circuit / System Verification...1670
Circuit / System Testing...1671
Repair Instructions...1673
DTC B133B...1674
DTC Description...1674
Circuit / System Description...1674
Conditions for Running the DTC...1674
Conditions for Setting the DTC...1674
Action Taken When the DTC Sets...1674
Circuit / System Verification...1674
Repair Instructions...1674
Rear Window Defogger...1675
Overview...1675
Rear Window Defogger System Components...1675
Rear Window Defogger Operation...1675
Heated Mirrors...1675
Rear Window Defogger Malfunction...1676
Diagnostic Instructions...1676
Circuit / System Description...1676
Diagnostic Aids...1676
Circuit / System Verification...1676
Circuit / System Testing...1677
Component Testing...1678
Relay Test...1678
Rear Defogger Grid Test...1679
Repair Instructions...1680
Steering Wheel Switches...1681
Overview...1681
Operational Checkout Procedure...1682
Visual / Physical Inspection...1682
Intermittent...1682
Symptom List...1682
Steering Wheel Controls Malfunction...1683
Circuit / System Description...1683
Circuit / System Verification...1683
Circuit / System Testing...1684
Steering Wheel Controls Switch – Radio Volume...1684
Steering Wheel Controls Switch – Radio Presets...1685
Steering Wheel Controls Switch – Right...1686
Component Testing...1687
Repair Instructions...1688
DTC B3622...1689
DTC Description...1689
Circuit / System Description...1689
Conditions for Running the DTC...1689
Conditions for Setting the DTC...1689
B3622 39...1689
B3622 59...1689
Action Taken When the DTC Sets...1689
Circuit / System Verification...1689
Circuit / System Testing...1690
Steering Wheel Controls Switch – Radio Volume...1690
Steering Wheel Controls Switch – Radio Presets...1691
Steering Wheel Controls Switch – Right...1692
Component Testing...1693
Repair Instructions...1694
Theft Systems...1695
Overview...1695
Arming the Content Theft Deterrent System...1695
Locking the Vehicle Without Arming the Content Theft Deterrent System...1695
Disarming an Armed System / Silencing an Alarm...1696
Content Theft Deterrent Circuit Description...1696
Body Control Module (BCM)...1696
Remote Control Door Lock Receiver...1696
Door Ajar Switches...1697
Hood Switch (Hood Ajar Switch)...1697
Rear Compartment Ajar Switch...1697
Inputs...1697
Outputs...1697
Operational Checkout Procedure...1698
Overview...1698
Visual / Physical Inspection...1698
Intermittent...1698
Symptom List...1698
Content Theft Deterrent Malfunction...1699
Circuit / System Description...1699
Diagnostic Aids...1699
Circuit / System Verification...1699
Repair Instructions...1699
DTC B291B...1700
DTC Descriptions...1700
Circuit / System Description...1700
Conditions for Running the DTC...1700
Conditions for Setting the DTC...1700
Action Taken When the DTC Sets...1700
Diagnostic Aids...1700
Circuit / System Verification...1700
Circuit / System Testing...1701
Repair Instructions...1702
DTC B2955...1703
DTC Description...1703
Circuit / System Description...1703
Conditions for Running the DTC...1703
Conditions for Setting the DTC...1703
Action Taken When the DTC Sets...1703
Diagnostic Aids...1703
Circuit / System Testing...1703
Repair Instructions...1705
DTC B3031...1706
DTC Description...1706
Circuit / System Description...1706
Conditions for Running the DTC...1706
Conditions for Setting the DTC...1706
Action Taken When the DTC Sets...1706
Circuit / System Verification...1706
Repair Instructions...1706
6. Alarms...1707
Overview...1707
Back Up Alarm...1708
Overview...1708
Backup Alarm Malfunction...1709
Circuit / System Description...1709
Circuit / System Verification...1709
Circuit / System Testing ...1709
Repair Instructions...1710
Seat Belt Reminder...1711
Overview...1711
Driver Seat Belt Reminder...1711
Passenger Seat Belt Reminder...1711
7. Body Builder...1712
PTO...1712
Overview...1712
Factory Installed PTO Components...1712
The in-cab PTO switch and cruise control SET (–) and RES (+) switches...1712
Power Take-Off Module (PTOM)...1712
Remote PTO Up-fitter Connector...1713
Modes of Operation...1713
Preset PTO Mode...1713
Variable PTO Mode...1713
In-cab PTO Switch Operation:...1714
Cruise Control SET (–) and RES (+) Switch Operation:...1714
PTO Enable Conditions...1715
Stationary PTO...1715
Mobile PTO...1715
PTO Disengage Conditions...1716
Stationary PTO...1716
Mobile PTO...1716
Remote Engine Start Control...1716
Remote Engine Shutdown Control...1717
PTO Factory Default Settings...1717
Reprogramming the PTOM for Fast Idle / PTO Using the Scan Tool...1719
DTC P061C...1720
DTC Description...1720
Circuit / System Description...1720
Conditions for Running the DTC...1720
Conditions for Setting the DTC...1720
Actions Taken When the DTC Sets...1720
Diagnostic Aids...1720
Circuit / System Verification...1720
Repair Instructions...1721
DTC P158F...1722
DTC Description...1722
Circuit / System Description...1722
Conditions for Running the DTC...1722
Conditions for Setting the DTC...1722
Taken When the DTC Sets...1722
Diagnostic Aids...1722
Circuit / System Testing...1722
Repair Instructions...1723
DTC P1598...1724
DTC Description...1724
Circuit / System Description...1724
Conditions for Running the DTC...1724
Conditions for Setting the DTC...1724
Actions Taken When the DTC Sets...1724
Circuit / System Verification...1724
Repair Instructions...1724
DTC P159C...1725
DTC Description...1725
Circuit / System Description...1725
Conditions for Running the DTC...1725
Conditions for Setting the DTC...1725
Taken When the DTC Sets...1725
Diagnostic Aids...1725
Circuit / System Testing...1725
Repair Instructions...1726
DTC P159D...1727
DTC Description...1727
Circuit / System Description...1727
Conditions for Running the DTC...1727
Conditions for Setting the DTC...1727
Action Taken When the DTC Sets...1727
Circuit / System Testing...1727
Repair Instructions...1728
DTC P251A or P258E...1729
DTC Descriptions...1729
Circuit / System Description...1729
Conditions for Running the DTC...1729
Conditions for Setting the DTC...1729
Action Taken When the DTC Sets...1729
Diagnostic Aids...1729
Circuit / System Testing...1729
Repair Instructions...1731
DTC P251E or P251F...1732
DTC Descriptions...1732
Circuit / System Description...1732
Conditions for Running the DTC...1732
Conditions for Setting the DTC...1732
Action Taken When the DTC Sets...1732
Diagnostic Aids...1732
Circuit / System Testing...1732
Repair Instructions...1733
DTC P253D...1734
DTC Description...1734
Circuit / System Description...1734
Conditions for Running the DTC...1734
Conditions for Setting the DTC...1734
Action Taken When the DTC Sets...1734
Circuit / System Verification...1734
Circuit / System Testing...1734
Repair Instructions...1735
DTC P260A - P260C...1736
DTC Descriptions...1736
Circuit / System Description...1736
Conditions for Running the DTC...1736
Conditions for Setting the DTC...1736
Action Taken When the DTC Sets...1736
Diagnostic Aids...1736
Circuit / System Testing...1736
Repair Instructions...1737
8. Bolted Exterior Body Panels and Closures...1738
Diagnostic Information and Procedures...1738
Symptoms – Bolted Exterior Body Panels and Closures...1739
Visual / Physical Inspection...1739
Intermittent...1739
Symptom List...1739
Hood Ajar Indicator / Message Malfunction...1740
Diagnostic Instructions...1740
Circuit / System Description...1740
Conditions for Running the DTC...1740
Conditions for Setting the DTC...1740
B3006 01...1740
B3006 02...1740
B3006 04...1740
Action Taken When the DTC Sets...1740
Conditions for Clearing the DTC...1740
Circuit / System Verification...1741
Circuit / System Testing...1741
Component Testing...1742
Repair Instructions...1742
Hood Ajar Indicator Description and Operation...1743
Hood Ajar Switch...1743
Hood Ajar Indicator / Message...1743
DTC B3006...1744
Diagnostic Instructions...1744
DTC Descriptions...1744
Circuit / System Description...1744
Conditions for Running the DTC...1744
Conditions for Setting the DTC...1744
B3006 01...1744
B3006 02...1744
B3006 04...1744
Action Taken When the DTC Sets...1744
Circuit / System Verification...1744
Circuit / System Testing...1745
Component Testing...1746
Repair Instructions...1746
9. Brakes...1747
Bosch Hydraulic Brake System...1747
Antilock Brake System (ABS)...1747
Overview...1747
Backup Pump...1747
Power Brake Fluid Flow Switch...1747
Differential Pressure Switch...1747
Fluid Level Switch...1747
ABS Description and Operation...1747
Power Up Self Test...1749
Initialization Sequence...1749
ABS...1749
Pressure Hold...1750
Pressure Decrease...1750
Pressure Increase...1750
Dynamic Rear Proportioning...1750
Hill Descent Control System...1750
Hill Hold Start Assist...1750
Hydraulic Brake Assist...1751
Intelligent Brake Assist...1751
Optimized Hydraulic Braking System...1751
Operational Checkout Procedure...1752
Visual / Physical Inspection...1752
Intermittent...1752
Symptom List...1752
Brake Assist System Diagnosis...1753
Disc Brake System Diagnosis...1758
Test Description...1758
Hydraulic Brake System Diagnosis...1766
Brake Fluid Loss...1771
Brake Pedal Excessive Effort...1773
Brake Pedal Excessive Travel...1775
Brake Pulsation...1779
Brakes Self Apply When Turning Steering Wheel...1781
Brake System Slow Release...1782
Brakes Drag...1784
Braking Action Uneven – Front to Rear...1787
Test Descriptions...1787
Braking Action Uneven – Pulls to One Side...1790
Test Description...1790
Brake System Internal Leak Test...1792
Brake System Vehicle Road Test...1794
Preliminary Inspections...1794
Road Testing Procedure...1794
Hydraulic Brake Booster Leak Inspection...1796
Brake System External Leak Inspection...1799
Brake Pipe and Hose Inspection...1800
Brake Pedal Push Rod Inspection...1802
DTC C0001 - C0004...1803
DTC Description...1803
Circuit / System Description ...1803
Conditions for Running the DTC ...1803
Conditions for Setting the DTC ...1803
Actions Taken When the DTC Sets ...1803
Circuit / System Verification ...1803
Repair Instructions...1803
DTC C0010 - C0019, C001C, or C001D...1804
DTC Description...1804
Circuit / System Description...1804
Conditions for Running the DTC...1804
Conditions for Setting the DTC...1804
Action Taken When the DTC Sets...1804
Circuit / System Testing...1804
Repair Instructions...1805
DTC C0020...1806
DTC Descriptions...1806
Circuit / System Description...1806
Conditions for Running the DTC...1806
Conditions for Setting the DTC...1806
Action Taken When the DTC Sets...1806
Circuit / System Verification...1806
Circuit / System Testing...1807
Repair Instructions...1807
DTC C0021...1808
DTC Descriptions...1808
Circuit / System Description...1808
Conditions for Running the DTC...1808
Conditions for Setting the DTC...1808
C0021 01...1808
C0021 02...1808
C0021 04...1808
C0021 08...1808
Action Taken When the DTC Sets...1808
Circuit / System Testing...1809
Component Testing...1811
Relay Test...1811
Repair Instructions...1811
DTC C0049...1812
DTC Description...1812
Circuit / System Description...1812
Circuit / System Testing...1812
Repair Instructions...1813
DTC C0500, C0506, C050C, or C0512...1814
DTC Description...1814
Circuit / System Description ...1814
Conditions for Running the DTC ...1814
Conditions for Setting the DTC ...1814
Actions Taken When the DTC Sets...1815
Circuit / System Verification...1815
Circuit / System Testing ...1815
Repair Instructions ...1816
DTC C053B...1817
DTC Description...1817
Circuit / System Description...1817
Conditions for Running the DTC...1817
Conditions for Setting the DTC...1817
Action Taken When DTC Sets...1817
Circuit / System Verification...1817
Circuit / System Testing...1817
Repair Instructions...1818
DTC C1076...1819
DTC Description...1819
Circuit / System Description...1819
Conditions for Running the DTC...1819
Conditions for Setting the DTC...1819
Action Taken When the DTC Sets...1819
Circuit / System Verification...1819
Repair Instructions...1819
DTC C109A...1820
DTC Description...1820
Circuit / System Description...1820
Conditions for Running the DTC...1820
Conditions for Setting the DTC...1820
Action Taken When the DTC Sets...1820
Circuit / System Verification...1820
Repair Instructions...1821
DTC C10EE...1822
DTC Descriptor...1822
Circuit / System Description...1822
Conditions for Running the DTC...1822
Conditions for Setting the DTC...1822
Action Taken When the DTC Sets...1822
Circuit / System Verification...1822
Repair Instructions...1823
DTC C112D...1824
DTC Descriptions...1824
Circuit / System Description...1824
Conditions for Running the DTC...1824
Conditions for Setting the DTC...1824
C112D 00...1824
C112D 02...1824
C112D 04...1824
C112D 08...1824
Action Taken When the DTC Sets...1824
Circuit / System Testing...1825
Component Testing...1826
Relay Test...1826
Repair Instructions...1827
DTC C113F...1828
DTC Description...1828
Circuit / System Description...1828
Conditions for Running the DTC...1828
Conditions for Setting the DTC...1828
Action Taken When the DTC Sets...1828
Circuit / System Testing...1828
Component Testing...1829
Relay Test...1829
Repair Instructions...1830
DTC C1140...1831
DTC Description...1831
Circuit / System Description...1831
Conditions for Running the DTC...1831
Conditions for Setting the DTC...1831
Action Taken When the DTC Sets...1831
Circuit / System Testing...1831
Component Testing...1832
Relay Test...1832
Repair Instructions...1833
DTC C1151 or C1154...1834
DTC Description...1834
Circuit / System Description...1834
Conditions for running DTC...1834
Conditions for setting DTC...1834
Action Taken When the DTC Sets...1834
Circuit / System Testing...1834
Repair Instructions...1834
DTC C143D...1835
DTC Description...1835
Circuit / System Description ...1835
Conditions for Running the DTC ...1835
Conditions for Setting the DTC ...1835
Actions Taken When the DTC Sets...1835
Circuit / System Verification...1835
Repair Instructions...1835
DTC C1445...1836
DTC Description...1836
Circuit / System Description...1836
Conditions for Running DTC...1836
Conditions for Setting the DTC...1836
Actions Taken When the DTC Sets...1836
Circuit / System Verification...1836
Repair Instructions ...1836
DTC C1449...1837
DTC Description...1837
Circuit / System Description...1837
Conditions for Running the DTC...1837
Conditions for Setting the DTC...1837
Actions Taken When the DTC Sets ...1837
Circuit / System Verification...1837
Repair Instructions ...1837
DTC P15FD...1838
DTC Description...1838
Circuit / System Description...1838
Conditions for Running the DTC...1838
Conditions for Setting the DTC...1838
Action Taken When the DTC Sets...1838
Circuit / System Verification...1838
Circuit / System Testing...1838
Repair Instructions...1838
Automatic Traction Control (ATC)...1839
Overview...1839
DTC B2745...1840
DTC Description...1840
Circuit / System Description...1840
Conditions for Running the DTC...1840
Conditions for Setting the DTC...1840
Action Taken When the DTC Sets...1840
Circuit / System Verification...1840
Circuit / System Testing...1840
Component Testing...1841
Repair Instructions...1842
DTC C109D...1843
DTC Description...1843
Circuit / System Description...1843
Conditions for Running the DTC...1843
Conditions for Setting the DTC...1843
Action Taken When the DTC Sets...1843
Circuit / System Verification...1843
Repair Instructions...1844
DTC P0856...1845
DTC Description...1845
Circuit / System Description...1845
Conditions for Running the DTC...1845
Conditions for Setting the DTC...1845
Action Taken When the DTC Sets...1845
Circuit / System Testing...1845
Repair Instructions...1845
Electronic Stability Control (ESC)...1846
Overview...1846
Cornering Brake Control...1846
DTC C0186, C0196, or C0287...1847
DTC Description...1847
Circuit / System Description...1847
Conditions for Running the DTC...1847
Conditions for Setting the DTC...1847
C0186 00...1847
C0196 5A...1847
C0196 00...1847
C0287 00...1847
C0287 5A...1847
Action Taken When the DTC Sets...1848
Circuit / System Verification...1848
Repair Instructions...1848
DTC C149D or C15DE...1849
Diagnostic Instructions...1849
DTC Description...1849
Circuit / System Description...1849
Conditions for Running the DTC...1849
Conditions for Setting the DTC...1849
Action Taken When the DTC Sets...1849
Circuit / System Testing...1849
Component Testing...1851
Relay Test...1851
Diode Test...1852
Repair Instructions...1852
10. Cellular, Entertainment, and Navigation...1853
Cellular, Navigation, and Radio...1853
Overview...1853
Data Communications...1853
Remote Radio Receiver...1853
Radio Power...1854
Radio Retained Accessory Power...1854
Radio Grounds...1854
Radio Audio Outputs...1854
Human Machine Interface (HMI) Module...1854
CD Player (Media Disc Player)...1854
Audio Amplifier (If equipped)...1854
Amplifier Interface...1854
Amplifier Operation...1854
Speaker Operation...1855
Infotainment Controls and Display...1855
Antenna System...1855
Mast Antenna...1855
Multi-Band Antenna...1855
Active Antenna (if equipped)...1856
Radio Reception...1856
AM / FM Radio Signal...1856
Digital Radio Receiver (If equipped)...1856
Digital Audio Broadcast (DAB)...1856
Radio Data System (RDS)...1857
Theft Deterrent...1857
Bluetooth® (If equipped)...1857
Applications (If equipped)...1858
Auxiliary Audio Input Jack (If equipped)...1859
USB Port and SD Card Reader...1859
USB Port...1859
SD Card Reader...1859
Navigation System Components and Features (if equipped)...1859
Global Positioning System (GPS) Antenna...1860
Route Guidance...1860
Points of Interest...1860
Valet Mode...1860
Steering Wheel Controls (If equipped)...1860
Auto Volume Control...1860
Firmware Over The Air...1861
Operational Checkout Procedure – Cellular Communication...1862
Visual / Physical Inspection...1862
Intermittent...1862
Symptom List...1862
Operational Checkout Procedure – Radio...1863
Visual / Physical Inspection...1863
Intermittent...1863
Symptom List...1863
Application Malfunction...1864
Circuit / System Description...1864
Diagnostic Aids...1864
Circuit / System Verification...1864
Repair Instructions...1865
Auxiliary Audio Input Malfunction (0008RNM)...1866
Circuit / System Description...1866
Auxiliary Audio Input Jack...1866
USB Port...1866
Diagnostic Aids...1866
Auxiliary Audio Input Jack...1866
USB...1867
Special Tools...1867
Circuit / System Verification...1867
Auxiliary Audio Input Jack...1867
USB Port...1868
Circuit / System Testing...1868
Auxiliary Audio Input Jack...1868
Circuit / System Testing...1870
USB Port...1870
Repair Instructions...1871
Auxiliary Audio Input Malfunction (0008RNN)...1872
Circuit / System Description...1872
Auxiliary Audio Input Jack...1872
USB Port...1872
Diagnostic Aids...1872
Auxiliary Audio Input Jack...1872
USB...1873
Special Tools...1873
Circuit / System Verification...1873
Auxiliary Audio Input Jack...1873
USB Port...1874
Circuit / System Testing...1874
Auxiliary Audio Input Jack...1874
Circuit / System Testing...1876
USB Port...1876
Repair Instructions...1877
Auxiliary Audio Input Malfunction (0008RNR / 0008RNX)...1878
Circuit / System Description...1878
Auxiliary Audio Input Jack...1878
USB Ports...1878
SD Card Reader...1879
Diagnostic Aids...1879
3.5 mm (1/8 in) Input Jack...1879
USB Ports and SD Card Reader...1879
Circuit / System Verification...1879
Auxiliary Audio Input Jack...1879
USB Ports and SD Card Reader...1880
Circuit / System Testing...1881
Auxiliary Audio Input Jack...1881
Circuit / System Testing...1882
USB Port and SD Card Reader...1882
Repair Instructions...1884
Bluetooth Malfunction (0008RNM)...1885
Circuit / System Description...1885
Diagnostic Aids...1885
Special Tools...1885
Circuit / System Verification...1885
Repair Instructions...1886
Bluetooth Malfunction (0008RNN)...1887
Circuit / System Description...1887
Diagnostic Aids...1887
Special Tools...1887
Circuit / System Verification...1887
Repair Instructions...1888
Bluetooth Malfunction (0008RNR / 0008RNX)...1889
Circuit / System Description...1889
Diagnostic Aids...1889
Special Tools...1889
Circuit / System Verification...1889
Repair Instructions...1890
No Global Positioning System (GPS) Reception...1891
DTC Description...1891
Circuit Description...1891
Conditions for Running the DTC...1891
Conditions for Setting the DTC...1891
Actions Taken When the DTC Sets...1891
Diagnostic Aids...1891
Special Tools...1891
Circuit / System Testing...1891
Component Testing...1892
Coax Cable Test...1892
Repair Instructions...1892
Phone Projection Malfunction (Android Auto®)...1893
Circuit / System Description...1893
Diagnostic Aids...1893
Special Tools...1893
Circuit / System Verification...1893
Repair Instructions...1895
Phone Projection Malfunction (Apple CarPlay®)...1896
Circuit / System Description...1896
Diagnostic Aids...1896
Special Tools...1896
Circuit / System Verification...1896
Repair Instructions...1897
Radio Information Display Malfunction (0008RNM)...1898
Circuit / System Description...1898
Diagnostic Aids...1898
Special Tools...1898
Circuit / System Verification...1898
Circuit / System Testing...1899
Blank Screen...1899
Circuit / System Testing...1900
Touch Screen...1900
Repair Instructions...1901
Radio Information Display Malfunction (0008RNN)...1902
Circuit / System Description...1902
Diagnostic Aids...1902
Special Tools...1902
Circuit / System Testing...1902
Repair Instructions...1903
Radio Information Display Malfunction (0008RNR / 0008RNX)...1904
DTC Description...1904
Circuit / System Description...1904
Diagnostic Aids...1904
Conditions for Running the DTC...1904
Conditions for Setting the DTC...1904
Action Taken When the DTC Sets...1904
Diagnostic Aids...1904
Circuit / System Verification...1904
Repair Instructions...1905
Radio Poor Reception...1906
DTC Descriptions...1906
Circuit / System Description...1906
Conditions for Running the DTC...1906
Conditions for Setting the DTC...1906
Action Taken When the DTC Sets...1906
Diagnostic Aids...1906
Circuit / System Verification...1906
Circuit / System Testing...1907
Component Testing...1908
Coax Cable Test...1908
Repair Instructions...1908
Speaker Malfunction...1909
Circuit / System Description...1909
Diagnostic Aids...1909
Special Tools...1909
Circuit / System Verification...1909
Circuit / System Testing...1910
Repair Instructions...1910
Voice Recognition Malfunction...1911
Circuit / System Description...1911
Diagnostic Aids...1911
Circuit / System Verification...1911
Circuit / System Testing...1911
Repair Instructions...1913
Diagnostic Information and Procedures...1915
DTC B0997...1915
DTC Description...1915
Circuit / System Description...1915
Conditions for Running DTC...1915
Conditions for Setting the DTC...1915
B0997 3A...1915
B0997 39...1915
Action Taken When DTC Sets...1915
Circuit / System Verification...1915
Repair Instructions...1916
DTC B1024...1917
DTC Description...1917
Circuit / System Description...1917
Conditions for Running the DTC...1917
Conditions for Setting the DTC...1917
B1024 53...1917
B1024 54...1917
Action Taken When the DTC Sets...1917
Circuit / System Verification...1917
Repair Instructions...1918
DTC B1025 – B1135...1919
DTC Description...1919
Circuit / System Description...1919
Conditions for Running the DTC...1919
Conditions for Setting the DTC...1919
Action Taken When the DTC Sets...1920
Circuit / System Verification...1920
Circuit / System Testing...1920
DTC B124B (0008RNN / 0008RNM)...1921
DTC Description...1921
Conditions for Running the DTC...1921
Conditions for Setting the DTC...1921
Action Taken When the DTC Sets...1921
Special Tools...1921
Circuit / System Verification...1922
Circuit / System Testing...1922
Repair Instructions...1923
DTC B124B (0008RNR / 0008RNX)...1924
DTC Description...1924
Circuit / System Description...1924
Auxiliary Audio Input Jack...1924
USB Port...1924
SD Card Reader...1925
Conditions for Running the DTC...1925
Conditions for Setting the DTC...1925
B124B 0B...1925
B124B 04...1925
B124B 11...1925
Action Taken When the DTC Sets...1925
Special Tools...1925
Circuit / System Verification...1925
Circuit / System Testing...1926
Repair Instructions...1927
DTC B124F...1928
DTC Description...1928
Circuit / System Description...1928
Conditions for Running the DTC...1928
Conditions for Setting the DTC...1928
Action Taken When the DTC Sets...1928
Circuit / System Verification...1928
Repair Instructions...1928
DTC B125A...1929
DTC Descriptions...1929
Circuit / System Description...1929
Conditions for Running the DTC...1929
Conditions for Setting the DTC...1929
B125A 02...1929
B125A 04...1929
B125A 01...1929
Action Taken When the DTC Sets...1929
Circuit / System Verification...1929
Circuit / System Testing...1930
Component Testing...1930
Coax Cable Test...1930
Repair Instructions...1931
DTC B125C...1932
DTC Descriptions...1932
Circuit / System Description...1932
Conditions for Running the DTC...1932
Conditions for Setting the DTC...1932
Action Taken When the DTC Sets...1932
Special Tools...1932
Circuit / System Verification...1932
Circuit / System Testing...1932
Component Testing...1933
Coax Cable Test...1933
Repair Instructions...1933
DTC B126A...1934
DTC Description...1934
Circuit / System Description...1934
Conditions for Running the DTC...1934
Conditions for Setting the DTC...1934
Action Taken When the DTC Sets...1934
Diagnostic Aids...1934
Circuit / System Verification...1934
Repair Instructions...1934
DTC B1271...1935
DTC Description...1935
Circuit / System Description...1935
Conditions for Running the DTC...1935
Conditions for Setting the DTC...1935
Action Taken When the DTC Sets...1935
Circuit / System Verification...1935
Repair Instructions...1935
DTC B1277 (0008RNR / 0008RNX)...1936
DTC Description...1936
Circuit / System Description...1936
Conditions for Running the DTC...1936
Conditions for Setting the DTC...1936
B1277 02...1936
B1277 04...1936
Action Taken When the DTC Sets...1936
Circuit / System Testing...1936
Repair Instructions...1938
DTC B1277 (0008RNM)...1939
DTC Description...1939
Circuit / System Description...1939
Conditions for Running the DTC...1939
Conditions for Setting the DTC...1939
B1277 02...1939
B1277 04...1939
Action Taken When the DTC Sets...1939
Circuit / System Testing...1939
Repair Instructions...1941
DTC B127E (0008RNN)...1942
DTC Description...1942
Circuit / System Description...1942
Conditions for Running the DTC...1942
Conditions for Setting the DTC...1942
Action Taken When the DTC Sets...1942
Special Tools...1942
Circuit / System Testing...1942
Repair Instructions...1943
DTC B127E (0008RNM)...1944
DTC Description...1944
Circuit / System Description...1944
Conditions for Running the DTC...1944
Conditions for Setting the DTC...1944
Action Taken When the DTC Sets...1944
Circuit / System Testing...1944
Repair Instructions...1945
DTC B127E (0008RNR / 0008RNX)...1946
DTC Description...1946
Circuit / System Description...1946
Conditions for Running the DTC...1946
Conditions for Setting the DTC...1946
Action Taken When the DTC Sets...1946
Diagnostic Aids...1946
Special Tools...1946
Circuit / System Verification...1946
Repair Instructions...1947
DTC B12A4...1948
DTC Descriptions...1948
Circuit / System Description...1948
Conditions for Running the DTC...1948
Conditions for Setting the DTC...1948
Action Taken when the DTC Sets...1948
Diagnostic Aids...1948
Circuit / System Verification...1948
Repair Instructions...1949
DTC B12A6...1950
DTC Description...1950
Circuit / System Description...1950
Conditions for Running the DTC...1950
Conditions for Setting the DTC...1950
Action Taken when the DTC Sets...1950
Diagnostic Aids...1950
Circuit / System Verification...1950
Repair Instructions...1950
DTC B12A8...1951
DTC Description...1951
Circuit / System Description...1951
Conditions for Running the DTC...1951
Conditions for Setting the DTC...1951
Action Taken When the DTC Sets...1951
Diagnostic Aids...1951
Circuit / System Verification...1951
Repair Instructions...1951
DTC B2455...1952
DTC Descriptors...1952
Circuit / System Description...1952
Conditions for Running the DTC...1952
Conditions for Setting the DTC...1952
B2455 01...1952
B2455 02...1952
B2455 04...1952
Action Taken When the DTC Sets...1952
Circuit / System Testing...1953
Repair Instructions...1954
DTC B2462...1955
DTC Description...1955
Circuit Description...1955
Conditions for Running the DTC...1955
Conditions for Setting the DTC...1955
Actions Taken When the DTC Sets...1955
Diagnostic Aids...1955
Special Tools...1955
Circuit / System Testing...1955
Component Testing...1956
Coax Cable Test...1956
Repair Instructions...1956
DTC B2470...1957
DTC Descriptions...1957
Circuit / System Description...1957
Conditions for Running the DTC...1957
Conditions for Setting the DTC...1957
Action Taken When the DTC Sets...1957
Special Tools...1957
Circuit / System Testing...1957
Component Testing...1958
Coax Cable Test...1958
Repair Instructions...1959
DTC B2476 or B2482...1960
DTC Descriptions...1960
Circuit / System Description...1960
Conditions for Running the DTC...1960
Conditions for Setting the DTC...1960
Action Taken When the DTC Sets...1960
Diagnostic Aids...1960
Circuit / System Verification...1961
Circuit / System Testing...1961
Repair Instructions...1962
11. Datalinks...1963
GMLAN Systems...1965
Overview...1965
Circuit Description...1965
High Speed GMLAN Circuit Description...1966
Chassis High Speed GMLAN Circuit Description...1966
Powertrain High Speed GMLAN Circuit Description...1966
Media Oriented Systems Transport (MOST) Circuit Description...1966
Low Speed GMLAN Circuit Description...1967
Local Interconnect Network (LIN) Circuit Description...1968
Communication Enable Circuit Description...1968
Data Link Connector (DLC)...1968
Serial Data Reference...1968
Data Link References...1968
Control Module U-code List...1970
Operational Checkout Procedure...1987
Visual / Physical Inspection...1987
Intermittent...1987
Symptom List...1987
Scan Tool Does Not Communicate with Gateway Expansion High Speed GMLAN Device...1988
Circuit / System Description...1988
Conditions for Running the DTC...1988
Conditions for Setting the DTC...1988
Action Taken When the DTC Sets...1988
Circuit / System Verification...1988
Circuit / System Testing...1989
Testing the Serial Data Circuits for a short to voltage...1990
Testing the Serial Data Circuits for a short to ground...1990
Testing the Serial Data Circuits for a Short between the Circuits...1991
Testing the Serial Data Circuits for an open / high resistance...1991
Testing the Device Circuits...1991
Repair Instructions...1993
Scan Tool Does Not Communicate with Gateway Isolated High Speed GMLAN Device...1994
Circuit / System Description...1994
Conditions for Running the DTC...1994
Conditions for Setting the DTC...1994
Action Taken When the DTC Sets...1994
Circuit/System Verification...1994
Circuit / System Testing...1995
Testing the Serial Data Circuits for a short to voltage...1996
Testing the Serial Data Circuits for a short to ground...1996
Testing the Serial Data Circuits for a Short between the Circuits...1997
Testing the Serial Data Circuits for an open / high resistance...1997
Testing the Device Circuits...1997
Repair Instructions...1999
Scan Tool Does Not Communicate with Gateway Isolated Low Speed GMLAN Device...2000
Circuit / System Description...2000
Conditions for Running the DTC...2000
Conditions for Setting the DTC...2000
Action Taken When the DTC Sets...2000
Circuit / System Verification...2000
Circuit / System Testing...2001
Testing the Serial Data Circuit for an open / high resistance...2002
Testing the Device Circuits...2003
Repair Instructions...2004
Scan Tool Does Not Communicate with High Speed GMLAN Device...2005
Circuit / System Description...2005
Diagnostic Aids...2005
Circuit / System Verification...2006
Verifying the Serial Data Circuits using Data Bus Diagnostic Tool...2006
Verifying the Serial Data Circuits using Digital Multimeter...2007
Circuit / System Testing...2009
Testing the Serial Data Circuits for a short to voltage...2009
Testing the Serial Data Circuits for a short to ground...2010
Testing the Serial Data Circuits for a Short between the Circuits...2010
Testing the Serial Data Circuits for an open / high resistance (Data Bus Diagnostic Tool)...2011
Testing the Serial Data Circuits for an open / high resistance (Digital Multimeter)...2011
Testing the Device Circuits...2012
Repair Instructions...2014
Scan Tool Does Not Communicate with Low Speed GMLAN Device...2015
Circuit / System Description...2015
Diagnostic Aids...2015
Circuit / System Verification...2016
Verifying the Serial Data Circuits using Data Bus Diagnostic Tool...2016
Verifying the Serial Data Circuits using Digital Multimeter...2016
Circuit / System Testing...2018
Testing the Serial Data Circuits for a short to voltage...2018
Testing the Serial Data Circuits for a short to ground...2019
Testing the Serial Data Circuit for an open / high resistance...2019
Testing the Device Circuits...2020
Repair Instructions...2022
Scan Tool Does Not Power Up...2023
Circuit / System Description...2023
Diagnostic Aids...2023
Circuit / System Testing...2023
DTC B1000...2025
DTC Description...2025
Circuit / System Description...2025
Conditions for Running the DTC...2025
Conditions for Setting the DTC...2025
Action Taken When the DTC Sets...2025
Diagnostic Aids...2025
Circuit / System Verification...2025
Repair Instructions...2025
DTC B1001...2026
DTC Description...2026
Circuit / System Description...2026
Conditions for Running the DTC...2026
Conditions for Setting the DTC...2026
Circuit / System Verification...2026
Repair Instructions...2026
DTC B101D...2027
DTC Description...2027
Circuit / System Description...2027
Conditions for Running the DTC...2027
Conditions for Setting the DTC...2027
Action Taken When the DTC Sets...2027
Diagnostic Aids...2027
Circuit / System Verification...2027
Repair Instructions...2027
DTC B101E...2028
DTC Description...2028
Circuit / System Description...2028
Conditions for Running the DTC...2028
Conditions for Setting the DTC...2028
Circuit / System Verification...2028
Repair Instructions...2028
DTC C0550...2029
DTC Description...2029
Circuit / System Description...2029
Conditions for Running the DTC...2029
Conditions for Setting the DTC...2029
Action Taken When the DTC Sets...2029
Diagnostic Aids...2029
Circuit / System Verification...2029
Repair Instructions...2030
DTC C056D...2031
DTC Description...2031
Circuit / System Description...2031
Conditions for Running the DTC...2031
Conditions for Setting the DTC...2031
Action Taken When the DTC Sets...2031
Diagnostic Aids...2031
Circuit / System Verification...2031
Repair Instructions...2031
DTC C056E...2032
DTC Description...2032
Circuit / System Description...2032
Conditions for Running the DTC...2032
Conditions for Setting the DTC...2032
Circuit / System Verification...2032
Repair Instructions...2032
DTC P0601 - P0607, P060A - P060C, P0610, P062F, P16E9 - P16F0, P262B, or P30D6 - P30DD...2033
DTC Descriptions...2033
Circuit / System Description...2033
Conditions for Running the DTC...2034
Conditions for Setting the DTC...2034
Action Taken When the DTC Sets...2034
Diagnostic Aids...2034
Circuit / System Verification...2034
Repair Instructions...2034
DTC U0020...2035
DTC Description...2035
Circuit / System Description...2035
Conditions for Running the DTCs...2035
Conditions for Setting the DTC...2035
Action Taken When the DTCs Sets...2035
Circuit / System Verification...2035
DTC U0028...2036
DTC Description...2036
Circuit / System Description...2036
Conditions for Running the DTC...2036
Conditions for Setting the DTC...2036
Action Taken When the DTC Sets...2036
Diagnostic Aids...2037
Special Tools...2037
Circuit / System Verification...2037
Circuit / System Testing...2038
Repair Instructions...2040
Repair Verification...2040
DTC U0029...2042
DTC Description...2042
Circuit / System Description...2042
Conditions for Running the DTC...2042
Conditions for Setting the DTC...2042
Action Taken When the DTC Sets...2042
Diagnostic Aids...2042
Circuit / System Verification...2042
Repair Instructions...2042
DTC U0073 or U2100...2043
DTC Descriptions...2043
Circuit / System Description...2043
Conditions for Running the DTCs...2043
Conditions for Setting the DTC...2043
Action Taken When the DTCs Sets...2043
Circuit / System Verification...2043
DTC U0074...2044
DTC Description...2044
Circuit / System Description...2044
Conditions for Running the DTC...2044
Conditions for Setting the DTC...2044
Action Taken When the DTC Sets...2044
Diagnostic Aids...2044
Circuit / System Testing...2045
Testing the Serial Data Circuits for a short to voltage...2046
Testing the Serial Data Circuits for a short to ground...2047
Testing the Serial Data Circuits for a Short between the Circuits...2047
Testing the Serial Data Circuits for an open / high resistance...2047
Testing the Device Circuits...2048
Repair Instructions...2049
DTC U0075...2050
DTC Description...2050
Circuit / System Description...2050
Conditions for Running the DTC...2050
Conditions for Setting the DTC...2050
Action Taken When the DTC Sets...2050
Diagnostic Aids...2050
Circuit / System Verification...2051
Circuit / System Testing...2053
Testing the Serial Data Circuits for a short to voltage...2053
Testing the Serial Data Circuits for a short to ground...2054
Testing the Serial Data Circuits for a Short between the Circuits...2054
Testing the Serial Data Circuits for an open / high resistance...2055
Testing the Device Circuits...2056
Repair Instructions...2057
DTC U0076...2058
DTC Description...2058
Circuit / System Description...2058
Conditions for Running the DTC...2058
Conditions for Setting the DTC...2058
Action Taken When the DTC Sets...2058
Description and Operation...2058
Circuit / System Testing...2059
Testing the Serial Data Circuits for a short to voltage...2060
Testing the Serial Data Circuits for a short to ground...2060
Testing the Serial Data Circuits for a Short between the Circuits...2060
Testing the Serial Data Circuits for an open / high resistance...2061
Testing the Device Circuits...2061
Repair Instructions...2063
DTC U0077...2064
DTC Description...2064
Circuit / System Description...2064
Conditions for Running the DTC...2064
Conditions for Setting the DTC...2064
Action Taken When the DTC Sets...2064
Diagnostic Aids...2065
Circuit / System Verification...2065
Circuit / System Testing...2067
Testing the Serial Data Circuits for a short to voltage...2067
Testing the Serial Data Circuits for a short to ground...2068
Testing the Serial Data Circuits for a Short between the Circuits...2068
Testing the Serial Data Circuits for an open / high resistance...2069
Testing the Device Circuits...2070
Repair Instructions...2071
DTC U0078...2072
DTC Description...2072
Circuit / System Description...2072
Conditions for Running the DTC...2072
Conditions for Setting the DTC...2072
Action Taken When the DTC Sets...2072
Circuit / System Verification...2072
DTC U007B...2073
DTC Description...2073
Circuit / System Description...2073
Conditions for Running the DTC...2073
Conditions for Setting the DTC...2073
Action Taken When the DTC Sets...2073
Circuit / System Verification...2073
Circuit / System Testing...2074
Testing the Serial Data Circuits for a short to voltage...2075
Testing the Serial Data Circuits for a short to ground...2075
Testing the Serial Data Circuits for a Short between the Circuits...2075
Testing the Serial Data Circuits for an open / high resistance...2076
Testing the Device Circuits...2076
Repair Instructions...2078
DTC U007C...2079
DTC Description...2079
Circuit / System Description...2079
Conditions for Running the DTC...2079
Conditions for Setting the DTC...2079
Action Taken When the DTC Sets...2079
Circuit / System Verification...2079
Circuit / System Testing...2080
Testing the Serial Data Circuits for a short to voltage...2081
Testing the Serial Data Circuits for a short to ground...2081
Testing the Serial Data Circuits for a Short between the Circuits...2081
Testing the Serial Data Circuits for an open / high resistance...2082
Testing the Device Circuits...2082
Repair Instructions...2084
DTC U007D...2085
DTC Description...2085
Circuit / System Description...2085
Conditions for Running the DTC...2085
Conditions for Setting the DTC...2085
Action Taken When the DTC Sets...2085
Circuit / System Verification...2085
Circuit / System Testing...2086
Testing the Serial Data Circuits for a short to voltage...2087
Testing the Serial Data Circuits for a short to ground...2088
Testing the Serial Data Circuits for an open / high resistance...2088
Testing the Device Circuits...2089
Repair Instructions...2091
DTC U0100 – U02FF...2092
DTC Description...2092
Circuit / System Description...2092
Conditions for Running the DTC...2092
Conditions for Setting the DTC...2092
Action Taken When the DTC Sets...2093
Diagnostic Aids...2093
Circuit / System Verification...2094
Circuit / System Testing...2095
Repair Instructions...2097
DTC U010C, U010E, U029D, U029E, or U02A3...2098
DTC Descriptions...2098
Circuit / System Description...2098
Conditions for Running the DTC...2098
Conditions for Setting the DTC...2099
Action Taken When the DTC Sets...2099
Circuit / System Verification...2099
Circuit / System Testing...2099
U010C...2099
U010E...2100
U029D...2102
U029E...2103
U02A3...2104
Repair Instructions...2105
DTC U01B0...2106
DTC Description...2106
Circuit / System Description...2106
Conditions for Running the DTC...2106
Conditions for Setting the DTC...2106
Action Taken When the DTC Sets...2106
Diagnostic Aids...2106
Circuit System Verification...2107
Circuit / System Testing...2107
Repair Instructions...2110
DTC U0300 - U0336...2111
DTC Descriptions...2111
Circuit / System Description...2111
Conditions for Running the DTC...2111
Conditions for Setting the DTC...2111
Circuit / System Verification...2111
Repair Instructions...2111
DTC U0400 - U05FF...2112
DTC Description...2112
Circuit / System Description...2112
Conditions for Running the DTC...2112
Conditions for Setting the DTC...2112
Diagnostic Aids...2112
Circuit / System Verification...2112
Repair Instructions...2113
DTC U1026...2114
DTC Description...2114
Circuit / System Description...2114
Conditions for Running the DTC...2114
Conditions for Setting the DTC...2114
Action Taken When the DTC Sets...2114
Circuit / System Verification...2114
Circuit / System Testing...2115
Repair Instructions...2117
DTC U1340 - U135F...2118
DTC Descriptions...2118
Circuit / System Description...2118
Conditions for Running the DTC...2118
Conditions for Setting the DTC...2118
Action Taken When the DTC Sets...2118
Diagnostic Aids...2118
Circuit / System Verification...2119
Circuit / System Testing...2119
Repair Instructions...2122
DTC U1500 - U15FF...2123
DTC Description...2123
Circuit / System Description...2123
Conditions for Running the DTC...2123
Conditions for Setting the DTC...2123
Action Taken When the DTC Sets...2123
Diagnostic Aids...2123
Circuit / System Verification...2124
Circuit / System Testing...2125
Repair Instructions...2128
DTC U1814...2129
DTC Description...2129
Circuit / System Description...2129
Conditions for Running the DTC...2129
Conditions for Setting the DTC...2129
Action Taken When the DTC Sets...2129
Circuit / System Testing...2129
Repair Instructions...2130
DTC U1818...2131
DTC Description...2131
Circuit / System Description...2131
Conditions for Running the DTC...2131
Conditions for Setting the DTC...2131
Action Taken When the DTC Sets...2131
Circuit / System Verification...2131
Circuit / System Testing...2132
Repair Instructions...2133
DTC U1833...2134
DTC Description...2134
Circuit / System Description...2134
Conditions for Running the DTC...2134
Conditions for Setting the DTC...2134
Action Taken When the DTC Sets...2134
Circuit / System Verification...2134
Circuit / System Testing...2135
Repair Instructions...2137
DTC U183A...2138
DTC Description...2138
Circuit / System Description...2138
Conditions for Running the DTC...2138
Conditions for Setting the DTC...2138
Action Taken When the DTC Sets...2138
Circuit / System Verification...2138
Circuit / System Testing...2139
Repair Instructions...2141
DTC U183E...2142
DTC Descriptor...2142
Circuit / System Description...2142
Conditions for Running the DTC...2142
Conditions for Setting the DTC...2142
Action Taken When the DTC Sets...2142
Circuit / System Verification...2142
Circuit / System Testing...2143
Repair Instructions...2144
DTC U184A...2145
DTC Description...2145
Circuit / System Description...2145
Conditions for Running the DTC...2145
Conditions for Setting the DTC...2145
Action Taken When the DTC Sets...2145
Diagnostic Aids...2146
Circuit / System Verification...2146
Circuit / System Testing...2146
Repair Instructions...2148
DTC U184C...2149
DTC Description...2149
Circuit / System Description...2149
Conditions for Running the DTC...2149
Conditions for Setting the DTC...2149
Action Taken When the DTC Sets...2149
Circuit / System Verification...2149
Circuit / System Testing...2150
Repair Instructions...2151
DTC U18A2...2152
DTC Description...2152
Circuit / System Description...2152
Conditions for Running the DTC...2152
Conditions for Setting the DTC...2152
Action Taken When the DTC Sets...2152
Circuit / System Verification...2152
Circuit / System Testing...2153
Repair Instructions...2155
DTC U18B9 - U18BF...2156
DTC Descriptions...2156
Circuit / System Description...2156
Conditions for Running the DTC...2156
Conditions for Setting the DTC...2156
Circuit / System Verification...2156
Repair Instructions...2156
DTC U18C8...2157
DTC Description...2157
Circuit / System Description...2157
Conditions for Running the DTC...2157
Conditions for Setting the DTC...2157
Action Taken When the DTC Sets...2157
Circuit / System Verification...2157
Circuit / System Testing...2158
Repair Instructions...2160
DTC U2098...2161
DTC Descriptions...2161
Circuit / System Description...2161
Conditions for Running the DTC...2161
Conditions for Setting the DTC...2161
Action Taken When the DTC Sets...2161
Circuit / System Testing...2161
Repair Instructions...2162
DTC U2099...2163
DTC Descriptor...2163
Circuit / System Description...2163
Conditions for Running the DTC...2163
Conditions for Setting the DTC...2163
Action Taken When the DTC Sets...2163
Circuit / System Testing...2163
Repair Instructions...2164
DTC U2160 - U2231...2165
DTC Descriptions...2165
Circuit / System Description...2165
Conditions for Running the DTC...2165
Conditions for Setting the DTC...2165
Action Taken When the DTC Sets...2166
Diagnostic Aids...2166
Circuit / System Verification...2166
Circuit / System Testing...2167
Repair Instructions...2169
DTC U2500 - U25FF...2170
DTC Descriptions...2170
Circuit / System Description...2170
Conditions for Running the DTC...2170
Conditions for Setting the DTC...2170
Circuit / System Verification...2170
Repair Instructions...2170
DTC U2616...2171
DTC Description...2171
Circuit / System Description...2171
Conditions for Running the DTC...2171
Conditions for Setting the DTC...2171
Action Taken When the DTC Sets...2171
Circuit / System Verification...2171
Circuit / System Testing...2172
Repair Instructions...2173
DTC U3000...2174
DTC Description...2174
Circuit / System Description...2174
Conditions for Running the DTC...2174
Conditions for Setting the DTC...2174
Action Taken When the DTC Sets...2174
Diagnostic Aids...2174
Circuit / System Verification...2174
Repair Instructions...2174
DTC U3012...2175
DTC Description...2175
Circuit / System Description...2175
Conditions for Running the DTC...2175
Conditions for Setting the DTC...2175
Action Taken When the DTC Sets...2175
Diagnostic Aids...2175
Circuit / System Verification...2175
Repair Instructions...2175
Serial Data Gateway Module...2176
Overview...2176
12. Engine...2177
Engine Cooling...2177
Operational Checkout Procedure...2177
Important Preliminary Inspections Before Starting...2177
Visual / Physical Inspection...2177
Identifying Intermittent Conditions...2178
Symptom List...2178
Engine Overheating...2179
Loss of Coolant...2181
Engine Fails To Reach Normal Operating Temperature...2185
Cooling System Leak Test...2186
Overview...2186
Special Tools...2186
Equipment Condition...2186
Test Setup...2186
Test Procedure...2187
Follow-On Procedures...2188
Pressure Cap Test...2189
Overview...2189
Special Tools...2189
Equipment Condition...2189
Test Setup...2189
Test Procedure...2189
Follow-On Procedure...2190
Thermostat Operational Test...2191
Overview...2191
Special Tools...2191
Equipment Condition...2191
Test Setup...2191
Test Procedure...2191
Expected Outcome...2191
Follow-On Procedure...2191
Diagnostic Information and Procedures...2192
Strategy Based Diagnosis...2192
Additional Information...2193
Diagnostic System Check Instructions...2195
Diagnostic Instructions...2195
Diagnostic System Check...2196
Diagnostic Starting Point – Vehicle...2203
Diagnostic System Check – Vehicle...2204
Diagnostic Instructions...2204
Diagnostic System Check...2204
Symptoms – Vehicle...2206
Body Repair...2206
Body Systems...2206
Brakes...2206
Driver Information and Entertainment...2207
Engine...2207
Power and Signal Distribution...2207
Safety and Security...2207
Seats...2207
Steering...2207
Engine Does Not Crank...2207
Engine Cranks But Does Not Run...2207
Inspection / Maintenance System Check...2208
Diagnostic Repair Verification...2209
Drive Belt Falls Off and Excessive Wear Diagnosis...2210
Diagnostic Aids...2210
Drive Belt Tensioner Diagnosis...2213
Exhaust Brake...2214
Exhaust Brake Switch Malfunction...2214
Circuit / System Description...2214
Circuit / System Verification...2214
Circuit / System Testing...2214
Exhaust Brake Switch Circuit Diagnosis...2214
Exhaust Brake Switch Indicator Circuit Diagnosis...2215
Repair Instructions...2216
Fan...2217
Fan Clutch Diagnosis...2217
Circuit / System Description...2217
Circuit / System Verification...2217
Circuit / System Testing...2218
Component Testing...2221
Fan Clutch Relay Test...2221
Repair Instructions...2221
DTC P0480, P0691, or P0692...2222
DTC Description...2222
Diagnostic Fault Information...2222
Circuit / System Description ...2222
Conditions for Running the DTC...2222
Conditions for Setting the DTC ...2222
Actions Taken When the DTC Sets...2222
Circuit / System Testing...2222
Repair Instructions...2225
13. Exhaust...2226
Horizontal Single Exit...2226
Operational Checkout Procedure...2226
Visual / Physical Inspection...2226
Intermittent...2226
Symptom List...2226
Restricted Exhaust...2227
Diagnostic Aids...2227
Test Description...2227
Repair Instructions...2229
Exhaust Leakage...2230
DEFINITION...2230
Repair Instructions...2231
14. Exterior Lighting...2232
Operational Checkout Procedure...2232
Visual / Physical Inspection...2232
Intermittent...2232
Symptom List...2232
Cargo Lights (Cargo Lamps)...2233
Cargo Lights (Cargo Lamps) Malfunction...2233
Circuit / System Description...2233
Diagnostic Aids...2233
Circuit / System Verification...2233
Circuit / System Testing...2234
Cargo Lamp Switch Malfunction...2234
Cargo Lamps Malfunction...2235
Repair Instructions...2237
DTC B2560...2238
DTC Descriptions...2238
Circuit / System Description...2238
Conditions for Running the DTC...2238
Conditions for Setting the DTC...2238
DTC B2560 01...2238
DTC B2560 02...2238
DTC B2560 04...2238
Actions Taken When the DTC Sets...2238
Circuit / System Testing...2239
Repair Instructions...2239
DTC B256B...2240
DTC Description...2240
Circuit / System Description...2240
Conditions for Running the DTC...2240
Conditions for Setting the DTC...2240
Actions Taken When the DTC Sets...2240
Circuit / System Testing...2240
Repair Instructions...2241
Fog Lights (Fog Lamps)...2242
Overview...2242
Front Fog Lamps...2242
Fog Lights (Fog Lamps) Malfunction...2243
Circuit / System Description...2243
Circuit / System Verification...2243
Circuit / System Testing...2244
Front Fog Light (Fog Lamp) Switch Malfunction...2244
BCM Relay Control Malfunction...2245
Fog Lamps Control Malfunction...2246
Repair Instructions...2246
DTC B2530...2247
DTC Descriptions...2247
Circuit / System Description...2247
Conditions for Running the DTC...2247
Conditions for Setting the DTC...2247
DTC B2530 01...2247
DTC B2530 02...2247
DTC B2530 04...2247
Actions Taken When the DTC Sets...2248
Circuit / System Testing...2248
Repair Instructions...2248
DTC B2740...2249
DTC Description...2249
Circuit / System Description...2249
Conditions for Running the DTC...2249
Conditions for Setting the DTC...2249
Actions Taken When the DTC Sets...2249
Circuit / System Testing...2250
Repair Instructions...2251
Headlights (Headlamps)...2252
Overview...2252
Low Beam Headlamps...2252
Low Beam Headlamps...2252
High Beam Headlamps...2252
Flash to Pass...2252
Daytime Running Lights (Daytime Running Lamps) Malfunction...2254
Circuit / System Description...2254
Circuit / System Verification...2254
Circuit / System Testing...2255
Daytime Running Lamps Malfunction...2255
Ambient Light Sensor Malfunction...2255
Repair Instructions...2256
Headlights (Headlamps) Malfunction...2257
Circuit / System Description...2257
Low Beam Headlamps...2257
High Beam Headlamps...2258
Flash to Pass...2258
Circuit / System Verification...2258
Circuit / System Testing...2259
Headlight (Headlamp) Switch Malfunction...2259
Turn Signal / Switch Pack (Multifunction Switch) Malfunction...2262
Headlamps Malfunction – Low Beam...2263
Headlamps Malfunction – High Beam...2264
High Beam Indicator Malfunction...2266
Repair Instructions...2266
DTC B2575 or B2699...2267
DTC Descriptions...2267
Circuit / System Description...2267
Conditions for Running the DTC...2267
Conditions for Setting the DTC...2267
DTC B2575 01 and B2575 04...2267
DTC B2575 02...2267
DTC B2699 01 and B2699 04...2268
DTC B2699 02...2268
Actions Taken When the DTC Sets...2268
Circuit / System Testing...2268
DTC B2575...2268
DTC B2699...2269
Repair Instructions...2271
DTC B2580...2272
DTC Descriptions...2272
Circuit / System Description...2272
Conditions for Running the DTC...2272
Conditions for Setting the DTC...2272
DTC B2580 01...2272
DTC B2580 02 and DTC B2580 04...2272
Actions Taken When the DTC Sets...2273
Circuit / System Testing...2273
Repair Instructions...2273
DTC B2645...2274
DTC Descriptions...2274
Circuit / System Description...2274
Conditions for Running the DTC...2274
Conditions for Setting the DTC...2274
DTC B2645 03...2274
DTC B2645 07...2274
Actions Taken When the DTC Sets...2274
Circuit / System Testing...2275
Repair Instructions...2276
Headlight Switch (Headlamp Switch)...2277
Overview...2277
Battery Run Down Protection / Inadvertent Power...2277
DTC B1395...2278
DTC Descriptions...2278
Circuit / System Description...2278
Conditions for Running the DTC...2278
Conditions for Setting the DTC...2278
DTC B1395 03...2278
DTC B1395 07...2278
Actions Taken When the DTC Sets...2278
Diagnostic Aids...2279
Circuit / System Testing...2279
Repair Instructions...2280
DTC B1480...2281
DTC Description...2281
Circuit / System Description...2281
Conditions for Running the DTC...2281
Conditions for Setting the DTC...2281
Actions Taken When the DTC Sets...2281
Circuit / System Testing...2282
Repair Instructions...2283
DTC B3650...2284
DTC Description...2284
Circuit / System Description...2284
Conditions for Running the DTC...2284
Conditions for Setting the DTC...2284
Actions Taken When the DTC Sets...2284
Circuit / System Testing...2285
Repair Instructions...2286
DTC B3806...2287
DTC Description...2287
Circuit / System Description...2287
Conditions for Running the DTC...2287
Conditions for Setting the DTC...2287
Actions Taken When the DTC Sets...2287
Circuit / System Testing...2288
Repair Instructions...2289
Park, Marker, and Clearance Lights (Roof Clearance Lamps)...2290
Overview...2290
Park, Tail, and License Lamps...2290
Park Lamps...2290
Exterior Courtesy Lights (Exterior Courtesy Lamps) Malfunction...2291
Circuit / System Description...2291
Circuit / System Testing...2291
Repair Instructions...2293
Park, License, and / or Tail Lamps Malfunction...2294
Circuit / System Description...2294
Park Lamps / Tail Lamps...2294
License Plate Lamps...2294
Diagnostic Aids...2295
Circuit / System Verification...2295
Circuit / System Testing...2295
Headlight (Headlamp) Switch Malfunction...2295
Park Lamps Malfunction...2296
License Plate Lamps Malfunction...2298
Repair Instructions...2299
Reverse Lights (Backup Lamps)...2300
Overview...2300
Backup Lamps...2300
Automatic Transmission...2300
Reverse Lights (Backup Lamps) Malfunction...2301
Circuit / System Description...2301
Diagnostic Aids...2301
Circuit / System Testing...2301
Repair Instructions...2303
DTC B2545...2304
DTC Descriptions...2304
Circuit / System Description...2304
Conditions for Running the DTC...2304
Conditions for Setting the DTC...2304
DTC B2545 01...2304
DTC B2545 02...2304
DTC B2545 04...2305
Actions Taken When the DTC Sets...2305
Circuit / System Testing...2305
Repair Instructions...2305
Stop / Turn Lights...2306
Overview...2306
Stop Lamps...2306
Turn Signal Lamps...2306
Hazard Lamps...2306
Hazard Lights (Hazard Lamps) Malfunction...2307
Circuit / System Description...2307
Circuit / System Verification...2307
Circuit / System Testing...2307
Repair Instructions...2308
Stop Lights (Stop Lamps) Malfunction...2309
Circuit / System Description...2309
Diagnostic Aids...2309
Circuit / System Verification...2309
Circuit / System Testing...2311
Brake Pedal Position Sensor Malfunction...2311
BCM Relay Control Malfunction...2311
Stop Lamp Control Malfunction...2312
Center High Mounted Stop Lamp Control Malfunction...2313
Repair Instructions...2314
Turn Signal Lights (Turn Signal Lamps) and / or Indicators Malfunction...2315
Circuit / System Description...2315
Diagnostic Aids...2315
Circuit / System Verification...2315
Circuit / System Testing...2317
Turn Signal / Switch Pack (Multifunction Switch) Malfunction...2317
Front Turn Signal Lamps Malfunction...2318
BCM Relay Control Malfunction...2322
Rear Turn Signal Control Malfunction...2323
Turn Signal Indicators Malfunction...2324
Repair Instructions...2324
DTC B3596...2325
DTC Description...2325
Circuit / System Description...2325
Conditions for Running the DTC...2325
Conditions for Setting the DTC...2325
Actions Taken When the DTC Sets...2325
Circuit / System Testing...2325
Repair Instructions...2326
DTC B3884...2327
DTC Descriptions...2327
Circuit / System Description...2327
Conditions for Running the DTC...2327
Conditions for Setting the DTC...2327
DTC B3884 01...2327
DTC B3884 02...2327
DTC B3884 04...2327
Actions Taken When the DTC Sets...2327
Circuit / System Testing...2328
Repair Instructions...2328
DTC B3948 or B3949...2329
DTC Descriptions...2329
Circuit / System Description...2329
Conditions for Running the DTC...2329
Conditions for Setting the DTC...2329
DTC B3948 01 and B3948 04...2329
DTC B3948 02...2330
DTC B3949 01 and B3949 04...2330
DTC B3949 02...2330
Actions Taken When the DTC Sets...2330
DTC B3948...2330
DTC B3949...2330
Diagnostic Aids...2330
Circuit / System Testing...2330
DTC B3948...2330
DTC B3949...2332
Repair Instructions...2333
DTC C0277 or C0890...2334
DTC Descriptions...2334
Circuit / System Description...2334
Conditions for Running the DTC...2334
Conditions for Setting the DTC...2334
DTC C0277 06 and C0277 12...2334
DTC C0277 07...2335
DTC C0277 09...2335
DTC C0277 4B...2335
DTC C0890 03...2335
DTC C0890 07...2335
Actions Taken When the DTC Sets...2335
Circuit / System Verification...2335
Circuit / System Testing...2336
DTC C0277 06, C0277 07, C0277 12, C0890 03, and C0890 07...2336
DTC C0277 4B...2337
DTC C0277 09...2337
Repair Instructions...2338
DTC C0297...2339
DTC Descriptions...2339
Circuit / System Description...2339
Conditions for Running the DTC...2339
Conditions for Setting the DTC...2339
DTC C0297 01...2339
DTC C0297 02...2339
Actions Taken When the DTC Sets...2339
Diagnostic Aids...2339
Circuit / System Testing...2339
Repair Instructions...2340
15. HVAC...2341
On-Highway HVAC System...2341
Front HVAC System...2341
Overview...2341
Control Components...2341
HVAC Control...2341
HVAC Control Module...2341
Actuators...2341
Blower Motor...2342
Freeze Probe (Evaporator Temperature Sensor)...2342
A/C Refrigerant Pressure Sensor...2342
A/C Compressor...2342
Air Speed...2343
After Blow...2343
Air Delivery...2343
Heating and A/C Operation...2344
Recirculation Operation...2345
Electric Auxiliary Heater...2345
Operational Checkout Procedure...2347
Overview...2347
Visual / Physical Inspection...2347
Intermittent...2347
Symptom List...2347
Air Conditioning Compressor Malfunction...2349
Circuit / System Description...2349
Diagnostic Aids...2349
Circuit / System Verification...2349
Repair Instructions...2350
Air Conditioning Compressor Oil Diagnosis...2351
Overview...2351
System Malfunction...2352
Diagnostic Aids...2352
Circuit / System Verification...2352
Repair Instructions...2353
DTC B0193...2354
DTC Descriptions...2354
Circuit / System Description...2354
Conditions for Running the DTC...2354
Conditions for Setting the DTC...2354
Action Taken When the DTC Sets...2354
Diagnostic Aids...2354
Circuit / System Testing...2354
Repair Instructions...2356
DTC B0223, B0228, B0233, B0408, B0413, B1395, or B374A...2357
DTC Descriptions...2357
Circuit / System Description...2358
Conditions for Running the DTC...2358
Conditions for Setting the DTC...2359
B0223, B0233, B0408...2359
B0228 02, B0413 02, or B374A 02...2359
B0228 05, B0413 05, or B374A 05...2359
B0228 61, B0413 61, or B374A 61...2359
B1395 03...2359
B1395 07...2359
Action Taken When the DTC Sets...2359
B1395...2359
B0223, B0228, B0233, B0408, B0413, or B374A...2359
Diagnostic Aids...2359
Circuit / System Testing...2359
DTC B1395...2360
DTC B0223, B0228, B0233, B0408, B0413, or B374A...2360
Repair Instructions...2362
DTC B048D or B048E...2363
DTC Descriptions...2363
Circuit / System Description...2363
Conditions for Running the DTC...2363
Conditions for Setting the DTC...2363
B048D 01...2363
B048D 06...2363
B048E 00...2363
Action Taken When the DTC Sets...2363
Circuit / System Verification...2364
Circuit / System Testing...2364
Electrical Auxiliary Heater Control Circuit Malfunction...2364
Electrical Auxiliary Heater Signal Circuit Malfunction...2366
Repair Instructions...2367
DTC B1020...2368
DTC Description...2368
Circuit / System Description...2368
Conditions for Running the DTC...2368
Conditions for Setting the DTC...2368
Action Taken when the DTC Sets...2368
Diagnostic Aids...2368
Circuit / System Verification...2368
Repair Instructions...2368
DTC B3933...2369
DTC Description...2369
Circuit / System Description...2369
Conditions for Running the DTC...2369
Conditions for Setting the DTC...2369
Action Taken When the DTC Sets...2369
Circuit / System Testing...2369
Repair Instructions...2370
DTC B393B...2371
DTC Descriptions...2371
Circuit / System Description...2371
Conditions for Running the DTC...2371
Conditions for Setting the DTC...2371
B393B 04...2371
B393B 0B...2371
Action Taken When the DTC Sets...2371
B393B 04...2371
B393B 0B...2371
Circuit / System Testing...2371
Component Testing...2372
A/C Compressor Solenoid Valve Test...2372
Repair Instructions...2373
DTC P0532 or P0533...2374
DTC Descriptions...2374
Circuit / System Description...2374
Conditions for Running the DTC...2374
Conditions for Setting the DTC...2374
P0532...2374
P0533...2374
Action Taken When the DTC Sets...2374
Diagnostic Aids...2374
Circuit / System Verification...2374
Circuit / System Testing...2375
Repair Instructions...2376
DTC P0645, P0646, or P0647...2377
DTC Descriptions...2377
Circuit / System Description...2377
Conditions for Running the DTC...2377
Conditions for Setting the DTC...2377
P0645 or P0646...2377
P0647...2377
Action Taken When the DTC Sets...2377
P0645 or P0646...2377
P0647...2377
Circuit / System Testing...2378
Component Testing...2380
Repair Instructions...2380
HVAC Tests...2381
Air Conditioning System Performance Test...2381
Overview...2381
Special Tools...2381
Equipment Condition...2382
Test Procedure...2383
Follow-On Procedure...2385
Noise Diagnosis – HVAC Module...2387
Noise Diagnosis – Air Conditioning (A/C) System...2389
Odor Diagnosis...2393
Cause of Odors...2393
Noise Diagnosis - Blower Motor...2396
16. Instrumentation / Gauges...2398
Gauge Cluster...2398
Overview...2398
Gauge Cluster (Instrument Cluster) (0016HCT and 0016HCU)...2398
Gauge Cluster (Instrument Cluster) (0016HLY and 0016HLZ)...2398
INDICATOR LIGHT ON...2399
MESSAGE DISPLAYED...2399
BRAKES OVERHEATED...2400
Operational Checkout Procedure...2401
Visual / Physical Inspection...2401
Intermittent...2401
Symptom List...2401
Chime Malfunction...2402
Circuit / System Description...2402
Circuit / System Verification...2402
Repair Instructions ...2403
DTC B124F...2404
DTC Description...2404
Circuit / System Description...2404
Conditions for Running the DTC...2404
Conditions for Setting the DTC...2404
Actions Taken When the DTC Sets...2404
Circuit / System Verification ...2404
Repair Instructions ...2404
Gauges...2405
Compass...2405
Overview...2405
DTC B0931...2406
DTC Description...2406
Circuit / System Description...2406
Conditions for Running the DTC...2406
Conditions for Setting the DTC...2406
Actions Taken When the DTC Sets...2406
Circuit / System Verification...2406
Repair Instructions ...2406
Engine Coolant Temperature Gauge...2407
Overview...2407
Engine Oil Pressure Gauge...2408
Circuit / System Description...2408
Engine Oil Pressure Gauge Inaccurate or Inoperative...2409
DTC Descriptions...2409
Conditions for Running the DTC...2409
Conditions for Setting the DTC...2409
P0521...2409
P0522...2409
P0523...2409
Action Taken When the DTC Sets...2409
Diagnostic Aids...2409
Circuit / System Verification...2410
Circuit / System Testing...2410
Repair Instructions ...2412
DTC P0521, P0522, or P0523...2413
DTC Descriptions...2413
Circuit / System Description...2413
Conditions for Running the DTC...2413
Conditions for Setting the DTC...2413
P0521...2413
P0522...2413
P0523...2413
Action Taken When the DTC Sets...2414
Diagnostic Aids...2414
Circuit / System Verification...2414
Circuit / System Testing...2414
Repair Instructions ...2416
Fuel Gauge...2417
Overview...2417
Fuel Gauge Malfunction (Single Fuel Tank)...2418
DTC Descriptions...2418
Circuit / System Description...2418
Conditions for Running the DTC...2418
Conditions for Setting the DTC...2418
P0461...2418
P0462...2418
P0463...2418
P0464...2419
Action Taken When the DTC Sets...2419
P0461, P0462, and P0463...2419
P0464...2419
Circuit / System Verification...2419
Circuit / System Testing...2420
Component Testing...2421
Repair Instructions...2421
Fuel Gauge Malfunction (Dual Fuel Tanks)...2422
DTC Descriptions...2422
Circuit / System Description...2422
Conditions for Running the DTC...2422
Conditions for Setting the DTC...2422
P0461 or P2066...2422
P0462 or P2067...2422
P0463 or P2068...2423
P0464...2423
Action Taken When the DTC Sets...2423
P0464...2423
Circuit / System Verification...2423
Circuit / System Testing...2424
Primary Fuel Level Sensor Malfunction...2424
Secondary Fuel Level Sensor Malfunction...2425
Component Testing...2426
Repair Instructions...2426
DTC P0461 - P0464 (Single Fuel Tank)...2427
DTC Descriptions...2427
Circuit / System Description...2427
Conditions for Running the DTC...2427
Conditions for Setting the DTC...2427
Action Taken When the DTC Sets...2428
Circuit / System Verification...2428
Circuit / System Testing...2428
Component Testing...2430
Repair Instructions ...2430
DTC P0461 - P0464, P2066, P2067, or P2068 (Dual Fuel Tanks)...2431
DTC Descriptions...2431
Circuit / System Description...2431
Conditions for Running the DTC...2431
Conditions for Setting the DTC...2431
Action Taken When the DTC Sets...2432
Circuit / System Verification...2432
Circuit / System Testing...2432
Primary Fuel Level Sensor Malfunction...2433
Secondary Fuel Level Sensor Malfunction...2434
Component Testing...2435
Repair Instructions ...2435
DTC P1100...2436
DTC Description...2436
Circuit / System Description...2436
Conditions for Running the DTC...2436
Conditions for Setting the DTC...2436
Actions Taken When the DTC Sets...2436
Circuit / System Verification...2436
Repair Instructions ...2436
DTC P1200...2437
DTC Description...2437
Circuit / System Description...2437
Conditions for Running the DTC...2437
Conditions for Setting the DTC...2437
Actions Taken When the DTC Sets...2437
Circuit / System Verification...2437
Repair Instructions ...2437
DTC P1434...2438
DTC Description...2438
Circuit / System Description...2438
Conditions for Running the DTC...2438
Conditions for Setting the DTC...2438
Actions Taken When the DTC Sets...2438
Circuit / System Verification...2438
Repair Instructions ...2439
DTC P143E...2440
DTC Description...2440
Circuit / System Description...2440
Conditions for Running the DTC...2440
Conditions for Setting the DTC...2440
Actions Taken When the DTC Sets...2440
Circuit / System Verification...2440
Repair Instructions ...2441
Odometer...2442
Overview...2442
DTC B0550...2443
DTC Description...2443
Circuit / System Description ...2443
Conditions for Running the DTC ...2443
Conditions for Setting the DTC ...2443
Actions Taken When the DTC Sets ...2443
Circuit / System Verification ...2443
Repair Instructions ...2443
Outside Air Temperature...2444
Overview...2444
Outside Air Temperature Display Malfunction...2445
DTC Descriptions...2445
Circuit / System Description...2445
Conditions for Running the DTC...2445
Conditions for Setting the DTC...2445
P0071...2445
P0072...2445
P0073...2445
P0074...2445
Action Taken When the DTC Sets...2445
Diagnostics Aids...2446
Circuit / System Verification...2446
Circuit / System Testing...2446
Repair Instructions...2447
DTC P0070...2448
DTC Description...2448
Circuit / System Description...2448
Conditions for Running the DTC...2448
Conditions for Setting the DTC...2448
Actions Taken When the DTC Sets ...2448
Diagnostic Aids...2448
Circuit / System Verification...2448
Repair Instructions ...2449
DTC P0071 - P0074...2450
DTC Descriptions...2450
Circuit / System Description...2450
Conditions for Running the DTC...2450
Conditions for Setting the DTC...2450
Action Taken When the DTC Sets...2450
Diagnostics Aids...2451
Circuit / System Verification...2451
Circuit / System Testing...2451
Repair Instructions ...2452
Speedometer...2453
Overview...2453
Speedometer and / or Odometer Malfunction...2454
Circuit / System Description...2454
Diagnostic Aids...2454
Circuit / System Verification...2454
Circuit / System Testing...2455
Correcting VIN mismatch: Gauge Cluster (Instrument Cluster) is Showing “----” (Dashes), odometer is still unlocked...2455
Correcting VIN mismatch: Gauge Cluster (Instrument Cluster) is Showing “----” (Dashes), odometer is locked...2455
Repair Instructions...2456
Tachometer...2457
Overview...2457
Indicators...2458
ABS Indicator...2458
Overview...2458
Airbag Indicator...2459
Operational Checkout Procedure...2460
Visual / Physical Inspection...2460
Intermittent...2460
Symptom List...2460
Airbag Indicator Malfunction...2461
Circuit / System Description...2461
Diagnostic Aids...2461
Circuit / System Verification...2461
Circuit / System Testing...2461
Repair Instructions...2461
Brake Warning Indicator...2462
Overview...2462
Brake Warning Indicator Malfunction...2463
Circuit / System Description...2463
Circuit / System Verification...2463
Circuit / System Testing...2463
Brake Fluid Level Switch Malfunction...2463
Park Brake Switch Malfunction...2464
Repair Instructions...2465
Door Ajar Indicator...2466
Overview...2466
Door Ajar Indicator System Components...2466
Door Ajar System...2466
Driver Door Ajar...2466
Passenger and Rear Doors Ajar...2466
Driver, Passenger and Rear Doors Ajar...2466
Door Ajar Indicator Malfunction...2467
Circuit / System Description ...2467
Circuit / System Verification...2467
Circuit / System Testing...2468
Test 1 ...2468
Test 2 ...2469
Test 3 ...2471
Test 4 ...2473
Component Testing ...2474
Repair Instructions...2475
Engine Oil Level Indicator...2476
Overview...2476
Engine Oil Level Sensor Diagnosis...2477
DTC Description...2477
Typical Scan Tool Data...2477
Circuit / System Description...2477
Conditions for Running the DTC...2477
Conditions for Setting the DTC...2477
Action Taken When the DTC Sets...2478
Circuit / System Verification...2478
Circuit / System Testing...2478
Repair Instructions...2479
DTC P250A...2480
DTC Description...2480
Typical Scan Tool Data...2480
Circuit / System Description...2480
Conditions for Running the DTC...2480
Conditions for Setting the DTC...2480
Action Taken When the DTC Sets...2481
Circuit / System Verification...2481
Circuit / System Testing...2481
Repair Instructions ...2482
Engine Oil Pressure Indicator...2483
Engine Oil Pressure Indicator Malfunction...2484
DTC Descriptions...2484
Circuit / System Description...2484
Conditions for Running the DTC...2484
Conditions for Setting the DTC...2484
P0521...2484
P0522...2484
P0523...2484
Action Taken When the DTC Sets...2485
Diagnostic Aids...2485
Circuit / System Verification...2485
Circuit / System Testing...2485
Repair Instructions...2487
Hill Descent Control Indicator...2488
Overview...2488
Low Washer Fluid Indicator...2489
Low Washer Fluid Indicator Malfunction...2489
Circuit / System Description...2489
Circuit / System Verification...2489
Circuit / System Testing...2489
Repair Instructions...2490
Seat Belt Indicator...2491
Operational Checkout Procedure...2492
Visual / Physical Inspection...2492
Intermittent...2492
Symptom List...2492
Driver Seat Belt Indicator Malfunction...2493
Circuit / System Description...2493
Circuit / System Verification...2493
Circuit / System Testing...2493
Component Testing...2494
Repair Instructions...2495
Security Indicator...2496
Circuit / System Description...2496
Security Indicator Malfunction...2497
Circuit / System Verification...2497
Circuit / System Testing...2497
Repair Instructions...2498
Stability Control Off Indicator...2499
Overview...2499
Traction Control Off Indicator...2500
Overview...2500
Traction / Stability Control Indicator...2501
Overview...2501
Traction Control / Stability Control Indicator Malfunction...2502
Circuit / System Description...2502
Circuit / System Verification...2502
Circuit / System Testing...2502
Component Testing...2503
Repair Instructions...2504
Transmission Shift Lever Position Indicator...2505
Overview...2505
17. Interior Lighting...2506
Operational Checkout Procedure...2506
Visual / Physical Inspection...2506
Intermittent...2506
Symptom List...2506
Dome Lights (Dome Lamps)...2507
Overview...2507
Dome Lights (Dome Lamps) Malfunction...2508
Circuit / System Description...2508
Circuit / System Verification...2508
Circuit / System Testing...2509
Dome Lamp Switch Malfunction...2509
Dome Lamp Malfunction...2511
Repair Instructions...2512
Door Lights (Door Lamps)...2513
DTC B255F...2513
DTC Descriptions...2513
Circuit / System Description...2513
Conditions for Running the DTC...2513
Conditions for Setting the DTC...2513
DTC B255F 02...2513
DTC B255F 04...2513
Actions Taken When the DTC Sets...2513
Circuit / System Testing...2514
Repair Instructions...2514
Center Console Compartment Lights...2515
Overview...2515
Courtesy Lights (Courtesy Lamps) Malfunction...2516
Circuit / System Description...2516
Circuit / System Testing...2516
Repair Instructions...2518
Instrument Panel Lights...2519
Overview...2519
Interior Lamps Dimming...2519
Keyless Entry Interior Illumination...2520
Battery Rundown Protection / Inadvertent Power...2520
Interior Accent Lighting Malfunction...2521
Circuit / System Description...2521
Circuit / System Testing...2521
Repair Instructions...2523
Interior Backlighting Malfunction...2524
Circuit / System Description...2525
Diagnostic Aids...2525
Circuit / System Verification...2525
Circuit / System Testing...2525
Dimmer Switch Malfunction...2525
Interior Backlighting Malfunction...2527
Switch Indicator LED Backlighting Malfunction...2528
Passenger Air Bag Disable Indicator Backlighting Malfunction...2529
Repair Instructions...2530
DTC B2610...2531
DTC Descriptions...2531
Circuit / System Description...2532
Conditions for Running the DTC...2533
Conditions for Setting the DTC...2533
DTC B2610 02...2533
DTC B2610 04...2533
Actions Taken When the DTC Sets...2533
Circuit / System Testing...2533
Repair Instructions...2534
DTC B2625...2535
DTC Descriptions...2535
Circuit / System Description...2535
Conditions for Running the DTC...2535
Conditions for Setting the DTC...2535
DTC B2625 01...2535
DTC B2625 02...2535
DTC B2625 04...2535
Actions Taken When the DTC Sets...2535
Circuit / System Testing...2536
Repair Instructions...2537
DTC B3600...2538
DTC Descriptions...2538
Circuit / System Description...2538
Conditions for Running the DTC...2538
Conditions for Setting the DTC...2538
DTC B3600 03...2538
DTC B3600 07...2538
Actions Taken When the DTC Sets...2538
Diagnostic Aids...2539
Circuit / System Testing...2539
Repair Instructions...2540
Reading Lights (Reading Lamps)...2541
Overview...2541
Sun Visor Mirror Lights (Sunshade Mirror Lamps)...2542
Overview...2542
18. Safety...2543
Restraints...2543
Overview...2543
Seat Belt Does Not Retract...2544
Supplemental Inflatable Restraints (SIR) System...2545
DTC B0012 or B0013...2545
DTC Descriptions...2545
Circuit / System Description...2545
Conditions for Running the DTC...2545
Conditions for Setting the DTC...2545
B0012 01 or B0013 01 ...2545
B0012 02 or B0013 02 ...2546
B0012 04 or B0013 04 ...2546
B0012 0D or B0013 0D ...2546
B0012 0E or B0013 0E ...2546
Action Taken When the DTC Sets...2546
Diagnostic Aids...2546
Special Tools...2546
Circuit / System Verification...2547
Circuit / System Testing...2548
Repair Instructions...2551
DTC B0014, B0021, B0031, or B0038...2552
DTC Descriptions...2552
Circuit / System Description...2552
Conditions for Running the DTC...2552
Conditions for Setting the DTC...2552
B0014 01, B0021 01...2552
B0014 02, B0021 02...2552
B0014 04, B0021 04 ...2553
B0014 0D, B0021 0D...2553
B0014 0E, B0021 0E...2553
Action Taken When the DTC Sets...2553
Conditions for Clearing the DTC...2553
Diagnostic Aid...2553
Special Tools...2553
Circuit / System Verification...2554
Circuit / System Testing...2555
Repair Instructions...2557
DTC B0015, B001A, B001B, B0022...2558
DTC Descriptions...2558
Circuit / System Description...2559
Conditions for Running the DTC...2559
Conditions for Setting the DTC...2559
B0015 01, B001A 01, B001B 01, B0022 01...2559
B0015 02, B001A 02, B001B 02, B0022 02...2559
B0015 04, B001A 04, B001B 04, B0022 04...2559
B0015 0D, B001A 0D, B001B 0D, B0022 0D...2559
B0015 0E, B001A 0E, B001B 0E, B0022 0E...2559
Action Taken When the DTC Sets...2559
Conditions for Clearing the DTC...2559
Diagnostic Aid...2560
Special Tools...2560
Circuit / System Verification...2560
Circuit / System Testing...2561
Repair Instructions...2564
DTC B0016, B0018, B0023, B0025...2565
DTC Descriptions...2565
Diagnostic Fault Information...2565
Circuit / System Description...2565
Conditions for Running the DTC...2565
Conditions for Setting the DTC...2565
B0016 01, B0023 01...2565
B0016 02, B0023 02...2565
B0016 04, B0023 04...2566
B0016 0D, B0023 0D...2566
B0016 0E, B0023 0E...2566
Action Taken When the DTC Sets...2566
Conditions for Clearing the DTC...2566
Diagnostic Aid...2566
Special Tools...2566
Circuit / System Verification...2566
Circuit / System Testing...2568
Repair Instructions...2570
DTC B0019 or B0020...2571
DTC Descriptions...2571
Circuit / System Description...2571
Conditions for Running the DTC...2571
Conditions for Setting the DTC...2571
B0019 01, B0020 01...2571
B0019 02, B0020 02...2571
B0019 04, B0020 04...2572
B0019 0D, B0020 0D...2572
B0019 0E, B0020 0E...2572
Action Taken When the DTC Sets...2572
Diagnostic Aid...2572
Circuit / System Verification...2572
Circuit / System Testing...2574
Repair Instructions...2577
DTC B0022...2578
DTC Descriptions...2578
Circuit / System Description...2578
Conditions for Running the DTC...2578
Conditions for Setting the DTC...2578
B0022 01...2578
B0022 02...2578
B0022 04...2578
B0022 0D...2578
B0022 0E...2578
Action Taken When the DTC Sets...2578
Diagnostic Aid...2579
Special Tools...2579
Circuit / System Verification...2579
Circuit / System Testing...2580
Repair Instructions...2583
DTC B0052...2584
DTC Descriptions...2584
Circuit / System Description...2584
Conditions for Running the DTC...2584
Conditions for Setting the DTC...2584
Action Taken When the DTC Sets...2584
Circuit / System Verification...2584
Repair Instructions...2584
DTC B0079 or B0080...2585
DTC Descriptions...2585
Diagnostic Fault Information...2585
Circuit / System Description...2585
Conditions for Running the DTC...2586
Conditions for Setting the DTC...2586
B0079 01, B0080 01...2586
B0079 02, B0080 02...2586
B0079 04, B0080 04...2586
B0079 05, B0080 05...2586
B0079 06, B0080 06...2586
B0079 08, B0080 08...2586
B0079 0C, B0080 0C...2586
Action Taken When the DTC Sets...2586
Conditions for Clearing the DTC...2586
Circuit / System Verification...2586
Circuit / System Testing...2587
Repair Instructions...2589
DTC B0082 - B0088...2590
DTC Descriptions...2590
Circuit / System Description...2591
Conditions for Running the DTC...2592
Conditions for Setting the DTC...2592
B0083 02, B0084 02, B0085 02, B0086 02, B0087 02, B0088 02...2592
B0083 05, B0084 05, B0085 05, B0086 05, B0087 05, B0088 05...2592
B0083 08, B0084 08, B0085 08, B0086 08, B0087 08, B0088 08...2592
B0083 0F, B0084 0F, B0085 0F, B0086 0F, B0087 0F, B0088 0F...2592
B0083 39, B0084 39, B0085 39, B0086 39, B0087 39, B0088 39...2592
B0083 3A, B0084 3A, B0085 3A, B0086 3A, B0087 3A, B0088 3A...2592
B0083 71, B0084 71, B0085 71, B0086 71, B0087 71, B0088 71...2592
Action Taken When the DTC Sets...2592
Conditions for Clearing the DTC...2592
Circuit / System Verification...2593
Circuit / System Testing...2594
Repair Instructions...2596
DTC B008F...2597
DTC Descriptions...2597
Circuit/System Description...2597
Conditions for Running the DTC...2597
Conditions for Setting the DTC...2597
B008F 02...2597
B008F 05...2597
Action Taken When the DTC Sets...2597
Conditions for Clearing the DTC...2597
Circuit / System Verification...2597
Circuit / System Testing...2598
Component Testing...2599
Repair Instructions...2599
DTC B0091...2600
DTC Descriptions...2600
Circuit / System Description...2600
Conditions for Running the DTC...2600
Conditions for Setting the DTC...2601
B0091 02...2601
B0091 04...2601
B0091 05...2601
B0091 08...2601
B0091 0F...2601
B0091 39...2601
B0091 3A...2601
B0091 71...2601
Action Taken When the DTC Sets...2601
Diagnostic Aid...2601
Circuit / System Verification...2602
Circuit / System Testing...2603
Repair Instructions...2605
DTC B0098...2606
DTC Descriptions...2606
Circuit / System Description...2606
Conditions for Running the DTC...2606
Conditions for Setting the DTC...2606
B0098 01...2606
B0098 02...2606
B0098 04...2606
Action Taken When the DTC Sets...2606
Circuit / System Verification...2606
Circuit / System Testing...2607
Component Testing...2608
Repair Instructions...2609
DTC B1001...2610
DTC Description...2610
Circuit / System Description...2610
Conditions for Running the DTC...2610
Conditions for Setting the DTC...2610
Action Taken When the DTC Sets...2610
Diagnostic Aids...2610
Circuit / System Verification...2610
Repair Instructions...2610
DTC B1019...2611
DTC Descriptor...2611
Circuit / System Description...2611
Conditions for Running the DTC...2611
Conditions for Setting the DTC...2611
Action Taken When the DTC Sets...2611
Diagnostic Aids...2611
Circuit / System Verification...2611
Repair Instructions...2613
19. Seats...2614
Manual Seats...2614
Operational Checkout Procedure...2614
Adjuster Track Locks Ahead of Other Track...2615
Hard to Move Forward and Rearward...2616
Manual Seat Adjuster Does Not Lock...2617
Manual Seat Adjuster Does Not Unlock...2618
Manual Seat Adjuster Locks Between Lock Positions...2619
Power Seats...2620
Overview...2620
Seat Motors...2620
Seat Operation...2620
Lumbar Support...2620
Operational Checkout Procedure...2621
Visual / Physical Inspection...2621
Intermittent...2621
Symptom List...2621
Lumbar Support Malfunction...2622
Circuit / System Description...2622
Circuit / System Verification...2622
Circuit / System Testing...2622
Component Testing...2623
Seat Adjuster Switch...2623
Seat Lumbar Support Horizontal Motor...2623
Repair Instructions...2624
Power Seat Adjuster Mechanical Diagnosis...2625
Power Seat Malfunction...2626
Circuit / System Description...2626
Circuit / System Verification...2626
Circuit / System Testing...2627
Seat Adjuster Switch Circuit Test...2627
Seat Motor Circuit Test...2628
Component Testing...2628
Seat Adjuster Switch Test...2628
Seat Motor...2629
Repair Instructions...2629
Heated / Vented Seats...2630
Overview...2630
Components...2630
Seat Switches...2630
Heated Seat Operation...2630
Temperature Regulation...2631
Vented Seat Operation...2631
Remote Start...2631
Load Shed...2631
DTC B191A...2632
DTC Description...2632
Circuit / System Description...2632
Conditions for Running the DTC...2632
Conditions for Setting the DTC...2632
Action Taken When the DTC Sets...2632
Circuit / System Verification...2632
Repair Instructions...2632
DTC B243A or B243B...2633
DTC Descriptions...2633
Circuit / System Description...2633
Conditions for Running the DTC...2633
Conditions for Setting the DTC...2633
Action Taken When the DTC Sets...2633
Circuit / System Verification...2633
DTC B243A...2633
DTC B243B...2633
Repair Instructions...2633
20. Steering...2634
Power Steering...2634
Operational Checkout Procedure...2634
Visual / Physical Inspection...2634
Symptoms List...2634
Poor Return of Steering Wheel...2635
Steering Wheel Surges / Jerks While Turning...2639
Steering Effort Hard in One or Both Directions...2642
Power Steering System Test...2643
Power Steering Fluid Leak Inspection...2647
Overview...2647
Special Tools...2647
Equipment Conditions...2647
Inspection Procedure...2647
Follow-On Procedure...2647
21. Trailer...2648
Electric Trailer Brake...2648
Overview...2648
Trailer Sway Control...2648
DTC C111A...2649
DTC Description...2649
Circuit / System Description...2649
Conditions for Running the DTC...2649
Conditions for Setting the DTC...2649
Action Taken When the DTC Sets...2649
Circuit / System Testing...2649
Repair Instructions...2649
DTC C1114, C111B, C1595, or C1596...2650
DTC Description...2650
Circuit / System Description...2650
Conditions for Running the DTC...2650
Conditions for Setting the DTC...2650
C111B 03...2650
C111B 07...2650
C111B 5A...2651
C1595 00...2651
C1596 01...2651
C1596 02...2651
C1114 00...2651
Action Taken When the DTC Sets...2651
C111B 03, C111B 07, C111B 5A...2651
C1595 00, C1595 01, C1595 02, C1114 00...2651
Diagnostic Aids...2651
Circuit / System Verification...2652
Circuit / System Testing...2653
Repair Instructions...2655
DTC C1115 - C1118 or C1562...2656
DTC Description...2656
Circuit / System Description...2656
Conditions for Running the DTC...2656
Conditions for Setting the DTC...2656
C1115 08 or C1115 5A...2656
C1116 00...2657
C1117 00...2657
C1118 00...2657
C1562 00...2657
Action Taken When the DTC Sets...2657
C1115 08 or C1115 5A...2657
C1116 00 or C1117 00...2657
C1118 00...2657
C1562 00...2657
Circuit / System Verification...2657
Circuit / System Testing...2658
Repair Instructions...2660
Trailer Lighting...2661
Overview...2661
Backup Lamps...2661
Park Lamps...2661
Stop Lamps...2661
Turn Signal Lamps...2661
Operational Checkout Procedure...2662
Visual / Physical Inspection...2662
Intermittent...2662
Symptom List...2662
Trailer Lights (Trailer Lamps) Malfunction...2663
Circuit / System Description...2663
Diagnostic Aids...2663
Circuit / System Verification...2663
Circuit / System Testing...2664
Trailer Backup Lamps Malfunction...2664
Trailer Park Lamps Malfunction...2665
Trailer Stop / Turn Signal Lamps Malfunction...2666
Repair Instructions...2668
22. Transmission...2669
Allison Transmission®...2669
Overview...2669
Shift Lock Control...2669
Diagnostic Information and Procedures...2670
DTC P0218 – Indicates a sump temperature threshold has been exceeded...2670
Circuit Description...2670
Action Taken When the DTC Sets...2670
Condition for Clearing the DTC ...2670
Diagnostic Aids...2670
DTC P0561 – Indicates that a voltage variation exists in the ignition voltage or at the battery direct input...2672
Circuit Description ...2672
Action Taken When the DTC Sets ...2672
Condition for Clearing the DTC ...2672
Diagnostic Aids...2672
DTC P0562 – Set when the TCM detects low ignition voltage by comparing to a calibration value...2675
Circuit Description...2675
Action Taken When the DTC Sets...2675
Condition for Clearing the DTC...2675
Diagnostic Aids...2675
DTC P0563 – Sets when the TCM detects high ignition voltage by comparing to a calibrated value for calibrated number of sample...2678
Circuit Description...2678
Action Taken When the DTC Sets ...2678
Condition for Clearing the DTC...2678
Diagnostic Aids...2678
DTC P0600 – Internal communication fault between the microprocessor and the solenoid control integrated circuits internal to t...2680
Circuit Description ...2680
Action Taken When the DTC Sets ...2680
Condition for Clearing the DTC ...2680
DTC P0602 – TCM performs a self-test to determine if the calibration in memory is valid...2682
Circuit Description...2682
Action Taken When the DTC Sets...2682
Condition for Clearing the DTC...2682
DTC P0603 – TCM performs an internal memory self-test at power up that tests Flash Memory...2683
Circuit Description...2683
Action Taken When the DTC Sets ...2683
Condition for Clearing the DTC...2683
Diagnostic Aids...2683
DTC P0604 – TCM performs an internal memory self-test at power up that writes and reads patterns at specific RAM locations...2684
Circuit Description...2684
Action Taken When the DTC Sets ...2684
Condition for Clearing the DTC...2684
Diagnostic Aids...2684
DTC P0607 – Diagnostic test reports when the TCM accelerometer is malfunctioning...2685
Circuit Description ...2685
Action Taken When the DTC Sets...2685
Condition for Clearing the DTC...2685
Diagnostic Aids...2685
DTC P060C – Detect an internal TCM failure...2686
Circuit Description ...2686
Action Taken When the DTC Sets...2686
Condition for Clearing the DTC ...2686
DTC P0634 – TCM will take action to protect against damage from overheat...2687
Circuit Description ...2687
Action Taken When the DTC Sets ...2687
Condition for Clearing the DTC...2687
Diagnostic Aids...2687
DTC P0642 – Sets if the 5 volt reference from the TCM is disabled or outside allowed voltage range...2689
Circuit Description...2689
Action Taken When the DTC Sets...2689
Condition for Clearing the DTC...2689
Diagnostic Aids...2689
DTC P0657 – Detects an open condition or high resistance in the HSD1 circuit...2693
Circuit Description...2693
Action Taken When the DTC Sets...2693
Condition for Clearing the DTC...2693
Diagnostic Aids...2693
DTC P0658 – Detects an open condition or high resistance in the HSD1 circuit...2696
Circuit Description...2696
Action Taken When the DTC Sets...2696
Condition for Clearing the DTC...2696
Diagnostic Aids...2696
DTC P0659 – Detects an open condition or high resistance in the HSD1 circuit...2699
Circuit Description...2699
Action Taken When the DTC Sets...2699
Condition for Clearing the DTC...2699
Diagnostic Aids...2699
DTC P0701 – TCM monitors pressure switches at startup to detect the presence of hydraulic pressure...2703
Circuit Description...2703
Action Taken When the DTC Sets ...2703
Condition for Clearing the DTC...2703
Diagnostic Aids...2703
DTC P0703 – Triggered when input wire is being used for the brake switch and when the number of vehicle accelerations with bra...2705
Circuit Description...2705
Action Taken When the DTC Sets ...2705
Condition for Clearing the DTC...2705
Diagnostic Aids...2705
DTC P0706 – Detect the angular position of the shift selector shaft...2708
Circuit Description...2708
Action Taken When the DTC Sets...2708
Condition for Clearing the DTC...2708
Diagnostic Aids...2708
DTC P0708 – TCM detects an invalid switch condition and parity errors occur over consecutive ignition cycles...2711
Circuit Description...2711
Action Taken When the DTC Sets...2711
Condition for Clearing the DTC...2711
Diagnostic Aids...2711
DTC P0711 – TCM uses information from TFT to determine sump temperature...2714
Circuit Description...2714
Action Taken When the DTC Sets...2714
Condition for Clearing the DTC...2714
Diagnostic Aids...2714
DTC P0712 – TCM uses information from TFT to determine sump temperature...2717
Circuit Description...2717
Action Taken When the DTC Sets ...2717
Condition for Clearing the DTC...2717
Diagnostic Aids...2717
DTC P0713 – TCM uses information from TFT to determine sump temperature...2721
Circuit Description...2721
Action Taken When the DTC Sets ...2721
Condition for Clearing the DTC...2721
Diagnostic Aids...2721
DTC P0715 – TCM calculates the frequency of the AC pulses and converts it to a speed value...2724
Circuit Description...2724
Action Taken When the DTC Sets...2724
Condition for Clearing the DTC...2724
Diagnostic Aids...2724
DTC P0716 – Sets when unrealistic large change in turbine speed or noisy turbine speed signal...2728
Circuit Description...2728
Action Taken When the DTC Sets...2728
Condition for Clearing the DTC...2728
Diagnostic Aids...2728
DTC P0717 – Sets when unrealistic large change in turbine speed is detected or when unrealistic low turbine speed is detected...2732
Circuit Description...2732
Action Taken When the DTC Sets...2732
Condition for Clearing the DTC...2732
Diagnostic Aids...2732
DTC P0720 – Detects an output speed sensor circuit short to battery, ground, or open...2735
Circuit Description...2735
Action Taken When the DTC Sets...2735
Condition for Clearing the DTC...2735
Diagnostic Aids...2735
DTC P0721 – Sets by an unrealistic large change in output speed or noisy output speed signal...2738
Circuit Description...2738
Action Taken When the DTC Sets...2738
Condition for Clearing the DTC...2738
Diagnostic Aids...2738
DTC P0722 – Sets by an unrealistic large change in output speed or unrealistic low value in output speed...2742
Circuit Description...2742
Action Taken When the DTC Sets...2742
Condition for Clearing the DTC...2742
Diagnostic Aids...2742
DTC P0729 – Sets during steady state condition when the calculated sixth gear ratio differs from the known sixth gear ratio fo...2745
Circuit Description...2745
Action Taken When the DTC Sets...2745
Condition for Clearing the DTC...2745
Diagnostic Aids...2745
DTC P0731 – Sets when the calculated 1 (first) range ratio (steady state) differs from the known 1 (first) range ratio...2748
Circuit Description...2748
Action Taken When the DTC Sets...2748
Condition for Clearing the DTC...2748
Diagnostic Aids...2748
DTC P0732 – Sets when the calculated 2 (second) range ratio (steady state) differs from the known 2 (second) range ratio...2750
Circuit Description...2750
Action Taken When the DTC Sets...2750
Condition for Clearing the DTC...2750
Diagnostic Aids...2750
DTC P0733 – Sets when the calculated 3 (third) range ratio (steady state) differs from the known 3 (third) range ratio...2752
Circuit Description...2752
Action Taken When the DTC Sets...2752
Condition for Clearing the DTC...2752
Diagnostic Aids...2752
DTC P0734 – Sets when the calculated 4 (fourth) range ratio (steady state) differs from the known 4 (fourth) range ratio...2754
Circuit Description...2754
Action Taken When the DTC Sets...2754
Condition for Clearing the DTC...2754
Diagnostic Aids...2754
DTC P0735 – Sets when the calculated 5 (fifth) ratio (steady state) differs from the known 5 (fifth) range ratio...2756
Circuit Description...2756
Action Taken When the DTC Sets...2756
Condition for Clearing the DTC...2756
Diagnostic Aids...2756
DTC P0736 – Sets when the calculated reverse range ratio (steady state) differs from the known reverse range ratio...2760
Circuit Description...2760
Action Taken When the DTC Sets...2760
Condition for Clearing the DTC...2760
Diagnostic Aids...2760
DTC P0741 – Sets when the TCM detects a slip speed exceeding a calibrated RPM for calibrated amount of time, indicating no TCC...2762
Circuit Description...2762
Action Taken When the DTC Sets...2762
Condition for Clearing the DTC...2762
Diagnostic Aids...2762
DTC P0742 – Sets when the TCM detects minimal converter slip speed for a calibrated time when TCC state is commanded OFF...2764
Circuit Description...2764
Action Taken When the DTC Sets ...2764
Condition for Clearing the DTC...2764
Diagnostic Aids...2764
DTC P0751 – Detects a shift valve time-out condition which normally indicates a stuck shift valve in the destroked state, mech...2766
Circuit Description...2766
Action Taken When the DTC Sets...2766
Condition for Clearing the DTC...2766
Diagnostic Aids...2766
DTC P0752 – Detects a shift valve time-out condition which normally indicates a stuck shift valve in the stroked state, mechan...2770
Circuit Description...2770
Action Taken When the DTC Sets...2770
Condition for Clearing the DTC...2770
Diagnostic Aids...2770
DTC P0756 – Detects a shift valve time-out condition which normally indicates a stuck shift valve in the stroked state, mechan...2774
Circuit Description...2774
Action Taken When the DTC Sets...2774
Condition for Clearing the DTC...2774
Diagnostic Aids...2774
DTC P0757 – Detects a shift valve time-out condition which normally indicates a stuck shift valve in the stroked state, mechan...2778
Circuit Description...2778
Action Taken When the DTC Sets...2778
Condition for Clearing the DTC...2778
Diagnostic Aids...2778
DTC P0761 – Detects a shift valve time-out condition which normally indicates a stuck shift valve in the stroked state, mechan...2782
Circuit Description...2782
Action Taken When the DTC Sets...2782
Condition for Clearing the DTC...2782
Diagnostic Aids...2782
DTC P0762 – Detects a shift valve time-out condition which normally indicates a stuck shift valve in the stroked state, mechan...2786
Circuit Description...2786
Action Taken When the DTC Sets...2786
Condition for Clearing the DTC...2786
Diagnostic Aids...2786
DTC P0776 – TCM detects an incorrect oncoming ratio (range-to-range) for an accumulated number of occurrences...2790
Circuit Description...2790
Action Taken When the DTC Sets...2790
Condition for Clearing the DTC...2790
Diagnostic Aids...2790
DTC P0777 – TCM detects an incorrect oncoming ratio (range-to-range) for an accumulated number of occurrences...2793
Circuit Description...2793
Action Taken When the DTC Sets...2793
Condition for Clearing the DTC...2793
Diagnostic Aids...2793
DTC P0842 – Shorts-to-ground in the pressure switch wiring circuit or the pressure switch...2797
Circuit Description...2797
Action Taken When the DTC Sets...2797
Condition for Clearing the DTC...2797
Diagnostic Aids...2797
DTC P0843 – open condition in pressure switch wiring circuit or the pressure switch...2801
Circuit Description...2801
Action Taken When the DTC Sets...2801
Condition for Clearing the DTC...2801
Diagnostic Aids...2801
DTC P0847 – Shorts-to-ground in the pressure switch wiring circuit or the pressure switch...2805
Circuit Description...2805
Action Taken When the DTC Sets...2805
Condition for Clearing the DTC...2805
Diagnostic Aids...2805
DTC P0848 – Shorts-to-ground in the pressure switch wiring circuit or the pressure switch...2809
Circuit Description...2809
Action Taken When the DTC Sets...2809
Condition for Clearing the DTC...2809
Diagnostic Aids...2809
DTC P0872 – Shorts-to-ground in the pressure switch wiring circuit or the pressure switch...2813
Circuit Description...2813
Action Taken When the DTC Sets...2813
Condition for Clearing the DTC...2813
Diagnostic Aids...2813
DTC P0873 – open condition in the pressure switch wiring circuit or the pressure switch...2817
Circuit Description...2817
Action Taken When the DTC Sets...2817
Condition for Clearing the DTC...2817
Diagnostic Aids...2817
DTC P0877 – Fluid pressure is supplied to PS4, holding it open when the manual selector valve is in any position except revers...2821
Circuit Description...2821
Action Taken When the DTC Sets...2821
Condition for Clearing the DTC...2821
Diagnostic Aids...2821
DTC P0878 – Fluid pressure is supplied to the reverse pressure switch, holding it open when the manual selector valve is in an...2825
Circuit Description...2825
Action Taken When the DTC Sets...2825
Condition for Clearing the DTC...2825
Diagnostic Aids...2825
DTC P0880 – Sets during the next ignition cycle if battery power is lost before the power down process is complete and the eng...2829
Circuit Description...2829
Action Taken When the DTC Sets...2829
Condition for Clearing the DTC...2829
Diagnostic Aids...2829
DTC P0881 – TCM requires input battery voltage which originates direct from the vehicle battery...2832
Circuit Description...2832
Action Taken When the DTC Sets ...2832
Condition for Clearing the DTC...2832
Diagnostic Aids...2832
DTC P0882 – TCM detects battery direct voltage below 9 volts...2835
Circuit Description...2835
Action Taken When the DTC Sets...2835
Condition for Clearing the DTC...2835
Diagnostic Aids...2835
DTC P0883 – TCM detects Battery direct voltage is above 16 volts for a 12 volt TCM or 32 volts for a 24 volt TCM...2838
Circuit Description...2838
Action Taken When the DTC Sets...2838
Condition for Clearing the DTC...2838
Diagnostic Aids...2838
DTC P088B – TCM determines control main filter life based on hours accumulated and vehicle mileage...2840
Circuit Description...2840
Action Taken When the DTC Sets...2840
Condition for Clearing the DTC...2840
Diagnostic Aids...2840
DTC P0897 – TCM determines vehicle duty cycles based on shifts per mile, transmission revolutions, and hours accumulated...2842
Circuit Description...2842
Action Taken When the DTC Sets ...2842
Condition for Clearing the DTC...2842
Diagnostic Aids...2842
DTC P0960 – TCM commands the MAIN MOD ON when specific transmission and engine conditions are met...2844
Circuit Description...2844
Action Taken When the DTC Sets...2844
Condition for Clearing the DTC...2844
Diagnostic Aids...2844
DTC P0961 – Ensure that the Main Pressure Modulation Solenoid defaults to full pressure if a clutch slip event occur...2847
Circuit Description...2847
Action Taken When the DTC Sets...2847
Condition for Clearing the DTC...2847
Diagnostic Aids...2847
DTC P0962 – TCM commands the MAIN MOD ON when specific transmission and engine conditions are met...2849
Circuit Description...2849
Action Taken When the DTC Sets...2849
Condition for Clearing the DTC...2849
Diagnostic Aids...2849
DTC P0963 – TCM commands the MAIN MOD ON when specific transmission and engine conditions are met...2852
Circuit Description...2852
Action Taken When the DTC Sets...2852
Condition for Clearing the DTC...2852
Diagnostic Aids...2852
DTC P0964 – TCM regulates the amount of current to PCS2 by switching the low side driver ON and OFF...2855
Circuit Description...2855
Action Taken When the DTC Sets...2855
Condition for Clearing the DTC...2855
Diagnostic Aids...2855
DTC P0965 – open, short to ground, Short-to-power or wire-to-wire Shorts condition in the electrical circuit...2858
Circuit Description...2858
Action Taken When the DTC Sets...2858
Condition for Clearing the DTC...2858
Diagnostic Aids...2858
DTC P0966 – TCM processor has detected a short to ground condition in the low side of the electrical circuit...2862
Circuit Description...2862
Action Taken When the DTC Sets...2862
Condition for Clearing the DTC...2862
Diagnostic Aids...2862
DTC P0967 – TCM processor has detected a short to battery condition in the low side of the electrical circuit...2866
Circuit Description...2866
Action Taken When the DTC Sets...2866
Condition for Clearing the DTC...2866
Diagnostic Aids...2866
DTC P0973 – TCM processor has detected a short to ground condition in the low side of the electrical circuit...2869
Circuit Description...2869
Action Taken When the DTC Sets...2869
Condition for Clearing the DTC...2869
Diagnostic Aids...2869
DTC P0974 – TCM processor has detected a short to battery condition in the low side of the electrical circuit...2873
Circuit Description...2873
Action Taken When the DTC Sets...2873
Condition for Clearing the DTC...2873
Diagnostic Aids...2873
DTC P0976 – TCM processor has detected a short to ground condition in the low side of the electrical circuit...2876
Circuit Description...2876
Action Taken When the DTC Sets...2876
Condition for Clearing the DTC...2876
Diagnostic Aids...2876
DTC P0977 – TCM processor has detected a short to battery condition in the low side of the electrical circuit...2880
Circuit Description...2880
Action Taken When the DTC Sets...2880
Condition for Clearing the DTC...2880
Diagnostic Aids...2880
DTC P0979 – TCM processor has detected a short to ground condition in the low side of the electrical circuit...2883
Circuit Description...2883
Action Taken When the DTC Sets...2883
Condition for Clearing the DTC...2883
Diagnostic Aids...2883
DTC P097A – TCM processor has detected an open condition in the electrical circuit...2887
Circuit Description...2887
Action Taken When the DTC Sets...2887
Condition for Clearing the DTC...2887
Diagnostic Aids...2887
DTC P097B – TCM processor has detected an open condition in the electrical circuit, open condition may exist in the high side ...2890
Circuit Description...2890
Action Taken When the DTC Sets...2890
Condition for Clearing the DTC...2890
Diagnostic Aids...2890
DTC P097C – TCM processor has detected an open condition in the electrical circuit, open condition may exist in the high side ...2893
Circuit Description...2893
Action Taken When the DTC Sets...2893
Condition for Clearing the DTC...2893
Diagnostic Aids...2893
DTC P0980 – TCM processor has detected a short to battery condition in the low side of the electrical circuit...2896
Circuit Description...2896
Action Taken When the DTC Sets...2896
Condition for Clearing the DTC...2896
Diagnostic Aids...2896
DTC P1762 – Transmission Mode Switch Signal Message Counter Incorrect...2899
DTC Description...2899
Circuit / System Description...2899
Conditions for Running the DTC...2899
Conditions for Setting the DTC...2899
Actions Taken When the DTC Sets ...2899
Circuit / System Verification...2899
Repair Instructions...2900
DTC P2534 – TCM processor has detected low and open conditions in the ignition switch run / start electrical circuit, open, sh...2901
Circuit Description...2901
Action Taken When the DTC Sets...2901
Condition for Clearing the DTC...2901
Diagnostic Aids...2901
DTC P2535 – TCM processor has detected high conditions in the ignition switch run / start electrical circuit, Short-to-power o...2906
Circuit Description...2906
Action Taken When the DTC Sets...2906
Condition for Clearing the DTC...2906
Diagnostic Aids...2906
DTC P2669 – TCM has detected multiple low side circuits are open while having HSD2 voltage of over a calibrated voltage...2910
Circuit Description...2910
Action Taken When the DTC Sets...2910
Condition for Clearing the DTC...2910
Diagnostic Aids...2910
DTC P2670 – Indicates a short to ground has occurred in the high side wiring attached to HSD2...2914
Circuit Description...2914
Action Taken When the DTC Sets...2914
Condition for Clearing the DTC...2914
Diagnostic Aids...2914
DTC P2671 – TCM has detected ≥ to a calibrated voltage in the HSD2 circuit when HSD2 is OFF during TCM initialization, indicat...2917
Circuit Description...2917
Action Taken When the DTC Sets ...2917
Condition for Clearing the DTC...2917
Diagnostic Aids...2917
DTC P2723 – Sets when the TCM detects an incorrect oncoming ratio (range-to-range) for an accumulated number of occurrences...2920
Circuit Description...2920
Action Taken When the DTC Sets...2920
Condition for Clearing the DTC...2920
Diagnostic Aids...2920
DTC P2724 – Sets when the TCM detects an incorrect range-to-range ratio for an accumulated number of occurrences...2923
Circuit Description...2923
Action Taken When the DTC Sets...2923
Condition for Clearing the DTC...2923
Diagnostic Aids...2923
DTC P2727 – TCM processor has detected an open condition in the electrical circuit, open condition may exist in the high side ...2926
Circuit Description...2926
Action Taken When the DTC Sets...2926
Condition for Clearing the DTC...2926
Diagnostic Aids...2926
DTC P2728 – Detects the performance of the solenoid by comparing desired current to current as measured by the control integra...2929
Circuit Description...2929
Action Taken When the DTC Sets...2929
Condition for Clearing the DTC...2929
Diagnostic Aids...2929
DTC P2729 – TCM processor has detected a short to ground condition in the low side of the electrical circuit...2934
Circuit Description...2934
Action Taken When the DTC Sets ...2934
Condition for Clearing the DTC...2934
Diagnostic Aids...2934
DTC P2730 – TCM processor has detected a short to battery condition in the low side of the electrical circuit...2938
Circuit Description...2938
Action Taken When the DTC Sets...2938
Condition for Clearing the DTC...2938
Diagnostic Aids...2938
DTC P2761 – TCM processor has detected an open condition in the electrical circuit, open condition may exist in the high side ...2942
Circuit Description...2942
Action Taken When the DTC Sets...2942
Condition for Clearing the DTC...2942
Diagnostic Aids...2942
DTC P2762 – TCM processor has detected an open condition, open condition may exist in the high side or low side...2945
Circuit Description...2945
Action Taken When the DTC Sets...2945
Condition for Clearing the DTC...2945
Diagnostic Aids...2945
DTC P2763 – TCM processor has detected a short to battery condition in the low side of the electrical circuit...2949
Circuit Description...2949
Action Taken When the DTC Sets...2949
Condition for Clearing the DTC...2949
Diagnostic Aids...2949
DTC P2764 – TCM processor has detected a short to ground condition in the low side of the electrical circuit...2952
Circuit Description...2952
Action Taken When the DTC Sets...2952
Condition for Clearing the DTC...2952
Diagnostic Aids...2952
DTC P2789 – TCM determines that clutch volumes are out of range for a specific clutch, a J1939 message is sent to a dash mount...2956
Circuit Description...2956
Action Taken When the DTC Sets ...2956
Condition for Clearing the DTC...2956
Diagnostic Aids...2956
DTC U0074 – TCM detects no communication on the CAN2 backbone harness for a period of time...2958
Circuit Description...2958
Action Taken When the DTC Sets...2958
Condition for Clearing the DTC...2958
Diagnostic Aids...2958
DTC U0100 – Detects the loss of certain messages from the CAN Bus...2960
Circuit Description...2960
Action Taken When the DTC Sets ...2960
Condition for Clearing the DTC...2960
Diagnostic Aids...2960
Transfer Case...2962
Overview...2962
Front Axle and 4x4 Declutch...2962
High-Low Shifting...2962
Meritor Transfer Case Bar Code Label...2963
Reference Information...2963
DTC B0775...2964
DTC Description...2964
Circuit / System Description ...2964
Conditions for Running DTC...2964
Conditions for Setting the DTC ...2964
Actions Taken When the DTC Sets ...2964
Circuit / System Verification...2964
Circuit / System Testing...2964
Repair Instructions ...2965
DTC B0780...2966
DTC Description...2966
Circuit / System Description ...2966
Conditions for Running DTC...2966
Conditions for Setting DTC...2966
Actions Taken When DTC Sets...2966
Circuit / System Verification...2966
Circuit / System Testing ...2966
Repair Instructions ...2967
DTC B0785...2968
DTC Description...2968
Circuit / System Description...2968
Conditions for Running DTC ...2968
Conditions for Setting the DTC ...2968
Actions Taken When the DTC Sets ...2968
Circuit / System Verification ...2968
Circuit / System Testing...2968
Repair Instructions ...2969
DTC B0790...2970
DTC Description...2970
Circuit / System Description...2970
Conditions for Running the DTC...2970
Conditions for Setting the DTC...2970
Actions Taken When the DTC Sets...2970
Circuit / System Verification ...2970
Circuit / System Testing...2970
Repair Instructions ...2971
DTC B2725...2972
DTC Description...2972
Circuit / System Description ...2972
Conditions for Running the DTC...2972
Conditions for Setting DTC...2972
Actions Taken When the DTC Sets...2972
Circuit / System Verification ...2972
Circuit / System Testing ...2973
Component Testing...2975
Transfer Case Shift Control Switch...2975
Repair Instructions...2976
DTC B27B1...2977
DTC Description ...2977
Circuit / System Description ...2977
Conditions for Running DTC...2977
Conditions for Setting DTC...2977
Actions Taken When DTC Sets...2977
Circuit / System Verification ...2977
Repair Instructions...2977
DTC C0306...2978
DTC Description ...2978
Circuit / System Description...2978
Conditions for Running DTC...2978
Conditions for Setting DTC...2978
Actions Taken When DTC Sets...2978
Circuit / System Verification...2978
Circuit / System Testing...2979
Repair Instructions...2980
DTC C2A24...2981
DTC Description...2981
Circuit / System Description ...2981
Conditions for Running DTC ...2981
Conditions for Setting DTC...2981
Actions Taken When DTC Sets...2981
Circuit / System Verification ...2981
Repair Instructions...2982
DTC C0396 or C039E...2983
DTC Descriptions...2983
Circuit / System Description ...2983
Conditions for Running the DTC ...2983
Conditions for Setting the DTC ...2983
C0396 00 ...2983
C0396 08 ...2983
C0396 26 ...2983
C0396 27 ...2983
C0396 28 ...2983
C039E 00 ...2983
Actions Taken When the DTC Sets ...2984
Circuit / System Verification ...2984
Circuit / System Testing ...2984
Repair Instructions...2986
DTC C0398...2987
DTC Description...2987
Circuit / System Description ...2987
Conditions for Running the DTC ...2987
Conditions for Setting the DTC ...2987
C0398 00 ...2987
C0398 5A ...2987
Actions Taken When the DTC Sets ...2987
Circuit / System Verification ...2987
Circuit / System Testing...2988
Repair Instructions...2989
DTC P0641...2990
DTC Description...2990
Circuit / System Description ...2990
Conditions for Running the DTC ...2990
P0641 ...2990
Conditions for Setting the DTC ...2990
P0641 01 ...2990
P0641 02 ...2990
P0641 03 ...2990
P0641 07 ...2990
Actions Taken When the DTC Sets ...2990
Circuit / System Verification ...2990
Circuit / System Testing ...2991
Repair Instructions...2992
DTC P0651...2993
DTC Description...2993
Circuit / System Description ...2993
Conditions for Running the DTC ...2993
Conditions for Setting the DTC ...2993
P0651 01 ...2993
P0651 02 ...2993
P0651 03 ...2993
P0651 07 ...2993
Actions Taken When the DTC Sets ...2993
Circuit / System Verification ...2993
Circuit / System Testing ...2994
Component Testing...2995
Transfer Case Shift Control Switch...2995
Repair Instructions...2995
DTC P0820...2996
DTC Description...2996
Circuit / System Description...2996
Conditions for Running DTC...2996
Conditions for Setting DTC...2996
Actions Taken When DTC Sets...2996
Circuit / System Verification ...2996
Repair Instructions...2996
DTC P17D4 or P279A - P279C...2997
Diagnostic Trouble Code (DTC) Description ...2997
Circuit / System Description ...2997
Conditions for Running the DTC...2997
Conditions for Setting the DTC ...2997
Actions Taken When the DTC Sets...2997
Circuit / System Verification ...2997
Repair Instructions...2998
DTC P215A...2999
DTC Description...2999
Circuit / System Description ...2999
Conditions for Running the DTC ...2999
P215A 5A ...2999
Conditions for Setting the DTC ...2999
P215A 5A ...2999
Actions Taken When the DTC Sets ...2999
Circuit / System Verification...2999
Repair Instructions...3000
DTC P2160 or P2161...3001
Diagnostic Trouble Code (DTC) Description...3001
Circuit / System Description ...3001
Diagnostic Fault Information...3001
Conditions for Running the DTC...3001
Conditions for Setting the DTC...3002
P2160...3002
P2161...3002
Actions Taken When the DTC Sets ...3002
Circuit / System Verification ...3002
Circuit / System Testing ...3002
Repair Instructions ...3004
Shifter...3005
Column Shifter...3005
Operational Checkout Procedure...3005
Visual / Physical Inspection...3005
Intermittent...3005
Symptom List...3005
Column Shifter (Transmission Control Lever) Malfunction...3006
Circuit / System Description...3006
Circuit / System Verification...3006
Circuit / System Testing...3006
Component Testing...3007
Repair Instructions...3007
23. Windshield Wiper System...3008
Overview...3008
Wiper / Washer System Components...3008
Windshield Wiper System...3008
Wiper High and Low Operation...3009
Parking The Wiper Motor...3009
Wiper Intermittent Operation...3009
Wiper Mist Operation...3010
Windshield Washer System...3010
Operational Checkout Procedure...3011
Visual / Physical Inspection...3011
Intermittent...3011
Symptom List...3011
Symptom Diagnostics...3012
Windshield Wiper System Malfunction...3012
Circuit / System Description...3012
Circuit / System Verification...3013
Circuit / System Testing...3014
Windshield Wiper / Washer Switch Malfunction...3014
Windshield Wiper Motor Malfunction...3015
Component Testing...3019
Windshield Wiper / Washer Switch...3019
Repair Instructions...3019
Washer Malfunction...3020
Circuit / System Description...3020
Circuit / System Verification...3020
Circuit / System Testing...3021
Windshield Washer Switch Malfunction...3021
Windshield Washer Pump Malfunction...3021
Component Testing...3024
Washer Switch...3024
Repair Instructions...3024
Diagnostic Information and Procedures...3024
DTC B3715 or B3875...3024
DTC Descriptions...3024
Circuit / System Description...3025
Conditions for Running the DTC...3025
Conditions for Setting the DTC...3025
B3715 01...3025
B3715 02...3025
B3715 04...3025
B3875 01...3025
B3875 02...3025
B3875 04...3025
Action Taken When the DTC Sets...3025
Circuit / System Verification...3026
Circuit / System Testing...3026
Repair Instructions...3029
DTC B3873...3030
DTC Description...3030
Circuit / System Description...3030
Conditions for Running the DTC...3030
Conditions for Setting the DTC...3030
B3873 01...3030
B3873 02...3030
B3873 04...3030
Action Taken When the DTC Sets...3030
Circuit / System Verification...3030
Circuit / System Testing...3031
Repair Instructions...3032
Front End...3033
1. Fenders...3035
Fender Extensions...3035
Front Fender Extension – Left (Inner)...3035
Removal...3035
Overview...3035
Special Tools...3035
Equipment Condition...3035
Procedure...3036
Follow-On Procedure...3038
Installation...3039
Overview...3039
Special Tools...3039
Equipment Condition...3039
Procedure...3040
Follow-On Procedure...3042
Front Fender Extension – Right (Inner)...3043
Removal...3043
Overview...3043
Special Tools...3043
Equipment Condition...3043
Procedure...3044
Follow-On Procedure...3046
Installation...3047
Overview...3047
Special Tools...3047
Equipment Condition...3047
Procedure...3048
Follow-On Procedure...3050
Front Fender Extension (Outer)...3051
Removal...3051
Overview...3051
Special Tools...3051
Equipment Condition...3051
Procedure...3052
Follow-On Procedure...3052
Installation...3053
Overview...3053
Special Tools...3053
Equipment Condition...3053
Procedure...3053
Follow-On Procedure...3054
2. Hood / Grille...3055
Tilting Hood...3055
Grille...3055
Removal...3055
Overview...3055
Special Tools...3055
Equipment Condition...3055
Procedure...3056
Follow-On Procedure...3056
Installation...3057
Overview...3057
Special Tools...3057
Equipment Condition...3057
Procedure...3058
Follow-On Procedure...3058
Headlight...3059
Removal...3059
Overview...3059
Special Tools...3059
Equipment Condition...3059
Procedure...3060
Follow-On Procedure...3060
Installation...3061
Overview...3061
Special Tools...3061
Equipment Condition...3061
Procedure...3061
Follow-On Procedure...3062
High Beam Headlight (Headlamp) Bulb Replacement...3063
Overview...3063
Special Tools...3063
Equipment Condition...3063
Procedure...3063
Follow-On Procedure...3064
Low Beam Headlight (Headlamp) Bulb Replacement...3065
Overview...3065
Special Tools...3065
Equipment Condition...3065
Procedure...3065
Follow-On Procedure...3066
Front Fog Light (Fog Lamp)...3067
Removal...3067
Overview...3067
Special Tools...3067
Equipment Condition...3067
Follow-On Procedure...3068
Installation...3069
Overview...3069
Special Tools...3069
Torque Specifications...3069
Equipment Conditions...3069
Follow-On Procedure...3069
Front Fog Light (Fog Lamp) Bulb Replacement...3071
Overview...3071
Special Tools...3071
Equipment Conditions...3071
Procedure...3071
Follow-On Procedure...3072
Front Fog Light (Fog Lamp) Bezel...3073
Removal...3073
Overview...3073
Special Tools...3073
Equipment Condition...3073
Procedure...3073
Follow-On Procedure...3075
Installation...3076
Overview...3076
Special Tools...3076
Equipment Condition...3076
Procedure...3076
Follow-On Procedure...3078
Hood...3079
Removal...3079
Overview...3079
Special Tools...3079
Equipment Condition...3079
Procedure...3079
Follow-On Procedure...3080
Installation...3081
Overview...3081
Special Tools...3081
Equipment Condition...3081
Procedure...3081
Follow-On Procedure...3082
Hood Hinge...3083
Removal...3083
Overview...3083
Special Tools...3083
Equipment Condition...3083
Procedure...3084
Follow-On Procedure...3084
Installation...3085
Overview...3085
Special Tools...3085
Equipment Condition...3085
Procedure...3085
Follow-On Procedure...3086
Hood Primary Latch...3087
Removal...3087
Overview...3087
Special Tools...3087
Equipment Condition...3087
Procedure...3088
Follow-On Procedure...3088
Installation...3089
Overview...3089
Special Tools...3089
Equipment Condition...3089
Procedure...3089
Follow-On Procedure...3090
Hood Primary Latch Support...3091
Removal...3091
Overview...3091
Special Tools...3091
Equipment Condition...3091
Procedure...3092
Follow-On Procedure...3092
Installation...3093
Overview...3093
Special Tools...3093
Equipment Condition...3093
Procedure...3093
Follow-On Procedure...3094
Hood Strut...3095
Removal...3095
Overview...3095
Special Tools...3095
Equipment Condition...3095
Procedure...3096
Follow-On Procedure...3096
Installation...3097
Overview...3097
Special Tools...3097
Equipment Condition...3097
Procedure...3097
Follow-On Procedure...3098
Hood Strut Bracket...3099
Removal...3099
Overview...3099
Special Tools...3099
Equipment Condition...3099
Procedure...3100
Follow-On Procedure...3100
Installation...3101
Overview...3101
Special Tools...3101
Equipment Condition...3101
Procedure...3101
Follow-On Procedure...3102
Hood Service Positioning...3103
Overview...3103
Special Tools...3103
Equipment Condition...3103
Opening Hood to Service Position:...3103
Closing the Hood...3105
Follow-On Procedure...3106
Hood Switch...3106
Removal...3106
Overview...3106
Special Tools...3106
Equipment Condition...3106
Procedure...3107
Follow-On Procedure...3107
Installation...3107
Overview...3107
Special Tools...3107
Equipment Condition...3108
Procedure...3108
Follow-On Procedure...3109
Miscellaneous...3111
1. Keys...3113
Programming Additional Keys (With SPS)...3113
Overview...3113
Special Tools...3113
Equipment Condition...3113
Key Adding Procedure...3113
Follow-On Procedure...3114
Programming Additional Keys (Without SPS)...3115
Overview...3115
Special Tools...3115
Equipment Condition...3115
Key Adding Procedure...3115
Follow-On Procedure...3116
Replacing Keys (With SPS)...3117
Overview...3117
Special Tools...3117
Equipment Condition...3117
Replacement Procedure...3117
Follow-On Procedure...3118
Replacing Keys (Without SPS)...3119
Overview...3119
Special Tools...3119
Equipment Condition...3119
Replacement Procedure...3119
Follow-On Procedure...3120
Engine...3121
1. Air Cleaner...3125
Air Cleaner Assembly...3125
Air Cleaner Assembly...3125
Removal...3125
Overview...3125
Special Tools...3125
Equipment Conditions...3125
Procedure...3126
Follow-On Procedure...3126
Installation...3127
Overview...3127
Special Tools...3127
Equipment Conditions...3127
Procedure...3127
Follow-On Procedure...3128
Air Cleaner Outlet Duct...3129
Removal...3129
Overview...3129
Special Tools...3129
Equipment Condition...3129
Procedure...3129
Follow-On Procedure...3130
Installation...3131
Overview...3131
Special Tools...3131
Equipment Condition...3131
Procedure...3131
Follow-On Procedure...3132
Air Filter Life System Reset...3133
Overview...3133
Special Tools...3133
Equipment Condition...3133
Reset Procedure...3133
Follow-On Procedure...3133
Mass Airflow Sensor with Intake Air Temperature Sensor...3134
Removal...3134
Overview...3134
Special Tools...3134
Equipment Conditions...3134
Procedure...3135
Follow-On Procedure...3135
Installation...3136
Overview...3136
Special Tools...3136
Equipment Conditions...3136
Procedure...3136
Follow-On Procedure...3137
2. Block Heater...3138
Engine Block Heater...3138
Engine Block Heater Cord...3138
Removal...3138
Overview...3138
Special Tools...3138
Equipment Conditions...3138
Procedure...3139
Follow-On Procedure...3140
Installation...3141
Overview...3141
Special Tools...3141
Equipment Conditions...3141
Procedure...3141
Follow-On Procedure...3143
3. Charging and Starting System...3144
Charging System...3144
Auxiliary Generator (0008GJC) Replacement...3144
Removal...3144
Overview...3144
Special Tools...3144
Equipment Condition...3144
Procedure...3145
Follow-On Procedure...3146
Installation...3147
Overview...3147
Special Tools...3147
Equipment Condition...3147
Procedure...3147
Follow-On Procedure...3148
Generator...3149
Removal...3149
Overview...3149
Special Tools...3149
Equipment Condition...3149
Procedure...3149
Follow-On Procedure...3151
Installation...3152
Overview...3152
Special Tools...3152
Equipment Condition...3152
Procedure...3152
Follow-On Procedure...3154
Starting System...3155
Starter Replacement...3155
Removal...3155
Overview...3155
Special Tools...3155
Equipment Condition...3155
Procedure...3155
Follow-On Procedure...3159
Installation...3160
Overview...3160
Special Tools...3160
Equipment Condition...3160
Procedure...3160
Follow-On Procedure...3164
4. Cooling System...3165
Cooling Package...3165
Radiator Surge Tank...3165
Removal...3165
Overview...3165
Special Tools...3165
Equipment Conditions...3165
Procedure...3166
Follow-On Procedure...3167
Installation...3168
Overview...3168
Special Tools...3168
Equipment Conditions...3168
Procedure...3168
Follow-On Procedure...3169
Coolant Drain...3171
Overview...3171
Special Tools...3171
Equipment Condition...3172
Procedure...3173
Follow-On Procedure...3176
Coolant Fill...3177
Overview...3177
Special Tools...3177
Equipment Condition...3177
Procedure...3178
Follow-On Procedure...3180
Coolant Flush...3181
Overview...3181
Special Tools...3181
Equipment Condition...3181
Procedure...3182
Follow-On Procedure...3182
Hose Clamp Replacement Guidelines – Spring Type...3183
Spring Type Hose Clamp Replacement Guidelines...3183
Removing Spring Type Hose Clamp...3184
If Spring Type Hose Clamp Is Being Reused...3184
When Reusing Spring Type Hose Clamp and Replacing Hose...3184
When Reusing Spring Type Hose Clamp with Existing Hose...3184
If Spring Type Hose Clamp Is Being Replaced...3184
When Replacing Spring Type Hose Clamp and Replacing Hose...3184
When Replacing Spring Type Hose Clamp with Existing Hose...3185
Engine Block Heater Cord Replacement...3186
Removal...3186
Overview...3186
Special Tools...3186
Equipment Condition...3186
Procedure...3187
Follow-On Procedure...3188
Installation...3189
Overview...3189
Special Tools...3189
Equipment Condition...3189
Procedure...3189
Follow-On Procedure...3191
Engine Coolant Fan Lower Shroud Replacement...3192
Removal...3192
Overview...3192
Special Tools...3192
Equipment Conditions...3192
Procedure...3192
Follow-On Procedure...3196
Installation...3197
Overview...3197
Special Tools...3197
Equipment Conditions...3197
Procedure...3197
Follow-On Procedure...3201
Engine Coolant Fan Upper Shroud Replacement...3202
Removal...3202
Overview...3202
Special Tools...3202
Equipment Conditions...3202
Procedure...3202
Follow-On Procedure...3204
Installation...3205
Overview...3205
Special Tools...3205
Equipment Conditions...3205
Procedure...3205
Follow-On Procedure...3207
Fan Blade Clutch Replacement...3208
Removal...3208
Overview...3208
Special Tools...3208
Equipment Conditions...3208
Procedure...3208
Follow-On Procedure...3211
Installation...3212
Overview...3212
Special Tools...3212
Equipment Conditions...3212
Procedure...3212
Follow-On Procedure...3215
Fan Blade Replacement...3216
Removal...3216
Overview...3216
Special Tools...3216
Equipment Conditions...3216
Procedure...3217
Follow-On Procedure...3219
Installation...3220
Overview...3220
Special Tools...3220
Equipment Conditions...3220
Procedure...3220
Follow-On Procedure...3222
Fan Pulley Replacement...3223
Removal...3223
Overview...3223
Special Tools...3223
Equipment Condition...3223
Procedure...3224
Follow-On Procedure...3226
Installation...3227
Overview...3227
Special Tools...3227
Equipment Conditions...3227
Procedure...3227
Follow-On Procedure...3229
Radiator Replacement...3230
Removal...3230
Overview...3230
Special Tools...3230
Equipment Conditions...3230
Procedure...3231
Follow-On Procedure...3233
Installation...3234
Overview...3234
Special Tools...3234
Equipment Conditions...3234
Procedure...3234
Follow-On Procedure...3236
Radiator Air Upper Baffle Replacement...3238
Removal...3238
Overview...3238
Special Tools...3238
Equipment Conditions...3238
Procedure...3238
Follow-On Procedure...3240
Installation...3241
Overview...3241
Special Tools...3241
Equipment Conditions...3241
Procedure...3241
Follow-On Procedure...3242
Radiator Air Side Baffle – Left Replacement...3243
Removal...3243
Overview...3243
Special Tools...3243
Equipment Conditions...3243
Procedure...3243
Follow-On Procedure...3244
Installation...3245
Overview...3245
Special Tools...3245
Equipment Conditions...3245
Procedure...3245
Follow-On Procedure...3246
Radiator Air Side Baffle – Right Replacement...3247
Removal...3247
Overview...3247
Special Tools...3247
Equipment Conditions...3247
Procedure...3247
Follow-On Procedure...3248
Installation...3249
Overview...3249
Special Tools...3249
Equipment Conditions...3249
Procedure...3249
Follow-On Procedure...3250
Radiator Inlet Hose Replacement...3251
Removal...3251
Overview...3251
Special Tools...3251
Equipment Conditions...3251
Procedure...3251
Follow-On Procedure...3252
Installation...3253
Overview...3253
Special Tools...3253
Equipment Conditions...3253
Procedure...3253
Follow-On Procedure...3255
Radiator Outlet Pipe Replacement...3256
Removal...3256
Overview...3256
Special Tools...3256
Equipment Conditions...3256
Procedure...3256
Follow-On Procedure...3258
Installation...3259
Overview...3259
Special Tools...3259
Equipment Conditions...3259
Procedure...3259
Follow-On Procedure...3261
Radiator Outlet Hose Replacement (Radiator to Radiator Outlet Pipe)...3262
Removal...3262
Overview...3262
Special Tools...3262
Equipment Conditions...3262
Procedure...3262
Follow-On Procedure...3263
Installation...3264
Overview...3264
Special Tools...3264
Equipment Conditions...3264
Procedure...3264
Follow-On Procedure...3266
Radiator Outlet Hose Replacement (Water Pump to Radiator Outlet Pipe)...3267
Removal...3267
Overview...3267
Special Tools...3267
Equipment Conditions...3267
Procedure...3268
Follow-On Procedure...3268
Installation...3269
Overview...3269
Special Tools...3269
Torque Specifications...3269
Equipment Conditions...3269
Procedure...3269
Follow-On Procedure...3271
Radiator Surge Tank Inlet Hose Replacement (Radiator Surge Tank To Engine Coolant Bleed Pipe)...3272
Removal...3272
Overview...3272
Special Tools...3272
Equipment Conditions...3272
Procedure...3273
Follow-On Procedure...3273
Installation...3274
Overview...3274
Special Tools...3274
Torque Specifications...3274
Equipment Conditions...3274
Procedure...3274
Follow-On Procedure...3275
Radiator Surge Tank Inlet Hose Replacement (Radiator to Engine Coolant Air Bleed Pipe)...3276
Removal...3276
Overview...3276
Special Tools...3276
Equipment Conditions...3276
Procedure...3276
Follow-On Procedure...3277
Installation...3278
Overview...3278
Special Tools...3278
Equipment Conditions...3278
Procedure...3278
Follow-On Procedure...3279
Radiator Surge Tank Outlet Pipe Replacement...3280
Removal...3280
Overview...3280
Special Tools...3280
Equipment Conditions...3280
Procedure...3280
Follow-On Procedure...3282
Installation...3283
Overview...3283
Special Tools...3283
Equipment Conditions...3283
Procedure...3283
Follow-On Procedure...3285
Radiator Surge Tank Outlet Hose Replacement (Radiator Surge Tank to Radiator Surge Tank Outlet Pipe)...3286
Removal...3286
Overview...3286
Special Tools...3286
Equipment Conditions...3286
Procedure...3286
Follow-On Procedure...3287
Installation...3288
Overview...3288
Special Tools...3288
Torque Specifications...3288
Equipment Conditions...3288
Procedure...3288
Follow-On Procedure...3288
Radiator Surge Tank Outlet Hose (Radiator Outlet Pipe to Radiator Surge Tank Outlet Pipe)...3289
Removal...3289
Overview...3289
Special Tools...3289
Equipment Conditions...3289
Procedure...3289
Follow-On Procedure...3290
Installation...3291
Overview...3291
Special Tools...3291
Torque Specifications...3291
Equipment Conditions...3291
Procedure...3291
Follow-On Procedure...3292
Radiator Surge Tank Outlet Hose (Radiator Surge Tank to Radiator Surge Tank Outlet Pipe)...3293
Removal...3293
Overview...3293
Special Tools...3293
Equipment Conditions...3293
Procedure...3293
Follow-On Procedure...3294
Installation...3295
Overview...3295
Special Tools...3295
Torque Specifications...3295
Equipment Conditions...3295
Procedure...3295
Follow-On Procedure...3296
Charge Air Cooler Assembly...3297
Charge Air Cooler...3297
Removal...3297
Overview...3297
Special Tools...3297
Equipment Conditions...3297
Procedure...3297
Follow-On Procedure...3299
Installation...3300
Overview...3300
Special Tools...3300
Equipment Conditions...3300
Procedure...3300
Follow-On Procedure...3302
Charge Air Cooler Inlet Air Hose...3303
Removal...3303
Overview...3303
Special Tools...3303
Equipment Condition...3303
Procedure...3303
Follow-On Procedure...3304
Installation ...3305
Overview...3305
Special Tools...3305
Equipment Condition...3305
Procedure...3305
Follow-On Procedure...3306
Charge Air Cooler Outlet Air Hose...3307
Removal...3307
Overview...3307
Special Tools...3307
Equipment Condition...3307
Procedure...3307
Follow-On Procedure...3308
Installation...3309
Overview...3309
Special Tools...3309
Equipment Condition...3309
Procedure...3309
Follow-On Procedure...3310
Transmissions...3311
1. Automatic Transmissions...3313
Allison Transmission®...3313
Transmission to Vehicle Attachment Points...3313
Removal Two Wheel (2WD)...3313
Overview...3313
Special Tool...3313
Equipment Condition...3313
Procedure...3314
Follow-On Procedure...3320
Installation Two Wheel Drive (2WD)...3321
Overview...3321
Special Tool...3321
Equipment Condition...3321
Procedure...3321
Follow-On Procedure...3326
Removal Four Wheel Drive (4WD)...3328
Overview...3328
Special Tools...3328
Equipment Condition...3328
Procedure...3328
Follow-On Procedure...3336
Installation Four Wheel Drive (4WD)...3337
Overview...3337
Special Tools...3337
Equipment Condition...3337
Procedure...3337
Follow-On Procedure...3342
2. Transfer Case...3344
Meritor®...3344
Transfer Case to Vehicle Attachment Points...3344
Removal...3344
Overview...3344
Special Tools...3344
Equipment Condition...3344
Procedure...3345
Follow-On Procedure...3354
Installation...3355
Overview...3355
Special Tools...3355
Equipment Condition...3355
Procedure...3356
Follow-On Procedure...3363
Rollover Stand Mounting...3364
Installation...3364
Overview...3364
Special Tools...3364
Torque Specifications...3364
Equipment Condition...3364
Procedure...3364
Follow-On Procedure...3367
Removal...3368
Overview...3368
Special Tools...3368
Equipment Condition...3368
Procedure...3368
Follow-On Procedure...3371
Transfer Case Component Replacement...3372
Speed Sensor Removal...3372
Overview...3372
Special Tools...3372
Equipment Condition...3372
Procedure...3372
Follow-On Procedure...3372
Speed Sensor Installation...3373
Overview...3373
Special Tool...3373
Equipment Condition...3373
Procedure...3373
Follow-On Procedure...3374
Transfer Case Actuator Removal...3375
Overview...3375
Special Tools...3375
Equipment Condition...3375
Procedure...3375
Follow-On Procedure...3375
Transfer Case Actuator Installation...3376
Overview...3376
Special Tool...3376
Equipment Condition...3376
Procedure...3376
Follow-On Procedure...3377
Disassembly (On Stand)...3378
Case Halves Disassembly and Input Shaft Removal...3378
Overview...3378
Special Tools...3378
Equipment Condition...3378
Procedure...3378
Follow-On Procedure...3396
Input Bearing Cage Disassembly...3397
Overview...3397
Special Tools...3397
Equipment Condition...3397
Procedure...3397
Follow-On Procedure...3399
Input Shaft Gear Removal and Disassembly...3400
Overview...3400
Special Tools...3400
Equipment Conditions...3400
Procedure...3400
Follow-On Procedure...3402
Front Output Shaft Gear Removal and Disassembly...3403
Overview...3403
Special Tools...3403
Equipment Condition...3403
Procedure...3403
Follow-On Procedure...3405
Idler Shaft Gear Removal and Disassembly...3406
Overview...3406
Special Tools...3406
Equipment Condition...3406
Procedure...3406
Follow-On Procedure...3407
Planetary Carrier Removal...3408
Overview...3408
Special Tool...3408
Equipment Condition...3408
Procedure...3408
Follow-On Procedure...3410
High / Low and 4 x 4 Shift Components Disassembly...3411
Overview...3411
Special Tool...3411
Equipment Condition...3411
Procedure...3411
Follow-On Procedure...3412
Bearing Cups Removal (Front Case Half)...3413
Overview...3413
Special Tool...3413
Equipment Condition...3413
Procedure...3413
Follow-On Procedure...3413
Oil Pump Line Removal...3414
Overview...3414
Special Tool...3414
Equipment Condition...3414
Procedure...3414
Follow-On Procedure...3415
Adjuster Cups Removal (Rear Case Half)...3416
Overview...3416
Special Tool...3416
Equipment Condition...3416
Procedure...3416
Follow-On Procedure...3417
Transfer Case Cleaning and Inspection...3418
Overview...3418
Special Tool...3418
Equipment Condition...3418
Inspection...3418
Parts with a Rough Finish...3418
Transfer Case Assemblies...3418
Dry Cleaned Parts...3418
Prevent Corrosion...3419
Oil Seals and O-rings...3419
Inspect Parts...3419
Helical Gears...3423
Shafts...3424
High and Low Shifting Components...3426
Oil and Lubrication System...3426
Oil Pump Assembly...3426
Transfer Case Halves...3427
Preparing the Case and Cover and Seal Replacement...3427
To prevent damage to property, never use a metallic scraper and / or wire brush when cleaning aluminum components and / or sealing surfaces. Metallic scrapers and wire brushes are made of materials harder than aluminum that can scratch, gouge, scrape, or...3427
Follow-On Procedure...3428
Assembly...3429
Output Shaft Installation...3429
Overview...3429
Special Tool...3429
Torque Specifications...3429
Equipment Condition...3429
Procedure...3429
Follow-On Procedure...3430
Idler Shaft Installation...3431
Overview...3431
Special Tool...3431
Torque Specifications...3431
Equipment Condition...3431
Procedure...3431
Follow-On Procedure...3432
Input Gear Installation...3433
Overview...3433
Special Tool...3433
Torque Specifications...3433
Equipment Condition...3433
Procedure...3433
Follow-On Procedure...3434
Front Output Gear Shaft and Idler Gear Installation...3435
Overview...3435
Special Tool...3435
Torque Specifications...3435
Equipment Condition...3435
Procedure...3435
Follow-On Procedure...3436
Oil Pump Line Installation...3437
Overview...3437
Special Tool...3437
Equipment Condition...3437
Procedure...3437
Follow-On Procedures...3438
Planetary Carrier Installation...3439
Overview...3439
Special Tool...3439
Equipment Condition...3439
Procedure...3439
Follow-On Procedure...3440
Input Bearing Cage Assembly and Installation...3441
Overview...3441
Special Tool...3441
Torque Specifications...3441
Equipment Condition...3441
Procedure...3441
Follow-On Procedure...3447
High / Low and 4 x 4 Shift Components Assembly...3448
Overview...3448
Special Tool...3448
Torque Specifications...3448
Equipment Condition...3448
Follow-On Procedure...3449
High / Low and 4 x 4 Shift Component Assemblies Installation...3450
Overview...3450
Special Tool...3450
Torque Specifications...3450
Equipment Condition...3450
Procedure...3450
Follow-On Procedure...3458
Case Halves Assembly and Input Drive Gear Assembly, Input Shaft Assembly, Oil Pump, Tooth Wheel, Bearing and Output Bearing Cage Installation...3459
Overview...3459
Special Tools...3459
Equipment Condition...3459
Procedure...3460
Follow-On Procedure...3474
Rear Output Yoke and Nut Installation...3475
Overview...3475
Special Tool...3475
Equipment Condition...3475
Procedure...3475
Follow-On Procedure...3477
Rear Output Shaft End Play Adjustment...3478
Overview...3478
Special Tools...3478
Equipment Condition...3478
Procedure...3478
Follow-On Procedure...3483
Front Output Shaft End Play Adjustment...3484
Overview...3484
Special Tool...3484
Equipment Condition...3484
Procedure...3484
Follow-On Procedure...3486
Front Output Yoke and Nut Installation...3487
Overview...3487
Special Tools...3487
Equipment Condition...3487
Procedure...3487
Follow-On Procedure...3489
Idler Shaft End Play Adjustment...3490
Overview...3490
Special Tool...3490
Equipment Condition...3490
Procedure...3490
Follow-On Procedure...3495
3. Transmission Oil Cooler...3496
Automatic Transmission Oil Cooler...3496
Overview...3496
Transmission Fluid Auxiliary Cooler...3497
Removal...3497
Overview...3497
Special Tools...3497
Equipment Condition...3497
Procedure...3498
Follow-On Procedure...3499
Installation...3500
Overview...3500
Special Tools...3500
Equipment Condition...3500
Procedure...3501
Follow-On Procedure...3502
Transmission Fluid Auxiliary Cooler Inlet Pipe...3503
Removal...3503
Overview...3503
Special Tools...3503
Equipment Condition...3503
Procedure...3504
Follow-On Procedure...3505
Installation ...3506
Overview...3506
Special Tools...3506
Equipment Condition...3506
Procedure...3506
Follow-On Procedure...3507
Transmission Fluid Cooler Inlet Pipe (Without Auxiliary Cooler)...3508
Removal...3508
Overview...3508
Special Tools...3508
Equipment Condition...3508
Procedure...3508
Follow-On Procedure...3510
Installation ...3511
Overview...3511
Special Tools...3511
Equipment Condition...3511
Procedure...3511
Follow-On Procedure...3513
Transmission Fluid Cooler Inlet Pipe (With Auxiliary Cooler)...3514
Removal...3514
Overview...3514
Special Tools...3514
Equipment Condition...3514
Procedure...3515
Follow-On Procedure...3517
Installation...3518
Overview...3518
Special Tools...3518
Equipment Condition...3518
Procedure...3518
Follow-On Procedure...3520
Transmission Fluid Cooler Outlet Pipe...3521
Removal...3521
Overview...3521
Special Tools...3521
Equipment Condition...3521
Procedure...3521
Follow-On Procedure...3523
Installation...3524
Overview...3524
Special Tools...3524
Equipment Condition...3524
Procedure...3524
Follow-On Procedure...3526
Transmission Fluid Cooler Pipe Connector (Outlet at Radiator)...3527
Removal...3527
Overview...3527
Special Tools...3527
Equipment Condition...3527
Procedure...3527
Follow-On Procedure...3528
Installation...3529
Overview...3529
Special Tools...3529
Equipment Condition...3529
Procedure...3529
Follow-On Procedure...3530
Transmission Fluid Cooler Pipe Connector (Outlet at Transmission)...3531
Removal...3531
Overview...3531
Special Tools...3531
Equipment Condition...3531
Procedure...3532
Follow-On Procedure...3532
Installation...3533
Overview...3533
Special Tools...3533
Equipment Condition...3533
Procedure...3533
Follow-On Procedure...3534
Transmission Fluid Cooler Pipe Connector (Inlet at Radiator)...3535
Removal...3535
Overview...3535
Special Tools...3535
Equipment Condition...3535
Procedure...3535
Follow-On Procedure...3536
Installation...3537
Overview...3537
Special Tools...3537
Equipment Condition...3537
Procedure...3537
Follow-On Procedure...3538
Transmission Fluid Cooler Pipe Connector (Inlet at Transmission)...3539
Removal...3539
Overview...3539
Special Tools...3539
Equipment Condition...3539
Procedure...3539
Follow-On Procedure...3540
Installation...3541
Overview...3541
Special Tools...3541
Equipment Condition...3541
Procedure...3541
Follow-On Procedure...3542
Rear Axle and Suspension...3543
1. Air Suspensions...3545
International Ride Optimized Suspension (IROS)...3545
Overview...3545
Air Bag Line (Driver)...3546
Removal...3546
Overview...3546
Special Tools...3546
Equipment Condition...3546
Procedure...3546
Follow-On Procedure...3547
Installation...3548
Overview...3548
Special Tools...3548
Equipment Condition...3548
Procedure...3548
Follow-On Procedure...3548
Air Bag Line (Passenger)...3550
Removal...3550
Overview...3550
Special Tools...3550
Equipment Condition...3550
Procedure...3550
Follow-On Procedure...3551
Installation...3552
Overview...3552
Special Tools...3552
Equipment Condition...3552
Procedure...3552
Follow-On Procedure...3553
Air Spring...3554
Removal...3554
Overview...3554
Special Tools...3554
Equipment Condition...3554
Procedure...3554
Follow-On Procedure...3555
Installation...3556
Overview...3556
Special Tools...3556
Equipment Condition...3556
Procedure...3556
Follow-On Procedure...3557
Air Supply Line (Tank to Ride Height Valve)...3558
Removal...3558
Overview...3558
Special Tools...3558
Equipment Condition...3558
Procedure...3558
Follow-On Procedure...3559
Installation...3560
Overview...3560
Special Tools...3560
Equipment Condition...3560
Procedure...3560
Follow-On Procedure...3561
Rear Air Suspension Leveling Control Valve...3562
Removal...3562
Overview...3562
Special Tools...3562
Equipment Condition...3562
Procedure...3562
Follow-On Procedure...3563
Installation...3564
Overview...3564
Special Tools...3564
Equipment Condition...3564
Procedure...3564
Follow-On Procedure...3565
Rear Shock Absorber...3566
Removal...3566
Overview...3566
Special Tools...3566
Equipment Condition...3566
Procedure...3566
Follow-On Procedure...3567
Installation...3568
Overview...3568
Special Tools...3568
Equipment Condition...3568
Procedure...3568
Follow-On Procedures...3568
Support Member...3569
Removal...3569
Overview...3569
Special Tools...3569
Equipment Condition...3569
Procedure...3570
Follow-On Procedure...3572
Installation...3573
Overview...3573
Special Tools...3573
Equipment Condition...3573
Procedure...3574
Follow-On Procedure...3576
Support Member Bushing...3578
Removal...3578
Overview...3578
Special Tools...3578
Equipment Condition...3578
Procedure...3579
Follow-On Procedure...3579
Installation...3580
Overview...3580
Special Tools...3580
Equipment Condition...3580
Procedure...3580
Follow-On Procedure...3581
Torque Rod...3582
Removal...3582
Overview...3582
Special Tools...3582
Equipment Condition...3582
Procedure...3583
Follow-On Procedure...3585
Installation...3586
Overview...3586
Special Tools...3586
Equipment Condition...3586
Procedure...3586
Follow-On Procedure...3588
Air Suspension System Depressurization...3589
Overview...3589
Special Tools...3589
Equipment Condition...3589
Depressurization Procedure...3589
Follow-On Procedure...3590
Air Suspension System Pressurization...3591
Overview...3591
Special Tools...3591
Equipment Condition...3591
Pressurization Procedure...3591
Follow-On Procedure...3592
Ride Height Measurement...3593
Overview...3593
Special Tools...3593
Equipment Condition...3593
Ride Height Measurement Procedure...3593
Follow-On Procedure...3594
Ride Height Adjustment...3595
Overview...3595
Special Tools...3595
Equipment Condition...3595
Procedure...3595
Follow-On Procedure...3596
2. Leaf Spring Suspensions...3597
International Spring...3597
Overview...3597
Vari-Rate Leaf Spring...3597
Rear Leaf Spring...3598
Removal...3598
Overview...3598
Special Tools...3598
Equipment Condition...3598
Procedure...3599
Follow-On Procedure...3602
Installation...3603
Overview...3603
Special Tools...3603
Equipment Condition...3603
Procedure...3603
Follow-On Procedure...3606
Rear Shock Absorber Replacement...3607
Removal...3607
Overview...3607
Special Tools...3607
Equipment Condition...3607
Procedure...3607
Follow-On Procedure...3608
Installation...3609
Overview...3609
Special Tools...3609
Equipment Condition...3609
Procedure...3609
Follow-On Procedure...3610
Rear Spring Anchor Plate...3611
Removal...3611
Overview...3611
Special Tools...3611
Equipment Condition...3611
Procedure...3612
Follow-On Procedure...3612
Installation...3613
Overview...3613
Special Tools...3613
Equipment Condition...3613
Procedure...3613
Follow-On Procedure...3614
3. Rear Axle...3615
Dana Spicer® 110...3615
Gear Tooth Contact Pattern Inspection...3615
Overview...3615
Special Tools...3615
Equipment Condition...3615
Procedure...3615
Follow-On Procedure...3620
Differential...3621
Removal...3621
Overview...3621
Special Tools...3621
Equipment Condition...3621
Procedure...3622
Follow-On Procedure...3625
Installation...3626
Overview...3626
Special Tools...3626
Equipment Condition...3626
Procedure...3627
Follow-On Procedure...3629
Disassembly...3630
Overview...3630
Special Tools...3630
Equipment Condition...3630
Procedure...3631
Follow-On Procedure...3638
Assembly...3639
Overview...3639
Special Tools...3639
Equipment Condition...3639
Procedure...3639
Follow-On Procedure...3651
Drive Pinion and Ring Gear Replacement...3652
Removal...3652
Overview...3652
Special Tools...3652
Equipment Condition...3652
Procedure...3653
Follow-On Procedure...3658
Installation...3659
Overview...3659
Special Tools...3659
Equipment Condition...3659
Procedure...3660
Follow-On Procedure...3669
Rear Wheel Hub, Inner and Outer Bearing, and Rear Axle Shaft Seal...3670
Removal...3670
Overview...3670
Special Tools...3670
Equipment Condition...3670
Procedure...3670
Follow-On Procedure...3671
Installation...3672
Overview...3672
Special Tools...3672
Torque Specifications...3672
Equipment Condition...3672
Procedure...3672
Follow-On Procedure...3672
Backlash Adjustment...3673
Overview...3673
Special Tools...3673
Equipment Condition...3673
Procedure...3674
Follow-On Procedure...3674
Differential Carrier Bearing Preload Adjustment...3675
Overview...3675
Special Tools...3675
Equipment Condition...3675
Procedure...3676
Follow-On Procedure...3678
Differential Pinion Input Shaft Runout Measurement...3679
Overview...3679
Special Tools...3679
Equipment Condition...3679
Measurement Procedure...3680
Follow-On Procedure...3682
Rear Axle End Play Adjustment...3683
Overview...3683
Special Tools...3683
Equipment Condition...3683
Procedure...3683
Follow-On Procedure...3684
Wheel Bearing Adjustment...3685
Overview...3685
Special Tools...3685
Equipment Condition...3685
Procedure...3686
Three-piece Dowel-type Lock Washer System...3687
Three-piece Tang-type Lock Washer System...3688
Four-piece Tang / Dowel-type Lock Washer System...3689
Follow-On Procedure...3690
Dana Spicer® 140...3690
Differential Replacement...3690
Removal...3690
Overview...3690
Special Tools...3690
Equipment Condition...3690
Procedure...3691
Follow-On Procedure...3694
Installation...3695
Overview...3695
Special Tools...3695
Equipment Condition...3695
Procedure...3696
Follow-On Procedure...3698
Disassembly...3699
Overview...3699
Special Tools...3699
Equipment Condition...3699
Procedure...3700
Follow-On Procedure...3709
Assembly...3710
Overview...3710
Special Tools...3710
Equipment Condition...3710
Procedure...3710
Follow-On Procedure...3724
Drive Pinion and Ring Gear Replacement...3725
Removal...3725
Overview...3725
Special Tools...3725
Equipment Condition...3725
Procedure...3726
Follow-On Procedure...3731
Installation...3732
Overview...3732
Special Tools...3732
Equipment Condition...3732
Procedure...3733
Follow-On Procedure...3742
Differential Carrier Assembly Replacement...3743
Removal...3743
Overview...3743
Special Tools...3743
Equipment Conditions...3743
Procedure...3743
Follow-On Procedure...3743
Installation...3744
Overview...3744
Special Tools...3744
Equipment Conditions...3744
Procedure...3744
Follow-On Procedure...3745
Rear Wheel Hub, Inner and Outer Bearing, and Rear Axle Shaft Seal...3746
Removal...3746
Special Tools...3746
Equipment Condition...3746
Procedure...3746
Follow-On Procedure...3747
Installation...3748
Overview...3748
Special Tools...3748
Torque Specifications...3748
Equipment Condition...3748
Procedure...3748
Follow-On Procedure...3749
Backlash Adjustment...3750
Overview...3750
Special Tools...3750
Equipment Condition...3750
Procedure...3751
Follow-On Procedure...3751
Differential Carrier Bearing Preload Adjustment...3752
Overview...3752
Special Tools...3752
Equipment Condition...3752
Procedure...3753
Follow-On Procedure...3755
Differential Pinion Input Shaft Runout Measurement...3756
Overview...3756
Special Tools...3756
Equipment Condition...3756
Measurement Procedure...3757
Follow-On Procedure...3759
Rear Axle End Play Adjustment...3760
Overview...3760
Special Tools...3760
Equipment Condition...3760
Procedure...3760
Follow-On Procedure...3761
Wheel Bearing Adjustment...3762
Overview...3762
Special Tools...3762
Equipment Condition...3762
Procedure...3762
Three-piece Dowel-type Lock Washer System...3764
Three-piece Tang-type Lock Washer System...3765
Four-piece Tang / Dowel-type Lock Washer System...3766
Follow-On Procedure...3767
Fuel System...3769
1. DEF System...3771
Diesel Exhaust Fluid (Emission Reduction Fluid) Controller...3771
Removal...3771
Overview...3771
Special Tools...3771
Equipment Conditions...3771
Procedure...3772
Follow-On Procedure...3772
Installation...3773
Overview...3773
Special Tools...3773
Equipment Conditions...3773
Procedure...3773
Follow-On Procedure...3774
Diesel Exhaust Fluid (DEF) Doser (Emission Reduction Fluid Injector)...3775
Removal...3775
Overview...3775
Special Tools...3775
Equipment Conditions...3775
Procedure...3775
Follow-On Procedure...3776
Installation...3777
Overview...3777
Special Tools...3777
Equipment Conditions...3777
Procedure...3777
Follow-On Procedure...3778
DEF Lines...3779
Diesel Exhaust Fluid (Emission Reduction Fluid) Exhaust Front Pipe Injector Supply Pipe...3779
Removal...3779
Overview...3779
Special Tools...3779
Equipment Conditions...3779
Procedure...3780
Follow-On Procedure...3781
Installation...3782
Overview...3782
Special Tools...3782
Torque Specifications...3782
Equipment Conditions...3782
Procedure...3782
Follow-On Procedure...3783
DEF Tank...3785
Diesel Exhaust Fluid (Emission Reduction Fluid) Tank...3785
Removal...3785
Overview...3785
Special Tools...3785
Equipment Conditions...3785
Procedure...3786
Follow-On Procedure...3788
Installation...3789
Overview...3789
Special Tools...3789
Equipment Conditions...3789
Procedure...3789
Follow-On Procedure...3791
Diesel Exhaust Fluid (Emission Reduction Fluid) Tank Filler Hose...3792
Removal...3792
Overview...3792
Special Tools...3792
Equipment Conditions...3792
Procedure...3793
Follow-On Procedure...3795
Installation...3796
Overview...3796
Special Tools...3796
Equipment Conditions...3796
Procedure...3796
Follow-On Procedure...3798
Diesel Exhaust Fluid (Emission Reduction Fluid) Tank Wire Harness...3799
Removal...3799
Overview...3799
Special Tools...3799
Equipment Conditions...3799
Procedure...3800
Follow-On Procedure...3800
Installation...3801
Overview...3801
Special Tools...3801
Torque Specifications...3801
Equipment Conditions...3801
Procedure...3801
Follow-On Procedure...3802
Diesel Exhaust Fluid (Emission Reduction Fluid) Tank Shield...3803
Removal...3803
Overview...3803
Special Tools...3803
Equipment Conditions...3803
Procedure...3804
Follow-On Procedure...3805
Installation...3806
Overview...3806
Special Tools...3806
Equipment Conditions...3806
Procedure...3807
Follow-On Procedure...3808
2. Diesel Fuel System...3809
Fuel System Priming...3809
Fuel Cooler...3810
Removal...3810
Overview...3810
Special Tools...3810
Equipment Condition...3810
Procedure...3810
Follow-On Procedure...3811
Installation...3812
Overview...3812
Special Tools...3812
Equipment Condition...3812
Procedure...3812
Follow-On Procedure...3812
Fuel Filter...3813
Fuel Filter Element...3813
Removal...3813
Overview...3813
Special Tools...3813
Equipment Conditions...3813
Procedure...3814
Follow-On Procedure...3814
Installation...3815
Overview...3815
Special Tools...3815
Torque Specifications...3815
Equipment Conditions...3815
Procedure...3815
Follow-On Procedure...3816
Water-in-Fuel Draining...3817
Overview...3817
Special Tools...3817
Equipment Conditions...3817
Procedure...3817
Follow-On Procedure...3818
Fuel Lines...3819
Fuel Feed Rear Hose...3819
Removal...3819
Overview...3819
Special Tools...3819
Equipment Conditions...3819
Procedure...3820
Follow-On Procedure...3821
Installation...3822
Overview...3822
Special Tools...3822
Torque Specifications...3822
Equipment Conditions...3822
Procedure...3822
Follow-On Procedure...3823
Fuel Feed and Return Front Hose (At Tank)...3824
Removal...3824
Overview...3824
Special Tools...3824
Equipment Conditions...3824
Procedure...3825
Follow-On Procedure...3825
Installation...3826
Overview...3826
Special Tools...3826
Equipment Conditions...3826
Procedure...3826
Follow-On Procedure...3827
Fuel Feed and Return Front Hose (Cooler to Filter to Hose)...3828
Removal...3828
Overview...3828
Special Tools...3828
Equipment Conditions...3828
Procedure...3829
Follow-On Procedure...3830
Installation...3831
Overview...3831
Special Tools...3831
Torque Specifications...3831
Equipment Conditions...3831
Procedure...3831
Follow-On Procedure...3832
Fuel Feed and Return Front Hose (Engine to Hose)...3833
Removal...3833
Overview...3833
Special Tools...3833
Equipment Conditions...3833
Procedure...3834
Follow-On Procedure...3835
Installation...3836
Overview...3836
Special Tools...3836
Equipment Conditions...3836
Procedure...3836
Follow-On Procedure...3837
Fuel Feed and Return Front Hose (Tank to Cooler to Filter)...3838
Removal...3838
Overview...3838
Special Tools...3838
Equipment Conditions...3838
Procedure...3839
Follow-On Procedure...3840
Installation...3841
Overview...3841
Special Tools...3841
Torque Specifications...3841
Equipment Conditions...3841
Procedure...3841
Follow-On Procedure...3842
Fuel Pressure Sensor...3843
Removal...3843
Overview...3843
Special Tools...3843
Equipment Conditions...3843
Procedure...3843
Follow-On Procedure...3844
Installation...3845
Overview...3845
Special Tools...3845
Torque Specifications...3845
Equipment Conditions...3845
Procedure...3845
Follow-On Procedure...3846
Fuel Tanks...3847
Fuel Level Sensor...3847
Removal...3847
Overview...3847
Special Tools...3847
Equipment Condition...3847
Procedure...3848
Follow-On Procedure...3848
Installation...3849
Overview...3849
Special Tools...3849
Torque Specifications...3849
Equipment Condition...3849
Procedure...3849
Follow-On Procedure...3850
Fuel Tank (Front Tank)...3851
Removal...3851
Overview...3851
Special Tools...3851
Equipment Conditions...3851
Procedure...3851
Follow-On Procedure...3854
Installation...3855
Overview...3855
Special Tools...3855
Equipment Conditions...3855
Procedure...3855
Follow-On Procedure...3858
Fuel Tank (Auxiliary Tank)...3859
Removal...3859
Overview...3859
Special Tools...3859
Equipment Conditions...3859
Procedure...3859
Follow-On Procedure...3862
Installation...3863
Overview...3863
Overview...3863
Special Tools...3863
Equipment Conditions...3863
Procedure...3863
Follow-On Procedure...3865
Fuel Tank Filler Pipe (Front Tank)...3866
Removal...3866
Overview...3866
Special Tools...3866
Equipment Conditions...3866
Procedure...3867
Follow-On Procedure...3867
Installation...3868
Overview...3868
Special Tools...3868
Equipment Conditions...3868
Procedure...3868
Follow-On Procedure...3869
Fuel Tank Filler Pipe (Auxiliary Tank)...3870
Removal...3870
Overview...3870
Special Tools...3870
Equipment Conditions...3870
Procedure...3871
Follow-On Procedure...3871
Installation...3872
Overview...3872
Special Tools...3872
Equipment Conditions...3872
Procedure...3872
Follow-On Procedure...3873
Fuel Tank Fuel Sending Unit (Fuel Pump Module) (Front Tank)...3874
Removal...3874
Overview...3874
Special Tools...3874
Equipment Condition...3874
Procedure...3875
Follow-On Procedure...3876
Installation...3877
Overview...3877
Special Tools...3877
Torque Specifications...3877
Equipment Condition...3877
Procedure...3877
Follow-On Procedure...3878
Fuel Tank Fuel Sending Unit (Fuel Pump Module) (Auxiliary Tank)...3879
Removal...3879
Overview...3879
Special Tools...3879
Equipment Condition...3879
Procedure...3880
Follow-On Procedure...3880
Installation...3881
Overview...3881
Special Tools...3881
Torque Specifications...3881
Equipment Condition...3881
Procedure...3881
Follow-On Procedure...3882
Fuel Tank Draining (Diesel)...3883
Overview...3883
Special Tools...3883
Equipment Condition...3883
Follow-On Procedure...3883
Fuel Pump Driver Control Module...3884
Fuel Pump Driver Control Module with Left Hand PTO option. (0012WGG)...3884
Removal...3884
Overview...3884
Special Tools...3884
Equipment Condition...3884
Procedure...3884
Follow-On Procedure...3885
Installation...3885
Overview...3885
Special Tools...3885
Equipment Condition...3886
Procedure...3886
Follow-On Procedure...3887
Fuel Pump Driver Control Module with Right Hand PTO (w/o 0012WGG)...3887
Removal...3887
Overview...3887
Special Tools...3887
Equipment Conditions...3887
Procedure...3888
Follow-On Procedure...3889
Installation...3889
Overview...3889
Special Tools...3890
Equipment Condition...3890
Procedure...3890
Follow-On Procedure...3891
Cab...3893
1. Accessories...3915
Auxiliary Power Outlets...3915
Power Inverter Module (Accessory AC and DC Power Inverter Module) ...3915
Removal...3915
Overview...3915
Special Tools...3915
Equipment Condition...3915
Procedure...3916
Follow-On Procedure...3916
Installation...3917
Overview...3917
Special Tools...3917
Equipment Condition...3917
Procedure...3917
Follow-On Procedure...3918
Accessory Power Outlet...3919
Removal...3919
Overview...3919
Special Tools...3919
Equipment Condition...3919
Procedure...3919
Follow-On Procedure...3920
Installation ...3921
Overview...3921
Special Tools...3921
Torque Specifications...3921
Equipment Condition...3921
Procedure...3921
Follow-On Procedure...3921
Accessory Power Outlet 120 Volt...3922
Removal...3922
Overview...3922
Special Tools...3922
Equipment Condition...3922
Procedure...3922
Follow-On Procedure...3923
Installation...3924
Overview...3924
Special Tools...3924
Torque Specifications...3924
Equipment Condition...3924
Procedure...3924
Follow-On Procedure...3924
Cellular, Navigation, and Radio...3925
Disc Player...3925
Removal...3925
Overview...3925
Special Tools...3925
Equipment Condition...3925
Procedure...3925
Follow-On Procedure...3926
Installation...3927
Overview...3927
Special Tools...3927
Equipment Condition...3927
Procedure...3927
Follow-On Procedure...3927
Communication Interface Module (0008RNN, 0008RNR, 0008RNX)...3928
Removal...3928
Overview...3928
Special Tools...3928
Equipment Condition...3928
Procedure...3928
Follow-On Procedure...3929
Installation...3930
Overview...3930
Special Tools...3930
Torque Specifications...3930
Equipment Condition...3930
Procedure...3930
Follow-On Procedure...3930
Communication Interface Module (0008RNM)...3931
Removal...3931
Overview...3931
Special Tools...3931
Equipment Condition...3931
Procedure...3931
Follow-On Procedure...3932
Installation...3933
Overview...3933
Special Tools...3933
Equipment Condition...3933
Procedure...3933
Follow-On Procedure...3934
High Frequency Antenna...3935
Removal...3935
Overview...3935
Special Tools...3935
Equipment Condition...3935
Procedure...3936
Follow-On Procedure...3936
Installation...3937
Overview...3937
Special Tools...3937
Equipment Condition...3937
Procedure...3937
Follow-On Procedure...3938
Human Machine Interface Module...3939
Removal...3939
Overview...3939
Special Tools...3939
Equipment Condition...3939
Procedure...3939
Follow-On Procedure...3940
Installation...3941
Overview...3941
Special Tools...3941
Torque Specifications...3941
Equipment Condition...3941
Procedure...3941
Follow-On Procedure...3941
Human Machine Interface Module Bracket...3942
Removal...3942
Overview...3942
Special Tools...3942
Equipment Condition...3942
Procedure...3943
Follow-On Procedure...3943
Installation...3944
Overview...3944
Special Tools...3944
Equipment Condition...3944
Procedure...3944
Follow-On Procedure...3944
Mobile Telephone Microphone...3945
Removal...3945
Overview...3945
Special Tools...3945
Equipment Condition...3945
Procedure...3945
Follow-On Procedure...3946
Installation...3947
Overview...3947
Special Tools...3947
Torque Specifications...3947
Equipment Condition...3947
Procedure...3947
Follow-On Procedure...3947
Multimedia Receptacle...3948
Removal...3948
Overview...3948
Special Tools...3948
Equipment Condition...3948
Procedure...3948
Follow-On Procedure...3949
Installation...3950
Overview...3950
Special Tools...3950
Torque Specifications...3950
Equipment Condition...3950
Procedure...3950
Follow-On Procedure...3950
Navigation Signal Splitter...3951
Removal...3951
Overview...3951
Special Tools...3951
Equipment Condition...3951
Procedure...3951
Follow-On Procedure...3952
Installation...3953
Overview...3953
Special Tools...3953
Torque Specifications...3953
Equipment Condition...3953
Procedure...3953
Follow-On Procedure...3953
Radio (0008RNM)...3954
Removal...3954
Overview...3954
Special Tools...3954
Equipment Condition...3954
Procedure...3954
Follow-On Procedure...3955
Installation...3956
Overview...3956
Special Tools...3956
Equipment Condition...3956
Procedure...3956
Follow-On Procedure...3956
Radio (0008RNN, 0008RNR, 0008RNX)...3957
Removal...3957
Overview...3957
Special Tools...3957
Equipment Condition...3957
Procedure...3957
Follow-On Procedure...3958
Installation...3959
Overview...3959
Special Tools...3959
Torque Specifications...3959
Equipment Condition...3959
Procedure...3959
Follow-On Procedure...3959
Radio Antenna...3960
Removal...3960
Overview...3960
Special Tools...3960
Equipment Condition...3960
Procedure...3961
Follow-On Procedure...3961
Installation...3962
Overview...3962
Special Tools...3962
Torque Specifications...3962
Equipment Condition...3962
Procedure...3962
Follow-On Procedure...3962
Radio Antenna Base...3963
Removal...3963
Overview...3963
Special Tools...3963
Equipment Conditions...3963
Procedure...3964
Follow-On Procedure...3965
Installation...3966
Overview...3966
Special Tools...3966
Equipment Conditions...3966
Procedure...3966
Follow-On Procedure...3967
Radio Antenna Cable Extension Cable...3968
Removal...3968
Overview...3968
Special Tools...3968
Equipment Condition...3968
Procedure...3969
Follow-On Procedure...3969
Installation...3970
Overview...3970
Special Tools...3970
Torque Specifications...3970
Equipment Condition...3970
Procedure...3970
Follow-On Procedure...3970
Radio Control Assembly...3971
Removal...3971
Overview...3971
Special Tools...3971
Equipment Condition...3971
Procedure...3971
Follow-On Procedure...3972
Installation...3973
Overview...3973
Special Tools...3973
Equipment Condition...3973
Procedure...3973
Follow-On Procedure...3973
Radio Control Bracket (0008RNM)...3974
Removal...3974
Overview...3974
Special Tools...3974
Equipment Condition...3974
Procedure...3974
Follow-On Procedure...3975
Installation...3976
Overview...3976
Special Tools...3976
Equipment Condition...3976
Procedure...3976
Follow-On Procedure...3977
Radio Front Side Door Speaker...3978
Removal...3978
Overview...3978
Special Tools...3978
Equipment Condition...3978
Procedure...3978
Follow-On Procedure...3979
Installation...3980
Overview...3980
Special Tools...3980
Equipment Condition...3980
Procedure...3980
Follow-On Procedure...3980
Radio Front Speaker...3981
Removal...3981
Overview...3981
Special Tools...3981
Equipment Condition...3981
Procedure...3981
Follow-On Procedure...3982
Installation...3983
Overview...3983
Special Tools...3983
Equipment Condition...3983
Procedure...3983
Follow-On Procedure...3983
Radio Function Switch...3984
Removal...3984
Overview...3984
Special Tools...3984
Equipment Condition...3984
Procedure...3984
Follow-On Procedure...3985
Installation...3986
Overview...3986
Special Tools...3986
Equipment Condition...3986
Procedure...3986
Follow-On Procedure...3987
Radio Rear Side Door Speaker...3988
Removal...3988
Overview...3988
Special Tools...3988
Equipment Condition...3988
Procedure...3988
Follow-On Procedure...3989
Installation...3990
Overview...3990
Special Tools...3990
Procedure...3990
Equipment Condition...3990
Follow-On Procedure...3990
Radio Rear Speaker...3991
Removal...3991
Overview...3991
Special Tools...3991
Equipment Condition...3991
Procedure...3991
Follow-On Procedure...3992
Installation...3993
Overview...3993
Special Tools...3993
Equipment Condition...3993
Procedure...3993
Follow-On Procedure...3993
USB Receptacle...3994
Removal...3994
Overview...3994
Special Tools...3994
Equipment Condition...3994
Procedure...3994
Follow-On Procedure...3995
Installation...3996
Overview...3996
Special Tools...3996
Torque Specifications...3996
Equipment Condition...3996
Procedure...3996
Follow-On Procedure...3996
USB 2 Port...3997
Removal...3997
Overview...3997
Special Tools...3997
Equipment Condition...3997
Procedure...3998
Follow-On Procedure...3998
Installation...3999
Overview...3999
Special Tools...3999
Torque Specifications...3999
Equipment Condition...3999
Procedure...3999
Follow-On Procedure...3999
Garage Door Opener...4000
Overview...4000
Immobilizer...4001
Theft Deterrent Module...4001
Removal...4001
Overview...4001
Special Tools...4001
Equipment Condition...4001
Procedure...4002
Follow-On Procedure...4002
Installation...4003
Overview...4003
Special Tools...4003
Equipment Condition...4003
Procedure...4003
Follow-On Procedure...4004
2. Electrical...4005
Harnesses...4005
Junction Block...4006
Body Harness Junction Block...4006
Removal...4006
Overview...4006
Special Tools...4006
Equipment Condition...4006
Procedure...4006
Follow-On Procedure...4009
Installation...4010
Overview...4010
Special Tools...4010
Equipment Condition...4010
Procedure...4010
Follow-On Procedure...4012
Modules...4013
Body Control Module...4013
Removal...4013
Overview...4013
Special Tools...4013
Equipment Condition...4013
Procedure...4013
Follow-On Procedure...4014
Installation...4015
Overview...4015
Special Tools...4015
Torque Specifications...4015
Equipment Condition...4015
Procedure...4015
Follow-On Procedure...4015
Body Control Module Bracket...4016
Removal...4016
Overview...4016
Special Tools...4016
Equipment Condition...4016
Procedure...4016
Follow-On Procedure...4017
Installation...4018
Overview...4018
Special Tools...4018
Equipment Condition...4018
Procedure...4018
Follow-On Procedure...4018
Serial Data Gateway Module...4019
Removal...4019
Overview...4019
Special Tools...4019
Equipment Condition...4019
Procedure...4019
Follow-On Procedure...4020
Installation...4021
Overview...4021
Special Tools...4021
Torque Specifications...4021
Equipment Condition...4021
Procedure...4021
Follow-On Procedure...4021
Serial Data Gateway Module Bracket...4022
Removal...4022
Overview...4022
Special Tools...4022
Equipment Condition...4022
Procedure...4022
Follow-On Procedure...4023
Installation...4024
Overview...4024
Special Tools...4024
Equipment Condition...4024
Procedure...4024
Follow-On Procedure...4024
3. Cab Exterior...4025
Doors...4025
Front Side Door Check Link...4025
Removal...4025
Overview...4025
Special Tools...4025
Equipment Condition...4025
Procedure...4026
Follow-On Procedure...4026
Installation...4027
Overview...4027
Special Tools...4027
Equipment Condition...4027
Procedure...4027
Follow-On Procedure...4027
Front Side Door Lock Cylinder...4028
Removal ...4028
Overview...4028
Special Tools...4028
Equipment Condition...4028
Procedure...4029
Follow-On Procedure...4029
Installation...4030
Overview...4030
Special Tools...4030
Torque Specifications...4030
Equipment Condition...4030
Procedure...4031
Follow-On Procedure...4031
Front Side Door Lock Cylinder Coding...4032
Coding...4032
Overview...4032
Special Tools...4032
Equipment Conditions...4032
Procedure...4032
Follow-On Procedure...4033
Front Side Door Lock Cylinder Rod Replacement...4034
Removal...4034
Overview...4034
Special Tools...4034
Equipment Conditions...4034
Procedure...4035
Follow-On Procedure...4035
Installation...4036
Overview...4036
Special Tools...4036
Torque Specifications...4036
Equipment Conditions ...4036
Procedure...4037
Follow-On Procedure...4037
Front Side Door Lock Cylinder Bezel...4038
Removal...4038
Overview...4038
Special Tools...4038
Equipment Condition...4038
Procedure...4039
Follow-On Procedure...4039
Installation...4040
Overview...4040
Special Tools...4040
Equipment Condition...4040
Procedure...4040
Follow-On Procedure...4040
Front Side Door Latch Replacement...4041
Removal ...4041
Overview...4041
Special Tools...4041
Equipment Conditions...4041
Procedure...4041
Follow-On Procedure...4042
Installation...4043
Overview...4043
Special Tools...4043
Equipment Conditions ...4043
Procedure...4044
Follow-On Procedure...4044
Front Side Door Inside Handle Cable...4046
Removal...4046
Overview...4046
Special Tools...4046
Equipment Conditions...4046
Procedure...4047
Follow-On Procedure...4047
Installation...4048
Overview...4048
Special Tools...4048
Torque Specifications...4048
Equipment Conditions...4048
Procedure...4049
Follow-On Procedure...4049
Front Side Door Outside Handle...4050
Removal...4050
Overview...4050
Special Tools...4050
Equipment Condition...4050
Procedure...4050
Follow-On Procedure...4058
Installation...4059
Overview...4059
Special Tools...4059
Torque Specifications...4059
Equipment Condition...4059
Procedure...4059
Follow-On Procedure...4062
Front Side Door Outside Handle Cable...4063
Removal...4063
Overview...4063
Special Tools...4063
Equipment Conditions...4063
Procedure...4064
Follow-On Procedure...4064
Installation...4065
Overview...4065
Special Tools...4065
Torque Specifications...4065
Equipment Conditions...4065
Procedure...4066
Follow-On Procedure...4066
Front Side Door Outside Handle Bracket...4067
Removal...4067
Overview...4067
Special Tools...4067
Equipment Condition...4067
Procedure...4068
Follow-On Procedure...4076
Installation...4077
Overview...4077
Special Tools...4077
Equipment Condition...4077
Procedure...4078
Follow-On Procedure...4086
Front Side Door Upper Hinge and Lower Hinge – Left...4087
Removal...4087
Overview...4087
Special Tools...4087
Equipment Condition...4087
Procedure...4087
Follow-On Procedure...4088
Installation...4089
Overview...4089
Special Tools...4089
Equipment Condition...4089
Procedure...4089
Follow-On Procedure...4090
Front Side Door Upper Hinge and Lower Hinge – Right...4091
Removal...4091
Overview...4091
Special Tools...4091
Equipment Condition...4091
Procedure...4091
Follow-On Procedure...4092
Installation...4093
Overview...4093
Special Tools...4093
Equipment Condition...4093
Procedure...4093
Follow-On Procedure...4094
Glass...4095
Front Side Door Window...4095
Removal...4095
Overview...4095
Special Tools...4095
Equipment Condition...4095
Procedure...4096
Follow-On Procedure...4097
Installation...4098
Overview...4098
Special Tools...4098
Equipment Condition...4098
Procedure...4098
Follow-On Procedure...4099
Rear Window...4100
Removal...4100
Overview...4100
Special Tools...4100
Equipment Condition...4100
Procedure...4100
Follow-On Procedure...4102
Installation...4103
Overview...4103
Special Tools...4103
Equipment Condition...4103
Procedure...4103
Follow-On Procedure...4105
Rear Window Adhesive...4106
Installation...4106
Overview...4106
Urethane Adhesive Cure Times...4106
Special Tools...4106
Torque Specification...4106
Equipment Condition...4107
Procedure...4108
Follow-On Procedure...4115
Windshield...4116
Removal...4116
Overview...4116
Special Tools...4116
Equipment Condition...4116
Procedure...4116
Follow-On Procedure...4117
Installation...4118
Overview...4118
Special Tools...4118
Torque Specifications...4118
Equipment Condition...4118
Procedure...4118
Follow-On Procedure...4118
Windshield Adhesive...4119
Installation...4119
Overview...4119
Special Tools...4119
Urethane Adhesive Cure Times...4119
Torque Specification...4119
Equipment Condition...4120
Procedure...4120
Follow-On Procedure...4128
Lighting...4129
Front Driver Clearance Lamp...4129
Removal...4129
Overview...4129
Special Tools...4129
Equipment Condition...4129
Procedure...4130
Follow-On Procedure...4130
Installation...4131
Overview...4131
Special Tools...4131
Torque Specifications...4131
Equipment Condition...4131
Procedure...4131
Follow-On Procedure...4132
Front Passenger Clearance Lamp...4133
Removal...4133
Overview...4133
Special Tools...4133
Equipment Condition...4133
Procedure...4134
Follow-On Procedure...4134
Installation...4135
Overview...4135
Special Tools...4135
Torque Specifications...4135
Equipment Condition...4135
Procedure...4135
Follow-On Procedure...4136
Front Clearance Lamp (Mirror)...4137
Removal...4137
Overview...4137
Special Tools...4137
Equipment Condition...4137
Procedure...4137
Follow-On Procedure...4138
Installation...4139
Overview...4139
Special Tools...4139
Equipment Condition...4139
Procedure...4139
Follow-On Procedure...4140
Front Identification Lamp...4141
Removal...4141
Overview...4141
Special Tools...4141
Equipment Condition...4141
Procedure...4142
Follow-On Procedure...4142
Installation...4143
Overview...4143
Special Tools...4143
Torque Specifications...4143
Equipment Condition...4143
Procedure...4143
Follow-On Procedure...4144
High Mount Stop and Cargo Lamp...4145
Removal...4145
Overview...4145
Special Tools...4145
Equipment Condition...4145
Procedure...4145
Follow-On Procedure...4146
Installation...4147
Overview...4147
Special Tools...4147
Equipment Condition...4147
Procedure...4147
Follow-On Procedure...4147
High Mount Stop and Cargo Lamp Assembly Cargo Bulb...4148
Removal...4148
Overview...4148
Special Tools...4148
Equipment Condition...4148
Procedure...4149
Follow-On Procedure...4149
Installation...4150
Overview...4150
Special Tools...4150
Torque Specifications...4150
Equipment Condition...4150
Procedure...4150
Follow-On Procedure...4151
High Mount Stop and Cargo Lamp Assembly Stop Bulb...4152
Removal...4152
Overview...4152
Special Tools...4152
Equipment Condition...4152
Procedure...4153
Follow-On Procedure...4153
Installation...4154
Overview...4154
Special Tools...4154
Torque Specifications...4154
Equipment Condition...4154
Procedure...4154
Follow-On Procedure...4154
High Mount Stop Lamp Wiring Harness...4155
Removal...4155
Overview...4155
Special Tools...4155
Equipment Condition...4155
Procedure...4156
Follow-On Procedure...4156
Installation...4157
Overview...4157
Special Tools...4157
Torque Specifications...4157
Equipment Condition...4157
Procedure...4157
Follow-On Procedure...4157
Rear Body Structure Stop Lamp – Left...4158
Removal...4158
Overview...4158
Special Tools...4158
Equipment Condition...4158
Procedure...4158
Follow-On Procedure...4159
Installation...4160
Overview...4160
Special Tools...4160
Equipment Condition...4160
Procedure...4160
Follow-On Procedure...4160
Rear Body Structure Stop Lamp – Right...4161
Removal...4161
Overview...4161
Special Tools...4161
Equipment Condition...4161
Procedure...4161
Follow-On Procedure...4162
Installation...4163
Overview...4163
Special Tools...4163
Equipment Condition...4163
Procedure...4163
Follow-On Procedure...4163
Tail Light (Feature Code 0008TUL)...4164
Bulb Replacement...4164
Overview...4164
Special Tools...4164
Equipment Conditions...4164
Procedure...4164
Follow-On Procedure...4165
Sun Load Temperature and Headlight (Headlamp) Automatic Control Ambient Light Sensor...4166
Removal...4166
Overview...4166
Special Tools...4166
Equipment Condition...4166
Procedure...4167
Follow-On Procedure...4167
Installation...4168
Overview...4168
Special Tools...4168
Torque Specifications...4168
Equipment Condition...4168
Procedure...4168
Follow on Procedure...4168
Fog Light (Fog Lamp) Aiming...4169
Overview...4169
Special Tools...4169
Equipment Condition...4169
Aiming Procedure...4170
Follow-On Procedure...4170
Mirrors...4171
Ambient Air Temperature Sensor (0016SPR)...4171
Removal...4171
Overview...4171
Special Tools...4171
Equipment Condition...4171
Procedure...4172
Follow-On Procedure...4172
Installation...4173
Overview...4173
Special Tools...4173
Torque Specifications...4173
Equipment Condition...4173
Procedure...4173
Follow-On Procedure...4173
Ambient Air Temperature Sensor (0016SPS)...4174
Removal...4174
Overview...4174
Special Tools...4174
Equipment Condition...4174
Procedure...4174
Follow-On Procedure...4175
Installation...4176
Overview...4176
Special Tools...4176
Torque Specifications...4176
Equipment Condition...4176
Procedure...4176
Follow-On Procedure...4176
Exterior Mirror (Outside Rearview Mirror) (0016SPR)...4177
Removal...4177
Overview...4177
Special Tools...4177
Equipment Conditions...4177
Procedure...4178
Follow-On Procedure...4178
Installation...4179
Overview...4179
Special Tools...4179
Equipment Conditions...4179
Procedure...4179
Follow-On Procedure...4179
Exterior Mirror (Outside Rearview Mirror) (0016SPS)...4180
Removal...4180
Overview...4180
Special Tools...4180
Equipment Condition...4180
Procedure...4181
Follow-On Procedure...4181
Installation...4182
Overview...4182
Special Tools...4182
Equipment Condition...4182
Procedure...4182
Follow-On Procedure...4183
Exterior Mirrors (Outside Rearview Mirror) Arm Cover...4184
Removal...4184
Overview...4184
Special Tools...4184
Equipment Condition...4184
Procedure...4185
Follow-On Procedure...4185
Installation...4186
Overview...4186
Special Tools...4186
Torque Specifications...4186
Equipment Condition...4186
Procedure...4186
Follow-On Procedure...4186
Exterior Mirrors (Outside Rearview Mirror) Gasket...4187
Removal...4187
Overview...4187
Special Tools...4187
Equipment Condition...4187
Procedure...4188
Follow-On Procedure...4188
Installation...4189
Overview...4189
Special Tools...4189
Torque Specifications...4189
Equipment Condition...4189
Procedure...4189
Follow-On Procedure...4190
Exterior Mirrors (Outside Rearview Mirror) Housing Upper Cover...4191
Removal...4191
Overview...4191
Special Tools...4191
Equipment Condition...4191
Procedure...4192
Follow-On Procedure...4192
Installation...4193
Overview...4193
Special Tools...4193
Torque Specifications...4193
Equipment Condition...4193
Procedure...4193
Follow-On Procedure...4193
Exterior Mirrors (Outside Rearview Mirror) Housing Lower Cover...4194
Removal...4194
Overview...4194
Special Tools...4194
Equipment Condition...4194
Procedure...4194
Follow-On Procedure...4195
Installation...4196
Overview...4196
Special Tools...4196
Torque Specifications...4196
Equipment Condition...4196
Procedure...4196
Follow-On Procedure...4196
Exterior Mirrors (Outside Rearview Mirror) Inner Actuator...4197
Removal...4197
Overview...4197
Special Tools...4197
Equipment Condition...4197
Procedure...4198
Follow-On Procedure...4199
Installation...4200
Overview...4200
Special Tools...4200
Equipment Condition...4200
Procedure...4200
Follow-On Procedure...4201
Exterior Mirrors (Outside Rearview Mirror) Lower Glass (0016SPR)...4202
Removal...4202
Overview...4202
Special Tools...4202
Equipment Condition...4202
Procedure...4203
Follow-On Procedure...4203
Installation...4204
Overview...4204
Special Tools...4204
Equipment Condition...4204
Procedure...4204
Follow-On Procedure...4205
Exterior Mirrors (Outside Rearview Mirror) Lower Glass (0016SPS)...4206
Removal...4206
Overview...4206
Special Tools...4206
Equipment Condition...4206
Procedure...4207
Follow-On Procedure...4207
Installation...4208
Overview...4208
Special Tools...4208
Torque Specifications...4208
Equipment Condition...4208
Procedure...4208
Follow-On Procedure...4208
Exterior Mirrors (Outside Rearview Mirror) Remote Control Switch...4209
Removal...4209
Overview...4209
Special Tools...4209
Equipment Condition...4209
Procedure...4210
Follow-On Procedure...4210
Installation...4211
Overview...4211
Special Tools...4211
Torque Specifications...4211
Equipment Condition...4211
Procedure...4211
Follow-On Procedure...4211
Exterior Mirrors (Outside Rearview Mirror) Upper Glass (0016SPS)...4212
Removal...4212
Overview...4212
Special Tools...4212
Equipment Conditions...4212
Procedure...4213
Follow-On Procedure...4213
Installation...4214
Overview...4214
Special Tools...4214
Torque Specifications...4214
Equipment Conditions...4214
Procedure...4214
Follow-On Procedure...4214
Exterior Mirrors (Outside Rearview Mirror) Upper Glass (0016SPR)...4215
Removal...4215
Overview...4215
Special Tools...4215
Equipment Condition...4215
Procedure...4216
Follow-On Procedure...4216
Installation...4217
Overview...4217
Special Tools...4217
Torque Specifications...4217
Equipment Condition...4217
Procedure...4217
Follow-On Procedure...4218
Ambient Air Temperature Calculation Reset...4219
Overview...4219
Special Tools...4219
Equipment Condition...4219
Reset Procedure...4219
Follow-On Procedure...4219
Steps...4220
Assist Step (Driver)...4220
Removal...4220
Overview...4220
Special Tools...4220
Equipment Condition...4220
Procedure...4221
Follow-On Procedure...4221
Installation...4222
Overview...4222
Special Tools...4222
Equipment Condition...4222
Procedure...4222
Follow-On Procedure...4223
Assist Step (Passenger)...4224
Removal...4224
Overview...4224
Special Tools...4224
Equipment Condition...4224
Procedure...4224
Follow-On Procedure...4225
Installation...4226
Overview...4226
Special Tools...4226
Equipment Condition...4226
Procedure...4226
Follow-On Procedure...4226
Trim...4227
Air Inlet Grille Panel...4227
Removal...4227
Overview...4227
Special Tools...4227
Equipment Condition...4227
Procedure...4228
Follow-On Procedure...4228
Installation...4229
Overview...4229
Special Tools...4229
Torque Specifications...4229
Equipment Condition...4229
Procedure...4229
Follow-On Procedure...4230
Body Pressure Relief Valve...4231
Removal...4231
Overview...4231
Special Tools...4231
Equipment Condition...4231
Procedure...4231
Follow-On Procedure...4234
Installation...4235
Overview...4235
Special Tools...4235
Torque Specifications...4235
Equipment Condition...4235
Procedure...4235
Follow-On Procedure...4237
Radio Antenna Base...4238
Removal...4238
Overview...4238
Special Tools...4238
Equipment Condition...4238
Procedure...4239
Follow-On Procedure...4241
Installation...4242
Overview...4242
Special Tools...4242
Equipment Condition...4242
Procedure...4242
Follow-On Procedure...4244
4. Cab Exterior – Crew...4245
Doors...4245
Rear Side Door Latch Replacement...4245
Removal...4245
Overview...4245
Special Tools...4245
Equipment Conditions...4245
Procedure...4245
Follow-On Procedure...4246
Installation...4247
Overview...4247
Special Tools...4247
Equipment Conditions...4247
Procedure...4248
Follow-On Procedure...4249
Rear Side Door Lock Cylinder Opening Cover...4249
Removal...4249
Overview...4249
Special Tools...4249
Equipment Condition...4250
Procedure...4250
Follow-On Procedure...4252
Installation...4253
Overview...4253
Special Tools...4253
Equipment Condition...4253
Procedure...4253
Follow-On Procedure...4255
Rear Side Door Outside Handle...4256
Removal ...4256
Overview...4256
Special Tools...4256
Equipment Condition...4256
Procedure...4257
Follow-On Procedure...4260
Installation...4261
Overview...4261
Special Tools...4261
Equipment Condition...4261
Procedure...4261
Follow-On Procedure...4264
Rear Side Door Outside Handle Cable Replacement...4265
Removal...4265
Overview...4265
Special Tools...4265
Equipment Conditions...4265
Procedure...4266
Follow-On Procedure...4266
Installation...4267
Overview...4267
Special Tools...4267
Torque Specifications...4267
Equipment Conditions...4267
Procedure...4267
Follow-On Procedure...4268
Rear Side Door Outside Handle Bracket...4269
Removal...4269
Overview...4269
Special Tools...4269
Equipment Condition...4269
Procedure...4270
Follow-On Procedure...4271
Installation...4272
Overview...4272
Special Tools...4272
Equipment Condition...4272
Procedure...4272
Follow-On Procedure...4273
Rear Side Door Upper Hinge and Lower Hinge...4274
Removal...4274
Overview...4274
Special Tools...4274
Equipment Condition...4274
Procedure...4275
Follow-On Procedure...4276
Installation...4277
Overview...4277
Special Tools...4277
Equipment Condition...4277
Procedure...4277
Follow-On Procedure...4278
Rear Side Door Check Link...4279
Removal...4279
Overview...4279
Special Tools...4279
Equipment Condition...4279
Procedure...4280
Follow-On Procedure...4280
Installation...4281
Overview...4281
Special Tools...4281
Equipment Condition...4281
Procedure...4282
Follow-On Procedure...4282
Rear Side Door Inside Handle Cable Replacement...4283
Removal...4283
Overview...4283
Special Tools...4283
Equipment Conditions...4283
Procedure...4284
Follow-On Procedure...4284
Installation...4285
Overview...4285
Special Tools...4285
Torque Specifications...4285
Equipment Conditions...4285
Procedure...4285
Follow-On Procedure...4286
Glass...4288
Rear Side Door Window...4288
Removal...4288
Overview...4288
Special Tools...4288
Equipment Condition...4288
Procedure...4289
Follow-On Procedure...4291
Installation...4292
Overview...4292
Special Tools...4292
Equipment Condition...4292
Procedure...4292
Follow-On Procedure...4294
Steps...4295
Assist Step (Crew Cab – Left Rear)...4295
Removal...4295
Overview...4295
Special Tools...4295
Equipment Condition...4295
Procedure...4296
Follow-On Procedure...4296
Installation...4297
Overview...4297
Special Tools...4297
Equipment Condition...4297
Procedure...4297
Follow-On Procedure...4297
Assist Step (Crew Cab – Right Rear)...4298
Removal...4298
Overview...4298
Special Tools...4298
Equipment Condition...4298
Procedure...4299
Follow-On Procedure...4299
Installation...4300
Overview...4300
Special Tools...4300
Procedure...4300
Follow-On Procedure...4300
5. Cab Interior...4301
Doors...4301
Door Window Regulator Handle...4301
Removal...4301
Overview...4301
Special Tools ...4301
Equipment Condition...4301
Procedure...4301
Follow-On Procedure...4304
Installation...4305
Overview...4305
Special Tools...4305
Torque Specifications...4305
Equipment Condition...4305
Procedure...4305
Follow-On Procedure...4307
Front Driver Door Accessory Switch Mount Plate...4308
Removal...4308
Overview...4308
Special Tools...4308
Equipment Condition...4308
Procedure...4308
Follow-On Procedure...4309
Installation...4310
Overview...4310
Special Tools...4310
Equipment Condition...4310
Procedure...4310
Follow-On Procedure...4310
Front Passenger Door Accessory Switch Mount Plate...4311
Removal...4311
Overview...4311
Special Tools...4311
Equipment Condition...4311
Procedure...4311
Follow-On Procedure...4312
Installation...4313
Overview...4313
Special Tools...4313
Equipment Condition...4313
Procedure...4313
Follow-On Procedure...4313
Front Side Door Armrest Cover Trim...4314
Removal...4314
Overview...4314
Special Tools...4314
Equipment Condition...4314
Procedure...4315
Follow-On Procedure...4316
Installation...4317
Overview...4317
Special Tools...4317
Torque Specifications...4317
Equipment Condition...4317
Procedure...4317
Follow-On Procedure...4318
Front Side Door Inside Handle...4319
Removal...4319
Overview...4319
Special Tools...4319
Equipment Condition...4319
Procedure...4319
Follow-On Procedure...4320
Installation...4321
Overview...4321
Special Tools...4321
Equipment Condition...4321
Procedure...4321
Follow-On Procedure...4322
Front Side Door Locking Rod Knob...4323
Removal...4323
Overview...4323
Special Tools...4323
Equipment Condition...4323
Procedure...4324
Follow-On Procedure...4324
Installation...4325
Overview...4325
Special Tools...4325
Equipment Condition...4325
Procedure...4325
Follow-On Procedure...4325
Front Side Door Locking Rod Push-button Bezel...4326
Removal...4326
Overview...4326
Special Tools...4326
Equipment Condition...4326
Procedure...4327
Follow-On Procedure...4327
Installation...4328
Overview...4328
Special Tools...4328
Torque Specifications...4328
Equipment Condition...4328
Procedure...4328
Follow-On Procedure...4328
Front Side Door Pull Handle Bracket...4329
Removal...4329
Overview...4329
Special Tools...4329
Equipment Condition...4329
Procedure...4330
Follow-On Procedure...4330
Installation...4331
Overview...4331
Special Tools...4331
Equipment Condition...4331
Procedure...4331
Follow-On Procedure...4331
Front Side Door Sill Garnish Molding Replacement...4332
Removal...4332
Overview...4332
Special Tools...4332
Equipment Condition...4332
Procedure...4333
Follow-On Procedure...4334
Installation...4335
Overview...4335
Special Tools...4335
Torque Specifications...4335
Procedure...4335
Follow-On Procedure...4336
Front Side Door Trim...4337
Removal...4337
Overview...4337
Special Tools...4337
Equipment Condition...4337
Procedure...4337
Follow-On Procedure...4341
Installation...4342
Overview...4342
Special Tools...4342
Equipment Condition...4342
Procedure...4342
Follow-On Procedure...4345
Front Side Door Water Deflector...4346
Removal...4346
Overview...4346
Special Tools...4346
Equipment Condition...4346
Procedure...4347
Follow-On Procedure...4347
Installation...4348
Overview...4348
Special Tools...4348
Torque Specifications...4348
Equipment Condition...4348
Procedure...4348
Follow-On Procedure...4348
Front Side Door Window Belt Reveal Molding...4349
Removal...4349
Overview...4349
Special Tools...4349
Equipment Condition...4349
Procedure...4350
Follow-On Procedure...4350
Installation...4351
Overview...4351
Special Tools...4351
Equipment Condition...4351
Procedure...4351
Follow-On Procedure...4352
Front Side Door Window Channel Retainer...4353
Removal...4353
Overview...4353
Special Tools...4353
Equipment Condition...4353
Procedure...4354
Follow-On Procedure...4354
Installation...4355
Overview...4355
Special Tools...4355
Equipment Condition...4355
Procedure...4355
Follow-On Procedure...4356
Front Side Door Window Garnish Molding...4357
Removal...4357
Overview...4357
Special Tools...4357
Equipment Condition...4357
Procedure...4358
Follow-On Procedure...4358
Installation...4359
Overview...4359
Special Tools...4359
Torque Specifications...4359
Equipment Condition...4359
Procedure...4359
Follow-On Procedure...4359
Front Side Door Window Inner Sealing Strip...4360
Removal...4360
Overview...4360
Special Tools...4360
Equipment Condition...4360
Procedure...4361
Follow-On Procedure...4361
Installation...4362
Overview...4362
Special Tools...4362
Torque Specifications...4362
Equipment Condition...4362
Procedure...4362
Follow-On Procedure...4362
Front Side Door Window Regulator (Manual)...4363
Removal...4363
Overview...4363
Special Tools...4363
Equipment Condition...4363
Procedure...4364
Follow-On Procedure...4365
Installation...4366
Overview...4366
Special Tools...4366
Equipment Condition...4366
Procedure...4366
Follow-On Procedure...4367
Front Side Door Window Regulator Handle...4368
Removal...4368
Overview...4368
Special Tools...4368
Equipment Condition...4368
Procedure...4368
Follow-On Procedure...4371
Installation...4372
Overview...4372
Special Tools...4372
Torque Specifications...4372
Equipment Condition...4372
Procedure...4372
Follow-On Procedure...4374
Front Side Door Window Weatherstrip...4375
Removal...4375
Overview...4375
Special Tools...4375
Equipment Condition...4375
Procedure...4376
Follow-On Procedure...4376
Installation...4377
Overview...4377
Special Tools...4377
Torque Specifications...4377
Equipment Condition...4377
Procedure...4377
Follow-On Procedure...4377
Floor...4378
Front Floor Panel Mat...4378
Removal...4378
Overview...4378
Special Tools...4378
Equipment Condition...4378
Procedure ...4379
Follow-On Procedure...4379
Installation...4380
Overview...4380
Special Tools...4380
Torque Specifications...4380
Equipment Condition...4380
Procedure...4380
Follow-On Procedure...4380
Roof...4382
Headliner Harness...4382
Removal...4382
Overview...4382
Special Tools...4382
Equipment Condition...4382
Procedure...4382
Follow-On Procedure...4382
Installation...4383
Overview...4383
Special Tools...4383
Torque Specifications...4383
Equipment Condition...4383
Procedure...4383
Follow-On Procedure...4383
Headliner Trim Panel...4384
Removal...4384
Overview...4384
Special Tools...4384
Equipment Condition...4384
Procedure...4385
Follow-On Procedure...4394
Installation...4395
Overview...4395
Special Tools...4395
Torque Specifications...4395
Equipment Condition...4395
Procedure...4396
Follow-On Procedure...4404
Roof Console...4405
Removal...4405
Overview...4405
Special Tools...4405
Equipment Condition...4405
Procedure...4406
Follow-On Procedure...4406
Installation...4407
Overview...4407
Special Tools...4407
Equipment Condition...4407
Procedure...4407
Follow-On Procedure...4408
Roof Console Filler...4409
Removal...4409
Overview...4409
Special Tools...4409
Equipment Condition...4409
Procedure...4410
Follow-On Procedure...4410
Installation...4411
Overview...4411
Special Tools...4411
Torque Specification...4411
Equipment Condition...4411
Procedure...4411
Follow-On Procedure...4411
Roof Console Opening Trim Plate...4412
Removal...4412
Overview...4412
Special Tools...4412
Equipment Condition...4412
Procedure...4412
Follow-On Procedure...4413
Installation...4414
Overview...4414
Special Tools...4414
Torque Specifications...4414
Equipment Condition...4414
Procedure...4414
Follow-On Procedure...4414
Roof Rail Assist Handle...4415
Removal...4415
Overview...4415
Special Tools...4415
Equipment Condition...4415
Procedure...4416
Follow-On Procedure...4416
Installation...4417
Overview...4417
Special Tools...4417
Equipment Condition...4417
Procedure...4417
Follow-On Procedure...4417
Sunshade...4418
Removal...4418
Overview...4418
Special Tools...4418
Equipment Condition...4418
Procedure...4418
Follow-On Procedure...4419
Installation...4420
Overview...4420
Special Tools...4420
Equipment Condition...4420
Procedure...4420
Follow-On Procedure...4421
Sunshade Support...4422
Removal...4422
Overview...4422
Special Tools...4422
Equipment Condition...4422
Procedure...4423
Follow-On Procedure...4423
Installation...4424
Overview...4424
Special Tools...4424
Equipment Condition...4424
Procedure...4424
Follow-On Procedure...4424
Instrument Panel...4425
Overview...4425
Fastener Specifications...4425
Driver Information Display (0008RNM)...4426
Removal...4426
Overview...4426
Special Tools...4426
Equipment Condition...4426
Procedure...4426
Follow-On Procedure...4427
Installation...4428
Overview...4428
Special Tools...4428
Equipment Condition...4428
Procedure...4428
Follow-On Procedure...4430
Electronic Gauge Cluster...4431
Removal...4431
Overview...4431
Special Tools...4431
Equipment Condition...4431
Procedure...4431
Follow-On Procedure...4432
Installation...4433
Overview...4433
Special Tools...4433
Equipment Condition...4433
Procedure...4433
Follow-On Procedure...4433
Instrument Panel Wiring Harness Junction Block Replacement...4434
Removal...4434
Overview...4434
Special Tools...4434
Equipment Conditions...4434
Procedure...4434
Follow-On Procedure...4435
Installation...4436
Overview...4436
Special Tools...4436
Torque Specifications...4436
Equipment Conditions...4436
Procedure...4436
Follow-On Procedure...4437
Instrument Panel Accessory Bezel...4438
Removal...4438
Overview...4438
Special Tools...4438
Equipment Condition...4438
Procedure...4438
Follow-On Procedure...4439
Installation...4440
Overview...4440
Special Tools...4440
Torque Specifications...4440
Equipment Condition...4440
Procedure...4440
Follow-On Procedure...4440
Instrument Panel Air Outlet Bezel – Left...4441
Removal...4441
Overview...4441
Special Tools...4441
Equipment Condition...4441
Procedure...4442
Follow-On Procedure...4442
Installation...4443
Overview...4443
Special Tools...4443
Torque Specifications...4443
Equipment Condition...4443
Procedure...4443
Follow-On Procedure...4443
Instrument Panel Air Outlet Bezel – Right...4444
Removal...4444
Overview...4444
Special Tools...4444
Equipment Condition...4444
Procedure...4445
Follow-On Procedure...4445
Installation...4446
Overview...4446
Special Tools...4446
Torque Specifications...4446
Equipment Condition...4446
Procedure...4446
Follow-On Procedure...4446
Instrument Panel Assembly ...4447
Removal...4447
Overview...4447
Special Tools...4447
Equipment Condition...4447
Procedure...4448
Follow-On Procedure...4453
Installation...4454
Overview...4454
Special Tools...4454
Equipment Condition...4454
Procedure...4455
Follow-On Procedure...4460
Reposition...4462
Overview...4462
Special Tools...4462
Equipment Condition...4462
Procedure...4463
Follow-On Procedure...4468
Reinstallation...4469
Overview...4469
Special Tools...4469
Equipment Condition...4469
Procedure...4470
Follow-On Procedure...4475
Instrument Panel Carrier...4477
Removal...4477
Overview...4477
Special Tools...4477
Equipment Condition...4477
Procedure...4478
Follow-On Procedure...4481
Installation...4482
Overview...4482
Special Tools...4482
Equipment Condition...4482
Procedure...4483
Follow-On Procedure...4486
Instrument Panel Center Compartment...4488
Removal...4488
Overview...4488
Special Tools...4488
Equipment Condition...4488
Procedure...4488
Follow-On Procedure...4489
Installation...4490
Overview...4490
Special Tools...4490
Equipment Condition...4490
Procedure...4490
Follow-On Procedure...4490
Instrument Panel Cluster Trim Plate...4491
Removal...4491
Overview...4491
Special Tools...4491
Equipment Condition...4491
Procedure...4492
Follow-On Procedure...4492
Installation...4493
Overview...4493
Special Tools...4493
Equipment Condition...4493
Procedure...4493
Follow-On Procedure...4493
Instrument Panel Compartment...4494
Removal...4494
Overview...4494
Special Tools...4494
Equipment Condition...4494
Procedure...4494
Follow-On Procedure...4494
Installation...4495
Overview...4495
Special Tools...4495
Equipment Condition...4495
Procedure...4495
Follow-On Procedure...4495
Instrument Panel Compartment Door Lock Cylinder...4496
Removal...4496
Overview...4496
Special Tools...4496
Equipment Condition...4496
Procedure...4497
Follow-On Procedure...4497
Installation...4498
Overview...4498
Special Tools...4498
Torque Specifications...4498
Equipment Condition...4498
Procedure...4498
Follow-On Procedure...4499
Instrument Panel Extension...4500
Removal...4500
Overview...4500
Special Tools...4500
Equipment Condition...4500
Procedure...4500
Follow-On Procedure...4501
Installation...4502
Overview...4502
Special Tools...4502
Torque Specifications...4502
Equipment Condition...4502
Procedure...4502
Follow-On Procedure...4502
Instrument Panel Power Distribution Module (Fuse Block) Access Hole Cover...4503
Removal...4503
Overview...4503
Special Tools...4503
Equipment Condition...4503
Procedure...4503
Follow-On Procedure...4504
Installation...4505
Overview...4505
Special Tools...4505
Torque Specifications...4505
Equipment Condition...4505
Procedure...4505
Follow-On Procedure...4506
Instrument Panel Insulator (0016XCN)...4507
Removal...4507
Overview...4507
Special Tools...4507
Equipment Condition...4507
Procedure...4507
Follow-On Procedure...4508
Installation...4509
Overview...4509
Special Tools...4509
Equipment Condition...4509
Procedure...4509
Follow-On Procedure...4509
Instrument Panel Insulator (Without 0016XCN)...4510
Removal...4510
Overview...4510
Special Tools...4510
Equipment Condition...4510
Procedure...4510
Follow-On Procedure...4511
Installation...4512
Overview...4512
Special Tools...4512
Equipment Condition...4512
Procedure...4512
Follow-On Procedure...4512
Instrument Panel Gauge Cluster (Instrument Cluster) Hood...4513
Removal...4513
Overview...4513
Special Tools...4513
Equipment Condition...4513
Procedure...4514
Follow-On Procedure...4514
Installation...4515
Overview...4515
Special Tools...4515
Torque Specifications...4515
Equipment Condition...4515
Procedure...4515
Follow-On Procedure...4515
Instrument Panel Knee Bolster...4516
Removal...4516
Overview...4516
Special Tools...4516
Equipment Condition...4516
Procedure...4516
Follow-On Procedure...4517
Installation...4518
Overview...4518
Special Tools...4518
Procedure...4518
Follow-On Procedure...4518
Auxiliary Switch Pack...4519
Removal...4519
Overview...4519
Special Tools...4519
Equipment Condition...4519
Procedure...4520
Follow-On Procedure...4520
Installation...4521
Overview...4521
Special Tools...4521
Equipment Condition...4521
Procedure...4521
Follow-On Procedure...4522
Instrument Panel Lower Center Trim Panel...4523
Removal...4523
Overview...4523
Special Tools...4523
Equipment Condition...4523
Procedure...4523
Follow-On Procedure...4524
Installation...4525
Overview...4525
Special Tools...4525
Torque Specifications...4525
Equipment Condition...4525
Procedure...4525
Follow-On Procedure...4525
Instrument Panel Switch Trim Plate...4526
Removal...4526
Overview...4526
Special Tools...4526
Equipment Condition...4526
Procedure...4526
Follow-On Procedure...4527
Installation...4528
Overview...4528
Special Tools...4528
Torque Specifications...4528
Equipment Condition...4528
Procedure...4528
Follow-On Procedure...4528
Instrument Panel Tie Bar...4529
Removal...4529
Overview...4529
Special Tools...4529
Equipment Condition...4529
Procedure...4530
Follow-On Procedure...4531
Installation...4532
Overview...4532
Special Tools...4532
Equipment Condition...4532
Procedure...4532
Follow-On Procedure...4533
Instrument Panel Tie Bar Brace...4534
Removal...4534
Overview...4534
Special Tools...4534
Equipment Condition...4534
Procedure...4535
Follow-On Procedure...4535
Installation...4536
Overview...4536
Special Tools...4536
Equipment Condition...4536
Procedure...4536
Follow-On Procedure...4536
Instrument Panel Upper Compartment...4537
Removal...4537
Overview...4537
Special Tools...4537
Equipment Condition...4537
Procedure...4538
Follow-On Procedure...4538
Installation...4539
Overview...4539
Special Tools...4539
Equipment Condition...4539
Procedure...4539
Follow-On Procedure...4539
Lighting...4540
Front Floor Console Flood Lamp...4540
Removal...4540
Overview...4540
Special Tools...4540
Equipment Conditions...4540
Procedure...4540
Follow-On Procedure...4541
Installation...4542
Overview...4542
Special Tools...4542
Torque Specifications...4542
Equipment Conditions...4542
Procedure...4542
Follow-On Procedure...4542
Front Side Door Inside Handle Illumination Lamp...4543
Removal...4543
Overview...4543
Special Tools...4543
Equipment Condition...4543
Procedure...4544
Follow-On Procedure...4544
Installation...4545
Overview...4545
Special Tools...4545
Torque Specifications...4545
Equipment Condition...4545
Procedure...4545
Follow-On Procedure...4545
Headlight (Headlamp) Switch...4546
Removal...4546
Overview...4546
Special Tools...4546
Equipment Condition...4546
Procedure...4547
Follow-On Procedure...4547
Installation...4548
Overview...4548
Special Tools...4548
Torque Specifications...4548
Equipment Condition...4548
Procedure...4548
Follow-On Procedure...4548
Interior Lamp Bezel...4549
Removal...4549
Overview...4549
Special Tools...4549
Equipment Condition...4549
Procedure...4550
Follow-On Procedure...4550
Installation...4551
Overview...4551
Special Tools...4551
Torque Specifications...4551
Equipment Condition...4551
Procedure...4551
Follow-On Procedure...4551
Interior Lamp Switch...4552
Removal...4552
Overview...4552
Special Tools...4552
Equipment Conditions...4552
Procedure...4552
Follow-On Procedure...4553
Installation...4554
Overview...4554
Special Tools...4554
Torque Specifications...4554
Equipment Conditions...4554
Procedure...4554
Follow-On Procedure...4554
Reading Lamp Switch Push-button...4555
Removal...4555
Overview...4555
Special Tools...4555
Equipment Condition...4555
Procedure...4555
Follow-On Procedure...4556
Installation...4557
Overview...4557
Special Tools...4557
Torque Specifications...4557
Equipment Condition...4557
Procedure...4557
Follow-On Procedure...4557
Mirrors...4558
Rearview Mirror (Interior)...4558
Removal...4558
Overview...4558
Special Tools...4558
Equipment Condition...4558
Procedure...4558
Follow-On Procedure...4560
Installation...4561
Overview...4561
Special Tools...4561
Equipment Condition...4561
Procedure...4561
Follow-On Procedure...4562
Seats / Console...4563
Driver or Passenger Seat...4563
Removal...4563
Overview...4563
Special Tools...4563
Equipment Condition...4563
Procedure...4564
Follow-On Procedure...4564
Installation...4565
Overview...4565
Special Tools...4565
Equipment Condition...4565
Procedure...4566
Follow-On Procedure...4566
Driver or Passenger Seat Heater Switch Replacement...4567
Removal...4567
Overview...4567
Special Tools...4567
Equipment Conditions...4567
Procedure...4568
Follow-On Procedure...4568
Installation...4569
Overview...4569
Special Tools...4569
Torque Specifications...4569
Equipment Conditions...4569
Procedure...4569
Follow-On Procedure...4569
Front Seat Heater Control Module Replacement...4570
Removal...4570
Overview...4570
Special Tools...4570
Equipment Conditions...4570
Procedure...4571
Follow-On Procedure...4571
Installation...4572
Overview...4572
Special Tools...4572
Equipment Conditions...4572
Procedure...4572
Follow-On Procedure...4573
Driver or Passenger Seat Back Heater Replacement...4574
Removal...4574
Overview...4574
Special Tools...4574
Equipment Conditions...4574
Procedure...4575
Follow-On Procedure...4575
Installation...4576
Overview...4576
Special Tools...4576
Torque Specifications...4576
Equipment Conditions...4576
Procedure...4576
Follow-On Procedure...4577
Front Seat Cushion Heater Replacement...4578
Removal...4578
Overview...4578
Special Tools...4578
Equipment Conditions...4578
Procedure...4579
Follow-On Procedure...4579
Installation...4580
Overview...4580
Special Tools...4580
Torque Specifications...4580
Equipment Conditions...4580
Procedure...4580
Follow-On Procedure...4581
Driver or Passenger Seat Adjuster Handle...4582
Removal...4582
Overview...4582
Special Tools...4582
Equipment Condition...4582
Procedure...4582
Follow-On Procedure...4583
Installation...4584
Overview...4584
Special Tools...4584
Equipment Condition...4584
Procedure...4584
Follow-On Procedure...4584
Driver or Passenger Seat Adjuster Switch...4585
Removal...4585
Overview...4585
Special Tools...4585
Equipment Condition...4585
Procedure...4586
Follow-On Procedure...4586
Installation...4587
Overview...4587
Special Tools...4587
Torque Specifications...4587
Equipment Condition...4587
Procedure...4587
Follow-On Procedure...4588
Driver or Passenger Seat Back Cover and Pad...4589
Removal...4589
Overview...4589
Special Tools...4589
Equipment Condition...4589
Procedure...4589
Follow-On Procedure...4590
Installation...4591
Overview...4591
Special Tools...4591
Torque Specifications...4591
Equipment Condition...4591
Procedure...4591
Follow-On Procedure...4592
Driver or Passenger Seat Back Cushion Frame...4593
Removal...4593
Overview...4593
Special Tools...4593
Equipment Condition...4593
Procedure...4594
Follow-On Procedure...4594
Installation...4595
Overview...4595
Special Tools...4595
Equipment Condition...4595
Procedure...4595
Follow-On Procedures...4595
Driver or Passenger Seat Cushion Frame (Except Passenger with 6-way Power)...4596
Removal...4596
Overview...4596
Special Tools...4596
Equipment Condition...4596
Procedure...4597
Follow-On Procedure...4597
Installation...4598
Overview...4598
Special Tools...4598
Equipment Condition...4598
Procedure...4599
Follow-On Procedures...4599
Driver or Passenger Seat Cushion Frame (Passenger with 6-way Power)...4600
Removal...4600
Overview...4600
Special Tools...4600
Equipment Condition...4600
Procedure...4601
Follow-On Procedure...4601
Installation...4602
Overview...4602
Special Tools...4602
Equipment Condition...4602
Procedure...4603
Follow-Up Procedure...4603
Driver or Passenger Seat Head Restraint...4604
Removal...4604
Overview...4604
Special Tools...4604
Equipment Condition...4604
Procedure...4604
Follow-On Procedure...4605
Installation...4606
Overview...4606
Special Tools...4606
Torque Specifications...4606
Equipment Condition...4606
Procedure...4606
Follow-On Procedure...4606
Driver or Passenger Seat Head Restraint Guide...4607
Removal...4607
Overview...4607
Special Tools...4607
Equipment Condition...4607
Procedure...4608
Follow-On Procedure...4608
Installation...4609
Overview...4609
Special Tools...4609
Torque Specifications...4609
Equipment Condition...4609
Procedure...4609
Follow-On Procedure...4609
Driver or Passenger Seat Inner Recliner Finish Cover...4610
Removal...4610
Overview...4610
Special Tools...4610
Equipment Condition...4610
Procedure...4611
Follow-On Procedure...4611
Installation...4612
Overview...4612
Special Tools...4612
Equipment Condition...4612
Procedure...4612
Follow-On Procedure...4612
Driver or Passenger Seat Recliner Actuator...4613
Removal...4613
Overview...4613
Special Tools...4613
Equipment Condition...4613
Procedure...4614
Follow-On Procedure...4614
Installation...4615
Overview...4615
Special Tools...4615
Equipment Condition...4615
Procedure...4615
Follow-On Procedure...4616
Driver or Passenger Seat Vertical Adjuster Actuator...4617
Removal...4617
Overview...4617
Special Tools...4617
Equipment Condition...4617
Procedure...4617
Follow-On Procedure...4618
Installation...4619
Overview...4619
Special Tools...4619
Equipment Condition...4619
Procedure...4619
Follow-On Procedure...4619
Front Center Seat...4620
Removal...4620
Overview...4620
Special Tools...4620
Equipment Condition...4620
Procedure...4620
Follow-On Procedure...4621
Installation...4622
Overview...4622
Special Tools...4622
Equipment Condition...4622
Procedure...4622
Follow-On Procedure...4622
Front Center Seat Back Cushion Latch Upper Cover...4623
Removal...4623
Overview...4623
Special Tools...4623
Equipment Condition...4623
Procedure...4624
Follow-On Procedure...4624
Installation...4625
Overview...4625
Special Tools...4625
Torque Specifications...4625
Equipment Condition...4625
Procedure...4625
Follow-On Procedure...4625
Front Center Seat Back Cushion Latch...4626
Removal...4626
Overview...4626
Special Tools...4626
Equipment Condition...4626
Procedure...4626
Follow-On Procedure...4627
Installation...4628
Overview...4628
Special Tools...4628
Equipment Condition...4628
Procedure...4628
Follow-On Procedure...4628
Front Floor Console...4629
Removal...4629
Overview...4629
Special Tools...4629
Equipment Condition...4629
Procedure...4630
Follow-On Procedure...4631
Installation...4632
Overview...4632
Special Tools...4632
Equipment Condition...4632
Procedure...4632
Follow-On Procedure...4634
Front Floor Console Accessory Trim Plate...4635
Removal...4635
Overview...4635
Special Tools...4635
Equipment Condition...4635
Procedure...4636
Follow-On Procedure...4636
Installation...4637
Overview...4637
Special Tools...4637
Equipment Condition...4637
Procedure...4637
Follow-On Procedure...4637
Front Floor Console Armrest...4638
Removal...4638
Overview...4638
Special Tools...4638
Equipment Condition...4638
Procedure...4639
Follow-On Procedure...4639
Installation...4640
Overview...4640
Special Tools...4640
Equipment Condition...4640
Procedure...4640
Follow-On Procedure...4640
Front Floor Console Armrest Hinge...4641
Removal...4641
Overview...4641
Special Tools...4641
Equipment Condition...4641
Procedure...4642
Follow-On Procedure...4642
Installation...4643
Overview...4643
Special Tools...4643
Equipment Condition...4643
Procedure...4643
Follow-On Procedure...4643
Front Floor Console Armrest Hinge Cover...4644
Removal...4644
Overview...4644
Special Tools...4644
Equipment Condition...4644
Procedure...4644
Follow-On Procedure...4645
Installation...4646
Overview...4646
Special Tools...4646
Torque Specifications...4646
Equipment Condition...4646
Procedure...4646
Follow-On Procedure...4646
Front Floor Console Compartment Bezel...4647
Removal...4647
Overview...4647
Special Tools...4647
Equipment Condition...4647
Procedure...4648
Follow-On Procedure...4648
Installation...4649
Overview...4649
Special Tools...4649
Equipment Condition...4649
Procedure...4649
Follow-On Procedure...4649
Front Floor Console Cup Holder Opening Trim Plate...4650
Removal...4650
Overview...4650
Special Tools...4650
Equipment Condition...4650
Procedure...4651
Follow-On Procedure...4651
Installation...4652
Overview...4652
Special Tools...4652
Torque Specifications...4652
Equipment Condition...4652
Procedure...4652
Follow-On Procedure...4652
Front Floor Console Extension Panel – Left...4653
Removal...4653
Overview...4653
Special Tools...4653
Equipment Condition...4653
Procedure...4653
Follow-On Procedure...4654
Installation...4655
Overview...4655
Special Tools...4655
Torque Specifications...4655
Equipment Condition...4655
Procedure...4655
Follow-On Procedure...4656
Front Floor Console Extension Panel – Right...4657
Removal...4657
Overview...4657
Special Tools...4657
Equipment Condition...4657
Procedure...4657
Follow-On Procedure...4658
Installation...4659
Overview...4659
Special Tools...4659
Torque Specifications...4659
Equipment Condition...4659
Procedure...4659
Follow-On Procedure...4659
Front Floor Console Front Compartment Cover...4660
Removal...4660
Overview...4660
Special Tools...4660
Equipment Condition...4660
Procedure...4660
Follow-On Procedure...4661
Installation...4662
Overview...4662
Special Tools...4662
Equipment Condition...4662
Procedure...4662
Follow-On Procedure...4663
Front Floor Console Rail...4664
Removal...4664
Overview...4664
Special Tools...4664
Equipment Condition...4664
Procedure...4664
Follow-On Procedure...4665
Installation...4666
Overview...4666
Special Tools...4666
Torque Specifications...4666
Equipment Condition...4666
Procedure...4666
Follow-On Procedure...4666
Front Floor Console Rear Cover...4667
Removal...4667
Overview...4667
Special Tools...4667
Equipment Condition...4667
Procedure...4667
Follow-On Procedure...4668
Installation...4669
Overview...4669
Special Tools...4669
Equipment Condition...4669
Procedure...4669
Follow-On Procedure...4670
Front Floor Console Trim Plate...4671
Removal...4671
Overview...4671
Special Tools...4671
Equipment Condition...4671
Procedure...4671
Follow-On Procedure...4672
Installation...4673
Overview...4673
Special Tools...4673
Torque Specifications...4673
Equipment Condition...4673
Procedure...4673
Follow-On Procedure...4673
Front Seat Armrest Lid...4674
Removal...4674
Overview...4674
Special Tools...4674
Equipment Condition...4674
Procedure...4675
Follow-On Procedure...4675
Installation...4676
Overview...4676
Special Tools...4676
Equipment Condition...4676
Procedure...4676
Follow-On Procedure...4676
Front Seat Back Lumbar...4677
Removal...4677
Overview...4677
Special Tools...4677
Equipment Condition...4677
Procedure...4677
Follow-On Procedure...4678
Installation...4679
Overview...4679
Special Tools...4679
Torque Specification...4679
Equipment Condition...4679
Procedure...4679
Follow-On Procedure...4679
Front Seat Back Recliner Handle...4680
Removal...4680
Overview...4680
Special Tools...4680
Equipment Condition...4680
Procedure...4680
Follow-On Procedure...4681
Installation...4682
Overview...4682
Special Tools...4682
Torque Specifications...4682
Equipment Condition...4682
Procedure...4682
Follow-On Procedure...4682
Front Seat Center Armrest...4683
Removal...4683
Overview...4683
Special Tools...4683
Equipment Condition...4683
Procedure...4684
Follow-On Procedure...4684
Installation...4685
Overview...4685
Special Tools...4685
Equipment Condition...4685
Procedure...4685
Follow-On Procedure...4685
Front Seat Center Armrest Hinge Finish Cover...4686
Removal...4686
Overview...4686
Special Tools...4686
Equipment Condition...4686
Procedure...4686
Follow-On Procedure...4687
Installation...4688
Overview...4688
Special Tools...4688
Equipment Condition...4688
Procedure...4688
Follow-On Procedure...4688
Front Seat Cushion Center Cover...4689
Removal...4689
Overview...4689
Special Tools...4689
Equipment Condition...4689
Procedure...4690
Follow-On Procedure...4690
Installation...4691
Overview...4691
Special Tools...4691
Equipment Condition...4691
Procedure...4691
Follow-On Procedure...4692
Front Seat Cushion Center Pad...4693
Removal...4693
Overview...4693
Special Tools...4693
Equipment Condition...4693
Procedure...4694
Follow-On Procedure...4694
Installation...4695
Overview...4695
Special Tools...4695
Equipment Condition...4695
Procedure...4695
Follow-On Procedure...4695
Front Seat Cushion Cover and Pad...4696
Removal...4696
Overview...4696
Special Tools...4696
Equipment Condition...4696
Procedure...4696
Follow-On Procedure...4697
Installation...4698
Overview...4698
Special Tools...4698
Torque Specifications...4698
Equipment Condition...4698
Procedure...4698
Follow-On Procedure...4699
Front Seat Cushion Center Frame...4700
Removal...4700
Overview...4700
Special Tools...4700
Equipment Condition...4700
Procedure...4701
Follow-On Procedure...4701
Installation...4702
Overview...4702
Special Tools...4702
Torque Specifications...4702
Equipment Condition...4702
Procedure...4702
Follow-On Procedure...4702
Front Seat Cushion Outer Finish Cover (Manual)...4703
Removal...4703
Overview...4703
Special Tools...4703
Equipment Condition...4703
Procedure...4704
Follow-On Procedure...4704
Installation...4705
Overview...4705
Special Tools...4705
Equipment Condition...4705
Procedure...4705
Follow-On Procedure...4706
Front Seat Cushion Outer Finish Cover (Power)...4707
Removal...4707
Overview...4707
Special Tools...4707
Equipment Condition...4707
Procedure...4708
Follow-On Procedure...4708
Installation...4709
Overview...4709
Special Tools...4709
Equipment Condition...4709
Procedure...4709
Follow-On Procedures...4710
Front Seat Cushion Pad Support Wire Spring...4711
Removal...4711
Overview...4711
Special Tools...4711
Equipment Condition...4711
Procedure...4712
Follow-On Procedure...4712
Installation...4713
Overview...4713
Special Tools...4713
Torque Specifications...4713
Equipment Condition...4713
Procedure...4713
Follow-On Procedure...4713
Front Seat Cushion Rear Frame Center Cover...4714
Removal...4714
Overview...4714
Special Tools...4714
Equipment Condition...4714
Procedure...4714
Follow-On Procedure...4715
Installation...4716
Overview...4716
Special Tools...4716
Torque Specifications...4716
Equipment Condition...4716
Procedure...4716
Follow-On Procedure...4716
Front Seat Recliner Control...4717
Removal...4717
Overview...4717
Special Tools...4717
Equipment Condition...4717
Procedure...4718
Follow-On Procedure...4718
Installation...4719
Overview...4719
Special Tools...4719
Equipment Condition...4719
Procedure...4719
Follow-On Procedure...4720
Front Seat Storage Tray...4721
Removal...4721
Overview...4721
Special Tools...4721
Equipment Condition...4721
Procedure...4722
Follow-On Procedure...4722
Installation...4723
Overview...4723
Special Tools...4723
Equipment Condition...4723
Procedure...4723
Follow-On Procedure...4723
Front Seat Tilt Adjuster Actuator...4724
Removal...4724
Overview...4724
Special Tools...4724
Equipment Condition...4724
Procedure...4724
Follow-On Procedure...4725
Installation...4726
Overview...4726
Special Tools...4726
Equipment Condition...4726
Procedure...4726
Follow-On Procedure...4726
Front Seat Wiring Harness...4727
Removal...4727
Overview...4727
Special Tools...4727
Equipment Condition...4727
Procedure...4728
Follow-On Procedure...4728
Installation...4729
Overview...4729
Special Tools...4729
Torque Specifications...4729
Equipment Condition...4729
Procedure...4730
Follow-On Procedures...4730
Front Seat Cable Adjustment (Manual Recliner)...4731
Overview...4731
Special Tools...4731
Equipment Condition...4731
Procedure...4731
Follow-On Procedure...4733
Trim...4734
Body Lock Pillar Garnish Molding Replacement (Crew and Regular Cab)...4734
Removal...4734
Overview...4734
Special Tools...4734
Equipment Condition...4734
Procedure...4735
Follow-On Procedure...4735
Installation...4736
Overview...4736
Special Tools...4736
Equipment Condition...4736
Procedure...4737
Follow-On Procedure...4737
Body Rear Panel Insulator...4738
Removal...4738
Overview...4738
Special Tools...4738
Equipment Condition...4738
Procedure...4739
Follow-On Procedure...4739
Installation...4740
Overview...4740
Special Tools...4740
Torque Specification...4740
Equipment Condition...4740
Procedure...4740
Follow-On Procedure...4740
Coat Hook...4742
Removal...4742
Overview...4742
Special Tools...4742
Equipment Condition...4742
Procedure...4742
Follow-On Procedure...4743
Installation...4744
Overview...4744
Special Tools...4744
Equipment Condition...4744
Procedure...4744
Follow-On Procedure...4744
Front Seat Back Body Panel Carpet (Regular Cab)...4745
Removal...4745
Overview...4745
Special Tools...4745
Equipment Condition...4745
Procedure...4746
Follow-On Procedure...4746
Installation...4747
Overview...4747
Special Tools...4747
Torque Specifications...4747
Equipment Condition...4747
Procedure...4747
Follow-On Procedure...4747
Rear Window Lower Garnish Molding Replacement (Crew Cab)...4748
Removal...4748
Overview...4748
Special Tools...4748
Equipment Conditions...4748
Procedure...4749
Follow-On Procedure...4749
Installation...4750
Overview...4750
Special Tools...4750
Torque Specifications...4750
Equipment Conditions...4750
Procedure...4750
Follow-On Procedure...4751
Rear Window Lower Garnish Molding Replacement (Regular Cab)...4752
Removal...4752
Overview...4752
Special Tools...4752
Equipment Condition...4752
Procedure...4752
Follow-On Procedure...4753
Installation...4754
Overview...4754
Special Tools...4754
Torque Specifications...4754
Equipment Condition...4754
Procedure...4754
Follow-On Procedure...4754
Windshield Garnish Molding...4755
Removal...4755
Overview...4755
Special Tools...4755
Equipment Condition...4755
Procedure...4756
Follow-On Procedure...4756
Installation...4757
Overview...4757
Special Tools...4757
Equipment Condition...4757
Procedure...4758
Follow-On Procedure...4758
6. Cab Interior - Crew...4759
Doors...4759
Auxiliary Rear Side Door Water Deflector...4759
Removal...4759
Overview...4759
Special Tools...4759
Equipment Condition...4759
Procedure...4760
Follow-On Procedure...4760
Installation...4761
Overview...4761
Special Tools...4761
Torque Specifications...4761
Equipment Condition...4761
Procedure...4761
Follow-On Procedure...4761
Rear Side Door Accessory Switch Mount Plate...4762
Removal...4762
Overview...4762
Special Tools...4762
Equipment Condition...4762
Procedure...4762
Follow-On Procedure...4763
Installation...4764
Overview...4764
Special Tools...4764
Torque Specifications...4764
Equipment Condition...4764
Procedure...4764
Follow-On Procedure...4764
Rear Side Door Armrest Cover Trim...4765
Removal...4765
Overview...4765
Special Tools...4765
Equipment Condition...4765
Procedure...4766
Follow-On Procedure...4766
Installation...4767
Overview...4767
Special Tools...4767
Torque Specifications...4767
Equipment Condition...4767
Procedure...4767
Follow-On Procedure...4767
Rear Side Door Locking Rod Clip...4768
Removal...4768
Overview...4768
Special Tools...4768
Equipment Condition...4768
Procedure...4769
Follow-On Procedure...4769
Installation...4770
Overview...4770
Special Tools...4770
Torque Specifications...4770
Equipment Condition...4770
Procedure...4770
Follow-On Procedure...4771
Rear Side Door Locking Rod Knob...4772
Removal...4772
Overview...4772
Special Tools...4772
Equipment Condition...4772
Procedure...4773
Follow-On Procedure...4773
Installation...4774
Overview...4774
Special Tools...4774
Torque Specifications...4774
Equipment Condition...4774
Procedure...4774
Follow-On Procedure...4774
Rear Side Door Locking Rod Push-button Bezel...4775
Removal...4775
Overview...4775
Special Tools...4775
Equipment Condition...4775
Procedure...4776
Follow-On Procedure...4776
Installation...4777
Overview...4777
Special Tools...4777
Torque Specifications...4777
Equipment Condition...4777
Procedure...4777
Follow-On Procedure...4777
Rear Side Door Pull Handle Bracket...4778
Removal...4778
Overview...4778
Special Tools...4778
Equipment Condition...4778
Procedure...4779
Follow-On Procedure...4779
Installation...4780
Overview...4780
Special Tools...4780
Equipment Condition...4780
Procedure...4780
Follow-On Procedure...4780
Rear Side Door Sill Garnish Molding...4781
Removal...4781
Overview...4781
Special Tools...4781
Equipment Condition...4781
Procedure...4782
Follow-On Procedure...4782
Installation...4783
Overview...4783
Special Tools...4783
Torque Specifications...4783
Equipment Condition...4783
Procedure...4783
Follow-On Procedure...4783
Rear Side Door Trim...4784
Removal...4784
Overview...4784
Special Tools...4784
Equipment Condition...4784
Procedure...4784
Follow-On Procedure...4787
Installation...4788
Overview...4788
Special Tools...4788
Equipment Condition...4788
Procedure...4788
Follow-On Procedure...4791
Rear Side Door Window Belt Reveal Molding...4792
Removal...4792
Overview...4792
Special Tools...4792
Equipment Condition...4792
Procedure...4793
Follow-On Procedure...4793
Installation...4794
Overview...4794
Special Tools...4794
Equipment Condition...4794
Procedure...4794
Follow-On Procedure...4794
Rear Side Door Window Garnish Molding...4795
Removal...4795
Overview...4795
Special Tools...4795
Equipment Condition...4795
Procedure...4796
Follow-On Procedure...4796
Installation...4797
Overview...4797
Special Tools...4797
Torque Specifications...4797
Equipment Condition...4797
Procedure...4797
Follow-On Procedure...4798
Rear Side Door Window Inner Sealing Strip...4799
Removal...4799
Overview...4799
Special Tools...4799
Equipment Condition...4799
Procedure...4800
Follow-On Procedure...4800
Installation...4801
Overview...4801
Special Tools...4801
Torque Specifications...4801
Equipment Condition...4801
Procedure...4801
Follow-On Procedure...4801
Rear Side Door Window Weatherstrip...4802
Removal...4802
Overview...4802
Special Tools...4802
Equipment Conditions...4802
Procedure...4803
Follow-On Procedure...4804
Installation...4805
Overview...4805
Special Tools...4805
Equipment Condition...4805
Procedure...4806
Follow-On Procedure...4807
Rear Side Door Lower Auxiliary Weatherstrip Replacement...4808
Removal...4808
Overview...4808
Special Tools...4808
Equipment Conditions...4808
Procedure...4809
Follow-On Procedure...4809
Installation...4810
Overview...4810
Special Tools...4810
Torque Specifications...4810
Equipment Conditions...4810
Procedure...4810
Follow-On Procedure...4811
Front Side Door Front Auxiliary Weatherstrip Replacement...4812
Overview...4812
Special Tools...4812
Equipment Conditions...4812
Procedure...4813
Follow-On Procedure...4813
Installation...4814
Overview...4814
Special Tools...4814
Torque Specifications...4814
Equipment Conditions...4814
Procedure...4814
Follow-On Procedure...4815
Front Side Door Weatherstrip Replacement – Door...4816
Overview...4816
Special Tools...4816
Equipment Conditions...4816
Procedure...4817
Follow-On Procedure...4817
Installation...4818
Overview...4818
Special Tools...4818
Torque Specifications...4818
Equipment Conditions...4818
Procedure...4818
Follow-On Procedure...4819
Front Side Door Weatherstrip Replacement – Body...4820
Overview...4820
Special Tools...4820
Equipment Conditions...4820
Procedure...4821
Follow-On Procedure...4821
Installation...4822
Overview...4822
Special Tools...4822
Torque Specifications...4822
Equipment Conditions...4822
Procedure...4822
Follow-On Procedure...4823
Front Side Door Lower Auxiliary Weatherstrip Replacement...4823
Overview...4823
Special Tools...4823
Equipment Conditions...4823
Procedure...4824
Follow-On Procedure...4824
Installation...4825
Overview...4825
Special Tools...4825
Torque Specifications...4825
Equipment Conditions...4825
Procedure...4825
Follow-On Procedure...4826
Rear Side Door Weatherstrip Replacement – Door...4826
Removal...4826
Overview...4826
Special Tools...4826
Equipment Conditions...4826
Procedure...4827
Follow-On Procedure...4827
Installation...4828
Overview...4828
Special Tools...4828
Torque Specifications...4828
Equipment Conditions...4828
Procedure...4828
Follow-On Procedure...4829
Rear Side Door Weatherstrip Replacement – Body...4830
Overview...4830
Special Tools...4830
Equipment Conditions...4830
Procedure...4831
Follow-On Procedure...4831
Installation...4832
Overview...4832
Special Tools...4832
Torque Specifications...4832
Equipment Conditions...4832
Procedure...4832
Follow-On Procedure...4833
Roof...4834
Headliner Trim Panel (Crew Cab)...4834
Removal...4834
Overview...4834
Special Tools...4834
Equipment Condition...4834
Procedure...4835
Follow-On Procedure...4836
Installation...4837
Overview...4837
Special Tools...4837
Torque Specifications...4837
Equipment Condition...4837
Procedure...4837
Follow-On Procedure...4838
Roof Rail Rear Assist Handle...4839
Removal...4839
Overview...4839
Special Tools...4839
Equipment Condition...4839
Procedure...4840
Follow-On Procedure...4840
Installation...4841
Overview...4841
Special Tools...4841
Equipment Condition...4841
Procedure...4841
Follow-On Procedure...4842
Lighting...4843
Center Reading and Courtesy Lamp...4843
Removal...4843
Overview...4843
Special Tools...4843
Equipment Condition...4843
Procedure...4844
Follow-On Procedure...4844
Installation...4845
Overview...4845
Special Tools...4845
Torque Specifications...4845
Equipment Condition...4845
Procedure...4845
Follow-On Procedure...4845
Rear Seat Position Center Reading and Courtesy Lamp...4846
Removal...4846
Overview...4846
Special Tools...4846
Equipment Condition...4846
Procedure...4846
Follow-On Procedure...4847
Installation...4848
Overview...4848
Special Tools...4848
Torque Specifications...4848
Equipment Condition...4848
Procedure...4848
Follow-On Procedure...4848
Seats / Console...4849
Front Floor Console Rear Trim Panel...4849
Removal...4849
Overview...4849
Special Tools...4849
Equipment Condition...4849
Procedure...4849
Follow-On Procedure...4850
Installation...4851
Overview...4851
Special Tools...4851
Equipment Condition...4851
Procedure...4851
Follow-On Procedure...4852
Rear Seat...4853
Removal...4853
Overview...4853
Special Tools...4853
Equipment Condition...4853
Procedure...4854
Follow-On Procedure...4854
Installation...4855
Overview...4855
Special Tools...4855
Equipment Condition...4855
Procedure...4855
Follow-On Procedure...4855
Separation...4856
Overview...4856
Special Tools...4856
Equipment Condition...4856
Procedure...4856
Follow-On Procedure...4856
Attachment...4857
Overview...4857
Special Tools...4857
Equipment Condition...4857
Procedure...4857
Follow-On Procedure...4857
Rear Seat Armrest...4858
Removal...4858
Overview...4858
Special Tools...4858
Equipment Condition...4858
Procedure...4859
Follow-On Procedure...4859
Installation...4860
Overview...4860
Special Tools...4860
Equipment Condition...4860
Procedure...4860
Follow-On Procedure...4860
Rear Seat Armrest Support Finish Cover...4861
Removal...4861
Overview...4861
Special Tools...4861
Equipment Condition...4861
Procedure...4862
Follow-On Procedure...4862
Installation...4863
Overview...4863
Special Tools...4863
Torque Specifications...4863
Equipment Condition...4863
Procedure...4863
Follow-On Procedure...4863
Rear Seat Back Cushion Cover and Pad (40 Percent Seat)...4864
Removal...4864
Overview...4864
Special Tools...4864
Equipment Condition...4864
Procedure...4865
Follow-On Procedure...4865
Installation...4866
Overview...4866
Special Tools...4866
Equipment Condition...4866
Procedure...4866
Follow-On Procedure...4867
Rear Seat Back Cushion Cover and Pad (60 Percent Seat)...4868
Removal...4868
Overview...4868
Special Tools...4868
Equipment Condition...4868
Procedure...4869
Follow-On Procedure...4869
Installation...4870
Overview...4870
Special Tools...4870
Torque Specifications...4870
Equipment Condition...4870
Procedure...4870
Follow-On Procedure...4871
Rear Seat Back Cushion Frame (40 Percent Seat)...4872
Removal...4872
Overview...4872
Special Tools...4872
Equipment Condition...4872
Procedure...4873
Follow-On Procedure...4873
Installation...4874
Overview...4874
Special Tools...4874
Equipment Condition...4874
Procedure...4874
Follow-On Procedure...4874
Rear Seat Back Cushion Frame (60 Percent Seat)...4875
Removal...4875
Overview...4875
Special Tools...4875
Equipment Condition...4875
Procedure...4876
Follow-On Procedure...4876
Installation...4877
Overview...4877
Special Tools...4877
Equipment Condition...4877
Procedure...4877
Follow-On Procedure...4877
Rear Seat Cushion Cover and Pad (40 Percent Seat)...4878
Removal...4878
Overview...4878
Special Tools...4878
Equipment Condition...4878
Procedure...4879
Follow-On Procedure...4879
Installation...4880
Overview...4880
Special Tools...4880
Torque Specifications...4880
Equipment Condition...4880
Procedure...4880
Follow-On Procedure...4881
Rear Seat Cushion Cover and Pad (60 Percent Seat)...4882
Removal...4882
Overview...4882
Special Tools...4882
Equipment Condition...4882
Procedure...4883
Follow-On Procedure...4883
Installation...4884
Overview...4884
Special Tools...4884
Torque Specifications...4884
Equipment Condition...4884
Procedure...4884
Follow-On Procedure...4885
Rear Seat Cushion Frame (40 Percent Seat)...4886
Removal...4886
Overview...4886
Special Tools...4886
Equipment Condition...4886
Procedure...4887
Follow-On Procedure...4887
Installation...4888
Overview...4888
Special Tools...4888
Equipment Condition...4888
Procedure...4888
Follow-On Procedure...4888
Rear Seat Cushion Frame (60 Percent Seat)...4889
Removal...4889
Overview...4889
Special Tools...4889
Equipment Condition...4889
Follow-On Procedure...4890
Installation...4891
Overview...4891
Special Tools...4891
Equipment Condition...4891
Procedure...4891
Follow-On Procedure...4891
Rear Seat Head Restraint...4892
Removal...4892
Overview...4892
Special Tools...4892
Equipment Condition...4892
Procedure...4893
Follow-On Procedure...4893
Installation...4894
Overview...4894
Special Tools...4894
Torque Specifications...4894
Equipment Condition...4894
Procedure...4894
Follow-On Procedure...4894
Rear Seat Head Restraint Guide...4895
Removal...4895
Overview...4895
Special Tools...4895
Equipment Condition...4895
Procedure...4896
Follow-On Procedure...4896
Installation...4897
Overview...4897
Special Tools...4897
Torque Specifications...4897
Equipment Condition...4897
Procedure...4897
Follow-On Procedure...4897
Rear Seat Hinge Finish Cover – Inner...4898
Removal...4898
Overview...4898
Special Tools...4898
Equipment Condition...4898
Procedure...4899
Follow-On Procedure...4899
Installation...4900
Overview...4900
Special Tools...4900
Torque Specifications...4900
Equipment Condition...4900
Procedure...4900
Follow-On Procedure...4900
Rear Seat Hinge Finish Cover – Outer...4901
Removal...4901
Overview...4901
Special Tools...4901
Equipment Condition...4901
Procedure...4902
Follow-On Procedure...4902
Installation...4903
Overview...4903
Special Tools...4903
Torque Specifications...4903
Equipment Condition...4903
Procedure...4903
Follow-On Procedure...4904
Rear Seat Latch...4905
Removal...4905
Overview...4905
Special Tools...4905
Equipment Condition...4905
Procedure...4906
Follow-On Procedure...4906
Installation...4907
Overview...4907
Special Tools...4907
Torque Specifications...4907
Equipment Condition...4907
Procedure...4907
Follow-On Procedure...4908
Trim...4909
Center Pillar Lower Trim Panel...4909
Removal...4909
Overview...4909
Special Tools...4909
Equipment Condition...4909
Procedure...4910
Follow-On Procedure...4910
Installation...4911
Overview...4911
Special Tools...4911
Torque Specifications...4911
Equipment Condition...4911
Procedure...4911
Follow-On Procedure...4911
Center Pillar Upper Trim Panel...4912
Removal...4912
Overview...4912
Special Tools...4912
Equipment Condition...4912
Procedure...4913
Follow-On Procedure...4913
Installation...4914
Overview...4914
Special Tools...4914
Equipment Condition...4914
Procedure...4915
Follow-On Procedure...4915
Rear Window Lower Garnish Molding...4916
Removal...4916
Overview...4916
Special Tools...4916
Equipment Condition...4916
Procedure...4917
Follow-On Procedure...4917
Installation...4918
Overview...4918
Special Tools...4918
Torque Specifications...4918
Equipment Condition...4918
Procedure...4918
Follow-On Procedure...4918
Rear Window Side Garnish Molding...4919
Removal...4919
Overview...4919
Special Tools...4919
Equipment Condition...4919
Procedure...4920
Follow-On Procedure...4920
Installation...4921
Overview...4921
Special Tools...4921
Torque Specifications...4921
Equipment Condition...4921
Procedure...4921
Follow-On Procedure...4921
7. HVAC...4922
Engine Coolant...4922
Auxiliary Electric Heater...4922
A/C Cycle...4922
Approximate Fluid Capacities...4923
Front HVAC System Repair...4924
Overview...4924
Air Inlet Valve Actuator...4925
Removal...4925
Overview...4925
Special Tools...4925
Equipment Condition...4925
Procedure...4926
Follow-On Procedure...4926
Installation ...4927
Overview...4927
Special Tools...4927
Equipment Condition...4927
Procedure...4927
Follow-On Procedure...4927
Air Inlet Valve Lever...4929
Removal...4929
Overview...4929
Special Tools...4929
Equipment Condition...4929
Procedure...4930
Follow-On Procedure...4930
Installation...4931
Overview...4931
Special Tools...4931
Torque Specifications...4931
Equipment Condition...4931
Procedure...4931
Follow-On Procedure...4931
Mode Valve Actuator...4933
Removal...4933
Overview...4933
Special Tools...4933
Equipment Condition...4933
Procedure...4933
Follow-On Procedure...4934
Installation...4935
Overview...4935
Special Tools...4935
Equipment Condition...4935
Procedure...4935
Follow-On Procedure...4935
Mode Control Cam...4936
Removal...4936
Overview...4936
Special Tools...4936
Equipment Condition...4936
Procedure...4937
Follow-On Procedure...4940
Installation...4941
Overview...4941
Special Tools...4941
Equipment Condition...4941
Procedure...4941
Follow-On Procedure...4946
Temperature Valve Actuator...4947
Removal...4947
Overview...4947
Special Tools...4947
Equipment Condition...4947
Procedure...4948
Follow-On Procedure...4948
Installation ...4949
Overview...4949
Special Tools...4949
Equipment Condition...4949
Procedure...4949
Follow-On Procedure...4949
Air Conditioning Compressor Replacement...4951
Removal...4951
Overview...4951
Special Tools...4951
Equipment Conditions...4951
Procedure...4951
Follow-On Procedure...4952
Installation...4953
Overview...4953
Special Tools...4953
Equipment Condition...4953
Procedure...4954
Follow-On Procedure...4954
Air Conditioning Compressor and Condenser Hose...4955
Removal...4955
Overview...4955
Special Tools...4955
Equipment Condition...4955
Procedure...4956
Follow-On Procedure...4958
Installation...4959
Overview...4959
Special Tools...4959
Equipment Condition...4959
Procedure...4959
Follow-On Procedure...4961
Air Conditioning Compressor and Evaporator Hose...4962
Removal...4962
Overview...4962
Special Tools...4962
Equipment Condition...4962
Procedure...4963
Follow-On Procedure...4964
Installation...4965
Overview...4965
Special Tools...4965
Equipment Condition...4965
Procedure...4965
Follow-On Procedure...4967
Air Conditioning Condenser...4968
Removal...4968
Overview...4968
Special Tools...4968
Equipment Condition...4968
Procedure...4969
Follow-On Procedure...4969
Installation...4970
Overview...4970
Special Tools...4970
Equipment Condition...4970
Procedure...4971
Follow-On Procedure...4971
Air Conditioning Condenser and Evaporator Hose...4972
Removal...4972
Overview...4972
Special Tools...4972
Equipment Condition...4972
Procedure...4973
Follow-On Procedure...4975
Installation...4976
Overview...4976
Special Tools...4976
Equipment Condition...4976
Procedure...4976
Follow-On Procedure...4979
Auxiliary Electric Heater...4980
Removal...4980
Overview...4980
Special Tools...4980
Equipment Condition...4980
Procedure...4981
Follow-On Procedure...4981
Installation...4982
Overview...4982
Special Tools...4982
Equipment Condition...4982
Procedure...4982
Follow-On Procedure...4982
Blower Motor...4984
Removal...4984
Overview...4984
Special Tools...4984
Equipment Condition...4984
Procedure...4984
Follow-On Procedure...4985
Installation...4986
Overview...4986
Special Tools...4986
Equipment Condition...4986
Procedure...4986
Follow-On Procedure...4986
Heater and Air Conditioning Evaporator Case Replacement (0016XZA)...4987
Removal...4987
Overview...4987
Special Tools...4987
Equipment Condition...4987
Procedure...4988
Follow-On Procedure...4988
Installation ...4989
Overview...4989
Special Tools...4989
Torque Specifications...4989
Equipment Condition...4989
Procedure...4989
Follow-On Procedure...4989
Heater and Air Conditioning Evaporator Case Replacement (0016BAL)...4991
Removal...4991
Overview...4991
Special Tools...4991
Equipment Conditions...4991
Procedure...4992
Follow-On Procedure...4992
Installation...4993
Overview...4993
Special Tools...4993
Torque Specifications...4993
Equipment Conditions...4993
Procedure...4993
Follow-On Procedure...4993
Evaporator Core Replacement...4995
Removal...4995
Overview...4995
Special Tools...4995
Equipment Condition...4995
Procedure...4997
Follow-On Procedure...4997
Installation...4998
Overview...4998
Special Tools...4998
Torque Specifications...4998
Equipment Condition...4998
Procedure...4998
Follow-On Procedure...4998
Evaporator Air Temperature Sensor Replacement...5000
Removal...5000
Overview...5000
Special Tools...5000
Equipment Condition...5000
Procedure...5000
Follow-On Procedure...5001
Installation...5002
Overview...5002
Special Tools...5002
Torque Specifications...5002
Equipment Condition...5002
Procedure...5002
Follow-On Procedure...5002
Evaporator and HVAC Module Lower Drain Hose Replacement...5003
Removal...5003
Overview...5003
Special Tools...5003
Equipment Condition...5003
Procedure...5004
Follow-On Procedure...5004
Installation...5005
Overview...5005
Special Tools...5005
Torque Specifications...5005
Equipment Condition...5005
Procedure...5005
Follow-On Procedure...5005
Heater Core Replacement (0016XZA)...5006
Removal...5006
Overview...5006
Special Tools...5006
Equipment Condition...5006
Procedure...5007
Follow-On Procedure...5009
Installation...5010
Overview...5010
Special Tools...5010
Torque Specifications...5010
Equipment Condition...5010
Procedure...5010
Follow-On Procedure...5012
Heater Core Replacement (0016BAL)...5013
Removal...5013
Overview...5013
Special Tools...5013
Equipment Conditions...5013
Procedure...5015
Follow-On Procedure...5015
Installation...5016
Overview...5016
Special Tools...5016
Torque Specifications...5016
Equipment Conditions...5016
Procedure...5017
Follow-On Procedure...5017
Heater Cover Replacement (0016XZA Heat Staked)...5019
Removal ...5019
Overview...5019
Special Tools...5019
Equipment Condition...5019
Procedure...5020
Follow-On Procedure...5021
Installation...5022
Overview...5022
Special Tools...5022
Equipment Condition...5022
Procedure...5022
Follow-On Procedure...5023
Heater Cover Replacement (0016XZA Non Heat Staked)...5025
Removal...5025
Overview...5025
Special Tools...5025
Equipment Conditions...5025
Procedure...5027
Follow-On Procedure...5028
Installation...5029
Overview...5029
Special Tools...5029
Equipment Conditions...5029
Procedure...5030
Follow-On Procedure...5031
Heater Cover Replacement (0016BAL Non Heat Staked)...5034
Removal...5034
Overview...5034
Special Tools...5034
Equipment Conditions...5034
Procedure...5036
Follow-On Procedure...5037
Installation...5038
Overview...5038
Special Tools...5038
Equipment Conditions...5038
Procedure...5039
Follow-On Procedure...5040
Heater Cover Replacement (0016BAL Heat Staked)...5042
Removal...5042
Overview...5042
Special Tools...5042
Equipment Conditions...5042
Procedure...5043
Follow-On Procedure...5044
Installation...5045
Overview...5045
Special Tools...5045
Equipment Conditions...5045
Procedure...5046
Follow-On Procedure...5047
Heater Inlet Hose Replacement (Heater Core to Heater Outlet Pipe)...5049
Removal...5049
Overview...5049
Special Tools...5049
Equipment Conditions...5049
Procedure...5049
Follow-On Procedure...5050
Installation...5051
Overview...5051
Special Tools...5051
Torque Specifications...5051
Equipment Conditions...5051
Procedure...5051
Follow-On Procedure...5052
Heater Inlet Hose Replacement (Heater Outlet Pipe to Automatic Level Control Air Compressor)...5053
Removal...5053
Overview...5053
Special Tools...5053
Equipment Conditions...5053
Procedure...5054
Follow-On Procedure...5054
Installation...5055
Overview...5055
Special Tools...5055
Torque Specifications...5055
Equipment Conditions ...5055
Procedure...5055
Follow-On Procedure...5056
Heater Outlet Hose Replacement (Heater Core to Heater Outlet Pipe)...5057
Removal...5057
Overview...5057
Special Tools...5057
Equipment Conditions...5057
Procedure...5057
Follow-On Procedure...5058
Installation...5059
Overview...5059
Special Tools...5059
Torque Specifications...5059
Equipment Conditions ...5059
Procedure...5059
Follow-On Procedure...5060
Heater Outlet Hose Replacement (Radiator Outlet Pipe to Heater Outlet Pipe)...5061
Removal...5061
Overview...5061
Special Tools...5061
Equipment Conditions...5061
Procedure...5061
Follow-On Procedure...5062
Installation...5063
Overview...5063
Special Tools...5063
Torque Specifications...5063
Equipment Conditions ...5063
Procedure...5063
Follow-On Procedure...5064
Heater Outlet Hose Replacement (Automatic Level Control Air Compressor to Heater Outlet Pipe)...5065
Removal...5065
Overview...5065
Special Tools...5065
Equipment Conditions...5065
Procedure...5066
Follow-On Procedure...5066
Installation...5067
Overview...5067
Special Tools...5067
Torque Specifications...5067
Equipment Conditions ...5067
Procedure...5067
Follow-On Procedure...5068
Heater Outlet Hose Replacement (Heater Outlet Pipe to Radiator Outlet Pipe)...5069
Removal...5069
Overview...5069
Special Tools...5069
Equipment Conditions...5069
Procedure...5070
Follow-On Procedure...5071
Installation...5072
Overview...5072
Special Tools...5072
Equipment Conditions ...5072
Procedure...5072
Follow-On Procedure...5073
Heater Outlet Pipe (From Heater Outlet Hose With Air Compressor)...5075
Removal...5075
Overview...5075
Special Tools...5075
Equipment Condition...5075
Procedure...5075
Follow-On Procedure...5077
Installation...5078
Overview...5078
Special Tools...5078
Equipment Condition...5078
Procedure...5078
Follow-On Procedure...5080
Heater Outlet Pipe (From Heater Outlet Hose Without Air Compressor)...5081
Removal...5081
Overview...5081
Special Tools...5081
Equipment Condition...5081
Procedure...5081
Follow-On Procedure...5083
Installation...5084
Overview...5084
Special Tools...5084
Equipment Condition...5084
Procedure...5084
Follow-On Procedure...5086
Heater Outlet Pipe (From Automatic Level Control Air Compressor)...5087
Removal...5087
Overview...5087
Special Tools...5087
Equipment Condition...5087
Procedure...5088
Follow-On Procedure...5090
Installation...5091
Overview...5091
Special Tools...5091
Torque Specifications...5091
Equipment Condition...5091
Procedure...5091
Follow-On Procedure...5093
HVAC Controls...5094
Removal...5094
Overview...5094
Special Tools...5094
Equipment Condition...5094
Procedure...5094
Follow-On Procedure...5095
Installation...5096
Overview...5096
Special Tools...5096
Torque Specifications...5096
Equipment Condition...5096
Procedure...5096
Follow-On Procedure...5096
HVAC Module...5097
Removal...5097
Overview...5097
Special Tools...5097
Equipment Condition...5097
Procedure...5098
Follow-On Procedure...5100
Installation...5101
Overview...5101
Special Tools...5101
Equipment Condition...5101
Procedure...5101
Follow-On Procedure...5103
HVAC Module Harness...5105
Removal...5105
Overview...5105
Special Tools...5105
Equipment Condition...5105
Procedure...5107
Follow-On Procedure...5107
Installation ...5108
Overview...5108
Special Tools...5108
Torque Specifications...5108
Equipment Condition...5108
Procedure...5108
Follow-On Procedure...5108
HVAC Remote Control...5111
Removal...5111
Overview...5111
Special Tools...5111
Equipment Condition...5111
Procedure...5111
Follow-On Procedure...5111
Installation...5112
Overview...5112
Special Tools...5112
Torque Specifications...5112
Equipment Condition...5112
Procedure...5112
Follow-On Procedure...5112
HVAC System Seal...5114
Removal...5114
Overview...5114
Special Tools...5114
Equipment Condition...5114
Procedure...5114
Follow-On Procedure...5114
Installation...5115
Overview...5115
Special Tools...5115
Torque Specifications...5115
Equipment Condition...5115
Procedure...5115
Follow-On Procedure...5115
Integrated Receiver Drier...5116
Removal...5116
Overview...5116
Special Tools...5117
Equipment Condition...5117
Procedure...5118
Follow-On Procedure...5119
Installation...5120
Overview...5120
Special Tools...5120
Equipment Condition...5120
Procedure...5121
Follow-On Procedure...5122
Refrigerant Pressure Sensor...5123
Removal...5123
Overview...5123
Special Tools...5123
Equipment Condition...5123
Procedure...5124
Follow-On Procedure...5124
Installation...5125
Overview...5125
Special Tools...5125
Equipment Condition...5125
Procedure...5126
Follow-On Procedure...5126
General HVAC System Maintenance...5127
Approximate Fluid Capacities...5127
Actuator Calibration...5128
Overview...5128
Special Tools...5128
Equipment Condition...5128
Preferred Method (with Scan Tool)...5128
Alternate Method (without Scan Tool)...5128
Follow-On Procedure...5128
Afterblow Enabling...5129
Overview...5129
Special Tools...5129
Equipment Conditions...5129
Procedure...5129
Follow-On Procedure...5129
Air Conditioning Compressor Oil Balancing...5130
Overview...5130
Special Tools...5130
Equipment Condition...5130
Draining Procedure...5130
Balancing Procedure with Service Compressor Replacement (Flushing Not Required)...5130
Balancing Procedure with Service Compressor Replacement (Flushing Required)...5130
Balancing Procedure (Flushing Required Only)...5131
Follow-On Procedure...5131
Hose Clamp...5132
Overview...5132
Special Tools ...5132
Spring Type Hose Clamp Replacement Guidelines...5132
Removing Spring Type Hose Clamp...5133
Reusing Spring Type Hose Clamp...5133
Reusing The Spring Type Hose Clamp and Replacing The Hose...5133
Reusing The Spring Type Hose Clamp with an Existing Hose...5133
Replacing Spring Type Hose Clamp...5133
Replacing The Spring Type Hose Clamp and Replacing The Hose...5133
Replacing The Spring Type Hose Clamp with an Existing Hose...5134
Odor Correction...5135
Overview...5135
Special Tools...5135
Equipment Condition...5135
Eliminating Air Conditioning (A/C) Odor...5135
Cooling Coil Coating Procedure...5136
Water And Vinegar Solution Cleaning Procedure...5137
Follow-On Procedure...5137
Radiator Cleaning...5138
Overview...5138
Special Tools...5138
Equipment Condition...5138
Cleaning Procedure...5138
Follow-On Procedure...5138
Refrigerant Leak Testing...5139
Special Tools...5139
Refrigerant Leak Testing...5139
Fluorescent Leak Detection...5139
Fluorescent Dye Injection...5140
Electronic Leak Detector-SAE J2913 Certified...5140
Refrigerant Recovery and Recharging...5141
Overview...5141
A/C Refrigerant System Oil Charge Replenishing...5141
Special Tools...5141
Flush and Purge Procedures...5142
Flush and Purge (General)...5142
Overview...5142
Special Tools...5142
Equipment Condition...5142
Discharge Barrel...5144
Fill Flush Tank...5146
Flush and Purge Procedure...5147
Follow-On Procedure...5148
Flush and Purge A/C Condenser...5149
Overview...5149
Special Tools...5149
Equipment Condition...5149
Procedure...5149
Follow-On Procedure...5151
Flush and Purge Cab Supply and Return Lines...5152
Overview...5152
Special Tools...5152
Equipment Condition...5152
Flush and Purge Cab Supply and Return Lines Procedure...5152
Follow-On Procedure...5156
Flush and Purge A/C Cab Evaporator...5157
Overview...5157
Special Tools...5157
Equipment Condition...5157
Procedure...5157
Follow-On Procedure...5158
Air Distribution...5159
Air Distributor Case Replacement (0016XZA)...5159
Removal...5159
Overview...5159
Special Tools...5159
Equipment Condition...5159
Procedure...5160
Follow-On Procedure...5161
Installation...5162
Overview...5162
Special Tools...5162
Equipment Condition...5162
Procedure...5162
Follow-On Procedure...5163
Air Distributor Case Replacement (0016BAL)...5165
Removal...5165
Overview...5165
Special Tools...5165
Equipment Conditions...5165
Procedure...5166
Follow-On Procedure...5167
Installation...5168
Overview...5168
Special Tools...5168
Equipment Conditions...5168
Procedure...5169
Follow-On Procedure...5170
Air Distributor Front Duct...5172
Removal...5172
Overview...5172
Special Tools...5172
Equipment Condition...5172
Procedure...5173
Follow-On Procedure...5173
Installation...5174
Overview...5174
Special Tools...5174
Equipment Condition...5174
Procedure...5174
Follow-On Procedure...5175
Air Inlet Housing...5176
Removal...5176
Overview...5176
Special Tools...5176
Equipment Condition...5176
Procedure...5177
Follow-On Procedure...5177
Installation...5178
Overview...5178
Special Tools...5178
Equipment Condition...5178
Procedure...5178
Follow-On Procedure...5178
Air Inlet Housing Replacement (00016BAL)...5181
Removal...5181
Overview...5181
Special Tools...5181
Equipment Conditions...5181
Procedure...5183
Follow-On Procedure...5183
Installation Procedure...5184
Overview...5184
Special Tools...5184
Equipment Conditions...5184
Procedure...5185
Follow-On Procedure...5185
Air Outlet Floor Duct – Center (Regular Cab)...5187
Removal...5187
Overview...5187
Special Tools...5187
Equipment Condition...5187
Procedure...5187
Follow-On Procedure...5187
Installation...5188
Overview...5188
Special Tools...5188
Equipment Condition...5188
Procedure...5188
Follow-On Procedure...5188
Air Outlet Floor Duct – Center (Crew Cab)...5189
Removal...5189
Overview...5189
Special Tools...5189
Equipment Condition...5189
Procedure...5189
Follow-On Procedure...5190
Installation...5191
Overview...5191
Special Tools...5191
Equipment Condition...5191
Procedure...5191
Follow-On Procedure...5191
Air Outlet Floor Front Duct – Driver...5193
Removal...5193
Overview...5193
Special Tools...5193
Equipment Condition...5193
Procedure...5193
Follow-On Procedure...5193
Installation...5194
Overview...5194
Special Tools...5194
Torque Specifications...5194
Equipment Condition...5194
Procedure...5194
Follow-On Procedure...5194
Air Outlet Floor Front Duct – Passenger...5195
Removal...5195
Overview...5195
Special Tools...5195
Equipment Condition...5195
Procedure...5195
Follow-On Procedure...5195
Installation...5196
Overview...5196
Special Tools...5196
Equipment Condition...5196
Procedure...5196
Follow-On Procedure...5196
Air Outlet Floor Rear Duct...5197
Removal...5197
Overview...5197
Special Tools...5197
Equipment Condition...5197
Procedure...5197
Follow-On Procedure...5197
Installation...5198
Overview...5198
Special Tools...5198
Torque Specifications...5198
Equipment Condition...5198
Procedure...5198
Follow-On Procedure...5198
Air Outlet Instrument Panel Center Duct...5199
Removal...5199
Overview...5199
Special Tools...5199
Equipment Condition...5199
Procedure...5199
Follow-On Procedure...5199
Installation...5200
Overview...5200
Special Tools...5200
Equipment Condition...5200
Procedure...5200
Follow-On Procedure...5200
Air Outlet Instrument Panel Outer – Driver...5201
Removal...5201
Overview...5201
Special Tools...5201
Equipment Condition...5201
Procedure...5201
Follow-On Procedure...5201
Installation...5202
Overview...5202
Special Tools...5202
Equipment Condition...5202
Procedure...5202
Follow-On Procedure...5202
Air Outlet Instrument Panel Outer – Passenger...5203
Removal...5203
Overview...5203
Special Tools...5203
Equipment Condition...5203
Procedure...5203
Follow-On Procedure...5203
Installation...5204
Overview...5204
Special Tools...5204
Equipment Condition...5204
Procedure...5204
Follow-On Procedure...5204
Passenger Compartment Air Filter...5205
Removal...5205
Overview...5205
Special Tools...5205
Equipment Condition...5205
Procedure...5205
Follow-On Procedure...5205
Installation...5206
Overview...5206
Special Tools...5206
Torque Specifications...5206
Equipment Condition...5206
Procedure...5206
Follow-On Procedure...5206
Side Window Defogger Outlet Duct – Driver...5207
Removal ...5207
Overview...5207
Special Tools...5207
Equipment Condition...5207
Procedure...5208
Follow-On Procedure...5208
Installation...5209
Overview...5209
Special Tools...5209
Equipment Condition...5209
Procedure...5209
Follow-On Procedure...5209
Side Window Defogger Outlet Duct – Passenger...5211
Removal...5211
Overview...5211
Special Tools...5211
Equipment Condition...5211
Procedure...5212
Follow-On Procedure...5212
Installation...5213
Overview...5213
Special Tools...5213
Equipment Condition...5213
Procedure...5213
Follow-On Procedure...5213
8. Power Door Locks / Windows...5215
Power Door Locks...5215
Front Door Lock Switch - Driver...5215
Removal...5215
Overview...5215
Special Tools...5215
Equipment Condition...5215
Procedure...5215
Follow-On Procedure...5215
Installation...5216
Overview...5216
Special Tools...5216
Torque Specifications...5216
Equipment Condition...5216
Procedure...5216
Follow-On Procedure...5216
Front Door Lock Switch - Driver-Side (Without Power Windows)...5217
Removal...5217
Overview...5217
Special Tools...5217
Equipment Condition...5217
Procedure...5218
Follow-On Procedure...5218
Installation...5219
Overview...5219
Special Tools...5219
Torque Specifications...5219
Equipment Condition...5219
Procedure...5220
Follow-On Procedure...5220
Front Door Lock Switch – Passenger...5221
Removal...5221
Overview...5221
Special Tools...5221
Equipment Condition...5221
Procedure...5221
Follow-On Procedure...5221
Installation...5222
Overview...5222
Special Tools...5222
Torque Specifications...5222
Equipment Condition...5222
Procedure...5222
Follow-On Procedure...5222
Front Door Lock Switch – Passenger (Without Power Windows)...5223
Removal...5223
Overview...5223
Special Tools...5223
Equipment Condition...5223
Procedure...5224
Follow-On Procedure...5224
Installation...5225
Overview...5225
Special Tools...5225
Torque Specifications...5225
Equipment Condition...5225
Procedure...5225
Follow-On Procedure...5226
Remote Control Door Lock Receiver...5227
Removal...5227
Overview...5227
Special Tools...5227
Equipment Condition...5227
Procedure...5227
Follow-On Procedure...5227
Installation...5228
Overview...5228
Special Tools...5228
Torque Specifications...5228
Equipment Condition...5228
Procedure...5228
Follow-On Procedure...5228
Remote Control Door Lock Transmitter Learn...5229
Overview...5229
Special Tools...5229
Equipment Condition...5229
Erase / Program All Key Fobs Procedure...5229
Next Available Slot Procedure...5229
Slot Programming Procedure...5230
Follow-On Procedure...5230
Power Windows...5231
Front Side Door Window Regulator (Power)...5231
Removal...5231
Overview...5231
Special Tools...5231
Equipment Condition...5231
Procedure...5232
Follow-On Procedure...5232
Installation...5233
Overview...5233
Special Tools...5233
Equipment Condition...5233
Procedure...5233
Follow-On Procedure...5234
Front Side Door Window Regulator Motor...5235
Removal...5235
Overview...5235
Special Tools...5235
Equipment Condition...5235
Procedure...5235
Follow-On Procedure...5235
Installation...5236
Overview...5236
Special Tools...5236
Equipment Condition...5236
Procedure...5236
Follow-On Procedure...5237
Front Side Door Window Switch – Left...5238
Removal...5238
Overview...5238
Special Tools...5238
Equipment Condition...5238
Procedure...5238
Follow-On Procedure...5238
Installation...5239
Overview...5239
Special Tools...5239
Torque Specifications...5239
Equipment Condition...5239
Procedure...5239
Follow-On Procedure...5239
Front Side Door Window Switch – Right...5240
Removal...5240
Overview...5240
Special Tools...5240
Equipment Condition...5240
Procedure...5240
Follow-On Procedure...5240
Installation ...5241
Overview...5241
Special Tools...5241
Torque Specifications...5241
Equipment Condition...5241
Procedure...5241
Follow-On Procedure...5241
Rear Side Door Window Regulator...5242
Removal...5242
Overview...5242
Special Tools...5242
Equipment Condition...5242
Procedure...5243
Follow-On Procedure...5243
Installation...5244
Overview...5244
Special Tools...5244
Equipment Condition...5244
Procedure...5244
Follow-On Procedure...5245
Rear Side Door Window Regulator Motor...5246
Removal...5246
Overview...5246
Special Tools...5246
Equipment Condition...5246
Procedure...5246
Follow-On Procedure...5246
Installation...5247
Overview...5247
Special Tools...5247
Equipment Condition...5247
Procedure...5247
Follow-On Procedure...5247
Rear Side Door Window Switch...5248
Removal...5248
Overview...5248
Special Tools...5248
Equipment Condition...5248
Procedure...5248
Follow-On Procedure...5248
Installation...5249
Overview...5249
Special Tools...5249
Torque Specifications...5249
Equipment Condition...5249
Procedure...5249
Follow-On Procedure...5249
9. Safety...5250
Restraints...5250
Child Seat Restraint System Belt Bracket...5250
Removal...5250
Overview...5250
Special Tools...5250
Equipment Condition...5250
Procedure...5250
Follow-On Procedure...5250
Installation...5251
Overview...5251
Special Tools...5251
Equipment Condition...5251
Procedure...5251
Follow-On Procedure...5251
Front Center Seat Belt...5252
Removal...5252
Overview...5252
Special Tools...5252
Equipment Condition...5252
Procedure...5252
Follow-On Procedure...5253
Installation...5254
Overview...5254
Special Tools...5254
Equipment Condition...5254
Procedure...5254
Follow-On Procedure...5255
Front Center Seat Belt Buckle...5256
Removal...5256
Overview...5256
Special Tools...5256
Equipment Condition...5256
Procedure...5256
Follow-On Procedure...5256
Installation...5257
Overview...5257
Special Tools...5257
Equipment Condition...5257
Procedure...5257
Follow-On Procedure...5257
Front Seat Belt Buckle...5258
Removal...5258
Overview...5258
Special Tools...5258
Equipment Condition...5258
Procedure...5258
Follow-On Procedure...5258
Installation...5259
Overview...5259
Special Tools...5259
Equipment Condition...5259
Procedure...5259
Follow-On Procedure...5259
Front Seat Belt Guide Adjuster...5260
Removal...5260
Overview...5260
Special Tools...5260
Equipment Condition...5260
Procedure...5260
Follow-On Procedure...5260
Installation...5261
Overview...5261
Special Tools...5261
Equipment Condition...5261
Procedure...5261
Follow-On Procedure...5261
Front Seat Belt Latch...5262
Removal...5262
Overview...5262
Special Tools...5262
Equipment Condition...5262
Procedure...5262
Follow-On Procedure...5262
Installation...5263
Overview...5263
Special Tools...5263
Equipment Condition...5263
Procedure...5263
Follow-On Procedure...5263
Rear Center Seat Belt Retractor...5264
Removal...5264
Overview...5264
Special Tools...5264
Equipment Condition...5264
Procedure...5264
Follow-On Procedure...5265
Installation...5266
Overview...5266
Special Tools...5266
Equipment Condition...5266
Procedure...5266
Follow-On Procedure...5267
Rear Seat Belt Buckle...5268
Removal...5268
Overview...5268
Special Tools...5268
Equipment Condition...5268
Procedure...5268
Follow-On Procedure...5268
Installation...5269
Overview...5269
Special Tools...5269
Equipment Condition...5269
Procedure...5269
Follow-On Procedure...5269
Rear Seat Belt Guide Adjuster Cover...5270
Removal...5270
Overview...5270
Special Tools...5270
Equipment Condition...5270
Procedure...5270
Follow-On Procedure...5270
Installation...5271
Overview...5271
Special Tools...5271
Torque Specifications...5271
Equipment Condition...5271
Procedure...5271
Follow-On Procedure...5271
Rear Seat Belt Retractor...5272
Removal...5272
Overview...5272
Special Tools...5272
Equipment Condition...5272
Procedure...5272
Follow-On Procedure...5273
Installation...5274
Overview...5274
Special Tools...5274
Equipment Condition...5274
Procedure...5274
Follow-On Procedure...5275
Supplemental Inflatable Restraints (SIR) System...5276
Overview...5276
General Service Instructions...5276
Discard any of the following components if it has been dropped from a height of 80 cm (31.49 in) or greater:...5276
Impact Sensor Replacement Guidelines...5276
Airbag Front End Discriminating Sensor...5278
Removal...5278
Overview...5278
Special Tools...5278
Equipment Condition...5278
Procedure...5279
Follow-On Procedure...5279
Installation...5280
Overview...5280
Special Tools...5280
Equipment Condition...5280
Procedure...5281
Follow-On Procedure...5281
Inflatable Restraint Sensing and Diagnostic Module (SDM)...5282
Removal...5282
Overview...5282
Special Tools...5282
Equipment Condition...5283
Procedure...5284
Follow-On Procedure...5285
Installation...5286
Overview...5286
Special Tools...5286
Equipment Condition...5286
Procedure...5287
Follow-On Procedure...5288
Rollover Protection Disable Switch...5289
Removal...5289
Overview...5289
Special Tools...5289
Equipment Conditions...5289
Procedure...5289
Follow-On Procedure...5290
Installation...5291
Overview...5291
Special Tools...5291
Equipment Conditions...5291
Procedure...5291
Follow-On Procedure...5291
Airbag Side Impact Front Sensor...5292
Removal...5292
Overview...5292
Special Tools...5292
Equipment Conditions...5292
Procedure...5293
Follow-On Procedure...5293
Installation...5293
Overview...5293
Special Tools...5293
Equipment Conditions...5294
Procedure...5295
Follow-On Procedure...5295
Airbag Side Impact Rear Sensor ...5296
Removal...5296
Overview...5296
Special Tools...5296
Equipment Conditions...5296
Procedure...5297
Follow-On Procedures...5297
Installation...5298
Overview...5298
Special Tools...5298
Equipment Conditions...5298
Procedure...5299
Follow-On Procedures...5299
Instrument Panel Airbag...5300
Removal...5300
Overview...5300
Special Tools...5300
Equipment Condition...5300
Procedure...5301
Follow-On Procedure...5301
Installation...5302
Overview...5302
Special Tools...5302
Torque Specifications...5302
Equipment Condition...5302
Procedure...5303
Follow-On Procedure...5303
Instrument Panel Airbag Arming Status Display...5304
Removal...5304
Overview...5304
Special Tools...5304
Equipment Condition...5304
Procedure...5304
Follow-On Procedure...5304
Installation...5305
Overview...5305
Special Tools...5305
Torque Specifications...5305
Equipment Condition...5305
Procedure...5305
Follow-On Procedure...5305
Airbag Front Seat Position Sensor...5306
Removal...5306
Overview...5306
Special Tools...5306
Procedure...5306
Follow-On Procedure...5306
Installation...5307
Overview...5307
Special Tools...5307
Torque Specifications...5307
Procedure...5307
Follow-On Procedure...5307
Front Seat Belt Retractor Pretensioner (Regular Cab)...5308
Removal...5308
Overview...5308
Special Tools...5308
Equipment Condition...5309
Procedure...5310
Follow-On Procedure...5310
Installation...5311
Overview...5311
Special Tools...5311
Equipment Condition...5312
Procedure...5313
Follow-On Procedure...5313
Front Seat Belt Retractor Pretensioner (Crew Cab)...5314
Removal...5314
Overview...5314
Special Tools...5314
Equipment Condition...5315
Procedure...5316
Follow-On Procedure...5316
Installation...5317
Overview...5317
Special Tools...5317
Equipment Condition...5318
Procedure...5319
Follow-On Procedure...5319
Front Seat Belt Anchor Plate Tensioner...5320
Removal...5320
Special Tools...5320
Equipment Conditions...5320
Follow-On Procedure...5321
Installation...5322
Special Tools...5322
Equipment Conditions...5323
Follow-On Procedures...5324
Steering Wheel Airbag...5325
Removal...5325
Overview...5325
Special Tools...5325
Equipment Condition...5325
Procedure...5326
Follow-On Procedure...5329
Installation...5330
Overview...5330
Special Tools...5330
Torque Specifications...5330
Equipment Condition...5330
Procedure...5331
Follow-On Procedure...5332
Steering Wheel Airbag Coil Replacement...5333
Removal...5333
Overview...5333
Special Tools...5333
Equipment Conditions...5333
Procedure...5334
Follow-On Procedure...5336
Installation...5337
Overview...5337
Special Tools...5337
Torque Specifications...5337
Equipment Conditions...5337
Procedure...5338
Follow-On Procedure...5340
Front and Rear Row Seat Roof Rail Airbag...5341
Removal...5341
Overview...5341
Special Tools...5341
Equipment Conditions...5341
Procedure...5342
Follow-On Procedure...5342
Installation...5343
Overview...5343
Special Tools...5343
Equipment Conditions...5343
Procedure...5344
Follow-On Procedure...5344
Front Seat Outboard Seat Back Airbag...5345
Removal...5345
Overview...5345
Special Tools...5345
Equipment Conditions...5346
Procedure...5347
Follow-On Procedure...5347
Installation...5348
Overview...5348
Special Tools...5348
Equipment Conditions...5349
Procedure...5350
Follow-On Procedure...5350
Airbag and Pretensioner Deployment - Inside Vehicle...5351
Overview...5351
Special Tools...5351
Equipment Condition...5351
Procedure...5351
Follow-On Procedure...5357
Airbag and Pretensioner Deployment - Outside Vehicle...5358
Overview...5358
Special Tools...5358
Equipment Conditions...5358
Procedure...5358
Follow-On Procedure...5358
Supplemental Inflatable Restraint (SIR) Disabling and Enabling...5359
Overview...5359
Special Tools...5359
Equipment Conditions...5360
Disabling Procedure, Air Bag Fuse...5360
Enabling Procedure, Air Bag Fuse...5360
Disabling Procedure, Negative Battery Cable...5360
Enabling Procedure, Negative Battery Cable...5360
Follow-On Procedure...5361
10. Windshield Wipers...5362
Windshield Wiper System...5362
Windshield Wiper Arm...5362
Removal...5362
Overview...5362
Special Tools...5362
Equipment Condition...5362
Procedure...5362
Follow-On Procedure...5363
Installation...5364
Overview...5364
Special Tools...5364
Equipment Condition...5364
Procedure...5364
Follow-On Procedure...5365
Windshield Wiper Blade...5366
Removal...5366
Overview...5366
Special Tools...5366
Equipment Condition...5366
Procedure...5366
Follow-On Procedure...5366
Installation...5367
Overview...5367
Special Tools...5367
Torque Specifications...5367
Equipment Condition...5367
Procedure...5367
Follow-On Procedure...5367
Windshield Wiper Motor...5368
Removal...5368
Overview...5368
Special Tools...5368
Equipment Condition...5368
Procedure...5368
Follow-On Procedure...5369
Installation...5370
Overview...5370
Special Tools...5370
Equipment Condition...5370
Procedure...5370
Follow-On Procedure...5371
Windshield Wiper Transmission...5372
Removal...5372
Overview...5372
Special Tools...5372
Equipment Condition...5372
Procedure...5372
Follow-On Procedure...5372
Installation...5373
Overview...5373
Special Tools...5373
Equipment Condition...5373
Procedure...5373
Follow-On Procedure...5373
Windshield Washer System...5374
Windshield Washer Pump Hose...5374
Removal...5374
Overview...5374
Special Tools...5374
Equipment Condition...5374
Procedure...5374
Follow-On Procedure...5377
Installation...5378
Overview...5378
Torque Specifications...5378
Equipment Condition...5378
Procedure...5378
Follow-On Procedure...5381
Windshield Washer Solvent Container...5382
Removal...5382
Overview...5382
Special Tools...5382
Equipment Condition...5382
Procedure...5382
Follow-On Procedure...5383
Installation...5384
Overview...5384
Special Tools...5384
Equipment Condition...5384
Installation Procedures...5384
Follow-On Procedure...5385
Wheels and Tires...5387
1. Front Wheels and Tires...5389
Single Front Wheels...5389
8 - Lug...5389
Removal...5389
Overview...5389
Special Tools...5389
Equipment Condition...5389
Procedure...5389
Follow-On Procedure...5390
Installation...5391
Overview...5391
Special Tools...5391
Equipment Condition...5391
Procedure...5391
Follow-On Procedure...5392
2. Rear Wheels and Tires...5393
Dual Rear Wheels...5393
8 - Lug...5393
Removal...5393
Overview...5393
Special Tools...5393
Equipment Condition...5393
Procedure...5393
Follow-On Procedure...5394
Installation...5395
Overview...5395
Special Tools...5395
Equipment Condition...5395
Procedure...5395
Follow-On Procedure...5396
1. 1. Naming Convention and Acronyms Table...5397
tables...12
Vehicle Identification Number (VIN) System...12
Rattle, Clunk, Pop or Shudder Noise from the Power Steering System...43
Whine or Growl Noise from the Power Steering System...46
Exhaust Noise...47
Torque Specifications...65
Torque Specifications...70
Torque Specifications...76
Reusable Threaded Fastener Torque Specifications...81
Torque Specifications...84
Torque Specifications...88
Torque Specifications...92
Reusable Threaded Fastener Torque Specifications...93
Torque Specifications...96
Torque Specifications...100
Torque Specifications...114
Torque Specifications...134
Torque Specifications...153
Torque Specifications...176
Torque Specifications...182
Torque Specifications...191
Specifications...214
Adhesives, Fluids, Lubricants, and Sealers...216
Torque Specifications...220
Torque Specifications...227
Torque Specifications...234
Specifications...239
Torque Specifications...249
Torque Specifications...260
Torque Specifications...267
Torque Specifications...274
Torque Specifications...280
Torque Specifications...284
Torque Specifications...288
Torque Specifications...292
Torque Specifications...297
Torque Specifications...302
Torque Specifications...307
Torque Specifications...313
Torque Specifications...320
Torque Specifications...325
Torque Specifications...342
Torque Specifications...356
Torque Specifications...364
Torque Specifications...368
Torque Specifications...397
Torque Specifications...401
Torque Specifications...407
Torque Specifications...419
Torque Specifications...429
Torque Specifications...437
Torque Specifications...451
Torque Specifications...458
Torque Specifications...463
Torque Specifications...467
Torque Specifications...471
Torque Specifications...476
Torque Specifications...480
Torque Specifications...487
Torque Specifications...495
Torque Specifications...501
Torque Specifications...506
Torque Specifications...510
Specifications...513
Specifications...516
Approximate Fluid Capacities...521
Adhesives, Fluids, Lubricants, and Sealers...521
Torque Specifications...521
Torque Specifications...525
Torque Specifications...529
Torque Specifications...535
Torque Specifications...540
Torque Specifications...546
Torque Specifications...554
Torque Specifications...563
Torque Specifications...574
Specifications...586
Torque Specifications...611
Torque Specifications...617
Torque Specifications...626
Torque Specifications...637
Torque Specifications...652
Torque Specifications...659
Torque Specifications...671
Torque Specifications...682
Power Steering Fluid Capacities (Approximate)...689
Power Steering Pump Specifications...690
Torque Specifications...693
Torque Specifications...699
Torque Specifications...705
Torque Specifications...710
Torque Specifications...714
Torque Specifications...719
Torque Specifications...724
Torque Specifications...729
Torque Specifications...734
Torque Specifications...739
Single Use Non-Threaded Fasteners / Components ...751
Torque Specifications for Reusable Threaded Fasteners...751
Torque Specifications...754
Torque Specifications...758
Torque Specifications...770
Torque Specifications...776
Torque Specifications...782
Single Use Non-Threaded Fasteners / Components ...788
Torque Specifications for Reusable Threaded Fasteners...788
Torque Specifications...791
Torque Specifications...794
Torque Specifications...800
Torque Specifications...806
Torque Specifications...811
Torque Specifications...817
Torque Specifications...838
Torque Specifications...843
Torque Specifications...849
Torque Specifications...852
Torque Specifications...858
Torque Specifications...868
Torque Specifications...884
Torque Specifications...903
Torque Specifications...931
Torque Specifications...941
Torque Specifications...952
Steering Axle Toe In Wheel Alignment Specifications...952
Torque Specifications...980
Torque Specifications...989
Single Use Threaded Fastener / Component Torque Specifications...994
Torque Specifications...1014
Torque Specifications...1026
Torque Specifications...1035
Torque Specifications...1043
Torque Specifications...1051
Torque Specifications...1057
Torque Specifications...1063
Torque Specifications...1073
Torque Specifications...1082
Torque Specifications...1087
Torque Specifications...1091
Torque Specifications...1102
Engine Control Module Scan Tool Data...1148
Glow Plug Control Module Scan Tool Information...1221
Special Functions...1225
Scan Tool Output Controls...1227
Scan Tool Data Parameters...1227
Power Mode Parameters ...1306
Diagnostic Fault Information...1310
Diagnostic Fault Information...1316
Resistance Test...1321
Splice Sleeve Selection...1333
Torque Specifications...1365
Torque Specifications...1370
Torque Specifications...1374
Torque Specifications...1381
Torque Specifications...1392
Diagnostic Fault Information...1407
Diagnostic Fault Information...1415
Diagnostic Fault Information...1419
Diagnostic Fault Information ...1425
Diagnostic Fault Information...1431
Circuit / System Description...1431
Diagnostic Fault Information...1437
Diagnostic Fault Information...1439
Resistance Test...1444
Diagnostic Fault Information...1445
Diagnostic Fault Information...1448
Diagnostic Fault Information...1450
Diagnostic Fault Information ...1459
Diagnostic Fault Information...1464
Diagnostic Fault Information...1468
Diagnostic Fault Information...1471
Diagnostic Fault Information...1473
Diagnostic Fault Information...1477
Diagnostic Fault Information...1490
Typical Scan Tool Data...1490
Diagnostic Fault Information ...1497
Conditions for Setting the DTC ...1498
Diagnostic Fault Information ...1503
Torque Specifications...1514
Reusable Threaded Fastener Tightening Specifications ...1515
Diagnostic Fault Information...1516
Diagnostic Fault Information ...1521
Diagnostic Fault Information...1555
Diagnostic Fault Information...1566
Diagnostic Fault Information ...1574
Diagnostic Fault Information...1577
Diagnostic Fault Information...1585
Diagnostic Fault Information...1594
Diagnostic Fault Information ...1596
Diagnostic Fault Information ...1599
Diagnostic Fault Information ...1606
Diagnostic Fault Information ...1613
Diagnostic Fault Information ...1618
Diagnostic Fault Information ...1625
Diagnostic Fault Information...1633
Diagnostic Fault Information...1637
Diagnostic Fault Information...1639
Diagnostic Fault Information ...1647
Diagnostic Fault Information ...1651
Diagnostic Fault Information ...1666
Diagnostic Fault Information...1670
Diagnostic Fault Information...1676
Diagnostic Fault Information...1683
Diagnostic Fault Information...1689
Diagnostic Fault Information...1700
Diagnostic Fault Information...1703
Diagnostic Fault Information ...1709
Power Take-Off (PTO) Description and Operation...1717
Diagnostic Fault Information...1722
Diagnostic Fault Information...1725
Diagnostic Fault Information...1727
Diagnostic Fault Information...1729
Diagnostic Fault Information...1732
Diagnostic Fault Information...1734
Diagnostic Fault Information...1736
Diagnostic Fault Information...1740
Diagnostic Fault Information...1744
Diagnostic Fault Information...1806
Diagnostic Fault Information...1808
Diagnostic Fault Information...1812
Diagnostic Fault Information ...1814
Diagnostic Fault Information...1817
Diagnostic Fault Information...1824
Diagnostic Fault Information...1828
Diagnostic Fault Information...1831
Diagnostic Fault Information...1840
Diagnostic Fault Information...1849
Diagnostic Fault Information...1866
Diagnostic Fault Information...1872
Diagnostic Fault Information...1878
Diagnostic Fault Information...1898
Diagnostic Fault Information...1906
Diagnostic Fault Information...1909
Diagnostic Fault Information...1911
Diagnostic Fault Information...1919
Diagnostic Fault Information...1921
Diagnostic Fault Information...1924
Diagnostic Fault Information...1929
Diagnostic Fault Information...1936
Diagnostic Fault Information...1939
Diagnostic Fault Information...1944
Diagnostic Fault Information...1952
Diagnostic Fault Information...1960
Control Module U-code List...1970
Diagnostic Fault Information...1988
Diagnostic Fault Information...1994
Diagnostic Fault Information...2000
Diagnostic Fault Information...2005
Diagnostic Fault Information...2015
Diagnostic Fault Information...2023
Diagnostic Fault Information...2036
Diagnostic Fault Information...2044
Diagnostic Fault Information...2050
Diagnostic Fault Information...2058
Diagnostic Fault Information...2064
Diagnostic Fault Information...2073
Diagnostic Fault Information...2079
Diagnostic Fault Information...2085
Diagnostic Fault Information...2092
Diagnostic Fault Information...2098
Diagnostic Fault Information...2106
Diagnostic Fault Information...2114
Diagnostic Fault Information...2118
Diagnostic Fault Information...2123
Diagnostic Fault Information...2129
Diagnostic Fault Information...2131
Diagnostic Fault Information...2134
Diagnostic Fault Information...2138
Diagnostic Fault Information...2142
Diagnostic Fault Information...2145
Diagnostic Fault Information...2149
Diagnostic Fault Information...2152
Diagnostic Fault Information...2157
Diagnostic Fault Information...2161
Diagnostic Fault Information...2163
Diagnostic Fault Information...2165
Diagnostic Fault Information...2171
Restricted Exhaust...2227
Exhaust Leakage...2230
Diagnostic Fault Information...2233
Diagnostic Fault Information...2238
Diagnostic Fault Information...2240
Diagnostic Fault Information...2243
Diagnostic Fault Information...2247
Diagnostic Fault Information...2249
Diagnostic Fault Information...2254
Diagnostic Fault Information...2257
Diagnostic Fault Information...2267
Diagnostic Fault Information...2272
Diagnostic Fault Information...2274
Diagnostic Fault Information...2278
Diagnostic Fault Information...2281
Diagnostic Fault Information...2284
Diagnostic Fault Information...2287
Diagnostic Fault Information...2291
Diagnostic Fault Information...2294
Diagnostic Fault Information...2301
Diagnostic Fault Information...2304
Diagnostic Fault Information...2307
Diagnostic Fault Information...2309
Diagnostic Fault Information...2315
Diagnostic Fault Information...2325
Diagnostic Fault Information...2327
Diagnostic Fault Information...2329
Diagnostic Fault Information...2334
Diagnostic Fault Information...2339
A/C Diagnostics Chart...2346
Air Conditioning Compressor Oil Diagnosis...2351
Diagnostic Fault Information...2354
Diagnostic Fault Information...2358
Diagnostic Fault Information...2363
Diagnostic Fault Information...2369
Diagnostic Fault Information...2371
Diagnostic Fault Information...2374
Diagnostic Fault Information...2377
Static Temperature / Pressure Table...2381
A/C Performance Table Specifications...2382
Diagnostic Fault Information...2409
Diagnostic Fault Information...2413
Diagnostic Fault Information...2418
Diagnostic Fault Information...2422
Diagnostic Fault Information...2427
Diagnostic Fault Information...2431
Diagnostic Fault Information...2445
Diagnostic Fault Information...2450
Diagnostic Fault Information...2463
Diagnostic Fault Information ...2467
Diagnostic Fault Information...2477
Engine Oil Level Switch...2477
Diagnostic Fault Information...2480
Engine Oil Level Switch...2480
Diagnostic Fault Information...2484
Diagnostic Fault Information...2489
Diagnostic Fault Information...2493
Diagnostic Fault Information...2497
Diagnostic Fault Information...2502
Diagnostic Fault Information...2508
Diagnostic Fault Information...2513
Diagnostic Fault Information...2516
Diagnostic Fault Information...2521
Diagnostic Fault Information...2524
Diagnostic Fault Information...2532
Diagnostic Fault Information...2535
Diagnostic Fault Information...2538
Diagnostic Fault Information...2545
Diagnostic Fault Information...2552
Diagnostic Fault Information...2558
Diagnostic Fault Information...2571
Diagnostic Fault Information...2578
Diagnostic Fault Information...2591
Diagnostic Fault Information...2597
Diagnostic Fault Information...2600
Manual Seat Adjuster Mechanical Diagnosis...2614
Seats - Adjuster Track Locks Ahead of Other Track...2615
Seat - Hard to Move Forward and Rearward...2616
Manual Seat Adjuster Does Not Lock...2617
Manual Seat Adjuster Does Not Unlock...2618
Manual Seat Adjuster Locks Between Lock Positions...2619
Diagnostic Fault Information...2622
Power Seat Adjuster Mechanical Diagnosis...2625
Diagnostic Fault Information...2626
Diagnostic Fault Information...2650
Diagnostic Fault Information...2656
Diagnostic Fault Information...2663
DTC P0600...2680
DTC P0602...2682
DTC P0603...2683
DTC P060C...2686
DTC P0634...2687
DTC P0642...2689
DTC P0657...2694
DTC P0658...2697
DTC P0659...2700
DTC P0701...2703
DTC P0703...2706
DTC P0706...2709
DTC P0708...2712
DTC P0711...2715
DTC P0712...2718
DTC P0713...2722
DTC P0715...2725
DTC P0716...2729
DTC P0717...2733
DTC P0720...2735
DTC P0721...2739
DTC P0722...2743
DTC P0729...2746
DTC P0731...2749
DTC P0732...2751
DTC P0733...2753
DTC P0734...2755
DTC P0735...2757
DTC P0736...2760
DTC P0741...2762
DTC P0742...2764
DTC P0751...2767
DTC P0752...2771
DTC P0756...2775
DTC P0757...2779
DTC P0761...2783
DTC P0762...2787
DTC P0776...2791
DTC P0777...2794
DTC P0842...2798
DTC P0843...2802
DTC P0847...2806
DTC P0848...2810
DTC P0872...2814
DTC P0873...2818
DTC P0877...2822
DTC P0878...2826
DTC P0880...2829
DTC P0881...2833
DTC P0882...2836
DTC P0883...2838
DTC P088B...2840
DTC P0897...2842
DTC P0960...2845
DTC P0961...2847
DTC P0962...2850
DTC P0963...2853
DTC P0964...2856
DTC P0965...2859
DTC P0966...2863
DTC P0967...2867
DTC P0973...2870
DTC P0974...2874
DTC P0976...2877
DTC P0977...2881
DTC P0979...2884
DTC P097A...2888
DTC P097B...2891
DTC P097C...2894
DTC P0980...2897
DTC P2534...2902
DTC P2535...2908
DTC P2669...2911
DTC P2670...2915
DTC P2671...2918
DTC P2723...2921
DTC P2724...2924
DTC P2727...2927
DTC P2728...2930
DTC P2730...2939
DTC P2761...2943
DTC P2762...2946
DTC P2763...2950
DTC P2764...2953
DTC P2789...2956
DTC U0074...2958
DTC U0100...2960
Diagnostic Fault Information ...2964
Diagnostic Fault Information...2966
Diagnostic Fault Information ...2968
Diagnostic Fault Information ...2970
Diagnostic Fault Information...2972
Diagnostic Fault Information ...2978
Diagnostic Fault Information...2983
Diagnostic Fault Information ...2990
Diagnostic Fault Information ...2993
Diagnostic Fault Information...3006
Diagnostic Fault Information...3012
Diagnostic Fault Information...3020
Diagnostic Fault Information...3025
Diagnostic Fault Information...3030
Torque Specifications...3039
Torque Specifications...3047
Torque Specifications...3053
Torque Specifications...3057
Torque Specifications...3061
Torque Specifications...3076
Torque Specifications...3081
Torque Specifications...3085
Torque Specifications...3089
Torque Specifications...3093
Torque Specifications...3097
Torque Specifications...3101
Torque Specifications...3107
Torque Specifications...3127
Torque Specifications...3131
Torque Specifications...3136
Torque Specifications...3141
Torque Specifications...3147
Torque Specifications...3152
Torque Specifications...3160
Torque Specifications...3168
Torque Specifications...3189
Torque Specifications...3197
Torque Specifications...3205
Torque Specifications...3212
Torque Specifications...3220
Torque Specifications...3227
Torque Specifications...3234
Torque Specifications...3241
Torque Specifications...3245
Torque Specifications...3249
Torque Specifications...3253
Torque Specifications...3259
Torque Specifications...3264
Torque Specifications...3278
Torque Specifications...3283
Torque Specifications...3300
Torque Specifications...3305
Torque Specifications...3309
Torque Specifications...3313
Torque Specifications...3321
Torque Specifications...3337
Torque Specifications...3355
Torque Specifications...3373
Torque Specifications...3376
Torque Specifications...3437
Torque Specifications...3439
Torque Specifications...3459
Torque Specifications...3475
Torque Specifications...3478
Table A: Preload Adjustment...3478
Torque Specifications...3484
Table A: Preload Adjustment...3484
Torque Specifications...3487
Torque Specifications...3490
Table A: Preload Adjustment...3490
Single Use Non-Threaded Fasteners / Components...3496
Torque Specifications...3500
Torque Specifications...3506
Torque Specifications...3511
Torque Specifications...3518
Torque Specifications...3524
Torque Specifications...3529
Torque Specifications...3533
Torque Specifications...3537
Torque Specifications...3541
Adhesives, Fluids, Lubricants, and Sealers ...3545
Torque Specifications...3548
Torque Specifications...3552
Torque Specifications...3556
Torque Specifications...3560
Torque Specifications...3564
Torque Specifications...3568
Torque Specifications...3573
Torque Specifications...3580
Torque Specifications...3586
Torque Specifications...3591
Axle Ride Height Specification...3593
Torque Specifications...3595
Torque Specifications...3603
Torque Specifications...3609
Torque Specifications...3613
Pattern Evaluation (Ring Gear)...3615
Torque Specifications...3626
Torque Specifications...3639
Torque Specifications...3659
Torque Specifications...3673
Specifications...3673
Specifications...3675
Specifications...3683
Torque Specifications...3685
Specifications...3685
Torque Specifications...3695
Torque Specifications...3710
Torque Specifications...3732
Torque Specifications...3744
Torque Specifications...3750
Specifications...3750
Specifications...3752
Specifications...3760
Torque Specifications...3762
Specifications...3762
Torque Specifications...3773
Torque Specifications...3777
Torque Specifications...3789
Torque Specifications...3796
Torque Specifications...3806
Torque Specifications...3812
Torque Specifications...3817
Torque Specifications...3826
Torque Specifications...3836
Torque Specifications...3855
Torque Specifications...3863
Torque Specifications...3868
Torque Specifications...3872
Torque Specifications...3885
Torque Specifications...3890
Torque Specifications...3917
Torque Specifications...3927
Torque Specifications...3933
Torque Specifications...3937
Torque Specifications...3944
Torque Specifications...3956
Torque Specifications...3966
Torque Specifications...3973
Torque Specifications...3976
Torque Specifications...3980
Torque Specifications...3983
Torque Specifications...3986
Torque Specifications...3990
Torque Specifications...3993
Torque Specifications...4003
Torque Specifications...4010
Torque Specifications...4018
Torque Specifications...4024
Torque Specifications...4027
Torque Specifications...4040
Torque Specifications...4043
Torque Specifications...4077
Torque Specifications...4089
Torque Specifications...4093
Torque Specifications...4098
Torque Specifications...4103
Torque Specifications...4139
Torque Specifications...4147
Torque Specifications...4160
Torque Specifications...4163
Torque Specifications...4164
Torque Specifications...4179
Torque Specifications...4182
Torque Specifications...4200
Torque Specifications...4204
Torque Specifications...4222
Torque Specifications...4226
Torque Specifications...4242
Torque Specifications...4247
Torque Specifications...4253
Torque Specifications...4261
Torque Specifications...4272
Torque Specifications...4277
Torque Specifications...4281
Torque Specifications...4292
Torque Specifications...4297
Torque Specifications...4300
Torque Specifications...4310
Torque Specifications...4313
Torque Specifications...4321
Torque Specifications...4331
Torque Specifications...4342
Torque Specifications...4351
Torque Specifications...4355
Torque Specifications...4366
Torque Specifications...4407
Torque Specifications...4417
Torque Specifications...4420
Torque Specifications...4424
Reusable Threaded Fastener Tightening Specifications ...4425
Torque Specifications...4428
Torque Specifications...4433
Torque Specifications...4454
Torque Specifications...4469
Torque Specifications...4482
Torque Specifications...4490
Torque Specifications...4493
Torque Specifications...4495
Torque Specifications...4509
Torque Specifications...4512
Torque Specifications...4518
Torque Specifications...4521
Torque Specifications...4532
Torque Specifications...4536
Torque Specifications...4539
Torque Specifications...4561
Torque Specifications...4565
Torque Specifications...4572
Torque Specifications...4584
Torque Specifications...4595
Torque Specifications...4598
Torque Specifications...4602
Torque Specifications...4612
Torque Specifications...4615
Torque Specifications...4619
Torque Specifications...4622
Torque Specifications...4628
Torque Specifications...4632
Torque Specifications...4637
Torque Specifications...4640
Torque Specifications...4643
Torque Specifications...4649
Torque Specifications...4662
Torque Specifications...4669
Torque Specifications...4676
Torque Specifications...4685
Torque Specifications...4688
Torque Specifications...4691
Torque Specifications...4695
Torque Specifications...4705
Torque Specifications...4709
Torque Specifications...4719
Torque Specifications...4723
Torque Specifications...4726
Specifications...4731
Torque Specifications...4736
Torque Specifications...4744
Torque Specifications...4757
Torque Specifications...4780
Torque Specifications...4788
Torque Specifications...4794
Torque Specifications...4805
Torque Specifications...4841
Torque Specifications...4851
Torque Specifications...4855
Torque Specifications...4857
Torque Specifications...4860
Torque Specifications...4874
Torque Specifications...4877
Torque Specifications...4888
Torque Specifications...4891
Torque Specifications...4914
Refrigerant System Capacities...4923
Torque Specifications...4927
Torque Specifications...4935
Torque Specifications...4941
Torque Specifications...4949
Torque Specifications...4953
Torque Specifications...4959
Torque Specifications...4965
Torque Specifications...4970
Torque Specifications...4976
Torque Specifications...4982
Torque Specifications...4986
Torque Specifications...5022
Torque Specifications...5029
Torque Specifications...5038
Torque Specifications...5045
Torque Specifications...5072
Torque Specifications...5078
Torque Specifications...5084
Torque Specifications...5101
Torque Specifications...5120
Torque Specifications...5125
Refrigerant System Capacities...5127
Torque Specifications...5157
Torque Specifications...5162
Torque Specifications...5168
Torque Specifications...5174
Torque Specifications...5178
Torque Specifications...5184
Torque Specifications...5188
Torque Specifications...5191
Torque Specifications...5196
Torque Specifications...5200
Torque Specifications...5202
Torque Specifications...5204
Torque Specifications...5209
Torque Specifications...5213
Torque Specifications...5233
Torque Specifications...5236
Torque Specifications...5244
Torque Specifications...5247
Torque Specifications...5251
Torque Specifications...5254
Torque Specifications...5257
Torque Specifications...5259
Torque Specifications...5261
Torque Specifications...5263
Torque Specifications...5266
Torque Specifications...5269
Torque Specifications...5274
Torque Specifications...5280
Torque Specifications...5286
Torque Specifications...5294
Torque Specifications...5298
Torque Specifications...5311
Torque Specifications...5317
Torque Specifications...5322
Torque Specifications...5343
Torque Specifications...5348
Torque Specifications...5364
Torque Specifications...5370
Torque Specifications...5373
Torque Specifications...5384
Torque Specifications...5391
Torque Specifications...5395
Naming Convention...5397
International CV-Series Models Repair Service Manual 2018-2020
