DaimlerChrysler Jeep Grand Cherokee 2002 User manual
TABLE OF CONTENTS
1.0 INTRODUCTION .........................................................1
1.1 SYSTEM COVERAGE ...............................................1
1.2 SIX-STEP TROUBLESHOOTING PROCEDURE ..........................1
2.0 IDENTIFICATION OF SYSTEM .............................................1
3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION ......................1
3.1 GENERAL DESCRIPTION ............................................1
3.2 FUNCTIONAL OPERATION ...........................................1
3.2.1 ECM ON-BOARD DIAGNOSTICS ..............................1
3.2.2 ECM OPERATING MODES ...................................2
3.2.3 MONITORED CIRCUITS......................................2
3.2.4 SKIS OVERIVEW ...........................................2
3.2.5 SKIS ON-BOARD DIAGNOSTICS ..............................2
3.2.6 SKIS OPERATION...........................................2
3.3 DIAGNOSTIC TROUBLE CODES ......................................3
3.3.1 HARD CODE...............................................3
3.3.2 INTERMITTENT CODE.......................................3
3.3.3 ECM DIAGNOSTIC TROUBLE CODES..........................3
3.3.4 SKIM DIAGNOSTIC TROUBLE CODES .........................6
3.3.5 HANDLING NO TROUBLE CODE PROBLEMS ...................7
3.4 USING THE DRBIIIT.................................................7
3.4.1 DRBIIITDOES NOT POWER UP...............................7
3.4.2 DISPLAY IS NOT VISIBLE....................................7
4.0 DISCLAIMERS, SAFETY, WARNINGS .......................................7
4.1 DISCLAIMERS......................................................7
4.2 SAFETY...........................................................7
4.2.1 TECHNICIAN SAFETY INFORMATION..........................7
4.2.2 VEHICLE PREPARATION FOR TESTING........................8
4.2.3 SERVICING SUB-ASSEMBLIES ...............................8
4.2.4 DRBIIITSAFETY INFORMATION...............................8
4.3 WARNINGS AND CAUTIONS .........................................8
4.3.1 ROAD TEST WARNINGS.....................................8
4.3.2 VEHICLE DAMAGE CAUTIONS ...............................8
5.0 REQUIRED TOOLS AND EQUIPMENT ......................................8
6.0 GLOSSARY OF TERMS...................................................9
7.0 DIAGNOSTIC INFORMATION AND PROCEDURES ...........................11
COMMUNICATION
*NO RESPONSE FROM ECM (PCI BUS) - DIESEL ONLY......................12
*NO RESPONSE FROM ECM (SCI ONLY) - DIESEL ONLY .....................13
*PCI BUS COMMUNICATION FAILURE .....................................15
DRIVEABILITY - DIESEL
P0070-AMBIENT AIR TEMPERATURE CIRCUIT SIGNAL VOLTAGE TOO HIGH ....18
P0070-AMBIENT AIR TEMPERATURE CIRCUIT SIGNAL VOLTAGE TOO LOW ....18
P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO HIGH ...............20
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P0100-MASS AIR FLOW SENSOR SIGNAL VOLTAGE TOO LOW ...............20
P0100-MASS AIR FLOW SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW ......20
P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO HIGH .......26
P0105-BAROMETRIC PRESSURE CIRCUIT SIGNAL VOLTAGE TOO LOW........26
P0606-ECM ERROR GATE ARRAY - COMMUNICATION .......................26
P0606-ECM ERROR GATE ARRAY - COMMUNICATION NOT VERIFIED..........26
P0606-ECM ERROR GATE ARRAY - QUANTITY STOP ........................26
P0606-ECM ERROR RECOVERY HAS OCCURRED ..........................26
P0606-ECM ERROR REDUNDANT OVERRUN MONITORING ..................26
P1206-CALCULATED INJECTOR VOLTAGE TOO HIGH........................26
P1206-CALCULATED INJECTOR VOLTAGE TOO LOW ........................26
P1601-CAPACITOR VOLTAGE 1 VOLTAGE TOO HIGH ........................26
P1601-CAPACITOR VOLTAGE 1 VOLTAGE TOO LOW.........................26
P1606-AFTER RUN SHUT OFF ERROR-INJECTION POWERSTAGE ............26
P1606-AFTER RUN SHUT OFF ERROR-ZERO QUANTITY.....................26
P1608-A/D CONVERTER ERROR APP SENSOR GROUND FAILURE ............26
P1608-A/D CONVERTER ERROR INTERNAL FAILURE........................26
P1608-A/D CONVERTER ERROR VOLTAGE FAILURE ........................26
P1610-VOLTAGE REGULATOR SIGNAL VOLTAGE TOO HIGH..................26
P1610-VOLTAGE REGULATOR SIGNAL VOLTAGE TOO LOW ..................26
P1680-EEPROM PLAUSIBILITY CHECKSUM ERROR .........................26
P1680-EEPROM PLAUSIBILITY CODE WORD INCORRECT OR MISSING ........26
P1680-EEPROM PLAUSIBILITY COMMUNICATION ERROR....................26
P1680-EEPROM PLAUSIBILITY VARIATION NUMBER ERROR .................26
P1680-EEPROM PLAUSIBILITY VIN CHECKSUM ERROR .....................26
P1680-EEPROM PLAUSIBILITY WRITE ERROR..............................26
P1685-SKIM SYSTEM INVALID SECRET KEY IN EEPROM.....................26
P1685-SKIM SYSTEM WRITE ACCESS TO EEPROM FAILURE .................26
P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH ......30
P0110-INTAKE AIR TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW.......33
P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO
HIGH .................................................................35
P0115-ENGINE COOLANT TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO
LOW..................................................................38
P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO HIGH.....40
P0190-FUEL PRESS SENSOR CIRCUIT MALF SIGNAL VOLTAGE TOO LOW .....44
P0190-FUEL PRESS SENSOR CIRCUIT MALF SUPPLY VOLTAGE TOO HIGH OR
LOW..................................................................46
P0201-CYLINDER 1-INJECTOR CIRCUIT CURRENT DECREASE ...............47
P0201-CYLINDER 1-INJECTOR CIRCUIT LOAD DROP........................47
P0201-CYLINDER 1-INJECTOR CIRCUIT OVERCURRENT HIGH SIDE...........47
P0201-CYLINDER 1-INJECTOR CIRCUIT OVERCURRENT LOW SIDE ...........47
P0202-CYLINDER 2-INJECTOR CIRCUIT CURRENT DECREASE ...............47
P0202-CYLINDER 2-INJECTOR CIRCUIT LOAD DROP........................47
P0202-CYLINDER 2-INJECTOR CIRCUIT OVERCURRENT HIGH SIDE...........47
P0202-CYLINDER 2-INJECTOR CIRCUIT OVERCURRENT LOW SIDE ...........47
P0203-CYLINDER 3-INJECTOR CIRCUIT CURRENT DECREASE ...............47
P0203-CYLINDER 3-INJECTOR CIRCUIT LOAD DROP........................47
P0203-CYLINDER 3-INJECTOR CIRCUIT OVERCURRENT HIGH SIDE...........47
P0203-CYLINDER 3-INJECTOR CIRCUIT OVERCURRENT LOW SIDE ...........47
P0204-CYLINDER 4-INJECTOR CIRCUIT CURRENT DECREASE ...............47
P0204-CYLINDER 4-INJECTOR CIRCUIT LOAD DROP........................47
P0204-CYLINDER 4-INJECTOR CIRCUIT OVERCURRENT HIGH SIDE...........47
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P0204-CYLINDER 4-INJECTOR CIRCUIT OVERCURRENT LOW SIDE ...........47
P0205-CYLINDER 5-INJECTOR CIRCUIT CURRENT DECREASE ...............47
P0205-CYLINDER 5-INJECTOR CIRCUIT LOAD DROP........................47
P0205-CYLINDER 5-INJECTOR CIRCUIT OVERCURRENT HIGH SIDE...........47
P0205-CYLINDER 5-INJECTOR CIRCUIT OVERCURRENT LOW SIDE ...........47
P0235-BOOST PRESSURE SENSOR PLAUSIBILITY..........................53
P0235-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO HIGH.............55
P0235-BOOST PRESSURE SENSOR SIGNAL VOLTAGE TOO LOW .............58
P0235-BOOST PRESSURE SENSOR SUPPLY VOLTAGE TOO HIGH OR LOW ....61
P0243-TURBOCHARGER WASTEGATE SOLENOID CIRCUIT OPEN CIRCUIT.....64
P0243-TURBOCHARGER WASTEGATE SOLENOID CIRCUIT SHORT CIRCUIT . . .67
P0335-CKP SENSOR CIRCUIT DYNAMIC PLAUSIBILITY ......................69
P0340-CMP/CKP POSITION SENSOR CIRCUIT - CKP DYNAMIC PLAUSIBILITY. . .71
P0340-CMP/CKP POSITION SENSOR CIRCUIT - CMP/CKP SYNC FAILURE ......74
P0340-CMP/CKP POSITION SENSOR CIRCUIT - SIGNAL FREQUENCY TOO
HIGH .................................................................77
P0340-CMP/CKP POSITION SENSOR CIRCUIT - STATIC PLAUSIBILITY .........77
P0380-GLOW PLUG 1 CONTROL CIRCUIT - OPEN CIRCUIT...................81
P0380-GLOW PLUG 1 CONTROL CIRCUIT - SHORT CIRCUIT .................81
P0382-GLOW PLUG 2 CONTROL CIRCUIT - OPEN CIRCUIT...................84
P0382-GLOW PLUG 2 CONTROL CIRCUIT - SHORT CIRCUIT .................84
P0403-EGR SOLENOID CIRCUIT NEGATIVE DEVIATION ......................87
P0403-EGR SOLENOID CIRCUIT OPEN CIRCUIT ............................89
P0403-EGR SOLENOID CIRCUIT SHORT CIRCUIT ...........................91
P0460-FUEL LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH...........93
P0460-FUEL LEVEL SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW ...........96
P0500-VEHICLE SPEED SENSOR FREQUENCY TOO HIGH ...................98
P0500-VEHICLE SPEED SENSOR HIGH LEVEL DURATION....................98
P0500-VEHICLE SPEED SENSOR PLAUSIBILITY ............................98
P0500-VEHICLE SPEED SENSOR SIGNAL VOLTAGE TOO HIGH ...............98
P0514-BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH.......101
P0514-BATTERY TEMP SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW .......103
P0520-OIL PRESS SENSOR CKT MALF SIGNAL VOLTAGE TOO HIGH .........105
P0520-OIL PRESS SENSOR CKT MALF SIGNAL VOLTAGE TOO LOW..........108
P0520-OIL PRESS SENSOR CKT MALF SUPPLY VOLTAGE TOO HIGH OR
LOW.................................................................110
P0530-A/C PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE TOO HIGH .......112
P0530-A/C PRESSURE SENSOR CIRCUIT SIGNAL VOLTAGE TOO LOW .......112
P0530-A/C PRESSURE SENSOR CIRCUIT SUPPLY VOLTAGE TOO HIGH OR
LOW.................................................................112
P0560-SYSTEM VOLTAGE TOO HIGH .....................................117
P0560-SYSTEM VOLTAGE TOO LOW .....................................119
P1536-GENERATOR FIELD CURRENT TOO HIGH...........................119
*CHECKING THE CHARGING SYSTEM OPERATION - DIESEL ................119
P0579-S/C SWITCH SIGNAL CIRCUIT PLAUSIBILITY ........................123
P0579-S/C SWITCH SIGNAL CIRCUIT SIGNAL VOLTAGE TOO HIGH...........125
P0579-S/C SWITCH SIGNAL CIRCUIT SIGNAL VOLTAGE TOO LOW ...........127
P0615-STARTER RELAY CIRCUIT SHORT CIRCUIT .........................129
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE DEVIATION
TOO HIGH............................................................131
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE DEVIATION
TOOLOW............................................................131
P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE TOO HIGH . . .131
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P0620-GENERATOR FIELD CONTROL MALF BATTERY VOLTAGE TOO LOW. . . .131
P0620-GENERATOR FIELD CONTROL MALF CHARGING VOLTS TOO LOW . . . .131
P0620-GENERATOR FIELD CONTROL MALF HIGH GENERATOR CURRENT . . . .131
P0620-GENERATOR FIELD CONTROL MALF OPEN CIRCUIT .................131
P0620-GENERATOR FIELD CONTROL MALF SHORT CIRCUIT................131
P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO HIGH..........135
P0641-SENSOR REFERENCE VOLTAGE A CKT VOLTAGE TOO LOW ..........137
P0645-A/C CLUTCH RELAY CIRCUIT OPEN CIRCUIT........................140
P0645-A/C CLUTCH RELAY CIRCUIT SHORT CIRCUIT ......................142
P0651-SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO HIGH..........144
P0651-SENSOR REFERENCE VOLTAGE B CKT VOLTAGE TOO LOW ..........146
P0685-ASD RELAY CONTROL CIRCUIT SHUTS OFF TOO EARLY .............149
P0685-ASD RELAY CONTROL CIRCUIT SHUTS OFF TOO LATE...............151
P0700-TRANS CONTROL 1-2/4-5 SOLENOID CIRCUIT.......................153
P0700-TRANS CONTROL 2-3 SOLENOID CIRCUIT ..........................153
P0700-TRANS CONTROL 3-4 SOLENOID CIRCUIT ..........................153
P0700-TRANS CONTROL INTERNAL CONTROLLER.........................153
P0700-TRANS CONTROL MOD. PRESS SOLENOID CIRCUIT .................153
P0700-TRANS CONTROL SHIFT PRESSURE SOLENOID CIRCUIT.............153
P0700-TRANS CONTROL SOLENOID SUPPLY VOLTAGE.....................153
P0700-TRANS CONTROL TCC SOLENOID CIRCUIT.........................153
P0702-TRANS CONTROL ABS SENSOR MESSAGE .........................153
P0702-TRANS CONTROL ENGINE T-CASE SWITCH MESSAGE ...............153
P0702-TRANS CONTROL IMPROPER GEAR ...............................153
P0702-TRANS CONTROL IMPROPER RATIO OR TRANSMISSION SLIPPING . . . .153
P0702-TRANS CONTROL INTERNAL SHIFTER FAILURE .....................153
P0702-TRANS CONTROL N2 OR N3 INPUT SENSOR CIRCUIT................153
P0702-TRANS CONTROL TCC FAULT.....................................153
P0703-BRAKE SWITCH SIGNAL CIRCUITS PLAUSIBILITY WITH REDUNDANT
CONTACT ............................................................154
P0703-BRAKE SWITCH SIGNAL CKTS PLAUS W/REDUNDANT CONTACT
AFTER INITIALIZATION .................................................154
P0836-TRANSFER CASE POSITION SENSOR PLAUSIBILITY .................158
P0836-TRANSFER CASE POSITION SENSOR PLAUSIBILITY 2 ...............158
P0836-TRANSFER CASE POSITION SENSOR SIGNAL VOLTAGE TOO HIGH. . . .158
P0836-TRANSFER CASE POSITION SENSOR SIGNAL VOLTAGE TOO LOW . . . .158
P0850-P/N SWITCH PLAUSIBILITY .......................................161
P1130-FUEL RAIL PRESSURE MALFUNCTION ACTUATOR STICKING..........163
P1130-FUEL RAIL PRESSURE MALFUNCTION LEAKAGE DETECTED..........163
P1130-FUEL RAIL PRESSURE MALFUNCTION POSITIVE DEVIATION ..........163
P1130-FUEL RAIL PRESSURE MALFUNCTION PRESSURE TOO HIGH-SHUT
OFF.................................................................163
P1130-FUEL RAIL PRESSURE MALFUNCTION PRESSURE TOO LOW .........163
P1130-FUEL RAIL PRESSURE MALFUNCTION SOLENOID OPEN .............163
P1131-FUEL PRESSURE SOLENOID OPEN CIRCUIT........................167
P1131-FUEL PRESSURE SOLENOID POWERSTAGE ERROR .................167
P1131-FUEL PRESSURE SOLENOID SHORT CIRCUIT.......................167
P1205-INJECTOR CLASSIFICATION ERROR ...............................171
P1205-INJECTOR CLASSIFICATION ERROR CHECKSUM ERROR.............171
P1235-EXTERNAL FUEL QUANTITY BIT ERROR............................172
P1235-EXTERNAL FUEL QUANTITY DEMAND ERROR.......................172
P1235-EXTERNAL FUEL QUANTITY PARITY ERROR ........................172
P1235-EXTERNAL FUEL QUANTITY TORQUE ERROR.......................172
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P1242-CAN BUS MESSAGE MISSING.....................................174
P1242-CAN BUS MESSAGE MISSING FROM TCM ..........................174
P1242-CAN BUS MUTE .................................................177
P1270-INTAKE PORT SWIRL ACTUATOR SHORT CIRCUIT ...................179
P1270-INTAKE PORT SWIRL ACTUATOR GROUND X........................181
P1270-INTAKE PORT SWIRL ACTUATOR OPEN CIRCUIT ....................182
P1499-HYDRAULIC COOLING FAN SOLENOID CIRCUIT OPEN CIRCUIT .......184
P1499-HYDRAULIC COOLING FAN SOLENOID CIRCUIT SHORT CIRCUIT ......187
P1511-BATTERY SENSE LINE 1 VOLTAGE TOO HIGH .......................189
P1511-BATTERY SENSE LINE 1 VOLTAGE TOO LOW .......................189
P1512-BATTERY SENSE LINE 2 VOLTAGE TOO HIGH .......................189
P1512-BATTERY SENSE LINE 2 VOLTAGE TOO LOW .......................189
P1605-IGNITION SWITCH PLAUSIBILITY ..................................192
P1643-VISCOUS HEATER RELAY OPEN CIRCUIT...........................194
P1643-VISCOUS HEATER RELAY SHORT CIRCUIT .........................194
P1651-MIL/DIAG LAMP VIA J1850 BUS IN FRAME RESPONSE ERROR ........197
P1651-MIL/DIAG LAMP VIA J1850 BUS STATUS ERROR .....................197
P1652-J1850 COMMUNICATION BUS LOST ARBITRATION ...................199
P1652-J1850 COMMUNICATION BUS RECEIVE TIMEOUT....................199
P1652-J1850 COMMUNICATION BUS SHORT TO GROUND ..................199
P1652-J1850 COMMUNICATION BUS SHORT TO VOLTAGE ..................199
P1652-J1850 COMMUNICATION BUS SPI ERROR...........................199
P1652-J1850 COMMUNICATION BUS TRANSMIT BUFFER OVERRUN..........199
P1652-J1850 COMMUNICATION BUS UNAUTHORIZED RESET ...............199
P1685-SKIM SYSTEM INVALID KEY CODE RECEIVED.......................202
P1685-SKIM SYSTEM KEY COMMUNICATION TIMED OUT ...................203
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY ................205
P2120-ACC PEDAL POSITION SENSOR 1 CKT PLAUSIBILITY WITH BRAKE
SWITCH..............................................................205
P2120-ACC PEDAL POSITION SENSOR 1 CKT SIGNAL VOLTAGE TOO HIGH . . .205
P2120-ACC PEDAL POSITION SENSOR 1 CKT SIGNAL VOLTAGE TOO LOW . . .205
P2120-ACC PEDAL POSITION SENSOR 1 CKT SUPPLY VOLTAGE TOO HIGH
ORLOW .............................................................205
P2125-ACC PEDAL POSITION SENSOR 2 CIRCUIT PLAUSIBILITY
(WITH SENSOR 1 CIRCUIT) .............................................205
P2125-ACC PEDAL POSITION SENSOR 2 CKT SIGNAL VOLTAGE TOO HIGH . . .205
P2125-ACC PEDAL POSITION SENSOR 2 CKT SUPPLY VOLTAGE TOO HIGH
ORLOW .............................................................205
*A/C INOPERATIVE ....................................................212
*A/C OPERATES IN ALL MODE SWITCH POSITIONS ........................215
*CHECKING THE ACCELERATOR PEDAL POSITION SENSOR CALIBRATION . . .217
*CHECKING THE BOOST PRESSURE SENSOR CALIBRATION................218
*CHECKING THE ECM POWER AND GROUND CIRCUITS....................219
*CHECKING THE EGR SYSTEM..........................................220
*CHECKING THE ENGINE COOLANT TEMPERATURE SENSOR CALIBRATION . .221
*CHECKING THE ENGINE MECHANICAL SYSTEMS.........................222
*CHECKING THE GLOW PLUG OPERATION ...............................223
*CHECKING THE PARK NEUTRAL SWITCH SIGNAL.........................225
*CHECKING THE SPEED CONTROL OPERATION...........................227
*CHECKING THE TRANSFER CASE POSITION SENSOR.....................229
*CHECKING THE VISCOUS/CABIN HEATER RELAY .........................230
*CHECKING THE WATER IN FUEL LAMP OPERATION.......................232
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*ENGINE CRANKS BUT WILL NOT START .................................234
*ENGINE WILL NOT CRANK .............................................238
SENTRY KEY IMMOBILIZER
ANTENNA FAILURE ....................................................241
COP FAILURE.........................................................241
EEPROM FAILURE.....................................................241
INTERNAL FAULT......................................................241
RAM FAILURE.........................................................241
SERIAL LINK INTERNAL FAULT ..........................................241
STACK OVERFLOW FAILURE............................................241
PCM STATUS FAILURE .................................................243
SERIAL LINK EXTERNAL FAULT .........................................243
ROLLING CODE FAILURE...............................................245
VIN MISMATCH........................................................245
TRANSPONDER COMMUNICATION FAILURE ..............................247
TRANSPONDER CYCLIC REDUNDANCY CHECK (CRC) FAILURE .............247
TRANSPONDER ID MISMATCH ..........................................247
TRANSPONDER RESPONSE MISMATCH..................................247
VERIFICATION TESTS
VERIFICATION TESTS..................................................250
8.0 COMPONENT LOCATIONS..............................................255
8.1 CONTROL MODULES .............................................255
8.2 CONTROLS AND SOLENOIDS ......................................255
8.3 DATA LINK CONNECTOR ..........................................256
8.4 FUEL SYSTEM ...................................................256
8.5 SENSORS .......................................................256
8.6 SWITCHES ......................................................258
9.0 CONNECTOR PINOUTS ................................................259
A/C COMPRESSOR CLUTCH - BLACK 2 WAY ..............................259
A/C PRESSURE TRANSDUCER - BLACK 4 WAY............................259
ACCELERATOR PEDAL POSITION SENSOR (DIESEL) - BLACK 10 WAY........259
BATTERY TEMPERATURE SENSOR - BLACK 2 WAY ........................259
BOOST PRESSURE SENSOR (DIESEL) - BLACK 3 WAY .....................260
BRAKE LAMP SWITCH - GRAY 6 WAY ....................................260
CAMSHAFT POSITION SENSOR (DIESEL) - BLACK 3 WAY...................260
CRANKSHAFT POSITION SENSOR (DIESEL) - BLACK 2 WAY ................260
DATA LINK CONNECTOR - BLACK 16 WAY ................................261
EGR SOLENOID (DIESEL) - BLACK 2 WAY ................................261
ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY..................262
ENGINE CONTROL MODULE C2 (DIESEL) - BLACK 40 WAY..................263
ENGINE COOLANT TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY .......263
ENGINE OIL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY .................264
FUEL INJECTOR NO. 1 (DIESEL) - BLACK 2 WAY...........................264
FUEL INJECTOR NO. 2 (DIESEL) - BLACK 2 WAY...........................264
FUEL INJECTOR NO. 3 (DIESEL) - BLACK 2 WAY...........................264
FUEL INJECTOR NO. 4 (DIESEL) - BLACK 2 WAY...........................264
FUEL INJECTOR NO. 5 (DIESEL) - BLACK 2 WAY...........................265
FUEL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY.......................265
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FUEL PRESSURE SOLENOID (DIESEL) - BLACK 2 WAY .....................265
FUEL TANK MODULE (DIESEL) - BLACK 6 WAY ............................265
GENERATOR (DIESEL) - LT. GRAY 2 WAY .................................266
INTAKE AIR TEMPERATURE SENSOR (DIESEL) - BLACK 2 WAY..............266
INTAKE PORT SWIRL ACTUATOR (DIESEL) - BLACK 3 WAY..................266
MASS AIR FLOW SENSOR (DIESEL) - BLACK 5 WAY........................266
FUSES (DIESEL) ......................................................268
A/C COMPRESSOR CLUTCH RELAY (DIESEL) .............................268
AUTO SHUT DOWN RELAY (DIESEL) .....................................268
ENGINE STARTER MOTOR RELAY (DIESEL)...............................269
GLOW PLUG RELAY NO. 1 (DIESEL) .....................................269
GLOW PLUG RELAY NO. 2 (DIESEL) .....................................269
VISCOUS/CABIN HEATER RELAY (DIESEL)................................269
SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY ......................270
SPEED CONTROL SWITCH NO. 1 - BLACK 4 WAY..........................270
SPEED CONTROL SWITCH NO. 2 - BLACK 4 WAY..........................270
TRANSFER CASE POSITION SENSOR - BLACK 2 WAY......................270
TRANSMISSION CONTROL MODULE C1 (DIESEL) - BLACK 18 WAY...........271
VISCOUS/CABIN HEATER (DIESEL) - BLACK 2 WAY ........................271
WASTEGATE SOLENOID (DIESEL)-2WAY................................271
WATER IN FUEL SENSOR (DIESEL) - BLACK 3 WAY ........................271
10.0 SCHEMATIC DIAGRAMS................................................273
10.1 ENGINE CONTROL MODULE .......................................273
11.0 CHARTS AND GRAPHS ................................................275
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1.0 INTRODUCTION
The procedures contained in this manual include
all specifications, instructions and graphics needed
to diagnose engine control module (ECM) and sen-
try key immobilizer system (SKIS) problems; they
are no start, diagnostic trouble code (DTC) and no
trouble code problems for the ECM. The diagnostics
in this manual are based on the trouble condition or
symptom being present at the time of diagnosis.
When repairs are required, refer to the appropri-
ate service information for the proper removal and
repair procedure.
Diagnostic procedures change every year. New
diagnostic systems may be added; carryover sys-
tems may be enhanced. IT IS RECOMMENDED
THAT YOU REVIEW THE ENTIRE MANUAL TO
BECOME FAMILIAR WITH ALL NEW AND
CHANGED DIAGNOSTIC PROCEDURES.
This manual will cover all the necessary require-
ments to begin a logical diagnostic path for each
problem. If there is a diagnostic trouble code (DTC)
detected, go to the trouble code test. If there are no
DTCs present, go to a no trouble code (*), symptom
based test.
This book reflects many suggested changes from
readers of past issues. After using this book, if you
have any comments or recommendations, please fill
out the form at the back of the book and mail it back
to us.
1.1 SYSTEM COVERAGE
This diagnostic procedures manual covers all
2002 WG body vehicles equipped with the 2.7L
direct injection diesel engine.
1.2 SIX-STEP TROUBLESHOOTING
PROCEDURE
Diagnosis of the engine control module (ECM)
and sentry key immobilizer system (SKIS) is done
in six basic steps:
•verification of complaint
•verification of any related symptom
•symptom analysis
•problem isolation
•repair of isolated problem
•verification of proper operation
NOTE: All tests in this manual should be per-
formed with the engine at operating temperature,
unless specified within a particular test.
2.0 IDENTIFICATION OF
SYSTEM
The ECM is located in the left side of the engine
compartment attached to the left inner fender be-
hind the battery. The sentry key immobilizer mod-
ule (SKIM) is located below the steering column
behind the steering wheel.
3.0 SYSTEM DESCRIPTION AND
FUNCTIONAL OPERATION
3.1 GENERAL DESCRIPTION
The 2.7L direct injection diesel engine system is
equipped with the latest in technical advances. The
on-board diagnostics incorporated in the engine
control module and SKIM are intended to assist the
field technician in repairing vehicle problems by the
quickest means.
The engine system incorporates a common rail
fuel delivery design. This design utilizes electroni-
cally controlled solenoid valve type fuel injectors.
Each injector is controlled individually by the ECM.
Injector timing and fuel quantity are controlled by
the ECM based on inputs from the various sensors.
The precision control of the injectors by the ECM
helps to reduce the engine noise, odor and smoke.
3.2 FUNCTIONAL OPERATION
3.2.1 ECM ON-BOARD DIAGNOSTICS
The ECM has been programmed to monitor many
different circuits of the diesel fuel injection system.
This monitoring is called on-board diagnostics.
Certain criteria must be met for a trouble code to
be entered into the ECM memory. The criteria may
be a range of: engine rpm, engine temperature, time
or other input signals to the ECM. If all of the
criteria for monitoring a system or circuit are met,
and a problem is sensed, then a DTC will be stored
in the ECM memory.
It is possible that a DTC for a monitored circuit
may not be entered into the ECM memory, even
though a malfunction has occurred. This may hap-
pen when the monitoring criteria has not been met.
The ECM compares input signal voltages from
each input device with specifications (the estab-
lished high and low limits of the input range) that
are programmed into it for that device. If the input
voltage is not within the specifications and other
trouble code criteria are met, a DTC will be stored
in the ECM memory.
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GENERAL INFORMATION
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3.2.2 ECM OPERATING MODES
As input signals to the ECM change, the ECM
adjusts its response to the output devices. For
example, the ECM must calculate a different fuel
quantity and fuel timing for engine idle condition
than it would for a wide open throttle condition.
There are several different modes of operation that
determine how the ECM responds to the various
input signals.
Ignition Switch On (Engine Off)
When the ignition switch is turned on, the ECM
activates the glow plug relay for a time period that
is determined by engine coolant temperature, atmo-
spheric temperature and battery voltage.
Engine Start-up Mode
The ECM uses the engine temperature sensor
and the crankshaft position sensor (engine speed)
inputs to determine fuel injection quantity.
Normal Driving Modes
Engine idle, warm-up, acceleration, deceleration
and wide open throttle modes are controlled based
on all of the sensor inputs to the ECM. The ECM
uses these sensor inputs to adjust fuel quantity and
fuel injector timing.
Overheat Protection Mode
If the engine temperature is above 105°C (221°F)
engine speed above 1000 rpm and vehicle speed is
above 30 km/h (19 MPH) the ECM will limit fuel
quantity for engine protection.
Limp-In Mode
If there is a fault detected with the accelerator
pedal position sensor, the ECM will set the engine
speed at 1100 RPM.
Overspeed Protection Mode
If the ECM detects engine RPM that exceeds
5000 RPM, the ECM will shut off fuel to the
injectors until engine RPM falls below 4850. (ADTC
does not set for engine overspeed. However, the
DRBIIItis able to display the absolute maximum
engine RPM, coolant temperature and vehicle speed
that the ECM has detected during the life of the
ECM).
After-Run Mode
The ECM transfers RAM information to ROM
and performs an Input/Output state check.
3.2.3 MONITORED CIRCUITS
The ECM is able to monitor and identify most
driveability related trouble conditions. Some cir-
cuits are directly monitored through ECM feedback
circuitry. In addition, the ECM monitors the voltage
state of some circuits and compares those states
with expected values. Other systems are monitored
indirectly when the ECM conducts a rationality test
to identify problems.
Although most subsystems of the engine control
module are either directly or indirectly monitored,
there may be occasions when diagnostic trouble
codes are not immediately identified. For a trouble
code to set, a specific set of conditions must occur
and unless these conditions occur, a DTC will not
set.
3.2.4 SKIS OVERIVEW
The sentry key immobilizer system (SKIS) is
designed to prevent unauthorized vehicle opera-
tion. The system consists of a sentry key immobi-
lizer module (SKIM), ignition key(s) equipped with
a transponder chip and the ECM. When the ignition
switch is turned on, the SKIM interrogates the
ignition key. If the ignition key is Valid or Invalid,
the SKIM sends a J1850 Bus message to the ECM
indicating ignition key status. Upon receiving this
message the ECM will terminate engine operation
or allow the engine to continue to operate.
3.2.5 SKIS ON-BOARD DIAGNOSTICS
The sentry key immobilizer module (SKIM) has
been programmed to transmit and monitor many
different coded messages as well as J1850 Bus
messages. This monitoring is called On-Board Di-
agnostics. Certain criteria must be met for a DTC to
be entered into SKIM memory. The criteria may be
a range of; input voltage, J1850 Bus message or
coded messages to the SKIM. If all of the criteria for
monitoring a circuit or function are met and a fault
is detected, a DTC will be stored in the SKIM
memory.
3.2.6 SKIS OPERATION
When ignition power is supplied to the SKIM, the
SKIM performs an internal self-test. After the self-
test is complete, the SKIM energizes the antenna
(this activates the transponder chip) and sends a
challenge to the transponder chip. The transponder
chip responds to the challenge by generating an
encrypted response message using the following:
Secret Key - an electronically stored value (identi-
fication number) that is unique to each SKIS. The
secret key is stored in the SKIM, ECM and all
ignition key transponders.
Challenge - a random number that is generated by
the SKIM at each ignition key cycle.
The secret key and challenge are the two vari-
ables used in the algorithm that produces the
encrypted response message. The transponder uses
the crypto algorithm to receive, decode and respond
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GENERAL INFORMATION
ProCarManuals.com
to the message sent by SKIM. After responding to
the coded message, the transponder sends a tran-
sponder ID message to the SKIM. The SKIM com-
pares the transponder ID message to the available
valid key codes in SKIM memory (8 key maximum
at any one time). After validating the ignition key,
the SKIM sends a J1850 Bus message called a seed
request to the ECM, then waits for the ECM re-
sponse. If the ECM does not respond, the SKIM will
send the seed request again. After twenty failed
attempts, the SKIM will stop sending the seed
request and store a trouble code in memory. If the
ECM sends a seed response, the SKIM sends a
valid/invalid key message to the ECM. This is an
encrypted message that is generated using the
following:
•VIN - Vehicle Identification Number.
•Seed - a random number that is generated by the
ECM at each ignition key cycle.
The VIN and seed are two variables used in the
rolling code algorithm that encrypts the valid/
invalid key message. The ECM uses the rolling code
algorithm to receive, decode and respond to the
valid/invalid key message sent by the SKIM. After
sending the valid/invalid key message, the SKIM
waits 3.5 seconds for an ECM status message from
the ECM. If the ECM does not respond with a valid
key message to the SKIM, a fault is detected and a
code is stored.
The SKIS incorporates a warning lamp located in
the instrument cluster. The lamp receives switched
ignition voltage and is hardwired to the instrument
cluster. The SKIS lamp is actuated when the SKIM
sends a J1850 Bus message to the instrument
cluster requesting the lamp on, off or flashing. The
instrument cluster then provides the ground for the
lamp.
The SKIM will request lamp operation for the
following:
– bulb check at ignition on
– to alert the vehicle operator to a SKIS malfunc-
tion
– when the SKIM is in customer key programming
mode
For all faults except transponder faults the lamp
remains on steady. In the event of a transponder
fault the lamp will flash at a rate of 1Hz (once per
second). If a fault is present, the lamp will remain
on or flashing for the complete ignition cycle. If a
fault is stored in SKIM memory which prevents the
system from operating properly, the ECM will allow
the engine to start and idle for 2 seconds then stall.
This may occur up to six times. After the sixth
attempt, the ECM prevents the engine from crank-
ing until the fault is corrected.
3.3 DIAGNOSTIC TROUBLE CODES
Each diagnostic trouble code (DTC) is diagnosed
by following a specific procedure. The diagnostic
test procedure contains step-by-step instruction for
determining the cause of the DTC as well as no
trouble code problems. It is not necessary to per-
form all of the tests in this book to diagnose an
individual code.
Always begin diagnosis by reading the DTCs
using the DRBIIIt. This will direct you to the
specific test(s) that must be performed.
3.3.1 HARD CODE
A DTC that comes back within one cycle of the
ignition key is a hard code. This means that the
problem is current every time the ECM/SKIM
checks that circuit or function. Procedures in this
manual verify if the DTC is a hard code at the
beginning of each test. When the fault is not a hard
code, an intermittent test must be performed.
NOTE: If the DRBIIItdisplays faults for multiple
components (i.e. ECT, VSS, IAT sensors) identify
and check the shared circuits for possible problems
before continuing (i.e. sensor grounds or 5-volt
supply circuits). Refer to the appropriate schematic
to identify shared circuits.
3.3.2 INTERMITTENT CODE
A DTC that is not current every time the ECM/
SKIM checks the circuit or function is an intermit-
tent code. Most intermittent DTCs are caused by
wiring or connector problems. Problems that come
and go like this are the most difficult to diagnose;
they must be looked for under specific conditions
that cause them. The following checks may assist
you in identifying a possible intermittent problem.
•Visually inspect the related wire harness connec-
tors. Look for broken, bent, pushed out, or cor-
roded terminals.
•Visually inspect the related wire harness. Look
for chafed, pierced, or partially broken wire.
•Refer to hotlines or technical service bulletins
that may apply.
NOTE: Electromagnetic (radio) interference can
cause an intermittent system malfunction. This
interference can interrupt communication between
the ignition key transponder and the SKIM.
3.3.3 ECM DIAGNOSTIC TROUBLE CODES
IMPORTANT NOTE: Before replacing the ECM
for a failed driver, control circuit or ground circuit,
be sure to check the related component/circuit in-
tegrity for failures not detected due to a double fault
in the circuit. Most ECM driver/control circuit fail-
ures are caused by internal failures to components
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GENERAL INFORMATION
ProCarManuals.com
(i.e. relays and solenoids) and shorted circuits (i.e.
sensor pull-ups, drivers and ground circuits). These
faults are difficult to detect when a double fault has
occurred and only one DTC has set.
If the DRBIIItdisplays faults for multiple com-
ponents (i.e. VSS, ECT, Batt Temp, etc.), identify
and check the shared circuits for possible problems
before continuing (i.e. sensor grounds or 5-volt
supply circuits). Refer to the appropriate wiring
diagrams to identify shared circuits.
A/C CLUTCH RELAY CIRCUIT OPEN CIRCUIT
A/C CLUTCH RELAY CIRCUIT SHORT CIR-
CUIT
A/C PRESSURE SENSOR CIRCUIT SIGNAL
VOLTAGE TOO HIGH
A/C PRESSURE SENSOR CIRCUIT SIGNAL
VOLTAGE TOO LOW
A/C PRESSURE SENSOR CIRCUIT SUPPLY
VOLTAGE TOO HIGH OR LOW
ACC PEDAL POSITION SENSOR 1 CKT PLAU-
SIBILITY WITH BRAKE SWITCH
ACC PEDAL POSITION SENSOR 1 CKT SIG-
NAL VOLTAGE TOO HIGH
ACC PEDAL POSITION SENSOR 1 CKT SUP-
PLY VOLTAGE TOO HIGH OR LOW
ACC PEDAL POSITION SENSOR 2 CKT PO-
TENTIOMETER PLAUSIBILITY 1/2
ACC PEDAL POSITION SENSOR 2 CKT SIG-
NAL VOLTAGE TOO HIGH
ACC PEDAL POSITION SENSOR 2 CKT SUP-
PLY VOLTAGE TOO HIGH OR LOW
A/D CONVERTER ERROR 5 VOLT SUPPLY
FAILURE
A/D CONVERTER ERROR GROUND TO APP
FAILURE
A/D CONVERTER ERROR RAM TEST FAIL-
URE
AFTER RUN SHUT OFF ERROR-INJ. POWER-
STAGE
AFTER RUN SHUT OFF ERROR-ZERO QUAN-
TITY
AMBIENT AIR TEMPERATURE CIRCUIT SIG-
NAL VOLTAGE TOO HIGH
AMBIENT AIR TEMPERATURE CIRCUIT SIG-
NAL VOLTAGE TOO LOW
ASD RELAY CONTROL CIRCUIT SHUTS OFF
TOO EARLY
ASD RELAY CONTROL CIRCUIT SHUTS OFF
TOO LATE
BAROMETRIC PRESSURE CIRCUIT SIGNAL
VOLTAGE TOO HIGH
BAROMETRIC PRESSURE CIRCUIT SIGNAL
VOLTAGE TOO LOW
BATTERY SENSE LINE 1 VOLTAGE TOO
HIGH
BATTERY SENSE LINE 1 VOLTAGE TOO LOW
BATTERY SENSE LINE 2 VOLTAGE TOO
HIGH
BATTERY SENSE LINE 2 VOLTAGE TOO LOW
BATTERY TEMP SENSOR CIRCUIT SIGNAL
VOLTAGE TOO HIGH
BATTERY TEMP SENSOR CIRCUIT SIGNAL
VOLTAGE TOO LOW
BOOST PRESSURE SENSOR PLAUSIBILITY
BOOST PRESSURE SENSOR SIGNAL VOLT-
AGE TOO HIGH
BOOST PRESSURE SENSOR SIGNAL VOLT-
AGE TOO LOW
BOOST PRESSURE SENSOR SUPPLY VOLT-
AGE TOO HIGH OR LOW
BRAKE SWITCH SIGNAL CIRCUITS PLAUSI-
BILITY AFTER INIT.
BRAKE SWITCH SIGNAL CIRCUITS PLAUSI-
BILITY WITH REDUNDANT CONTACT
CALCULATED INJECTOR VOLTAGE TOO
HIGH
CAN BUS MESSAGE MISSING FROM TCM
CAN BUS MUTE
CAN BUS OPEN
CAPACITOR VOLTAGE 1 VOLTAGE TOO HIGH
CAPACITOR VOLTAGE 1 VOLTAGE TOO LOW
CKP POSITION SENSOR CIRCUIT DYNAMIC
PLAUSIBILITY
CMP POSITION SENSOR CIRCUIT CMP/CKP
SYNC FAILURE
CMP POSITION SENSOR CIRCUIT DYNAMIC
PLAUSIBILITY
CMP POSITION SENSOR CIRCUIT SIGNAL
FREQUENCY TOO HIGH
CMP POSITION SENSOR CIRCUIT STATIC
PLAUSIBILITY
CYLINDER 1-INJECTOR CIRCUIT CURRENT
DECREASE
CYLINDER 1-INJECTOR CIRCUIT LOAD
DROP
CYLINDER 1-INJECTOR CIRCUIT OVERCUR-
RENT HIGH SIDE
CYLINDER 1-INJECTOR CIRCUIT OVERCUR-
RENT LOW SIDE
CYLINDER 2-INJECTOR CIRCUIT CURRENT
DECREASE
CYLINDER 2-INJECTOR CIRCUIT LOAD
DROP
CYLINDER 2-INJECTOR CIRCUIT OVERCUR-
RENT HIGH SIDE
CYLINDER 2-INJECTOR CIRCUIT OVERCUR-
RENT LOW SIDE
CYLINDER 3-INJECTOR CIRCUIT CURRENT
DECREASE
CYLINDER 3-INJECTOR CIRCUIT LOAD
DROP
CYLINDER 3-INJECTOR CIRCUIT OVERCUR-
RENT HIGH SIDE
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GENERAL INFORMATION
ProCarManuals.com
CYLINDER 3-INJECTOR CIRCUIT OVERCUR-
RENT LOW SIDE
CYLINDER 4-INJECTOR CIRCUIT CURRENT
DECREASE
CYLINDER 4-INJECTOR CIRCUIT LOAD
DROP
CYLINDER 4-INJECTOR CIRCUIT OVERCUR-
RENT HIGH SIDE
CYLINDER 4-INJECTOR CIRCUIT OVERCUR-
RENT LOW SIDE
CYLINDER 5-INJECTOR CIRCUIT CURRENT
DECREASE
CYLINDER 5-INJECTOR CIRCUIT LOAD
DROP
CYLINDER 5-INJECTOR CIRCUIT OVERCUR-
RENT HIGH SIDE
CYLINDER 5-INJECTOR CIRCUIT OVERCUR-
RENT LOW SIDE
ECM ERROR GATE ARRAY - COMMUNICA-
TION
ECM ERROR GATE ARRAY - QUANTITY STOP
ECM ERROR RECOVERY HAS OCCURRED
ECM ERROR REDUNDANT OVERRUN MONI-
TORING
EEPROM PLAUSIBILITY CHECKSUM ER-
ROR
EEPROM PLAUSIBILITY CODE WORD IN-
CORRECT OR MISSING
EEPROM PLAUSIBILITY COMMUNICATION
ERROR
EEPROM PLAUSIBILITY VARIATION NUM-
BER ERROR
EEPROM PLAUSIBILITY VIN CHECKSUM
ERROR
EEPROM PLAUSIBILITY WRITE ERROR
EGR SOLENOID CIRCUIT NEGATIVE DEVIA-
TION
EGR SOLENOID CIRCUIT OPEN CIRCUIT
EGR SOLENOID CIRCUIT SHORT CIRCUIT
ENGINE COOLANT TEMP SENSOR CIRCUIT
SIGNAL VOLTAGE TOO HIGH
ENGINE COOLANT TEMP SENSOR CIRCUIT
SIGNAL VOLTAGE TOO LOW
EXTERNAL FUEL QUANTITY ACCESS DE-
MAND NOT PLAUSIBLE
EXTERNAL FUEL QUANTITY ACCESS PAR-
ITY
EXTERNAL FUEL QUANTITY ACCESS TOG-
GLE BIT
EXTERNAL FUEL QUANTITY ACCESS
TORQUE
FUEL LEVEL SENSOR CIRCUIT SIGNAL
VOLTAGE TOO HIGH
FUEL LEVEL SENSOR CIRCUIT SIGNAL
VOLTAGE TOO LOW
FUEL PRESS SENSOR CIRCUIT MALF SIG-
NAL VOLTAGE TOO HIGH
FUEL PRESS SENSOR CIRCUIT MALF SIG-
NAL VOLTAGE TOO LOW
FUEL PRESS SENSOR CIRCUIT MALF SUP-
PLY VOLTAGE TOO HIGH OR LOW
FUEL PRESSURE SOLENOID OPEN CIRCUIT
FUEL PRESSURE SOLENOID POWER STAGE
ERROR
FUEL PRESSURE SOLENOID SHORT CIR-
CUIT
FUEL RAIL PRESSURE MALFUNCTION AC-
TUATOR STICKING
FUEL RAIL PRESSURE MALFUNCTION
LEAKAGE DETECTED
FUEL RAIL PRESSURE MALFUNCTION POS-
ITIVE DEVIATION AT ENGINE SPEED TOO
HIGH
FUEL RAIL PRESSURE MALFUNCTION
PRESSURE TOO HIGH - SHUT OFF
FUEL RAIL PRESSURE MALFUNCTION
PRESSURE TOO LOW
GENERATOR FIELD CONTROL MALF BAT-
TERY VOLTAGE DEVIATION TOO HIGH
GENERATOR FIELD CONTROL MALF BAT-
TERY VOLTAGE DEVIATION TOO LOW
GENERATOR FIELD CONTROL MALF BAT-
TERY VOLTAGE TOO HIGH
GENERATOR FIELD CONTROL MALF BAT-
TERY VOLTAGE TOO LOW
GENERATOR FIELD CONTROL MALF HIGH
GENERATOR CURRENT
GENERATOR FIELD CONTROL MALF OPEN
CIRCUIT
GENERATOR FIELD CONTROL MALF SHORT
CIRCUIT
GENERATOR FIELD CURRENT TOO HIGH
GLOW PLUG 1 CONTROL CIRCUIT OPEN
CIRCUIT
GLOW PLUG 1 CONTROL CIRCUIT SHORT
CIRCUIT
GLOW PLUG 2 CONTROL CIRCUIT OPEN
CIRCUIT
GLOW PLUG 2 CONTROL CIRCUIT SHORT
CIRCUIT
HYDRAULIC COOLING FAN SOLENOID
OPEN CIRCUIT
HYDRAULIC COOLING FAN SOLENOID
SHORT CIRCUIT
IGNITION SWITCH PLAUSIBILITY
INJECTOR CLASSSIFICATION ERROR
CHECKSUM ERROR
INJECTOR CLASSIFICATION ERROR IN-
VALID INJECTOR CLASS
INTAKE AIR TEMPERATURE SENSOR CIR-
CUIT SIGNAL VOLTAGE TOO HIGH
INTAKE AIR TEMPERATURE SENSOR CIR-
CUIT SIGNAL VOLTAGE TOO LOW
INTAKE PORT SWIRL ACTUATOR INTERNAL
FAULT
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GENERAL INFORMATION
ProCarManuals.com
INTAKE PORT SWIRL ACTUATOR OPEN CIR-
CUIT
INTAKE PORT SWIRL ACTUATOR SHORT
CIRCUIT
J1850 COMMUNICATION BUS LOST ARBI-
TRATION
J1850 COMMUNICATION BUS RECEIVE TIM-
EOUT
J1850 COMMUNICATION BUS SHORT TO
GROUND
J1850 COMMUNICATION BUS SHORT TO
VOLTAGE
J1850 COMMUNICATION BUS SPI ERROR
J1850 COMMUNICATION BUS TRANSMIT
BUFFER OVERRUN
J1850 COMMUNICATION BUS UNAUTHO-
RIZED RESET
MASS AIR FLOW SENSOR SIGNAL VOLTAGE
TOO HIGH
MASS AIR FLOW SENSOR SIGNAL VOLTAGE
TOO LOW
MASS AIR FLOW SENSOR SUPPLY VOLTAGE
TOO HIGH OR LOW
MIL/DIAG LAMP VIA J1850 BUS - IN FRAME
RESPONSE ERROR
MIL/DIAG LAMP VIA J1850 BUS - STATUS
ERROR
OIL PRESS SENSOR CKT MALF SIGNAL
VOLTAGE TOO HIGH
OIL PRESS SENSOR CKT MALF SIGNAL
VOLTAGE TOO LOW
OIL PRESS SENSOR CKT MALF SUPPLY
VOLTAGE TOO HIGH OR LOW
P/N SWITCH CIRCUIT RATIONALITY PLAU-
SIBILITY
S/C SWITCH SIGNAL CIRCUIT PLAUSIBILITY
S/C SWITCH SIGNAL CIRCUIT SIGNAL VOLT-
AGE TOO HIGH
S/C SWITCH SIGNAL CIRCUIT SIGNAL VOLT-
AGE TOO LOW
SENSOR REFERENCE VOLTAGEACKT VOLT-
AGE TOO HIGH
SENSOR REFERENCE VOLTAGEACKT VOLT-
AGE TOO LOW
SENSOR REFERENCE VOLTAGE B CKT
VOLTAGE TOO HIGH
SENSOR REFERENCE VOLTAGE B CKT
VOLTAGE TOO LOW
SKIM SYSTEM INVALID KEY CODE RE-
CEIVED
SKIM SYSTEM INVALID SECRET KEY IN EE-
PROM
SKIM SYSTEM KEY COMMUNICATION
TIMED OUT
SKIM SYSTEM WRITE ACCESS TO EEPROM
FAILURE
STARTER RELAY CIRCUIT SHORT CIRCUIT
SYSTEM VOLTAGE TOO HIGH
SYSTEM VOLTAGE TOO LOW
TRANSFER CASE POSITION SENSOR PLAU-
SIBILITY
TRANSFER CASE POSITION SENSOR PLAU-
SIBILITY 2
TRANSFER CASE POSITION SENSOR SIG-
NAL VOLTAGE TOO HIGH
TRANSFER CASE POSITION SENSOR SIG-
NAL VOLTAGE TOO LOW
TRANS CONTROL INTERNAL CONTROLLER
TRANS CONTROL 1-2/4-5 SOLENOID CIR-
CUIT
TRANS CONTROL 2-3 SOLENOID CIRCUIT
TRANS CONTROL 3-4 SOLENOID CIRCUIT
TRANS CONTROL TCC SOLENOID CIRCUIT
TRANS CONTROL MOD. PRESS SOLENOID
CIRCUIT
TRANS CONTROL SHIFT PRESSURE SOLE-
NOID CIRCUIT
TRANS CONTROL SOLENOID SUPPLY VOLT-
AGE
TRANS CONTROL N2 OR N3 INPUT SENSOR
CIRCUIT
TRANS CONTROL INTERNAL SHIFT FAIL-
URE
TRANS CONTROL ABS SENSOR MESSAGE
TRANS CONTROL IMPROPER RATIO OR
TRANSMISSION SLIPPING
TRANS CONTROL ENGINE T-CASE SWITCH
MESSAGE
TRANS CONTROL TCC FAULT
TRANS CONTROL IMPROPER GEAR
TURBOCHARGER WASTEGATE SOL CKT
NEGATIVE DEVIATION
TURBOCHARGER WASTEGATE SOL CKT
OPEN CIRCUIT
TURBOCHARGER WASTEGATE SOL CKT
POSITIVE DEVIATION
TURBOCHARGER WASTEGATGE SOL CKT
SHORT CIRCUIT
VEHICLE SPEED SENSOR FREQUENCY TOO
HIGH
VEHICLE SPEED SENSOR PLAUSIBILITY
VEHICLE SPEED SENSOR SIGNAL VOLTAGE
TOO HIGH
VISCOUS HEATER OPEN CIRCUIT
VISCOUS HEATER SHORT CIRCUIT
VOLTAGE REGULATOR SIGNAL VOLTAGE
TOO HIGH
VOLTAGE REGULATOR SIGNAL VOLTAGE
TOO LOW
3.3.4 SKIM DIAGNOSTIC TROUBLE
CODES
ANTENNA FAILURE
COP FAILURE
EEPROM FAILURE
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GENERAL INFORMATION
ProCarManuals.com
INTERNAL FAULT
PCM STATUS FAILURE
RAM FAILURE
ROLLING CODE FAILURE
SERIAL LINK EXTERNAL FAULT
SERIAL LINK INTERNAL FAULT
STACK OVERFLOW FAILURE
TRANSPONDER COMMUNICATION FAILURE
TRANSPONDER CRC (CYCLIC REDUN-
DANCY CHECK) FAILURE
TRANSPONDER ID MISMATCH
TRANSPONDER RESPONSE MISMATCH
VIN MISMATCH
3.3.5 HANDLING NO TROUBLE CODE
PROBLEMS
After reading Section 3.0 (System Description
and Functional Operation), you should have a bet-
ter understanding of the theory and operation of the
on-board diagnostics and how this relates to the
diagnosis of a vehicle that may have a driveability-
related symptom or complaint. When there are no
trouble codes present, refer to the no trouble code
(*) tests.
3.4 USING THE DRBIIIT
Refer to the DRBIIItuser’s guide for instructions
and assistance with reading the DTCs, erasing the
DTCs, lab scope usage and other DRBIIItfunc-
tions.
3.4.1 DRBIIITDOES NOT POWER UP
If the LEDs do not light or no sound is emitted at
start up, check for loose cable connections or a bad
cable. Check the vehicle battery voltage at data link
connector cavity 16. A minimum of 11.0 volts is
required to adequately power the DRBIIIt. Check
for proper ground connection at data link connector
cavities 4 and 5.
If all connections are proper between the
DRBIIItand the vehicle or other devices, and the
vehicle battery is fully charged, an inoperative
DRBIIItmay be the result of a faulty cable or
vehicle wiring. For a blank screen, refer to the
appropriate diagnostic manual.
3.4.2 DISPLAY IS NOT VISIBLE
Low temperatures will affect the visibility of the
display. Adjust the contrast to compensate for this
condition.
4.0 DISCLAIMERS, SAFETY,
WARNINGS
4.1 DISCLAIMERS
All information, illustrations, and specifications
contained in this manual are based on the latest
information available at the time of publication.
The right is reserved to make changes at any time
without notice.
4.2 SAFETY
4.2.1 TECHNICIAN SAFETY INFORMATION
WARNING: ENGINES PRODUCE CARBON
MONOXIDE THAT IS ODORLESS, CAUSES
SLOWER REACTION TIME, AND CAN LEAD
TO SERIOUS INJURY. WHEN THE ENGINE IS
OPERATING, KEEP SERVICE AREAS WELL
VENTILATED OR ATTACH THE VEHICLE
EXHAUST SYSTEM TO THE SHOP EXHAUST
REMOVAL SYSTEM.
Set the parking brake and block the wheels before
testing or repairing the vehicle. It is especially
important to block the wheels on front wheel drive
vehicles; the parking brake does not hold the drive
wheels.
When servicing a vehicle, always wear eye pro-
tection, and remove any metal jewelry such as
watchbands or bracelets that might make electrical
contact.
When diagnosing a powertrain system problem,
it is important to follow approved procedures where
applicable. These procedures can be found in the
service manual. Following these procedures is very
important to the safety of individuals performing
diagnostic tests.
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GENERAL INFORMATION
ProCarManuals.com
4.2.2 VEHICLE PREPARATION FOR
TESTING
Make sure the vehicle being tested has a fully
charged battery. If it does not, false diagnostic codes
or error messages may occur.
4.2.3 SERVICING SUB-ASSEMBLIES
Some components of the powertrain system are
intended to be serviced as an assembly only. At-
tempting to remove or repair certain system sub-
components may result in personal injury and/or
improper system operation. Only those components
with approved repair and installation procedures in
the service manual should be serviced.
4.2.4 DRBIIITSAFETY INFORMATION
WARNING: EXCEEDING THE LIMITS OF THE
DRBIIITMULTIMETER IS DANGEROUS. IT
CAN EXPOSE YOU TO SERIOUS OR
POSSIBLY FATAL INJURY. CAREFULLY
READ AND UNDERSTAND THE CAUTIONS
AND SPECIFICATION LIMITS.
Follow the vehicle manufacturer’s service specifi-
cations at all times.
•Do not use the DRBIIItif it has been damaged.
•Do not use the test leads if the insulation is
damaged or if metal is exposed.
•To avoid electrical shock, do not touch the test
leads, tip or the circuit being tested.
•Choose the proper range and function for the
measurement. Do not try voltage or current mea-
surements that may exceed the rated capacity.
•Do not exceed the limits shown in the table below:
FUNCTION INPUT LIMIT
Volts 0-500 peak volts AC
0-500 volts DC
Ohms (Resistance)* 0-1.12 megohms
Frequency Measure
Frequency Generated 0-10 kHz
Temperature -58 - +1100°F
-50 - +600°C
* Ohms cannot be measured if voltage is present.
Ohms can be measured only in a non-powered
circuit.
•Voltage between any terminal and ground must
not exceed 500v DC or 500v peak AC.
•Use caution when measuring voltage above 25v
DC or 25v AC.
•The circuit being tested must be protected by a 10
amp fuse or circuit breaker.
•Use the low current shunt to measure circuits up
to 10 amps. Use the high current shunt to mea-
sure circuits exceeding 10 amps.
•When testing for the presence of voltage or cur-
rent, make sure the meter is functioning cor-
rectly. Take a reading of a known voltage or
current before accepting a zero reading.
•When measuring current, connect the meter in
series with the load.
•Disconnect the live test lead before disconnecting
the common test lead.
4.3 WARNINGS AND CAUTIONS
4.3.1 ROAD TEST WARNINGS
Some complaints will require a test drive as part
of the repair verification procedure. The purpose of
the test drive is to try to duplicate the diagnostic
code or symptom condition.
CAUTION: Before road testing a vehicle, be
sure that all components are reassembled.
During the test drive, do not hang the DRBIIIT
from the rear view mirror. Do not attempt to
read the DRBIIITwhile driving. Have an
assistant available to operate the DRBIIIT.
4.3.2 VEHICLE DAMAGE CAUTIONS
Before disconnecting any control module, make
sure the ignition is off. Failure to do so could
damage the module. When testing voltage or circuit
integrity at any control module, use the terminal
side (not the wire end) of the harness connector. Do
not probe through the insulation; this will damage
it and eventually cause it to fail because of corro-
sion.
Be careful when performing electrical test so as to
prevent accidental shorting of terminals. Such a
mistake can damage fuses or components. Also, a
second code could be set, making diagnosis of the
original problem more difficult.
5.0 REQUIRED TOOLS AND
EQUIPMENT
DRBIIIt(diagnostic read-out box) scan tool
vacuum gauge
ammeter
ohmmeter
voltmeter
jumper wires and probes
oscilloscope
8
GENERAL INFORMATION
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6.0 GLOSSARY OF TERMS
A/C air conditioning
APP accelerator pedal position (sensor)
ASD automatic shut down
backfire,
popback fuel ignites in either the intake or
the exhaust system
BCM body control module
BP boost pressure (sensor)
CKP crankshaft position (sensor)
CMP camshaft position (sensor)
cuts out,
misses a steady pulsation or the inability of
the engine to maintain a consistent
rpm
DLC data link connector
detona-
tion,
spark
knock
a mild to severe ping, especially un-
der loaded engine conditions
ECM engine control module
ECT engine coolant temperature (sensor)
EGR exhaust gas recirculation
(solenoid/valve)
hard
start the engine takes longer than usual
to start, even though it is able to
crank at normal speed.
IAT intake air temperature (sensor)
lack of
power,
sluggish
the engine power output has been
reduced
MAF mass air flow (sensor)
MIL malfunction indicator lamp
ms millisecond(s)
PDC power distribution center
poor fuel
economy there is significantly less fuel mile-
age than other vehicles of the same
design and configuration
runs
rough/
unstable
idle
the engine runs unevenly at idle
causing the engine to shake if it is
severe enough
S/C speed control
SCI standard corporate interface
SKIM sentry key immobilizer module
SKIS sentry key immobilizer system
start and
stall The engine starts but immediately
dies (stalls)
surge engine rpm fluctuation without cor-
responding change in accelerator
pedal position
SRC signal range check
WIF water in fuel (sensor)
VSS vehicle speed sensor
9
GENERAL INFORMATION
ProCarManuals.com
Symptom:
*NO RESPONSE FROM ECM (PCI BUS) - DIESEL ONLY
POSSIBLE CAUSES
ECM PCI NO RESPONSE
PCI BUS CIRCUIT OPEN
ENGINE CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
NOTE: As soon as one or more module communicates with the DRB, answer
the question.
With the DRB, enter Body then Body Computer.
With the DRB, enter Anti-Lock Brakes.
With the DRB, enter Body then Electro/Mechanical Cluster (MIC).
With the DRB, enter Passive Restraints then Airbag.
Were you able to establish communications with any of the modules?
All
Yes →Go To 2
No →Refer to symptom PCI Bus Communication Failure in the Com-
munications category.
Perform ROAD TEST VERIFICATION - VER-2.
2 With the DRB read ECM Diagnostic Trouble Codes. This is to ensure power and
grounds to the ECM are operational.
NOTE: If the DRB will not read ECM DTCs, follow the NO RESPONSE TO
ECM (SCI only) symptom path, if vehicle will start. For NO START Condi-
tions follow the no start symptom in the powertrain diagnostic information.
Turn the ignition off.
Disconnect the ECM C1 harness connector.
Use Scope input cable CH7058, Cable to Probe adapter CH7062, and the red and
black test probes.
Connect the scope input cable to the channel one connector on the DRB. Attach the
red and black leads and the cable to probe adapter to the scope input cable.
With the DRBIIItselect Pep Module Tools.
Select lab scope.
Select Live Data.
Select 12 volt square wave.
Press F2 for Scope.
Press F2 and use the down arrow to set voltage range to 20 volts. Set Probe to x10.
Press F2 again when complete.
Connect the Black lead to ground. Connect the Red lead to the PCI Bus circuit in the
ECM connector.
Turn the ignition on.
Observe the voltage display on the DRB Lab Scope.
Does the voltage pulse from 0 to approximately 7.5 volts?
All
Yes →Replace and program the Engine Control Module in accordance
with the Service Information.
Perform ROAD TEST VERIFICATION - VER-2.
No →Repair the PCI Bus circuit for an open.
Perform ROAD TEST VERIFICATION - VER-2.
12
COMMUNICATION
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