Suzuki XL7 JC636 2007 Service Manual 99500S78J00-33E

Download

Page 1

2007

SERVICE MANUAL

JC636

99500S78J00-33E

Page 2

IMPORTANT

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the words

WARNING

lighted by these signal words.

WARNING

Indicates a potential hazard that could result in death or injury.

CAUTION

Indicates a potential hazard that could result in vehicle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

WARNING

This service manual is intended for authorized Suzuki dealers and qualified service technicians only. Inexperienced technicians or technicians without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the technician and may render the vehicle unsafe for the driver and passengers.

, and NOTE have special meanings. Pay special attention to the messages high-

CAUTION

WARNING

For vehicles equipped with a Supplemental Restraint (Air Bag) System:

• Service on and around the air bag system components or wiring must be performed only by an authorized SUZUKI dealer. Refer to “Air Bag System Components and Wiring Location View” under “General Description” in air bag system section in order to confirm whether you are performing service on or near the air bag system components or wiring. Please observe all WARNINGS and “Service Precautions” under “On-Vehicle Service” in air bag system section before performing service on or around the air bag system components or wiring. Failure to follow WARNINGS could result in unintentional activation of the system or could render the system inoperative. Either of these two conditions may result in severe injury.

• If the air bag system and another vehicle system both need repair, Suzuki recommends that the air bag system be repaired first, to help avoid unintended air bag system activation.

• Do not modify the steering wheel, instrument panel or any other air bag system component on or around air bag system components or wiring. Modifications can adversely affect air bag system performance and lead to injury.

• If the vehicle will be exposed to temperatures over 93 °C (200 °F), for example, during a paint baking process, remove the air bag system components, that is air bag (inflator) modules, SDM and/or seat belt with pretensioner, beforehand to avoid component damage or unintended activation.

Page 3

FOREWORD

This manual contains procedures for diagnosis, maintenance, adjustments, minor service operations, replacement of components (Service) and for disassembly and assembly of major components (Unit RepairOverhaul).

Applicable model: 2007 XL7 (JC636)

The contents are classified into sections each of which is given a section number as indicated in the Table of Contents on following page. And on the first page of each individual section is an index of that section. This manual should be kept in a handy place for ready reference of the service work. Strict observance of the so specified items will enable one to obtain the full performance of the vehicle.

When replacing parts or servicing by disassembling, it is recommended to use SUZUKI genuine parts, tools and service materials as specified in each description.

All information, illustrations and specifications contained in this literature are based on the latest product information available at the time of publication approval. And used as the main subject of description is the vehicle of standard specifications among others. Therefore, note that illustrations may differ from the vehicle being actually serviced. The right is reserved to make changes at any time without notice.

No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of Suzuki Motor Corporation.

Page 4

Page 5

TABLE OF CONTENTS

Precautions................................................................00–i

Precautions ............................................................ 00–1

Transmission / Transaxle ...........................................5–i

Automatic Transmission........................................ 5A–1

General Information ....................................................0–i

General Information .............................................. 0A–1

Maintenance and Lubrication ................................ 0B–1

Engine ..........................................................................1–i

Engine General Information and Diagnosis .......... 1A–1

Aux. Emission Control Devices ............................. 1B–1

Engine Electrical Devices...................................... 1C–1

Engine Mechanical................................................ 1D–1

Engine Lubrication System ................................... 1E–1

Engine Cooling System......................................... 1F–1

Fuel System .......................................................... 1G–1

Ignition System...................................................... 1H–1

Starting System....................................................... 1I–1

Charging System.................................................... 1J–1

Exhaust System .................................................... 1K–1

Suspention...................................................................2–i

Suspension General Diagnosis............................. 2A–1

Front Suspension .................................................. 2B–1

Rear Suspension................................................... 2C–1

Wheels and Tires .................................................. 2D–1

Driveline / Axle ............................................................3–i

Drive Shaft ............................................................ 3A–1

Differential ............................................................. 3B–1

Transfer................................................................. 3C–1

Propeller Shafts..................................................... 3D–1

Brakes ..........................................................................4–i

Brake Control System and Diagnosis ................... 4A–1

Front Brakes.......................................................... 4B–1

Rear Brakes .......................................................... 4C–1

Parking Brake........................................................ 4D–1

ABS ....................................................................... 4E–1

Steering........................................................................6–i

Steering Wheel and Column ................................. 6B–1

Power Assisted Steering System .......................... 6C–1

HVAC ............................................................................7–i

Heating, Ventilation and Air Conditioning.............. 7A–1

Restraints.....................................................................8–i

Seat Belts.............................................................. 8A–1

Air Bag System ..................................................... 8B–1

Body, Cab and Accessories.......................................9–i

Wiring Systems ..................................................... 9A–1

Lighting Systems................................................... 9B–1

Instrumentation / Driver Info. / Horn ...................... 9C–1

Wipers / Washers.................................................. 9D–1

Glass / Windows / Mirrors ..................................... 9E–1

Security and Locks................................................ 9F–1

Seats ..................................................................... 9G–1

Interior Trim........................................................... 9H–1

Sun Roof / T-Top / Convertible Top ........................ 9I–1

Hood / Fenders / Doors.......................................... 9J–1

Body Structure ...................................................... 9K–1

Paint / Coatings...................................................... 9L–1

Exterior Body Panels............................................. 9M–1

Cellular / Entertainment / Navigation / Audio ........ 9O–1

Control Systems........................................................10–i

Cruise Control System ........................................ 10A–1

Data Communications......................................... 10B–1

Immobilizer Control System ................................ 10C–1

Tire Pressure Monitoring System........................ 10D–1

Frame and Frame Accessories ................................11–i

Body Frame......................................................... 11A–1

Page 6

Page 7

Section 00

Precautions

CONTENTS

Table of Contents 00- i

Precautions .............................................. 00–1

Precautions........................................................... 00–1

Definition of Caution, Notice, and Important ....... 00–1

Approved Equipment for

Collision Repair Caution ................................... 00–1

Assistant Driving Caution .................................... 00–1

Cleaning Solvent Caution ................................... 00–1

Eye Protection Caution ....................................... 00–2

Foam Sound Deadeners Caution ....................... 00–2

Gasoline/Gasoline Vapors Caution..................... 00–2

Glass and Sheet Metal Handling Caution ........... 00–2

Moving Parts and Hot Surfaces Caution ............. 00–2

Protective Goggles and Glove Caution ............... 00–2

Road Test Caution ............................................. 00–2

Work Stall Test Caution ..................................... 00–2

Belt Dressing Notice........................................... 00–3

Brake Fluid Effects on Paint and

Electrical Components Notice .......................... 00–3

Clean, Dry, Low Pressure Gas Source Notice ... 00–3

Clearcoat/Ultraviolet Screeners Notice .............. 00–3

Component Fastener Tightening Notice ............ 00–3

Fastener Notice.................................................. 00–3

Machined Surface Damage Notice .................... 00–3

OBDII Symbol Description Notice ...................... 00–4

Pipe Wrench Positioning Notice......................... 00–4

Test Probe Notice .............................................. 00–4

Page 8

00-1 Precautions:

Precautions

Definition of Caution, Notice, and Important

The diagnosis and repair procedures in the Service Manual contain both general and specific Cautions, Notices, and Importants. SUZUKI is dedicated to the presentation of service information that helps the technician to diagnose and repair the systems necessary for the proper operation of the vehicle, however, certain procedures may present a hazard to the technician if they are not followed in the recommended manner. Cautions, Notices, and Importants are elements designed to prevent these hazards, however, not all hazards can be foreseen. This information is placed at strategic locations within the service manual. This information is designed to prevent the following from occurring:

• Serious bodily injury to the technician

• Damage to the vehicle

• Unnecessary vehicle repairs

• Unnecessary component replacement

• Improper repair or replacement of vehicle components. Any caution or notice that appears in general information is referenced from the individual service categories.

• Improper operation or performance of any systems or components which are dependent upon the proper operation or performance of the system or component under repair

• Damage to fasteners, basic tools, or special tools

• The leakage of coolant, lubricant, or other vital fluids

IMPORTANT Defined

IMPORTANT statements emphasize a necessary characteristic of a diagnostic or repair procedure. IMPORTANT statements are designed to do the following:

• Clarify a procedure

• Present additional information for accomplishing a procedure

• Give insight into the reason or reasons for performing a procedure in the manner recommended

• Present information that will help to accomplish a procedure in a more effective manner

• Present information that gives the technician the benefit of past experience in accomplishing a procedure with greater ease

CAUTION Defined

When encountering a CAUTION, you will be asked to take a necessary action or not to take a prohibited action. If a CAUTION is not heeded, the following consequences may occur:

• Serious bodily injury to the technician

• Serious bodily injury to other technicians in the workplace area

• Serious bodily injury to the driver and/or passenger(s) of the vehicle, if the vehicle has been improperly repaired

NOTICE Defined

Notices call special attention to a necessary action or to a prohibited action. If a NOTICE is not heeded, the following consequences may occur:

• Damage to the vehicle

• Unnecessary vehicle repairs

• Unnecessary component replacement

• Improper operation or performance of the system or component under repair

• Damage to any systems or components which are dependent upon the proper operation of the system or component under repair

Approved Equipment for Collision Repair Caution

WARNING

To avoid personal injury when exposed to welding flashes or to galvanized (Zinc Oxide) metal toxic fumes while grinding/cutting on any type of metal or sheet molded compound, you must work in a properly ventilated area, wearing an approved respirator, eye protection, earplugs, welding gloves, and protective clothing.

Assistant Driving Caution

WARNING

An assistant should drive the vehicle while the technician checks for the location of the reported condition. Otherwise, personal injury could result.

Cleaning Solvent Caution

WARNING

Bodily injury may occur if the cleaning solvent is inhaled or exposed to the skin.

Page 9

Precautions: 00-2

Eye Protection Caution

WARNING

Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury.

Foam Sound Deadeners Caution

WARNING

Foam sound deadeners must be removed from areas within 152.4 mm (6 in) of where flame is to be used for body repairs. When reinstalling foam sound deadeners, avoid inhaling fumes as bodily injury may result.

Gasoline/Gasoline Vapors Caution

WARNING

Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

Glass and Sheet Metal Handling Caution

WARNING

When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to reduce the chance of personal injury.

Moving Parts and Hot Surfaces Caution

WARNING

Avoid contact with moving parts and hot surfaces while working around a running engine in order to prevent physical injury.

Protective Goggles and Glove Caution

WARNING

Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

Road Test Caution

WARNING

Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage.

Work Stall Test Caution

WARNING

One or more of the following guidelines may apply when performing specific required tests in the work stall:

• When a test requires spinning the drive wheels with the vehicle jacked up, adhere to the following precautions:

– Do not exceed 56 km/h (35 mph) when

spinning one drive wheel with the other drive wheel stopped. This limit is necessary because the speedometer indicates only one-half the actual vehicle speed under these conditions. Personal injury may result from excessive wheel spinning.

– If all of the drive wheels are spinning at

the same speed, do not exceed 112 km/h (70 mph). Personal injury may result from excessive wheel spinning.

– All persons should stay clear of the

rotating components and the balance weight areas in order to avoid possible personal injury.

– When running an engine in the repair

stall for an extended period of time, use care not to overheat the engine and the transmission.

• When a test requires jacking up the vehicle and running with the wheels and brake rotors removed, adhere to the following precautions:

– Support the suspension at normal ride

height.

– Do not apply the brake with the brake

rotors removed.

– Do not place the transmission in PARK

with the drive axles spinning.

– Turn Off the ignition in order to stop the

powertrain components from spinning.

• When running an engine in the work stall, use the exhaust removal system to prevent breathing dangerous gases.

Page 10

00-3 Precautions:

Belt Dressing Notice

CAUTION

Do not use belt dressing on the drive belt. Belt dressing causes the breakdown of the composition of the drive belt. Failure to follow this recommendation will damage the drive belt.

Brake Fluid Effects on Paint and Electrical Components Notice

CAUTION

Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will damage painted surfaces and cause corrosion to electrical components. If any brake fluid comes in contact with painted surfaces, immediately flush the area with water. If any brake fluid comes in contact with electrical connections, wiring, or cables, use a clean shop cloth to wipe away the fluid.

Clean, Dry, Low Pressure Gas Source Notice

CAUTION

Use the EVAP Pressure/Purge Diagnostic Station J 41413 in order to provide a clean, dry, low pressure gas source. Do not substitute any other pressurized gas source. Damage may result to the EVAP system.

Clearcoat/Ultraviolet Screeners Notice

CAUTION

Removing more than 0.5 mils of the clearcoat can result in early paint failure. The clearcoat contains ultraviolet screeners. Do not finesse sand more than what is required to remove the defect.

Component Fastener Tightening Notice

CAUTION

Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage.

Fastener Notice

CAUTION

Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Machined Surface Damage Notice

CAUTION

Do not nick, scratch or damage the sealing surface. The sealing surface is a machined surface. Damage to the machined surface can cause leakage.

Page 11

Precautions: 00-4

OBDII Symbol Description Notice

CAUTION

The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit.

Pipe Wrench Positioning Notice

CAUTION

The pipe wrench must be placed at the valve end of the steering gear and positioned up against the inner tie rod housing. Placing the pipe wrench in any other location will cause damage to the steering gear.

Test Probe Notice

CAUTION

Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J35616 GM-Approved Terminal Test Kit in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size.

Page 12

00-5 Precautions:

Page 13

Section 0

General Information

CONTENTS

Table of Contents 0- i

General Information ............................... 0A–1

General Description ............................................ 0A–1

Abbreviations and Meanings.............................. 0A–1

Registered and Non-Registered Trademarks .... 0A–6

Arrows and Symbols .......................................... 0A–7

RPO Code List ................................................... 0A–7

US English/Metric Conversion ........................... 0A–8

Decimal and Metric Equivalents......................... 0A–9

Fasteners ......................................................... 0A–10

Thread Inserts.................................................. 0A–13

Lifting and Jacking the Vehicle ........................ 0A–14

Vehicle, Engine and Transmission,

Transfer Case, Axle ID, and

VIN Location, Derivative and Usage .............. 0A–15

Vehicle Certification, Tire Placard, Anti-Theft,

and Service Parts ID Label ............................ 0A–16

Vibration Theory and Terminology................... 0A–18

Service Programming System (SPS) ............... 0A–26

DTC Symptom Description -

Vehicle Diagnostic Information ...................... 0A–27

Service Materials (Lubricants, Oil, Grease,

Sealant, Adhesive, Cleaner, etc) ................... 0A–29

Component Location ........................................ 0A–32

Engine Identification......................................... 0A–32

Transmission Identification Information ........... 0A–33

Diagnostic Information and Procedures......... 0A–33

Diagnostic Procedure Instructions -

Vehicle Diagnostic Information ...................... 0A–33

Strategy Based Diagnosis -

Vehicle Diagnostic Information ...................... 0A–36

Strategy Based Diagnosis................................ 0A–37

Vehicle-to-Vehicle Diagnostic Comparison...... 0A–38

Diagnostic Trouble Code (DTC) List -

Vehicle Diagnostic Information ...................... 0A–39

Diagnostic Starting Point -

Vehicle Diagnostic Information ...................... 0A–55

Diagnostic Starting Point -

Vibration Diagnosis and Correction ............... 0A–55

Diagnostic System Check -

Vehicle Diagnostic Information ...................... 0A–56

Diagnostic Repair Verification -

Vehicle Diagnostic Information....................... 0A–58

Symptoms - Vehicle Diagnostic Information .... 0A–58

Symptoms -

Vibration Diagnosis and Correction................ 0A–59

Squeaks and Rattles ........................................ 0A–60

Vibration Analysis - Road Testing .................... 0A–61

Vibration Diagnostic Aids ................................. 0A–64

Vibration Diagnostic Aids -

Vibration Intermittent or Not Duplicated ......... 0A–64

Vibration Diagnostic Aids - Vibration

Duplicated, Component Not Identified ........... 0A–66

Vibration Diagnostic Aids -

Vibration Duplicated, Difficult to Isolate/

Balance Component....................................... 0A–66

Vibration Diagnostic Aids -

Vibration Duplicated, Appears to be

Potential Operating Characteristic ................. 0A–66

Vibration in Service-Stall Test

(Non-Torque Sensitive) .................................. 0A–67

Vibration in Service-Stall Test

(Torque Sensitive).......................................... 0A–67

Control Module References ............................. 0A–68

Special Tools and Equipment .......................... 0A–70

Substitute Special Tool Table .......................... 0A–70

Electronic Vibration Analyzer (EVA)

Description and Operation ............................. 0A–79

Vibrate Software Description and Operation.... 0A–81

Reed Tachometer Description ......................... 0A–81

Special Tools - Squeaks and Rattles ............... 0A–81

Special Tools and Equipment -

Vibration Diagnosis and Correction................ 0A–81

Maintenance and Lubrication ................ 0B–1

Scheduled Maintenance ..................................... 0B–1

Maintenance Items............................................. 0B–1

Maintenance Schedule

(North American Emissions) ............................ 0B–1

Oil Life System Resetting................................... 0B–1

Specifications...................................................... 0B–1

Approximate Fluid Capacities ............................ 0B–1

Fluid and Lubricant Recommendations.............. 0B–1

Page 14

0A-1 General Information:

General Information

General Description

Abbreviations and Meanings

Abbreviation Meaning

A Ampere(s)

ABS Antilock Brake System

A/C Air Conditioning

AC Alternating Current

ACC

ACL Air Cleaner

ACM Air Conditioning Module

ACR4

AD Automatic Disconnect

A/D Analog to Digital

ADL Automatic Door Lock

A/F Air/Fuel Ratio

AH Active Handling

AIR Secondary Air Injection

ALC

AM/FM

Ant Antenna AP Accelerator Pedal

APCM Accessory Power Control Module

API American Petroleum Institute

APP Accelerator Pedal Position

APT Adjustable Part Throttle

ASM

ASR Acceleration Slip Regulation

A/T Automatic Transmission/Transaxle

ATC

ATDC After Top Dead Center

ATSLC

Auto Automatic

avg Average

A4WD Automatic Four-Wheel Drive

AWG American Wire Gage

B+ Battery Positive Voltage

BARO Barometric Pressure

BATT Battery

BBV Brake Booster Vacuum BCA Bias Control Assembly

BCM Body Control Module

BHP Brake Horsepower

BLK Black

BLU Blue

BP Back Pressure BPCM Battery Pack Control Module BPMV Brake Pressure Modulator Valve

Accessory, Automatic Climate Control

Air Conditioning Refrigerant, Recovery, Recycling, Recharging

Automatic Level Control, Automatic Lamp Control Amplitude Modulation/Frequency Modulation

Assembly, Accelerator and Servo Control Module

Automatic Transfer Case, Automatic Temperature Control

Automatic Transmission Shift Lock Control

Abbreviation Meaning

BPP Brake Pedal Position BRN Brown

BTDC Before Top Dead Center

BTM Battery Thermal Module BTSI Brake Transmission Shift Interlock

Btu British Thermal Units

°C Degrees Celsius

CAC Charge Air Cooler

CAFE Corporate Average Fuel Economy

Cal Calibration

Cam Camshaft

CARB California Air Resources Board

CC Coast Clutch

3 Cubic Centimeters

CCM

CCOT Cycling Clutch Orifice Tube

CCP Climate Control Panel

CD Compact Disc

CE Commutator End CEAB Cold Engine Air Bleed CEMF Counter Electromotive Force

CEX Cabin Exchanger

cfm Cubic Feet per Minute

cg Center of Gravity

CID Cubic Inch Displacement CKP Crankshaft Position CKT Circuit

C/Ltr Cigar Lighter

CL Closed Loop

CLS Coolant Level Switch CMC Compressor Motor Controller CMP Camshaft Position CNG Compressed Natural Gas

CO Carbon Monoxide

CO2 Carbon Dioxide

Coax Coaxial

COMM Communication

Conn Connector

CPA Connector Position Assurance CPP Clutch Pedal Position CPS Central Power Supply CPU Central Processing Unit CRT Cathode Ray Tube

CRTC Cathode Ray Tube Controller

CS Charging System

CSFI Central Sequential Fuel Injection

CTP Closed Throttle Position

cu ft Cubic Foot/Feet

cu in Cubic Inch/Inches

CV Constant Velocity Joint

CVRSS

Convenience Charge Module, Chassis Control Module

Continuously Variable Road Sensing Suspension

Page 15

General Information: 0A-2

Abbreviation Meaning

Cyl Cylinder(s)

DAB Delayed Accessory Bus

dB Decibels

dBA Decibels on A-weighted Scale

DC Direct Current, Duty Cycle

DCM Door Control Module

DE Drive End

DEC Digital Electronic Controller

DERM Diagnostic Energy Reserve Module

DI Distributor Ignition

dia Diameter

DIC Driver Information Center

Diff Differential

DIM Dash Integration Module

DK Dark

DLC Data Link Connector

DMCM Drive Motor Control Module

DMM Digital Multimeter

DMSDS

DMU Drive Motor Unit

DOHC Dual Overhead Camshafts

DPM Driver Position Module

DR, Drvr Driver

DRL Daytime Running Lamps DTC Diagnostic Trouble Code

EBCM Electronic Brake Control Module

EBTCM

EC Electrical Center, Engine Control

ECC Electronic Climate Control

ECI Extended Compressor at Idle

ECL Engine Coolant Level

ECM

ECS Emission Control System ECT Engine Coolant Temperature

EEPROM

EEVIR

EFE Early Fuel Evaporation

EGR Exhaust Gas Recirculation

EGR TVV

EHPS Electro-Hydraulic Power Steering

EI Electronic Ignition

ELAP Elapsed

ELC Electronic Level Control

E/M English/Metric

EMF Electromotive Force

EMI Electromagnetic Interference

Eng Engine EOP Engine Oil Pressure EOT Engine Oil Temperature EPA Environmental Protection Agency EPR Exhaust Pressure Regulator

Drive Motor Speed and Direction Sensor

Electronic Brake and Traction Control Module

Engine Control Module, Electronic Control Module

Electrically Erasable Programmable Read Only Memory Evaporator Equalized Values in Receiver

Exhaust Gas Recirculation Thermal Vacuum Valve

Abbreviation Meaning

EPROM

ESB Expansion Spring Brake ESC Electronic Suspension Control ESD Electrostatic Discharge ESN Electronic Serial Number

ETC

ETCC Electronic Touch Climate Control

ETR Electronically Tuned Receiver ETS Enhanced Traction System

EVAP Evaporative Emission

EVO Electronic Variable Orifice

Exh Exhaust

°F Degrees Fahrenheit

FC Fan Control

FDC Fuel Data Center

FED

FEDS Fuel Enable Data Stream

FEX Front Exchanger

FF Flexible Fuel

FFH Fuel-Fired Heater

FI Fuel Injection

FMVSS

FP Fuel Pump

ft Foot/Feet

FT Fuel Trim F4WD Full Time Four-Wheel Drive 4WAL Four-Wheel Antilock

4WD Four-Wheel Drive

FW Flat Wire

FWD Front Wheel Drive, Forward

g Grams, Gravitational Acceleration GA Gage, Gauge gal Gallon

gas Gasoline

GCW Gross Combination Weight

Gen Generator

GL Gear Lubricant

GM General Motors

GM SPO

gnd Ground

gpm Gallons per Minute GRN Green GRY Gray

GVWR Gross Vehicle Weight Rating

H Hydrogen

H2O Water Harn Harness

HC Hydrocarbons

HCM HVAC Control Module

H/CMPR High Compression

Erasable Programmable Read Only Memory

Electronic Throttle Control, Electronic Temperature Control, Electronic Timing Control

Federal All United States except California

Federal U.S. Motor Vehicle Safety Standards

General Motors Service Parts Operations

Page 16

0A-3 General Information:

Abbreviation Meaning

HD Heavy Duty

HDC Heavy Duty Cooling

hex Hexagon, Hexadecimal

Hg Mercury

Hi Alt High Altitude

HO2S Heated Oxygen Sensor

hp Horsepower HPL High Pressure Liquid HPS High Performance System HPV High Pressure Vapor

HPVS Heat Pump Ventilation System

Htd Heated

HTR Heater

HUD Head-up Display

HVAC Heater-Ventilation-Air Conditioning

HVACM Heater-Vent-Air Conditioning Module

HVIL High Voltage Interlock Loop HVM Heater Vent Module

Hz Hertz

IAC Idle Air Control

IAT Intake Air Temperature

IC Integrated Circuit, Ignition Control

ICCS Integrated Chassis Control System

ICM Ignition Control Module

ID Identification, Inside Diameter

IDI Integrated Direct Ignition

IGBT Insulated Gate Bi-Polar Transistor

ign Ignition

ILC Idle Load Compensator

in Inch/Inches

INJ Injection

inst Instantaneous, Instant

IP Instrument Panel

IPC Instrument Panel Cluster

IPM Instrument Panel Module

I/PEC Instrument Panel Electrical Center

ISC Idle Speed Control ISO International Standards Organization ISS Input Speed Shaft, Input Shaft Speed

KAM Keep Alive Memory KDD Keyboard Display Driver

kg Kilogram

kHz Kilohertz

km Kilometer

km/h Kilometers per Hour

km/l Kilometers per Liter

kPa Kilopascals

KS Knock Sensor

kV Kilovolts

LLiter L4 Four Cylinder Engine, In-Line L6 Six-Cylinder Engine, In-Line

lb Pound

lb ft Pound Feet Torque

lb in Pound Inch Torque

LCD Liquid Crystal Display

Abbreviation Meaning

LDCL Left Door Closed Locking

LDCM Left Door Control Module

LDM Lamp Driver Module

LED Light Emitting Diode LEV Low Emissions Vehicle

LF Left Front

lm Lumens

LR Left Rear

LT L eft LT L ight LT Long Term

LTPI Low Tire Pressure Indicator

LTPWS Low Tire Pressure Warning System

LWB Long Wheel Base

MAF Mass Air Flow

Man Manual

MAP Manifold Absolute Pressure

MAT Manifold Absolute Temperature

max Maximum M/C Mixture Control

MDP Manifold Differential Pressure

MFI Multiport Fuel Injection

mi Miles MIL Malfunction Indicator Lamp min Minimum

MIN Mobile Identification Number

mL Milliliter

mm Millimeter

mpg Miles per Gallon mph Miles per Hour

ms Millisecond

MST Manifold Surface Temperature

MSVA

M/T Manual Transmission/Transaxle

MV Megavolt mV Millivolt

NAES North American Export Sales

NC Normally Closed

NEG Negative

Neu Neutral

NI Neutral Idle

NiMH Nickel Metal Hydride

NLGI National Lubricating Grease Institute

N⋅m Newton-meter Torque

NO Normally Open

NOx Oxides of Nitrogen NPTC National Pipe Thread Coarse NPTF National Pipe Thread Fine

NOVRAM

O2 Oxygen

O2S Oxygen Sensor

OBD On-Board Diagnostics

OBD II

Magnetic Steering Variable Assist, Magnasteer®

Non-Volatile Random Access Memory

On-Board Diagnostics Second Generation

Page 17

General Information: 0A-4

Abbreviation Meaning

OC Oxidation Converter Catalytic

OCS Opportunity Charge Station

OD Outside Diameter ODM Output Drive Module ODO Odometer

OE Original Equipment OEM Original Equipment Manufacturer OHC Overhead Camshaft

Ω Ohm

OL Open Loop, Out of Limits

ORC

Oxidation Reduction Converter Catalytic

ORN Orange

ORVR On-Board Refueling Vapor Recovery

OSS Output Shaft Speed

oz Ounce(s)

PAG Polyalkylene Glycol

PAIR Pulsed Secondary Air Injection

PASS, PSGR Passenger

PASS-Key®

Personalized Automotive Security System

P/B Power Brakes

PC Pressure Control

PCB Printed Circuit Board

PCM Powertrain Control Module

PCS Pressure Control Solenoid PCV Positive Crankcase Ventilation PEB Power Electronics Bay

PID Parameter Identification

PIM Power Inverter Module

PM Permanent Magnet Generator

P/N Part Number PNK Pink PNP Park/Neutral Position

PRNDL Park, Reverse, Neutral, Drive, Low

POA Pilot Operated Absolute Valve POS Positive, Position POT Potentiometer Variable Resistor

PPL Purple

ppm Parts per Million

PROM Programmable Read Only Memory

P/S, PS Power Steering

PSCM

Power Steering Control Module,

Passenger Seat Control Module PSD Power Sliding Door PSP Power Steering Pressure

psi Pounds per Square Inch psia Pounds per Square Inch Absolute psig Pounds per Square Inch Gauge

pt Pint

PTC Positive Temperature Coefficient

PWM Pulse Width Modulated

QDM Quad Driver Module

qt Quart(s)

R-12 Refrigerant-12

R-134a Refrigerant-134a

Abbreviation Meaning

Random Access Memory, Non-

RAM

permanent memory device, memory contents are lost when power is

removed. RAP Retained Accessory Power RAV Remote Activation Verification

RCDLR Remote Control Door Lock Receiver

RDCM Right Door Control Module

Ref Reference

Rev Reverse

REX Rear Exchanger

RIM Rear Integration Module

RF Right Front, Radio Frequency

RFA Remote Function Actuation

RFI Radio Frequency Interference

RH Right Hand

RKE Remote Keyless Entry

Rly Relay

Read Only Memory, Permanent

ROM

memory device, memory contents

are retained when power is removed.

RPM

Revolutions per Minute Engine

Speed

RPO Regular Production Option

RR Right Rear RSS Road Sensing Suspension RTD Real Time Damping

RT Right

RTV

Room Temperature Vulcanizing Sealer

RWAL Rear Wheel Antilock

RWD Rear Wheel Drive

s Second(s)

SAE Society of Automotive Engineers

SC Supercharger SCB Supercharger Bypass

SCM Seat Control Module SDM Sensing and Diagnostic Module SEO Special Equipment Option

SFI Sequential Multiport Fuel Injection

System International Modern Version of Metric System

SIAB Side Impact Air Bag

SIR Supplemental Inflatable Restraint

SLA Short/Long Arm Suspension

sol Solenoid SO2 Sulfur Dioxide

SP Splice Pack

S/P Series/Parallel

SPO Service Parts Operations

SPS

sq ft, ft

sq in, in

Service Programming System, Speed Signal

2 Square Foot/Feet

2 Square Inch/Inches

SRC Service Ride Control

SRI Service Reminder Indicator

SRS Supplemental Restraint System

SS Shift Solenoid

Page 18

0A-5 General Information:

Abbreviation Meaning

ST Scan Tool

STID Station Identification Station ID

S4WD Selectable Four-Wheel Drive

Sw Switch

SWB Short Wheel Base

SWPS Steering Wheel Position Sensor

syn Synchronizer

TAC Throttle Actuator Control

Ta ch Ta ch om et er

TAP

TBI Throttle Body Fuel Injection

TC Turbocharger, Transmission Control TCC Torque Converter Clutch TCS Traction Control System TDC Top Dead Center

TEMP Temperature

Te rm Te r mi na l

TFP Transmission Fluid Pressure TFT Transmission Fluid Temperature

THM Turbo Hydro-Matic

TIM

TOC Transmission Oil Cooler

TP Throttle Position

TPA Terminal Positive Assurance

TPM

TR Transmission Range

TRANS Transmission/Transaxle

TT Tell Tail Warning Lamp

TV Throttle Valve

TVRS Television and Radio Suppression

TVV Thermal Vacuum Valve

TWC Three Way Converter Catalytic

TWC+OC

TXV Thermal Expansion Valve

UART

U/H Underhood

U/HEC Underhood Electrical Center

U-joint Universal Joint

UTD Universal Theft Deterrent

UV Ultraviolet

V Volt(s), Voltage V6 Six-Cylinder Engine, V-Type V8 Eight-Cylinder Engine, V-Type

Vac Vacuum

VAC Vehicle Access Code

VATS Vehicle Anti-Theft System

VCIM

VCM Vehicle Control Module

V dif Voltage Difference

VDOT Variable Displacement Orifice Tube

Transmission Adaptive Pressure, Throttle Adaptive Pressure

Tire Inflation Monitoring, Tire Inflation Module

Tire Pressure Monitoring, Tire Pressure Monitor

Three Way + Oxidation Converter Catalytic

Universal Asynchronous Receiver Transmitter

Vehicle Communication Interface Mode

Abbreviation Meaning

VDV Vacuum Delay Valve

vel Velocity

VES Variable Effort Steering

VF Vacuum Fluorescent VIO Violet VIN Vehicle Identification Number

VLR Voltage Loop Reserve

VMV Vacuum Modulator Valve

VR Voltage Regulator

V ref Voltage Reference

VSES

VSS Vehicle Speed Sensor

w/ With

W/B Wheel Base WHL Wheel WHT White

w/o Without

WOT Wide Open Throttle

W/P Water Pump

W/S Windshield WSS Wheel Speed Sensor

WU-OC

WU-TWC

X-valve Expansion Valve

yd Yard(s)

YEL Yellow

Vehicle Stability Enhancement System

Warm Up Oxidation Converter Catalytic Warm Up Three-Way Converter Catalytic

Page 19

General Information: 0A-6

Registered and Non-Registered Trademarks

Listed below are Registered Trademarks (®) or NonRegistered Trademarks (™) which may appear in this service manual.

AC® ACCUTURN® ACDelco® Active Fuel Management™ Acuzinc® Airbank® Allison® AMMCO® AUTOFUSE® AUTOTRAC®

Bendix® BON-AMI® Bosch® Bose®

Catapillar® CAT® C-Quam®

Delco® Delco Bose® Delco Electronics® Delco Freedom® Delco LOC II® Delco Moraine® Delco Remy® Delco Sound® Delco Supreme® Delco Tech® DELCORE® Delphi® DEX-COOL® DEXOIL® DEXRON® DEXSTEER™ DNR® Dolby® DR® Duracell® Duraguard® Durastop® Duramax™

Eaton Corporation® EMD® ETR®

FLO-LITE®

General Motors® GM® GM Goodwrench Service® GM Optikleen GM Parts™

GM Pass® GM Ultralite® GMAC® Goodwrench® GTP®

Homelink™ HYDRA-MATIC®

Illumination® INSTA-TRAC® Intune®

LOCTITE™

MAGNASTEER® Maxifuse® Metripack® Micropack® Minifuse® Mr Goodwrench®

Northstar®

OnStar® Optikleen®

PASS-KEY® PASS-KEYII® PASSLOCK™ PK3® Posidrive® Pro®

Quad 4®

RAINSENSE™ Rapid Fire®

ScotchBrite™ Scotchguard™ Signals® Sikkens™ Soft-Ray® Solar-Ray® Stabilitrak® Sunrayce® Superlube® Syclone®

Tech 2® Techline® Te fl o n® Te fz e l® Theft-I® Theftlock® Tiltmaster® TORX® Transjel® Transguide®

Page 20

0A-7 General Information:

Twilight Sentinel®

Ultralite®

Velcro®

Weatherpack™

Arrows and Symbols

This service manual uses various symbols in order to describe different service operations.

1. Front of Vehicle

2. View Detail

3. Ambient Air Mixed With Another Gas or Indicate Temperature Change

4. Motion or Direction

5. View Angle

6. Dimension (1:2)

7. Ambient/Clean Air Flow or Cool Air Flow

8. Lubrication Point — Oil or Fluid

9. Task Related

10. Sectioning (1:3)

11. Gas Other Than Ambient Air or Hot Air Flow

12. Lubrication Point — Grease or Jelly

13. Multidirectional Arrow

RPO Code List

RPO Description

AG1

AJ1

AK5

AM9 Seat Rear, Split Back, Folding

AR9 Seat, Front Bucket, Deluxe

ASF

BMI

BMJ Merchandised, Suzuki XL-7 Limited B1A Plant Code Ingersol, Ontario, Canada CF5 Roof, Sun, Glass, Sliding, Electric C4Y GVW RATING, 2 425 kg (5,346 lbs) C6B GVW RATING, 2 475 kg (5,456 lbs)

C67

C68

C69 HVAC System Rear, Air Conditioner

DD7

DD8 Mirror Inside Rearview, Light Sensitive

DG7

DT4 Ashtray, Cigarette Lighter

D22

FE1 Suspension System, Soft Ride FE9 Certification, Emission, Federal

FR4 Ratio, Transaxle Final Drive 2.48

JL9

KA1 Heater, Seat, Front KC5 Receptacle, Electrical, Accessory KG4 Generator, 150 AMP

KW7 Generator, 170 AMP

K05 Heater Engine, Block K34 Cruise Control, Automatic, Electronic

*LY7

MX0

M09

M45

NE1

NK5 Steering Wheel, Standard NP5 Steering Wheel, Leather Wrapped NT7 Emission System, Federal, Tier 2 NU1 Emission System, California, Lev2

N75 Wheel, 17 x 7 Aluminum, Custom

Adjuster Front Seat, Power, Multidirectional, Driver Window Tinted, Deep, All Except Windshield and Doors Restraint System, Seat, Inflatable, Driver and Passenger

Restraint, Roof Side, LH and RH, Inflatable Merchandised Package, Suzuki XL-7 To ur i ng

HVAC System, Air Conditioner Front, Electronic Controls HVAC System, Air Conditioner Front, Auto, Electronic Controls

Mirror Inside Rearview, Light Sensitive, Compass

Mirror Outside, LH and RH, Remote Control, Electric, Color

Mirror Outside, LH and RH, Remote Control, Electric

Brake System, Power Front and Rear Disc, Antilock, Front and Rear Wheel

Engine, Gas, 6 Cyl, 3.6L, SFI, V6, Alum, 60 Degrees, N36A Merchandised Trans, Auto Provisions, O/ D Transmission, Auto 5 SPD, Aisin, AF33, (Tiptronic) Transmission, Auto 5 SPD, Opel, AF33, (Tiptronic) Certification, Emission, Geographically Restricted Registration For Vehicles Up To 14,000 lbs GVW (Use 2003 Model Year )

Page 21

General Information: 0A-8

RPO Description

QB5 Wheel, 16 x 6.5 Steel

QKJ

QLJ

Tire All, P235/65R16 - 101S BW R/PE ST TL AL2 Tire All, P235/60R17 - 100S BW R/PE ST TL AL2

T96 Lamp, Fog, Front

UE1

UH8

Communication System, Vehicle, G.P.S. 1 Cluster, Instrument, Cool Temp, Trip Odometer, Tach

UQ4 Speaker System, 4, Base

US8

Radio, AM/FM Stereo, Seek/Scan, CD, Auto Tone, Clock, ETR, MP3, RDS Radio, AM/FM Stereo, Seek/Scan, RDS,

US9

Multiple Compact Disc, Auto Tone Control, Clock, ETR, MP3

UUC

Radio, AM/FM Stereo, Seek/Scan, CD, DVD, Auto Tone, Clock, ETR, MP3, RDS

UW6 Speaker System, 6, Custom

U1C

Radio, AM/FM Stereo, Seek/Scan, CD, Clock, ETR

U2K Digital Audio System, S Band

Radio, Am/FM Stereo, Seek/Scan, DVD,

U3U

CD, Clock, ETR, Navigation, Voice Recorder, MP3

U19

Speedometer, Instr, Kilo and Miles, Kilo Odometer

U65 Speaker System, 7, Premium

V1K Bar, Luggage Carrier, Center Cross

V92 Trailer Provisions

YB6

Axle, (Base Equip) (Keep as Processing Option)

YF5 Certification, Emission, California

NOTE

*GM PRO code “LY7” described throughout in this manual means the engine type name for the engine with “N36A” indication on the cylinder block and installed in XL7.

US English/Metric Conversion

English

In order to calculate English measurement, divide by the number in the center column. In order to calculate metric measurement, multiply by the number in the center column.

in 25.4 mm

ft 0.3048 yd 0.9144 mi 1.609 km

sq in

sq ft 0.0929

sq yd 0.8361

cu in

gal 3.7854

cu yd 0.764 cu m

lb 0.4536

ton

kg F 9.807

lb F 4.448

ft/s

2 0.3048

in/s2 0.0254

lb in 0.11298

lb ft 1.3558

hp 0.745 kW

inches of H2O 0.2488

lb/sq in 6.895

Btu 1055.0

kW hour 3,600,000.0

Foot Candle 10.764 lm/m

mph 1.6093 km/h

(°F − 32) 5/9 = °C

°F=(9/5 °C + 32)

235.215/mpg = 100 km/L

Multiply/ Divide

Length

Area

645.2 sq mm

6.45 sq cm

Volume

16,387.0 cu mm

16.387 cu cm

0.0164

Mass

907.18

0.907 tonne (t)

Force

Acceleration

Torque

Power

Pressure (Stress)

Energy (Work)

Light

Velocity

Temperatu r e

Fuel Performance

newtons (N)oz F 0.2780

J (J= one Ws)lb ft 1.3558

Metric

sq m

Lqt 0.9464

m/s

N⋅m

kPa

Page 22

0A-9 General Information:

Decimal and Metric Equivalents

Fraction (in) Decimal (in) Metric (mm)

1/64 0.015625 0.39688 1/32 0.03125 0.79375 3/64 0.046875 1.19062 1/16 0.0625 1.5875 5/64 0.078125 1.98437 3/32 0.09375 2.38125 7/64 0.109375 2.77812

1/8 0.125 3.175 9/64 0.140625 3.57187 5/32 0.15625 3.96875

11/64 0.171875 4.36562

3/16 0.1875 4.7625

13/64 0.203125 5.15937

7/32 0.21875 5.55625

15/64 0.234375 5.95312

1/4 0.25 6.35

17/64 0.265625 6.74687

9/32 0.28125 7.14375

19/64 0.296875 7.54062

5/16 0.3125 7.9375

21/64 0.328125 8.33437 11/32 0.34375 8.73125 23/64 0.359375 9.12812

3/8 0.375 9.525

25/64 0.390625 9.92187 13/32 0.40625 10.31875 27/64 0.421875 10.71562

7/16 0.4375 11.1125

29/64 0.453125 11.50937 15/32 0.46875 11.90625 31/64 0.484375 12.30312

1/2 0.5 12.7

33/64 0.515625 13.09687 17/32 0.53125 13.49375 35/64 0.546875 13.89062

9/16 0.5625 14.2875

37/64 0.578125 14.68437 19/32 0.59375 15.08125 39/64 0.609375 15.47812

5/8 0.625 15.875

41/64 0.640625 16.27187 21/32 0.65625 16.66875 43/64 0.671875 17.06562 11/16 0.6875 17.4625 45/64 0.703125 17.85937 23/32 0.71875 18.25625 47/64 0.734375 18.65312

3/4 0.75 19.05

49/64 0.765625 19.44687 25/32 0.78125 19.84375 51/64 0.796875 20.24062 13/16 0.8125 20.6375 53/64 0.828125 21.03437 27/32 0.84375 21.43125 55/64 0.859375 21.82812

7/8 0.875 22.225

57/64 0.890625 22.62187 29/32 0.90625 23.01875

Fraction (in) Decimal (in) Metric (mm)

59/64 0.921875 23.41562 15/16 0.9375 23.8125 61/64 0.953125 24.20937 31/32 0.96875 24.60625 63/64 0.984375 25.00312

1 1.0 25.4

Page 23

General Information: 0A-10

Fasteners

Metric Fasteners

This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength. A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive® or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive® recess head screws. North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches.

Fastener Strength Identification

1. English Bolt, Grade 2 (Strength Class) 4. English Bolt, Grade 8 (Strength Class)

2. English Bolt, Grade 5 (Strength Class) 5. Metric Nut, Strength Class 9

3. English Bolt, Grade 7 (Strength Class) 6. Metric Bolts, Strength Class Increases as Numbers Increase

The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following:

• Lower strength

• No numbered head marking system

• Wrong thread pitch

Page 24

0A-11 General Information:

The metric fasteners on this vehicle is designed to new, international standards. The following are the common sizes and pitches, except for special applications:

• M6.0 X 1

• M8 X 1.25

• M10 X 1.5

• M12 X 1.75

• M14 X 2.00

• M16 X 2.00

Prevailing Torque Fasteners

Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening.

All Metal Prevailing Torque Fasteners

These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener.

Nylon Interface Prevailing Torque Fasteners

These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads.

Adhesive Coated Fasteners

These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener.

1. Prevailing Torque Nut, Center Lock Type

2. Prevailing Torque Nut, Top Lock Type

3. Prevailing Torque Nut, Nylon Patch Type

4. Prevailing Torque Nut, Nylon Washer Insert Type

5. Prevailing Torque Nut, Nylon Insert Type

6. Prevailing Torque Bolt, Dry Adhesive Coating Type

7. Prevailing Torque Bolt, Thread Profile Deformed Type

8. Prevailing Torque Bolt, Nylon Strip Type

9. Prevailing Torque Bolt, Out-of-Round Thread Area Type

A prevailing torque fastener may be reused ONLY if:

• The fastener and the fastener counterpart are clean and not damaged

• There is no rust on the fastener

• The fastener develops the specified minimum torque against its counterpart prior to the fastener seating

Page 25

General Information: 0A-12

Metric Prevailing Torque Fastener Minimum Torque Development

Application

All Metal Prevailing Torque Fasteners

6 mm 0.4 N⋅m 4 lb in 8 mm 0.8 N⋅m 7 lb in 10 mm 1.4 N⋅m 12 lb in 12 mm 2.1 N⋅m 19 lb in 14 mm 3 N⋅m 27 lb in 16 mm 4.2 N⋅m 37 lb in 20 mm 7 N⋅m 62 lb in 24 mm 10.5 N⋅m 93 lb in

Nylon Interface Prevailing Torque Fasteners

6 mm 0.3 N⋅m 3 lb in 8 mm 0.6 N⋅m 5 lb in 10 mm 1.1 N⋅m 10 lb in 12 mm 1.5 N⋅m 13 lb in 14 mm 2.3 N⋅m 20 lb in 16 mm 3.4 N⋅m 30 lb in 20 mm 5.5 N⋅m 49 lb in 24 mm 8.5 N⋅m 75 lb in

Metric English

Specification

English Prevailing Torque Fastener Minimum Torque Development

Application

All Metal Prevailing Torque Fasteners

1/4 in 0.5 N⋅m 4.5 lb in 5/16 in 0.8 N⋅m 7.5 lb in 3/8 in 1.3 N⋅m 11.5 lb in 7/16 in 1.8 N⋅m 16 lb in 1/2 in 2.3 N⋅m 20 lb in 9/16 in 3.2 N⋅m 28 lb in 5/8 in 4 N⋅m 36 lb in 3/4 in 7 N⋅m 54 lb in

Nylon Interface Prevailing Torque Fasteners

1/4 in 0.3 N⋅m 3 lb in 5/16 in 0.6 N⋅m 5 lb in 3/8 in 1 N⋅m 9 lb in 7/16 in 1.3 N⋅m 12 lb in 1/2 in 1.8 N⋅m 16 lb in 9/16 in 2.5 N 5/8 in 3.4 N⋅m 30 lb in 3/4 in 5 N⋅m 45 lb in

Metric English

Specification

⋅m 22 lb in

Page 26

0A-13 General Information:

Thread Inserts

General purpose thread repair kits. These kits are available commercially.

Repair Procedure

WARNING

Refer to Safety Glasses Caution.

NOTE

Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and tap to use. Avoid any buildup of chips. Back out the tap every few turns and remove the chips.

4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel.

NOTE

The insert should be flush to one turn below the surface.

5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert.

6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift.

1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth.

2. Drill out the damaged threads. Clean out any chips.

3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads.

Page 27

Lifting and Jacking the Vehicle

General Information: 0A-14

WARNING

To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

WARNING

To avoid any vehicle damage, serious personal injury or death, always use the jackstands to support the vehicle when lifting the vehicle with a jack.

CAUTION

Perform the following steps before beginning any vehicle lifting or jacking procedure:

• Remove or secure all of the vehicle's contents in order to avoid any shifting or any movement that may occur during the vehicle lifting or jacking procedure.

• The lifting equipment or the jacking equipment weight rating must meet or exceed the weight of the vehicle and any vehicle contents.

• The lifting equipment or the jacking equipment must meet the operational standards of the lifting equipment or jacking equipment's manufacturer.

• Perform the vehicle lifting or jacking procedure on a clean, hard, dry, level surface.

• Perform the vehicle lifting or jacking procedure only at the identified lift points. DO NOT allow the lifting equipment or jacking equipment to contact any other vehicle components.

Failure to perform the previous steps could result in damage to the lifting equipment or the jacking equipment, the vehicle, and/or the vehicle's contents.

Page 28

0A-15 General Information:

Vehicle Lifting-Frame Contact Lift

Front Lift Pads

When lifting the vehicle with a frame-contact lift, place the front lift pads approximately 12.2 in (310 mm) inboard from the front pinchweld flanges.

Rear Lift Pads

When lifting the vehicle with a frame-contact lift, place the rear lift pads 10.0 in (255 mm) inboard from the rear pinchweld flanges.

Vehicle Jacking

Under the Center of the Rear Suspension

Lift the rear of the vehicle by placing the floor jack lift pad at the center of the rear suspension.

Supporting the Vehicle with Jackstands

NOTE

Place jackstands ONLY under strong and stable vehicle structures.

Vehicle, Engine and Transmission, Transfer Case, Axle ID, and VIN Location, Derivative and Usage

Position Definition Character Description

Vehicle Identification Number (VIN) System

The VIN plate (1) is the legal identifier of the vehicle. The VIN plate is located on the upper left corner of the instrument panel and can be seen through the windshield from the outside of the vehicle.

1, 2, 3 Manufacturer 2 S 3 SUZUKI (Canada CAMI production)

4 Line D SUZUKI XL7

5Chassis TypeA, B

6 7

Grade Type

11, 21, 41,

51, 71, 91

A: AWD B: FWD

—

8 Engine Type 7 3.6L V6 SFI 60 Degree V Aluminum (RPO LY7) 9 Check Digit — Check Digit

10 Model Year 7 2007

11 Plant Location 6 CAMI

12-17 Plant Sequence Number — Plant Sequence Number

VIN Derivative Characters

All engines and transmissions are stamped with a partial VIN. This table identifies the different VIN derivative characters and their respective positions.

1 Division S Suzuki 2 Model Year 7 2007 3 Plant Location 6 CAMI

Page 29

General Information: 0A-16

Position Definition Character Description

4--9 Plant Sequence Number — Plant Sequence Number A VIN derivative can be used to determine if a vehicle contains the original engine or transmission by matching the VIN derivative positions to their accompanying positions in the complete VIN. AF33-5 M09-M45 Transaxle ID and VIN Derivative Locations Refer to “Transmission Identification Information”.

3.6L LY7 Engine ID and VIN Derivative Locations

Refer to “Engine Identification: ”.

Vehicle Certification, Tire Placard, Anti-Theft, and Service Parts ID Label

Page 30

0A-17 General Information:

Callout Description

Vehicle Certification Label

The vehicle certification label is located on the driver door and displays the following assessments:

• Gross vehicle weight rating (GVWR)

• Gross axle weight rating (GAWR), front and rear

• The gross vehicle weight (GVW) is the weight of the vehicle and everything it carries. The GVW must not exceed the GVWR. Include the following items when figuring the GVW:

– The base vehicle weight (factory weight) – The weight of all vehicle accessories – The weight of the driver and the passengers – The weight of the cargo

1 Name of Manufacturer 2 Gross Vehicle Weight Rating 3 Gross Axle Weight Rating (Front, Rear) 4 Canadian Safety Mark (w/RPO Z49) 5 Certification Statement 6 Vehicle Class Type (Pass Car, etc.) 7 Vehicle Identification Number 8 Date of Manufacture (Mo/Yr)

Tire Placard

The tire placard label is located on the center pillar and displays the following assessments:

9 Specified Occupant Seating Positions 10 Maximum Vehicle Capacity Weight 11 Original Equipment Tires Size 12 Tire Pressure, Front, Rear, and Spare (Cold)

Service Parts ID Label

The vehicle service parts identification label is located in the instrument panel (I/P) compartment. The label is use to help identify the vehicle original parts and options.

13 Model Designation 14 Order Number 15 Exterior Color 16 Paint Technology 17 Vehicle Identification Number 18 Wheel Base 19 Part Number Location

Anti-Theft Label

The Federal law requires that manufacturer label certain body parts on this vehicle with the VIN. The purpose of the law is to reduce the number of motor vehicle thefts by helping in the tracing and recovery of parts from stolen vehicles. Labels are permanently affixed to an interior surface of the part. The label on the replacement part

contains the letter R, the manufacturer's logo, and the DOT symbol. The anti-theft label must be covered before any painting, and rustproof procedures, and uncovered after the procedures. Failure to follow the precautionary steps may result in liability for violation of the Federal Vehicle Theft Prevention Standard and possible suspicion to the owner that the part was stolen.

Page 31

Vibration Theory and Terminology

Vibration Theory

The designs and engineering requirements of vehicles have undergone drastic changes over the last several years. Vehicles are stiffer and provide more isolation from road input than they did previously. The structures of today's stiffer vehicles are less susceptible to many of the vibrations which could be present in vehicles of earlier designs, however, vibrations can still be detected in a more modern vehicle if a transfer path is created between a rotating component and the body of the vehicle. There are not as many points of isolation from the road in many vehicles today. If a component produces a strong enough vibration, it may overcome the existing isolation and the component needs to be repaired or replaced. The presence/absence of unwanted noise and vibration is linked to the customer's perception of the overall quality of the vehicle. Vibration is the repetitive motion of an object, back and forth, or up and down. The following components cause most vehicle vibrations:

• A rotating component

• The engine combustion process firing impulses Rotating components will cause vibrations when excessive imbalance or runout is present. During vibration diagnosis, the amount of allowable imbalance or runout should be considered a TOLERANCE and not a SPECIFICATION. In other words, the less imbalance or runout the better. Rotating components will cause a vibration concern when they not properly isolated from the passenger compartment: Engine firing pulses can be detected as a vibration if a motor mount is collapsed. A vibrating component operates at a consistent rate (km/ h, mph, or RPM). Measure the rate of vibration in question. When the rate/speed is determined, relate the vibration to a component that operates at an equal rate/ speed in order to pinpoint the source. Vibrations also tend to transmit through the body structure to other components. Therefore, just because the seat vibrates does not mean the source of vibration is in the seat. Vibrations consist of the following three elements:

• The source - the cause of the vibration

• The transfer path - the path the vibration travels through the vehicle

• The responder - the component where the vibration is felt

General Information: 0A-18

In the preceding picture, the source is the unbalanced tire. The transfer path is the route the vibrations travels through the vehicle's suspension system into the steering column. The responder is the steering wheel, which the customer reports as vibrating. Eliminating any one of these three elements will usually correct the condition. Decide, from the gathered information, which element makes the most sense to repair. Adding a brace to the steering column may keep the steering wheel from vibrating, but adding a brace is not a practical solution. The most direct and effective repair would be to properly balance the tire.

Vibration can also produce noise. As an example, consider a vehicle that has an exhaust pipe grounded to the frame. The source of the vibration is the engine firing impulses traveling through the exhaust. The transfer path is a grounded or bound-up exhaust hanger. The responder is the frame. The floor panel vibrates, acting as a large speaker, which produces noise. The best repair would be to eliminate the transfer path. Aligning the exhaust system and correcting the grounded condition at the frame would eliminate the transfer path.

Page 32

0A-19 General Information:

Basic Vibration Terminology

The following are the 2 primary components of vibration diagnosis:

• The physical properties of objects

• The object's properties of conducting mechanical energy

The repetitive up and down or back and forth movement of a component cause most customer vibration complaints. The following are the common components that vibrate:

• The steering wheel

• The seat cushion

•The frame

•The IP

Vibration diagnosis involves the following simple outline:

1. Measure the repetitive motion and assign a value to

the measurement in cycles per second or cycles per minute.

2. Relate the frequency back on terms of the rotational

speed of a component that is operating at the same rate or speed.

3. Inspect and test the components for conditions that

cause vibration. For example, performing the following steps will help demonstrate the vibration theory:

The motion of the stick occurs in repetitive cycles. The cycle begins at midpoint, continues through the lowest extreme of travel, then back past the midpoint, through the upper extreme of travel, and back to the midpoint where the cycle begins again. The cycle occurs over and over again at the same rate, or frequency. In this case, about 10 cycles in one second. If we measure the frequency to reflect the number of complete cycles that the yardstick made in one minute, the measure would be 10 cycles x 60 seconds = 600 cycles per minute (cpm). We have also found a specific amount of motion, or amplitude, in the total travel of the yardstick from the very top to the very bottom. Redo the experiment as follows:

1. Reclamp the yardstick to the edge of a table, leaving about 25 cm (10 in) hanging over the edge of the table.

2. Pull down on the edge of the stick and release while observing the movement of the stick.

The stick vibrates at a much faster frequency: 30 cycles per second (1,800 cycles per minute).

1. Clamp a yardstick to the edge of a table, leaving about 50 cm (20 in) hanging over the edge of the table.

2. Pull down on the edge of the stick and release while observing the movement of the stick.

Page 33

Cycle

1. 1st Cycle 3. 3rd Cycle

2. 2nd Cycle 4. Time

General Information: 0A-20

Vibration Cycles in Powertrain Components

1. Spindle

2. Pinion Nose

The word cycle comes from the same root as the word circle. A circle begins and ends at the same point, as thus, so does a cycle. All vibrations consist of repetitive cycles.

Page 34

0A-21 General Information:

Frequency

1. Amplitude 3. Time in Seconds

2. Reference 4. 1 Second

Frequency is defined as the rate at which an event occurs during a given period of time. With a vibration, the event is a cycle, and the period of time is 1 second. Thus, frequency is expressed in cycles per second. The proper term for cycles per seconds is Hertz (Hz). This is the most common way to measure frequency. Multiply the Hertz by 60 to get the cycles or revolutions per minute (RPM).

Amplitude

4. Peak-to-Peak Amplitude

Amplitude is the maximum value of a periodically varying quantity. Used in vibration diagnostics, we are referring it to the magnitude of the disturbance. A severe disturbance would have a high amplitude; a minor disturbance would have a low amplitude. Amplitude is measured by the amount of actual movement, or the displacement. For example, consider the vibration caused by an out-of-balance wheel at 80 km/h (50 mph) as opposed to 40 km/h (25 mph). As the speed increases, the amplitude increases.

Free Vibration

Free vibration is the continued vibration in the absence of any outside force. In the yardstick example, the yardstick continued to vibrate even after the end was released.

1. Maximum

2. Minimum

3. Zero-to-Peak Amplitude

Forced Vibration

Forced vibration is when an object is vibrating continuously as a result of an outside force.

Page 35

Centrifugal Force Due to an Imbalance

General Information: 0A-22

1. Location of Imbalance (Degrees) 2. Centrifugal Force Acting on Spindle

A spinning object with an imbalance generates a centrifugal force. Performing the following steps will help to demonstrate centrifugal force:

1. Tie a nut to a string.

2. Hold the string. The nut hangs vertically due to gravity.

3. Spin the string. The nut will spin in a circle. Centrifugal force is trying to make the nut fly outward, causing the pull you feel on your hand. An unbalanced tire follows the same example. The nut is the imbalance in the tire. The string is the tire, wheel, and suspension assembly. As the vehicle speed increases, the disturbing force of the unbalanced tire can be felt in the steering wheel, the seat, and the floor. This disturbance will be repetitive (Hz) and the amplitude will increase. At higher speeds, both the frequency and the amplitude will increase. As the tire revolves, the imbalance, or the centrifugal force, will alternately lift the tire up and force the tire downward, along with the spindle, once for each revolution of the tire.

Page 36

0A-23 General Information:

Natural or Resonant Frequency

The natural frequency is the frequency at which an object tends to vibrate. Bells, guitar strings, and tuning forks are all examples of objects that tend to vibrate at specific frequencies when excited by an external force. Suspension systems, and even engines within the mounts, have a tendency to vibrate at certain frequencies. This is why some vibration complaints occur only at specific vehicle speeds or engine RPM. The stiffness and the natural frequency of a material have a relationship. Generally, the stiffer the material, the higher the natural frequency. The opposite is also true. The softer a material, the lower the natural frequency. Conversely, the greater the mass, the lower the natural frequency.

Resonance

1. Frequency - cps

2. Suspension Frequency

3. Unbalanced Excitation

4. Point of Resonance

5. Problem Speed

All objects have natural frequencies. The natural frequency of a typical automotive front suspension is in the 10-15 Hz range. This natural frequency is the result of the suspension design. The suspension's natural frequency is the same at all vehicle speeds. As the tire speed increases along with the vehicle speed, the disturbance created by the tire increases in frequency. Eventually, the frequency of the unbalanced tire will intersect with the natural frequency of the suspension. This causes the suspension to vibrate. The intersecting point is called the resonance. The amplitude of a vibration will be greatest at the point of resonance. While the vibration may be felt above and below the problem speed, the vibration may be felt the most at the point of resonance.

Page 37

Damping

General Information: 0A-24

1. Low Damping 2. High Damping

Damping is the ability of an object or material to dissipate or absorb vibration. The automotive shock absorber is a good example. The function of the shock absorber is to absorb or dampen the oscillations of the suspension system.

Page 38

0A-25 General Information:

Beating (Phasing)

Two separate disturbances that are relatively close together in frequency will lead to a condition called beating, or phasing. A beating vibration condition will increase in intensity or amplitude in a repetitive fashion as the vehicle travels at a steady speed. This beating vibration can produce the familiar droning noise heard in some vehicles. Beating occurs when 2 vibrating forces are adding to each other's amplitude. However, 2 vibrating forces can also subtract from each other's amplitude. The adding and subtracting of amplitudes in similar frequencies is called beating. In many cases, eliminating either one of the disturbances can correct the condition.

Order

Order refers to how many times an event occurs during 1 revolution of a rotating component.

For example, a tire with 1 high spot would create a disturbance once for every revolution of the tire. This is called first-order vibration.

Page 39

General Information: 0A-26

An oval-shaped tire with 2 high spots would create a disturbance twice for every revolution. This is called second-order vibration. Three high spots would be thirdorder, and so forth. Two first-order vibrations may add or subtract from the overall amplitude of the disturbance, but that is all. Two first-order vibrations do not equal a second-order. Due to centrifugal force, an unbalanced component will always create at least a first-order vibration.

Service Programming System (SPS)

For step by step programming instructions, please refer to the techline information system (TIS) terminal. Review the information below to ensure proper programming protocol.

NOTE

• DO NOT program a control module unless you are directed by a service procedure or you are directed by a service bulletin. Programming a control module at any other time will not permanently correct a customer's concern.

• It is essential that the Tech 2 and the TIS terminal are both equipped with the latest software before performing service programming system (SPS).

• Some modules will require additional programming/setup events performed before or after programming.

• Some vehicles may require the use of a CANDi module for programming.

• Review the appropriate service information for these procedures.

• DTCs may set during programming. Clear DTCs after programming is complete.

• Clearing powertrain DTCs will set the Inspection/Maintenance (I/M) system status indicators to NO.

Ensure the following conditions are met before programming a control module:

• Vehicle system voltage – There is not a charging system concern. All

charging system concerns must be repaired before programming a control module.

– Battery voltage is greater than 12 volts but less

than 16 volts. The battery must be charged before programming the control module if the battery voltage is low.

– A battery charger is NOT connected to the vehicle's

battery. Incorrect system voltage or voltage fluctuations from a battery charger, may cause programming failure or control module damage.

– Turn OFF or disable any system that may put a

load on the vehicle's battery, such as the following components:

– Twilight sentinel – Interior lights – Daytime running lights (DRL)—Applying the

parking brake, on most vehicles, disables the DRL system.

– Heating, ventilation, and air conditioning (HVAC)

systems

– Engine cooling fans, radio, etc.

• The ignition switch must be in the proper position. The Tech 2 prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so.

• Make certain all tool connections are secure, including the following components and circuits:

– The RS-232 communication cable port – The connection at the data link connector (DLC) – The voltage supply circuits

• DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur.

• DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date. Attempt to reprogram the control module. If the control module cannot be programmed, replace the control module.

Page 40

0A-27 General Information:

DTC Symptom Description - Vehicle Diagnostic Information

A DTC symptom is a 2-digit number which adds additional detail to a DTC. The DTC symptom provides additional information without requiring a large increase in the number of new DTCs.

DTC Symptom Categories

The DTC symptom is made up of 2 alphanumeric digits. The first digit following the DTC indicates the DTC symptom category. There are 16 possible categories available in the range of 0 through the letter F. Currently there are 8 categories in use, 0 through 7. These 8 categories together with their definitions are given below.

Category

Number

0 General Electrical Failures

1 Additional General Electrical Failures

3 ECU Internal Failures

4 ECU Programming Failures

5 Algorithm Based Failures

6 Mechanical Failures

7 Bus Signal/Message Failures

8-F Reserved by Document Not in use at this time.

FM/PWM (Frequency/Pulse Width Modulated) Failures

Category Name Category Description

This category includes standard wiring failure modes, direct current quantities related by Ohm's Law and quantities related to amplitude, frequency or rate of change, and wave shape. This category includes the overflow from the previous category. This category includes faults related to frequency modulated and pulse width modulated inputs and outputs of the electronic control module (ECU). This category also includes faults where position is determined by counts. This category includes faults related to memory, software, and internal electrical circuitry; requiring ECU replacement. This category includes faults related to operational software, calibrations, and options, remedied by programming the ECU. This category includes faults based on comparing two or more input parameters for plausibility or comparing a single parameter to itself with respect to time. This category includes faults detected by inappropriate motion in response to an ECU controlled output. This category includes faults related to bus hardware and signal integrity. This category is also used when the physical input for a signal is located in one ECU and another ECU diagnoses the circuit.

Page 41

General Information: 0A-28

DTC Symptom Subtypes

The second digit of the DTC symptom is the subtype of the DTC symptom. These subtypes and their categories, together with their definitions, are given in the following table. DTC symptom 00 is a special case. If 00 is displayed, only the base code number and its description apply. Information regarding the fault will be provided in the code setting criteria.

Example

The DTC symptoms associated with each DTC provide more information about the fault that caused that DTC. An example of a DTC displayed can be B1451 05 where the B1451 is the DTC, and 05 after the space represents the DTC symptom. While the DTC indicates that the fault is in the accessory power circuit, this DTC symptom indicates the circuit is shorted to battery or open. Another possible symptom for this code is B1451 02, where B1451 indicates the accessory power circuit, and 02 indicates the circuit is shorted to ground.

DTC Symptom DTC Symptom Description

00 No Additional Information 01 Short to Battery 02 Short to Ground 03 Voltage Below Threshold 04 Open Circuit 05 Short to Battery or Open 06 Short to Ground or Open 07 Voltage Above Threshold 08 Signal Invalid

09 Rate of Change Above Threshold 0A Rate of Change Below Threshold 0B Current Above Threshold 0C Current Below Threshold 0D Resistance Above Threshold 0E Resistance Below Threshold 0F Erratic

10 Reserved

11 Above Maximum Threshold

12 Below Minimum Threshold

13 Voltage Low/High Temperature

14 Voltage High/Low Temperature

15 Signal Rising Time Failure

16 Signal Falling Time Failure

17 Signal Shape/Waveform Failure

1A Bias Level Out of Range 1F Intermittent

21 Incorrect Period

22 Low Time Less Than Minimum

23 Low Time Greater Than Maximum

24 High Time Less Than Minimum

25 High Time Greater Than Maximum

26 Frequency Too Low

27 Frequency Too High

28 Incorrect Frequency

29 Too Few Pulses 2A Too Many Pulses

Signal Amplitude Less Than Minimum Signal Amplitude Greater Than Maximum

DTC Symptom DTC Symptom Description

2B Missing Reference 2C Reference Compare Error

31 General Checksum Failure 32 General Memory Failure 33 Special Memory Failure 34 RAM Failure 35 ROM Failure 36 EEPROM Failure 37 Watchdog/Safety Processor Failure 38 Supervision Software Failure 39 Internal Electronic Failure

43 EEPROM Error 44 Security Access Not Activated 45 Variant Not Programmed

47 VIN Not Programmed 48 Theft/Security Data Not Programmed

49 RAM Error 4A Checksum Error 4B Calibration Not Learned

51 Calculation Failure

52 Compare Failure

53 Temperature Low

54 Temperature High

58 Incorrect Reaction After Event

61 Actuator Stuck

62 Actuator Stuck Open

63 Actuator Stuck Closed

64 Actuator Slipping

65 Emergency Position Not Reachable

72 Alive Counter Incorrect/Not Updated

73 Parity Error

75 Signal Above Allowable Range

76 Signal Below Allowable Range 7F Erratic

Operational Software/Calibration Data Set Not Programmed Calibration Data Set Not Programmed

Vehicle Configuration Not Programmed

Expected Number of Transitions/ Events Not Reached Allowable Number of Transitions/ Events Exceeded Expected Reaction After Event Did Not Occur

Circuit/Component Protection TimeOut

Invalid Serial Data Received (Signal Validity Bit Indicates Failure)

Value of Signal Protection Calculation Incorrect

Page 42

0A-29 General Information:

Service Materials (Lubricants, Oil, Grease, Sealant, Adhesive, Cleaner, etc)

General

Standard

Name

EOS Engine Assembly Prelube

Upper Engine and Fuel Injector CleanerAerosol GM top engine cleaner, GM P/ N 1052626 (Canadian P/N

993026) or AC-Delco Carburetor Tune-Up Conditioner, Hi Temp, High Strength Threadlocker LOCKTITE 277®

GM 5W-30

Permatex 56521

Use 12378556 USA except California Use 12378392

Anti-seize compound

Three Bond TB1217

DEX-COOL antifreeze

Supplier Application

• Crankshaft prelube

• Piston pin bores in the piston and

Valspa r

AC-Delco carburetor tune-up conditioner P/ N X66-P

GM Goodwrench

GM Goodwrench, Various

Permatex

GM Goodwrench, Various

Various

Three Bond

GM Goodwrench

the connecting rod

• Upper and lower bearing surfaces Engine Section

Throttle body Engine Controls Throttle body service section

Insert OD threads Engine Mechanical and Transfer case sections

Engine oil Hydraulic lash adjuster Engine Mechanical Section

• Coolant and oil plug threads

• Drain plug threads

• Left side oil gallery threaded plug

• Left side coolant drain threaded plug

Tapped hole Engine Mechanical Section

Reinstalled HO2S thread Engine Electrical Devices Section such as O2 sensor replacement

• Oil pan

• PCV orifice

• Coolant expansion plugs

• Crankshaft rear oil seal housing

• Block pan rail and the crankshaft rear oil seal housing

• Engine front cover

• Engine front cover split

Mixture of 50/50 DEX-COOL antifreeze and clean water

Engine

Gm Part

Name

Lubricant

GM top engine cleaner

Threadlocker (Thread lock sealant)

Engine oil

Sealant

Spray cleaner

Anti-seize compound

Sealant RTV (Room Te mp . Vulcanizing) sealant

DEX-COOL antifreeze

Gm Part NO.

GM P/N 1052367 (Canadian P/N

992869)

GM P/N 1052626 (Canadian P/N

993026)

GM P/N 89021297 (Canadian P/N

10953488) J 42385-109 GM P/N 12345610 (Canadian P/N

993193)

GM P/N 12346004 (Canadian P/N

10953480)

GM P/N 12346139 or 12377981 (Canadian P/N

10953463)

GM P/N 12377953

GM P/N 12378521 (Canadian P/N

88901148)

GM P/N 12346290 (Canadian P/N

10953464)

Page 43

General Information: 0A-30

Gm Part

Name

Automatic transmission fluid Type T- IV

Transmission /Transaxle

Brake — — DOT 3

Driveline /Axle

Steering

Threadlocker

Sealant

Threadlocker (Thread lock sealant)

Synthetic Gear Oil GL75W90

Threadlocker

Power steering fluid

Gm Part NO.

GM P/N 88900925 (Canadian P/N

22689186) GM P/N 12345382 (Canadian P/N

10953489) GM P/N

89020326 (Canadian P/N

89021188)

GM P/N 89021297 (Canadian P/N

10953488) J 42385-109

GM P/N 89021677 (Canadian P/N

89021678)

GM P/N 89021297 (Canadian P/N

10953488) GM P/N 89021184 (Canadian P/N

89021186)

General

Standard

Name

MOBIL ATF 3309 SUZUKI ATF 3317

Permatex® 24200

Three Bond TB1281

Hi Temp, High Strength Threadlocker LOCKTITE 277®

75W-90GL5synthetic

Threadlocker Permatex

Supplier Application

Exxon mobile Automatic transmission inner parts

Permatex

Three Bond

GM Goodwrench, Various

GM Goodwrench

BURMAH CASTROL BOT 190 Chev-Tex, flexpac

— — Power steering system

All seat belt fasteners AT case cover bolts

Case sealing surfaces

• Control valve body cover

• Torque converter housing assembly Automatic Trans Section

Brake fluid

Insert OD threads Engine Mechanical and Transfer case sections

Rear differential Transfer case fill

Propeller shaft mounting/CVJ bolts Center bearing to vehicle bolts Propeller shaft rear attaching bolts Differential and Prop Shaft Sections

Page 44

0A-31 General Information:

Gm Part

Name

Windshield cleaner

Polyolefin adhesive primer Urethane adhesive kit GM spec. GM 3651G GM Goodwrench structural bonding Epoxy GM Goodwrench SRIM repair kit

Metal panel bonding adhesive (Fast set) GM 6449G

Body

Medium set panel bonding adhesive

Repair compound

GM-approved weld-thru coating or equivalent Fusor super flexible antiflutter foamfast set, Fusor P/N 121/ 124 or equivalent

Panel bonding adhesive

HVAC —

Others

Cutting type fluid

General

Gm Part NO.

GM P/N 89021822 (Canadian P/N

992727)

—

GM P/N 12346392 (Canadian P/ N 10952983)

GM P/N 12345726

GM P/N 12378523

GM P/N 12378566 (Canadian P/N

88901674) Lord Fusor P/N 110B/111B

GM P/N 12378567 (Canadian P/N

88901675) Lord Fusor P/N 108B/109B

GM P/N 88861039 or 8886140

— 3M 05917 3M Body panel mating surfaces

——

—

GM P/N 12378526 (Canadian P/N

88900060) GM P/N 1052864 (Canadian P/N

992881)

Standard

Name

Glass Cleaner

Adhesion Promoter

—

Epoxy

—

Fast Set Panel Bonding Adhesive

Medium Set Panel Bonding Adhesive

—

3M P/N 8116 Ashland Plio Grip Panel

PAG oil Polyalkylene glycol

WD 40® Vals par

Supplier Application

Accrapac/ Kemkrest

GM Goodwrench, Various

GM Goodwrench

GM Goodwrench, Various

GM Goodwrench, Various General Motors materials and products manufactured by Lord Adhesives General Motors materials and products manufactured by Lord Adhesives GM Goodwrench, Various

GM Goodwrench, Various

3M Body Structure Section

Windshield

High strength plastic (Flexible plastic part) Body section Urethane adhesive-installed window Adhesive service kit description in Body general description section

Seat metal (Rigid plastic part) Body Structure Section

SRIM most rigid plastic part Body Structure Section

Door panel hemming Door outer panel replacement Body/Door Section

Body Structure Section

High strength plastic (Flexible plastic part) Body Structure Section

Between door outer panel and inner safety beam Body Structure Section

— Compressor

When performing the drilling, counterboring and tapping procedures. Base engine service thread repair

Page 45

Component Location

Engine Identification

Vehicle Identification Number

The Vehicle Identification Number (VIN) Derivative is located in one place on the engine and is a seventeen digit number stamped or laser etched onto the block at the vehicle assembly plant. If reading the identification number the following information can be obtained:

• The first three digits identify the vehicle make.

• The fourth digit is the vehicle line.

• The fifth digit identifies the chassis type.

• The sixth & seventh digits are the grade type.

• The eight digit is the engine.

• The ninth digit is a check digit.

• The tenth digit is the model year.

• The eleventh digit is the manufacturing plant.

• The twelfth to seventeenth digits are the serial number.

General Information: 0A-32

The engine block is marked with the engine plant sequence number on a pad area on the left rear side (1).

The engine block is marked with the VIN on a pad area on the left rear side (1).

Engine Plant Sequence Number

The engine plant sequence number is located in one place on the engine and is a twelve digit number stamped or laser etched onto the block at the engine assembly plant.

Engine Traceability Label

The engine traceability label is located in a place on the engine and consists of the broadcast code, bar code and sequence number.

The engine traceability label (1) is located on the rear of the left cylinder head.

Engine Barcode Description

Position Definition Character Description Engine Barcode Description The Engine Barcode format is 10XXX-XXXXXXXXX, totaling 15 characters.

1-2 Flex ID 10 Component ID 3-5 Broadcast Code BWD Broadcast Code

6 Hyphen — Hyphen

7-13 Serial Number — Serial Number

14-15 Blank — Intentionally Blank

Page 46

0A-33 General Information:

Transmission Identification Information

1. Transmission I.D. Location 7. Serial Number During the Month of Manufacture

2. Model Number 8. Assembly Line Code

3. I.D. Code 9. Model of Transaxle, V = 55-50SN

4. GM Part Number 10. Month of Manufacture, A = Jan, B = Feb, etc

5. Calibration Code 11. Year of Manufacture, 03 = 2003

6. AW Production Unit Number

Diagnostic Information and Procedures

Diagnostic Procedure Instructions - Vehicle Diagnostic Information

The following is an overview of instructions for all 16 categories which may be included in a diagnostic procedure.

Diagnostic Instructions

A link to the “Diagnostic System Check - Vehicle Diagnostic Information” is provided here. This procedure should be performed prior to performing other diagnostic procedures, as this prevents misdiagnosis where there are integrated system dependencies. A link to the “Strategy Based Diagnosis: ” is provided here. This provides an overview on how a technician should diagnose a vehicle. A link to the “Diagnostic Procedure Instructions - Vehicle Diagnostic Information” is provided here. This information is an overview of instructions for all 16 categories which may be included in a diagnostic procedure.

DTC Descriptor

Describes what DTCs are diagnosed in this procedure. The DTC number, with Symptom Description when applicable, and descriptor are written out.

Page 47

General Information: 0A-34

Diagnostic Fault Information

The diagnostic Fault Information table identifies each circuit that makes up an electrical subsystem and the associated circuit faults. DTCs and symptoms are listed in the table for all circuit fault modes. This information can be used to diagnose an electrical fault, or as a quick visual aid showing how the different symptoms and DTCs apply for the subsystem being diagnosed. Even though all the DTCs and symptoms are shown in this table it does not mean they will all be diagnosed in the same procedure. An example table from an engine coolant temperature (ECT) procedure:

Circuit

ECT Sensor Signal P0117 P0118 P0118

ECT Low Reference — P0118 P0118

Short to

Ground

Open/High

Resistance

Short to Voltage

Signal

Performance

P0125 P0128 P0125 P0128

Typical Scan Tool Data

The Typical Scan Tool Data table identifies a scan tool data parameter and its value in reference to potential circuit faults. An example table from an ECT procedure:

ECT Sensor Temperature - PCM

Circuit Short to Ground Open Short to Voltage

Operating Conditions: Engine Running Parameter Normal Range:−32 to +130°C (−26 to +275°F)

ECT Signal −40°C (−40°F) 140°C (284°F) −40°C (−40°F) Low Reference — −40°C (−40°F) −40°C (−40°F)

Internal ECM damage may occur if shorted to B+

Circuit/System Description

Circuit/System Description identifies how a circuit/ system normally functions.

Conditions for Running the DTC

Conditions for Running the DTC, identifies what conditions must be present to allow the diagnostic to run.

Conditions for Setting the DTC

Conditions for Setting the DTC, identifies the condition(s) that must be present in order to fail the diagnostic and when to set the DTC.

Action Taken When the DTC Sets

Actions Taken When the DTC sets, identifies the default actions taken when a control module sets a DTC.

Conditions for Clearing the DTC

Conditions for Clearing the DTC, identifies the conditions that must be met in order to clear the DTC.

Diagnostic Aids

Diagnostic Aids are suggestions which explain other methods to diagnose the condition. It also provides unique information about the system used to assist the technician in finding and repairing a vehicle condition.

Reference Information

Reference Information includes links providing additional information for the diagnostic procedure. For example:

• Schematic Reference

• Connector End View Reference

• Description and Operation

• Electrical Information Reference

• DTC Type Reference

• Scan Tool Reference

• Special Tools Required

Page 48

0A-35 General Information:

Circuit/System Verification

The diagnostic format does not force a technician to any of the 3 diagnostic categories (Circuit/System Verification, Circuit/System Testing and Component Testing). However, performing the Circuit/System Verification category first, aids in determining if a vehicle condition is current. This category also serves to route the technician to another diagnostic procedure which should be performed first; for example, a DTC with a higher priority. Circuit/System Verification is a non-intrusive procedure outlining how to verify that a system or a portion of a system is functioning correctly. During the verification process, the vehicle is kept intact and tested as a complete system. This verification is used to assist the technician in determining whether a condition is current or intermittent. When a condition is determined to be intermittent, a technician can use the link in Electrical Information Reference: “Testing for Intermittent Conditions and Poor Connections: ”. The technician should be able to identify if the fault is occurring on the input circuit - signal or on the output circuit - control when applicable. The technician will need to decide from the verification results if the system is working correctly or if further diagnosis needs to be performed in either Circuit/System Testing and/or Component Testing.

Circuit/System Testing

The diagnostic format does not force a technician to any of the 3 diagnostic categories (Circuit/System Verification, Circuit/System Testing and Component Testing). However, beginning with the Circuit/System Verification category aids in determining if a vehicle condition is current. Circuit/System Testing is a step by step, positive-flow, testing sequence which allows the technician to perform each test step, in sequence, until a fault is detected. If the result of a test step is achieved, the normal flow is to proceed to the next step. If the result is NOT achieved, the repair arrow bullet will identify what actions need to take place. Intrusive diagnostics are performed to locate the system fault. System harness connections are disconnected from the module or component to test individual circuit functions. The module or component will be used to assist in verifying the circuit function. When a test does not pass, the repair steps will indicate what circuit faults to test. For example, short to voltage, short to ground or open/high resistance.

When testing for individual circuit faults, the technician is expected to include terminal inspections such as connection surfaces and terminal tension at both the harness and component/module. Additionally, a technician can use the links in Electrical Information Reference: “Testing for Intermittent Conditions and Poor Connections: ” or “Circuit Testing: ”. The control modules and components will also be diagnosed during these test steps. A retest of a control module or component should always be performed before replacement. For example, re-connect all components and modules and retest the system to verify the condition still exists before replacing modules or components.

Component Testing

Repair Instructions

Repair Instructions provides a link to “Diagnostic Repair Verification - Vehicle Diagnostic Information”. This link describes how to verify the vehicle is repaired. All links to Repair or Replacement procedures are located here.

Repair Verification

Repair Verification describes how to verify the vehicle is repaired when additional instructions are needed beyond what is in Diagnostic Repair Verification.

Page 49

General Information: 0A-36

Strategy Based Diagnosis - Vehicle Diagnostic Information

The goal of Strategy Based Diagnostics is to provide guidance when you create a plan of action for each specific diagnostic situation. Following a similar plan for each diagnostic situation, you will achieve maximum efficiency when you diagnose and repair vehicles. Although each of the Strategy Based Diagnostics boxes is numbered, you are not required to complete every box in order to successfully diagnose a customer concern. The first step of your diagnostic process should always be, verify the Customer Concern box. The final step of your diagnostic process should be Repair and verify the Fix box 7. Refer to the following chart for the correct Strategy Based Diagnostics.

1. Verify the Customer Concern: The first part of this step is to obtain as much information as possible from the customer. Are there aftermarket accessories on the vehicle? When does the condition occur? Where does the condition occur? How long does the condition last? How often does the condition occur? In order to verify the concern, the technician should be familiar with the normal operation of the system and refer to the owner or service manual for any information needed.

2. Preliminary Checks: Conduct a thorough visual inspection. Review the service history. Detect unusual sounds or odors. Gather diagnostic trouble code (DTC) information in order to achieve an effective repair.

5.3. No Published Diagnostics: Analyze the Concern. Develop a plan for the diagnostics. The service manual schematics will help you to see system power, ground, input and output circuits. You can also identify splices and other areas where multiple circuits are tied together. Look at component locations to see if components, connectors or harnesses may be exposed to extreme temperature, moisture, road salt or other corrosives battery acid, oil or other fluids. Utilize the wiring diagrams, system description and operation, and system circuit description.

5.4. Intermittents: An intermittent condition is one that does not occur continuously and will occur when certain conditions are met. Generally, intermittents are caused by faulty electrical connections and wiring, malfunctioning components, electromagnetic/radio frequency interference, and aftermarket equipment. Combine technician knowledge with efficient use of the available service information. Evaluate the symptoms and conditions described by the customer. Use a check sheet or other method in order to identify the component. Follow the suggestions for intermittent diagnosis found in the service manual. A scan tool and a digital multi-meter may have data capturing capabilities that can assist in detection of intermittents.

Page 50

0A-37 General Information:

3. Perform Published Diagnostic System Check: The Diagnostic System Check verifies the proper operation of the system. This will lead the technician in an organized approach to diagnostics.

4. Check Bulletins, Recalls and Preliminary Information (PI)s. 6. Re-examine the Concern: If a technician cannot successfully find or

5.1. Stored DTCs: Follow the designated DTC in order to make an effective repair.

5.2. Symptom No DTC: Select the appropriate symptom. Follow the diagnostic steps or suggestions in order to complete the repair.

5.5. Vehicle Operates as Designed: This condition exists when the vehicle is found to operate normally. The condition described by the customer may be normal. Compare with another like vehicle that is operating normally under the same conditions described by the customer. Explain your findings and the operation of that system to the customer.

isolate the concern, a re-evaluation is necessary. Re-verify the concern. The concern could be an intermittent or normal condition.

7. Repair and Verify Fix: After isolating the cause, make the repairs and validate for the correct operation. Verify that the symptom has been corrected, which may involve road testing the vehicle.

Strategy Based Diagnosis

Page 51

General Information: 0A-38

3. Perform Published Diagnostic System Check: The Diagnostic System Check verifies the proper operation of the system. This will lead the technician in an organized approach to diagnostics.

4. Check Bulletins, Recalls and Preliminary Information (PI)s. 6. Re-examine the Concern: If a technician cannot successfully find or

5.1. Stored DTCs: Follow the designated DTC in order to make an effective repair.

5.2. Symptom No DTC: Select the appropriate symptom. Follow the diagnostic steps or suggestions in order to complete the repair.

isolate the concern, a re-evaluation is necessary. Re-verify the concern. The concern could be an intermittent or normal condition.

7. Repair and Verify Fix: After isolating the cause, make the repairs and validate for the correct operation. Verify that the symptom has been corrected, which may involve road testing the vehicle.

Vehicle-to-Vehicle Diagnostic Comparison

Comparing the customer's vehicle to a KNOWN GOOD vehicle that is essentially identical will help determine if the customer's concern may be characteristic of a vehicle design. To arrive at a valid conclusion, the comparison must be performed under the same conditions, using the same criteria, on a vehicle that has the same option content as the customer's vehicle. The comparison vehicle must match the customer's vehicle in the following areas:

• Model Year

•Make

• Model

• Body style

• Powertrain configuration

• Driveline configuration

• Final drive ratio

• Tire/wheel size and type

• Suspension package

• Trailering package

•GVW rating

• Performance options

• Luxury options

Page 52

0A-39 General Information:

Diagnostic Trouble Code (DTC) List - Vehicle Diagnostic Information

This master DTC list includes all applicable DTCs in alphanumeric order with descriptors. The GM LAN modules on this vehicle also support DTC Symptom information. Refer to “DTC Symptom Description Vehicle Diagnostic Information” for additional information on DTC symptoms.

DTC DTC Descriptor

NOTE

Do not clear any DTCs unless instructed to do so by a diagnostic procedure

NOTE

If any DTCs are Powertrain related DTCs, select Capture Info in order to store the DTC information with the scan tool

Diagnose any current DTCs in the following order:

1. DTCs that begin with a U

2. B1000, B1001, B1016, B1019, C0550, C0551, C0558, P0601, P0602, P0603, P0604, P0606, P2101, P2107, or P2610

3. B1325, B1424, B1517, C0800, C0899, C0900, P0560, P0562, or P0563

4. Component level DTCs

5. System level DTCs

6. Any remaining DTCs

Module that

Sets the DTC

Diagnostic Procedure

B0000 Vehicle Speed Information Circuit Radio “DTC B0000: ” B0005 In Park Switch Signal Circuit BCM “DTC B0005: ”

B0012

B0013

Driver Frontal Deployment Loop Stage 1 Driver Frontal Deployment Loop Stage 2

SDM “DTC B0012 or B0013: ”

B0014 Driver Side Frontal Deployment Loop SDM “DTC B0014-B0045: ” B0015 Driver Pretensioner Loop SDM “DTC B0014-B0045: ”

B0016

B0019

B0020

B0022

B0023

Left Roof Rail Initiator 1 Deployment Loop Passenger Frontal Deployment Loop Stage 1 Passenger Frontal Deployment Loop Stage 2 Passenger Pretensioner Deployment Loop Right Roof Rail Initiator 1 Deployment Loop

SDM “DTC B0014-B0045: ”

B0052 Deployment Commanded SDM “DTC B0052 or B0053: ”

B0053

Deployment Commanded With Loop DTCs Present

SDM “DTC B0052 or B0053: ”

B0055 Side Airbag Deployment Commanded SDM “DTC B0055: ” B0056 Passenger Frontal Airbag Suppressed SDM “DTC B0056: ” B0057 Passenger Side Airbag Suppressed SDM “DTC B0057: ” B0058 Passenger Pretensioner Suppressed SDM “DTC B0058: ” B0073 Passenger Seat Belt Sensor Circuit SDM “DTC B0073: ” B0081 Passenger Presence System SDM “DTC B0081: ” B0083 Front End Sensor 1 SDM “DTC B0083 or B0084: ” B0084 Front End Sensor 2 SDM “DTC B0083 or B0084: ” B0085 Left Front Side Impact Sensor SDM “DTC B0085 or B0086: ” B0086 Right Front Side Impact Sensor SDM “DTC B0085 or B0086: ” B0090 Rollover Sensor SDM “DTC B0090: ”

B0158

B0228 Recirculate Position Feedback Circuit HVAC

Outside Air Temperature Sensor Circuit

BCM “DTC B0158: ”

“DTC B0228, B0413, B0423, B0433, B3779 or B3782: ”

Page 53

General Information: 0A-40

DTC DTC Descriptor

B0285 Electric Rear Defrost Circuit Low BCM “DTC B0285 or B0286: ” B0286 Electric Rear Defrost Circuit High BCM “DTC B0285 or B0286: ”

B0413

B0423

B0433

B0835

B1000

B1001 Option Configuration Error

B1016 VIN Not Programmed BCM, TDM “DTC B1016: ” B1019 System Configuration Error SDM “DTC B1019: ” B1025 Left Front Audio Output Circuit Radio “DTC B1025, B1035, B1045, or B1055: ” B1035 Right Front Audio Output Circuit Radio “DTC B1025, B1035, B1045, or B1055: ” B1045 Left Rear Audio Output Circuit Radio “DTC B1025, B1035, B1045, or B1055: ” B1055 Right Rear Audio Output Circuit Radio “DTC B1025, B1035, B1045, or B1055: ” B1259 Antenna Ground Circuit DRR “DTC B1259: ” B1287 Amplifier Control Signal Circuit Radio “DTC B1287: ”

B1325 Device Power Circuit

B1370

B1380 Device Ignition Accessory Circuit BCM “DTC B1380: ” B1395 Analog Reference Voltage HSM “DTC B1395: ”

B1405

B1424 Device 1 Voltage Low TDM “DTC B1424: ”

B1428

B1433

B1441 Device Ignition Off/Run/Crank Circuit BCM “DTC B1441: ” B1475 Retained Accessory Power Circuit BCM “DTC B1475: ” B1516 Battery Current Sensor Signal BCM “DTC B1516: ” B1517 Battery Voltage BCM “DTC B1517: ” B1527 High Parasitic Load Detected BCM “DTC B1527: ”

B1529

B1925

B2170

B2345 Seat Heater Disable Circuit HSM “DTC B2345: ” B2425 Left Seat Heater Circuit HSM “DTC B2425 or B2430: ” B2430 Right Seat Heater Circuit HSM “DTC B2425 or B2430: ”

B2462 Global Positioning System (GPS)

Temperature Control 1 Feedback Circuit Temperature Control 2 Feedback Circuit Temperature Control 3 Feedback Circuit Cruise Control System Active Indicator Circuit

Electronic Control Unit (ECU) Performance

Device Ignition 1 ON and START Circuit Device Ignition 1 Circuit SDM “DTC B1370: ”

Device Voltage Reference Output 2 Circuit

Ignition Switched Power Run/Crank Relay Circuit Ignition Switched Power Relay 2 Circuit

Device Voltage Reference Output Circuit Left Seat Cushion Heater Sensor Circuit Right Seat Cushion Heater Sensor Circuit

Module that

Sets the DTC

HVAC

BCM “DTC B0835: ”

BCM, DRR, IPC, PPS, Radio, RCDLR, ROS, RSA, SDM, TDM, VCIM BCM, HVSM, PPS, Radio, ROS, SDM, VCIM SDM “DTC B1001 (SDM): ”

HVSM, IPC, PPS, Radio

BCM “DTC B1370: ”

BCM “DTC B1405: ”

BCM “DTC B1428: ”

BCM “DTC B1433: ”

BCM “DTC B1529: ”

HSM “DTC B1925 or B2170: ”

Navigation Radio

“DTC B0228, B0413, B0423, B0433, B3779 or B3782: ” “DTC B0228, B0413, B0423, B0433, B3779 or B3782: ” “DTC B0228, B0413, B0423, B0433, B3779 or B3782: ”

“DTC B1000: ”

“DTC B1001: ”

“DTC B1325: ”

“DTC B2462: ”

Diagnostic Procedure

Page 54

0A-41 General Information:

DTC DTC Descriptor

B2474

B2508 Seat Heater Relay Circuit HSM “DTC B2508 or B2509: ” B2530 Front Fog Lamp Control Circuit BCM “DTC B2530: ” B2545 Backup Lamps Circuit BCM “DTC B2545: ” B2575 Headlamp Control Circuit BCM “DTC B2575: ”

B257A

B2580 Headlamp High Beam Control Circuit BCM “DTC B2580: ” B2585 Park Lamp Control Circuit BCM “DTC B2585: ” B2600 Daytime Running Lamp Control Circuit BCM “DTC B2600: ”

B2610

B2615

B2645 Ambient Light Sensor Circuit BCM “DTC B2645: ”

B2652

B2705 Gearshift Unlock Circuit BCM “DTC B2705: ” B2750 Horn Relay Coil Circuit BCM “DTC B2750: ” B2965 Key In Ignition Circuit Open BCM “DTC B2965: ” B3006 Hood Ajar Circuit Plausibility Failure BCM “DTC B3006: ”

B3031

B3055

B3060

B3105

B3109

B3110

B3111

B3112

B3445 Stop Lamp Circuit BCM “DTC B3445: ”

B3600

B3622 Steering Wheel Controls Signal Circuit BCM “DTC B3622: ” B3715 Front Wiper Relay Drive Circuit BCM “DTC B3715: ”

B3779 Air Flow Control 9 Feedback Circuit HVAC

B3782 Air Flow Control 10 Feedback Circuit HVAC

B3794

B3867 Right Park Lamp Control Circuit BCM “DTC B3867: ” B3873 Front Washer Relay Circuit BCM “DTC B3873: ” B3875 Wiper High Speed Relay Circuit BCM “DTC B3875: ”

B3884

B3922 Front Wiper Function Select Circuit BCM “DTC B3922: ”

B3933

B3935 Transponder Authentication Error VTD “DTC B3935: ”

Navigation Display Head Backlighting Performance

Headlamp Switch Input Signal Mismatch

Passenger Compartment Dimming 1 Circuit Passenger Compartment Dimming 2 Circuit

Passenger Compartment Dimming 3 Circuit

Security System Controller In Learn Mode No Transponder Modulation or No Transponder Unprogrammed Transponder Identification Code Received Keyless Entry System Key Fobs Not Programmed Keyless Entry Transmitter 1 Low Battery Keyless Entry Transmitter 2 Low Battery Keyless Entry Transmitter 3 Low Battery Keyless Entry Transmitter 4 Low Battery

Passenger Compartment Dimming Request Signal Circuit

Cruise Control Function Request Circuit

Center High Mounted Stop Lamp (CHMSL) Circuit

Evaporator Temperature Sensor Circuit

Module that

Sets the DTC

Navigation Radio

BCM “DTC B257A: ”

BCM “DTC B2610: ”

BCM “DTC B2615: ”

BCM “DTC B2652: ”

TDM “DTC B3031: ”

TDM “DTC B3055: ”

TDM “DTC B3060: ”

RCDLR “DTC B3105: ”

RCDLR “DTC B3109: ”

RCDLR “DTC B3110: ”

RCDLR “DTC B3111: ”

RCDLR “DTC B3112: ”

BCM “DTC B3600: ”

BCM “DTC B3794: ”

BCM “DTC B3884: ”

HVAC “DTC B3933: ”

“DTC B2474: ”

“DTC B0228, B0413, B0423, B0433, B3779 or B3782: ” “DTC B0228, B0413, B0423, B0433, B3779 or B3782: ”

Diagnostic Procedure

Page 55

General Information: 0A-42

DTC DTC Descriptor

B3976

C0035 Left Front Wheel Speed Sensor Circuit EBCM “DTC C0035-C0050: ”

C0040

C0045 Left Rear Wheel Speed Sensor Circuit EBCM “DTC C0035-C0050: ”

C0050

C0110 Pump Motor Circuit EBCM “DTC C0110: ” C0131 ABS Pressure Circuit EBCM “DTC C0131: ”

C0161

C0186 Lateral Accelerometer Circuit EBCM “DTC C0186: ” C0196 Yaw Rate Circuit EBCM “DTC C0196: ”

C0201

C0252

C0267 Low Brake Fluid Indicated EBCM “DTC C0267: ” C0277 Brake Pedal Position Sensor Circuit EBCM “DTC C0277 or DTC C0890: ” C0280 Stability System Active Too Long EBCM “DTC C0280: ” C0292 VSES Combination Sensor Circuits EBCM “DTC C0292: ” C0297 Brake Applied Output Circuit BCM “DTC C0297: ”

C0393

C0394

C0460 Steering Position Signal EBCM “DTC C0460: ”

C0550

C0551 Option Configuration Error EBCM “DTC C0551: ” C0558 Calibration Mismatch CCM “DTC C0558: ”

C0561 System Disabled Information Stored

C0750 Left Front Low Tire Pressure Sensor RCDLR “DTC C0750, C0755, C0760, or C0765: ” C0755 Right Front Low Tire Pressure Sensor RCDLR “DTC C0750, C0755, C0760, or C0765: ” C0760 Left Rear Low Tire Pressure Sensor RCDLR “DTC C0750, C0755, C0760, or C0765: ” C0765 Right Rear Low Tire Pressure Sensor RCDLR “DTC C0750, C0755, C0760, or C0765: ”

C0775

C0890

C0899 Device Voltage Low EBCM “DTC C0899: ” C0900 Device Voltage High EBCM “DTC C0900: ”

P0008

P0009

P0010

P0011

P0013

P0014

Unconfigured Transponder/Vehicle Configuration Not Programmed

Right Front Wheel Speed Sensor Circuit

Right Rear Wheel Speed Sensor Circuit

Antilock Brake System (ABS) Brake Switch/Sensor Circuit

Antilock Brake System (ABS) Enable Relay Contact Circuit Steering Wheel Position Sensor Uncorrelated

Rear Axle Coupling Solenoid Control Circuit Rear Axle Coupling Temperature Sensor Circuit

Electronic Control Unit (ECU) Performance

Low Tire Pressure System Sensors Not Learned Device Voltage Reference Output 3 Circuit

Engine Position System Performance Bank 1 Engine Position System Performance Bank 2 Intake Camshaft Position (CMP) Actuator Solenoid Control Circuit Bank 1 Intake Camshaft Position (CMP) System Performance Bank 1 Exhaust Camshaft Position (CMP) Actuator Solenoid Control Circuit Bank 1 Exhaust Camshaft Position (CMP) System Performance Bank 1

Module that

Sets the DTC

TDM “DTC B3976: ”

EBCM “DTC C0035-C0050: ”

EBCM “DTC C0161: ”

EBCM “DTC C0201: ”

EBCM “DTC C0252: ”

CCM “DTC C0393: ”

CCM “DTC C0394: ”

EBCM “DTC C0550: ” CCM “DTC C0550: ”

EBCM “DTC C0561: ” CCM “DTC C0561: ”

RCDLR “DTC C0775: ”

BCM “DTC C0277 or DTC C0890: ”

ECM “DTC P0008 or P0009: ”

“DTC P0010, P0013, P0020, P0023, P2088,

ECM

ECM “DTC P0011, P0014, P0021, or P0024: ”

ECM

ECM “DTC P0011, P0014, P0021, or P0024: ”

P2089, P2090, P2091, P2092, P2093, P2094, or P2095: ”

“DTC P0010, P0013, P0020, P0023, P2088, P2089, P2090, P2091, P2092, P2093, P2094, or P2095: ”

Diagnostic Procedure

Page 56

0A-43 General Information:

DTC DTC Descriptor

Crankshaft Position (CKP) - Intake

P0016

P0017

P0018

P0019

P0020

P0021

P0023

P0024

P0030

P0031

P0032

P0036

P0037

P0038

P0050

P0051

P0052

P0056

P0057

P0058

Camshaft Position (CMP) Correlation Bank 1 Crankshaft Position (CKP) - Exhaust Camshaft Position (CMP) Correlation Bank 1 Crankshaft Position (CKP) - Intake Camshaft Position (CMP) Correlation Bank 2 Crankshaft Position (CKP) - Exhaust Camshaft Position (CMP) Correlation Bank 2 Intake Camshaft Position (CMP) Actuator Solenoid Control Circuit Bank 2 Intake Camshaft Position (CMP) System Performance Bank 2 Exhaust Camshaft Position (CMP) Actuator Solenoid Control Circuit Bank 2 Exhaust Camshaft Position (CMP) System Performance Bank 2

HO2S Heater Control Circuit Bank 1 Sensor 1

HO2S Heater Control Circuit Low Voltage Bank 1 Sensor 1

HO2S Heater Control Circuit High Voltage Bank 1 Sensor 1

Heater Control Circuit Bank 1 Sensor 2

HO2S Heater Control Circuit Low Voltage Bank 1 Sensor 2

HO2S Heater Control Circuit High Voltage Bank 1 Sensor 2

HO2S Heater Control Circuit Bank 2 Sensor 1

HO2S Heater Control Circuit Low Voltage Bank 2 Sensor 1

HO2S Heater Control Circuit High Voltage Bank 2 Sensor 1

HO2S Heater Control Circuit Bank 2 Sensor 2

HO2S Heater Control Circuit Low Voltage Bank 2 Sensor 2

HO2S Heater Control Circuit High Voltage Bank 2 Sensor 2

Module that

Sets the DTC

ECM “DTC P0016, P0017, P0018, or P0019: ”

“DTC P0010, P0013, P0020, P0023, P2088,

ECM

ECM “DTC P0011, P0014, P0021, or P0024: ”

ECM

ECM “DTC P0011, P0014, P0021, or P0024: ”

ECM

P2089, P2090, P2091, P2092, P2093, P2094, or P2095: ”

“DTC P0010, P0013, P0020, P0023, P2088, P2089, P2090, P2091, P2092, P2093, P2094, or P2095: ”

“DTC P0030, P0031, P0032, P0036, P0037, P0038, P0050, P0051, P0052, P0056, P0057, or P0058: ” “DTC P0030, P0031, P0032, P0036, P0037, P0038, P0050, P0051, P0052, P0056, P0057, or P0058: ” “DTC P0030, P0031, P0032, P0036, P0037, P0038, P0050, P0051, P0052, P0056, P0057, or P0058: ” “DTC P0030, P0031, P0032, P0036, P0037, P0038, P0050, P0051, P0052, P0056, P0057, or P0058: ” “DTC P0030, P0031, P0032, P0036, P0037, P0038, P0050, P0051, P0052, P0056, P0057, or P0058: ” “DTC P0030, P0031, P0032, P0036, P0037, P0038, P0050, P0051, P0052, P0056, P0057, or P0058: ” “DTC P0030, P0031, P0032, P0036, P0037, P0038, P0050, P0051, P0052, P0056, P0057, or P0058: ” “DTC P0030, P0031, P0032, P0036, P0037, P0038, P0050, P0051, P0052, P0056, P0057, or P0058: ” “DTC P0030, P0031, P0032, P0036, P0037, P0038, P0050, P0051, P0052, P0056, P0057, or P0058: ” “DTC P0030, P0031, P0032, P0036, P0037, P0038, P0050, P0051, P0052, P0056, P0057, or P0058: ” “DTC P0030, P0031, P0032, P0036, P0037, P0038, P0050, P0051, P0052, P0056, P0057, or P0058: ” “DTC P0030, P0031, P0032, P0036, P0037, P0038, P0050, P0051, P0052, P0056, P0057, or P0058: ”

Diagnostic Procedure

Page 57

General Information: 0A-44

DTC DTC Descriptor

P0100 Mass Air Flow (MAF) Sensor Circuit ECM “DTC P0100, P0102, or P0103: ”

P0101

P0102

P0103

P0111

P0112

P0113

P0115

P0116

P0117

P0118

P0119

P0120 Throttle Position (TP) Sensor Circuit TCM

P0121

P0122

P0123

P0125

P0128

P0131

P0132

P0133

P0134

P0135

P0137

P0138

P0140

P0141

P0151

P0152

Mass Air Flow (MAF) Sensor Performance Mass Air Flow (MAF) Sensor Circuit Low Frequency Mass Air Flow (MAF) Sensor Circuit High Frequency Intake Air Temperature (IAT) Sensor Circuit Performance Intake Air Temperature (IAT) Sensor Circuit Low Voltage Intake Air Temperature (IAT) Sensor Circuit High Voltage Engine Coolant Temperature (ECT) Sensor Circuit Engine Coolant Temperature (ECT) Sensor Performance Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage Engine Coolant Temperature (ECT) Sensor Circuit High Voltage Engine Coolant Temperature (ECT) Sensor Circuit Intermittent

Throttle Position (TP) Sensor 1 Performance Throttle Position (TP) Sensor 1 Circuit Low Voltage Throttle Position (TP) Sensor 1 Circuit High Voltage Engine Coolant Temperature (ECT) Insufficient for Closed Loop Engine Coolant Temperature (ECT) Below Thermostat Regulating Temperature HO2S Circuit Low Voltage Bank 1 Sensor 1 HO2S Circuit High Voltage Bank 1 Sensor 1 HO2S Slow Response Bank 1 Sensor 1 HO2S Circuit Insufficient Activity Bank 1 Sensor 1 HO2S Heater Performance Bank 1 Sensor 1 HO2S Circuit Low Voltage Bank 1 Sensor 2 HO2S Circuit High Voltage Bank 1 Sensor 2 HO2S Circuit Insufficient Activity Bank 1 Sensor 2 HO2S Heater Performance Bank 1 Sensor 2 HO2S Circuit Low Voltage Bank 2 Sensor 1 HO2S Circuit High Voltage Bank 2 Sensor 1

Module that

Sets the DTC

ECM “DTC P0101: ”

ECM “DTC P0100, P0102, or P0103: ”

ECM “DTC P0111, P0112 or P0113: ”

TCM

ECM “DTC P0116: ”

ECM “DTC P0117 or P0118: ”

ECM “DTC P0119: ”

ECM

ECM “DTC P0125 or P0128: ”

ECM “DTC P0131 or P0151: ”

ECM “DTC P0132 or P0152: ”

ECM “DTC P0133 or P0153: ”

ECM “DTC P0134 or P0154: ”

ECM “DTC P0135, P0141, P0155, or P0161: ”

ECM

ECM “DTC P0135, P0141, P0155, or P0161: ”

ECM “DTC P0131 or P0151: ”

ECM “DTC P0132 or P0152: ”

“DTC P0115, P0120, P0703, P0727, P0826, P1779, P2544, or P2637: ”

“DTC P0115, P0120, P0703, P0727, P0826, P1779, P2544, or P2637: ” “DTC P0121, P0122, P0123, P0221, P0222, or P0223: ” “DTC P0121, P0122, P0123, P0221, P0222, or P0223: ” “DTC P0121, P0122, P0123, P0221, P0222, or P0223: ”

“DTC P0137, P0138, P0140, P0157, P0158, or P0160: ” “DTC P0137, P0138, P0140, P0157, P0158, or P0160: ” “DTC P0137, P0138, P0140, P0157, P0158, or P0160: ”

Diagnostic Procedure

Page 58

0A-45 General Information:

DTC DTC Descriptor

P0153

P0154

P0155

P0157

P0158

P0160

P0161

P0201 Injector 1 Control Circuit ECM

P0202 Injector 2 Control Circuit ECM

P0203 Injector 3 Control Circuit ECM

P0204 Injector 4 Control Circuit ECM

P0205 Injector 5 Control Circuit ECM

P0206 Injector 6 Control Circuit ECM

P0221

P0222

P0223

P0261 Injector 1 Control Circuit Low Voltage ECM

P0262 Injector 1 Control Circuit High Voltage ECM

P0264 Injector 2 Control Circuit Low Voltage ECM

HO2S Slow Response Bank 2 Sensor 1 HO2S Circuit Insufficient Activity Bank 2 Sensor 1 HO2S Heater Performance Bank 2 Sensor 1 HO2S Circuit Low Voltage Bank 2 Sensor 2 HO2S Circuit High Voltage Bank 2 Sensor 2 HO2S Circuit Insufficient Activity Bank 2 Sensor 2 HO2S Heater Performance Bank 2 Sensor 2

Throttle Position (TP) Sensor 2 Performance Throttle Position (TP) Sensor 2 Circuit Low Voltage Throttle Position (TP) Sensor 2 Circuit High Voltage

Module that

Sets the DTC

ECM “DTC P0133 or P0153: ”

ECM “DTC P0134 or P0154: ”

ECM “DTC P0135, P0141, P0155, or P0161: ”

ECM

ECM “DTC P0135, P0141, P0155, or P0161: ”

ECM

Diagnostic Procedure

“DTC P0137, P0138, P0140, P0157, P0158, or P0160: ” “DTC P0137, P0138, P0140, P0157, P0158, or P0160: ” “DTC P0137, P0138, P0140, P0157, P0158, or P0160: ”

“DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277: ” “DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277: ” “DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277: ” “DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277: ” “DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277: ” “DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277: ” “DTC P0121, P0122, P0123, P0221, P0222, or P0223: ” “DTC P0121, P0122, P0123, P0221, P0222, or P0223: ” “DTC P0121, P0122, P0123, P0221, P0222, or P0223: ” “DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277: ” “DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277: ” “DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277: ”

Page 59

General Information: 0A-46

DTC DTC Descriptor

P0265 Injector 2 Control Circuit High Voltage ECM

P0267 Injector 3 Control Circuit Low Voltage ECM

P0268 Injector 3 Control Circuit High Voltage ECM

P0270 Injector 4 Control Circuit Low Voltage ECM

P0271 Injector 4 Control Circuit High Voltage ECM

P0273 Injector 5 Control Circuit Low Voltage ECM

P0274 Injector 5 Control Circuit High Voltage ECM

P0276 Injector 6 Control Circuit Low Voltage ECM

P0277 Injector 6 Control Circuit High Voltage ECM

P0300 Engine Misfire Detected ECM “DTC P0300-P0306: ” P0301 Cylinder 1 Misfire Detected ECM “DTC P0300-P0306: ” P0302 Cylinder 2 Misfire Detected ECM “DTC P0300-P0306: ” P0303 Cylinder 3 Misfire Detected ECM “DTC P0300-P0306: ” P0304 Cylinder 4 Misfire Detected ECM “DTC P0300-P0306: ” P0305 Cylinder 5 Misfire Detected ECM “DTC P0300-P0306: ” P0306 Cylinder 6 Misfire Detected ECM “DTC P0300-P0306: ”

P0327

P0328

P0332

P0333

P0335

P0336

P0338

Knock Sensor (KS) Circuit Low Voltage Bank 1 Knock Sensor (KS) Circuit High Frequency Bank 1 Knock Sensor (KS) Circuit Low Voltage Bank 2 Knock Sensor (KS) Circuit High Frequency Bank 2 Crankshaft Position (CKP) Sensor A Circuit Crankshaft Position (CKP) Sensor Performance Crankshaft Position (CKP) Sensor Circuit High Duty Cycle

Module that

Sets the DTC

“DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277: ” “DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277: ” “DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277: ” “DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277: ” “DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277: ” “DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277: ” “DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277: ” “DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277: ” “DTC P0201, P0202, P0203, P0204, P0205, P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, or P0277: ”

ECM

ECM “DTC P0335, P0336, or P0338: ”

“DTC P0326, P0327, P0328, P0331, P0332, or P0333: ” “DTC P0326, P0327, P0328, P0331, P0332, or P0333: ” “DTC P0326, P0327, P0328, P0331, P0332, or P0333: ” “DTC P0326, P0327, P0328, P0331, P0332, or P0333: ”

Diagnostic Procedure

Page 60

0A-47 General Information:

DTC DTC Descriptor

P0341

P0342

P0343

P0346

P0347

P0348

P0366

P0367

P0368

P0391

P0392

P0393

P0420

P0430

P0442

P0443

P0446

P0449

P0451

P0452

P0453

P0455

P0458

Intake Camshaft Position (CMP) Sensor Performance Bank 1

Intake Camshaft Position (CMP) Sensor Circuit Low Voltage Bank 1

Intake Camshaft Position (CMP) Sensor Circuit High Voltage Bank 1

Intake Camshaft Position (CMP) Sensor Performance Bank 2

Intake Camshaft Position (CMP) Sensor Circuit Low Voltage Bank 2

Intake Camshaft Position (CMP) Sensor Circuit High Voltage Bank 2

Exhaust Camshaft Position (CMP) Sensor Performance Bank 1

Exhaust Camshaft Position (CMP) Sensor Circuit Low Voltage Bank 1

Exhaust Camshaft Position (CMP) Sensor Circuit High Voltage Bank 1

Exhaust Camshaft Position (CMP) Sensor Performance Bank 2

Exhaust Camshaft Position (CMP) Sensor Circuit Low Voltage Bank 2

Exhaust Camshaft Position (CMP) Sensor Circuit High Voltage Bank 2

Catalyst System Low Efficiency Bank 1 Catalyst System Low Efficiency Bank 2 Evaporative Emission (EVAP) System Small Leak Detected Evaporative Emission (EVAP) Purge Solenoid Control Circuit Evaporative Emissions (EVAP) Vent System Performance Evaporative Emission (EVAP) Vent Solenoid Valve Control Circuit Fuel Tank Pressure (FTP) Sensor Performance Fuel Tank Pressure (FTP) Sensor Circuit Low Voltage Fuel Tank Pressure (FTP) Sensor Circuit High Voltage Evaporative Emission (EVAP) System Large Leak Detected Evaporative Emission (EVAP) Purge Solenoid Control Circuit Low Voltage

Module that

Sets the DTC

“DTC P0341, P0342, P0343, P0346, P0347,

ECM

ECM “DTC P0420 or P0430: ”

ECM “DTC P0442: ”

ECM “DTC P0443, P0458, or P0459: ”

ECM “DTC P0446: ”

ECM “DTC P0449, P0498, or P0499: ”

ECM “DTC P0451: ”

ECM “DTC P0452 or P0453: ”

ECM “DTC P0455: ”

ECM “DTC P0443, P0458, or P0459: ”

P0348, P0366, P0367, P0368, P0391, P0392, or P0393: ” “DTC P0341, P0342, P0343, P0346, P0347, P0348, P0366, P0367, P0368, P0391, P0392, or P0393: ” “DTC P0341, P0342, P0343, P0346, P0347, P0348, P0366, P0367, P0368, P0391, P0392, or P0393: ” “DTC P0341, P0342, P0343, P0346, P0347, P0348, P0366, P0367, P0368, P0391, P0392, or P0393: ” “DTC P0341, P0342, P0343, P0346, P0347, P0348, P0366, P0367, P0368, P0391, P0392, or P0393: ” “DTC P0341, P0342, P0343, P0346, P0347, P0348, P0366, P0367, P0368, P0391, P0392, or P0393: ” “DTC P0341, P0342, P0343, P0346, P0347, P0348, P0366, P0367, P0368, P0391, P0392, or P0393: ” “DTC P0341, P0342, P0343, P0346, P0347, P0348, P0366, P0367, P0368, P0391, P0392, or P0393: ” “DTC P0341, P0342, P0343, P0346, P0347, P0348, P0366, P0367, P0368, P0391, P0392, or P0393: ” “DTC P0341, P0342, P0343, P0346, P0347, P0348, P0366, P0367, P0368, P0391, P0392, or P0393: ” “DTC P0341, P0342, P0343, P0346, P0347, P0348, P0366, P0367, P0368, P0391, P0392, or P0393: ” “DTC P0341, P0342, P0343, P0346, P0347, P0348, P0366, P0367, P0368, P0391, P0392, or P0393: ”

Diagnostic Procedure

Page 61

General Information: 0A-48

DTC DTC Descriptor

P0459

P0461 Fuel Level Sensor 1 Performance ECM “DTC P0461: ”

P0462

P0463

P0464

P0480 Cooling Fan Relay 2 Control Circuit ECM

P0481

P0496

P0498

P0499

P0506 Idle Speed Low ECM “DTC P0506, P0507, or P050A: ” P0507 Idle Speed High ECM “DTC P0506, P0507, or P050A: ”

P050A

P0513 Theft Deterrent Key Incorrect ECM “DTC P0513: ”

P0520

P0532

P0533

P0560 System Voltage ECM “DTC P0560: ”

P0562 System Voltage Low

P0563 System Voltage High

P0571 Cruise Control Brake Switch Circuit ECM “DTC P0571: ” P0572 Brake Switch Circuit 1 Low Voltage ECM “DTC P0572: ” P0573 Brake Switch Circuit 1 High Voltage ECM “DTC P0573: ” P0575 Cruise Control Switch Signal Circuit ECM “DTC P0575: ”

P0601

P0602

P0603

Evaporative Emission (EVAP) Purge Solenoid Control Circuit High Voltage

Fuel Level Sensor 1 Circuit Low Voltage Fuel Level Sensor 1 Circuit High Voltage Fuel Level Sensor 1 Circuit Intermittent

Cooling Fan Relay 2 and 3 Control Circuit Evaporative Emission (EVAP) System Flow During Non-Purge Evaporative Emission (EVAP) Vent Solenoid Valve Control Circuit Low Voltage Evaporative Emission (EVAP) Vent Solenoid Valve Control Circuit High Voltage

Cold Start Idle Air Control (IAC) System Performance

Engine Oil Pressure (EOP) Sensor Circuit Air Conditioning (A/C) Refrigerant Pressure Sensor Circuit Low Voltage Air Conditioning (A/C) Refrigerant Pressure Sensor Circuit High Voltage

Control Module Read Only Memory (ROM)

Transmission Control Module (TCM) Read Only Memory (ROM)

Control Module Not Programmed ECM

Transmission Control Module (TCM) Not Programmed

Control Module Long Term Memory Reset

Transmission Control Module (TCM) Long Term Memory Reset

Module that

Sets the DTC

ECM “DTC P0443, P0458, or P0459: ”

ECM “DTC P0462: ”

ECM “DTC P0463: ”

ECM “DTC P0464: ”

“DTC P0480, P0481, P0691, P0692, P0693, or P0694: ”

ECM

ECM “DTC P0496: ”

ECM “DTC P0449, P0498, or P0499: ”

ECM “DTC P0506, P0507, or P050A: ”

ECM “DTC P0520: ”

ECM “DTC P0532 or P0533: ”

ECM “DTC P0562: ” TCM “DTC P0562 or P0563: ” ECM “DTC P0563: ” TCM “DTC P0562 or P0563: ”

ECM

TCM “DTC P0601, P0602, P0603, or P0604: ”

ECM

TCM “DTC P0601, P0602, P0603, or P0604: ”

“DTC P0480, P0481, P0691, P0692, P0693, or P0694: ”

“DTC P0601, P0602, P0603, P0604, P0605, P0606, P0607, P1600, P1621, P1627, P1680, P1681, P1683, or P2610: ”

Diagnostic Procedure

Page 62

0A-49 General Information:

DTC DTC Descriptor

Control Module Random Access

P0604

P0606 Control Module Internal Performance ECM

P0615 Starter Relay Control Circuit ECM “DTC P0615: ”

P0616

P0617

P0621 Generator L-Terminal Circuit ECM “DTC P0621: ” P0622 Generator F-Terminal Circuit ECM “DTC P0622: ”

P0625

P0626

P0627 Fuel Pump Relay Control Circuit ECM “DTC P0627, P0628, or P0629: ”

P0628

P0629

P0633 Theft Deterrent Key Not Programmed ECM “DTC P0633: ”

P0638

P0642 5 Volt Reference 1 Circuit Low Voltage ECM “DTC P0642 or P0643: ”

P0643

P0645

P0646

P0647

P0650

P0652 5 Volt Reference 2 Circuit Low Voltage ECM “DTC P0652 or P0653: ”

P0653

P0685

P0686

P0687

P0689

P0690

P0691

P0692

P0693

Memory (RAM)

Transmission Control Module (TCM) Random Access Memory (RAM)

Starter Relay Control Circuit Low Voltage Starter Relay Control Circuit High Voltage

Generator F-Terminal Circuit Low Voltage Generator F-Terminal Circuit High Voltage

Fuel Pump Relay Control Circuit Low Voltage Fuel Pump Relay Control Circuit High Voltage

Throttle Actuator Control (TAC) Command Performance

6 Volt Reference 1 Circuit High Voltage Air Conditioning (A/C) Clutch Relay Control Circuit Air Conditioning (A/C) Clutch Relay Control Circuit Low Voltage Air Conditioning (A/C) Clutch Relay Control Circuit High Voltage Malfunction Indicator Lamp (MIL) Control Circuit

6 Volt Reference 2 Circuit High Voltage Engine Controls Ignition Relay Control Circuit Engine Controls Ignition Relay Control Circuit Low Voltage Engine Controls Ignition Relay Control Circuit High Voltage Engine Controls Ignition Relay Feedback Circuit Low Voltage Engine Controls Ignition Relay Feedback Circuit High Voltage Cooling Fan Relay 1 Control Circuit Low Voltage Cooling Fan Relay 1 Control Circuit High Voltage Cooling Fan Relays 2 and 3 Control Circuit Low Voltage

Module that

Sets the DTC

“DTC P0601, P0602, P0603, P0604, P0605,

ECM

TCM “DTC P0601, P0602, P0603, or P0604: ”

ECM “DTC P0616: ”

ECM “DTC P0617: ”

ECM “DTC P0625: ”

ECM “DTC P0626: ”

ECM “DTC P0627, P0628, or P0629: ”

ECM “DTC P0638, P2100, P2101, or P2119: ”

ECM “DTC P0642 or P0643: ”

ECM “DTC P0645, P0646, or P0647: ”

ECM “DTC P0650: ”

ECM “DTC P0652 or P0653: ”

ECM “DTC P0685, P0686, P0687, P0689, or P0690: ”

ECM

P0606, P0607, P1600, P1621, P1627, P1680, P1681, P1683, or P2610: ”

“DTC P0601, P0602, P0603, P0604, P0605, P0606, P0607, P1600, P1621, P1627, P1680, P1681, P1683, or P2610: ”

“DTC P0480, P0481, P0691, P0692, P0693, or P0694: ” “DTC P0480, P0481, P0691, P0692, P0693, or P0694: ” “DTC P0480, P0481, P0691, P0692, P0693, or P0694: ”

Diagnostic Procedure

Page 63

General Information: 0A-50

DTC DTC Descriptor

P0694

P0698 5 Volt Reference 3 Circuit Low Voltage ECM “DTC P0698 or P0699: ”

P0699

P0700

P0703 Brake Switch Circuit ECM

P0706

P0707

P0708

P0711

P0712

P0713

P0717

P0722

P0727 Engine Speed No Signal TCM

P0730 Incorrect Gear Ratio TCM “DTC P0730: ” P0731 Incorrect 1st Gear Ratio TCM “DTC P0731: ” P0732 Incorrect 2nd Gear Ratio TCM “DTC P0732: ” P0733 Incorrect 3rd Gear Ratio TCM “DTC P0733: ” P0734 Incorrect 4th Gear Ratio TCM “DTC P0734: ” P0735 Incorrect 5th Gear Ratio TCM “DTC P0735: ” P0736 Incorrect Reverse Ratio TCM “DTC P0736: ”

P0741

P0742

P0762

P081A Starter Inhibit Circuit Low Voltage TCM “DTC P081A or P081B: ” P081B Starter Inhibit Circuit High Voltage TCM “DTC P081A or P081B: ”

P0826 Up and Down Shift Switch Circuit TCM

P0864

P0897 Transmission Fluid Life TCM “DTC P0897: ”

P0962

P0963

P0966

P0967

Cooling Fan Relays 2 and 3 Control Circuit High Voltage

5 Volt Reference 3 Circuit High Voltage Transmission Control Module (TCM) Requested MIL Illumination

Transmission Range (TR) Switch Performance Transmission Range (TR) Switch Circuit Low Voltage Transmission Range (TR) Switch Circuit High Voltage Transmission Fluid Temperature (TFT) Sensor Performance Transmission Fluid Temperature (TFT) Sensor Circuit Low Voltage Transmission Fluid Temperature (TFT) Sensor Circuit High Voltage Input Speed Sensor Circuit Low Voltage Output Speed Sensor Circuit Low Voltage

Torque Converter Clutch (TCC) System - Stuck Off Torque Converter Clutch (TCC) System - Stuck On Shift Solenoid (SS) 3 Valve Performance - Stuck On

TCM Communication Circuit Performance

Line Pressure Control (PC) Solenoid Control Circuit Low Voltage Line Pressure Control (PC) Solenoid Control Circuit High Voltage Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Control Circuit Low Voltage Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Control Circuit High Voltage

Module that

Sets the DTC

ECM

ECM “DTC P0698 or P0699: ”

ECM “DTC P0700: ”

TCM “DTC P0706-P0708: ”

TCM “DTC P0711, P0712, or P0713: ”

TCM “DTC P0717 or P0722: ”

TCM “DTC P0741: ”

TCM “DTC P0742: ”

TCM “DTC P0762: ”

ECM “DTC P0864: ”

TCM

“DTC P0480, P0481, P0691, P0692, P0693, or P0694: ”

“DTC P0115, P0120, P0703, P0727, P0826, P1779, P2544, or P2637: ”

“DTC P0962, P0963, P0966, P0967, P0970, or P0971: ” “DTC P0962, P0963, P0966, P0967, P0970, or P0971: ”

“DTC P0962, P0963, P0966, P0967, P0970, or P0971: ”

Diagnostic Procedure

Page 64

0A-51 General Information:

DTC DTC Descriptor

P0970

P0971

P0973

P0974

P0976

P0977

P0979

P0980

P0982

P0983

P0985

P0986

P1011

P1012

P1013

P1014

P1380

P1551

P1629

P1631

P1632

P167D Ignition Control (IC) Performance ECM “DTC P167D: ”

P1719 Incorrect Shifting Detected TCM “DTC P1719: ”

P1779 Torque Delivered Signal TCM

P2088

P2089

P2090

P2091

Shift Pressure Control (PC) Solenoid Control Circuit Low Voltage Shift Pressure Control (PC) Solenoid Control Circuit High Voltage Shift Solenoid (SS) 1 Control Circuit Low Voltage Shift Solenoid (SS) 1 Control Circuit High Voltage Shift Solenoid (SS) 2 Control Circuit Low Voltage Shift Solenoid (SS) 2 Control Circuit High Voltage Shift Solenoid (SS) 3 Control Circuit Low Voltage Shift Solenoid (SS) 3 Control Circuit High Voltage Shift Solenoid (SS) 4 Control Circuit Low Voltage Shift Solenoid (SS) 4 Control Circuit High Voltage Shift Solenoid (SS) 5 Control Circuit Low Voltage Shift Solenoid (SS) 5 Control Circuit High Voltage Intake Camshaft Position (CMP) Actuator Park Position Bank 1 Exhaust Camshaft Position (CMP) Actuator Park Position Bank 1 Intake Camshaft Position (CMP) Actuator Park Position Bank 2 Exhaust Camshaft Position (CMP) Actuator Park Position Bank 2 Misfire Detected - Rough Road Data Not Available Throttle Valve Rest Position Not Reached During Learn Theft Deterrent Fuel Enable Signal Not Received Theft Deterrent Fuel Enable Signal Not Correct Theft Deterrent Fuel Disable Signal Received

Intake Camshaft Position (CMP) Actuator Solenoid Control Circuit Low Voltage Bank 1 Intake Camshaft Position (CMP) Actuator Solenoid Control Circuit High Voltage Bank 1 Exhaust Camshaft Position (CMP) Actuator Solenoid Control Circuit Low Voltage Bank 1 Exhaust Camshaft Position (CMP) Actuator Solenoid Control Circuit High Voltage Bank 1

Module that

Sets the DTC

TCM

ECM “DTC P1011-P1014: ”

ECM “DTC P1380: ”

ECM “DTC P1551: ”

ECM “DTC P1629: ”

ECM “DTC P1631: ”

ECM “DTC P1632: ”

ECM

“DTC P0962, P0963, P0966, P0967, P0970, or P0971: ” “DTC P0962, P0963, P0966, P0967, P0970, or P0971: ” “DTC P0973, P0974, P0976, P0977, P0979, P0980, P0982, P0983, P0985, or P0986: ” “DTC P0973, P0974, P0976, P0977, P0979, P0980, P0982, P0983, P0985, or P0986: ” “DTC P0973, P0974, P0976, P0977, P0979, P0980, P0982, P0983, P0985, or P0986: ” “DTC P0973, P0974, P0976, P0977, P0979, P0980, P0982, P0983, P0985, or P0986: ” “DTC P0973, P0974, P0976, P0977, P0979, P0980, P0982, P0983, P0985, or P0986: ” “DTC P0973, P0974, P0976, P0977, P0979, P0980, P0982, P0983, P0985, or P0986: ” “DTC P0973, P0974, P0976, P0977, P0979, P0980, P0982, P0983, P0985, or P0986: ” “DTC P0973, P0974, P0976, P0977, P0979, P0980, P0982, P0983, P0985, or P0986: ” “DTC P0973, P0974, P0976, P0977, P0979, P0980, P0982, P0983, P0985, or P0986: ” “DTC P0973, P0974, P0976, P0977, P0979, P0980, P0982, P0983, P0985, or P0986: ”

“DTC P0115, P0120, P0703, P0727, P0826, P1779, P2544, or P2637: ” “DTC P0010, P0013, P0020, P0023, P2088, P2089, P2090, P2091, P2092, P2093, P2094, or P2095: ” “DTC P0010, P0013, P0020, P0023, P2088, P2089, P2090, P2091, P2092, P2093, P2094, or P2095: ” “DTC P0010, P0013, P0020, P0023, P2088, P2089, P2090, P2091, P2092, P2093, P2094, or P2095: ” “DTC P0010, P0013, P0020, P0023, P2088, P2089, P2090, P2091, P2092, P2093, P2094, or P2095: ”

Diagnostic Procedure

Page 65

General Information: 0A-52

DTC DTC Descriptor

Intake Camshaft Position (CMP)

P2092

P2093

P2094

P2095

P2096

P2097

P2098

P2099

P2100

P2101

P2105

P2107

P2119 Throttle Closed Position Performance ECM “DTC P0638, P2100, P2101, or P2119: ”

P2122

P2123

P2127

P2128

P2138

P2176

P2177

P2178

P2179

P2180

P2187 Fuel Trim System Lean at Idle Bank 1 ECM “DTC P2177, P2179, P2187, or P2189: ” P2188 Fuel Trim System Rich at Idle Bank 1 ECM “DTC P2178, 2180, P2188, or P2190: ” P2189 Fuel Trim System Lean at Idle Bank 2 ECM “DTC P2177, P2179, P2187, or P2189: ” P2190 Fuel Trim System Rich at Idle Bank 2 ECM “DTC P2178, 2180, P2188, or P2190: ”

P2227

P2228

Actuator Solenoid Control Circuit Low Voltage Bank 2 Intake Camshaft Position (CMP) Actuator Solenoid Control Circuit High Voltage Bank 2 Exhaust Camshaft Position (CMP) Actuator Solenoid Control Circuit Low Voltage Bank 2 Exhaust Camshaft Position (CMP) Actuator Solenoid Control Circuit High Voltage Bank 2 Post Catalyst Fuel Trim System Low Limit Bank 1 Post Catalyst Fuel Trim System High Limit Bank 1 Post Catalyst Fuel Trim System Low Limit Bank 2 Post Catalyst Fuel Trim System High Limit Bank 2 Throttle Actuator Control (TAC) Motor Control Circuit Control Module Throttle Actuator Position Performance Throttle Actuator Control (TAC) System - Forced Engine Shutdown Throttle Actuator Control (TAC) Module Internal Circuit

Accelerator Pedal Position (APP) Sensor 1 Circuit Low Voltage Accelerator Pedal Position (APP) Sensor 1 Circuit High Voltage Accelerator Pedal Position (APP) Sensor 2 Circuit Low Voltage Accelerator Pedal Position (APP) Sensor 2 Circuit High Voltage Accelerator Pedal Position (APP) Sensor 1-2 Correlation Minimum Throttle Position Not Learned Fuel Trim System Lean at Cruise or Accel Bank 1 Fuel Trim System Rich at Cruise or Accel Bank 1 Fuel Trim System Lean at Cruise or Accel Bank 2 Fuel Trim System Rich at Cruise or Accel Bank 2

Barometric Pressure (BARO) Sensor Performance Barometric Pressure (BARO) Sensor Circuit Low Voltage

Module that

Sets the DTC

“DTC P0010, P0013, P0020, P0023, P2088,

ECM

ECM “DTC P2096 or P2098: ”

ECM “DTC P2097 or P2099: ”

ECM “DTC P2096 or P2098: ”

ECM “DTC P2097 or P2099: ”

ECM “DTC P0638, P2100, P2101, or P2119: ”

ECM “DTC P2105: ”

ECM “DTC P2107: ”

ECM “DTC P2122, P2123, P2127, P2128, or P2138: ”

ECM “DTC P2176: ”

ECM “DTC P2177, P2179, P2187, or P2189: ”

ECM “DTC P2178, 2180, P2188, or P2190: ”

ECM “DTC P2177, P2179, P2187, or P2189: ”

ECM “DTC P2178, 2180, P2188, or P2190: ”

ECM “DTC P2227, P2228, or P2229: ”

P2089, P2090, P2091, P2092, P2093, P2094, or P2095: ” “DTC P0010, P0013, P0020, P0023, P2088, P2089, P2090, P2091, P2092, P2093, P2094, or P2095: ” “DTC P0010, P0013, P0020, P0023, P2088, P2089, P2090, P2091, P2092, P2093, P2094, or P2095: ” “DTC P0010, P0013, P0020, P0023, P2088, P2089, P2090, P2091, P2092, P2093, P2094, or P2095: ”

Diagnostic Procedure

Page 66

0A-53 General Information:

DTC DTC Descriptor

P2229

P2231

P2232

P2234

P2235

P2270

P2271

P2272

P2273

P2300

P2301

P2303

P2304

P2306

P2307

P2309

P2310

P2312

P2313

P2315

P2316

P2534 Ignition 1 Switch Circuit Low Voltage TCM “DTC P2534: ” P2536 Ignition Accessory Switch Circuit TCM “DTC P2536: ”

P2544 Transmission Torque Request Circuit TCM

Barometric Pressure (BARO) Sensor Circuit High Voltage HO2S Signal Circuit Shorted to Heater Circuit Bank 1 Sensor 1 HO2S Signal Circuit Shorted to Heater Circuit Bank 1 Sensor 2 HO2S Signal Circuit Shorted to Heater Circuit Bank 2 Sensor 1 HO2S Signal Circuit Shorted to Heater Circuit Bank 2 Sensor 2 HO2S Signal Stuck Lean Bank 1 Sensor 2 HO2S Signal Stuck Rich Bank 1 Sensor 2 HO2S Signal Stuck Lean Bank 2 Sensor 2 HO2S Signal Stuck Rich Bank 2 Sensor 2

Ignition Coil 1 Control Circuit Low Voltage

Ignition Coil 1 Control Circuit High Voltage

Ignition Coil 2 Control Circuit Low Voltage

Ignition Coil 2 Control Circuit High Voltage

Ignition Coil 3 Control Circuit Low Voltage

Ignition Coil 3 Control Circuit High Voltage

Ignition Coil 4 Control Circuit Low Voltage

Ignition Coil 4 Control Circuit High Voltage

Ignition Coil 5 Control Circuit Low Voltage

Ignition Coil 5 Control Circuit High Voltage

Ignition Coil 6 Control Circuit Low Voltage

Ignition Coil 6 Control Circuit High Voltage

Module that

Sets the DTC

ECM “DTC P2227, P2228, or P2229: ”

ECM “DTC P2231 or P2234: ”

ECM “DTC P2232 or P2235: ”

ECM “DTC P2231 or P2234: ”

ECM “DTC P2232 or P2235: ”

ECM “DTC P2270 or P2272: ”

ECM “DTC P2271 or P2273: ”

ECM “DTC P2270 or P2272: ”

“DTC P2300, P2301, P2303, P2304, P2306,

ECM

P2307, P2309, P2310, P2312, P2313, P2315, or P2316: ” “DTC P2300, P2301, P2303, P2304, P2306, P2307, P2309, P2310, P2312, P2313, P2315, or P2316: ” “DTC P2300, P2301, P2303, P2304, P2306, P2307, P2309, P2310, P2312, P2313, P2315, or P2316: ” “DTC P2300, P2301, P2303, P2304, P2306, P2307, P2309, P2310, P2312, P2313, P2315, or P2316: ” “DTC P2300, P2301, P2303, P2304, P2306, P2307, P2309, P2310, P2312, P2313, P2315, or P2316: ” “DTC P2300, P2301, P2303, P2304, P2306, P2307, P2309, P2310, P2312, P2313, P2315, or P2316: ” “DTC P2300, P2301, P2303, P2304, P2306, P2307, P2309, P2310, P2312, P2313, P2315, or P2316: ” “DTC P2300, P2301, P2303, P2304, P2306, P2307, P2309, P2310, P2312, P2313, P2315, or P2316: ” “DTC P2300, P2301, P2303, P2304, P2306, P2307, P2309, P2310, P2312, P2313, P2315, or P2316: ” “DTC P2300, P2301, P2303, P2304, P2306, P2307, P2309, P2310, P2312, P2313, P2315, or P2316: ” “DTC P2300, P2301, P2303, P2304, P2306, P2307, P2309, P2310, P2312, P2313, P2315, or P2316: ” “DTC P2300, P2301, P2303, P2304, P2306, P2307, P2309, P2310, P2312, P2313, P2315, or P2316: ”

“DTC P0115, P0120, P0703, P0727, P0826, P1779, P2544, or P2637: ”

Diagnostic Procedure

Page 67

General Information: 0A-54

DTC DTC Descriptor

P2610

P2636 Fuel Transfer Pump Flow Insufficient ECM “DTC P2636: ”

P2637 Transmission Torque Delivered Circuit TCM

P280A

U0073 High Speed Communication Bus

U0100

U0101

U0104

U0121

U0122

U0131

U0140

U0151

U0155

U0164

U0168

U0170

U0184 Lost Communication With Radio

U0198

U0214

U1500 Inter-Device Dedicated Bus 1 EBCM, VCIM “DTC U1500: ”

U1814

U2099

U2100

U2105

Control Module Ignition Off Timer Performance

Transmission Range (TR) Switch Circuit Not Learned

Lost Communication With Engine/ Powertrain Control Module (ECM/ PCM) Lost Communication With Transmission Control Module (TCM) Lost Communication With Cruise Control Module Lost Communication With Electronic Brake Control Module (EBCM) Lost Communication With Vehicle Dynamics Control Module Lost Communication With Power Steering Control Module

Lost Communication With Body Control Module (BCM)

Lost Communication With Sensing and Diagnostic Module (SDM)

Lost Communication With Instrument Panel Cluster (IPC) Control Module

Lost Communication With HVAC Control Module Lost Communication With Vehicle Theft Deterrent (VTD) Control Module Lost Communication With Passenger Presence System (PPS)

Lost Communication With Communication Interface Module (OnStar®) Lost Communication With Remote Function Actuator (RFA)

Powertrain High Speed Communication Enable Circuit High Speed Communication Enable Circuit Controller Area Network (CAN) Bus Communication

Lost Communication With Engine Control System

Module that

Sets the DTC

“DTC P0601, P0602, P0603, P0604, P0605,

ECM

TCM “DTC P280A: ”

BCM, DRR, HVSM, PPS, PSCM, Radio, RCDLR, ROS, RSA

BCM, PSCM “DTC U0100-U0299: ”

BCM “DTC U0100-U0299: ”

HVSM, PPS, PSCM, RCDLR, ROS, RSA, TDM

PPS, ROS “DTC U0100-U0299: ”

BCM, HVSM, PPS, RCDLR, ROS, RSA, TDM

BCM, HVSM “DTC U0100-U0299: ”

BCM “DTC U0100-U0299: ”

SDM “DTC U0100-U0299: ”

BCM, DRR, RSA

BCM “DTC U0100-U0299: ”

BCM “DTC U1814: ”

BCM “DTC U2099: ”

EBCM, IPC “DTC U2100: ”

EBCM

P0606, P0607, P1600, P1621, P1627, P1680, P1681, P1683, or P2610: ”

“DTC P0115, P0120, P0703, P0727, P0826, P1779, P2544, or P2637: ”

“DTC U0073: ”

“DTC U0100-U0299: ”

“DTC U2105-U2199 (Except U2142 and U2143): ” “DTC U2105-U2199 (U2142 or U2143 only): ”

Diagnostic Procedure

Page 68

0A-55 General Information:

DTC DTC Descriptor

U2106

U2107

U2142

U2143

Lost Communications With Transmission Control System

Lost Communications With Body Control System

Lost Communication With Yaw Rate Sensor (YRS)

Lost Communications With Steering Angle Sensor (SAS)

Module that

Sets the DTC

EBCM

Diagnostic Starting Point - Vehicle Diagnostic Information

Begin the system diagnosis with “Diagnostic System Check - Vehicle Diagnostic Information”. The Diagnostic System Check - Vehicle will provide the following information:

• The identification of the control modules which are not communicating through the serial data circuit.

• The identification of any stored diagnostic trouble codes (DTCs) and their status.

The use of the Diagnostic System Check - Vehicle will identify the correct procedures to begin vehicle diagnosis. These must be performed before system DTC or symptom diagnosis.

Diagnostic Procedure

“DTC U2105-U2199 (Except U2142 and U2143): ” “DTC U2105-U2199 (U2142 or U2143 only): ” “DTC U2105-U2199 (Except U2142 and U2143): ” “DTC U2105-U2199 (U2142 or U2143 only): ” “DTC U2105-U2199 (Except U2142 and U2143): ” “DTC U2105-U2199 (U2142 or U2143 only): ” “DTC U2105-U2199 (Except U2142 and U2143): ” “DTC U2105-U2199 (U2142 or U2143 only): ”

2. Review the following Vibration Diagnostic Process.

3. Review the general descriptions to familiarize yourself with vibration theory and terminology, the J 38792-A, Electronic Vibration Analyzer (EVA) 2 and the J 38792-VS, Vibrate Software. Reviewing this information will help you determine whether the condition described by the customer is a potential operating characteristic or not. Refer to the following:

– “Vibration Theory and Terminology” – “Electronic Vibration Analyzer (EVA) Description

and Operation” – “Vibrate Software Description and Operation” – “Reed Tachometer Description”

Diagnostic Starting Point - Vibration Diagnosis and Correction

The information contained in this Vibration Diagnosis and Correction section is designed to cover various vehicle designs and configurations. Not all content will apply to all vehicles.

NOTE

The following steps must be completed before using the analysis tables or the symptom tables.

1. Perform the “Vibration Analysis - Road Testing” table before using the other Vibration Analysis tables or the Symptom tables in order to effectively diagnose the customer's concern. The use of Vibration Analysis - Road Testing will first provide duplication of virtually any vibration concern and then identify the correct procedure for diagnosing the area of concern which has been duplicated.

Vibration Diagnostic Process

NOTE

Using the following steps of the vibration diagnostic process will help you to effectively narrow-down and pin-point the search for the specific source of a vibration concern and to arrive at an accurate repair.

1. Gather specific information on the customer's vibration concern.

2. Perform the road testing steps in sequence as identified in Vibration Analysis - Road Testing in order to duplicate the customer's concern and evaluate the symptoms of the concern under changing conditions. Observe what the vibration feels like and what it sounds like. Observe when the symptoms first appear, when they change, and when they cease.

Page 69

General Information: 0A-56

3. Determine if the customer's vibration concern is truly an abnormal condition or something that is potentially an operating characteristic of the vehicle.

4. Systematically eliminate or “rule-out” possible vehicle systems.

5. Focus diagnostic efforts on the remaining vehicle system and systematically eliminate or “rule-out” possible components of that system.

6. Make a repair on the remaining component, or components, which have not been eliminated systematically, and must therefore be the cause of the vibration.

7. Verify that the customer's concern has been eliminated or at least brought to an acceptable level.

8. Again perform the road testing steps in sequence as identified in Vibration Analysis - Road Testing in order to verify that the vehicle did not have more than one vibration occurring.

Preliminary Visual/Physical Inspection

• Inspect for aftermarket equipment and modifications

which could affect the operation of the vehicle rotating component systems.

• Inspect the easily accessible or visible components of

the vehicle rotating component systems for obvious damage or conditions which could cause the symptom.

• Inspect the tire inflation pressures for the proper

pressure.

Diagnostic Aids

Improper component routing or isolation, or components which are worn or faulty may be the cause of intermittent conditions that are difficult to duplicate. If the vibration concern could not be duplicated by following the steps of the Vibration Diagnostic Process, refer to “Vibration Diagnostic Aids”.

Diagnostic System Check - Vehicle Diagnostic Information

1. Verify that none of the following preliminary inspections/tests reveal the cause of the vehicle concern before beginning diagnosis:

– Ensure that the battery is fully charged. Refer to

“Battery Inspection/Test: ”. – Ensure that the battery cables are clean and tight. – Inspect for any open fuses. Refer to “Power

Distribution Schematics: ” and “Electrical Center

Identification Views: ”. – Ensure that the grounds are clean, tight, and in

the correct location. Refer to “Ground Distribution

Schematics: ” and “Power and Grounding

Component Views: ”. – Inspect the easily accessible systems or the

visible system components for obvious damage or

conditions that could cause the concern. This

would include checking to ensure that all

connections/connectors are fully seated and

secured. – Inspect for aftermarket devices that could affect

the operation of the system. Refer to “Checking

Aftermarket Accessories: ”. – Search for applicable service bulletins.

➢ If the preceding inspections/tests resolve the

concern, go to“Diagnostic Repair Verification Vehicle Diagnostic Information”.

2. Install a scan tool. Verify that the scan tool powers up.

➢ If the scan tool does not power up, refer to “Scan

Tool Does Not Power Up: ”.

3. Ignition ON, Engine OFF, verify communication with all of the control modules on the vehicle. Refer to “Data Link References: ” for information on the modules you should expect to communicate.

➢ If the scan tool does not communicate with one or

more of the expected control modules, refer to “Data Link References: ”.

Page 70

0A-57 General Information:

4. Verify that the following DTCs are not set: U1814, B1428.

➢ If either of the DTCs are set, refer to “DTC U1814: ”

or “DTC B1428: ”.

NOTE

Open the drivers door to ensure retained accessory power mode (RAP) is inactive during this test. The engine may start during this test. Turn the engine OFF as soon as the crank power mode has been observed.

5. With a scan tool, access the Body Control Module Power Mode data display list. Verify that all the parameters listed in the following table correspond to the ignition key position. The PMM Power Mode parameters table below illustrates the correct state of these parameters (circuits) with the corresponding ignition switch positions. The circuits related to the parameters are in parenthesis.

➢ If any of the power mode parameters do not match

in any ignition switch position, refer to “Power Mode Mismatch: ”.

6. Ignition ON, view the security indicator. The security indicator should not remain illuminated after the vehicle bulb check has completed.

➢ If the security indicator remains illuminated after the

bulb check, refer to “Diagnostic Trouble Code (DTC) List - Vehicle Diagnostic Information” and diagnose any of the following theft deterrent DTCs set as current: B1000, B302A, B3031, B3055, B3060, B3935, B3976, P0513, P0633, P1629, P1631, or P1632.

7. Attempt to start the engine. Verify that the engine cranks.

➢ If the engine does not crank, refer to “Symptoms -

Engine Electrical: ”.

8. Attempt to start the engine. Verify the engine starts and runs.

➢ If the engine does not start and run, refer to “Engine

Cranks but Does Not Run: ”.

NOTE

Do not clear any DTCs unless instructed to do so by a diagnostic procedure.

NOTE

If any DTCs are Powertrain related DTCs, select Capture Info in order to store the DTC information with the scan tool.

9. Use the appropriate scan tool selections to obtain DTCs from each of the vehicle modules. Verify there are no DTCs reported from any module.

➢ If any DTCs are present, refer to “Diagnostic

Trouble Code (DTC) List - Vehicle Diagnostic Information” and diagnose any current DTCs in the

following order: a. DTCs that begin with a U. b. B1000, B1001, B1016, B1019, C0550, C0551,

C0558, P0601, P0602, P0603, P0604, P0606, P2101, P2107, or P2610

c. B1325, B1424, B1517, C0800, C0899, C0900,

P0560, P0562, or P0563 d. Component level DTCs. e. System level DTCs. f. Any remaining DTCs.

10. If the customer concern is related to inspection/ maintenance (I/M) testing, refer to “Evaporative Emission Control System Description: ”.

➢ If none of the previous tests or inspections

addresses the concern, refer to “Symptoms -

PMM Power Mode Parameters

Ignition Switch Position

Off Key Out Off Key Out/ACC Inactive Inactive

Off Key IN Off Key In/Off Inactive Inactive Accessory Accessory Key In/ACC Active Inactive

Run Run Run Active Active

Start Crank Request Crank Inactive Active

Current Power

Mode

Ign. Off/Run/

Crank (Off/Run Crank voltage circuit)

Ignition

Accessory/Run

(Accessory

voltage circuit)

Ignition Run/

Crank

(Ignition 1

Voltage circuit)

Page 71

General Information: 0A-58

Diagnostic Repair Verification - Vehicle Diagnostic Information

1. Install any components or connectors that have been removed or replaced during diagnosis.

2. Perform any adjustment, programming or setup procedures that are required when a component or module is removed or replaced.

3. Clear the DTCs.

4. Turn OFF the ignition for 60 seconds.

5. If the repair was related to a DTC, duplicate the Conditions for Running the DTC and use the Freeze Frame/Failure Records, if applicable, in order to verify the DTC does not reset. If the DTC resets or another DTC is present, refer to the “Diagnostic Trouble Code (DTC) List - Vehicle Diagnostic Information” and perform the appropriate diagnostic procedure. Or If the repair was symptom related, duplicate the conditions under which the customer concern occurred to verify the repair. If the customer concern reoccurs, return to “Symptoms - Vehicle Diagnostic Information” and perform the appropriate symptom diagnostic.

Driver Information and Entertainment

• “Symptoms - Entertainment: ”

• “Symptoms - Displays and Gages: ”

• “Symptoms - Secondary and Configurable Customer Controls: ”

Engine

• “Symptoms - Cruise Control: ”

• “Symptoms - Engine Controls: ”

• “Symptoms - Engine Cooling: ”

• “Symptoms - Engine Electrical: ”

• “Symptoms - Engine Exhaust: ”

• “Symptoms - Engine Mechanical: ”

HVAC

“Symptoms - HVAC Systems - Automatic: ”

Power and Signal Distribution

• “Symptoms - Data Communications: ”

• “Symptoms - Wiring Systems: ”

Roof

“Symptoms - Roof: ”

Symptoms - Vehicle Diagnostic Information

General Information

“Symptoms - Vibration Diagnosis and Correction: ”

Body Systems

• “Symptoms - Fixed and Moveable Windows: ”

• “Symptoms - Horns: ”

• “Symptoms - Lighting Systems: ”

• “Symptoms - Vehicle Access: ”

• “Symptoms - Wipers and Washers: ”

Brakes

• “Symptoms - Antilock Brake System: ”

• “Symptoms - Hydraulic Brakes: ”

• “Symptoms - Park Brake: ”

Driveline/Axle

• “Symptoms - Propeller Shaft: ”

• “Symptoms - Rear Drive Axle: ”

• “Symptoms - Wheel Drive Shafts: ”

Safety and Security

• “Symptoms - Remote Functions: ”

• “Symptoms - Seat Belts: ”

• “Symptoms - SIR: ”

• “Symptoms - Theft Deterrent: ”

Seats

• “Symptoms - Seats: ”

• “Symptoms - Seat Heating and Cooling: ”

Steering

• “Symptoms - Power Steering System: ”

• “Symptoms - Steering Wheel and Column: ”

Suspension

• “Symptoms - Suspension General Diagnosis: ”

• “Symptoms - Tire Pressure Monitoring: ”

Transmission/Transaxle

• “Symptoms - Automatic Transmission: ”

• “Symptoms - Automatic Transmission Shift Lock Control: ”

• “Symptoms - Transfer Case: ”

Page 72

0A-59 General Information:

Symptoms - Vibration Diagnosis and Correction

NOTE

Perform the following steps in sequence BEFORE using these symptom tables.

1. Begin the diagnosis of a vibration concern by reviewing “Diagnostic Starting Point - Vibration Diagnosis and Correction” to become familiar with the diagnostic process used to properly diagnose vibration concerns.

2. Perform the “Vibration Analysis - Road Testing” table before using these symptom tables in order to duplicate and effectively diagnose the customer's concern.

Symptom Tables

Refer to a Vibration Analysis table as indicated in the following symptom tables, based on the most dominant characteristic of the customer's vibration concern, felt or heard, that is evident during the appropriate condition of the occurrence.

Vibration Symptoms that are Felt

Typical

Category Description

Can sometimes be seen or felt in the steering wheel, seat or

Shake

console. Related terminology: shimmy, wobble, waddle, shudder, hop

Roughness

Similar to the feeling of holding a jigsaw.

Similar to the feeling of holding an electric razor.

Buzz

May be felt in the hands through the steering wheel, in the feet through the floor, or in the seat of the pants.

May produce a “pins and needles” sensation or may put hands or

Tingling

feet “to sleep”. Highest vibration frequency range that can still be felt.

Frequency

Range

5-20 Hz

20-50 Hz

50-100 Hz

Greater

than 100 Hz

Condition of Occurrence Area of Focus

Vehicle Speed Sensitive Still occurs during coast down in NEUTRAL Vehicle Speed Sensitive Affected by torque/load

Vehicle Speed Sensitive Affected by steering input

Engine Speed Sensitive

Vehicle Speed Sensitive Still occurs during coast down in NEUTRAL Vehicle Speed Sensitive Affected by torque/load

Vehicle Speed Sensitive Affected by steering input

Engine Speed Sensitive

Vehicle Speed Sensitive Affected by torque/load

Vehicle Speed Sensitive Affected by steering input

Engine Speed Sensitive

Vehicle Speed Sensitive Affected by torque/load

Vehicle Speed Sensitive Affected by steering input

Engine Speed Sensitive

Go to “Vibration Analysis - Tire and Wheel: ” Go to “Vibration Analysis - Driveline: ” Go to “Vibration Analysis - Hub and/or Axle Input: ” Go to “Vibration Analysis - Engine: ” Go to “Vibration Analysis - Tire and Wheel: ” Go to “Vibration Analysis - Driveline: ” Go to “Vibration Analysis - Hub and/or Axle Input: ” Go to “Vibration Analysis - Engine: ” Go to “Vibration Analysis - Driveline: ” Go to “Vibration Analysis - Hub and/or Axle Input: ” Go to “Vibration Analysis - Engine: ” Go to “Vibration Analysis - Driveline: ” Go to “Vibration Analysis - Hub and/or Axle Input: ” Go to “Vibration Analysis - Engine: ”

Page 73

Vibration Symptoms that are Heard

Category Description

Usually heard as an interior noise similar to the noise of a bowling ball rolling down an alley, deep thunder, or a bass drum.

Boom

• Related terminology - droning, growling, moaning, roaring, rumbling, humming

• May not be accompanied by a perceptible vibration (roughness)

Similar to the sound of a bumblebee or blowing air across the top of a bottle.

Moan or

Drone

• Related terminology humming, buzzing, resonance

• May be accompanied by a perceptible vibration (buzz)

Howl

Similar to the sound of the wind howling.

Similar to the sound of

Whine

mosquitoes, turbine engines, or vacuum cleaners.

Typical

Frequency

Range

20-60 Hz

60-120 Hz

120-300 Hz

300-500 Hz

General Information: 0A-60

Condition of Occurrence Area of Focus

Vehicle Speed Sensitive Still occurs during coast down in NEUTRAL Vehicle Speed Sensitive Affected by torque/load

Vehicle Speed Sensitive Affected by steering input

Vehicle Speed Sensitive Affected by torque/load

Vehicle Speed Sensitive Affected by steering input

Engine Speed Sensitive

Go to “Vibration Analysis - Tire and Wheel: ” Go to “Vibration Analysis - Driveline: ”

Go to “Vibration Analysis - Hub and/or Axle Input: ”

Go to “Vibration Analysis - Driveline: ” Go to “Vibration Analysis - Hub and/or Axle Input: ”

Go to “Vibration

Analysis - Engine: ” Vehicle Speed Sensitive Affected by torque/load

Vehicle Speed Sensitive Affected by steering input

Engine Speed Sensitive

Vehicle Speed Sensitive Affected by torque/load 2WD mode Vehicle Speed Sensitive Affected by torque/load 4WD mode

Go to “Vibration

Analysis - Driveline: ”

Go to “Vibration

Analysis - Hub and/or

Axle Input: ”

Go to “Vibration

Analysis - Engine: ”

Go to Transmission

diagnostic information

Go to Transfer Case

diagnostic information

Squeaks and Rattles

Special tool J 39570 Chassis Ear J 41416 Ultrasonic Leak Detector

NOTE

Squeaks and rattles are caused by improperly controlled relative motion between vehicle components. There are 4 ways to prevent squeaks and rattles. To aid in diagnosing, use J 39570 or J 41416.

• Attach the component that squeaks or rattles securely.

• Separate the components that squeak or rattle to prevent contact.

• Insulate the components that squeak or rattle.

• Insulate low uniform friction surfaces to eliminate stickslip motion.

Page 74

0A-61 General Information:

Vibration Analysis - Road Testing

Test Description

The numbers below refer to the step numbers on the diagnostic table.

Obtaining rotational speed for the components rotating at tire/wheel speed is critical to systematically eliminating specific vehicle component groups. These component rotational speeds can be generated by using the J 38792-VS Vibrate Software, or through calculating them manually.

14.

NOTE

Be certain to OBSERVE for disturbances that match the customer's description FIRST, then look at the J 38792-A frequency which corresponds with that disturbance.

Proper location of the J 38792-A Electronic Vibration Analyzer (EVA) 2, sensor onto the component which is most excited by the vibration disturbance is critical to obtaining an accurate frequency reading. This test will duplicate virtually any disturbance which occurs while the vehicle is in motion.

17.

Accelerate to a speed high enough above the speed of the disturbance to allow for the time needed to shift into NEUTRAL and for the engine to decrease in RPM to idle speed, before coasting down through the disturbance range.

18.

This test will either eliminate or confirm the engine as a contributing cause of the customer concern.

Step Action Yes No

WARNING

Refer to “Road Test Caution: ”.

Did you review the Diagnostic Starting Point - Vibration Diagnosis?

Did the customer concern indicate that the vibration occurs

ONLY while the vehicle is standing still? Visually inspect the tire and wheel assemblies, steering components and suspension components for any possible

faults. Are the tire and wheel assemblies, steering components and suspension components in good working condition?

NOTE

Do NOT operate the vehicle until the faults are corrected.

Correct the faults with the tire and wheel assemblies, steering

components, and/or the suspension components before proceeding. Did you correct the faults with the tire and wheel assemblies, steering components, and/or the suspension components?

1. Obtain the drive axle final drive ratio.

2. If the J 38792-VS, Vibrate Software, IS available, obtain the transmission gear ratios.

3. If the J 38792-VS is NOT available, take note of the tire size on each axle, then calculate the tire rotational speed

for each size tire used and calculate the propeller shaft rotational speed, if equipped. Refer to “Component Rotational Speed Calculation: ”.

Did you obtain the powertrain ratios for use with the J 38792VS, or calculate the component rotational speeds, if J 38792VS is NOT available?

Go to “Diagnostic

Go to Step 2

Starting Point Vibration Diagnosis and Correction”

Go to Step 6 Go to Step 3

Go to Step 5 Go to Step 4

Go to Step 5 Go to Step 3

Go to Step 6 —

Page 75

General Information: 0A-62

Step Action Yes No

1. Install a scan tool.

2. With the scan tool, bring up the Powertrain Control Module

data list and select Engine Speed.

Is the scan tool operating properly?

Go to Step 7

Go to “Diagnostic System Check Vehicle Diagnostic Information”

Using the J 38792-A, Electronic Vibration Analyzer (EVA) 2 is the preferred method for gathering necessary vibration frequency data. If the J 38792-A is not available, the necessary vibration frequency data will have to be obtained based on symptoms observed during testing. Review “Symptoms - Vibration

Go to Step 8 Go to Step 9 Diagnosis and Correction” to become familiar with the possible frequency ranges. Review Symptoms - Vibration Diagnosis and Correction, as necessary throughout the remainder of diagnostics. Is the J 38792-A available for use? Install the J 38792-A. Is the J 38792-A operating properly?

Go to Step 9

Go to “Electronic Vibration Analyzer (EVA) Description and Operation”

Did the customer concern indicate that the vibration occurs

ONLY while the vehicle is standing still? Did the customer concern indicate that the vibration occurs

ONLY during heavy acceleration at launch?

Go to “Vibration Analysis - Engine: ”

Go to Step 10

Go to Step 11 Go to Step 14

1. Install the J 38792-A sensor, if available, to the pinion area

of the drive axle. Route the sensor lead wire clear of rotating parts and loosely secure the wire clear of moving parts. If it is not possible to install the J 38792-A sensor, if available, to the drive axle, install the sensor to an exposed portion of the floor panel or seat track in the area that the customer noted is most respondent to the vibration.

2. Select a smooth, level road.

3. With the vehicle at a stand-still, apply the regular brake

and place the transmission in the lowest forward gear.

NOTE

Do not accelerate to the point of causing the drive wheels to squeal, slip or hop - this would obscure

Go to Step 12 Go to Step 14

the results of the test.

4. Release the regular brakes and accelerate aggressively to

32 km/h (20 mph).

5. Observe the vehicle for disturbances that match the

customer's description and note the following conditions: – The vibration frequency reading, if detected by the J

38792-A

– The feel and/or sound of the disturbance

6. If a reading could not be obtained by the J 38792-A, move

the J 38792-A sensor, if available, to another part that is respondent to the vibration and repeat steps 3-5.

Were you able to duplicate the customer's concern?

12 Is the vehicle primary driveline configuration rear wheel drive? Go to Step 13 Go to Step 14

Is the vehicle equipped with a solid drive axle?

Go to “Vibration Analysis - Driveline: ”

Go to “Vibration Analysis - Hub and/or Axle Input: ”

Page 76

0A-63 General Information:

Step Action Yes No

1. Install the J 38792-A sensor, if available, to the component identified by the customer as most respondent to the vibration. If no component was identified, install the J 38792-A sensor, if available, to the steering column. You may have to move the sensor to other locations later.

2. Select a smooth, level road and slowly accelerate the vehicle up to highway speed.

3. Observe the vehicle for disturbances that match the customer's description and note the following conditions:

– The vehicle speed

– The engine RPM

Go to Step 17 Go to Step 15

– The transmission gear range and the specific gear – The vibration frequency reading, if detected by the J

38792-A

– The feel and/or sound of the disturbance

4. If the vibration seems to excite a particular component of the vehicle more than the steering column, then move the J 38792-A sensor, if available, onto that component and repeat steps 2 and 3.

Were you able to duplicate the customer's concern? Is the vehicle equipped with selectable four-wheel or all-wheel

drive?

Go to Step 16 Go to Step 17

1. With the J 38792-A sensor still installed in the same position, activate/engage all-wheel drive.

2. Select a smooth, level road and slowly accelerate the vehicle up to highway speed.

3. Observe the vehicle for disturbances that match the customer's description and note the following conditions:

– The vehicle speed

– The engine RPM – The transmission gear range and the specific gear

Go to Step 17

Go to “Vibration Diagnostic Aids”

– The vibration frequency reading, if detected by the J

38792-A

– The feel and/or sound of the disturbance

4. If the vibration seems to excite a particular component of the vehicle more than the steering column, then move the J 38792-A sensor, if available, onto that component and repeat steps 2 and 3.

Were you able to duplicate the customer's concern?

1. Accelerate the vehicle to a speed higher than the speed at which the disturbance occurs.

NOTE

If the vehicle is equipped with a continuously variable type automatic transmission, let the

vehicle coast to a stop before shifting back into gear.

2. Shift the vehicle into NEUTRAL and allow the vehicle to coast down through the disturbance range.

Does the disturbance still occur while coasting-down in NEUTRAL?

Go to Step 19 Go to Step 18

Page 77

General Information: 0A-64

Step Action Yes No

1. Select a smooth, level road and slowly accelerate the vehicle up to the speed at which the disturbance occurs.

2. Decelerate and safely downshift by one gear range.

3. Operate the vehicle at the same VEHICLE SPEED at which the disturbance occurs.

Go to “Vibration Analysis - Hub and/or Axle Input: ”

Go to “Vibration Analysis - Engine: ”

Does the same disturbance still occur while going the same vehicle speed in a lower gear range? If the J 38792-A is not available, refer to “Symptoms -

Vibration Diagnosis and Correction”. Did the J 38792-A detect a dominant frequency?

Go to Step 20

Go to “Symptoms Vibration Diagnosis and Correction”

1. If the J 38792-VS IS available, use the drive axle final drive ratio, the specific transmission gear ratio, and the engine RPM to make a comparison to the dominant frequency reading recorded.

2. If the J 38792-VS is NOT available, compare the dominant frequency reading recorded to the component rotational

Go to “Vibration Analysis - Tire and Wheel: ”

Go to Step 21

data which you calculated previously.

Does the frequency data clearly fall within the tire/wheel parameters ONLY? Does the frequency data clearly fall within the propeller shaft

parameters ONLY? Is the vehicle equipped with a solid drive axle? Go to “Symptoms -

Go to “Vibration Analysis - Driveline: ”

Vibration Diagnosis and Correction”

Go to Step 22

Go to “Vibration Analysis - Hub and/or Axle Input: ”

Vibration Diagnostic Aids

NOTE

If you have not reviewed the Diagnostic Starting Point - Vibration Diagnosis and completed the Vibration Analysis tables as indicated, refer to “Diagnostic Starting Point Vibration Diagnosis and Correction” BEFORE proceeding.

The diagnostic information contained in this Diagnostic Aids section will help you determine the correct course of action to take for the following 4 main conditions. Refer to the appropriate condition from this list:

• “Vibration Diagnostic Aids - Vibration Intermittent or Not Duplicated”

• “Vibration Diagnostic Aids - Vibration Duplicated, Component Not Identified”

• “Vibration Diagnostic Aids - Vibration Duplicated, Difficult to Isolate/Balance Component”

• “Vibration Diagnostic Aids - Vibration Duplicated, Appears to be Potential Operating Characteristic”

Vibration Diagnostic Aids - Vibration Intermittent or Not Duplicated

NOTE

If you have not completed the Vibration Analysis tables as indicated and reviewed Vibration Diagnostic Aids, refer to “Vibration Diagnostic Aids” BEFORE proceeding.

If you have not been able to duplicate the vibration concern or have only been able to duplicate the concern intermittently, review the following information. Most vibration concerns that cannot be duplicated are due to either specific conditions that are not present during the duplicating attempts, or due to not following the procedures designed to duplicate concerns properly and in the sequence indicated.

Page 78

0A-65 General Information:

Specific Conditions Can Affect the Condition

Consider the following conditions which may not have been present while attempts were made to duplicate the vibration concern. Attempt to obtain more specific information from the customer as to the EXACT conditions that are present when they experience the vibration which they are concerned about. Attempt to duplicate the vibration concern again while recreating the EXACT conditions necessary, except those which pose a safety concern or are outside the boundaries of normal operating conditions, such as loading the vehicle beyond its designed weight ratings, etc. Most attempts to duplicate a vibration concern are made after the vehicle has been driven to the repair facility and perhaps even sat inside the building for a time; the vehicle may be too warm to detect the concern during duplication efforts. The opposite could also occur; perhaps the vehicle has sat out in the cold for a time and fails to reach full operating temperatures during attempts to duplicate the concern.

Temperature, Ground-Out, Accessory Load

Flat Spots on Tires

Tires which have sat and been cool for a time can develop flat spots.

Irregular Wear on Tire Treads

Tires which have sat and been cool for a time will be stiffer and any irregular wear conditions will be more noticeable than they will be once the tires have warmed and softened.

Exhaust System Growth

Exhaust systems may exhibit a ground-out condition when cool which goes away once the system is hot. The opposite may be true that the exhaust system is fine when cool but a ground-out condition occurs once the system reaches operating temperatures. Exhaust systems can grow by 2½-5 cm (1-2 in) when hot.

Engine-Driven Accessory Noises

NOTE

When a stethoscope equipped with a probe is used to assist in identifying possible vibrating components, the results must be compared to the sound quality of the same accessory, in a equally-equipped, same model year and type, KNOWN GOOD vehicle, and under the same conditions. Refer to “Vehicle-to-Vehicle Diagnostic Comparison”.

A stethoscope equipped with a probe can be used as an additional means to assist in identifying accessories which may be causing or contributing to a vibration concern.

• Belt Whipping An engine accessory drive belt, or belts could exhibit a whipping condition if a belt is deteriorating and deposits are building up on the underside of the belt.

• Loose Mounting Brackets or Component Ground-Out Engine-driven accessories such as a generator, a power steering pump, or an air conditioning compressor could exhibit noise conditions due to either loose mounting brackets or due to related components of the system in a ground-out condition during certain operation of that accessory system.

• Cold or Hot Accessories could exhibit noise conditions when cool which go away once they are fully warmed-up, or the opposite may be true.

• Load on an Accessory Component Accessories could exhibit a noise condition while under a heavy load - perhaps when combined with a cool or fully warmed-up condition.

• Bent or Misaligned Pulleys Bent or mis-aligned pulleys in one or more enginedriven accessory systems could contribute to a noise or vibration condition.

• Fluid Level in Accessory Systems Accessories could exhibit a noise condition due to an abnormal amount of fluid contained in the system of which the accessory is a part. For example:

– An improper power steering fluid level could

produce noises in the power steering system.

– An improper air conditioning refrigerant level or an

excessive amount of refrigerant oil could produce noises or possibly vibrations in the air conditioning system.

• Incorrect Fluid Type in Accessory Systems Accessories could exhibit a noise condition due to the incorrect type of fluid contained in the system of which the accessory is a part.

Vehicle Payload

The vibration concern may only occur when the vehicle is carrying heavy payloads or towing a trailer; the vehicle may have been empty during duplication efforts.

Heavy Payload

The vehicle may have been empty during attempts to duplicate the vibration concern, but the customer may actually experience the vibration concern while the vehicle is carrying a large payload.

Trailer Towing

The customer may experience the vibration concern only while towing a trailer.

Roadway Selection

The selection of roadways used to perform the vibration duplication procedures is likely to be in the near vicinity of the repair facility and may not provide a road surface that is similar enough to the surface on which the customer usually drives the vehicle. The customer may only experience the vibration on a particular roadway. Perhaps the roadway is overly crowned or is very bumpy or rough.

Page 79

General Information: 0A-66

Vibration Diagnostic Aids - Vibration Duplicated, Component Not Identified

NOTE

If you have not completed the Vibration Analysis tables as indicated and reviewed Vibration Diagnostic Aids, refer to “Vibration Diagnostic Aids” BEFORE proceeding.

Aftermarket Add-On Accessories

Aftermarket accessories which have been added to the vehicle can actually transmit and magnify INHERENT component rotational frequencies, if the accessories were not installed correctly. An accessory should be installed in such a way that it is isolated from becoming a possible transfer path into the rest of the vehicle. For example, if a set of running boards has been installed improperly and they are sensitive to a particular frequency of a rotating component, the running boards could begin to respond to the frequency and actually create a disturbance once the amplitude of the frequency reaches a high enough point, probably at a higher vehicle speed. If the same set of running boards were installed properly—isolated properly—the transfer path would be removed and the disturbance would no longer be present.

Vibration Diagnostic Aids - Vibration Duplicated, Difficult to Isolate/Balance Component

NOTE

If you have not completed the Vibration Analysis tables as indicated and reviewed Vibration Diagnostic Aids, refer to “Vibration Diagnostic Aids” BEFORE proceeding.

If you have duplicated the vibration concern but have had difficulty in balancing a component or isolating a component, refer to the following information. Most vibration concerns are corrected or eliminated through correcting excessive runout of a component, correcting balance of a component, or isolating a component which has come into abnormal contact with another object/component. Components which can generate a lot of energy and are experiencing excessive runout, imbalance, or groundout can produce a vibration with a strong enough amplitude that the vibration can transmit to components which are closely related. This type of a condition is usually related to and sensitive to torque-load. The most likely system that could exhibit this type of a condition is the driveline.

Driveline Torque-Load Conditions

An drive axle that has internal conditions such as excessive runout of components, misalignment of components, imbalance, etc., can produce vibration concerns which may be transmitted into the propeller shaft, or shafts. This sort of a vibration occurrence can increase or decrease in severity based primarily upon torque-load, but can also be affected by cold or hot conditions. The propeller shaft and other related components may or may not pass inspections for wear or damage, runout, alignment, etc., depending upon whether there is only one vibration source or more than one.

Difficult to System Balance the Driveline

If after following the Vibration Analysis - Driveline table you were instructed to system balance the driveline and you experienced difficulty in doing so while CAREFULLY following the procedures indicated—the EVA strobe readings seem to keep changing—then the axle differential to which the propeller shaft is attached should be suspected to have internal problems which are being transmitted to the propeller shaft. Refer to the drive axle diagnosis information, for internal axle diagnostics.

Vibration Diagnostic Aids - Vibration Duplicated, Appears to be Potential Operating Characteristic

NOTE

If you have not completed the Vibration Analysis tables as indicated and reviewed Vibration Diagnostic Aids, refer to “Vibration Diagnostic Aids” BEFORE proceeding.

Check Service Bulletins

If BOTH of the following statements are TRUE, then check service bulletins for the condition identified. If the condition has already been identified and investigated prior to this vehicle, and has been determined to be something that is not truly an operating characteristic or that perhaps is not design-intent, there will likely be adjustments or corrections identified which will address the condition.

• You CAREFULLY followed the steps indicated through reviewing the Diagnostic Starting Point Vibration Diagnosis and completing the Vibration Analysis tables identified and you have duplicated the vibration concern.

• You have come to the conclusion through comparison with a very equally-equipped, same model year and type, KNOWN GOOD vehicle that the customer's concern is a condition that appears to be a potential operating characteristic of the vehicle.

Page 80

0A-67 General Information:

Vibration in Service-Stall Test (Non-Torque Sensitive)

Special tool J 38792-A Electronic Vibration Analyzer (EVA) 2

CAUTION

Do not fill the propeller shaft with foam, oil, or any other substance in order to correct a vibration. Filling the propeller shaft is only effective in reducing an unrelated condition called Torsional Rattle. Filling the propeller shaft should only be done in strict adherence to the procedure outlined in corporate bulletins that address Torsional Rattle. Failure to follow the correct procedure will induce a vibration and/or affect the structural integrity of the propeller shaft. The propeller shaft will then have to be replaced.

1. Turn the ignition ON but do not start the engine.

2. Place the transmission in NEUTRAL.

3. Raise and support the vehicle. Support the drive axle or axles at curb height. Refer to “Lifting and Jacking the Vehicle”.

4. Remove the tire and wheel assemblies from the vehicle. Refer to “Tire and Wheel Removal and Installation: ”.

5. Remove the brake rotors or drums, if equipped, from the drive axle or axles.

6. Inspect the propeller shaft or shafts. All propeller shafts should be free of undercoating before continuing.

CAUTION

Do not depress the brake pedal with the brake rotors and/or the brake drums removed, or with the brake calipers repositioned away from the brake rotors, or damage to the brake system may result.

7. Have an assistant start the engine.

8. Place the transmission in the highest forward gear.

9. Accelerate and decelerate the vehicle through the speed range at which the vibration was first noted during the Vibration Analysis-Road Testing procedure.

10. Record whether the vibration was present, and at what speed.

11. If the vibration is present, determine which end of the propeller shaft is vibrating the most. Hold the vibration sensor of the J 38792-A Electronic Vibration Analyzer (EVA) 2, up to the pinion nose and the transmission or transfer case tailshaft housing.

12. If the vehicle is equipped with a multiple-piece propeller shaft, hold the vibration sensor of the J 38792-A up to the propeller shaft support bearing assembly, or assemblies to inspect for vibration.

13. If the transmission or transfer case output shaft housing is vibrating, hold the vibration sensor of the J 38792-A up to the transmission crossmember under the transmission mount. If there is no vibration on the crossmember, then the transmission mount is working properly.

14. Record which end of the propeller shaft is vibrating the most, and how severe the vibration is. The inspection will be a reference by which to judge future progress.

Vibration in Service-Stall Test (Torque Sensitive)

Special tool J 38792-A Electronic Vibration Analyzer (EVA) 2

CAUTION

1. Turn the ignition ON but do not start the engine.

2. Place the transmission in NEUTRAL.

3. Raise and support the vehicle. Support the drive axle or axles at curb height. Refer to “Lifting and Jacking the Vehicle”.

4. Remove the tire and wheel assemblies from the vehicle. Refer to “Tire and Wheel Removal and Installation: ”.

5. Remove the brake rotors or drums, if equipped, from the drive axle or axles.

6. Hold the vibration sensor of the J 38792-A Electronic Vibration Analyzer (EVA) 2, against the pinion nose.

CAUTION

Do not depress the brake pedal with the brake rotors and/or the brake drums removed, or with the brake calipers repositioned away from the brake rotors, or damage to the brake system may result.

Page 81

General Information: 0A-68

7. Have an assistant start the vehicle.

8. Place the transmission in the highest forward gear.

9. Accelerate and decelerate the vehicle through the speed range at which the vibration was first noted during the Vibration Analysis - Road Testing procedure.

10. If a vibration is present, note the J 38792-A reading during acceleration or deceleration.

11. Note as to whether or not the pinion nose vibrates under load during acceleration or deceleration.

12. If the vibration is not reproduced, reinstall the brake rotors and/or drums and the wheel/tire assemblies to put an additional load on the system. Perform steps 7-11 and check the components again.

13. If the vibration is still not reproduced with rotors and/ or drums reinstalled, lightly apply the brakes to further load the system while maintaining the vibration concern speed.

14. If the pinion nose vibrates under acceleration or deceleration, and other driveline components have been eliminated as a cause, the vibration may be an internal axle problem.

Control Module References

Control Module Schematic Repair Instruction Programming and Setup

• “Diagnostic System Check - Vehicle Diagnostic Information”

• “Diagnostic Trouble Code (DTC) List - Vehicle Diagnostic Information”

• “DTC Symptom Description - Vehicle Diagnostic Information”

• “Symptoms - Vehicle Diagnostic Information” Audio Amplifier “Radio/Navigation System

Schematics: ” Auxiliary Blower Control Module Blower Control Module

Body Control Module “Body Control System

Digital Radio Receiver

Electronic Brake Control Module (ABS)

Engine Control Module “Engine Controls

Heated Seat Control Module

Inflatable Restraint Passenger Presence System

Inflatable Restraint Sensing and Diagnostic Module “SIR Schematics: ”

Inside Rearview Mirror

Instrument Panel Cluster “Instrument Cluster

Radio “Radio/Navigation System

Rear Differential Clutch Control Module

“HVAC Schematics: ”

Schematics: ”

“Radio/Navigation System

Schematics: ”

“Antilock Brake System

Schematics: ”

“Heated/Cooled Seat

Schematics: ”

“SIR Schematics: ”

“Inside Rearview Mirror

Schematics: ”

“All-Wheel Drive

Schematics: ”

“Amplifier Replacement: ”

“Auxiliary Blower Control Module Replacement: ” “Blower Motor Control Module Replacement: ” “Body Control Module Replacement: ”

“Digital Radio Receiver Replacement: ”

“Electronic Brake Control Module Replacement: ”

“Engine Control Module Replacement: ”

“Front Seat Heater Control Module Replacement: ”

“Inflatable Restraint Passenger Presence System Replacement Front: ” “Inflatable Restraint Sensing and Diagnostic Module Replacement: ”

“Rearview Mirror Replacement: ”

“Instrument Cluster Replacement: ”

“Radio Replacement: ”

“Rear Differential Clutch Control Module Replacement: ”

This device requires no programming or setup This device requires no programming or setup This device requires no programming or setup “Body Control Module Programming and Setup: ” “Digital Radio Receiver Setup: ” after DRR replacement “Electronic Brake Control Module Programming and Setup: ” “Engine Control Module Programming and Setup: ” “Service Programming System (SPS)” after heated seat control module replacement

“Passenger Presence System Programming and Setup: ”

“Inflatable Restraint Sensing and Diagnostic Module Programming and Setup: ” “Compass Calibration and Magnetic Variance: ” after rear view mirror replacement “Instrument Cluster Programming and Setup: ” “Radio Setup: ” after radio replacement “Rear Differential Clutch Control Module Programming and Setup: ”

Page 82

0A-69 General Information:

Control Module Schematic Repair Instruction Programming and Setup

Remote Control Door Lock Receiver Sunroof Control Module

Theft Deterrent Module

Transmission Control Module

“Remote Function Schematics: ”

“Sunroof Schematics: ”

“Immobilizer Schematics: ”

“Automatic Transmission Controls Schematics: ”

“Remote Control Door Lock Receiver Replacement: ” “Sunroof Control Module Replacement: ”

“Theft Deterrent Module Replacement: ”

“Transmission Control Module Removal: ” and “Transmission Control Module Installation: ”

“Transmitter Programming: ” after RCDLR replacement This device requires no programming or setup “Theft Deterrent Control Module Programming and Setup: ”

“Transmission Control Module Programming and Setup: ”

Page 83

General Information: 0A-70

Special Tools and Equipment

Substitute Special Tool Table

The substitute special tools below are usable instead of the special tools described in this manual.

NOTE

“—” indicates the substitute special tool is not available.

Engine

Special Tools Described in This Manual Substitute Special Tools

EN-46119 09916-14521 Off-Vehicle Valve Spring Compressor Adapter

J-24460-01 09918-78211 Cooling System Pressure Tes te r

Valve Spring Compressor Attachment

Radiator Cap Tester Kit

J-6125-1B 09921-96010 Slide Hammer with Adapter Oil Seal Remover & Slider

Page 84

0A-71 General Information:

Suspension

Special Tools Described in This Manual Substitute Special Tools

J-45097 09913-75821 Rear Control Arm Bushing Remover

J-45400 09943-25010 Strut Spring Compressor Spring Compressor

Bearing Installer Attachment

Driveline/Axle

Special Tools Described in This Manual Substitute Special Tools

DT-48074 09924-07710 Input and Output Shaft Seal Installer

Synchronizer Hub Installer

Page 85

Special Tools Described in This Manual Substitute Special Tools

J-33832 09913-75821 Output Shaft Seal Installer Bearing Installer Attachment

J-8092 Driver Handle

General Information: 0A-72

J-35910 09943-57010 Drive Axle Seal Clamp Pliers Band Compressor

09943-57021 Pliers, Low-Profile Clamp

Page 86

0A-73 General Information:

Transmission/Transaxle

Special Tools Described in This Manual Substitute Special Tools

J-23327 09926-96040 Clutch Spring Compressor Clutch Spring Compressor

No.8

J-35582 09913-85210 Oil Pump Seal Installer Bearing Installer

J-41236 09926-98350 Coast Clutch Spring Compressor

J-44809 09924-07730 Output Shaft Seal Installer Bearing Installer

Spring Compressor No.4

Page 87

Special Tools Described in This Manual Substitute Special Tools

J-45000 09913-50121 Seal Remover Oil Seal Remover

J-45124 09942-15511 Removal Bridge Sliding Hammer

General Information: 0A-74

J-45160 09944-96011 Differential Bearing Race Remover

J-45161 09943-88211 Manual Shift Shaft Bearing Replacer

J-45164 09941-51012 Spring Compressor Bridge Ring Lock Nut Wrench

Bearing Outer Rase Remover

Pinion Bearing Installer

Page 88

0A-75 General Information:

Special Tools Described in This Manual Substitute Special Tools

J-45166 09900-20701 Dial Indicator Extension Rod

- 8 inch

J-45185 09900-22403 Bore Gage Set Small Bore Gauge (18-35

Magnetic Stand

mm)

J-45186 09926-95420 Forward and Direct Clutch Spring Compressor

J-45187 09924-07730 Differential Output Shaft Oil Seal Installer

Clutch Spring Compressor

Bearing Installer

Page 89

Special Tools Described in This Manual Substitute Special Tools

J-45200 09900-20607 Dial Indicator Set Dial Gauge

09900-20701 Magnetic Stand

General Information: 0A-76

Page 90

0A-77 General Information:

Steering

Special Tools Described in This Manual Substitute Special Tools

J-1859-A 09944-36011 Steering Wheel Puller Steering Wheel Remover

J-22610 09943-57010 Keystone Clamp Pliers Band Compressor

09943-57021 Pliers, Low-Profile Clamp

Page 91

HVAC

Special Tools Described in This Manual Substitute Special Tools

GE-47849 09991-06530 Clutch Remover Armature Plate Remover

GE-47851 09951-15511 Armature Installer Magnet Clutch Installer

General Information: 0A-78

J-37872 09991-06310 Universal Spanner Wrench Armature Plate Holder

J-39400-A 09990-86012 Halogen Leak Detector Gas Leak Detector

Page 92

0A-79 General Information:

Electronic Vibration Analyzer (EVA) Description and Operation

Special tool J 38792-A Electronic Vibration Analyzer

The J 38792-A, electronic vibration analyzer (EVA), is a 12-volt powered hand-held device, similar to a scan tool, which receives input from an attached vibration sensor or accelerometer and displays the most dominate input frequency(ies) (up to three) on its liquid crystal display. The vibration concern frequency(ies) are obtained through the use of the J 38792-A while following the Vibration Analysis Diagnostic Tables. The frequency(ies) obtained, when applied to the Vibration Analysis Diagnostic Tables, are used as a primary input to help determine the source of the vibration concern.

EVA Vibration Sensor

The J 38792-A vibration sensor incorporates a 6.1 m (20 ft) cord, that allows the sensor to be placed on virtually any component of the vehicle where a vibration concern is felt. The J 38792-A contains 2 sensor input ports which can be activated individually to allow for 2 individual vibration sensor inputs. The vibration sensors can then be placed in 2 different locations in the vehicle and their individual inputs can be read without having to stop a test, move the sensor and resume the test. The use of 2 vibration sensors can help in more quickly finding and recording an accurate frequency of the vibration concern, and in more quickly making comparisons between 2 different areas of a single component, or a vehicle system, during the diagnostic process.

EVA Vibration Sensor Placement

Proper placement of the J 38792-A vibration sensor (accelerometer) is critical to ensure that proper vibration readings are obtained by the J 38792-A. The vibration sensor should be placed on the specific vehicle component identified as being the most respondent to the vibration. If no component has been identified, install the sensor to the steering column as a starting point.

EVA Vibration Sensor-to-Component Attachment

The vibration sensor of the J 38792-A is designed to pickup disturbances which primarily occur in the vertical plane, since most vibrations are felt in that same up-anddown direction. The J 38792-A vibration sensor is therefore directional sensitive and must be attached to vehicle components such that the side of the sensor marked UP is always facing upright and the sensor body is as close to horizontal as possible. The sensor must be installed in the exact same position each time tests are repeated or comparisons are made to other vehicles. The J 38792-A vibration sensor can be attached to vehicle components in various ways. For non-ferrous surfaces, such as the shroud of a steering column, the sensor can be attached using putty, or hook and loop fasteners. For ferrous surfaces, the sensor can be attached using a magnet supplied with the sensor.

EVA Software Cartridge

The J 38792-A uses a software cartridge, the J 3879260, which provides various information to the J 38792-A. The J 38792-60 provides the J 38792-A with an additional feature which can be selected and utilized to assist in diagnosing vibration concerns.

NOTE

The Auto-Mode function of the J 38792-A cartridge, J 38792-60, is designed to be used in SUPPORT of the Vibration Analysis Diagnostic Tables ONLY.

This support-feature is available through the J 38792-A Auto-Mode function. When selected, the J 38792-A will prompt the user to select which one of 2 vehicle systems (vehicle speed or engine speed), is the SUSPECTED source of the vibration concern. Using the inputted vehicle data parameters along with the most dominate vibration frequency obtained, it will identify a SUSPECTED source of the vibration concern, such as first-order tire and wheel. This can be a useful feature when used in conjunction with the Vibration Analysis Diagnostic Tables, to confirm results obtained through the diagnostic process.

NOTE

The J 38792-A vibration sensor must be attached to vehicle components in the manner indicated in order to achieve accurate frequency readings of the vibration disturbance.

EVA Smart Strobe Function

The J 38792-A can be used to identify some rotating components/systems which exhibit imbalance IF the component rotational speed is the dominant frequency of the vibration concern. The J 38792-A is equipped with a strobe light trigger wire which can be used with an inductive pickup timing light, J 38792-25, or equivalent included with the J 38792-KIT, or available separately. Using the Smart Strobe function enables the user to input the vibration frequency to which the strobe will flash. By marking the suspected rotating component, such as a pulley, adjusting the strobe frequency to match the dominant vibration frequency at the engine RPM noted during diagnosis, and then operating the engine at that specific RPM, the mark on the object will appear to be stationary if that object is imbalanced.

Page 93

General Information: 0A-80

EVA Strobe Balancing Function

The J 38792-A can be used to identify the light spot on a propeller shaft IF the propeller shaft rotational speed is the dominant frequency of the vibration concern. The J 38792-A is equipped with a strobe light trigger wire which can be used with an inductive pickup timing light, J 38792-25, or equivalent included with the J 38792-KIT, or available separately, and in conjunction with the J 38792-A vibration sensor to identify the light spot on a propeller shaft and to help in making a determination as to when propeller shaft balance is obtained.

Averaging/Non-Averaging Modes

The EVA provides 2 modes of displaying the most dominate frequencies which the EVA vibration sensor (accelerometer) detects; averaging and non-averaging (instantaneous). The averaging mode uses multiple vibration samples taken over a period of time and then displays the most dominant frequencies which have been averaged-out. Using the averaging mode minimizes the distractions caused by a sudden vibration frequency being displayed that is not related to the concern vibration, such as from pot holes or from uneven road surfaces. The non-averaging (instantaneous) mode is more sensitive to vibration disturbances than the averaging mode. Using the non-averaging mode will generate instantaneous frequency displays which are not averaged across multiple samples over a period of time; the specific vibration frequencies that occur at a specific moment during diagnostic testing will be displayed at that moment. The non-averaging (instantaneous) mode is useful when measuring a vibration disturbance that exists for only a short period of time or during acceleration/deceleration testing. When operating the EVA in the averaging mode along with the Auto Mode, “A” will be displayed along the top of the screen to the left of the vibration sensor input port being used. When operating the EVA in the averaging mode and the Manual Mode, “AVG” will be displayed along the top center of the screen. When operating the EVA in the non-averaging (instantaneous) mode along with the Auto Mode, “I” will be displayed along the top of the screen to the left of the vibration sensor input port being used. When operating the EVA in the non-averaging (instantaneous) mode and the Manual Mode, the top center of the screen will be blank.

EVA Display

The most dominant input frequencies, up to three, received from the J 38792-A vibration sensor, are displayed in descending order of amplitude strength. The frequency readings are displayed along the left side of the screen, followed to the right by either a bar graph or the suspected source of the vibration - depending upon the mode selected, then the amplitude reading for each frequency along the right side of the screen. The top row of the screen indicates the units of measure being displayed for the frequencies along the left side and for the amplitudes along the right side. The top row also indicates the vibration sensor input port which was selected on the keypad (A or B) and which mode was selected: averaging or non-averaging (instantaneous). The frequency(ies) can be displayed in either revolutions per minute (RPM) or revolutions per second; Hertz (Hz). The selected display type (RPM or Hz) will be indicated at the left side of the screen, above the frequency readings. When the AUTO MODE function is not in use, a bar graph is displayed next to each frequency to provide a quick visual indication of the relative amplitude strength. When the AUTO MODE function is being used, the suspected source of the vibration is displayed next to each frequency to provide support to the diagnostic process. The actual amplitude strength of each frequency is displayed at the right side of the screen and shown in G’s-of-acceleration force.

Page 94

0A-81 General Information:

Vibrate Software Description and Operation

The J 38792-VS, Vibrate Software, is a computer software program which is designed to be used in support of the Vibration Analysis diagnostic tables, along with the J 38792-A, Electronic Vibration Analyzer (EVA) and a scan tool, to help in determining the source of a vibration concern. The J 38792-VS is designed to provide quick calculations and produce a chart of the rotational speeds and frequency ranges for specific vehicle systems and components, based upon vehicle data parameters inputted by the user. The J 38792-VS uses the vehicle data parameters, such as axle ratio, number of engine cylinders, etc. to create the base chart, depicting the relationships of the various vehicle systems and/or components. The chart view can be modified to show data related to vehicle speed only, engine speed only, or both vehicle speed and engine speed. The user can then plot the dominant frequency reading obtained on the J 38792-A which correlates with the vibration concern, and the engine RPM obtained on a scan tool which correlates with the concern. Once these pieces of data are correctly plotted, the chart will point to the source of the vibration concern, which should confirm the results obtained through the following the Vibration Analysis diagnostic tables.

Due to the limited diagnostic capability, limited availability and increasing costs of the reed tachometer, it is NOT recommended as the primary tool to use in diagnosing a vibration concern. When diagnosing a vibration concern, use the J 38792A, electronic vibration analyzer (EVA). The J 38792-A has been designed to overcome the shortcomings to the reed tachometer. Refer to “Electronic Vibration Analyzer (EVA) Description and Operation”.

Special Tools - Squeaks and Rattles

Illustration Tool Number/ Description

J 39570

Chassis Ear

Reed Tachometer Description

The reed tachometer consists of 2 rows of reeds arranged side-by-side. Each reed is tuned to vibrate or resonate when it is excited by a specific frequency. The reeds are arranged by their specific resonant frequency, increasing from left to right, ranging from 10-80 Hz. This arrangement allows for a visual display of the most dominate frequencies which fall within this range. The reed tachometer can be a helpful diagnostic tool, however it is extremely sensitive to external inputs that are not related to the vibration concern, such as rough road surfaces, etc., and it is difficult to master its use. Due to these conditions, the reed tachometer has limited diagnostic capability.

J 41416

Ultrasonic Leak Detector

Special Tools and Equipment - Vibration Diagnosis and Correction

Illustration Tool Number/Description

J 7872

Magnetic Base Dial

Indicator Set

Page 95

General Information: 0A-82

Illustration Tool Number/Description

J 8001

Dial Indicator Set

J 23409

Dial Indicator Extension - 7

5/8 in

Illustration Tool Number/Description

J 38792-A

Electronic Vibration

Analyzer 2

J 38792-VS

Vibrate Software

J 23498-A

Driveshaft Inclinometer

J 23498-20

Driveshaft Inclinometer

Adapter

J 35819

Flange Runout Gage

J 38792-20

20-Foot Timing Light

Power Cord Extension

J 38792-25

Inductive Pickup Timing

Light

J 38792-27

6-Foot EVA Power Cord

Extension

Page 96

0B-1 Maintenance and Lubrication:

Maintenance and Lubrication

Scheduled Maintenance

Maintenance Items

The Normal Maintenance Replacement Parts information will only be found in the Owner's Manual. Refer to the Maintenance Schedule subsection of the Owner's Manual. You may be able to use the Search information function using the words Replacement Parts.

Maintenance Schedule (North American Emissions)

The Maintenance Schedule information will only be found in the Owner's Manual. Refer to the Maintenance Schedule subsection of the Owner's Manual, or you may be able to use the Search information function using the words Scheduled Maintenance.

Oil Life System Resetting

When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. A CHANGE ENGINE OIL light will come on. Change the engine oil as soon as possible within the next 600 miles (1 000 km). It is possible that, if driving under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, the engine oil and filter must be changed at least once a year and at this time the system must be reset. If the system is ever reset accidentally, change the engine oil at 3,000 miles (5 000 km) since last oil change.

How to Reset the Engine Oil Life System

The Engine Oil Life System calculates when to change the engine oil and filter based on vehicle use. Anytime the oil is changed, reset the system so it can calculate when the next oil change is required. If a situation occurs where the oil is changed prior to a CHANGE ENGINE OIL SOON message being turned on, reset the system.

1. Press the vehicle information button on the driver information center (DIC) until OIL LIFE REMAINING displays.

2. Press and hold the Set/Reset button on the DIC for more than 5 seconds. The oil life will change to 100 percent. If the light or message comes back on and stays on when you start the vehicle, the Engine Oil Life System has not reset. Repeat the procedure.

Specifications

Approximate Fluid Capacities

The following approximate capacities are given in English and metric conversions. See “Fluid and Lubricant Recommendations” for more information. All capacities are approximate. When adding, be sure to fill to the approximate level, as recommended in this manual. Recheck fluid level after filling.

Application

Cooling System 10.0 liters 10.6 quarts Engine Oil with Filter

3.6L Engine RPO LY7 5.2 liters 5.5 quarts

Engine Oil without Filter

3.6L Engine RPO LY7 4.8 liters 5.2 quarts Fuel Tank 70.0 liters 18.5 gallons Automatic Transaxle - AF33-5

Automatic - Drain and Refill 7.1 liters 7.5 quarts Automatic - Complete Overhaul 7.8 liters 8.2 quarts Transaxle Fluid 3.9 liters 4.1 quarts

Transfer Case - Getrag 760 0.8 liters 0.85 quarts

Metric English

Specification

Fluid and Lubricant Recommendations

The Recommended Fluids and Lubricants information will only be found in the Owner's Manual. Refer to the Maintenance Schedule subsection of the Owner's Manual. You may be able to use the Search information function using the words Fluids or Lubricants.

Page 97

Section 1

Engine

CONTENTS

Table of Contents 1- i

Engine General Information and

Diagnosis ................................................ 1A–1

General Description ............................................ 1A–1

OBD System Description -

Mode $06 Data Definitions............................... 1A–1

Schematic and Routing Diagram....................... 1A–4

Engine Controls Schematic Icons ...................... 1A–4

Engine Controls Schematics .............................. 1A–4

Engine Control Module Connector End Views. 1A–17

Engine Controls Connector End Views............ 1A–19

Component Location ........................................ 1A–30

Engine Controls Component Views ................. 1A–30

Diagnostic Information and Procedures......... 1A–38

Diagnostic Starting Point - Engine Controls..... 1A–38

Diagnostic Starting Point - Engine Electrical.... 1A–38

Scan Tool Output Controls -

Engine Controls - 3.6L (LY7) ......................... 1A–38

Scan Tool Output Controls - Engine Electrical. 1A–41 Scan Tool Data List -

Engine Controls - 3.6L (LY7) ......................... 1A–41

Scan Tool Data List - Engine Electrical............ 1A–46

Scan Tool Data Definitions -

Engine Controls - 3.6L (LY7) ......................... 1A–48

Scan Tool Data Definitions - Engine Electrical 1A–54 Powertrain Diagnostic Trouble Code (DTC) Type

Definitions ...................................................... 1A–55

DTC P0008 or P0009....................................... 1A–56

DTC P0010, P0013, P0020, P0023, P2088,

P2089, P2090, P2091, P2092, P2093,

P2094, or P2095 ............................................ 1A–57

DTC P0011, P0014, P0021, or P0024............. 1A–59

DTC P0016, P0017, P0018, or P0019............. 1A–61

DTC P0030, P0031, P0032, P0036, P0037,

P0038, P0050, P0051, P0052, P0056,

P0057, or P0058 ............................................ 1A–63

DTC P0100, P0102, or P0103 ......................... 1A–66

DTC P0101 ...................................................... 1A–68

DTC P0111, P0112 or P0113 .......................... 1A–70

DTC P0116 ...................................................... 1A–72

DTC P0117 or P0118....................................... 1A–75

DTC P0119 ...................................................... 1A–77

DTC P0121, P0122, P0123, P0221, P0222,

or P0223 ........................................................ 1A–79

DTC P0125 or P0128....................................... 1A–82

DTC P0131 or P0151....................................... 1A–84

DTC P0132 or P0152....................................... 1A–86

DTC P0133 or P0153....................................... 1A–88

DTC P0134 or P0154....................................... 1A–90

DTC P0135, P0141, P0155, or P0161 ............. 1A–92

DTC P0137, P0138, P0140, P0157, P0158,

or P0160......................................................... 1A–95

DTC P0201, P0202, P0203, P0204, P0205,

P0206, P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274,

P0276, or P0277 ............................................ 1A–97

DTC P0300-P0306........................................... 1A–99

DTC P0324 .................................................... 1A–102

DTC P0326, P0327, P0328, P0331, P0332,

or P0333....................................................... 1A–103

DTC P0335, P0336, or P0338 ....................... 1A–105

DTC P0341, P0342, P0343, P0346, P0347,

P0348, P0366, P0367, P0368, P0391,

P0392, or P0393 .......................................... 1A–107

DTC P0420 or P0430..................................... 1A–109

DTC P0442 .................................................... 1A–111

DTC P0443, P0458, or P0459 ....................... 1A–113

DTC P0446 .................................................... 1A–115

DTC P0449, P0498, or P0499 ....................... 1A–117

DTC P0451 .................................................... 1A–119

DTC P0452 or P0453..................................... 1A–120

DTC P0455 .................................................... 1A–122

DTC P0496 .................................................... 1A–125

DTC P0506, P0507, or P050A ....................... 1A–127

DTC P0560 .................................................... 1A–128

DTC P0562 .................................................... 1A–129

DTC P0563 .................................................... 1A–130

DTC P0601, P0602, P0603, P0604, P0605,

P0606, P0607, P1600, P1621, P1627,

P1680, P1681, P1683, or P2610 ................. 1A–131

DTC P0627, P0628, or P0629 ....................... 1A–132

DTC P0638, P2100, P2101, or P2119 ........... 1A–134

DTC P0642 or P0643..................................... 1A–136

DTC P0650 .................................................... 1A–138

DTC P0652 or P0653..................................... 1A–139

DTC P0685, P0686, P0687, P0689,

or P0690....................................................... 1A–140

DTC P0698 or P0699..................................... 1A–143

DTC P0700 .................................................... 1A–144

DTC P0864 .................................................... 1A–144

DTC P1011-P1014......................................... 1A–145

DTC P1380 .................................................... 1A–146

DTC P1551 .................................................... 1A–147

DTC P167D.................................................... 1A–149

DTC P2096 or P2098..................................... 1A–150

DTC P2097 or P2099..................................... 1A–152

DTC P2105 .................................................... 1A–154

DTC P2107 .................................................... 1A–155

Page 98

1- ii Table of Contents

DTC P2122, P2123, P2127, P2128,

or P2138....................................................... 1A–156

DTC P2176 .................................................... 1A–158

DTC P2177, P2179, P2187, or P2189 ........... 1A–159

DTC P2178, 2180, P2188, or P2190 ............. 1A–162

DTC P2227, P2228, or P2229 ....................... 1A–164

DTC P2231 or P2234..................................... 1A–165

DTC P2232 or P2235..................................... 1A–166

DTC P2270 or P2272..................................... 1A–168

DTC P2271 or P2273..................................... 1A–170

DTC P2300, P2301, P2303, P2304, P2306,

P2307, P2309, P2310, P2312, P2313,

P2315, or P2316 .......................................... 1A–172

DTC P2636 .................................................... 1A–174

Symptoms - Engine Controls ......................... 1A–175

Engine Cranks but Does Not Run .................. 1A–177

Inspection/Maintenance (I/M) System Check. 1A–179 Inspection/Maintenance (I/M) Complete

System Set Procedure ................................. 1A–181

Inspection/Maintenance (I/M) System

DTC Table.................................................... 1A–182

Repair Instructions ......................................... 1A–182

Idle Learn ....................................................... 1A–182

Specifications.................................................. 1A–183

Temperature Versus Resistance -

Engine Coolant Temperature Sensor........... 1A–183

Temperature Versus Resistance -

Intake Air Temperature Sensor .................... 1A–183

Altitude Versus Barometric Pressure ............. 1A–183

Special Tools and Equipment ........................ 1A–184

Special Tools - Engine Controls - 3.6L (LY7). 1A–184

Aux. Emission Control Devices............. 1B–1

Precautions.......................................................... 1B–1

Fuel and Evaporative Emission Hose/

Pipe Connection Cleaning Notice .................... 1B–1

General Description ............................................ 1B–1

Evaporative Emission Control System

Description ....................................................... 1B–1

Crankcase Ventilation System Description ........ 1B–2

Schematic and Routing Diagram....................... 1B–3

Emission Hose Routing Diagram ....................... 1B–3

Evaporative Emissions Hose Routing Diagram . 1B–4

Repair Instructions ............................................. 1B–5

Evaporative Emission Canister Purge Solenoid

Valve Replacement.......................................... 1B–5

Evaporative Emission Canister Vent Solenoid

Valve Replacement.......................................... 1B–6

Evaporative Emission Canister Vent Hose

Replacement.................................................... 1B–7

Evaporative Emission Pipe Replacement .......... 1B–8

Evaporative Emission Canister Replacement.. 1B–12 Evaporative Emission Canister Filter

Replacement.................................................. 1B–14

Evaporative Emission System Cleaning .......... 1B–15

Specifications.................................................... 1B–16

Fastener Tightening Specifications -

Engine Controls - 3.6L (LY7).......................... 1B–16

Special Tools and Equipment .......................... 1B–16

Special Tools -

Engine Controls - 3.6L (LY7).......................... 1B–16

Engine Electrical Devices...................... 1C–1

Precautions.......................................................... 1C–1

Heated Oxygen and Oxygen Sensor Notice ...... 1C–1

Heated Oxygen Sensor Resistance Learn

Reset Notice..................................................... 1C–1

Silicon Contamination of

Heated Oxygen Sensors Notice....................... 1C–1

General Description ............................................ 1C–2

Air Intake System Description ............................ 1C–2

Camshaft Actuator System Description ............. 1C–3

Engine Control Module Description.................... 1C–4

Knock Sensor (KS) System Description............. 1C–7

Throttle Actuator Control (TAC) System

Description ....................................................... 1C–7

Repair Instructions.............................................. 1C–9

Engine Coolant Temperature Sensor

Replacement .................................................... 1C–9

Mass Airflow Sensor/Intake Air Temperature

Sensor Replacement...................................... 1C–10

Heated Oxygen Sensor Replacement -

Bank 1 Sensor 1............................................. 1C–11

Heated Oxygen Sensor Replacement -

Bank 1 Sensor 2............................................. 1C–12

Heated Oxygen Sensor Replacement -

Bank 2 Sensor 1............................................. 1C–14

Heated Oxygen Sensor Replacement -

Bank 2 Sensor 2............................................. 1C–16

Heated Oxygen Sensor Wiring Repairs ........... 1C–18

Accelerator Pedal Position Sensor

Replacement .................................................. 1C–18

Crankshaft Position Sensor Replacement ....... 1C–20

Camshaft Position Sensor Replacement -

Bank 1 (Right Side) Exhaust .......................... 1C–21

Camshaft Position Sensor Replacement -

Bank 1 (Right Side) Intake ............................. 1C–22

Camshaft Position Sensor Replacement -

Bank 2 (Left Side) Exhaust ............................ 1C–23

Camshaft Position Sensor Replacement -

Bank 2 (Left Side) Intake................................ 1C–24

Camshaft Position Actuator Solenoid Valve

Solenoid Replacement -

Bank 1 (Right Side) Intake ............................. 1C–25

Camshaft Position Actuator Solenoid Valve

Solenoid Replacement -

Bank 1 (Right Side) Exhaust .......................... 1C–26

Camshaft Position Actuator Solenoid Valve

Solenoid Replacement -

Bank 2 (Left Side) Intake................................ 1C–27

Camshaft Position Actuator Solenoid Valve

Solenoid Replacement -

Bank 2 (Left Side) Exhaust ............................ 1C–28

Knock Sensor Replacement - Bank 1 .............. 1C–29

Knock Sensor Replacement - Bank 2 .............. 1C–30

Engine Control Module Replacement .............. 1C–31

Engine Control Module

Programming and Setup ................................ 1C–33

Page 99

Table of Contents 1- iii

Specifications.................................................... 1C–34

Fastener Tightening Specifications -

Engine Controls - 3.6L (LY7) ......................... 1C–34

Special Tools and Equipment .......................... 1C–34

Special Tools - Engine Controls - 3.6L (LY7)... 1C–34

Engine Mechanical ................................. 1D–1

Precautions.......................................................... 1D–1

Torque Reaction Against Timing

Drive Chain Notice ........................................... 1D–1

General Description ............................................ 1D–1

Drive Belt System Description ........................... 1D–1

Engine Component Description ......................... 1D–1

Cleanliness and Care......................................... 1D–3

Separating Parts ................................................ 1D–3

Replacing Engine Gaskets................................. 1D–4

Use of Room Temperature Vulcanizing (RTV)

and Anaerobic Sealer ...................................... 1D–4

Schematic and Routing Diagram....................... 1D–6

Camshaft Timing Drive Chain Alignment Diagram

(Third Design) .................................................. 1D–6

Camshaft Timing Drive Chain Alignment Diagram

(Fourth Design) ................................................ 1D–9

Component Location ........................................ 1D–12

Disassembled Views........................................ 1D–12

Diagnostic Information and Procedures......... 1D–26

Diagnostic Starting Point -

Engine Mechanical......................................... 1D–26

Symptoms - Engine Mechanical ...................... 1D–26

Base Engine Misfire without Internal Engine

Noises ............................................................ 1D–27

Base Engine Misfire with

Abnormal Internal Lower Engine Noises........ 1D–28

Base Engine Misfire with

Abnormal Valve Train Noise .......................... 1D–29

Base Engine Misfire with

Coolant Consumption .................................... 1D–29

Base Engine Misfire with

Excessive Oil Consumption ........................... 1D–29

Engine Noise on Start-Up,

but Only Lasting a Few Seconds ................... 1D–29

Upper Engine Noise, Regardless of

Engine Speed ................................................ 1D–30

Lower Engine Noise, Regardless of

Engine Speed ................................................ 1D–30

Engine Noise Under Load................................ 1D–31

Engine Will Not Crank -

Crankshaft Will Not Rotate............................. 1D–32

Coolant in Combustion Chamber..................... 1D–33

Coolant in Engine Oil ....................................... 1D–33

Engine Compression Test................................ 1D–34

Cylinder Leakage Test ..................................... 1D–34

Crankcase Ventilation System

Inspection/Diagnosis...................................... 1D–35

Drive Belt Chirping, Squeal, and

Whine Diagnosis ............................................ 1D–35

Drive Belt Rumbling and Vibration Diagnosis .. 1D–38 Drive Belt Falls Off and

Excessive Wear Diagnosis ............................ 1D–40

Drive Belt Tensioner Diagnosis........................ 1D–41

Vibration Analysis - Engine .............................. 1D–42

Vibration Analysis -

Engine/Accessory Isolation ............................ 1D–44

Vibration Analysis - Engine Balance ................ 1D–50

Engine Order Classification.............................. 1D–55

Repair Instructions ........................................... 1D–58

Air Cleaner Outlet Duct Replacement .............. 1D–58

Air Cleaner Element Replacement................... 1D–59

Air Cleaner Assembly Replacement ................ 1D–60

Throttle Body Assembly Replacement ............. 1D–61

Throttle Body Service....................................... 1D–62

Drive Belt Replacement ................................... 1D–62

Drive Belt Tensioner Replacement .................. 1D–63

Drive Belt Idler Pulley Replacement................. 1D–64

Engine Mount Inspection.................................. 1D–65

Engine Rear Mount Replacement .................... 1D–66

Engine Mount Replacement - Right Side ......... 1D–66

Engine Mount Bracket Replacement -

Right Side....................................................... 1D–68

Engine Mount Strut Replacement -

Right Side....................................................... 1D–70

Engine Mount Strut Bracket Replacement -

Right Side....................................................... 1D–71

Fuel Injector Sight Shield Replacement ........... 1D–72

Crankcase Ventilation Hoses/

Pipes Replacement (Front) ............................ 1D–72

Crankcase Ventilation Hoses/

Pipes Replacement (Rear)............................. 1D–73

Upper Intake Manifold Replacement................ 1D–73

Lower Intake Manifold Replacement................ 1D–77

Crankshaft Balancer Replacement .................. 1D–77

Crankshaft Front Oil Seal Replacement........... 1D–79

Camshaft Cover Replacement - Left Side........ 1D–80

Camshaft Cover Replacement - Right Side ..... 1D–82

Engine Front Cover Replacement.................... 1D–84

Secondary Camshaft Drive Chain

Replacement - Left Side................................. 1D–88

Secondary Camshaft Drive Chain

Replacement - Right Side .............................. 1D–89

Secondary Camshaft Drive Chain Tensioner

Replacement - Left Side................................. 1D–90

Secondary Camshaft Drive Chain Tensioner

Replacement - Right Side .............................. 1D–90

Secondary Camshaft Drive Chain Shoe

Replacement - Left Side................................. 1D–91

Secondary Camshaft Drive Chain Shoe

Replacement - Right Side .............................. 1D–92

Secondary Camshaft Drive Chain Guide

Replacement - Left Side................................. 1D–93

Secondary Camshaft Drive Chain Guide

Replacement - Right Side .............................. 1D–94

Primary Camshaft Drive Chain and Sprockets

Replacement.................................................. 1D–95

Camshaft Intermediate Drive Chain Idler

Sprocket Replacement - Left Side ................. 1D–97

Primary Camshaft Drive Chain Tensioner

Replacement.................................................. 1D–99

Primary Camshaft Drive Chain Guide

Replacement - Lower ................................... 1D–100

Page 100

1- iv Table of Contents

Primary Camshaft Drive Chain Guide

Replacement - Upper................................... 1D–100

Camshaft Position Actuator Replacement -

Bank 2 (Left Side) Exhaust .......................... 1D–101

Camshaft Position Actuator Replacement -

Bank 1 (Right Side) Exhaust ........................ 1D–104

Camshaft Position Actuator Replacement -

Bank 2 (Left Side) Intake.............................. 1D–104

Camshaft Position Actuator Replacement -

Bank 1 (Right Side) Intake ........................... 1D–105

Setting Camshaft Timing................................ 1D–105

Camshaft Replacement - Left Side ................ 1D–106

Camshaft Replacement - Right Side.............. 1D–108

Valve Rocker Arm Replacement - Left Side... 1D–110 Valve Rocker Arm Replacement - Right Side 1D–110

Valve Lifter Replacement - Left Side.............. 1D–111

Valve Lifter Replacement - Right Side ........... 1D–111

Valve Stem Oil Seal and Valve Spring

Replacement - Left Side............................... 1D–112

Valve Stem Oil Seal and Valve Spring

Replacement - Right Side ............................ 1D–114

Cylinder Head Replacement - Left Side......... 1D–117

Cylinder Head Replacement - Right Side ...... 1D–118

Engine Flywheel Replacement....................... 1D–120

Crankshaft Rear Oil Seal and Housing

Replacement................................................ 1D–120

Engine Replacement...................................... 1D–121

Drive Belt Tensioner Removal ....................... 1D–130

Crankshaft Balancer Removal ....................... 1D–130

Engine Flywheel Removal.............................. 1D–131

Intake Manifold Removal................................ 1D–132

Camshaft Cover Removal - Left Side............. 1D–135

Camshaft Cover Removal - Right Side .......... 1D–136

Engine Front Cover Removal (Third Design) . 1D–137 Engine Front Cover Removal

(Fourth Design) ............................................ 1D–139

Secondary Camshaft Drive Chain Tensioner

Removal - Right Side (Third Design) ........... 1D–141

Secondary Camshaft Drive Chain Tensioner

Removal - Right Side (Fourth Design) ......... 1D–142

Secondary Camshaft Drive Chain Shoe

Removal - Right Side (Third Design) ........... 1D–142

Secondary Camshaft Drive Chain Shoe

Removal - Right Side (Fourth Design) ......... 1D–143

Secondary Camshaft Drive Chain Guide

Removal - Right Side (Third Design) ........... 1D–143

Secondary Camshaft Drive Chain Guide

Removal - Right Side (Fourth Design) ......... 1D–143

Secondary Camshaft Drive Chain Removal -

Right Side (Third Design)............................. 1D–144

Secondary Camshaft Drive Chain Removal -

Right Side (Fourth Design)........................... 1D–144

Primary Camshaft Drive Chain Tensionser

Removal (Third Design) ............................... 1D–144

Primary Camshaft Drive Chain Tensionser

Removal (Fourth Design) ............................. 1D–145

Primary Camshaft Drive Chain Guide

Removal - Upper (Third Design) .................. 1D–145

Primary Camshaft Drive Chain Guide

Removal - Upper (Fourth Design) ................ 1D–145

Primary Camshaft Drive Chain Guide

Removal - Lower (Third Design) .................. 1D–146

Primary Camshaft Drive Chain Guide

Removal - Lower (Fourth Design) ................ 1D–146

Primary Camshaft Drive Chain Removal

(Third Design) .............................................. 1D–146

Primary Camshaft Drive Chain Removal

(Fourth Design) ............................................ 1D–146

Camshaft Intermediate Drive Chain Idler

Removal - Right Side (Third Design) ........... 1D–147

Camshaft Intermediate Drive Chain Idler

Removal - Right Side (Fourth Design) ......... 1D–147

Secondary Camshaft Drive Chain Tensioner

Removal - Left Side (Third Design).............. 1D–147

Secondary Camshaft Drive Chain Tensioner

Removal - Left Side (Fourth Design)............ 1D–148

Secondary Camshaft Drive Chain Shoe

Removal - Left Side (Third Design).............. 1D–148

Secondary Camshaft Drive Chain Shoe

Removal - Left Side (Fourth Design)............ 1D–149

Secondary Camshaft Drive Chain Guide

Removal - Left Side (Third Design).............. 1D–149

Secondary Camshaft Drive Chain Guide

Removal - Left Side (Fourth Design)............ 1D–149

Secondary Camshaft Drive Chain Removal -

Left Side (Third Design) ............................... 1D–150

Secondary Camshaft Drive Chain Removal -

Left Side (Fourth Design) ............................. 1D–150

Camshaft Intermediate Drive Chain Idler

Removal - Left Side (Third Design).............. 1D–150

Camshaft Intermediate Drive Chain Idler

Removal - Left Side (Fourth Design)............ 1D–150

Crankshaft Sprocket Removal

(Third Design) .............................................. 1D–151

Crankshaft Sprocket Removal

(Fourth Design) ............................................ 1D–151

Camshaft Position Actuator Removal -

Left Side Exhaust (Third Design) ................. 1D–151

Camshaft Position Actuator Removal -

Left Side Exhaust (Fourth Design) ............... 1D–152

Camshaft Position Actuator Removal -

Left Side Intake (Third Design) .................... 1D–152

Camshaft Position Actuator Removal -

Left Side Intake (Fourth Design) .................. 1D–152

Camshaft Position Actuator Removal -

Right Side Exhaust (Third Design)............... 1D–153

Camshaft Position Actuator Removal -

Right Side Exhaust (Fourth Design)............. 1D–153

Camshaft Position Actuator Removal -

Right Side Intake (Third Design) .................. 1D–153

Camshaft Position Actuator Removal -

Right Side Intake (Fourth Design)................ 1D–154

Camshaft Removal - Left Side ....................... 1D–154

Valve Rocker Arm Removal - Left Side.......... 1D–155

Valve Lifter Removal - Left Side..................... 1D–155

Cylinder Head Removal - Left Side................ 1D–156

Camshaft Removal - Right Side..................... 1D–156

Valve Rocker Arm Removal - Right Side ....... 1D–157

Valve Lifter Removal - Right Side .................. 1D–157

Cylinder Head Removal - Right Side ............. 1D–158

Suzuki XL7 JC636 2007 Service Manual 99500S78J00-33E

Specifications and Main Features

Frequently Asked Questions

User Manual