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* BEST * 2000 2001 2002 2003 HUMMER 6.5L TURBO DIESEL COMMERCIAL VEHICLE SERVICE / REPAIR / WORKSHOP MANUAL (COMPLETE & EXHAUSTIVE) - PDF DOWNLOAD !!
MASSIVE MASSIVE MANUAL!! 1200+ PAGES!!
NEATLY INDEXED, SEARCHABLE, CATEGORIZED, WELL ORGANISED AND MORE IMPORTANTLY THIS IS THE SAME EXACT OEM MANUAL USED BY YOUR DEALERS!!!
WHAT ELSE YOU WANT?? JUST GO FOR IT!!
TABLE OF CONTENTS
General Information 1
Engine 2
Fuel, Emissions and Exhaust 3
Cooling System 4
Transmission/Transfer Case 5
Wheels and Tires/
Central Tire Inflation System
6
Brake System 7
Steering System 8
Axles/Suspension and Frame 9
Body 10
Heating/Ventilation/
Air Conditioning (HVAC)
11
Electrical 12
Accessories 13
Index
Index 14-1
®
5745159
A
A/C Compressor Removal 2-50
A/C System Refrigerant and Capacity 11-5
Abbreviations 1-12
Air Cleaner Assembly
Air Cleaner Filter Element Service 3-21
Air Cleaner Service 3-19
Air Conditioning/Heater Duct Replacement 11-25
Air Horn 3-21
Air Induction Hose Replacement 3-22
Air Intake Vent Line Replacement 3-23
Air Restriction Gauge 13-34
Airlift Brackets 9-48, 9-49
Airlift to Hood Seal Replacement 10-51
Anti-lock Brake System (ABS) and Automatic
Traction Control, TorqTrac 4 (TT4)
ABS ECU Replacement 7-50
ABS Modulator Replacement 7-48
Installation 7-49
Removal 7-48
ABS/TT4 Diagnostics 7-34
Fault Diagnostic Procedure 7-34
Fuse and Relay Replacement 7-50
System Description 7-34
System Operation 7-34
Armrest Replacement 10-24
Ashtray Replacement 10-20
Audio
Antenna System Test 12-157
CD Changer (Delco) Replacement 12-140
Diagnosis-Delco Audio System 12-144
Corrective Action 12-145
Identifying Concerns 12-144
Electrical Harness Replacement, Delco
Monsoon (Models 83, 84 & 91) 12-142
Electrical Harness Replacement, Delco
Standard (Model 89) 12-143
Electrical Harness Replacement, Delco
Standard (Model 90) 12-144
Electrical Harness Replacement, Delco
Standard (Models 83, 84 & 91) 12-143
Generator Whine Concerns 12-146
Overhead Console, Speaker and Amplifier
Replacement (Delco Monsoon) 12-140
Radio (Delco) Replacement 12-140
Rear Seat Audio (RSA) Unit
Replacement 12-141
Symptom Table 12-151
System Description 12-139
Test Antenna 12-146
Auxiliary Seat 13-27
Belt Replacement 13-27
Frame Replacement 13-28
Locking Pin Replacement 13-28
Replacement 13-27
Axle
Output Shaft Seal Replacement 9-25
Pinion Seal Replacement 9-26
Support and Side Mounting Brackets 9-59
Vent Line Replacement 9-23
Axle Assembly
Cover Service 9-25
Repair 9-28
Replacement 9-26
B
Basic Symptom Checks 5-14
Cuts Out, Misses 5-21
Engine Cranks but Does Not Run 5-15
Excessive Smoke 5-22
Fuel Knock/Combustion Noise 5-20
Hard Start 5-18
Hesitation, Sag, Stumble 5-20
Intermittent Condition 5-17
Lack of Power, Sluggishness, or
Sponginess 5-19
Poor Fuel Economy 5-22
Surges/Chugs 5-19
Battery
Battery Charging 12-14
Cable Maintenance 12-16
Power Distribution 12-21
3-1-02
Section 14 ndex
14-2 Index
______________________________________________________________________
®
Replacement 12-18
Splash Shield and Seal Service 12-19
Tray Replacement 12-18
Blower Motor Resistor Replacement 11-35
Body Inspection and Repair 10-3
Aluminum Repair 10-8
Fiberglass Repair 10-11
Lockbolt Failure 10-4
Rivet Failure 10-3
Rivet Replacement 10-4
Body Mount Replacement 10-61
Bolt Identification and Torque Limits (Dry) 1-13
Bolt Identification and Torque Limits (Wet) 1-14
Boost Pressure Test 2-16
Brake Master Cylinder
Bench Bleeding 7-12
Bleeding 7-12
Replacement 7-11
Brake Shift Interlock System 12-51
Brake Shift Interlock Cable Inoperative 12-51
Ignition Switch Replacement 12-51
Shift Interlock Cable Schematic 12-52
Brake System
Bleeding Instructions 7-8
Brake Line Replacement 7-14
Brake Rotor 7-32
Refinishing 7-32
Burnishing Linings and Rotors 7-10
Caliper Overhaul, Rear 7-29
Description 7-1
Diagnosis 7-2
Disc Brake Caliper Repair, Front 7-27
Front Service Brake Caliper 7-10
Hydro-Boost System
Accumulator Leakdown Test 7-8
Booster Functional Test 7-8
Noise Diagnosis 7-7
Hydro-Boost System Diagnosis 7-7
Left Parking Brake Cable Replacement 7-23
Pad Replacement, Service Brake 7-9
Parking Brake
Lever Adjustment 7-33
Lever Replacement 7-26
Switch Replacement 7-33
Parking Brake Cable Replacement, L 7-24
Parking Brake Cable Replacement, R 7-23
Pedal Replacement, Service Brake 7-17
Proportioning Valve Replacement 7-17
Rear Dual Service/Parking Brake
Adjustment 7-25
Caliper Replacement 7-20
Pad Replacement 7-18
Rod Replacement 7-25
Rotor Replacement, Service Brake 7-17
Troubleshooting 7-4
Brushguard Assembly Replacement 13-10
Bulkhead, 76 Way 5-28
Bumpers
Front Bumper and Towing Brackets 9-45
Rear Bumper Outer Mounting and
Tiedown Brackets 9-53
Rear Bumper Replacement 9-52
C
Camshaft
Bearing Replacement 2-64
Installation 2-85
Removal 2-59
Timing Chain, Sprocket and Drive Gears 2-71
Carbon Monoxide 1-2
Cargo Tiedown Replacement 10-72
Center Console Replacement 10-13
Central Tire Inflation System
Air Intake Line and Assembly 6-51
Air Leak Troubleshooting 6-32
Air Pressure Gauge 6-40
Air Pressure Gauge Lamp 6-41
Air Pressure Indicator Lines 6-45
Air Pressure Switch 6-44
Auxiliary Air Hose 6-54
Compressor Fuse 6-46
Compressor Relay 6-46
Compressor Service 6-36
Deflate Valve Assembly 6-47
3-1-02
_____________________________________________________________________
Index 14-3
®
5745159
Description 6-30
Dust Excluder Replacement 6-48
Front CTI Line Replacement 6-50
Front Supply Tube and Hose 6-49
Geared Hub Replacement 6-53
Inflate/Deflate and Tire Selector Switches 6-38
Instrument Cluster 6-37
Interior Harness 6-43
Low Pressure Alarm 6-42
Quick-Disconnect Valve and Tube 6-52
Rear CTI Line Replacement 6-50
Rear Tube Connection Shield 6-53
Spindle Extension and Seal 6-54
Supply Line 6-49
Troubleshooting 6-31
Tube Shield Replacement 6-51
Charging System
Alternator 12-22
Alternator Overhaul 12-23
Diagnostics 12-28
Cigarette Lighter Replacement 10-19, 12-68
Climate Control System
A/C Pressure Hose Replacement 11-18
Condenser Replacement 11-20
Control Head Replacement 11-16
Heater Hose Replacement 11-22
Heater/A/C Diagnosis 11-2
System Performance Checks 11-2
Compressor
Clutch Core Replacement 11-32
Clutch Rotor and/or Bearing Replacement 11-30
Replacement 11-28
Shaft Seal Replacement 11-32
Connectors
24 Way PCM-Brown 5-149
32 Way PCM-Blue 5-147
32 Way PCM-Brown 5-145
40 Way GM Engine 5-143
56 Way Instrument Panel 5-141
76 Way Bulkhead 5-138
Converter Housing
Lower Cover Replacement 5-123
Upper Cover Replacement 5-123
Crankshaft
Bearing Replacement 2-42
Connecting Rod Journal Diameter 2-97
Crankshaft and Main Bearings Removal 2-60
End Play Check 2-81
Main Journal Diameter 2-97
Pulley Replacement 2-20
Cruise Control
Cruise Control Inoperative VIN Z 12-135
Cruise Control Schematic 12-137
Cruise Control Systems 12-134 4
CTIS
CTIS Compressor Inoperative 12-53
CTIS Exhaust Valve Inoperative 12-54
CTIS Front Inflate Valve Inoperative 12-55
CTIS Rear Inflate Valve Inoperative 12-56
CTIS Schematic 12-57
Customer Assistance
Hummer Service Hotline 1-2
Service Manual Revisions 1-2
Cylinder Block
Cylinder Bore and Piston Measurement 2-62
Service 2-60
Cylinder Head
Cylinder Head And Gasket Service 2-37
Installation 2-89
Overhaul 2-72
Removal 2-55
D
Damper and Flywheel Service 2-76
Delco Compact Disc Changer Replacement 13-36
Diagnostic System Check 5-5
Diesel Fuel Injection System 3-36
Digital Ratio Adapter 12-75
Dimmer Control Switch Replacement 10-17
Door Glass
Wind Noise 10-43
Replacement 10-41
Door Stop Strap Assembly Replacement 10-41
3-1-02
14-4 Index
______________________________________________________________________
®
Doors
Disassembly, Replacement and Repair 10-36
Door Glass 10-41
Door Seals Replacement 10-41
Rear Vertical Door Replacement 10-74
Drainage Bracket Replacement 3-23
Dual Oil Filter 13-35
E
Engine
Assembly and Adjustment 2-80
Block, Camshaft and Bearing Sizes 2-98
Cleaning Materials 2-4
Compression Test 2-4
Description 2-2
Disassembly 2-49
Engine Diagnosis 2-7
Engine Noise
Diagnosis Equipment 2-6
Essential Tools 2-99
Identification 2-3
Identification Number 1-5
Installation 2-48
Lubricants/Sealants/Coolant
Coolant 2-4
Engine Oil 2-3
Sealants 2-4
Mounting Bracket/Insulator 2-19
Noise Diagnosis 2-5
Removal 2-45
Scan Tool Use 2-6
Service Piston and Cylinder Bore 2-97
Special Service Tools 2-3
Specifications 2-96
Engine Access Cover 10-20
Hold-Down Striker Replacement 10-20
Inner Flexible Latch Replacement 10-20
Engine Access Cover Maintenance 10-20
Engine Assembly and Adjustment
Crankshaft and Main Bearing Installation 2-80
Crankshaft Main Bearing Selection 2-80
Engine Cooling System
Description 4-1
Diagnosis and Troubleshooting 4-3
Service 4-6
Engine Temperature Sender Replacement 3-40
Evaporator 11-43
Air Intake Assembly Replacement 11-45
Cycling Switch Replacement 11-45
Exhaust Manifold
Installation 2-92
Removal 2-51
Service 2-35
Exhaust System
Catalytic Converter Replacement 3-44
Crossover Pipe Replacement 3-44
Muffler Replacement 3-42
Extension Housing Bushing and Seal 5-157
F
Fan and Clutch Assembly Service 4-16
Fan-Pulley-Damper Removal 2-50
Flexplate Replacement 5-127
Fluid Capacities 1-10
Fuel/Fluids/Lubricants 1-24
Flushing Engine Cooler 2-78
Flywheel Removal 2-60
Former Assembly Replacement, A Pillar 10-60
Frame
Front Suspension Brace Replacement 9-50
Front Suspension Front Crossmember 9-60
Front Suspension Rear Crossmember 9-61
Inspection 9-64
Left Engine Mount Bracket 9-54
Left Intermediate Body Mount Bracket 9-57
Lifting Shackle Replacement 9-47
Radiator Front Mount Bracket 9-46
Rear Suspension Front Crossmember 9-62
Rear Suspension Rear Crossmember 9-63
Rear-Front Tiedown Bracket 9-59
3-1-02
_____________________________________________________________________
Index 14-5
®
5745159
Rear-Rear Tiedown Bracket 9-58
Repairs 9-67
Right Engine Mount Bracket 9-55
Right Front Body Mount Bracket 9-55
Right Intermediate Body Mount Bracket 9-57
Transmission Crossmember Support 9-56
Transmission Mount Crossmember 9-56
Transmission Mount Replacement 9-56
Front Console Replacement 10-13
Front Cover and Baffle Installation 2-86
Front Cover and Oil Filler Tube 2-71
Front Cover And Timing Chain 2-23
Front Cover Oil Seal Replacement 2-22
Front Cover Removal 2-57
Front License Plate Bracket Replacement 10-62
Front Output Shaft
Bearing and Seal Replacement 5-154
Seal Replacement 5-143
Front Striker Replacement 10-61
Fuel Filler Housing Replacement 10-63
Fuel Filter
Drain Hose and Valve Replacement 3-32
Service 3-31
Fuel Filter Warning Lamp 2-4
Fuel Injection Line
Installation 2-92
Removal 2-53
Fuel Injection Pump
Fuel Supply and Return Line Removal 2-53
Installation 2-87
Removal 2-56
Fuel Injection Pump Boot Replacement 3-33
Fuel Injection System
Injection Line Bracket and Clamp 3-36
Fuel Lift Pump Service
Fuel System
Contamination 3-41
Diagnosis 3-6
Electronic Accelerator Pedal 3-4
Electronic Injection Pump 3-3
Essential Tools 3-45
Fuel Filter-Water Separator 3-3
Fuel Injectors 3-4
Fuel Lift Pump 3-2
Fuel Lift Pump Inoperative 12-44
Fuel Lift Pump Schematic 12-46
Fuel Manager Schematic 12-50
Fuel Selector Valve 3-30
Fuel Selector Valve Schematic 12-49
Fuel Tank Selector System Inoperative 12-47
Fuel Tanks, Lines, and Valves 3-4
Glow Plugs 3-4
Fuel Tank
Auxiliary Fuel Tank 3-26
Draining 3-22
Fuel Level Transmitter and Tank
Access Plate Service 3-28
Fuel Tank Vent Line Service 3-29
Main Fuel Tank 3-24
Main/Auxiliary Tank Fuel Line 3-29
Vent Filter Replacement 3-29
G
Geared Hub
Input Seal Replacement 9-11
Repair 9-12
Replacement 9-8
Side Cover Replacement 9-11
Spindle Bearing Adjustment 9-19
Spindle Seal Replacement 9-17
Vent Line Replacement 9-24
General Body Information 10-2
General Information
Auxiliary Power Point, Interior
Fuse Box 12-10
Auxiliary Power Studs, Exterior
Fuse Box 12-13
Circuit Faults 12-4
Diagnostic Tests 12-5
Fuse/Relay Location and Identification 12-10
Ground Points 12-13
Preliminary Checks 12-3
Glovebox Replacement 10-19
3-1-02
14-6 Index
______________________________________________________________________
®
Glow Plug
Glow Plug and Injection Nozzle 2-90
Glow Plug Removal 2-54
Glow Plug Test 2-6
Operation and Testing 2-6
Relay/Controller Replacement 3-40
Service 3-35
Glow Plugs
Diagnostics 12-40
Schematic 12-43
H
Halfshaft Boot Replacement 9-21
Heated Glass
Both Heated Windshields Inoperative 12-92
Heated Windshield Schematic 12-93
Left Heated Windshield Inoperative 12-90
Rear Window Defroster Inoperative 12-94
Rear Window Defroster Schematic 12-95
Right Heated Windshield Inoperative 12-91
Hood
Center Hood Stop Replacement 10-49
Front Hood Screen Replacement 10-50
Grille and Screen Replacement 10-49
Guide Bracket Assembly Replacement 10-50
Hood and Hinge Replacement 10-47
Hood Latch And Prop Rod 10-43
Hood Prop Rod and Bracket Replacement 10-45
Hood Release Cable Replacement 10-44
Hood Retainer Bracket, L 10-50
Hood Retainer Bracket, R 10-50
Latch and Bracket Replacement 10-43
Outer Hood Seal Replacement 10-48
Right Close-Out Seal and Retainer 10-51
Side Hood Stop Replacement 10-49
Horn 12-61
Horn Assembly Replacement 10-53
Horn Replacement 12-61
Horn Schematic 12-63
Horns Inoperative 12-62
Mounting Bracket Replacement 10-53
Hourmeter 13-30
Hummer Service Hotline 1-2
HVAC
Ambient Temperature Switch 11-34
Auxiliary HVAC Unit
A/C Drain Tube(s) Replacement 11-48
Blower Motor Replacement 11-49
Blower Switch Replacement 11-47
Evaporator/Heater Core Replacement 11-49
Expansion Valve Replacement 11-50
Heater Hose Replacement 11-47
High-Pressure Hose Replacement 11-48
Low-Pressure Hose Replacement 11-49
Replacement 11-46
Blend Door Motor 11-42
Compressor
Description 11-1
Condenser 11-34
Controls 11-36
Defrost Duct and Windshield Nozzles
Replacement 11-26
Drain Tube Replacement 11-24
Essential Tools 11-51
Heater Hose Replacement 11-22
High Pressure Cutoff Switch 11-35
Low Pressure Cutoff Switch 11-34
Main HVAC Unit 11-37
Blower Motor 11-38
Diverter Doors 11-37
Evaporator 11-38
Expansion Valve 11-38
Heat Unit Cowl Insulation
Replacement 11-24
Heater Core 11-38
High Pressure Cutoff Switch 11-38
Replacement 11-39
Thermostatic Cycling Switch 11-38
Rear Console Replacement 11-46
Receiver Dryer Replacement 11-21
Receiver/Dryer 11-34
Receiver/Dryer Pressure Switch
Replacement 11-21
Special Tools 11-52
Specifications 11-13
3-1-02
_____________________________________________________________________
Index 14-7
®
5745159
System Description 11-1
System Diagnosis 11-8
System Performance Checks 11-2
Unit Service 11-37
Vacuum Door Motor 11-41
Water Control Valve 11-22
Water Control Valve Replacement 11-23
HVAC Systems
HVAC Blower Schematic 12-80
HVAC Compressor Inoperative 12-75
HVAC Compressor Schematic 12-82
HVAC Main Blower Inoperative
ALL BUT High 12-75
HVAC Temp Blend Door/Rear Blower 12-81
HVAC Temperature Door Inoperative 12-77
Hydro-Boost
Bleeding the Hydro-boost System 7-13
Hydro-Boost Replacement 7-13
I
Identification Numbers
Engine Identification Number 1-5
Transfer Case Identification Number 1-5
Transmission Identification Number 1-4
Vehicle Identification Number
Decoding Chart 1-6
Vehicle Identification Number (VIN) 1-5
Indicator Lights
Compressor/Low Pressure 6-39
Information Labels
Emission Control Information Label 1-3
EPA Noise Emission Label 1-5
Safety Certification Label 1-4
Input Gear Bearing Replacement 5-156
Instrument Panel 12-64
Dashpad Replacement 10-15
Engine Temperature Gauge Inoperative 12-73
Fuel Gauge Inoperative 12-72
Gauge Replacement 10-16, 12-65
Gauges and Switches 10-14, 12-64
Gauges Schematic 12-74
Indicator Lamp Replacement 10-16
Instrument Panel Replacement 10-14
Low Coolant Lamp Inoperative 12-69
Oil Pressure Gauge Inoperative 12-71
Replacement 12-64
Switch Replacement 10-17
Instrument Panel, 56 way 5-31
Intake and Exhaust Manifolds 2-79
Intake Manifold 2-43
Removal 2-52
Interior Trim
B-Bar Replacement 10-25
Drivers Compartment Trim
Replacement 10-28
Floor Carpeting and Padding
Replacement 10-34
Inner Kick Panels Replacement 10-32
Outer Kick Panel Replacement 10-33
Passengers Compartment Trim 10-26
Replacement 10-25
Station Wagon Rear Compartment Trim 10-30
Interior Trim, Four-Passenger Soft Top 10-65
Intermediate Steering Shaft
Dust Boot Replacement 8-14
Installation 8-13
Removal 8-13
Replacement 8-13
Introduction 2-1
In-Vehicle Service, Diesel Engine 2-19
J
Jump Starting 1-20
K
Keys
Replacement Keys 1-16
3-1-02
14-8 Index
______________________________________________________________________
®
L
License Plate Brackets 10-62
Lift Gate Assembly 10-74
Lifter, Pushrod, Rocker Arm Service 2-76
Lighting Systems
Key/Headlight Chime Schematic 12-60
Lights Schematic 12-58
Lights
Backup Light Switch Replacement 10-86
Front Courtesy Light 10-85
Interior and Exterior Lighting 10-78
Backup Light Switch 10-84
Cargo Light 10-82
Courtesy Light 10-84
Domelight Replacement 10-82
Front Turn Signal Light Replacement 10-80
Identification Light Replacement 10-79
Maplight Replacement 10-83
Optional Trouble Light Replacement 10-84
Rear Turn Signal Light Replacement 10-81
Service Headlight Assembly 10-78
Service Headlight Electrical Connector
and Grommet Replacement 10-85
Side Marker Light Assembly 10-79
Side Marker Light Lens and Lamp 10-79
Underhood Light Replacement 10-84
Rear Seat Courtesy Light 10-83
Stoplight Switch Replacement 10-86
Load Barrier and Mounting Brackets 10-25
Low Coolant Sensor 4-12
Lubricants/Sealants/Coolant 2-3
Lubrication and Maintenance Items 1-25
Axle and Geared Hub 1-27
Body Lubrication Points 1-30
Cooling System Fluid Level Check 1-29
Engine Oil and Filter Change 1-25
Engine Oil Level 1-25
Master Cylinder Fluid Level Check 1-29
Power Steering Fluid 1-29
Steering and Suspension Lubrication
Points 1-28
Transfer Case Fluid 1-26
Transmission Fluid 1-26
Universal and Slip Joint Lubrication 1-27
M
Main Fuel Tank
Fuel Level Transmitter 3-25
Tank Cleaning 3-25
Mainshaft Pilot Bearing Replacement 5-156
Maintenance
Inspection Groups 1-21
Maintenance Schedule 1-21
Scheduled Maintenance Chart 1-22
Maintenance Items
Serpentine Belt 1-29
Wheels/Tires/CTIS 1-29
Metric System and Equivalents 1-15
Metric Conversions 1-15
Mirrors 10-35
Lighted Visor Mirror Replacement 10-84
Power Mirrors 10-35
Rearview Mirror Replacement 10-36
Side Mirror Replacement 10-35
O
OBD II Diagnostic Trouble Codes 5-23
P0112 Intake Air Temperature (IAT)
Sensor Circuit Low Voltage 5-34
P0113 Intake Air Temperature (IAT)
Sensor Circuit High Voltage 5-36
P0117 Engine Coolant Temperature (ECT)
Sensor Circuit Low Voltage 5-38
P0118 Engine Coolant Temperature (ECT)
Sensor Circuit High Voltage 5-40
P0121 Accelerator Pedal Position (APP)
Sensor 1 Circuit Performance 5-42
P0122 Accelerator Pedal Position (APP)
Sensor 1 Circuit Low Voltage 5-44
P0123 Accelerator Pedal Position (APP)
Sensor 1 Circuit High Voltage 5-46
3-1-02
_____________________________________________________________________
Index 14-9
®
5745159
P0126 Engine Coolant Temperature
Insufficient For Stable Operation 5-48
P0182 Fuel Temperature Sensor
Circuit Low Voltage 5-50
P0183 Fuel Temperature Sensor
Circuit High Voltage 5-52
P0215 Engine Shutoff Solenoid
Control Circuit 5-54
P0216 Injection Timing Control System 5-56
P0219 Engine Overspeed Condition 5-59
P0220 Accelerator Pedal Position
(APP) Sensor 2 Circuit 5-60
P0221 Accelerator Pedal Position
(APP) Sensor 2 Circuit Performance 5-62
P0222 Accelerator Pedal Position
(APP) Sensor 2 Circuit Low Voltage 5-64
P0223 Accelerator Pedal Position
(APP) Sensor 2 Circuit High Voltage 5-66
P0225 Accelerator Pedal Position
(APP) Sensor 3 Circuit 5-68
P0226 Accelerator Pedal Position (APP)
Sensor 3 Circuit Performance 5-70, 5-71
P0227 Accelerator Pedal Position (APP)
Sensor 3 Circuit Low Voltage 5-72
P0228 Accelerator Pedal Position (APP)
Sensor 3 Circuit High Voltage 5-74
P0231 Fuel Lift Pump Secondary
Circuit Low Voltage 5-76
P0236 Turbocharger (TC) Boost System 5-79
P0237 Turbocharger (TC) Boost
Sensor Circuit Low Voltage 5-82
P0238 Turbocharger (TC) Boost
Sensor Circuit High Voltage 5-84
P0251 Injection Pump Cam System 5-87
P0263, P0266, P0269, P0272,
P0275, P0278, P0281 and P0284
Cylinder Balance System Faults 5-90
P0300 Engine Misfire Detected 5-92
P0301-P0308 Specific Cylinder
Misfire Detected 5-94
P0335 Crankshaft Position (CKP)
Sensor Circuit Performance 5-96
P0370 Timing Reference High Resolution 5-99
P0380 Glow Plug Circuit Performance 5-102
P0501 Vehicle Speed Sensor Circuit 5-106
P0567 Cruise Resume Circuit 5-109
P0568 Cruise Set Circuit 5-111
P0571 Cruise Brake Switch Circuit 5-113
P0601, P0602 and P0606 Internal
PCM Errors 5-116
P1125 Accelerator Pedal Position
(APP) System 5-117
P1214 Injection Pump Timing Offset
Error 5-119
P1216 Fuel Solenoid Response
Time Too Short 5-120
P1217 Fuel Solenoid Response
Time Too Long 5-122
P1218 Injection Pump Calibration Circuit 5-124
P1627 Analog to Digital Performance 5-126
P1635 PCM 5 Volt Reference Low 5-127
P1641 Malfunction Indicator Lamp
(MIL) Control Circuit 5-129
P1643 Wait to Start Lamp Control
Circuit 5-131
P1654 Check Throttle Circuit 5-133
P1656 Wastegate Solenoid Control
Circuit 5-135
Off Road Light Package 13-31
Oil Filter
Adapter Service 2-78
Filter, Adapter, Fittings 2-87
Oil Filter/Adapter/Oil Pressure Sending Unit 2-57
Oil Pan Removal 2-58
Oil Pump
Oil Pump and Drive Removal 2-58
Oil Pump and Pump Drive Service 2-77
Oil Pump Drive 2-22
Oil Pump Pressure Test 2-7
Service 2-28
Oil Pump, Oil Pan, Flywheel Installation 2-84
P
Paint and Trim Colors 1-16
PCM, 24 Way, Brown 5-38
PCM, 32 Way, Blue 5-36
3-1-02
14-10 Index
_____________________________________________________________________
®
PCM, 32 Way, Brown 5-34
Piston/Connecting Rod
Installation and Bearing Fit 2-83
Removal 2-59
Piston/Connecting Rod Overhaul 2-67
Piston and Connecting Rod Assembly 2-69
Piston Ring Installation 2-70
Piston Selection and Fit 2-68
Power Door Locks
Front Door Harness Replacement 12-120
Power Locks
Cargo Door Lock Inoperative 12-113
General Replacement 12-102
Keyless Entry & Theft Detterent
System Operating Instructions 12-105
Keyless Entry Programming 12-108
Keyless Entry System Features 12-106
Power Locks HMC4, XLC2 , HMSB 12-117
Power Locks HMCS W/ Remote Entry 12-115
Power Locks Inoperative 12-110
Rear Door and Jumper Harness 12-121
Remote Entry Module Power/Ground 12-119
Remote Entry System Inoperative 12-114
Slant Door Lock Inoperative 12-112
Power Mirrors
Ambient Temperature Sensor 12-131
Auto-Dimming Compass Mirror
Calibration and Zone Adjustments 12-129
Auto-Dimming Rear View Mirror 12-129
Compass Mirror Display Inoperative 12-132
Compass Mirror Schematic 12-133
Power Side Mirror 12-134
Power Steering Pump
Assembly 8-42
Cleaning and Inspection 8-41
Disassembly 8-39
Repair 8-39
Power Steering Pump and Bracket 2-50
Power Window and Door Locks
Front Door Harness Replacement 12-123
Power Windows
Power Window Schematic 12-101
Power Windows Inoperative, All
Windows 12-96
Power Windows and Door Locks
Rear Door Harness Replacement 12-126
Powertrain Control Module 3-6
Powertrain Control Module (PCM) 5-2
Repair 5-2
Replacement 5-2
Reprogramming 5-2
Schematics 5-27
TDC Offset 5-3
Verifying Vehicle Repair 5-2
Pressure Hose Torque Specifications 11-17
Propeller Shaft
Torque Specifications 5-169
Pushrod, Rocker Arm and Shaft Installation 2-90
R
Radiator
Lower Hose Replacement 4-9
Lower Tube Assembly Replacement 4-10
Rear Support Bracket 4-7
Shroud Shield Assembly Replacement 4-7
Upper Hose Replacement 4-9
Radiator and Fan Shroud Assembly 4-4
Rear License Plate Bracket Replacement 10-62
Rear Main Oil Seal Replacement 2-29
Rear Main Seal Installation 2-82
Rear Striker Assembly Replacement 10-61
Rear Support Bow Bracket, Station Wagon 10-61
Rear Vertical Door
Door Frame and Seal Replacement 10-77
Door Handle Replacement 10-75
Door Latch and Latch Rod Replacement 10-75
Door Replacement 10-74
Door Stop Replacement 10-77
Window Replacement 10-74
Road Testing 2-5
Roadside Emergency Equipment 10-64
3-1-02
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Index 14-11
®
5745159
Rocker Arm
Cover Removal 2-54
Cover Service 2-30
Shaft and Pushrod Removal 2-54
Shaft and Pushrod Service 2-33
Rocker Cover Installation 2-91
Rocker Panel Protection Replacement 13-18
Roof Rack 13-24
Clamp Replacement 13-26
Crossbar Replacement 13-25
End Replacement 13-25
Runflat
Compressor Belt Replacement 6-12
Running Board Replacement 13-21
S
Safety Summary 1-1
Non-approved accessories 1-1
Warnings, cautions, and notes 1-1
Scan Tool Diagnosis 3-11
Seat Belts
Seat Belt Assembly Replacement 10-22
Seat Heater 13-37
Seats
Front Seats 10-23
Reclining Seat Replacement 10-24
Standard Seat Pedestal Repair 10-23
Sensor and Switch Service 3-40
Sensor, Oil Pressure Switch, and Transmitter 3-40
Serpentine Belt Removal 2-49
Serpentine Belt Replacement 4-16
Shift Control Assembly
Installation 5-135
Removal 5-131
Service 5-132
Shift Linkage Adjustment 5-136
Slant Back
Glass and Body 10-91
Slant Door and Torsion Assembly
Replacement 10-87
Slant Door Handle, Latch, And
Lock Actuator 10-88
Wiper Motor and Components 10-90
Soft Top
Mounting Components and Accessories 10-67
Soft Top Support/Roll Cage Assembly 10-71
Spare Tire Carrier
Cargo DeckMounted 13-13
Swing-Away 13-10
Specifications
Bolt Identification and Torque
Limits (Dry) 1-13
Bolt Identification and Torque
Limits (Wet) 1-14
Cooling System 1-7
Cylinders 1-7
Engine 1-7
Engine Dimensions 1-7
Fluid Capacities 1-10
Fuel/Air System 1-7
General
A/C Refrigerant and Compressor Oil 1-25
Air Conditioner 1-9
Axle/Differential 1-8
Batteries 1-8
Body Lubrication 1-24
Brake Fluid 1-24
Engine Coolant 1-24
Engine Oil 1-24
Frame 1-9
Front/Rear Axle and Geared Hub 1-24
Geared Hub 1-8
Recommended Fuel 1-24
Service Brake Caliper (Front) 1-9
Service/Parking Brake Caliper (Rear) 1-9
Service/Parking Brake Rotor (Rear) 1-9
Steering Gear and Pump Fluid 1-24
Steering Linkage and Suspension 1-24
Steering System 1-9
Transfer Case 1-8
Transmission 1-8
Transmission/Transfer Case 1-24
Wheels and Tires 1-9
Winch 1-9
Generator 1-8
Governed Speed 1-7
3-1-02
14-12 Index
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®
Lubricating System 1-7
Starter 1-7
Vehicle Dimensions 1-11
Vehicle Weights 1-10
Speed Sensor Replacement 7-49
Installation 7-50
Removal 7-49
Speedometer/Odometer Replacement 10-17
Splash Shield (Engine) Replacement 10-52
Splash Shield Support Bracket Replacement 9-51
Spring Seat Replacement 9-53
Starter 12-30
Diagnostics 12-37
Overhaul 12-31
Steering Specifications 8-44
Steering Gear Adjustment Preload
Torques 8-44
Steering Pump Flow Rates and
Operating Pressures 8-44
Torque Specifications 8-44
Steering Stop Adjustment 6-29
Steering System
Center Link Replacement 8-3
Description 8-1
Essential Tools 8-45
Idler Arm Replacement 8-6
Pitman Arm Replacement 8-2
Power Steering
Cooler and Hose Replacement 8-17
Fluid Reservoir Replacement 8-16
Gear Adjustments 8-36
Gear Assembly and Adjustment 8-30
Gear Cleaning and Inspection 8-28
Gear Disassembly and Overhaul 8-23
Hydraulic System Pressure 8-16
Power Steering Gear Service 8-18
Pressure Test 8-22
Pump and Pulley Replacement 8-15
Purging Air from the System 8-22
System Diagnosis Charts 8-19
System Flushing 8-44
Special Tools 8-46
Steering Column
Ignition Interlock Cable Replacement 8-11
Ignition Switch Lock Cylinder 8-11
Lock and Switch Housing 8-8
Multi-Switch Replacement 8-8
Steering Column Repair 8-9
Steering Column Replacement 8-7
Steering Gear Replacement 8-12
Steering Wheel Hub/ Column Shroud 8-10
Steering Wheel Replacement 8-6
Tie Rod End Replacement 8-4
Tie Rod Replacement 8-5
Surge Tank
Overflow Hose Replacement 4-11
Replacement 4-7
Tank-to-Lower Radiator Tube Hose 4-12
Tank-to-Radiator Vent Hose 4-8
Suspension System
Control Arm Bushing Replacement 9-7
Frame Extension Replacement 9-47
Front Bumper and Towing Brackets 9-45
Front Bumper Mounting Bracket 9-46
Lower Ball Joint Replacement 9-5
Lower Control Arm Replacement 9-7
Radius Rod Replacement 9-3
Rear Upper Control Arm Bracket 9-58
Stabilizer Bar Link Replacement 9-2
Stabilizer Bar Replacement 9-2
Upper Ball Joint Replacement 9-4
Upper Control Arm Replacement 9-5
T
Tachometer Replacement 10-19
Tailgate 10-72
Chain Brackets Replacement 10-72
Chain Replacement 10-73
Tailgate and Seals Replacement 10-72
Tech 2
Data List 5-6
Diagnosis 5-4
Information 5-4
Thermostat Bypass Hose Replacement 4-8
Thermostat Replacement 4-13
3-1-02
____________________________________________________________________
Index 14-13
®
5745159
Timing Chain/Drive Sprockets/Drive Gear 2-57
Timing Chain-Sprocket-Gear Installation 2-85
Tire Jack
Jack and Triangle Warning Kit
Hold-Down Bracket Replacement 10-64
Tone Wheel Replacement 7-50
Torque Converter/Oil Pump Seal 5-127
Torsional Damper 2-21
Torsional Damper/Crankshaft Pulley 2-93
Towing
Cautions 1-18
Conventional Towing Procedures 1-19
Hoisting the Vehicle 1-17
Recommendations 1-18
Recreational 1-19
Vehicle Lifting/Jacking Points 1-17
When Keys Are Not Available 1-19
Towing, Lifting, Jump Starting 1-17
Trailer Hitch Replacement 13-20
Trailer Towing Connector 13-19
Transfer Case
Assembly 5-158
Cleaning and Inspection 5-153
Description 5-137
Diagnosis 5-139
Disassembly and Overhaul 5-145
Fluid Change 5-143
Fluid Level 5-138
Guide Cable Replacement 5-142
Identification 5-138
Identification Number 1-5
Installation 5-144
Oil Cooler 5-138
Operating Ranges 5-139
Recommended Lubricant 5-138
Removal 5-144
Shift Rod Service 5-141
Shifting 5-139
Speed Sensor and Switch Replacement 5-142
Torque Specifications 5-169
Vent Line Replacement 5-141
Transmission
Cooler Line and Bypass Valve Service 5-121
Diagnosis 5-11
Line Pressure Test 5-15
Pressure Control Solenoid Test 5-15
Road Test 5-12
Electronic Shift Control Components 5-3
Engine Sensor Inputs 5-9
Essential Tools 5-170
Fill Tube Replacement 5-121
Fluid And Filter Replacement 5-120
Fluid Temperature Sensor 5-6
Gear Ranges 5-2
Gear Ratios 5-2
Identification 5-3
Input and Output Speed Sensors 5-6
Input Speed Sensor Replacement 5-136
Installation 5-130
Park Lock Component Service 5-125
Park/Neutral Position Switch
Replacement 5-133
Pressure Control Solenoid 5-8
Rear Mount Replacement 5-136
Recommended Fluid 5-15
Removal 5-127
Scan Tool Diagnosis 5-18
Serviceability 5-11
Shift Rod Replacement 5-135
Shift Solenoids 5-7
Shifter Boot Cover Replacement 5-134
Special Tools 5-171
Torque Converter 5-9
Torque Converter Clutch Solenoid 5-8
Torque Specifications 5-169
Valve Body Switch and Solenoid Service 5-124
Vent Line Service 5-122
Warning Lamps 5-13
Transmission Identification 1-4
Transmission Passthrough, 20 way 5-41
Transmission, 10 Way, Black 5-40
Transmission, 10 Way, Grey 5-39
3-1-02
14-14 Index
_____________________________________________________________________
®
Turbocharger
Diagnosis 2-18
Installation 2-17
Operation 2-16
Removal 2-17
Service 2-16
Service and Diagnosis 2-15
Turbocharger and Center Manifold Removal 2-52
Turbocharger and Intake Manifold 2-93
U
Underbody Protection 13-14
Front Shield Replacement 13-15
Intermediate Shield Replacement 13-16
Rear Shield Replacement 13-17
Skid Plate Replacement 13-14
Transfer Case Shield Replacement 13-17
V
Vacuum Pump Service 2-44
Valve Lifter
Installation 2-88
Removal 2-55
Replacement 2-41
Vehicle Identification Number
Decoding Chart 1-6
Vehicle Identification Number (VIN) 1-5
Visor Replacement 10-34
W
Water Crossover
Installation 2-92
Removal 2-52
Water Crossover Service 4-15
Water Leak Detection and Repair 10-12
Water Pump
Inlet Hose Replacement 4-11
Water Pump and Adapter Plate 4-13, 4-14
Water Pump and Adapter Plate Installation 2-87
Water Pump and Adapter Plate Removal 2-56
Weathercap Replacement 3-22
Wheels and Tires
Balancing 6-18
Checking Wheel Alignment 6-25
One-Piece Aluminum Wheel and
Two-Piece Runflat Service 6-12
Special Tools 6-56
Tire, Two-Piece Wheel, and
Runflat Replacement 6-2
Troubleshooting 6-20
Wheel Alignment 6-22
Wheel Alignment Correction 6-26
Wheel and Tire Assembly Replacement 6-1
Wheel Half Stud Replacement 6-10
Wheel Runout Inspection 6-20
Winch
Assembly Repair 9-72, 9-81, 13-3
Cable Replacement 9-71, 9-80, 13-2
Electric Thermal Switch/Brush
Assembly 9-76, 9-85, 13-7
Replacement 9-70, 9-79, 13-1
Troubleshooting 9-70, 13-1
Windshield 12-83, 12-84
Assembly Maintenance 10-54
Glass and Weatherstrip Replacement 10-53
Heated Windshield 10-55
Reservoir and Pump Assembly 10-58
Washer Hoses Replacement 10-58
Washer Nozzle Replacement 10-58
Washer System and Components 10-58
Windshield Assembly 10-53
Wiper Jumper Harness Replacement 10-58
Wiper Linkage Replacement 10-57
Wiper Motor Assembly Replacement 10-56
Wiper Pivot Replacement 10-57
Wiper System and Components 10-56
3-1-02
_____________________________________________________________________________
MASSIVE MASSIVE MANUAL!! 1200+ PAGES!!
NEATLY INDEXED, SEARCHABLE, CATEGORIZED, WELL ORGANISED AND MORE IMPORTANTLY THIS IS THE SAME EXACT OEM MANUAL USED BY YOUR DEALERS!!!
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