coolant CHRYSLER CARAVAN 2002 Manual PDF
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2002, Model line: CARAVAN, Model: CHRYSLER CARAVAN 2002Pages: 2399, PDF Size: 57.96 MB
Page 367 of 2399
SHIFT SCHEDULES
As mentioned earlier, the TCM has programming that
allows it to select a variety of shift schedules. Shift
schedule selection is dependent on the following:
²Shift lever position
²Throttle position
²Engine load²Fluid temperature
²Software level
As driving conditions change, the TCM appropri-
ately adjusts the shift schedule. Refer to the follow-
ing chart to determine the appropriate operation
expected, depending on driving conditions.
Schedule Condition Expected Operation
Extreme ColdOil temperature at start-up below
-16É FPark, Reverse, Neutral and 2nd
gear only (prevents shifting which
may fail a clutch with frequent
shifts)
ColdOil temperature at start-up above
-12É F and below 36É F± Delayed 2-3 upshift
(approximately 22-31 mph)
± Delayed 3-4 upshift (45-53 mph)
± Early 4-3 costdown shift
(approximately 30 mph)
± Early 3-2 coastdown shift
(approximately 17 mph)
± High speed 4-2, 3-2, 2-1 kickdown
shifts are prevented
± No EMCC
WarmOil temperature at start-up above
36É F and below 80 degree F± Normal operation (upshift,
kickdowns, and coastdowns)
± No EMCC
HotOil temperature at start-up above
80É F± Normal operation (upshift,
kickdowns, and coastdowns)
± Full EMCC, no PEMCC except to
engage FEMCC (except at closed
throttle at speeds above 70-83 mph)
OverheatOil temperature above 240É F or
engine coolant temperature above
244É F± Delayed 2-3 upshift (25-32 mph)
± Delayed 3-4 upshift (41-48 mph)
± 3rd gear FEMCC from 30-48 mph
± 3rd gear PEMCC from 27-31 mph
Super OverheatOil temperature above 260É F ± All9Overheat9shift schedule
features apply
± 2nd gear PEMCC above 22 mph
± Above 22 mph the torque
converter will not unlock unless the
throttle is closed or if a wide open
throttle 2nd PEMCC to 1 kickdown
is made
8E - 30 ELECTRONIC CONTROL MODULESRS
TRANSMISSION CONTROL MODULE (Continued)
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ELECTRONIC CONTROL MODULES
TABLE OF CONTENTS
page page
ENGINE CONTROL MODULE
DESCRIPTION..........................1
OPERATION............................1
STANDARD PROCEDURE - PCM/ECM/SKIM
PROGRAMMING - DIESEL...............2REMOVAL.............................4
INSTALLATION..........................4
ENGINE CONTROL MODULE
DESCRIPTION
The ECM is located in the left front corner of the
engine compartment attached to the radiator support
(Fig. 1).
OPERATION
The ECM has been programmed to monitor differ-
ent circuits of the diesel fuel injection system. Thismonitoring is called on-board diagnostics. Certain cri-
teria must be met for a diagnostic trouble code to be
entered into the ECM memory. The criteria may be a
range of: engine rpm, engine temperature, time or
other input signals to the ECM. If all of the criteria
for monitoring a system or circuit are met, and a
problem is sensed, then a DTC will be stored in the
ECM memory. It is possible that a DTC for a moni-
tored circuit may not be entered into the ECM mem-
ory, even though a malfunction has occurred. This
may happen when the monitoring criteria have not
been met. The ECM compares input signal voltages
from each input device with specifications (the estab-
lished high and low limits of the input range) that
are programmed into it for that device. If the input
voltage is not within the specifications and other
trouble code criteria are met, a DTC will be stored in
the ECM memory.
ECM OPERATING MODES
As input signals to the ECM change, the ECM
adjusts its response to the output devices. For exam-
ple, the ECM must calculate a different fuel quantity
and fuel timing for engine idle condition than it
would for a wide open throttle condition. There are
several different modes of operation that determine
how the ECM responds to the various input signals.
Ignition Switch On (Engine Off)
When the ignition is turned on, the ECM activates
the glow plug relay for a time period that is deter-
mined by engine coolant temperature, atmospheric
temperature and battery voltage.
Engine Start-Up Mode
The ECM uses the engine temperature sensor and
the crankshaft position sensor (engine speed) inputs
to determine fuel injection quantity.
Normal Driving Modes
Engine idle, warm-up, acceleration, deceleration
and wide open throttle modes are controlled based on
all of the sensor inputs to the ECM. The ECM uses
Fig. 1 ENGINE CONTROL MODULE LOCATION-
TYPICAL
1 - BATTERY
2 - IPM (INTEGRATED POWER MODULE)
3 - ECM (ENGINE CONTROL MODULE)
4 - RETAINING BOLT
5 - RADIATOR SUPPORT
6 - CLUTCH CABLE BRACKET (LHD)
7 - CLUTCH CABLE BRACKET RETAINING BOLT (LHD)
RGELECTRONIC CONTROL MODULES8Ea-1
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The Check Gauges Lamp (if equipped) or Battery
Lamp monitors:charging system voltage,engine
coolant temperature and engine oil pressure. If an
extreme condition is indicated, the lamp will be illu-
minated. The signal to activate the lamp is sent via
the PCI bus circuits. The lamp is located on the
instrument panel. Refer to the Instrument Cluster
section for additional information.
The PCM uses the inlet air temperature sensor to
control the charge system voltage. This temperature,
along with data from monitored line voltage, is used
by the PCM to vary the battery charging rate. The
system voltage is higher at cold temperatures and is
gradually reduced as the calculated battery tempera-
ture increases.
The ambient temperature sensor is used to control
the battery voltage based upon ambient temperature
(approximation of battery temperature). The PCM
maintains the optimal output of the generator by
monitoring battery voltage and controlling it to a
range of 13.5 - 14.7 volts based on battery tempera-
ture.
DIAGNOSIS AND TESTING - ON-BOARD
DIAGNOSTIC SYSTEM
The Powertrain Control Module (PCM) monitors
critical input and output circuits of the charging sys-
tem, making sure they are operational. A Diagnostic
Trouble Code (DTC) is assigned to each input and
output circuit monitored by the OBD system. Some
circuits are checked continuously and some are
checked only under certain conditions.
If the OBD system senses that a monitored circuit
is bad, it will put a DTC into electronic memory. The
DTC will stay in electronic memory as long as the
circuit continues to be bad. The PCM is programmed
to clear the memory after 50 engine starts if the
problem does not occur again.
DIAGNOSTIC TROUBLE CODES
A DTC description can be read using the DRBIIIt
scan tool. Refer to the appropriate Powertrain Diag-
nostic Procedures manual for information.
A DTC does not identify which component in a cir-
cuit is bad. Thus, a DTC should be treated as a
symptom, not as the cause for the problem. In some
cases, because of the design of the diagnostic test
procedure, a DTC can be the reason for another DTC
to be set. Therefore, it is important that the test pro-
cedures be followed in sequence, to understand what
caused a DTC to be set.
ERASING DIAGNOSTIC TROUBLE CODES
The DRBIIItScan Tool must be used to erase a
DTC.The following procedures may be used to diagnose
the charging system if:
²the check gauges lamp or battery lamp is illumi-
nated with the engine running
²the voltmeter (if equipped) does not register
properly
²an undercharged or overcharged battery condi-
tion occurs.
Remember that an undercharged battery is often
caused by:
²accessories being left on with the engine not
running
²a faulty or improperly adjusted switch that
allows a lamp to stay on. Refer to Ignition-Off Draw
Test (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/
BATTERY - STANDARD PROCEDURE)
INSPECTION
The Powertrain Control Module (PCM) monitors
critical input and output circuits of the charging sys-
tem, making sure they are operational. A Diagnostic
Trouble Code (DTC) is assigned to each input and
output circuit monitored by the On-Board Diagnostic
(OBD) system. Some charging system circuits are
checked continuously, and some are checked only
under certain conditions.
Refer to Diagnostic Trouble Codes in; Powertrain
Control Module; Electronic Control Modules for more
DTC information. This will include a complete list of
DTC's including DTC's for the charging system.
To perform a complete test of the charging system,
refer to the appropriate Powertrain Diagnostic Proce-
dures service manual and the DRBIIItscan tool.
Perform the following inspections before attaching
the scan tool.
(1) Inspect the battery condition. Refer to the Bat-
tery section (Refer to 8 - ELECTRICAL/BATTERY
SYSTEM - DIAGNOSIS AND TESTING) for proce-
dures.
(2) Inspect condition of battery cable terminals,
battery posts, connections at engine block, starter
solenoid and relay. They should be clean and tight.
Repair as required.
(3) Inspect all fuses in both the fuseblock and
Power Distribution Center (PDC) for tightness in
receptacles. They should be properly installed and
tight. Repair or replace as required.
(4) Inspect generator mounting bolts for tightness.
Replace or tighten bolts if required. Refer to the Gen-
erator Removal/Installation section of this group for
torque specifications (Refer to 8 - ELECTRICAL/
CHARGING - SPECIFICATIONS).
(5) Inspect generator drive belt condition and ten-
sion. Tighten or replace belt as required. Refer to
Belt Tension Specifications(Refer to 7 - COOLING/
ACCESSORY DRIVE - SPECIFICATIONS).
8F - 22 CHARGINGRS
CHARGING (Continued)
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Page 432 of 2399
ULES/POWERTRAIN CONTROL MODULE -
DESCRIPTION) section for more DTC information.
The Check Gauges Lamp (if equipped) or Battery
Lamp monitors:charging system voltage,engine
coolant temperature and engine oil pressure. If an
extreme condition is indicated, the lamp will be illu-
minated. The signal to activate the lamp is sent via
the PCI bus circuits. The lamp is located on the
instrument panel. Refer to the Instrument Cluster
section for additional information.
The PCM uses the inlet air temperature sensor to
control the charge system voltage. This temperature,
along with data from monitored line voltage, is used
by the PCM to vary the battery charging rate. The
system voltage is higher at cold temperatures and is
gradually reduced as the calculated battery tempera-
ture increases.
The ambient temperature sensor is used to control
the battery voltage based upon ambient temperature
(approximation of battery temperature). The PCM
maintains the optimal output of the generator by
monitoring battery voltage and controlling it to a
range of 13.5 - 14.7 volts based on battery tempera-
ture.
DIAGNOSIS AND TESTING - ON-BOARD
DIAGNOSTIC SYSTEM
The Powertrain Control Module (PCM) monitors
critical input and output circuits of the charging sys-
tem, making sure they are operational. A Diagnostic
Trouble Code (DTC) is assigned to each input and
output circuit monitored by the OBD system. Some
circuits are checked continuously and some are
checked only under certain conditions.
If the OBD system senses that a monitored circuit
is bad, it will put a DTC into electronic memory. The
DTC will stay in electronic memory as long as the
circuit continues to be bad. The PCM is programmed
to clear the memory after 50 engine starts if the
problem does not occur again.
DIAGNOSTIC TROUBLE CODES
A DTC description can be read using the DRBIIIt
scan tool. Refer to the appropriate Powertrain Diag-
nostic Procedures manual for information.
A DTC does not identify which component in a cir-
cuit is bad. Thus, a DTC should be treated as a
symptom, not as the cause for the problem. In some
cases, because of the design of the diagnostic test
procedure, a DTC can be the reason for another DTC
to be set. Therefore, it is important that the test pro-
cedures be followed in sequence, to understand what
caused a DTC to be set.ERASING DIAGNOSTIC TROUBLE CODES
The DRBIIItScan Tool must be used to erase a
DTC.
The following procedures may be used to diagnose
the charging system if:
²the check gauges lamp or battery lamp is illumi-
nated with the engine running
²the voltmeter (if equipped) does not register
properly
²an undercharged or overcharged battery condi-
tion occurs.
Remember that an undercharged battery is often
caused by:
²accessories being left on with the engine not
running
²a faulty or improperly adjusted switch that
allows a lamp to stay on. Refer to Ignition-Off Draw
Test (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/
BATTERY - STANDARD PROCEDURE)
INSPECTION
The Powertrain Control Module (PCM) monitors
critical input and output circuits of the charging sys-
tem, making sure they are operational. A Diagnostic
Trouble Code (DTC) is assigned to each input and
output circuit monitored by the On-Board Diagnostic
(OBD) system. Some charging system circuits are
checked continuously, and some are checked only
under certain conditions.
Refer to Diagnostic Trouble Codes in; Powertrain
Control Module; Electronic Control Modules for more
DTC information. This will include a complete list of
DTC's including DTC's for the charging system.
To perform a complete test of the charging system,
refer to the appropriate Powertrain Diagnostic Proce-
dures service manual and the DRBIIItscan tool.
Perform the following inspections before attaching
the scan tool.
(1) Inspect the battery condition. Refer to the Bat-
tery section (Refer to 8 - ELECTRICAL/BATTERY
SYSTEM - DIAGNOSIS AND TESTING) for proce-
dures.
(2) Inspect condition of battery cable terminals,
battery posts, connections at engine block, starter
solenoid and relay. They should be clean and tight.
Repair as required.
(3) Inspect all fuses in both the fuseblock and
Power Distribution Center (PDC) for tightness in
receptacles. They should be properly installed and
tight. Repair or replace as required.
(4) Inspect generator mounting bolts for tightness.
Replace or tighten bolts if required. Refer to the Gen-
erator Removal/Installation section of this group for
torque specifications (Refer to 8 - ELECTRICAL/
CHARGING - SPECIFICATIONS).
RGCHARGING8Fa-21
CHARGING (Continued)
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IGNITION CONTROL
TABLE OF CONTENTS
page page
GLOW PLUG
DESCRIPTION..........................1
OPERATION............................1
GLOW PLUG RELAY
DESCRIPTION..........................1
OPERATION............................1CAMSHAFT POSITION SENSOR
DESCRIPTION..........................2
OPERATION............................2
REMOVAL.............................2
INSTALLATION..........................2
GLOW PLUG
DESCRIPTION
Glow plugs are used to help start a cold or cool
engine (Fig. 1). The glow plugs will heat up and glow
to heat the combustion chamber of each cylinder. An
individual glow plug is used for each cylinder. Each
glow plug is threaded into the left side of the cylinder
head below the cylinder head cover/intake manifold.
OPERATION
Each glow plug will momentarily draw approxi-
mately 25 amps of electrical current during the ini-
tial key ªONº cycle. This is on a cold or cool engine.
After heating the current draw will drop to approxi-
mately 9±12 amps per plug.
Total momentary cuurent draw for all four glow
plugs is approximately 100 amps on a cold engine
dropping to a total of approximately 40 amps after
the plugs are heated.
Electrical operation of the glow plugs is controlled
by two glow plug relays. Each glow plug relay con-
trols two glow plugs. Refer to glow plug relays for
more information.
GLOW PLUG RELAY
DESCRIPTION
There are two glow plug relays. These relays are
located in the Power Distribution Center (PDC) in
the engine compartment (Fig. 2).
OPERATION
When the ignition (key) switch is place in the ON
position, a signal is sent to the ECM relating current
engine coolant temperature. This signal is sent from
the engine coolant temperature sensor.
After receiving this signal, the ECM will determine
if, when and for how long of a period the glow plug
relays should be activated. This is done before, dur-
ing and after the engine is started. Whenever the
glow plug relays are activated, it will control the 12
volt 100 amp circuit for the operation of the four
glow plugs. Each relay control two glow plugs.
Fig. 1 GLOW PLUG
Fig. 2 RELAY LOCATIONS
1 - GLOW PLUG RELAY
2 - RADIATOR SUPPORT
3 - CHARGE AIR COOLER OUTLET HOSE
4 - COOLING FAN RELAY
5 - UPPER RADIATOR HOSE
6 - EGR SOLENOID
RGIGNITION CONTROL8Ia-1
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Page 487 of 2399
The Glow Plug lamp is tied to this circuit. Lamp
operation is also controlled by the ECM.
With a cold engine, the glow plug relays and glow
plugs may be activated for a maximum time of 200
seconds. Refer to the following Glow Plug Control
chart for a temperature/time comparison of the glow
plug relay operation.
In this chart, Pre-Heat and Post-Heat times are
mentioned. Pre-Heat is the amount of time the glow
plug relay control circuit is activated when the igni-
tion (key) is switched ON, without the engine run-
ning. Post-Heat is the amount of time the glow plug
relay control circuit is activated after the engine is
operated. The Glow Plug lamp will not be activated
during the post-heat cycle.
Engine
Coolant
Temperature
9Key ON9Wait-To
Start Lamp
9ON9
(Seconds)Pre-Heat
Cycle
(Glow
Plugs On
Seconds)Post-Heat
Cycle
(Seconds)
-30C 20 SEC. 35 SEC. 200 SEC.
-10C 8 SEC. 23 SEC. 180 SEC.
+10C 6 SEC. 21 SEC. 160 SEC.
+30C 5 SEC. 20 SEC. 140 SEC.
+40C 4 SEC. 19 SEC. 70 SEC.
+70C 1 SEC. 16 SEC. 20 SEC.
CAMSHAFT POSITION
SENSOR
DESCRIPTION
The camshaft position (CMP) sensor is mounted in
the top of cylinder head cover/intake manifold at the
rear of the engine. The CMP sensor is a hall effect
device (Fig. 3).
OPERATION
The CMP sensor is a hall effect switch. A tooth
made of a ferromagnetic material is attached to the
camshaft. When this tooth passes the CMP sensor an
lectronic signal is created. This signal is then sent to
the engine control module (ECM). This signal is used
by the ECM to determine which cylinder has just
entered its compression phase.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE
COVER - REMOVAL).
(3) Disconnect camshaft position sensor electrical
connector (Fig. 4).
(4) Remove sensor retaining bolt and remove sen-
sor from cylinder head cover.
INSTALLATION
(1) Lubricate O-ring and install sensor in cylinder
head cover. Torque retaining bolt to 5.4 N´m.
(2) Connect camshaft position sensor electrical
connector.
(3) Install engine cover (Refer to 9 - ENGINE
COVER - INSTALLATION).
(4) Connect negative battery cable.
Fig. 3 CAMSHAFT POSITION SENSOR
Fig. 4 CAMSHAFT POSITION SENSOR LOCATION
1 - CAMSHAFT POSITION SENSOR
2 - CAMSHAFT POSITION SENSOR ELCTRICAL SENSOR
3 - FUEL INJECTOR
4 - CYLINDER HEAD COVER
5 - OIL SEPARATOR
8Ia - 2 IGNITION CONTROLRG
GLOW PLUG RELAY (Continued)
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INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - SELF-
DIAGNOSTICS.........................2
DIAGNOSIS AND TESTING - CLUSTER
DIAGNOSIS...........................2
REMOVAL.............................11
INSTALLATION.........................12CLUSTER LENS
REMOVAL.............................12
INSTALLATION.........................12
MECHANICAL TRANSMISSION RANGE
INDICATOR
REMOVAL.............................12
INSTALLATION.........................12
RED BRAKE WARNING INDICATOR
DESCRIPTION.........................13
OPERATION...........................13
INSTRUMENT CLUSTER
DESCRIPTION
The instrumentation gauges are contained in a
subdial assembly within the instrument cluster. The
individual gauges are not serviceable. If one of the
cluster gauges becomes faulty, the entire cluster
would require replacement.
The mechanical instrument cluster with a tachom-
eter is equipped with a electronic vacuum fluorescent
transmission range indicator (PRND3L), odometer,
and trip odometer display.
The mechanical instrument cluster without a
tachometer is equipped with a cable operated trans-
mission range indicator (PRND21) and a vacuum flu-
orescent odometer display. It also has the following
indicators:
²Turn Signals
²High Beam
²Oil Pressure
²MIL
The instrument cluster is equipped with the follow-
ing warning lamps.
²Lift Gate Ajar
²Low Fuel Level
²Low Windshield Washer Fluid Level
²Cruise
²Battery Voltage
²Fasten Seat Belt
²Door Ajar
²Coolant Temperature
²Anti-Lock Brake
²Brake
²Airbag
²Traction Control
²AutostickThe mechanical instrument cluster without a
tachometer also has the following warning lamps:
²Turns Signals
²High Beam
²Oil Pressure
²Malfunction Indicator Lamp (MIL)
WATER IN FUEL LAMP - EXPORT
The Water In Fuel Lamp is located in the instru-
ment cluster. When moisture is found within the fuel
system, the sensor sends a message via the PCI data
bus to the instrument cluster. The sensor is located
underneath the vehicle, directly above the rear axle.
The sensor is housed within the fuel filter/water sep-
arator assembly cover. The sensor is not serviced sep-
arately. If found defective, the entire assembly cover
must be replaced.
OPERATION
Refer to the vehicle Owner's Manual for operation
instructions and conditions for the Instrument Clus-
ter Gauges.
WATER IN FUEL LAMP - EXPORT
The Water In Fuel Sensor is a resistive type
switch. It is calibrated to sense the different resis-
tance between diesel fuel and water. When water
enters the fuel system, it is caught in the bottom of
the fuel filter/water separator assembly, where the
sensor is located. Water has less resistance than die-
sel fuel. The sensor then sends a PCI data bus mes-
sage to the instrument cluster to illuminate the
lamp.
If the lamp is inoperative, perform the self diag-
nostic test on the instrument cluster to check the
lamp operation before continuing diagnosis.
RSINSTRUMENT CLUSTER8J-1
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CONDITION POSSIBLE CAUSES CORRECTION
ERRATIC POINTER
MOVEMENT.1. BAD PCI FUEL
MESSAGE FROM THE
BODY CONTROLLER.1. USE A DRB IIITSCAN TOOL TO CHECK THE BCM.
IF OK, GO TO STEP 2. IF NOT OK, REFER TO THE
PROPER BODY DIAGNOSTIC PROCEDURES
MANUAL TO PROPERLY DIAGNOSE AND REPAIR.
2. REFER TO THE FUEL SECTION OF THE SERVICE
MANUAL FOR THE FUEL LEVEL SENDING UNIT
TEST PROCEDURE. TEST UNIT. IF OK, LOOK FOR
ANOTHER POSSIBLE CAUSE FOR FUEL GAUGE
FAILURE. IF NOT OK, REPAIR SENDING UNIT.
2. INTERNAL CLUSTER
FAILURE.2. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
AND CHECK FOR FAULT CODES.
²IF THE POINTER MOVES DURING TEST BUT
STILL APPEARS ERRATIC, REPLACE CLUSTER
ASSEMBLY.
FUEL GAUGE
INACCURATE.1. FUEL GAUGE OUT OF
CALIBRATION.1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST. IF
POINTER IS ACCURATE TO THE CALIBRATION
POINTS LOOK FOR ANOTHER POSSIBLE CAUSE
OF FAILURE. IF POINTER IS INACCURATE TO THE
CALIBRATION POINTS, REPLACE CLUSTER
ASSEMBLY.
2. FUEL LEVEL SENDING
UNIT IS OUT OF
CALIBRATION.2. REFER TO THE FUEL SECTION OF THE SERVICE
MANUAL FOR TESTING AND REPAIR PROCEDURE.
TEMPERATURE GAUGE DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
NO POINTER
MOVEMENT.1. INTERNAL CLUSTER
FAILURE.1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
AND CHECK.
²IF TEMPERATURE GAUGE POINTER MOVES TO
CALIBRATION POINTS, LOOK FOR ANOTHER
POSSIBLE CAUSE OF FAILURE.
²IF THE POINTER DOESN'T MOVE DURING TEST,
VERIFY POWER AND GROUND ARE BEING
PROVIDED TO THE CLUSTER. IF YES, REPLACE
CLUSTER. IF NO, DETERMINE CAUSE OF NO
POWER OR NO GROUND.
2. NO PCI
TEMPERATURE
MESSAGE OR COLD PCI
BUS MESSAGE FROM
THE POWERTRAIN
CONTROL MODULE.2.A. CHECK PCM FAULT CODES USING A DRB IIIT
SCAN TOOL. IF THERE ARE NO FAULTS, GO TO
STEP 2.B. IF THERE ARE FAULTS, REFER TO THE
PROPER POWERTRAIN DIAGNOSTIC
PROCEDURES MANUAL TO PROPERLY DIAGNOSE
AND REPAIR.
2.B. REFER TO FUEL, COOLANT TEMPERATURE
SENSOR, DIAGNOSIS AND TESTING. REPAIR
SENSOR AS NEEDED.
8J - 8 INSTRUMENT CLUSTERRS
INSTRUMENT CLUSTER (Continued)
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Page 496 of 2399
CONDITION POSSIBLE CAUSES CORRECTION
ERRATIC POINTER
MOVEMENT.1. BAD PCI BUS
MESSAGE FROM THE
POWERTRAIN CONTROL
MODULE.1.A. CHECK PCM FAULT CODES USING A DRB IIIT
SCAN TOOL. IF THERE ARE NO FAULTS, GO TO
STEP 1.B. IF THERE ARE FAULTS, REFER TO THE
PROPER POWERTRAIN DIAGNOSTIC
PROCEDURES MANUAL TO PROPERLY DIAGNOSE
AND REPAIR.
1.B. REFER TO FUEL, COOLANT TEMPERATURE
SENSOR, DIAGNOSIS AND TESTING. REPAIR
SENSOR AS NEEDED.
2. INTERNAL CLUSTER
FAILURE.2. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
AND CHECK FOR FAULT CODES.
²IF THE POINTER MOVES DURING TEST BUT
STILL APPEARS ERRATIC, REPLACE CLUSTER
ASSEMBLY.
TEMPERATURE GAUGE
INACCURATE.1. TEMPERATURE
GAUGE OUT OF
CALIBRATION.1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST.
²IF POINTER IS ACCURATE TO THE CALIBRATION
POINTS LOOK FOR ANOTHER POSSIBLE CAUSE
OF FAILURE.
²IF POINTER IS INACCURATE TO THE
CALIBRATION POINTS, REPLACE CLUSTER
ASSEMBLY.
2. COOLANT SENSOR
OUT OF CALIBRATION.2. REFER TO FUEL, COOLANT TEMPERATURE
SENSOR FOR TEST AND REPAIR PROCEDURE.
ODOMETER DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
NO DISPLAY. 1. NO PCI BUS
ODOMETER MESSAGE
FROM BCM.1. USE A DRB IIITSCAN TOOL TO CHECK THE
BCM. REFER TO THE PROPER BODY DIAGNOSTIC
PROCEDURES MANUAL TO PROPERLY DIAGNOSE
AND REPAIR.
2. INTERNAL CLUSTER
FAILURE.2. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
AND CHECK FOR FAULT CODES.
²IF ODOMETER PASSES THE SEGMENT CHECK,
LOOK FOR ANOTHER POSSIBLE CAUSE OF
FAILURE. IF IT FAILS VERIFY POWER AND
GROUND ARE BEING PROVIDED TO THE
CLUSTER. IF YES, REPLACE CLUSTER. IF NO,
DETERMINE CAUSE OF NO POWER OR GROUND.
RSINSTRUMENT CLUSTER8J-9
INSTRUMENT CLUSTER (Continued)
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Page 620 of 2399
(13) Install second row seat to vehicle. Refer to
Owner's Manual for proper procedures.
SEAT BELT SECOND RIGHT
ROW OUTBOARD - LBW WITH
REAR HVAC
REMOVAL
(1) Remove second row seat from vehicle. Refer to
Owner's Manual for proper procedures.
(2) Slide lower anchor cover from over the anchor
shoulder-nut.
(3) Remove lower anchor shoulder-nut.
(4) Remove lower anchor from wheelhouse.
(5) Fold upper turning loop extension cover down-
ward to gain access to anchor bolt.
(6) Remove bolt attaching turning loop to exten-
sion bracket above quarter glass.
(7) Remove turning loop from extension bracket.
(8) Remove D-pillar trim panel.
(9) Remove quarter trim bolster.(10) Remove quarter trim panel as necessary to
gain access to HVAC unit.
(11) Route seat belt webbing and turning loop
through access hole in quarter trim.
(12) Loosen HVAC unit enough to gain access to
seat belt retractor fasteners.
(a) Remove bracket around HVAC unit (Fig. 6).
(b) Remove air duct (Fig. 7).
(c) Remove fasteners attaching HVAC unit to
inner quarter panel (Fig. 8).
(d) Remove screws attaching upper evaporator
housing to lower evaporator housing.
(e) Remove coolant line retaining bracket hold
down bolt.
(13) Remove bolts attaching seat belt guide loop to
inner quarter panel.
(14) Pull outward on HVAC unit and remove bolt
attaching retractor to inner quarter panel.
(15) Remove screw attaching retractor to inner
quarter panel.
(16) Remove second row seat belt retractor from
vehicle.INSTALLATION
(1) Position second row seat belt retractor to vehi-
cle.
(2) Install screw attaching retractor to inner quar-
ter panel.
(3) Pull outward on HVAC unit and install bolt
attaching retractor to inner quarter panel. Tighten-
ing specifications for all seat belt bolts is 39 N´m (29
ft. lbs.) torque.
(4) Install bolts attaching seat belt guide loop to
inner quarter panel.
(5) Install coolant line retaining bracket hold down
bolt.
Fig. 5 SECOND RIGHT ROW OUTBOARD SEAT
BELT - LWB
1 - TURNING LOOP GUIDE
2 - RETRACTOR 2nd REAR
3 - LOWER QUARTER TRIM
4 - LOWER ANCHOR
5 - RETRACTOR 1st REAR
6 - ANCHOR BRACKET
7 - QUARTER PANEL
8 - C-PILLAR TRIM
9 - HEIGHT ADJUSTER
Fig. 6 TRIM PANEL MOUNTING BRACKET
1 - TRIM PANEL MOUNTING BRACKET
RSRESTRAINTS8O-11
SEAT BELT SECOND RIGHT ROW OUTBOARD - LWB (Continued)
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