ESP inoperative CHRYSLER VOYAGER 2003 Service Manual

Refer to the appropriate Powertrain Diagnostic Man-
ual and the DRBIIItscan tool.
(1) Install PCM module to the mounting bracket.
(2) Install electrical connectors and lock.
(3) Install the splash shield.
(4) Lower vehicle.
(5) Connect the negative battery cable.
(6) Using DRBIIItscan tool, program mileage and
vehicle identification number (VIN) into PCM. Refer
to the DRBIIItscan tool and the appropriate Power-
train Diagnostic Manual.
SENTRY KEY IMMOBILIZER
MODULE
DESCRIPTION
The Sentry Key Immobilizer Module (SKIM) con-
tains a Radio Frequency (RF) transceiver and a
microprocessor. The SKIM retains in memory the ID
numbers of any Sentry Key that is programmed to it.
The maximum number of keys that may be pro-
grammed to each module is eight (8). The SKIM also
communicates over the Programmable Communica-
tion Interface (PCI) data bus with the Powertrain
Control Module (PCM), the Body Control Module
(BCM), the Mechanical Instrument Cluster (MIC),
and the DRB IIItscan tool. The SKIM transmits and
receives RF signals through a tuned antenna
enclosed within a molded plastic ring formation that
is integral to the SKIM housing. When the SKIM is
properly installed on the steering column, the
antenna ring fits snugly around the circumference of
the ignition lock cylinder housing. If this ring is not
mounted properly, communication problems may
arise in the form of transponder-related faults.
For added system security, each SKIM is pro-
grammed with a unique9Secret Key9code. This code
is stored in memory and is sent over the PCI bus to
the PCM and to each key that is programmed to
work with the vehicle. The9Secret Key9code is there-
fore a common element found in all components of
the Sentry Key Immobilizer System (SKIS). In the
event that a SKIM replacement is required, the
9Secret Key9code can be restored from the PCM by
following the SKIM replacement procedure found in
the DRB IIItscan tool. Proper completion of this
task will allow the existing ignition keys to be repro-
grammed. Therefore, new keys will NOT be needed.
In the event that the original9Secret Key9code can
not be recovered, new ignition keys will be required.
The DRB IIItscan tool will alert the technician if
key replacement is necessary. Another security code,
called a PIN, is used to gain secured access to the
SKIM for service. The SKIM also stores in its mem-
ory the Vehicle Identification Number (VIN), which itlearns through a bus message from the assembly
plant tester. The SKIS scrambles the information
that is communicated between its components in
order to reduce the possibility of unauthorized SKIM
access and/or disabling.
OPERATION
When the ignition switch is moved to the RUN
position, the Sentry Key Immobilizer Module (SKIM)
transmits an Radio Frequency (RF) signal to the
transponder in the ignition key. The SKIM then
waits for a response RF signal from the transponder
in the key. If the response received identifies the key
as valid, the SKIM sends a9valid key9message to
the Powertrain Control Module (PCM) over the Pro-
grammable Communication Interface (PCI) data bus.
If the response received identifies the key as invalid
or no response is received from the transponder in
the ignition key, the SKIM sends an9invalid key9
message to the PCM. The PCM will enable or disable
engine operation based upon the status of the SKIM
messages. It is important to note that the default
condition in the PCM is9invalid key.9Therefore, if no
response is received by the PCM, the engine will be
immobilized after two (2) seconds of running.
The SKIM also sends indicator light status mes-
sages to the Mechanical Instrument Cluster (MIC) to
operate the light. This is the method used to turn the
light ON solid or to flash it after the indicator light
test is complete to signify a fault in the SKIS. If the
light comes ON and stays ON solid after the indica-
tor light test, this signifies that the SKIM has
detected a system malfunction and/or that the SKIS
has become inoperative. If the SKIM detects an
invalid keyORa key-related fault exists, the indica-
tor light will flash following the indicator light test.
The SKIM may also request an audible chime if the
customer key programming feature is available and
the procedure is being utilized (Refer to 8 - ELEC-
TRICAL/VEHICLE THEFT SECURITY/TRANSPON-
DER KEY - STANDARD PROCEDURE).
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove Lower Instrument Panel Cover. Refer
to Body, Instrument Panel, Lower Instrument Panel
Cover, Removal.
(3) Remove the steering column upper and lower
shrouds. Refer to Steering, Column, Column Shroud,
Removal.
(4) Disengage the steering column wire harness
from the Sentry Key Immobilizer Module (SKIM).
(5) Remove the one screws securing the SKIM to
the steering column.
8E - 18 ELECTRONIC CONTROL MODULESRS
POWERTRAIN CONTROL MODULE (Continued)
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INSTRUMENT CLUSTER DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
INSTRUMENT CLUSTER
INOPERATIVE. NO
RESPONSE FROM
INSTRUMENT CLUSTER.NO PCI BUS MESSAGES
FROM THE BCM.USE A DRB IIITSCAN TOOL TO CHECK THE BCM.
IF OK, LOOK FOR ANOTHER POSSIBLE CAUSE
FOR CLUSTER FAILURE. IF NOT OK, REFER TO
THE PROPER BODY DIAGNOSTIC PROCEDURES
MANUAL.
SPREAD TERMINAL(S)
ON WIRING HARNESS
CLUSTER CONNECTOR.REMOVE CLUSTER FROM INSTRUMENT PANEL
AND CHECK WIRING HARNESS CONNECTOR FOR
SPREAD TERMINAL. IF OK, LOOK FOR ANOTHER
POSSIBLE CAUSE FOR THE CLUSTER FAILURE. IF
NOT OK, REPAIR CONNECTOR.
BCM IS NOT RECEIVING
PROPER INPUT FROM
THE IGNITION SWITCH.1. USE A DRB IIITSCAN TOOL TO VERIFY IGNITION
SWITCH STATUS INTO THE BCM. IF NOT OK, GO
TO STEP (2). IF OK, LOOK AT ANOTHER POSSIBLE
CAUSE OF FAILURE.
2. CHECK IGNITION SWITCH FUNCTION AND
WIRING.
INTERNAL CLUSTER
FAILURE.REPLACE CLUSTER.
WAKE UP CIRCUIT
FAULTY.VERIFY CONTINUITY OF WAKE UP CIRCUIT FROM
BCM TO MIC. CIRCUIT SHALL BE LOW WHENEVER
BCM IS AWAKE.
POWER OR GROUND
MISSING.IF NO RESPONSE FROM THE MIC, CHECK FOR
POWER AND GROUND AT THE MIC CONNECTOR.
REFER TO WIRING DIAGRAMS FOR CONNECTOR
CALL OUTS.
RSINSTRUMENT CLUSTER8J-3
INSTRUMENT CLUSTER (Continued)
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DIAGNOSIS AND TESTING - COMPASS
MINI-TRIP COMPUTER
Compass Mini-Trip Computer (CMTC) and Com-
pass Temperature (CT) data is obtained from the
Body Control Module (BCM) on the J1850 Data Bus
circuit. The CMTC and CT will display dashes (- -)
for any of the screens it did not receive the bus mes-
sages. The label corresponding to the missing infor-
mation will be lit. If no compass mini-trip computer
data is displayed, check the J1850 Data Bus circuit
communications and the BCM. If the brightness level
is improper check the J1850 Data Bus circuit.
The DRB IIItis recommended for checking the
J1850 Data Bus circuit and the BCM. Perform the
CMTC, CT self diagnosis before replacing the CMTC
or CT module.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove overhead console(Refer to 8 - ELEC-
TRICAL/OVERHEAD CONSOLE - REMOVAL).
(3) Remove the screws holding Compass Mini-Trip
Computer module in the overhead console.
(4) Remove CMTC module from console assembly.
INSTALLATION
(1) Position the compass mini-trip computer mod-
ule in the overhead console.
(2) Install the ten screws holding the compass
mini-trip computer module in the overhead console.
(3) Install the overhead console (Refer to 8 -
ELECTRICAL/OVERHEAD CONSOLE - INSTALLA-
TION).
(4) Connect the battery negative cable.
NOTE: If a new EVIC module has been installed, the
compass will have to be calibrated and the variance
set. Refer to compass variation adjustment and
compass calibration in standard procedures.
UNIVERSAL TRANSMITTER
DESCRIPTION
On some RS models a Universal Transmitter trans-
ceiver is standard factory-installed equipment. The
universal transmitter transceiver is integral to the
Electronic Vehicle Information Center (EVIC) and the
Compass Mini-Trip Computer (CMTC) modules,
which is located in the overhead console. The only
visible component of the universal transmitter are
the three transmitter push buttons centered between
the modules push buttons located just rearward of
the display screen in the overhead console. The threeuniversal transmitter push buttons are identified
with one, two or three light indicators so that they be
easily identified by sight or by feel.
Each of the three universal transmitter push but-
tons controls an independent radio transmitter chan-
nel. Each of these three channels can be trained to
transmit a different radio frequency signal for the
remote operation of garage door openers, motorized
gate openers, home or office lighting, security sys-
tems or just about any other device that can be
equipped with a radio receiver in the 286 to 399
MegaHertz (MHz) frequency range for remote opera-
tion. The universal transmitter is capable of operat-
ing systems using either rolling code or non-rolling
code technology.
The electronics module displays messages and a
small house-shaped icon with one, two or three dots
corresponding to the three transmitter buttons to
indicate the status of the universal transmitter. The
EVIC messages are:
²Cleared Channels- Indicates that all of the
transmitter codes stored in the universal transmitter
have been successfully cleared.
²Training- Indicates that the universal trans-
mitter is in its transmitter learning mode.
²Trained- Indicates that the universal transmit-
ter has successfully acquired a new transmitter code.
²Transmit- Indicates that a trained universal
transmitter button has been depressed and that the
universal transmitter is transmitting.
The universal transmitter cannot be repaired, and
is available for service only as a unit with the EVIC
or CMTC modules. If any of these components is
faulty or damaged, the complete EVIC or CMTC
module must be replaced.
OPERATION
The universal transmitter operates on a non-
switched source of battery current so the unit will
remain functional, regardless of the ignition switch
position. For more information on the features, pro-
gramming procedures and operation of the universal
transmitter, see the owner's manual in the vehicle
glove box.
DIAGNOSIS AND TESTING - UNIVERSAL
TRANSMITTER
If the Universal Transmitter is inoperative, but the
Electronic Vehicle Information Center (EVIC) is oper-
ating normally, see the owner's manual in the vehicle
glove box for instructions on training the Transmit-
ter. Retrain the Transmitter with a known good
transmitter as instructed in the owner's manual and
test the Transmitter operation again. If the unit is
still inoperative, test the universal transmitter with
Radio Frequency Detector special tool. If both the
8M - 10 MESSAGE SYSTEMSRS
COMPASS/MINI-TRIP COMPUTER (Continued)
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Transmitter and the EVIC module are inoperative,
refer toElectronic Vehicle Information Center
Diagnosis and Testingin this group for further
diagnosis. For complete circuit diagrams, refer to
Wiring Diagrams. (Fig. 5) as described below:
(1) Turn the Radio Frequency (RF) Detector ON. A
ªchirpº will sound and the green power LED will
light. If the green LED does not light, replace the
battery.
(2) Hold the RF detector within one inch of the
TRAINED universal transmitter and press any of the
transmitters buttons.
(3) The red signal detection LEDs will light and
the tool will beep if a radio signal is detected. Repeat
this test three times.
STANDARD PROCEDURE
STANDARD PROCEDURE - SETTING
TRANSMITTER CODES
(1) Turn off the engine.
(2) Erase the codes by pressing the two outside
buttons. Release the buttons when the display con-
firms the operation (about 20 seconds).
(3) Choose one of the three buttons to train. Place
the hand-held transmitter within one inch of the uni-
versal transmitter and push the buttons on both
transmitters.(4) Release both buttons. Your universal transmit-
ter is now ªtrainedº. To train the other buttons,
repeat Step 3 and Step 4. Be sure to keep your hand-
held transmitter in case you need to retrain the uni-
versal transmitter.
STANDARD PROCEDURE - ERASING
TRANSMITTER CODES
To erase the universal transmitter codes, simply
hold down the two outside buttons until the display
confirms the operation.
NOTE: Individual channels cannot be erased. Eras-
ing the transmitter codes will erase ALL pro-
grammed codes.
REMOVAL
(1) For universal transmitter removal and installa-
tion procedure, (Refer to 8 - ELECTRICAL/OVER-
HEAD CONSOLE/COMPASS/MINI-TRIP
COMPUTER - REMOVAL and INSTALLATION).
AMBIENT TEMP SENSOR
DESCRIPTION
Ambient air temperature is monitored by the over-
head console through ambient temperature messages
received from the Front Control Module (FCM) over
the Programmable Communications Interface (PCI)
J1850 data bus circuit. The FCM receives a hard
wired input from the ambient temperature sensor.
The ambient temperature sensor is a variable resis-
tor mounted to a bracket that is secured with a screw
to the right side of the headlamp mounting module
grille opening, behind the radiator grille and in front
of the engine compartment.
For more information on the Front Control Module
refer to the Electronic Control Modules section of this
manual. For complete circuit diagrams, refer to the
appropriate wiring information. The ambient temper-
ature sensor cannot be adjusted or repaired and, if
faulty or damaged, it must be replaced.
OPERATION
The ambient temperature sensor is a variable
resistor that operates on a five-volt reference signal
sent to it by the Front Control Module. The resis-
tance in the sensor changes as temperature changes,
changing the temperature sensor signal circuit volt-
age to the Front Control Module. Based upon the
resistance in the sensor, the Front Control Module
senses a specific voltage on the temperature sensor
signal circuit, which it is programmed to correspond
to a specific temperature. The Front Control Module
Fig. 5 RADIO FREQUENCY DETECTOR
1 - SIGNAL DETECTION LED'S
2 - POWER LED
3 - ON/OFF SWITCH
4 - 9V BATTERY
RSMESSAGE SYSTEMS8M-11
UNIVERSAL TRANSMITTER (Continued)
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AUTOMATIC SPEED CONTROL OVERSPEED
REDUCTION
DESCRIPTION
Transmission control software includes an auto-
matic speed control overspeed reduction feature. This
maintains vehicle speed at the selected set point
when descending a grade.
OPERATION
The TCM (on SBEC vehicles) (PCM on NGC vehi-
cles) first senses that the speed control is set. If the
set speed is exceeded by more than 4 mph (6.5
km/hr) and the throttle is closed, the TCM (on SBEC
vehicles) (PCM on NGC vehicles) causes the trans-
axle to downshift to THIRD gear. After downshifting,
the automatic speed control resumes normal opera-
tion. To ensure that an upshift is appropriate after
the set speed is reached, the TCM (on SBEC vehi-
cles) (PCM on NGC vehicles) waits until the speed
control system opens the throttle at least 6 degrees
before upshifting to OVERDRIVE again.
If the driver applies the brakes, canceling auto-
matic speed control operation with the transaxle still
in THIRD gear, the TCM (on SBEC vehicles) (PCM
on NGC vehicles) maintains this gear until the driver
opens the throttle at least 6 degrees to avoid an inap-
propriate upshift. The upshift is also delayed for 2.5
seconds after reaching the 6 degrees throttle opening
in anticipation that the driver might open the throt-
tle enough to require THIRD gear. This will avoid
unnecessary and disturbing transmission cycling. If
the automatic speed control RESUME feature is used
after braking, the upshift is delayed until the set
speed is achieved to reduce cycling and provide bet-
ter response.
DIAGNOSIS AND TESTING - ROAD TEST
Perform a vehicle road test to verify reports of
speed control system malfunction. The road test
should include attention to the speedometer. Speed-
ometer operation should be smooth and without flut-
ter at all speeds.
Flutter in the speedometer indicates a problem
which might cause surging in the speed control sys-
tem. The cause of any speedometer problems should
be corrected before proceeding. Refer to the Instru-
ment Cluster for speedometer diagnosis.
If a road test verifies an inoperative system, and
the speedometer operates properly, check for:
²A Diagnostic Trouble Code (DTC). If a DTC
exists, conduct tests per the Powertrain Diagnostic
Procedures manual.
²A misadjusted brake (stop) lamp switch. This
could also cause an intermittent problem.
²Loose or corroded electrical connections at the
servo. Corrosion should be removed from electrical
terminals and a light coating of Mopar Multipurpose
Grease, or equivalent, applied.
²Leaking vacuum reservoir.
²Loose or leaking vacuum hoses or connections.
²Defective one-way vacuum check valve.
²Secure attachment at both ends of the speed
control servo cable.
²Smooth operation of throttle linkage and throttle
body air valve.
²Conduct electrical test at PCM.
²Failed speed control servo. Do the servo vacuum
test.
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals or seals. If
these components are damaged, intermittent or
complete system failure may occur.
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Servo Mounting Bracket
Nuts14 10.3 123.9
Servo Mounting Bracket
Bolts14 10.3 123.9
Servo Mounting Nuts 6.7 60
RSSPEED CONTROL8P-3
SPEED CONTROL (Continued)
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(3) Clutch circuit leaks are indicated if pressures
do not fall within the specified pressure range.
(4)
If the overdrive clutch pressure is greater than 5
psi in Step 4 of Test Three, a worn reaction shaft seal
ring or a defective solenoid assembly is indicated.
(5) If the underdrive clutch pressure is greater
than 5 psi in Step 4 of Test Two A, a defective sole-
noid assembly or PCM/TCM is the cause.
PRESSURE CHECK SPECIFICATIONS
Gear Selector
PositionActual GearPressure Taps
Underdrive
ClutchOverdrive
ClutchReverse
ClutchTorque
Converter
Clutch
Off2/4
ClutchLow/
Reverse
Clutch
Park *
PARK 0-2 0-5 0-2 60-110 0-2 115-145
0 mph
REVERSE *
REVERSE 0-2 0-7 165-235 50-100 0-2 165-235
0 mph
NEUTRAL *
NEUTRAL 0-2 0-5 0-2 60-110 0-2 115-145
0 mph
L#
FIRST 110-145 0-5 0-2 60-110 0-2 115-145
20 mph
3#
SECOND 110-145 0-5 0-2 60-110 115-145 0-2
30 mph
3#
DIRECT 75-95 75-95 0-2 60-90 0-2 0-2
45 mph
OD #
OVERDRIVE 0-2 75-95 0-2 60-90 75-95 0-2
30 mph
OD #
OVERDRIVE
WITH TCC0-2 75-95 0-2 0-5 75-95 0-2
50 mph
* Engine speed at 1500 rpm
# CAUTION: Both front wheels must be turning at the same speed.
DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS
Inoperative clutches can be located using a series
of tests by substituting air pressure for fluid pressure
(Fig. 5) (Fig. 6). The clutches may be tested by apply-
ing air pressure to their respective passages. The
valve body must be removed and Tool 6056 installed.
To make air pressure tests, proceed as follows:
NOTE: The compressed air supply must be free of
all dirt and moisture. Use a pressure of 30 psi.
Remove oil pan and valve body. See Valve body
removal.
OVERDRIVE CLUTCH
Apply air pressure to the overdrive clutch apply
passage and watch for the push/pull piston to moveforward. The piston should return to its starting
position when the air pressure is removed.
REVERSE CLUTCH
Apply air pressure to the reverse clutch apply pas-
sage and watch for the push/pull piston to move rear-
ward. The piston should return to its starting
position when the air pressure is removed.
2/4 CLUTCH
Apply air pressure to the feed hole located on the
2/4 clutch retainer. Look in the area where the 2/4
piston contacts the first separator plate and watch
carefully for the 2/4 piston to move rearward. The
piston should return to its original position after the
air pressure is removed.
21 - 122 41TE AUTOMATIC TRANSAXLERS
41TE AUTOMATIC TRANSAXLE (Continued)
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period the switch ratio reaches a predetermined
value, a counter is incremented by one. The monitor
is enabled to run another test during that trip. When
the test fails 6 times, the counter increments to 3, a
malfunction is entered, and a Freeze Frame is stored,
the code is matured and the MIL is illuminated. If
the first test passes, no further testing is conducted
during that trip.
The MIL is extinguished after three consecutive
good trips. The good trip criteria for the catalyst
monitor is more stringent than the failure criteria. In
order to pass the test and increment one good trip,
the downstream sensor switch rate must be less than
45% of the upstream rate. The failure percentages
are 59% respectively.
Enabling ConditionsÐThe following conditions
must typically be met before the PCM runs the cat-
alyst monitor. Specific times for each parameter may
be different from engine to engine.
²Accumulated drive time
²Enable time
²Ambient air temperature
²Barometric pressure
²Catalyst warm-up counter
²Engine coolant temperature
²Vehicle speed
²MAP
²RPM
²Engine in closed loop
²Fuel level
Pending ConditionsÐ
²Misfire DTC
²Front Oxygen Sensor Response
²Front Oxygen Sensor Heater Monitor
²Front Oxygen Sensor Electrical
²Rear Oxygen Sensor Rationality (middle check)
²Rear Oxygen Sensor Heater Monitor
²Rear Oxygen Sensor Electrical
²Fuel System Monitor
²All TPS faults
²All MAP faults
²All ECT sensor faults
²Purge flow solenoid functionality
²Purge flow solenoid electrical
²All PCM self test faults
²All CMP and CKP sensor faults
²All injector and ignition electrical faults
²Idle Air Control (IAC) motor functionality
²Vehicle Speed Sensor
²Brake switch (auto trans only)
²Intake air temperature
ConflictÐThe catalyst monitor does not run if any
of the following are conditions are present:
²EGR Monitor in progress (if equipped)
²Fuel system rich intrusive test in progress
²EVAP Monitor in progress²Time since start is less than 60 seconds
²Low fuel level-less than 15 %
²Low ambient air temperature
²Ethanol content learn is taking place and the
ethanol used once flag is set
SuspendÐThe Task Manager does not mature a
catalyst fault if any of the following are present:
²Oxygen Sensor Monitor, Priority 1
²Oxygen Sensor Heater, Priority 1
²EGR Monitor, Priority 1 (if equipped)
²EVAP Monitor, Priority 1
²Fuel System Monitor, Priority 2
²Misfire Monitor, Priority 2
OPERATION - NON-MONITORED CIRCUITS
The PCM does not monitor all circuits, systems
and conditions that could have malfunctions causing
driveability problems. However, problems with these
systems may cause the PCM to store diagnostic trou-
ble codes for other systems or components. For exam-
ple, a fuel pressure problem will not register a fault
directly, but could cause a rich/lean condition or mis-
fire. This could cause the PCM to store an oxygen
sensor or misfire diagnostic trouble code.
The major non-monitored circuits are listed below
along with examples of failures modes that do not
directly cause the PCM to set a DTC, but for a sys-
tem that is monitored.
FUEL PRESSURE
The fuel pressure regulator controls fuel system
pressure. The PCM cannot detect a clogged fuel
pump inlet filter, clogged in-line fuel filter, or a
pinched fuel supply or return line. However, these
could result in a rich or lean condition causing the
PCM to store an oxygen sensor, fuel system, or mis-
fire diagnostic trouble code.
SECONDARY IGNITION CIRCUIT
The PCM cannot detect an inoperative ignition coil,
fouled or worn spark plugs, ignition cross firing, or
open spark plug cables. The misfire will however,
increase the oxygen content in the exhaust, deceiving
the PCM in to thinking the fuel system is too lean.
Also see misfire detection.
CYLINDER COMPRESSION
The PCM cannot detect uneven, low, or high engine
cylinder compression. Low compression lowers O2
content in the exhaust. Leading to fuel system, oxy-
gen sensor, or misfire detection fault.
EXHAUST SYSTEM
The PCM cannot detect a plugged, restricted or
leaking exhaust system. It may set a EGR (if
equipped) or Fuel system or O2S fault.
RSEMISSIONS CONTROL25-5
EMISSIONS CONTROL (Continued)
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