charging DODGE RAM 2001 Service Manual PDF

TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(2) Remove the secondary clip from the spring-lock
coupler.
(3) Fit the proper size A/C line disconnect tool
(Special Tool Kit 7193) over the spring-lock coupler
cage (Fig. 2).
(4) Close the two halves of the A/C line disconnect
tool around the spring-lock coupler.
(5) Push the A/C line disconnect tool into the open
side of the coupler cage to expand the garter spring.
Once the garter spring is expanded and while still
pushing the disconnect tool into the open side of the
coupler cage, pull on the refrigerant line attached to
the female half of the coupler fitting until the flange
on the female fitting is separated from the garter
spring and cage on the male fitting within the dis-
connect tool.
INSTALLATION
(1) Check to ensure that the garter spring is
located within the cage of the male coupler fitting,
and that the garter spring is not damaged.
(a) If the garter spring is missing, install a new
spring by pushing it into the coupler cage opening.
(b) If the garter spring is damaged, remove it
from the coupler cage with a small wire hook (DO
NOT use a screwdriver) and install a new garter
spring.
(2) Clean any dirt or foreign material from both
halves of the coupler fitting.(3) Install new O-rings on the male half of the cou-
pler fitting.
CAUTION: Use only the specified O-rings as they
are made of a special material for the R-134a sys-
tem. The use of any other O-rings may allow the
connection to leak intermittently during vehicle
operation.
(4) Lubricate the male fitting and O-rings, and the
inside of the female fitting with clean R-134a refrig-
erant oil. Use only refrigerant oil of the type recom-
mended for the compressor in the vehicle.
(5) Fit the female half of the coupler fitting over
the male half of the fitting.
(6) Push together firmly on the two halves of the
coupler fitting until the garter spring in the cage on
the male half of the fitting snaps over the flanged
end on the female half of the fitting.
(7) Ensure that the spring-lock coupler is fully
engaged by trying to separate the two coupler halves.
This is done by pulling the refrigerant lines on either
side of the coupler away from each other.
(8) Reinstall the secondary clip over the spring-
lock coupler cage.
STANDARD PROCEDURE - REFRIGERANT
SYSTEM SERVICE EQUIPMENT
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
When servicing the air conditioning system, a
R-134a refrigerant recovery/recycling/charging sta-
tion that meets SAE Standard J2210 must be used.
Contact an automotive service equipment supplier for
refrigerant recovery/recycling/charging equipment.
Refer to the operating instructions supplied by the
equipment manufacturer for proper care and use of
this equipment.
A manifold gauge set may be needed with some
recovery/recycling/charging equipment (Fig. 3). The
service hoses on the gauge set being used should
have manual (turn wheel), or automatic back-flow
valves at the service port connector ends. This will
prevent refrigerant from being released into the
atmosphere.
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not com-
patible and system damage will result.
Fig. 2 REFRIGERANT LINE SPRING-LOCK
COUPLER DISCONNECT
24 - 44 PLUMBINGBR/BE
PLUMBING (Continued)

LOW PRESSURE GAUGE HOSE The low pressure
hose (Blue with Black stripe) attaches to the suction
service port. This port is located on the suction line
between the accumulator outlet and the compressor.
HIGH PRESSURE GAUGE HOSE The high pres-
sure hose (Red with Black stripe) attaches to the dis-
charge service port. This port is located on the
discharge line between the compressor and the con-
denser inlet.
RECOVERY/RECYCLING/EVACUATION/CHARG-
ING HOSE The center manifold hose (Yellow, or
White, with Black stripe) is used to recover, evacu-
ate, and charge the refrigerant system. When the low
or high pressure valves on the manifold gauge set
are opened, the refrigerant in the system will escape
through this hose.
STANDARD PROCEDURE - REFRIGERANT
RECOVERY
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
A R-134a refrigerant recovery/recycling/charging
station that meets SAE Standard J2210 must be
used to recover the refrigerant from an R-134a refrig-
erant system. Refer to the operating instructions sup-
plied by the equipment manufacturer for the proper
care and use of this equipment.
STANDARD PROCEDURE - REFRIGERANT
SYSTEM EVACUATE
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
If the refrigerant system has been open to the
atmosphere, it must be evacuated before the system
can be charged. If moisture and air enters the system
and becomes mixed with the refrigerant, the com-
pressor head pressure will rise above acceptable
operating levels. This will reduce the performance of
the air conditioner and damage the compressor.
Evacuating the refrigerant system will remove the
air and boil the moisture out of the system at near
room temperature. To evacuate the refrigerant sys-
tem, use the following procedure:
(1) Connect a R-134a refrigerant recovery/recy-
cling/charging station that meets SAE Standard
J2210 and a manifold gauge set to the refrigerant
system of the vehicle.
(2) Open the low and high side valves and start
the charging station vacuum pump. When the suc-
tion gauge reads 88 kPa (26 in. Hg.) vacuum or
greater, close all of the valves and turn off the vac-
uum pump.
(a) If the refrigerant system fails to reach the
specified vacuum, the system has a leak that must
be corrected. (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - DIAGNOSIS AND
TESTING - REFRIGERANT SYSTEM LEAKS)
(b) If the refrigerant system maintains the spec-
ified vacuum for five minutes, restart the vacuum
pump, open the suction and discharge valves and
evacuate the system for an additional ten minutes.
(3) Close all of the valves, and turn off the charg-
ing station vacuum pump.
(4) The refrigerant system is now ready to be
charged with R-134a refrigerant. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
Fig. 3 MANIFOLD GAUGE SET - TYPICAL
1 - HIGH PRESSURE GAUGE
2 - VALVE
3 - VACUUM/REFRIGERANT HOSE (YELLOW W/ BLACK
STRIPE)
4 - HIGH PRESSURE HOSE (RED W/ BLACK STRIPE)
5 - LOW PRESSURE HOSE (BLUE W/ BLACK STRIPE)
6 - VALVE
7 - LOW PRESSURE GAUGE
BR/BEPLUMBING 24 - 45
PLUMBING (Continued)

STANDARD PROCEDURE - REFRIGERANT
SYSTEM CHARGE
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
After the refrigerant system has been tested for
leaks and evacuated, a refrigerant charge can be
injected into the system. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - SPECIFICA-
TIONS - CHARGE CAPACITY)
A R-134a refrigerant recovery/recycling/charging
station that meets SAE Standard J2210 must be
used to charge the refrigerant system with R-134a
refrigerant. Refer to the operating instructions sup-
plied by the equipment manufacturer for proper care
and use of this equipment.
SPECIFICATIONS
SPECIFICATIONS
The R-134a refrigerant system charge capacity for
this vehicle is: 0.907 kilograms (32 ounces).
A/C COMPRESSOR
DESCRIPTION - A/C COMPRESSOR
The air conditioning system uses a Sanden
SD7H15 seven cylinder, reciprocating wobble plate-
type compressor on all models. This compressor has a
fixed displacement of 150 cubic centimeters (9.375
cubic inches), and has both the suction and discharge
ports located on the cylinder head. A label identifying
the use of R-134a refrigerant is located on the com-
pressor.
DESCRIPTION - HIGH PRESSURE RELIEF
VALVE
A high pressure relief valve is located on the com-
pressor cylinder head, which is at the rear of the
compressor. This mechanical valve is designed to
vent refrigerant from the system to protect against
damage to the compressor and other system compo-
nents, caused by condenser air flow restriction or an
overcharge of refrigerant.
OPERATION - A/C COMPRESSOR
The compressor is driven by the engine through an
electric clutch, drive pulley and belt arrangement.
The compressor is lubricated by refrigerant oil that iscirculated throughout the refrigerant system with the
refrigerant.
The compressor draws in low-pressure refrigerant
vapor from the evaporator through its suction port. It
then compresses the refrigerant into a high-pressure,
high-temperature refrigerant vapor, which is then
pumped to the condenser through the compressor dis-
charge port.
The compressor cannot be repaired. If faulty or
damaged, the entire compressor assembly must be
replaced. The compressor clutch, pulley and clutch
coil are available for service.
OPERATION - HIGH PRESSURE RELIEF VALVE
The high pressure relief valve vents the system
when a discharge pressure of 3445 to 4135 kPa (500
to 600 psi) or above is reached. The valve closes with
a minimum discharge pressure of 2756 kPa (400 psi)
is reached.
The high pressure relief valve vents only enough
refrigerant to reduce the system pressure, and then
re-seats itself. The majority of the refrigerant is con-
served in the system. If the valve vents refrigerant, it
does not mean the valve is faulty.
The high pressure relief valve is a factory-cali-
brated unit. The valve cannot be adjusted or
repaired, and must not be removed or otherwise dis-
turbed. The valve is only serviced as a part of the
compressor assembly.
DIAGNOSIS AND TESTING - A/C COMPRESSOR
When investigating an air conditioning related
noise, you must first know the conditions under
which the noise occurs. These conditions include:
weather, vehicle speed, transmission in gear or neu-
tral, engine speed, engine temperature, and any
other special conditions. Noises that develop during
air conditioning operation can often be misleading.
For example: What sounds like a failed front bearing
or connecting rod, may be caused by loose bolts, nuts,
mounting brackets, or a loose compressor clutch
assembly.
Drive belts are speed sensitive. At different engine
speeds and depending upon belt tension, belts can
develop noises that are mistaken for a compressor
noise. Improper belt tension can cause a misleading
noise when the compressor clutch is engaged, which
may not occur when the compressor clutch is disen-
gaged. Check the serpentine drive belt condition and
tension as described in Cooling before beginning this
procedure.
(1) Select a quiet area for testing. Duplicate the
complaint conditions as much as possible. Switch the
compressor on and off several times to clearly iden-
tify the compressor noise. Listen to the compressor
while the clutch is engaged and disengaged. Probe
24 - 46 PLUMBINGBR/BE
PLUMBING (Continued)

the compressor with an engine stethoscope or a long
screwdriver with the handle held to your ear to bet-
ter localize the source of the noise.
(2) Loosen all of the compressor mounting hard-
ware and retighten. Tighten the compressor clutch
mounting nut. Be certain that the clutch coil is
mounted securely to the compressor, and that the
clutch plate and pulley are properly aligned and have
the correct air gap. (Refer to 24 - HEATING & AIR
CONDITIONING/CONTROLS/A/C COMPRESSOR
CLUTCH - INSTALLATION)
(3) To duplicate a high-ambient temperature condi-
tion (high head pressure), restrict the air flow
through the condenser. Install a manifold gauge set
to be certain that the discharge pressure does not
exceed 2760 kPa (400 psi).
(4) Check the refrigerant system plumbing for
incorrect routing, rubbing or interference, which can
cause unusual noises. Also check the refrigerant lines
for kinks or sharp bends that will restrict refrigerant
flow, which can cause noises. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - CAU-
TION)
(5) If the noise is from opening and closing of the
high pressure relief valve, recover, evacuate, and
recharge the refrigerant system. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE - REFRIGERANT RECOVERY)
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - STANDARD PROCEDURE - REFRIG-
ERANT SYSTEM EVACUATE) (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE) If the high pressure relief valve still
does not seat properly, replace the compressor.
(6) If the noise is from liquid slugging on the suc-
tion line, replace the accumulator. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/AC-
CUMULATOR - REMOVAL) Check the refrigerant oil
level and the refrigerant system charge. (Refer to 24
- HEATING & AIR CONDITIONING/PLUMBING/
REFRIGERANT OIL - STANDARD PROCEDURE -
REFRIGERANT OIL LEVEL) (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - SPECI-
FICATIONS - CHARGE CAPACITY) If the liquid
slugging condition continues following accumulator
replacement, replace the compressor.
(7) If the noise continues, replace the compressor
and repeat Step 1.
REMOVAL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
The compressor may be removed and repositioned
without disconnecting the refrigerant lines or dis-
charging the refrigerant system. Discharging is not
necessary if servicing the compressor clutch or clutch
coil, the engine, the cylinder head, or the generator.
(1) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the serpentine drive belt. Refer to
Cooling for the procedures.
(4) Unplug the compressor clutch coil wire harness
connector.
(5) Remove the bolt that secures the refrigerant
line manifold to the compressor. Install plugs in, or
tape over all of the opened refrigerant line fittings.
(6) Remove the four bolts that secure the compres-
sor to the mounting bracket (Fig. 4) or (Fig. 5).
(7) Remove the a/c compressor from the mounting
bracket.
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)(Refer to
24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION - REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS)
NOTE: If a replacement compressor is being
installed, be certain to check the refrigerant oil
level. (Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT OIL - STANDARD PRO-
CEDURE) Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT OIL - DESCRIPTION)
(1) Install the compressor to the mounting bracket.
Tighten the four mounting bolts to 24 N´m (210 in.
lbs.).
(2) Remove the tape or plugs from all of the
opened refrigerant line fittings. Install the suction
and discharge line manifold to the compressor. (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING/A/C SUCTION AND DISCHARGE LINE -
INSTALLATION)
BR/BEPLUMBING 24 - 47
A/C COMPRESSOR (Continued)

EMISSIONS CONTROL
TABLE OF CONTENTS
page page
EMISSIONS CONTROL
DESCRIPTION............................1
OPERATION.............................18AIR INJECTION..........................25
EVAPORATIVE EMISSIONS.................31
EMISSIONS CONTROL
DESCRIPTION - DIESEL
Two different modules are used for powertrain con-
trol with the diesel engine. The Powertrain Control
Module (PCM) is used primarily for charging system,
transmission, A/C compressor clutch operation and
speed control functions. The Engine Control Module
(ECM) is used to control thefuel and emissions
systems.The PCM is located in the right/rear of
engine compartment (Fig. 1). The ECM is bolted to
the left side of the engine cylinder block (Fig. 2).
DESCRIPTION - STATE DISPLAY TEST MODE
The switch inputs to the Powertrain Control Mod-
ule (PCM) have two recognized states; HIGH and
LOW. For this reason, the PCM cannot recognize the
difference between a selected switch position versus
an open circuit, a short circuit, or a defective switch.
If the State Display screen shows the change from
HIGH to LOW or LOW to HIGH, assume the entire
switch circuit to the PCM functions properly. Connectthe DRB scan tool to the data link connector and
access the state display screen. Then access either
State Display Inputs and Outputs or State Display
Sensors.
DESCRIPTION - CIRCUIT ACTUATION TEST
MODE
The Circuit Actuation Test Mode checks for proper
operation of output circuits or devices the Powertrain
Control Module (PCM) may not internally recognize.
The PCM attempts to activate these outputs and
allow an observer to verify proper operation. Most of
the tests provide an audible or visual indication of
device operation (click of relay contacts, fuel spray,
etc.). Except for intermittent conditions, if a device
functions properly during testing, assume the device,
its associated wiring, and driver circuit work cor-
rectly. Connect the DRB scan tool to the data link
connector and access the Actuators screen.
Fig. 1 Powertrain Control Module (PCM) Location
1 - PCM MOUNTING BOLTS (3)
2 - POWERTRAIN CONTROL MODULE (PCM)
3 - (3) 32±WAY CONNECTORS
Fig. 2 Engine Control Module (ECM) Location
1 - ENGINE CONTROL MODULE (ECM)
2 - HEX HEADED BOLT
3 - FUEL TRANSFER PUMP
4 - MOUNTING BOLTS (3)
5 - 50±WAY CONNECTOR
BR/BEEMISSIONS CONTROL 25 - 1

(M)Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded
(depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G)Generator lamp illuminated
Generic Scan
Tool P-CodeDRB Scan Tool Display Brief Description of DTC
P0505 (M) Idle Air Control Motor Circuits SBEC II
P0522 Oil Pressure Voltage Too Low Oil pressure sending unit (sensor) voltage input below the
minimum acceptable voltage.
P0523 Oil Pressure Voltage Too High Oil pressure sending unit (sensor) voltage input above the
maximum acceptable voltage.
P0524 Oil Pressure Too Low Engine oil pressure is low. Engine power derated.
P0545 A/C Clutch Relay Circuit Problem detected in air conditioning clutch relay control
circuit.
P0551 Power Steering Switch Failure Incorrect input state detected for the power steering
switch circuit. PL: High pressure seen at high speed.
P0562 Charging System Voltage Too Low Supply voltage sensed at ECM too low.
P0563 Charging System Voltage Too High Supply voltage sensed at ECM too high.
P0600 PCM Failure SPI Communications No communication detected between co-processors in the
control module.
P0601 (M) Internal Controller Failure Internal control module fault condition (check sum)
detected.
P0602 (M) ECM Fueling Calibration Error ECM Internal fault condition detected.
P0604 RAM Check Failure Transmission control module RAM self test fault detected.
-Aisin transmission
P0605 ROM Check Falure Transmission control module ROM self test fault detected
-Aisin transmission
P0606 (M) ECM Failure ECM Internal fault condition detected.
P0615 Starter Relay Control Circuit An open or shorted condition detected in the starter relay
control circuit.
P0622 (G) Generator Field Not Switching
ProperlyAn open or shorted condition detected in the generator
field control circuit.
P0645 A/C Clutch Relay Circuit An open or shorted condition detected in the A/C clutch
relay control circuit.
P0700 EATX Controller DTC Present This SBEC III or JTEC DTC indicates that the EATX or
Aisin controller has an active fault and has illuminated the
MIL via a CCD (EATX) or SCI (Aisin) message. The
specific fault must be acquired from the EATX via CCD or
from the Aisin via ISO-9141.
P0703 Brake Switch Stuck Pressed or
ReleasedIncorrect input state detected in the brake switch circuit.
(Changed from P1595)
P0711 (M) Trans Temp Sensor, No Temp Rise
After StartRelationship between the transmission temperature and
overdrive operation and/or TCC operation indicates a
failure of the Transmission Temperature Sensor. OBD II
Rationality. Was MIL code 37.
P0712 Trans Temp Sensor Voltage Too Low Transmission fluid temperature sensor input below
acceptable voltage. Was MIL code 37.
P0712 (M) Trans Temp Sensor Voltage Too Low Voltage less than 1.55 volts (4-speed auto. trans. only).
25 - 8 EMISSIONS CONTROLBR/BE
EMISSIONS CONTROL (Continued)

(M)Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded
(depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G)Generator lamp illuminated
Generic Scan
Tool P-CodeDRB Scan Tool Display Brief Description of DTC
P1482 Catalyst Temperature Sensor Circuit
Shorted LowCatalyst temperature sensor circuit shorted low.
P1483 Catalyst Temperature Sensor Circuit
Shorted High.Catalyst temperature sensor circuit shorted high.
P1484 Catalytic Converter Overheat
DetectedA catalyst overheat condition has been detected by the
catalyst temperature sensor.
P1485 Air Injection Solenoid Circuit An open or shorted condition detected in the air assist
solenoid circuit.
P1486 Evap Leak Monitor Pinched Hose
FoundLDP has detected a pinched hose in the evaporative hose
system.
P1487 Hi Speed Rad Fan CTRL Relay
CircuitAn open or shorted condition detected in the control
circuit of the #2 high speed radiator fan control relay.
P1488 Auxiliary 5 Volt Supply Output Too
LowAuxiliary 5 volt sensor feed is sensed to be below an
acceptable limit.
P1488 5 Volt Supply Voltage Low Sensor supply voltage for ECM sensors is too low.
P1489 High Speed Fan CTRL Relay Circuit An open or shorted condition detected in the control
circuit of the high speed radiator fan control relay.
P1490 Low Speed Fan CTRL Relay Circuit An open or shorted condition detected in control circuit of
the low speed radiator fan control relay.
P1491 Rad Fan Control Relay Circuit An open or shorted condition detected in the radiator fan
control relay control circuit. This includes PWM solid state
relays.
P1492 Ambient/Batt Temp Sen Volts Too
HighExternal temperature sensor input above acceptable
voltage.
P1492 (M) Ambient/Batt Temp Sensor Volts Too
HighBattery temperature sensor input voltage above an
acceptable range.
P1493 (M) Ambient/Batt Temp Sen Volts Too
LowExternal temperature sensor input below acceptable
voltage.
P1493 (M) Ambient/Batt Temp Sen Volts Too
LowBattery temperature sensor input voltage below an
acceptable range.
P1494 (M) Leak Detection Pump Sw or
Mechanical FaultIncorrect input state detected for the Leak Detection
Pump (LDP) pressure switch.
P1495 Leak Detection Pump Solenoid
CircuitAn open or shorted condition detected in the Leak
Detection Pump (LDP) solenoid circuit.
P1496 5 Volt Supply, Output Too Low 5 volt sensor feed is sensed to be below an acceptable
limit. ( less than 4v for 4 sec )
P1498 High Speed Rad Fan Ground CTRL
Rly CircuitAn open or shorted condition detected in the control
circuit of the #3 high speed radiator fan control relay.
P1499 Hydraulic cooling fan solenoid circuit An open or shorted condition detected in the cooling fan
control solenoid circuit.
P1594 (G) Charging System Voltage Too High Battery voltage sense input above target charging voltage
during engine operation.
P1594 Charging System Voltage Too High Battery voltage sense input above target charging voltage
during engine operation.
25 - 12 EMISSIONS CONTROLBR/BE
EMISSIONS CONTROL (Continued)

(M)Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded
(depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G)Generator lamp illuminated
Generic Scan
Tool P-CodeDRB Scan Tool Display Brief Description of DTC
P1595 Speed Control Solenoid Circuits An open or shorted condition detected in either of the
speed control vacuum or vent solenoid control circuits.
P1595 Speed Control Solenoid Circuits An open or shorted condition detected in the speed
control vacuum or vent solenoid circuits.
P1596 Speed Control Switch Always High Speed control switch input above maximum acceptable
voltage.
P1597 Speed Control Switch Always Low Speed control switch input below minimum acceptable
voltage.
P1597 Speed Control Switch Always Low Speed control switch input below the minimum acceptable
voltage.
P1598 A/C Pressure Sensor Volts Too High A/C pressure sensor input above maximum acceptable
voltage.
P1598 A/C Sensor Input Hi Problem detected in air conditioning electrical circuit.
P1599 A/C Pressure Sensor Volts Too Low A/C pressure sensor input below minimum acceptable
voltage.
P1599 A/C Sensor Input Lo Problem detected in air conditioning electrical circuit.
P1680 Clutch Released Switch Circuit Problem detected in clutch switch electrical circuit.
P1681 No I/P Cluster CCD/J1850
Messages ReceivedNo CCD/J1850 messages received from the cluster
control module.
P1682 (G) Charging System Voltage Too Low Battery voltage sense input below target charging voltage
during engine operation and no significant change in
voltage detected during active test of generator output
circuit.
P1682 Charging System Voltage Too Low Charging system output voltage low.
P1683 SPD CTRL PWR Relay; or S/C 12v
Driver CKTAn open or shorted condition detected in the speed
control servo power control circuit.
P1683 Spd ctrl pwr rly, or s/c 12v driver
circuitAn open or shorted condition detected in the speed
control servo power control circuit.
P1684 Batt Loss in 50 Star The battery has been disconnected within the last 50
starts
P1685 SKIM Invalid Key The engine controler has received an invalid key from the
SKIM.
P1686 No SKIM BUS Messages Received No CCD/J1850 messages received from the Smart Key
Immobilizer Module (SKIM).
P1687 No MIC BUS Message No CCD/J1850 messages received from the Mechanical
Instrument Cluster (MIC) module.
P1688 (M) Internal Fuel Injection Pump
Controller FailureInternal problem within the fuel injection pump. Low
power, engine derated, or engine stops.
P1689 (M) No Communication Between ECM
and Injection Pump ModuleData link circuit failure between ECM and fuel injection
pump. Low power, engine derated, or engine stops.
P1690 (M) Fuel Injection Pump CKP Sensor
Does Not Agree With ECM CKP
SensorProblem in fuel sync signal. Possible injection pump
timing problem. Low power, engine derated, or engine
stops.
BR/BEEMISSIONS CONTROL 25 - 13
EMISSIONS CONTROL (Continued)

INSPECTION - BATTERY
When battery is easily accessible, check the test
indicator (green dot), terminal tightness and felt
(grease) washer on battery posts. Recharge battery as
required to assure that the green dot is visible.
When battery is not easily accessible check battery
condition with a voltmeter at the jump start loca-
tions, or check the voltmeter on the instrument panel
(Fig. 11) or (Fig. 12). The reading should be at least
12.4 volts. Recharge battery as required.
NOTE: Refer to service information for proper bat-
tery charging rates and times.
INSPECTION - WIRING
The assembly plant has shipped all vehicles with
the interior lights and most electronic memories non-
functional by way of an Ignition Off Draw (IOD) fuse
removed. The purpose is to reduce the possibility of
battery run-down during shipping and storage.
Vehicles stored after prep should have the IOD
fuse that activates the accessories pulled to prevent
battery drain.
NOTE: Ensure that the IOD fuse is removed to pre-
vent battery drain and possible damage. Vehicles
stored for extended periods after prep should be
washed frequently, to prevent environmental dam-age, and reinspected for storage-related problems
before delivery.
(1) Install the IOD fuse as equipped. (ON vehicles
being delivered, remember to reset radio, clock, com-
pass, etc., as required.)
(2) Check routing and connections of all underhood
wiring-reroute and connect as required.
(3) Make sure the starter, generator and air condi-
tioning clutch wiring are correctly installed, routed,
and in the clips where provided.
(4) For predelivery storage, always pull the IOD
fuse that activates accessories.
Fig. 10 TRANSMISSION COOLER LINES AND
RADIATOR HOSE
1 - TRANSMISSION OIL COOLER LINES
2 - RADIATOR LOWER HOSE
Fig. 11 BATTERY VOLTAGE GAUGE DIESEL ENGINE
Fig. 12 BATTERY VOLTAGE GAUGE GAS ENGINE
BR/BENEW VEHICLE PREPARATION 30 - 7
UNDER HOOD (Continued)

AUTOMATIC TRANSMISSION - 44RE -
REMOVAL.........................21-330
AUTOMATIC TRANSMISSION - 46RE -
ASSEMBLY.........................21-510
AUTOMATIC TRANSMISSION - 46RE -
CLEANING.........................21-509
AUTOMATIC TRANSMISSION - 46RE -
DESCRIPTION......................21-478
AUTOMATIC TRANSMISSION - 46RE -
DISASSEMBLY......................21-503
AUTOMATIC TRANSMISSION - 46RE -
INSPECTION.......................21-510
AUTOMATIC TRANSMISSION - 46RE -
INSTALLATION......................21-518
AUTOMATIC TRANSMISSION - 46RE -
OPERATION........................21-480
AUTOMATIC TRANSMISSION - 46RE -
REMOVAL.........................21-502
AUTOMATIC TRANSMISSION - 47RE -
ASSEMBLY.........................21-681
AUTOMATIC TRANSMISSION - 47RE -
CLEANING.........................21-680
AUTOMATIC TRANSMISSION - 47RE -
DESCRIPTION......................21-649
AUTOMATIC TRANSMISSION - 47RE -
DISASSEMBLY......................21-674
AUTOMATIC TRANSMISSION - 47RE -
INSPECTION.......................21-681
AUTOMATIC TRANSMISSION - 47RE -
INSTALLATION......................21-688
AUTOMATIC TRANSMISSION - 47RE -
OPERATION........................21-651
AUTOMATIC TRANSMISSION - 47RE -
REMOVAL...........................21-673
AUTOMATIC TRANSMISSION -
DIAGNOSIS AND TESTING......21-143,21-314,
21-486,21-657
AUTOMATIC TRANSMISSION FLUID -
DESCRIPTION.........................0-5
AUTOMATIC TRANSMISSION FLUID -
OPERATION...........................0-5
AXLE - 216FBI - ADJUSTMENTS, FRONT . . . 3-17
AXLE - 216FBI - DESCRIPTION, FRONT....3-12
AXLE - 216FBI - INSTALLATION, FRONT....3-17
AXLE - 216FBI - OPERATION, FRONT......3-12
AXLE - 216FBI - REMOVAL, FRONT.......3-16
AXLE - 248FBI - ADJUSTMENTS, FRONT . . . 3-50
AXLE - 248FBI - DESCRIPTION, FRONT....3-45
AXLE - 248FBI - INSTALLATION, FRONT....3-50
AXLE - 248FBI - OPERATION, FRONT......3-45
AXLE - 248FBI - REMOVAL, FRONT.......3-50
AXLE - 248RBI - ADJUSTMENTS, REAR . . . 3-114
AXLE - 248RBI - DESCRIPTION, REAR....3-109
AXLE - 248RBI - INSTALLATION, REAR . . . 3-114
AXLE - 248RBI - OPERATION, REAR......3-109
AXLE - 248RBI - REMOVAL, REAR.......3-113
AXLE - 267RBI - ADJUSTMENTS, REAR . . . 3-145
AXLE - 267RBI - DESCRIPTION, REAR....3-140
AXLE - 267RBI - INSTALLATION, REAR . . . 3-145
AXLE - 267RBI - OPERATION, REAR......3-140
AXLE - 267RBI - REMOVAL, REAR.......3-144
AXLE - 286RBI - ADJUSTMENTS, REAR . . . 3-174
AXLE - 286RBI - DESCRIPTION, REAR....3-169
AXLE - 286RBI - INSTALLATION, REAR . . . 3-174
AXLE - 286RBI - OPERATION, REAR......3-169
AXLE - 286RBI - REMOVAL, REAR.......3-173
AXLE - 9 1/4 - ADJUSTMENTS, REAR.....3-84
AXLE - 9 1/4 - DESCRIPTION, REAR......3-77
AXLE - 9 1/4 - INSTALLATION, REAR......3-84
AXLE - 9 1/4 - OPERATION, REAR........3-77
AXLE - 9 1/4 - REMOVAL, REAR..........3-83
AXLE - DIAGNOSIS AND TESTING . . . 3-111,3-13,
3-142,3-171,3-46,3-80
AXLE - INSTALLATION, INTERMEDIATE....3-61
AXLE - REMOVAL, INTERMEDIATE........3-60
AXLE, 216FBI - FRONT.................3-25
AXLE, 248FBI - FRONT.................3-58
AXLE, 248RBI - REAR.................3-122
AXLE, 267RBI - REAR.................3-153
AXLE, 286 RBI - REAR................3-182
AXLE, 286RBI - REAR
.................3-182
AXLE, 9 1/4 - REAR
...................3-90
AXLE BEARINGS - INSTALLATION
. . 3-125,3-156,
3-185,3-95
AXLE BEARINGS - REMOVAL
. 3-125,3-156,3-185,
3-94
AXLE SHAFT SEALS - INSTALLATION
. 3-29,3-61,
3-94AXLE SHAFT SEALS - REMOVAL . 3-29,3-61,3-94
AXLE SHAFTS - INSTALLATION....3-125,3-156,
3-185,3-28,3-60,3-93
AXLE SHAFTS - INTERMEDIATE -
INSTALLATION........................3-28
AXLE SHAFTS - INTERMEDIATE -
REMOVAL...........................3-28
AXLE SHAFTS - REMOVAL . . . 3-125,3-156,3-185,
3-28,3-60,3-93
AXLE, SPECIAL TOOLS - FRONT..........3-58
AXLE VACUUM MOTOR - ASSEMBLY . . 3-33,3-65
AXLE VACUUM MOTOR - DESCRIPTION . . . 3-29,
3-62
AXLE VACUUM MOTOR - DISASSEMBLY . . . 3-33,
3-65
AXLE VACUUM MOTOR - INSTALLATION . . . 3-33,
3-65
AXLE VACUUM MOTOR - OPERATION . 3-30,3-62
AXLE VACUUM MOTOR - REMOVAL . . . 3-33,3-65
AXLES, SPECIAL TOOLS - FRONT.........3-25
BACK - BENCH SEAT - INSTALLATION,
SEAT .............................23-135
BACK - BENCH SEAT - REMOVAL, SEAT . . 23-135
BACK - SPLIT BENCH - INSTALLATION,
SEAT .............................23-136
BACK - SPLIT BENCH - REMOVAL, SEAT . 23-135
BACK COVER - INSTALLATION, SEAT....23-137
BACK COVER - REMOVAL, SEAT........23-137
BACK COVER - SPLIT BENCH -
INSTALLATION, SEAT.................23-138
BACK COVER - SPLIT BENCH -
REMOVAL, SEAT....................23-137
BACK RECLINER - INSTALLATION, SEAT . 23-138
BACK RECLINER - REMOVAL, SEAT.....23-138
BACKLITE - INSTALLATION............23-145
BACKLITE - REMOVAL................23-145
BACKLITE LATCH AND KEEPER -
INSTALLATION......................23-146
BACKLITE LATCH AND KEEPER -
REMOVAL.........................23-146
BACKLITE VENT GLASS - INSTALLATION . 23-147
BACKLITE VENT GLASS - REMOVAL.....23-147
BAFFLE - INSTALLATION, HVAC
HOUSING INLET.....................24-37
BAFFLE - REMOVAL, HVAC HOUSING
INLET..............................24-36
BALANCE - STANDARD PROCEDURES,
TIRE AND WHEEL.....................22-4
BALL JOINT - DIAGNOSIS AND TESTING,
LOWER.............................2-10
BALL JOINT - DIAGNOSIS AND TESTING,
UPPER..............................2-12
BALL JOINT - INSTALLATION, LOWER.....2-25
BALL JOINT - INSTALLATION, UPPER.....2-25
BAND OPERATION - DIAGNOSIS AND
TESTING, AIR CHECKING
TRANSMISSION CLUTCH.......21-147,21-318
BAND OPERATION - DIAGNOSIS AND
TESTING, AIR TESTING
TRANSMISSION CLUTCH.......21-490,21-661
BANDS - ADJUSTMENT . . 21-193,21-364,21-539,
21-709
BANDS - DESCRIPTION . . 21-192,21-363,21-538,
21-709
BANDS - OPERATION....21-192,21-364,21-539,
21-709
BAR - DESCRIPTION, STABILIZER....2-12,2-22,
2-30
BAR - DESCRIPTION, TRACK............2-23
BAR - DIAGNOSIS AND TESTING, TRACK . . . 2-23
BAR - INSTALLATION, STABILIZER . . . 2-12,2-23,
2-30
BAR - INSTALLATION, TRACK............2-23
BAR - OPERATION, STABILIZER . . 2-12,2-22,2-30
BAR - OPERATION, TRACK..............2-23
BAR - REMOVAL, STABILIZER . . . 2-12,2-22,2-30
BAR - REMOVAL, TRACK...............2-23
BARRELS - INSTALLATION, PANEL
OUTLET............................24-32
BARRELS - REMOVAL, PANEL OUTLET . . . 24-32
BASE BRAKE, SPECIFICATIONS
............5-2
BASE BRAKE SYSTEM - DIAGNOSIS AND
TESTING
.............................5-5
BASE BRAKES, SPECIAL TOOLS
...........5-4
BASE COAT/CLEAR COAT FINISH -
DESCRIPTION
......................23-129
BASE COAT/CLEAR COAT FINISH -
OPERATION
........................23-129BATTERIES - STANDARD PROCEDURE,
RKE TRANSMITTER...................8N-8
BATTERY - DESCRIPTION...............8F-6
BATTERY - DIAGNOSIS AND TESTING.....8F-7
BATTERY - INSPECTION................30-7
BATTERY - INSTALLATION..............8F-17
BATTERY - OPERATION.................8F-7
BATTERY - REMOVAL.................8F-17
BATTERY CABLE - DESCRIPTION........8F-19
BATTERY CABLE - OPERATION..........8F-20
BATTERY CABLES - DIAGNOSIS &
TESTING...........................8F-20
BATTERY CHARGING - STANDARD
PROCEDURE.........................8F-9
BATTERY ELECTROLYTE LEVEL -
STANDARD PROCEDURE, CHECKING......8F-8
BATTERY HOLDDOWN - DESCRIPTION....8F-18
BATTERY HOLDDOWN - INSTALLATION . . . 8F-18
BATTERY HOLDDOWN - OPERATION.....8F-18
BATTERY HOLDDOWN - REMOVAL.......8F-18
BATTERY, SPECIFICATIONS..............8F-6
BATTERY SYSTEM - CLEANING...........8F-5
BATTERY SYSTEM - DESCRIPTION........8F-1
BATTERY SYSTEM - DIAGNOSIS AND
TESTING............................8F-2
BATTERY SYSTEM - INSPECTION.........8F-5
BATTERY SYSTEM - OPERATION.........8F-2
BATTERY TEMPERATURE SENSOR -
DESCRIPTION.......................8F-29
BATTERY TEMPERATURE SENSOR -
INSTALLATION.......................8F-29
BATTERY TEMPERATURE SENSOR -
OPERATION.........................8F-29
BATTERY TEMPERATURE SENSOR -
REMOVAL..........................8F-29
BATTERY TRAY - DESCRIPTION.........8F-24
BATTERY TRAY - INSTALLATION.........8F-25
BATTERY TRAY - OPERATION...........8F-25
BATTERY TRAY - REMOVAL............8F-25
BEAM INDICATOR - DESCRIPTION, HIGH . . 8J-21
BEAM INDICATOR - DIAGNOSIS AND
TESTING, HIGH......................8J-22
BEAM INDICATOR - OPERATION, HIGH....8J-22
BEARING - CENTER BEARING
ADJUSTMENT, CENTER.................3-10
BEARING - DESCRIPTION, CENTER.......3-10
BEARING - DESCRIPTION, CLUTCH
RELEASE............................6-14
BEARING - DESCRIPTION, PILOT.........6-17
BEARING - INSTALLATION, CENTER.......3-10
BEARING - INSTALLATION, CLUTCH
RELEASE............................6-15
BEARING - INSTALLATION, HUB
...........2-9
BEARING - INSTALLATION, OUTPUT
SHAFT FRONT
....21-213,21-384,21-560,21-730
BEARING - INSTALLATION, OUTPUT
SHAFT REAR
.....21-213,21-384,21-560,21-731
BEARING - INSTALLATION, PILOT
........6-18
BEARING - INSTALLATION, PITMAN
......19-21
BEARING - OPERATION, CENTER
.........3-10
BEARING - OPERATION, CLUTCH
RELEASE
............................6-14
BEARING - OPERATION, PILOT
...........6-18
BEARING - REMOVAL, CENTER
...........3-10
BEARING - REMOVAL, CLUTCH RELEASE
. . . 6-15
BEARING - REMOVAL, HUB
..............2-9
BEARING - REMOVAL, OUTPUT SHAFT
FRONT
..........21-213,21-384,21-559,21-730
BEARING - REMOVAL, OUTPUT SHAFT
REAR
...........21-213,21-384,21-560,21-731
BEARING - REMOVAL, PILOT
............6-18
BEARING - REMOVAL, PITMAN
..........19-20
BEARING ADJUSTMENT, CENTER
BEARING - CENTER
....................3-10
BEARING AND CRANKSHAFT JOURNAL
CLEARANCE - STANDARD
PROCEDURE, CONNECTING ROD
........9-274
BEARING CLEARANCE - STANDARD
PROCEDURE, MAIN
...................9-275
BEARING FITTING - STANDARD
PROCEDURE, CONNECTING ROD
. . . 9-144,9-202,
9-88
BEARING FITTING - STANDARD
PROCEDURE, CRANKSHAFT MAIN
. . . 9-146,9-90
BEARING FITTING - STANDARD
PROCEDURE, MAIN
...............9-203,9-33
BR/BEINDEX 3
Description Group-Page Description Group-Page Description Group-Page