* 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 ____________________________________________________________________ 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 _____________________________________________________________________ ® 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!!! WHAT ELSE YOU WANT?? JUST GO FOR IT!! ______________________________________________________________________ IF IT IS NOT AS DESCRIBED, FULL REFUND WILL BE GRANTED. NO QUESTIONS ASKED!! THATS OUR PROMISE!!