Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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This PI was superseded to advise dealers there is no repair for early oil change messages or erratic OlM operation. Please discard PIP4540B. The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI. Condition I Concern: A dealer may encounter a customer concern of the oil life monitor (OlM) percentage dropping too qUickly, or an early oil change message. A customer utilizing the oil life monitor may be directed to change the oil at (or near) 1000 mile intervals. Recommendation Ilnstructions: Please do not replace the IPC or ECM for an early oil change message. Oil life monitoring is dependent on vehicle use. Oil life monitoring and change intervals will differ depending on how the vehicle is driven. Please complete the current SI diagnostics for any trouble code or symptom found. Engine drivability concerns may induce early oil change messages or erratic OlM operation. Dealers should verify there are no intake or exhaust leaks by completing Charge Air Cooler Diagnosis (Full System Air leak Test and the Induction System Smoke Test). Discuss driving habits with the customer. The main contributor to early or erratic oil change messages may be some of the customers driving habits. Drive cycles that include short trip, stop and go, and extended idle times are a few of the contributors to early oil change messages. Customers with more exhaust regenerations (due to driving habits) are more susceptible to qUicker oil change messages. There is no repair for early oil change messages or erratic OlM operation. If a dealer is to encounter a vehicle with a customer concern of early oil change complete a Field Product Report using the newest version of bulletin 02-00-89-002. Note: If an oil analysis has been completed fuel dilution should not be over 12%.

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Description The Engine Cranks but Does Not Run diagnostic table assumes that the battery condition and the engine cranking speed are OK. If the battery condition and the cranking speed are not OK, refer to Diagnostic System Check – Engine Electrical in Engine Electrical for diagnosis. Make sure that there is adequate fuel in the fuel tanks. Diagnostic Aids • Check the duct work between the mass air flow (MAF) sensor and the throttle body for air leaks. • A malfunctioning MAF sensor may cause a no start or a stall after start. If you suspect this, disconnect the MAF sensor. The powertrain control module (PCM) will default to the speed density in order to calculate the load and the air flow. If this corrects the condition and the connections are OK, replace the MAF sensor. If the steps above check OK, refer to Symptoms . Test Description The numbers below refer to the step numbers on the diagnostic table. 4. It may be necessary to connect a battery charger to the battery for this step. If the battery state of charge is low, the scan tool may reset during the cranking test. 5. This step tests the ignition relay for proper operation. The ignition relay supplies voltage to the injectors and the ignition coils. When the ignition relay is not operating properly, a no start condition occurs. If the test lamp does not illuminate, this indicates the ignition relay is not suppling a voltage to the fuses. 6. The crankshaft position (CKP) sensor is located above the starter. 7. The camshaft position (CMP) sensor is located at the rear of the engine behind the intake manifold. 8. The ignition feed circuit for the CMP and CKP sensors is internally connected within the PCM. A short to ground on either circuit will cause a no start condition. 10. The fuel cap may need to be removed in order to hear if the fuel pump is operating. 12. At this point the engine should start. Refer to Hard Start for further diagnosis.

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1. Remove the auxiliary battery. For additional information, refer to Section 414-01. 2. Remove the air cleaner assembly. For additional information, refer to Section 303-12. 3. Remove the cooling fan-blade, clutch and shroud, 6.0L diesel engine. For additional information, refer to Section 303-03. 4. Remove the coolant reservoir. For additional information, refer to Section 303-03. 5. Remove the upper radiator hose. 6. NOTE: Engine side shown, charge air cooler (CAC) side similar. Remove the turbocharger-to-charge air cooler pipe. 7. NOTE: Engine side shown, charge air cooler side similar. Remove the charge air cooler-to-engine pipe. Vehicles with dual generators 8. Remove the accessory drive belt. 9. Remove the bolt and the accessory drive belt tensioner. 10. Remove the accessory drive belt. 11. Remove the bolts, bracket and accessory drive belt idler pulley. 12. Remove the bolts and the accessory drive belt tensioner. 13. Disconnect the wire retainer, generator electrical connector and B+ wire. 14. Remove the bolts and the generator with mounting bracket. Vehicles with single generator 15. Remove the accessory drive belt. All vehicles 16. Position the boot back and disconnect the generator B+ wire and electrical connector. 17. Remove the three bolts and the generator. 18. Remove the turbocharger and the turbocharger pedestal. For additional information, refer to Section 303-04F. 19. Remove the bolts and position the heater hose tube aside. ? Remove and discard the O-ring. 20. Disconnect the manifold absolute pressure (MAP) sensor hose. 21. Disconnect the engine coolant vent hose. 22. Remove the fuel injector control module. For additional information, refer to Section 303-14C. 23. Disconnect the wiring retainer, injector pressure regulator and injector control pressure (ICP) sensor electrical connector. 24. Disconnect the exhaust gas recirculation (EGR) valve electrical connector. 25. Disconnect the oil pressure sensor electrical connector. 26. Disconnect the oil temperature sensor electrical connector.

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Removal 1. Disconnect positive and negative battery cables from battery terminals. Remove the retaining bolt from battery cable support-to-frame bracket at left front of engine. Secure cables to engine . 2. Loosen radiator drain cock and drain coolant from radiator . Refer to Section 03-03. 3. Disconnect PCV closure hose at engine air cleaner outlet tube (9B659) . Release clips retaining air cleaner tap. Loosen air cleaner outlet duct clamp at throttle body (9E926) and remove air cleaner top and air cleaner outlet tube together. 4. Remove vacuum supply hoses from: a. Power brake booster (2005). b. Cruise control at check valve near throttle linkage (if equipped). c. Manifold absolute pressure sensor (MAP sensor) (9F479). d. Heater and air conditioner supply hose at A/C vacuum check valve (19A563) near A/C vacuum reservoir tank and bracket (19A566) . 5. Secure vacuum hoses to engine. 6. Remove upper radiator hose (8260) and lower radiator hose (8286) . 7. Disconnect power steering pressure switch (PSP switch) (3N824) . 8. Remove power steering pressure hose (3A719) from clips in fan shroud (8146) . 9. Remove two screws holding fan shroud to radiator and pull fan shroud out of lower clips. Rest fan shroud on radiator fan. 10. Disconnect automatic transmission cooler lines, if so equipped, from radiator . 11. Remove two radiator upper retaining bolts and lift radiator from core support. 12. Remove fan shroud from engine compartment. 13. Disconnect fuel charge wiring connectors at top center of dash panel. 14. Loosen clamps and disconnect heater supply hose at hot water heater elbow connection (18599) in lower intake manifold. Disconnect heater return hose at water pump. 15. Loosen retaining bolt and disconnect steering column at intermediate shaft. 16. Determine which type of air conditioning refrigerant is used in the vehicle. Follow the procedure for that specific refrigerant as outlined in Section 12-00 to drain air conditioning system and recycle refrigerant. NOTE: All openings in the air conditioning system must be capped to keep dirt, foreign material, and excess moisture out of the system. 17. Disconnect air conditioner liquid line at condenser and suction line from accumulator. 18. Disconnect canister purge hose at fuel vapor canister (9D653) under engine air cleaner base and secure to engine . 19. Release fuel system pressure as outlined in Section 03-04A. 20. Remove oil level indicator (7A020) . 21. Place a piece of 4×4 wooden block or other suitable material between the rear of the engine cradle and the forward surface of the oil pan sump to keep the engine from tilting rearward and damaging components when removing the transmission. 22. Remove transmission as outlined in Section 07-01 for automatic transmission and Section 07-03 for manual transmission. 23. Loosen and remove exhaust manifold stud nuts. Remove bolts retaining three-way catalytic converter (5E212) to muffler (5230) . Disconnect and remove muffler and three-way catalytic converter . Refer to Section 09-00 for specific removal and installation procedures. 24. Remove wheel hub bolt nuts (1012) and remove both front wheel (1007) and tire assemblies. 25. Remove dash panel ground cables (14303) . One is located on cylinder head just behind power steering pump (3A674) . The other is located just above where exhaust manifold (9430) and three-way catalytic converter connect. 26. Remove nuts and disconnect front stabilizer bar (5482) from front suspension lower arms (3079) . Discard nuts. 27. Remove front disc brake calipers (2B120) as outlined in Section 06-03 and secure to front suspension upper arms (3083) 28. Disconnect fuel lines along left frame rail near engine mounts as outlined in Section 03-04A. 29. Position a jack under front suspension lower arm and raise arm until tension is applied to front coil spring (5310) . Remove bolt and nut retaining spindle to front suspension upper arm ball joint. Slowly lower jack under front suspension lower arm to disconnect spindle from ball joint. 30. Position Drive Train Removal Lift 109-00002 or equivalent under crossmember and engine . 31. Lower vehicle until crossmember rests on removal lift. Place wood blocks under front crossmember and rear of cylinder block to keep engine and crossmember assembly level. Install safety chains around crossmember and lift. 32. Remove three nuts from bolts that retain engine crossmember assembly to frame on each side of vehicle.

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A/C and heating system components, engine compartment CAUTION! Parts marked with an asterisk (*) can be serviced only after the A/C refrigerant system has been discharged by a certified technician using EPA-approved refrigerant recovery and recycling equipment safety measures, A/C refrigerant system (R-134a), safety measures . Dust and pollen filter Where applicable 2- . Plenum cover Removing/installing 3- – -”> Evaporator water drain valve Located behind bulkhead insulation Removing/installing 4- . Heater core connections and vacuum hose guide 5- . Fresh Air/Recirculating Flap Two-Way Valve N63 Valve open when voltage applied Vacuum hose layout 6- . Coolant Fan Control (FC) Control Module J293 With fuse Fuse Strip S88 (1993 m.y.) With fuses Coolant Fan Second and Third Speed Fuse S107 and Coolant Fan First Speed and A/C Clutch Fuse S108 (1994 m.y. micro ) Connector terminal identification: micro 09.93 Fig. 5 Connector terminal identification of Coolant Fan Control (FC) Control Module J293 ( 09.93) 10.93 micro Fig. 6 Connector terminal identification of Coolant Fan Control (FC) Control Module J293 (10.93 ) 7- . Vacuum reservoir Insert vacuum hose 30 mm (1.2 in.) into reservoir Removing/installing Fig. 2 Removing and installing evaporator water drain valve Vacuum hose layout Fig. 7 Removing and installing vacuum reservoir