NOTE: All active codes must be resolved before diagnosing store
codes.
1) Raise and support vehicle. Start engine and let idle with
transmission in PARK position. Wiggle wiring harness and connectors of
air bag system and rotate steering wheel from stop to stop.
2) Visually inspect related wire harness connectors. Look for
broken, bent, pushed out, spread, corroded or contaminated terminals.
Also, look for chafed, pierced, pinched or partially broken wires.
3) Check for trouble codes as you work through system. If
stored trouble code becomes active, perform appropriate diagnostic
test. If stored code is reproducible, repair or replace wiring
harness, harness connector or terminals or replace component as
necessary.
CLUSTER MESSAGE MISMATCH
NOTE: Perform AIR BAG VERIFICATION TEST after
all repairs. Each time a connector is disconnected, inspect
it to ensure it is in good condition. Always focus on circuit
being tested. Dirt, water and corrosion, are most common
problems in connectors. Due to manufacturer changes in wire
colors, use terminal identification whenever possible.
1) If AIR BAG warning light is on, go to next step. If AIR
BAG warning light is not on, go to step 5).
2) Using DRB, select PASSIVE RESTRAINTS, AIRBAG and MONITOR
DISPLAY. Read WARNING LAMP STATUS. If DRB does not display MIC LAMP
STATUS ON, replace instrument cluster. If DRB displays MIC LAMP STATUS
ON, go to next step.
3) If DRB displays ACM LAMP REQUEST: ON, go to next step. If
DRB does not display ACM LAMP REQUEST: ON, replace instrument cluster.
4) If there are no potential causes for this DTC remaining,
ACM is assumed to be defective. Replace ACM. See
AIR BAG CONTROL MODULE (ACM) under REMOVAL & INSTALLATION.
NOTE: If AIR BAG warning light is defective, instrument cluster
will flash seat belt light for 30 seconds starting 10 seconds
after bulb check stops.
5) Using DRB, read air bag control module active codes
(messages). If CLUSTER MISMATCH is only active message, go to next
step. If other messages are present, go to appropriate diagnostic test
to continue diagnosis.
6) If seat belt warning light flashes for 30 seconds after
bulb check is complete, replace instrument cluster. If seat belt
warning light does not flashes for 30 seconds after bulb check is
complete, go to next step.
7) Using DRB, select PASSIVE RESTRAINTS, AIRBAG and MONITOR
DISPLAY. Read WARNING LAMP STATUS. If DRB displays ACM LAMP REQUEST:
OFF, go to next step. If DRB does not display ACM LAMP REQUEST: OFF,
replace instrument cluster.
8) If DRB displays MIC LAMP REQUEST: OFF, go to next step. If
DRB does not display MIC LAMP REQUEST: OFF, replace instrument
cluster.
9) If there are no potential causes for this DTC remaining,
ACM is assumed to be defective. Replace ACM. See
AIR BAG CONTROL MODULE (ACM) under REMOVAL & INSTALLATION.
DRIVER SQUIB CIRCUIT OPEN
NOTE: Perform AIR BAG VERIFICATION TEST after
all repairs. Each time a connector is disconnected, inspect
connector terminal No. 14 (Light Green/Yellow wire). If voltage is
less than 10 volts, repair open in Light Green/Yellow wire. If voltage
is more than 10 volts, replace ACM.
4) If there are no potential causes for this DTC remaining,
ACM is assumed to be defective. Replace ACM. See
AIR BAG CONTROL MODULE (ACM) under REMOVAL & INSTALLATION.
5) Turn ignition off. Turn PAD switch to the ON position (if
equipped). Using an ohmmeter, check resistance at fused ignition
switch output RUN/START circuit between fuse No. 19 and ground. If
resistance is more than 5 ohms, replace fuse. If resistance is less
than 5 ohms, disconnect battery and wait 2 minutes before proceeding.
Disconnect ACM connector. Using an ohmmeter, check resistance between
ground and ACM connector terminal No. 14 (Light Green/Yellow wire). If\
resistance is less than 5 ohms, go to next step. If resistance is more
than 5 ohms, replace ACM and fuse No. 19.
6) Disconnect PAD switch. Using an ohmmeter, check resistance
between ground and ACM connector terminal No. 14 (Light Green/Yellow
wire). If resistance is less than 5 ohms, repair short to ground in
Light Green/Yellow wire and replace fuse No. 19. If resistance is more
than 5 ohms, replace fuse No. 19 located in junction block and go to
next step.
7) If there are no potential causes for this DTC remaining,
ACM is assumed to be defective. Replace ACM. See
AIR BAG CONTROL MODULE (ACM) under REMOVAL & INSTALLATION.
MISSING OR INVALID VIN MESSAGE
NOTE: Perform AIR BAG VERIFICATION TEST after
all repairs. Each time a connector is disconnected, inspect
it to ensure it is in good condition. Always focus on circuit
being tested. Dirt, water and corrosion, are most common
problems in connectors. Due to manufacturer changes in wire
colors, use terminal identification whenever possible.
1) Using DRB, select ENGINE PCM. If DRB displays NO RESPONSE
from PCM, go to NO RESPONSE FROM POWERTRAIN CONTROL MODULE under
VEHICLE COMMUNICATIONS. If DRB does not display NO RESPONSE from PCM
and vehicle is a Club Cab (BE) model, go to next step. If vehicle is
not a Club Cab (BE model), go step 3).
2) Using DRB, select PASSIVE RESTRAINTS, AIRBAG AND MONITORS.
Select VIN type (7th digit of VIN; VIN 2 or 3 on Club Cab). If DRB
does not display PCM VIN: BE, replace Powertrain Control Module (PCM).\
If DRB displays PCM VIN: BE, replace ACM.
3) Using DRB, select PASSIVE RESTRAINTS, AIRBAG AND MONITORS.
Select VIN type (7th digit of VIN; VIN 6 on Standard Cab). If DRB does\
not display PCM VIN: BR, replace Powertrain Control Module (PCM). If
DRB displays PCM VIN: BR, replace ACM.
NO CCD COMMUNICATION
NOTE: Perform AIR BAG VERIFICATION TEST after
all repairs. Each time a connector is disconnected, inspect
it to ensure it is in good condition. Always focus on circuit
being tested. Dirt, water and corrosion, are most common
problems in connectors. Due to manufacturer changes in wire
colors, use terminal identification whenever possible.
Using DRB, read active codes. If DRB displays NO CCD
COMMUNICATION as an active code, replace ACM. If DRB does not display
NO CCD COMMUNICATION as an active code, go to
REPAIRING STORED TROUBLE CODES .
NO CLUSTER CCD MESSAGE
colors, use terminal identification whenever possible.
1) If seat belt light is on, go to step 4). If seat belt
light is not on, go to next step.
2) Using DRB, select PASSIVE RESTRAINTS, AIRBAG AND MONITOR
DISPLAY. Read WARNING LAMP STATUS. If DRB does not display MIC S/B
LAMP STATE: OFF, replace instrument cluster. If DRB displays MIC S/B
LAMP STATE: OFF, go to next step.
3) If DRB displays ACM S/B LAMP REQUEST: OFF, replace ACM. If
DRB does not display ACM S/B LAMP REQUEST: OFF, replace instrument
cluster.
4) Using DRB, select PASSIVE RESTRAINTS, AIRBAG AND MONITOR
DISPLAY. Read WARNING LAMP STATUS. If DRB does not display MIC S/B
LAMP STATE: ON, replace instrument cluster. If DRB displays MIC S/B
LAMP STATE: ON, go to next step.
5) Using DRB, read WARNING LAMP STATUS. If DRB does not
display ACM S/B LAMP REQUEST: ON, replace instrument cluster. If DRB
displays ACM S/B LAMP REQUEST: ON, replace ACM.
REPAIRING VIN MESSAGE MISMATCH
NOTE: Perform AIR BAG VERIFICATION TEST after
all repairs. Each time a connector is disconnected, inspect
it to ensure it is in good condition. Always focus on circuit
being tested. Dirt, water and corrosion, are most common
problems in connectors. Due to manufacturer changes in wire
colors, use terminal identification whenever possible.
1) Using DRB, select ENGINE (PCM). If DRB displays NO
RESPONSE FROM PCM, perform REPAIRING SHORT TO BATTERY under VEHICLE
COMMUNICATIONS. If DRB does not display NO RESPONSE FROM PCM, and
vehicle is a Club Cab (BE), go to next step. If DRB does not display
NO RESPONSE FROM PCM, and vehicle is a Standard Cab (BR), go to step
3).
2) Using DRB, select PASSIVE RESTRAINTS, AIRBAG AND MONITOR
DISPLAY. Select VIN type to identify 7th digit of VIN (VIN 2 or 3 is
for Club Cab; VIN B is for a Standard Cab). If DRB does not display
PCM VIN: BE, replace powertrain control module. If DRB displays PCM
VIN: BE, replace ACM.
3) Using DRB, select PASSIVE RESTRAINTS, AIRBAG AND MONITOR
DISPLAY. Select VIN type to identify 7th digit of VIN (VIN B is for a
Standard Cab). If DRB does not display PCM VIN: BE, replace powertrain
control module. If DRB displays PCM VIN: BE, replace ACM.
WARNING LAMP CIRCUIT OPEN/SHORTED
NOTE: Perform AIR BAG VERIFICATION TEST after
all repairs. Each time a connector is disconnected, inspect
it to ensure it is in good condition. Always focus on circuit
being tested. Dirt, water and corrosion, are most common
problems in connectors. Due to manufacturer changes in wire
colors, use terminal identification whenever possible.
1) Using DRB, select MECHANICAL INSTRUMENT CLUSTER (MIC). If\
DRB displays NO RESPONSE FROM MIC, go to
NO RESPONSE FROM INSTRUMENT CLUSTER under VEHICLE COMMUNICATIONS. If
DRB does not display NO RESPONSE FROM MIC, go to next step.
2) Using DRB, select PASSIVE RESTRAINTS AIRBAG AND MONITOR
DISPLAY. Read WARNING LAMP status. If DRB does not display MIC BULB
STATE, replace instrument cluster. If DRB displays MIC BULB STATE, go
to next step.
3) If DRB does not display MIC DRIVER STATE OK, replace
instrument cluster. If DRB displays MIC DRIVER STATE OK, go to next
BR3500 (8 Stud Dual Wheel)........................ 145 (195)\
\
\
\
\
\
BATTERY SPECIFICATIONS
Vehicle is factory equipped with a maintenance free battery.
The top of the battery is permanently sealed, and water never has to
be added, and periodic maintenance is not required either. But,
periodically check the battery terminals and battery hold-down bracket
for corrosion. Replace with a battery of the same group number as
shown on original battery's label.
CAUTION: When battery is disconnected, vehicles equipped with
computers may lose memory data. When battery power is
restored, driveability problems may exist on some vehicles.
These vehicles may require a relearn procedure. See COMPUTER
RELEARN PROCEDURES article in the GENERAL INFORMATION
section.
CAUTIONS & WARNINGS
SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG)
NOTE: See the AIR BAGS article in the ACCESSORIES/SAFETY EQUIPMENT
Section.
Modifications or improper maintenance, including incorrect
removal and installation of the Supplemental Restraint System (SRS),
can adversely affect system performance. DO NOT cover, obstruct or
change the steering wheel horn pad in any way, as such action could
cause improper function of the system. Use only plain water when
cleaning the horn pad. Solvents or cleaners could adversely affect the
air bag cover and cause improper deployment of the system.
WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all warnings and service precautions. See
appropriate AIR BAGS article in ACCESSORIES/SAFETY EQUIPMENT.
WARNING: Any maintenance performed on or near the components of the
SRS must be performed only by an authorized dealer.
Do not permit anyone else to service, inspect maintain, or
service any SRS components or wiring. Similarly, no part of
the SRS should ever be handled or disposed of by anyone
except an authorized dealer.
Improper work on the SRS components or wiring could result in
inadvertent deployment of the airbags or could render the SRS
system inoperative. Either situation could result in serious
injury
WARNING: If the car has had any front-end damage, have the SRS system
inspected by an authorized dealer to ensure it is working
properly.
WARNING: If any of the following conditions occur, the SRS is not
working properly. Immediately have it inspected by an
authorized dealer:
* The SRS warning light does not illuminate when you start
the car.
* The SRS warning light does not go off after about 7 seconds.
* The SRS warning light illuminates while driving.
F1 - Not Used
F2 - 30 Amp (Lt. Green)
Blower Motor
CB1 - 30 Amp (Circuit Breaker)
Power Windows
CB2 - 30 Amp (Circuit Breaker)
Power Seats
1 - 20 Amp (Yellow)
Power Outlet
2 - Not Used
3 - Not Used
4 - Not Used
5 - 20 Amp (Yellow)
Cigar Lighter
6 - 20 Amp (Yellow)
Turn Signal Flasher
7 - 15 Amp (Lt. Blue)
Radio
8 - 20 Amp (Yellow)
Windshield Wipers
9 - 10 Amp (Red)
Fuel Pump Relay, A/C Compressor Clutch Relay
Automatic Shutdown Relay, Transmission Overdrive
Solenoid, EGR Solenoid, Powertrain Control Module (PCM)
Ignition Module
High Pressure Fuel Shut-Off Solenoid Relay (CNG Models Only)
EGR Solenoid (CNG Models Only)
10 - Not Used
Vehicle Speed Control
11 - 10 Amp (Red)
Buzzer, Overhead Console
12 - 15 Amp (Lt. Blue)
Airbag Diagnostic Module, Cluster, Message Center,
13 - 5 Amp (Tan)
Illumination
14 - 20 Amp (Yellow)
RWAL and ABS Module
15 - 15 Amp (Lt. Blue)
Automatic Day/Night Mirror, Back-up Lights,
Daytime Running Lamps
16 - 15 Amp (Lt. Blue)
Airbag Diagnostic Module
17 - 15 Amp (Lt. Blue)
Ignition Off Draw, Radio and Clock Memory
18 - 15 Amp (Lt. Blue)
Parking Lamps
19 - 20 Amp (Yellow)
Power Door Locks
20 - 15 Amp (Lt. Blue)
Stop Lamps
POWER DISTRIBUTION CENTER