1997-2006 Jeep Wrangler TJ Service & Repair Manual

TABLE OF CONTENTS 1.0 INTRODUCTION .........................................................1 1.1 SYSTEM COVERAGE ...............................................1 1.2 SIX-STEP TROUBLESHOOTING PROCEDURE ..........................1 2.0 IDENTIFICATION OF SYSTEM .............................................1 3.0 SYSTEM DESCRIPTION AND FUNCTIONAL OPERATION ......................1 3.1 AIRBAG SYSTEM ...................................................1 3.1.1 PASSENGER AIRBAG ON-OFF SWITCH ........................2 3.1.2 SPECIAL TOOLS............................................3 3.1.3 DIAGNOSTIC TROUBLE CODES ..............................3 3.1.3.1 ACTIVE CODES ............................................3 3.1.3.2 STORED CODES ...........................................3 3.2 AUDIO SYSTEM ....................................................4 3.3 ELECTROCHROMIC COMPASS/TEMPERATURE MIRROR WITH LIGHTS ....4 3.4 ELECTRO/MECHANICAL INSTRUMENT CLUSTER (EMIC) .................7 3.4.1 SMART CLUSTER FEATURES ................................7 3.4.2 INSTRUMENT CLUSTER SELF TEST...........................7 3.5 VEHICLE COMMUNICATION ..........................................8 3.6 USING THE DRBIIIT .................................................9 3.6.1 DRBIIIT ERROR MESSAGES AND BLANK SCREEN ..............9 3.6.2 DRBIIIT DOES NOT POWER UP...............................9 3.6.3 DISPLAY IS NOT VISIBLE ....................................9 4.0 DISCLAIMERS, SAFETY, WARNING ........................................9 4.1 DISCLAIMERS......................................................9 4.2 SAFETY ...........................................................9 4.2.1 TECHNICIAN SAFETY INFORMATION ..........................9 4.2.2 VEHICLE PREPARATION FOR TESTING.......................10 4.2.3 SERVICING SUB-ASSEMBLIES ..............................10 4.2.4 DRBIIIT SAFETY INFORMATION..............................10 4.3 WARNINGS .......................................................10 4.3.1 VEHICLE DAMAGE WARNINGS ..............................10 4.3.2 ROAD TESTING A COMPLAINT VEHICLE ......................11 5.0 REQUIRED TOOLS AND EQUIPMENT .....................................11 6.0 GLOSSARY OF TERMS ..................................................11 7.0 DIAGNOSTIC INFORMATION AND PROCEDURES ...........................13 AIRBAG ACCELEROMETER 1 ....................................................14 INTERNAL 1 ...........................................................14 OUTPUT DRIVER 1 .....................................................14 SAFING SENSOR .......................................................14 STORED ENERGY FIRING 1..............................................14 STORED ENERGY LOGIC ................................................14 AIRBAG WARNING INDICATOR OPEN .....................................16 AIRBAG WARNING INDICATOR SHORT ....................................16 CLUSTER MESSAGE MISMATCH .........................................18 i

TABLE OF CONTENTS - Continued DRIVER SQUIB 1 CIRCUIT OPEN .........................................20 DRIVER SQUIB 1 CIRCUIT SHORT ........................................23 DRIVER SQUIB 1 SHORT TO BATTERY ....................................26 DRIVER SQUIB 1 SHORT TO GROUND ....................................29 LOSS OF IGNITION RUN - START .........................................32 LOSS OF IGNITION RUN ONLY ...........................................34 MODULE NOT CONFIGURED FOR PAB OFF SWITCH ........................36 NO CLUSTER MESSAGE ................................................39 NO PCI TRANSMISSION .................................................41 PASSENGER AIRBAG ON - OFF SWITCH SHORT TO BATTERY................43 PASSENGER AIRBAG ON - OFF SWITCH SHORT TO GROUND ................46 PASSENGER OFF INDICATOR CIRCUIT SHORTTO BATTERY .................49 PASSENGER OFF INDICATOR CIRCUIT SHORT TO GROUND .................52 PASSENGER SQUIB 1 CIRCUIT OPEN .....................................55 PASSENGER SQUIB 1 CIRCUIT SHORT ....................................58 PASSENGER SQUIB 1 SHORT TO BATTERY ................................60 PASSENGER SQUIB 1 SHORT TO GROUND ................................62 PASSENGER AIRBAG ON - OFF SWITCH OPEN .............................64 *AIRBAG INDICATOR ON WITHOUT ACTIVE TROUBLE CODES ................67 AUDIO ALL OUTPUTS SHORT - BASE AUDIO SYSTEM .............................68 ALL OUTPUTS SHORT - PREMIUM AUDIO SYSTEM .........................70 CASSETTE PLAYER INOP ...............................................73 CD MECHANICAL FAILURE ..............................................73 *AM/FM SWITCH INOPERATIVE ...........................................73 *ANY STATION PRESET SWITCH INOPERATIVE .............................73 *BALANCE INOPERATIVE ................................................73 *CD EJECT SWITCH INOPERATIVE........................................73 *EQUALIZER INOPERATIVE ..............................................73 *FADER INOPERATIVE ..................................................73 *FF/RW SWITCH INOPERATIVE ...........................................73 *HOUR/MINUTE SWITCHES INOPERATIVE .................................73 *PAUSE/PLAY SWITCH INOPERATIVE .....................................73 *PWR SWITCH INOPERATIVE ............................................73 *SCAN SWITCH INOPERATIVE............................................73 *SEEK SWITCH INOPERATIVE ............................................73 *SET SWITCH INOPERATIVE .............................................73 *TAPE EJECT SWITCH INOPERATIVE......................................73 *TIME SWITCH INOPERATIVE ............................................73 *TUNE SWITCH INOPERATIVE............................................73 CD PLAY FAILURE ......................................................75 CD READ FAILURE .....................................................76 CD TEMPERATURE HIGH ................................................77 LOW VOLTAGE LEVEL ..................................................78 NO ANTENNA CONNECTION .............................................79 POWER AMP SHUTDOWN - BASE AUDIO SYSTEM ..........................80 POWER AMP SHUTDOWN - PREMIUM AUDIO SYSTEM ......................82 CHIME *CHIME INOPERATIVE AT ALL TIMES ......................................85 *CHIME INOPERATIVE WITH DRIVER SEAT BELT UNFASTENED...............86 *CHIME INOPERATIVE WITH EXTERIOR LAMPS ON AND DRIVER DOOR OPEN .87 ii

TABLE OF CONTENTS - Continued *CHIME INOPERATIVE WITH KEY IN IGNITION, DRIVER’S DOOR OPEN ........88 *CHIME SOUNDS WITH DRIVER SEAT BELT FASTENED......................91 *CHIME SOUNDS WITH DRIVER’S DOOR OPEN, KEY REMOVED ..............93 COMMUNICATION *NO RESPONSE FROM AIRBAG CONTROL MODULE ........................94 *NO RESPONSE FROM CONTROLLER ANTILOCK BRAKE ....................96 *NO RESPONSE FROM INSTRUMENT CLUSTER ............................98 *NO RESPONSE FROM PCM (PCI BUS) ...................................100 *NO RESPONSE FROM PCM (SCI ONLY) ..................................101 *NO RESPONSE FROM RADIO ..........................................104 *NO RESPONSE FROM SENTRY KEY IMMOBILIZER MODULE ...............106 *NO RESPONSE FROM TRANSMISSION CONTROL MODULE ................108 *PCI BUS COMMUNICATION FAILURE ....................................111 COMPASS/MINI-TRIP COMPUTER *COMPASS/TEMP MODULE WILL NOT CALIBRATE .........................113 *COMPASS/TEMPERATURE MODULE INOPERATIVE ........................114 *TEMPERATURE DISPLAY INACCURATE OR INOPERATIVE ..................115 ELECTRICALLY HEATED SYSTEMS *REAR DEFFOGER RELAY OPEN ........................................117 *REAR DEFOGGER RELAY SHORT TO VOLTAGE ...........................119 *REAR DEFOGGER SWITCH INDICATOR INOPERATIVE .....................120 *REAR WINDOW DEFOGGER GRID INOPERATIVE .........................121 INSTRUMENT CLUSTER ACM MESSAGE NOT REC’D BY MIC......................................125 AIR BAG LAMP CIRCUIT OPEN ..........................................126 AIR BAG LAMP CIRCUIT SHORT .........................................127 CHECKSUM FAILURE ..................................................128 PANEL DIMMER OPEN .................................................129 PCM MESSAGE NOT REC’D BY MIC......................................131 SKIM MESSAGE NOT REC’D BY MIC .....................................132 *9NO BUS9 IN VF DISPLAY ..............................................133 *9NO FUSE9 IN VF DISPLAY .............................................134 *4WD INDICATOR INOPERATIVE .........................................135 *ABS INDICATOR INOPERATIVE .........................................138 *AIR BAG INDICATOR INOPERATIVE .....................................139 *ALL GAUGES INOPERATIVE ............................................140 *ANY PCI BUS INDICATOR INOPERATIVE .................................142 *AXLE LOCK INDICATOR PROBLEMS .....................................143 *BRAKE WARNING INDICATOR ALWAYS ON ...............................146 *BRAKE WARNING INDICATOR INOPERATIVE .............................147 *FOG LAMP INDICATOR INOPERATIVE - DOMESTIC ........................149 *HIGH BEAM INDICATOR INOPERATIVE...................................150 *ONE GAUGE INOPERATIVE ............................................151 *PANEL DIMMNG INOPERATIVE .........................................152 *REAR FOG LAMP INDICATOR INOPERATIVE - BUX ONLY...................153 *SEAT BELT INDICATOR NOT OPERATING PROPERLY ......................154 *SPEEDOMETER INACCURATE OR INOPERATIVE ..........................156 *VF DISPLAY INOPERATIVE .............................................157 *VF ODOMETER INOPERATIVE WITH DOOR OPEN .........................158 iii

TABLE OF CONTENTS - Continued INTERIOR LIGHTING *COURTESY LAMPS INOPERATIVE - ALL LAMPS ...........................160 *COURTESY LAMPS ON AT ALL TIMES ...................................161 *ILLUMINATED ENTRY INOPERATIVE .....................................163 VERIFICATION TESTS VERIFICATION TESTS ..................................................164 8.0 SYSTEM COMPONENT LOCATIONS......................................167 8.1 DATA LINK CONNECTOR ..........................................167 8.2 AIRBAG .........................................................167 8.2.1 DRIVER AIRBAG MODULE & CLOCKSPRING .................167 8.2.2 DRIVER/PASSENGER AIRBAG MODULES & MECHANICAL INSTRUMENT CLUSTER ...................................168 8.2.3 AIRBAG CONTROL MODULE AND PASSENGER AIRBAG ON/OFF SWITCH .................................................168 8.3 FUSE BLOCK ....................................................169 8.4 INSTRUMENT CLUSTER ...........................................169 8.4.1 FRONT VIEW ............................................169 8.4.2 REAR VIEW..............................................170 8.5 POWER DISTRIBUTION CENTER (PDC) ..............................170 8.6 POWERTRAIN CONTROL MODULE..................................171 9.0 CONNECTOR PINOUTS ................................................173 AIRBAG CONTROL MODULE ............................................173 AMBIENT TEMPERATURE SENSOR ......................................173 AXLE LOCK SWITCH (OFF-ROAD PACKAGE) ..............................173 BRAKE WARNING INDICATOR SWITCH ...................................174 CLOCKSPRING C2 .....................................................174 COMPASS/TEMPERATURE MIRROR ......................................174 CONTROLLER ANTILOCK BRAKE ........................................175 DATA LINK CONNECTOR ...............................................175 DRIVER AIRBAG SQUIB 1 ...............................................176 FRONT LOCKER INDICATOR SWITCH (OFF-ROAD PACKAGE) ...............176 FRONT LOCKER PUMP (OFF-ROAD PACKAGE) ............................176 FUSES (FUSE/RELAY BLOCK) ...........................................178 IGNITION SWITCH .....................................................178 INSTRUMENT CLUSTER C1 .............................................179 INSTRUMENT CLUSTER C2 .............................................179 LEFT FRONT SPEAKER ................................................179 LEFT REAR SPEAKER..................................................180 MULTI-FUNCTION SWITCH C1 ...........................................180 PASSENGER AIRBAG ON ...............................................180 PASSENGER AIRBAG SQUIB 1 ..........................................181 FUSES (PDC) .........................................................183 FRONT LOCKER RELAY (OFF-ROAD PACKAGE) ...........................183 REAR LOCKER RELAY (OFF-ROAD PACKAGE).............................183 REAR WINDOW DEFOGGER RELAY......................................184 POWERTRAIN CONTROL MODULE C1 ....................................185 POWERTRAIN CONTROL MODULE C2 ....................................186 POWERTRAIN CONTROL MODULE C3 ....................................187 iv

TABLE OF CONTENTS - Continued RADIO ...............................................................188 REAR LOCKER INDICATOR SWITCH (OFF-ROAD PACKAGE) .................188 REAR LOCKER PUMP (OFF-ROAD PACKAGE) .............................188 REAR WINDOW DEFOGGER SWITCH (HARD TOP) .........................189 RIGHT FRONT SPEAKER ...............................................189 RIGHT REAR SPEAKER ................................................189 SEAT BELT SWITCH (EXCEPT LHD EXPORT) ..............................189 SENTRY KEY IMMOBILIZER MODULE ....................................189 SUBWOOFER .........................................................190 TRANSFER CASE SWITCH (EXCEPT OFF-ROAD PACKAGE) .................190 TRANSFER CASE SWITCH (OFF-ROAD PACKAGE) .........................190 TRANSMISSION CONTROL MODULE .....................................191 TRANSMISSION CONTROL MODULE .....................................192 10.0 SCHEMATIC DIAGRAMS................................................193 10.1 AIRBAG SYSTEM .................................................193 10.2 AUDIO SYSTEM ..................................................194 10.2.1 BASE AUDIO SYSTEM.....................................194 10.2.2 PREMIUM AUDIO SYSTEM .................................195 10.3 CHIME SYSTEM ..................................................196 10.4 COMPASS/TEMPERATURE MIRROR .................................196 10.5 INSTRUMENT CLUSTER ...........................................197 10.5.1 INSTRUMENT CLUSTER/AXLE LOCKER SYSTEM .............197 10.6 INTERIOR LIGHTING ..............................................197 10.7 REAR DEFOGGER ................................................198 10.8 VEHICLE COMMUNICATIONS.......................................199 v

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1997-2006 Jeep Wrangler TJ Service & Repair Manual

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