John Deere XUV590E,= XUV590E S4 XUV590M and XUV590M S4 Gator Utility Vehicles Technical Manual TM149719 20JUL22

Introduction
Foreword
Contents
General Information
Safety
Recognize Safety Information
Understand Signal Words
Follow Safety Instructions
Practice Safe Maintenance
Use Proper Tools
Handle Fluids Safely—Avoid Fires
Drain Gasoline When Storing Machine
Handling Batteries Safely
Prepare for Emergencies
Park Machine Safely
Support Machine Properly
Wear Protective Clothing
Work in Clean Area
Service Machines Safely
Work In Ventilated Area
Illuminate Work Area Safely
Replace Safety Signs
Use Proper Lifting Equipment
Keep ROPS Installed Properly
Follow Tire Recommendations
Decommissioning—Proper Recycling and Disposal of Fluids and Components
Protect Against High Pressure Spray
Live With Safety
General Specifications
Service Recommendations for O-Ring Boss Fittings
Straight Fitting
Angle Fitting
Service Recommendations For Flat Face O-Ring Seal Fittings
Metric Cap Screw Torque Values—Grade 7
Metric Bolt and Screw Torque Values
Unified Inch Bolt and Screw Torque Values
Fuel and Lubricants
Gasoline Engine Oil
John Deere Turf-Gard™ is preferred.
Oil Filters
Gasoline Fuel for 4-Cycle Engines
Transmission and Hydraulic Oil
Grease
Mixing of Lubricants
Alternative and Synthetic Lubricants
Lubricant Storage
Machine Specifications
Machine Specifications
Product Identification Number Location
Engine Repair
Engine
Summary of References
Service Equipment and Tools
Other Material
Specifications
Remove Power Train Assembly
Install Power Train Assembly
Separate Transmission and Engine
Connect Transmission and Engine
Remove Timing Belt
Install Timing Belt
Remove Water Pump
Install Water Pump
Remove Throttle Body
Install Throttle Body
Remove Intake Manifold
Install Intake Manifold
Remove Exhaust Manifold
Install Exhaust Manifold
Remove Muffler and Exhaust System
Install Muffler and Exhaust System
Remove Alternator
Install Alternator
Remove Starting Motor
Install Starting Motor
Remove Valve Cover
Install Valve Cover
Remove Camshafts
Install Camshafts
Inspect Camshafts
Remove Cylinder Head
Install Cylinder Head
Recondition Cylinder Head
Equipment
Disassembly and Assembly
Inspection and Replacement
Cylinder Head
Intake and Exhaust Valves
Valve Guide Measurement
Valve Springs
Valve Seat Grinding
Valve Lapping
Remove Oil Pan
Install Oil Pan
Remove Oil Pump
Install Oil Pump
Inspect Oil Pump
Disassembly, Inspection and Assembly
Assembly
Remove Crankshaft Front Oil Seal
Install Crankshaft Front Oil Seal
Check Crankshaft Main Bearing Clearance
Reason
Procedure
Results
Check Connecting Rod Bearing Clearance
Reason
Procedure
Results
Check Connecting Rod Side Play
Reason
Procedure
Results
Remove Piston and Connecting Rod
Install Piston and Connecting Rod
Installation
Inspect Piston and Connecting Rod
Disassembly
Assembly
Inspection and Replacement
Cylinder Bore
Inspection
Deglazing
Remove Crankshaft and Main Bearings
Install Crankshaft Main Bearings
Inspect Crankshaft and Main Bearings
Remove Crankshaft Rear Oil Seal Case
Install Crankshaft Rear Oil Seal Case
Fuel Injector Replacement
Removal
Installation
Replace Oxygen (O2 Sensor)
Replace Temperature/Mass Air Pressure (TMAP) Sensor
Replace Idle Air Control Motor (IAC) Sensor
Replace Knock Sensor
Installation
Replace Throttle Position Sensor (TPS)
Replace Camshaft Position Sensor
Remove
Install
Replace Crankshaft Position Sensor
Installation
Electrical Repair
Wiring Harnesses
Summary of References
Wire Colors and Abbreviations
Load Center
Main Wiring Harness, 590E (2 Pass)
Harness, 590E (2 Pass) Page 2 of 5
Harness, 590E (2 Pass) Page 3 of 5
Harness, 590E (2 Pass) Page 4 of 5
Harness, 590E (2 Pass) Page 5 of 5
Main Wiring Harness, 590E (4 Pass)
Harness, 590E (4 Pass) Page 2 of 5
Harness, 590E (4 Pass) Page 3 of 5
Harness, 590E (4 Pass) Page 4 of 5
Harness, 590E (4 Pass) Page 5 of 5
Main Wiring Harness Color Codes, 590E
Main Wiring Harness Splices, 590E
Main Wiring Harness, 590M (2 Pass)
Harness, 590M (2 Pass) Page 2 of 5
Harness, 590M (2 Pass) Page 3 of 5
Harness, 590M (2 Pass) Page 4 of 5
Harness, 590M (2 Pass) Page 5 of 5
Main Wiring Harness, 590M (4 Pass)
Harness, 590M (4 Pass) Page 2 of 5
Harness, 590M (4 Pass) Page 3 of 5
Harness, 590M (4 Pass) Page 4 of 5
Harness, 590M (4 Pass) Page 5 of 5
Main Wiring Harness Color Codes, 590M
Main Wiring Harness Splices, 590M
Brake/Tail Light Wiring Harness
Homologation Brake/Tail Light Wiring Harness
Homologation Wiring Harness
Homologation Harness 2 of 5
Homologation Harness 3 of 5
Homologation Harness 4 of 5
Homologation Harness 5 of 5
Homologation Wiring Harness Color Codes
Homologation Wiring Harness Splices
Engine Wiring Harness
Engine Wiring Harness (2 of 2)
Load Center, Homologation Harness
Engine Wiring Harness Color Codes
Engine Wiring Harness Splices
Main Winch Kit Wiring Harness
Winch Control Wiring Harness
Winch Remote Wiring Harness
Power Train Repair
Transmission
Summary of References
Essential or Recommended Tools
Other Material
Specifications
Changing Transmission Oil
Remove and Install Clutch Covers
Remove and Install Drive Belt
Remove Clutches
Install Clutches
Disassemble Drive Clutch
Assemble Drive Clutch
Disassemble Driven Clutch
Assemble Driven Clutch
Remove Transmission
Install Transmission
Disassemble Transmission
Shift Shaft Disassembly
Differential Lock Engagement Disassembly
Assemble Transmission
Disassemble Transmission Differential
Assemble Transmission Differential
Disassemble Front Drive Gearbox
Assemble Front Drive Gearbox
Mechanical Front Wheel Drive
Summary of References
Essential or Recommended Tools
Specifications
Changing Front Differential Oil
Remove and Install Front Differential
Remove Front Differential
Install Front Differential
Disassemble Front Differential
Pinion Housing Disassembly
Differential Disassembly
Assemble Front Differential
Assemble Pinion
Assemble Differential
Check Front Differential Backlash
Axles and Driveshaft
Summary of References
Service Equipment and Tools
Other Material
Specifications
Remove and Install Driveshaft
Installation
Remove DOJ
Remove DOJ Joint and Boot
Install DOJ Boot and Joint
Remove and Install Rear Axle Halfshaft
Installation
Remove and Install Front Axle Halfshaft
Installation
Replace Front Axle Halfshaft CV Boots
Outer Boot Removal
Inner Boot Removal
Axle Shaft Assembly
Replace Rear Axle Halfshaft CV Boots
Outer Boot Removal
Inner Boot Removal
Axle Shaft Assembly
Steering and Brake Repair
Steering
Summary of References
Other Material
Specifications
Remove Steering Wheel
Install Steering Wheel
Remove Steering Knuckle
Install Steering Knuckle
Remove Front Coil Over Shock Absorber
Remove Rear Coil Over Shock Absorber
Install Front Coil Over Shock Absorber
Install Rear Coil Over Shock Absorber
Remove Tie Rod End
Install Tie Rod End
Remove Anti-Sway Bar
Install Anti-Sway Bar
Remove Steering Gearbox
Install Steering Gearbox, Non EPAS
Install Steering Gearbox, EPAS
Remove Steering Shaft, Non EPAS
Remove and Install Upper Steering Shaft, EPAS
Remove and Install Lower Steering Shaft, EPAS
Install Steering Shaft, Non EPAS
Remove Front Suspension Arms
Install Front Suspension Arms
Remove Ball Joints
Install Ball Joints
Remove Front Wheel Bearing
Install Front Wheel Bearing
Remove Rear Axle Bearing Carrier
Install Rear Axle Bearing Carrier
Disassemble Rear Axle Bearing Carrier
Remove Upper Rear Suspension Arm
Remove Lower Rear Suspension Arm
Install Upper Rear Suspension Arm
Install Lower Rear Suspension Arm
Remove Steering Shaft
Install Steering Shaft
Remove EPAS Assembly
Install EPAS Assembly
Replace Steering Shaft Bearings
Brakes
Summary of References
Essential or Recommended Tools
Other Material
Specifications
Remove Brake Pad
Install Brake Pad
Remove Brake Caliper
Install Brake Caliper
Remove Master Cylinder
Install Master Cylinder
Remove Brake Line
Front Brake Line Remove
Rear Brake Line Remove
Install Brake Line
Front Brake Line Install
Rear Brake Line Install
Remove Brake Rotor
Remove Front Rotor
Remove Rear Rotor
Install Brake Rotor
Remove Brake Pedal Assembly
Install Brake Pedal Assembly
Disassemble Park and Service Brake Pedal
Assemble Park and Service Brake Pedal
Remove Park Brake Control Cable
Install Park Brake Control Cable
Remove Four Wheel Drive Engagement Cable
Install Four Wheel Drive Engagement Cable
Remove Differential Lock Cable
Install Differential Lock Cable
Remove Park Brake
Install Park Brake
Disassemble and Assemble Park Brake
Disassemble Park Brake
Assemble Park Brake
Remove and Install Park Brake Disc
Remove Park Brake Disc
Miscellaneous Repair
Wheels
Summary of References
Specifications
Remove and Install Wheels
Hood, Cargo Box, and Bumper
Summary of References
Specifications
Remove and Install Hood
Remove Cargo Box
Install Cargo Box
Remove Front Bumper
Install Front Bumper
Fuel and Air System
Summary of References
Remove and Install Air Cleaner
Remove
Install
Remove Fuel Filter
Relieve Fuel Line Pressure
Remove Old Filter
Install Fuel Filter
Remove Fuel Tank
Install Fuel Tank
Remove Throttle Pedal and Linkage
Install Throttle Pedal and Linkage
Cooling System
Summary of References
Specifications
Drain Coolant System
Fill and Bleed Coolant System
Remove Radiator
Install Radiator
Remove Radiator Fan
Install Radiator Fan
Engine Operation, Tests and Adjustments
Component Location
Summary of References
Engine and Powertrain Mount
Engine
Timing Drive
Intake Manifold Assembly
Exhaust Manifold Assembly
Cooling System
Starting Motor and Generator
Electronic Fuel Injection and Ignition
Crankcase Ventilation System
Cylinder Block
Valve Train
Cylinder Head
Crankshaft Assembly
Lubrication System
Tests and Adjustments
Summary of References
Service Equipment and Tools
Other Material
Specifications
Adjust Throttle Cable
Idle Speed Check
Purpose:
Equipment:
Procedure:
Results:
Fuel Pump/Regulator Pressure Test
Purpose:
Test Equipment:
Procedure:
Cylinder Leak-Down Test
Reason:
Test Equipment:
Procedure:
Results:
Valve Clearance Adjustment
Purpose:
Equipment:
Procedure:
Oil Pressure Test
Radiator Cap Pressure Test
Purpose:
Equipment:
Procedure:
Results:
Thermostat Test
Purpose:
Procedure:
Results:
Diagnosis
General Engine Problems
Engine Will Not Crank
Engine Cranks But Will Not Start
Engine Loss of Power
Engine Runs Erratically
Engine Misses at High rpm
Engine Misses at Low rpm
Engine Over Heats
Electrical Operation, Tests and Adjustments
Component Location
Summary of References
Engine Control Unit (ECU) Signal Locations
ICC Pinout and Signal Locations
Main Wiring Harness Component Location (2-Pass)
Main Wiring Harness Component Location (4-Pass)
Engine Harness Component Location
Homologation Wiring Harness Component Location
Theory of Operation
Summary of References
Power Circuit Operation
Function:
Operating Condition, Unswitched Power
Operating Conditions, Switched Power Circuits
Power Circuit Schematic (1 of 3)
Power Circuit Schematic (2 of 3)
Power Circuit Schematic (3 of 3)
Cranking Circuit Operation
Charging Circuit Operation
Function
Operating Conditions
Theory of Operation
Light Circuit Operation
Headlights
Brake Lights
Seat Belt Circuit Input
Park Brake Input
Function:
Operation:
Temperature/Mass Air Pressure (TMAP) Sensor Circuit Operation
Function:
Operating Conditions:
Theory of Operation:
Throttle Position Sensor (TPS)
Function:
Operating Conditions:
Theory of Operation:
Coolant Temperature Sensor Circuit Operation
Function:
Operating Conditions:
Theory of Operation:
Knock Sensor Circuit Operation
Function:
Operating Conditions:
Theory of Operation:
Oxygen (O2 Sensor) (Heated Exhaust Gas)
Idle Air Control Motor (IAC) Circuit Operation
Function:
Operating Conditions:
Theory of Operation:
Ignition Coil Operation
Function:
Operating Conditions:
Theory of Operation:
Fuel Injector Operation
Function:
Operating Conditions:
Theory of Operation:
Fuel Pump Operation
Function:
Operating Conditions:
Theory of Operation:
Control Unit Locations and Identification
Electric Power Assist Steering (EPAS) Operation
Fuel Gauge Logic
Tachometer Logic
Starter Lockout
Temperature Warning Lamp Logic
Temperature Gauge Logic
Supervisor Mode
Schematics
Summary of References
Main Electrical Schematic, 590E
Main Schematic, Non-EPAS (2 of 5)
Main Schematic, Non-EPAS (3 of 5)
Main Schematic, Non-EPAS (4 of 5)
Main Schematic, Non-EPAS (5 of 5)
Main Electrical Schematic, 590M
Main Schematic, EPAS (2 of 5)
Main Schematic, EPAS (3 of 5)
Main Schematic, EPAS (4 of 5)
Main Schematic, EPAS (5 of 5)
Engine Schematic
Engine Schematic (2 of 3)
Engine Schematic (3 of 3)
Winch Schematic
Tests and Adjustments
Summary of References
Service Equipment and Tools
Specifications
Common Circuit Tests
Ground Circuit Test
Reason:
Ohmmeter Procedure:
Voltmeter Procedure:
Results:
Battery, Charging, and Starting System Tests
Reason:
Out of Vehicle Battery Test-Procedure:
Out of Vehicle Battery Test-Results:
In Vehicle System Test-Procedure:
In Vehicle System Test-Results:
Amperage Draw Test-Procedure:
Spark Test
Reason:
Equipment:
Procedure:
Results:
Key Switch Test
Brake Switch Test
Headlight Switch Test (2 Position) (AM147340)
Hazard Lights Switch Test (AM147346)
Turn Signal Lights Switch Test (AM147344)
Horn Switch Test (AM147527)
Reverse Switch Test
Results
Engine Oil Pressure Switch Test
Relay Test
Results:
Coolant Temperature Gauge Command
Cooling Fan Relay Command
Fuel Pump Relay Command
Idle Air Control (IAC) Command
Ignition Coil Test Command
MIL Test Command
Troubleshooting Electronic Controllers
Problems Due to Specific Operating Conditions:
Problems Due to Intermittent Electrical Failures:
Problems Due to Control Unit Failures:
CAN Bus Terminator Test
Reason:
Equipment:
Procedure:
Results:
CAN Network Voltage Checks
Reason:
Check for proper voltage:
Check for Short Circuits to CAN Hi and CAN Lo:
Compare CAN Hi and CAN Lo Voltages:
Voltages Within Range but Out of Specification:
CAN Communication Fault Checks
Reason:
Equipment:
Procedure:
Condition 1:
Condition 2:
Condition 4:
CAN Message Not Received
CAN Message Received Error
CAN Message Received Is Incorrect
Odometer, Trip, and Hour Meter Modes
Verification Procedure
Wiggle Test
Terminal Test
Ground Speed Sensor Test
Reason:
Procedure:
Inspection:
Installation:
Engine Coolant Temperature Sensor Test
Reason:
Equipment:
Procedure – Part A:
Procedure – Part B:
Results:
Camshaft Position Sensor Test
Crankshaft Position Sensor Test
Temperature/Mass Air Pressure (TMAP) Sensor Test
Knock Sensor Test
Idle Air Control (IAC) Test
Oxygen (O2 Sensor) (Heated Exhaust Gas) Test
Throttle Position Sensor (TPS) Test
Ignition Coil Test
Fuel Injector Test
Brake Float Switch Test
Reason
Equipment:
Procedure
Connector Information
Summary of References
A04-1 Instrument Cluster Connector J1
A04-2 Instrument Cluster Connector J2
A29 Globe EPAS Controller Connector
A33 Box Lift Control Connector
A35 Globe EPAS Power Connector
B1 Fuel Level Sensor Connector
CE-1 Fuel Injector #1 Connector
CE-2 Fuel Injector #2 Connector
CE-3 Engine Control Unit (ECU) Connector
CE-4 Oxygen Sensor Connector
CE-5 Cam Position Sensor Connector
CE-6 Crank Position Sensor Connector
CE-7 TMAP Sensor Connector
CE-8 Idle Air Control Connector
CE-9 Coolant Temp Sensor Connector
CE-10 Throttle Position Sensor Connector
CE-11 Ignition Coil #1 Connector
CE-12 Ignition Coil #2 Connector
CE-13 Knock Sensor Connector
CE-14 Speed Sensor Connector
CE-15 Alternator Connector
CE-16 Engine Interface Connector
CE-17 Engine Interface Connector
E3 & E4 Low Beam Connectors
E18 Turn Signal Connector
E34 & E35 HB/LB Headlamp Connectors
E42 Brake Tail Light Harness Connector
F50 Main Fuse Block Connectors
H1 Alarm Buzzer Connector
M2 Fuel Transfer Pump Connector
M11 Radiator Fan Connector
S1 Key Switch Connector
S1 Key Switch Connector
S5 Park Brake Switch Connector
S10 Headlight Switch Connector
S34 Service Brake Connector
S38 Box Lift Switch Connector
S44 Supervisor Mode Switch Connector
S46 Brake Float Switch Connector
S48 Seat Belt Buckle Switch Connector
S49 LB/HB Headlight Switch Connector
X1 Front Power Port Connector
X2 Power Lift Connector
X3 Switch Bank Power Connector
X4 Cab Sol. +VE Connector
X5 Cab Sol. -VE Connector
X6 Engine Interface Connector
X12 Engine Interface Connector
X13 Diagnostic Interface Connector
X15 Power Port Connector
X17 Attachment Key Power Connector
X19 Rear Power Port Connector
X20 CAN Bus Access Connector
X27 Front Homologation Interface Connector
X29 Dash Homologation Interface Connector
X44 Jumper-Supervisor Mode Switch Connector
Control Unit Operation, Tests, and Adjustments
Theory of Operation
Summary of References
ECU and General Sensor Circuit Operation
Function:
Operating Conditions:
Theory of Operation:
MIL Circuit Function:
Limp Home Mode:
ECU Sensor and Diagnostic Circuit Diagnosis
Test Procedure:
CAN Bus Message Structure
CAN Bus Operation
Data Bus Systems
CAN Trace
Control Unit Messaging Errors
Approved Software for Control Units
Erroneous Diagnostic Trouble Codes
Diagnostic Trouble Codes Overview
SPN.FMI Codes
Failure Modes:
Engine Speed and Tachometer Function
Engine Speed Limit, ECU Controlled
Machine Ground Speed Limits, ECU Controlled
Coolant Fan Control
Starting Authorization and Protection
Belt Slip Protection
Engine Braking (Deceleration)
ECU Electrical Protection
ECU Software Capabilities
Low Voltage Indicator
Engine Start and Stop Control
Starter Crank Protection
Fuel Level Display
Low Fuel Warning
Brake MIL Operation (Homologated Only)
Engine Hour Operation
Engine Oil Pressure Monitor Operation
Rollaway Prevention Operation (Export Only)
Park Brake Indicator
Power On Self Test Operation (POST)
Seat Belt Indicator
Steering MIL
Engine Coolant Temperature Gauge
Engine RPM Bar Gauge Operation
Odometer Operation
Ground Speed Limiting
Parked Drive Away Operation
Exit Lighting Operation
Signal Lighting Operation
ICC System Settings Menu
Function:
Menu Structure:
Menu Navigation:
Setup Menu and Options:
System Backlighting Screens:
System Menu Settings
Reading ICC On-Borard DTCs
Diagnostic Trouble Codes, ICC
ICC Quick Reference
ICC 000084.00— Wheel-Based Vehicle Speed
ICC 000084.31— Wheel-Based Vehicle Speed-Abnormal Update
ICC 000100.01— Engine Oil Pressure
ICC 000168.00— Battery Potential / Power
ICC 000168.01— Battery Potential / Power
ICC 000190.00— Engine Speed
ICC 000190.09— Engine Speed
ICC 000629.12— Control Unit-Bad Device / Component
ICC 000629.13— Control Unit-Out of Calibration
ICC 000639.12— J1939 Network #1 / Primary Vehicle Network-Bad Intelligent Device
ICC 000639.14— J1939 Network #1 / Primary Vehicle Network-CAN Bus Off
ICC 000677.03— Engine Starter Motor Relay-Short to High
ICC 000677.04— Engine Starter Motor Relay-Short to Low
ICC 003353.03— Load Shed-Short to High
ICC 003353.04— Load Shed-Short to Low
ICC 520425.07— Network Message-Receive Error Counter
ICC 520426.07— Network Message-Receive Error Counter
ICC 520542.03— CAN Network High Line-Short To High
ICC 520543.04— CAN Network Low Line-Short To Low
ICC 520870.31— ICC Internal Memory Failure
ICC 520871.31— EEROM Non-Critical Data Checksum Fail
ICC 520872.31— EEROM Critical Data Checksum Fail
ICC 520873.31— ICC Internal Memory Failure
ICC 520874.31— ICC Internal Memory Failure
ICC 520875.31— ICC Internal Memory Failure
ICC 520876.31— ICC Internal Memory Failure
ICC 523910.31— Data Memory
ICC 524265.31— ICC Internal Memory Failure
Diagnostic Trouble Codes, ECU
ECU DTC Quick Reference
ECU 000051.03— Throttle Position Signal Out of Range High
ECU 000051.04— Throttle Position Signal Out of Range Low
ECU 000084.00— Wheel Based Vehicle Speed Too High
ECU 000084.12— Wheel Based Vehicle Speed Missing
ECU 000100.01— Engine Oil Pressure Signal Low
ECU 000102.02— Engine Intake Manifold Pressure
ECU 000102.03— Manifold Air Pressure Signal Out of Range High
ECU 000102.04— Manifold Air Pressure Signal Out of Range Low
ECU 000105.02— Manifold Air Temperature Signal
ECU 000105.03— Manifold Air Temperature Signal Out of Range High
ECU 000105.04— Manifold Air Temperature Signal Out of Range Low
ECU 000110.00— Engine Coolant Temperature
ECU 000110.02— Engine Coolant Temperature
ECU 000110.03— Engine Coolant Temperature Signal Out of Range High
ECU 000110.04— Engine Coolant Temperature Signal Out of Range Low
ECU 000158.03— Key Switch Battery Potential Too High
ECU 000158.04— Key Switch Battery Potential Too Low
ECU 000190.00— Engine Speed Exceeds Maximum RPM
ECU 000636.08— Camshaft Position Sensor Malfunction
Engine Performance Effect:
Control Unit Response:
Required Tools:
Preliminary Checks:
Diagnosis
ECU 000636.09— Engine Position Sensor
ECU 000637.02— Crankshaft Position Sensor Malfunction
Engine Performance Effect:
Control Unit Response:
Required Tools:
Preliminary Checks:
Diagnosis
ECU 000637.08— Engine Timing Sensor
Engine Performance Effect:
Control Unit Response:
Required Tools:
Preliminary Checks:
Diagnosis
ECU 000637.09— Engine Timing Sensor
Engine Performance Effect:
Control Unit Response:
Required Tools:
Preliminary Checks:
Diagnosis
ECU 000651.03— Injector #1 Circuit Out of Range High
ECU 000651.04— Injector #1 Circuit Out of Range Low
ECU 000651.05— Injector #1 Circuit Has High Resistance
ECU 000652.03— Injector #2 Circuit Out of Range High
ECU 000652.04— Injector #2 Circuit Out of Range Low
ECU 000652.05— Injector #2 Circuit Has High Resistance
ECU 000977.03— Cooling Fan Relay-Circuit Malfunction-High Circuit
Control Unit Response:
ECU 000977.04— Cooling Fan Relay-Circuit Malfunction-Low Circuit
Control Unit Response:
ECU 000977.05— Fan Drive State
Control Unit Response:
ECU 001322.07— Engine Misfire for Multiple Cylinders
ECU 001323.04— Engine Misfire Cylinder #1
ECU 001324.04— Engine Misfire Cylinder #2
ECU 001696.03— Engine Exhaust O2 (Oxygen) Sensor Closed Loop Operation
ECU 001696.04— Engine Exhaust O2 (Oxygen) Sensor Closed Loop Operation
ECU 003673.05— Engine Throttle Valve 2 Position
ECU 003673.07— Engine Throttle Valve 2 Position
ECU 004082.03— Fuel Pump Primer Control
ECU 004082.04— Fuel Pump Primer Control
ECU 004082.05— Fuel Pump Primer Control
Diagnostic Trouble Codes, SCU
SCU Quick Reference
SCU 000084.00— Ground Speed Signal Too High
SCU 000084.08— Ground Speed Signal Missing
SCU 000084.09— Ground Speed Signal CAN Fault
SCU 000084.10— Ground Speed Signal Plausibility
SCU 000084.19— Ground Speed Sensor Signal Error
SCU 000084.31— Ground Speed Circuit Error
SCU 000168.03— Battery Voltage Fault—High
SCU 000168.04— Battery Voltage Fault—Low
SCU 000190.00— Engine RPM Exceeds Max Limit
SCU 000190.08— Engine RPM Signal Missing
SCU 000190.09— Engine RPM Signal CAN Fault
SCU 000190.10— Engine RPM Signal Plausibility
SCU 000190.19— Undefined Engine RPM
SCU 000628.12— EEPROM Read/Write Error
SCU 000630.13— EEPROM CRC Error
SCU 520192.06— Internal Short Detected
SCU 520193.05— Current Error
SCU 520194.31— Torque Sensor Range
SCU 520195.31— Torque Sensor Linearity
SCU 520196.12— Encoder Fault
SCU 520196.31— Encoder Variance Fault
SCU 520197.00— Temperature Lockout
SCU 520197.16— Temperature Warning
SCU 520198.31— Ignition Timeout Fault
SCU 520199.31— Manufacturer CRC Error
SCU 520200.04— Gate Drive Voltage Low
SCU 520201.31— CAN Bus Error
SCU 520202.31— Dual Signal Loss
SCU 524032.31— Load Fail
SCU 524033.31— Application CRC Error
SCU 524034.31— Boot Counter Exceeded
Service ADVISOR Readings
Summary of References
EPAS Readings
Engine Readings
Power Train Operation, Tests and Adjustments
Component Location
Summary of References
MFWD Front Differential Components
MFWD Input Components
Front Drive Gear Box Components
Transmission Input Shaft Components
Transmission Reduction Shaft Components
Transmission Differential
Drive Shaft and Axles
Theory of Operation
Summary of References
Transmission Gear Train
Tests, and Adjustments
Summary of References
Essential or Recommended Tools
Specifications
Adjust Transmission Shift Cable
Adjust Differential Lock
Results:
Adjust FWD and Rear Lock Cable
Check 4WD Front Differential Oil Level
Adjust Bearing Gap
Check Bearing Gap
Adjust Bearing Gap
Check Clutch Alignment
Steering and Brake Operation, Tests and Adjustments
Component Location
Summary of References
Front Suspension Components
Rear Suspension Components
Brake System Components, Front
Brake System Components, Rear
Park Brake Assembly Components
Theory of Operation
Summary of References
Brakes Operation
Steering Operation
Diagnosis
Diagnose Brakes Will Not Engage
Diagnose Brake Effort Excessive
Diagnose Wheel Brakes Will Not Release
Diagnose Brakes are Noisy or Chattering
Diagnose Excessive Brake Pad Wear
Diagnose Brake Pedal Travel is Excessive
Diagnose Brakes Pull Left or Right
Diagnose Pedal Feels Hard With Little Travel
Diagnose Park Brake Pedal Will Not Engage or Hold
Diagnose Park Brake Pedal Will Not Release
Diagnose Steering Pulls in One Direction
Diagnose Steering Wanders or Vibrates
Diagnose Wheel Bearing Noise
Diagnose Steers Hard in One or Both Directions
Diagnose Steering Locks in Hard Left or Right Turn
Diagnose Steering Wheel Pulls Upward
Diagnose Steering Wheel Spins Freely
Diagnose Noise During Turn
Tests and Adjustments
Summary of References
Other Material
Specifications
Check Brake Fluid Level
Adjust Master Cylinder Rod
Adjust Park Brake Cable
Bleed Brakes
Bleed Master Cylinder
Burnish Brakes
Centering Steering Rack
Adjust Suspension
Adjust Toe-In
Service Tools
Service Tools and Kits
Essential or Recommended Tools
Service Equipment and Tools
Other Material
Kits
Brake Pad Kits
Boot Kit
Page Number
Section 10
Group 10
Group 20
Group 30
Group 40
Section 20
Group 10
Section 30
Group 10
Section 40
Group 10
Group 20
Group 30
Section 50
Group 10
Group 20
Section 60
Group 10
Group 20
Group 30
Group 40
Section 70
Section 220
Group 10
Group 20
Group 30
Section 230
Group 10
Group 20
Group 30
Group 40
Group 50
Section 240
Group 10
Group 20
Group 30
Group 40
Group 50
Section 250
Group 10
Group 20
Group 30
Section 260
Group 10
Group 20
Group 30
Group 40
Section 299
Group 10