John Deere HPX815E Gator Utility Vehicles Technical Manual TM151019 20JUL22

Introduction
Foreword
Contents
General Information
Safety
Recognize Safety Information
Understand Signal Words
Practice Safe Maintenance
Use Proper Tools
Handle Fluids Safely—Avoid Fires
Prevent Acid Burns
Prevent Battery Explosions
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
Follow Tire Recommendations
Protect Against High Pressure Spray
Decommissioning—Proper Recycling and Disposal of Fluids and Components
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, Lubricants, and Coolant
Diesel Fuel—North America
Required fuel properties
Sulfur content
Handling and Storing Diesel Fuel
Diesel Fuel—Europe
Diesel Fuel Storage
4-Cycle Diesel Engine Oil—North America
Diesel Engine Oil—Europe
Biodegradable Oil
Application
Cold Weather Operation
Transaxle and MFWD Differential Oil
Converting From HY-GARD to BIO HY-GARD
Grease – North America
Grease – Europe
Alternative Lubricants
Synthetic Lubricants
Lubricant Storage
Mixing of Lubricants
Oil Filters
Operating in Warm Temperature Climates
Diesel Engine Coolant (engine without wet sleeve cylinder liners)
Preferred Coolants
Additional Recommended Coolants
Other Coolants
Water Quality
Coolant Drain Intervals
John Deere COOL-GARD™ II Coolant Extender
Testing Diesel Engine Coolant
Coolant Test Strips
When Using John Deere COOL-GARD II
When Using Nitrite-Containing Coolants
Coolant Analysis
Machine Specifications
Machine Specifications
Product Serial Number
Engine Serial Number Location
Engine Repair
Repair
Summary of References
Essential or Recommended Tools
Service Equipment and Tools
Other Material
Specifications
Remove and Install Engine
Removal:
Installation:
Remove and Install Muffler
Removal:
Installation:
Remove and Install Rocker Arm Cover
Remove and Install Rocker Arm and Push Rods
Rocker Arm Removal:
Rocker Arm Disassembly:
Rocker Arm Inspection:
Push Rod Inspection:
Rocker Arm Assembly:
Rocker Arm Installation:
Remove and Install Cylinder Head
Removal:
Installation:
Recondition Cylinder Head
Disassembly:
Assembly:
Inspection/Replacement:
Cylinder Head:
Intake and Exhaust Valves:
Valve Guides:
Valve Guide Replacement:
Valve Stem Seal Installation:
Valve Springs:
Valve Seat Grinding:
Valve Lapping:
Remove and Install Exhaust Manifold
Removal:
Installation:
Remove and Install Rear Crankshaft Oil Seal
Rear Oil Seal Case:
Remove and Install Front Crankshaft Oil Seal
Remove and Install Timing Gear Cover
Removal and Installation:
Check Camshaft End Play
Reason:
Procedure:
Results:
Check Timing Gear Backlash
Reason:
Procedure:
Results:
Remove and Install Idler Gear
Removal and Installation:
Inspection/Replacement:
Remove and Install Cam Followers
Removal:
Installation:
Inspection:
Remove and Install Camshaft
Camshaft Removal:
Camshaft Installation:
Camshaft Side Gap Measurement:
Camshaft Gear Removal:
Camshaft Gear Installation:
Camshaft Inspection:
Remove and Install Oil Pan and Strainer
Removal:
Installation:
Check Connecting Rod Side Play
Reason:
Equipment:
Procedure:
Results:
Check Crankshaft End Play
Reason:
Equipment:
Procedure:
Results:
Check Connecting Rod Bearing Clearance
Reason:
Procedure:
Results:
Check Crankshaft Main Bearing Clearance
Reason:
Procedure:
Results:
Remove, Inspect, and Install Connecting Rod
Removal:
Inspection/Replacement:
Installation:
Disassemble and Assemble Pistons
Disassembly:
Assembly:
Cylinder Bore
Inspection:
Results:
Deglazing:
Reboring:
Remove and Install Crankshaft and Main Bearings
Removal:
Installation:
Inspection/Replacement:
Remove and Install Flywheel
Removal:
Installation:
Remove and Install Flywheel Plate
Removal:
Installation:
Remove and Install Timing Gear Housing
Removal:
Installation:
Remove and Install Oil Pump
Removal/Installation
Oil Pressure Regulating Valve
Coolant Temperature Switch
Removal:
Installation:
Remove and Install Thermostat
Removal:
Installation:
Remove and Install Water Pump
Removal:
Installation:
Remove and Install Fuel Filter
Remove and Install Fuel Filter Assembly
Removal:
Installation:
Remove and Install Fuel Transfer Pump
Removal:
Installation:
Remove and Install Fuel Injection Nozzle
Removal:
Installation:
Repair:
Cleaning and Inspection:
Remove and Install Fuel Injection Pump
Removal:
Installation:
Remove and Install Fuel Control and Governor Linkage
Removal:
Installation:
Remove and Install Fuel Shutoff Solenoid
Repair Starting Motor
Removal
Installation
Analyze Condition
Disassembly
Assembly
Inspection and Test
40 Amp Alternator
Required Tools:
Disassembly:
Inspection:
Assembly:
Electrical Repair
General Information
Common Circuit Tests
Shorted Circuit:
High Resistance or Open Circuit:
Grounded Circuit:
Conductors For 12 Volt Circuits
Main Wire Harness
Summary of References
Main Wire Harness
Main Wire Harness Color Codes
Main Wire Harness Splices
Load Center, EEC
Main Wiring Harness, EEC
Main Wiring Harness, EEC 2 of 5
Main Wiring Harness, EEC 3 of 5
Main Wiring Harness, EEC 4 of 5
Main Wiring Harness, EEC 5 of 5
Main Wiring Harness Color Codes, EEC
Main Wiring Harness Splices, EEC
Jumper Harnesses
Wiring Harnesses, Kits
Summary of References
Lights Wiring Harness, AM140950
Lights Wiring Harness, AM146377
Turn Signal with Flasher Harness, AM145664
Canopy Wiring Harness, AM143139
Roof Work Lights Wiring Harness, AM146905
Roof Light Wiring Harness, AM144192
Beacon Light Wiring Harness, AM146422
Horn Wiring Harness, VGA10902
Horn Wiring Harness, VGA10903
Backup Alarm Wiring Harness, AM144181
Rear Lights Wiring Harness, AM146376
Winch Control Wiring Harness, AM142263
Winch Rear Mount Wiring Harness, AM144132
Winch Front Wiring Harness, AM144133
Winch Contactor to Battery Wire, AM144134
Winch Contactor to Battery Ground Wire, AM144135
Winch Wiring Harness AM144136
Homologation Front Wiring Harness, AM147613
Homologation Jumper Wiring Harness, AUC12396
Homologation Dash Wiring Harness, AM147614
Homologation Rear Wiring Harness, AM148772
Cargo Box Lift Wiring Harness, AM136637
Brake Light Wiring Harness, VGA12026
Deluxe Signal Light Wiring Harness, AM142893
Deluxe Light Wiring Harness, AM147610
Cab Power Splitter Wiring Harness, AM140972
Headlight Jumper Wiring Harness, AM147740
Trailer Connector Wiring Harness
Repair
Summary of References
Specifications
Alternator Removal and Installation
Removal:
Equipment:
Disassembly:
Inspection:
Assembly:
Installation:
Power Train Repair
Repair
Summary of References
Essential or Recommended Tools
Other Material
Specifications
Changing EMFWD Differential Oil
Changing Transaxle Oil
Primary Drive Clutch Removal
Primary Drive Clutch Repair
Procedure:
Inspection
Cleaning Primary Drive Clutch
Driven Clutch Removal and Installation
Removal:
Installation:
Driven Clutch Disassembly and Assembly
Disassembly:
Inspection:
Assembly:
Transaxle Removal and Installation
Transaxle Disassembly
Disassembly
Rear Idler Shaft Disassembly:
Shift Shaft Disassembly:
Differential Disassembly:
Transaxle Assembly
Differential Assembly
Assembly:
Front Drive Gearbox Disassembly and Assembly
Disassembly:
Assembly
EMFWD Driveshaft Removal and Installation
Removal:
Installation:
Hub Removal
Hub Installation
Front Axle Driveshaft Removal and Installation
Removal:
Installation:
Front Differential Removal and Installation
Removal:
Installation:
Front Differential Disassembly
Disassembly
Inspection:
Front Differential Assembly
CV Joint (Front or Rear Axle Drive Shafts) Disassembly and Assembly
Disassembly
Assembly
Steering Repair
Repair
Summary of References
Specifications
Remove and Install Steering Wheel
Removal:
Installation:
Tie Rod End Removal and Installation
Removal:
Installation:
Steering Rack Removal and Installation
Removal:
Installation:
Steering Shaft Removal and Installation
Removal:
Installation:
Front Strut/Shock Removal and Installation
Strut Removal:
Shock Removal:
Installation:
Front Wheel Bearing Removal and Installation
Removal:
Installation
Ball Joint Removal and Installation
Removal:
Installation:
Front A-Arm Removal and Installation
Removal:
Installation:
A-Arm Bushing Removal and Installation
Removal
Installation
Brake Repair
Brake Repair
Summary of References
Specifications
Brake Pad Replacement
Remove and Install Master Cylinder
Removal:
Installation:
Brake Line Removal and Replacement
Setup:
Front Brake Line Removal:
Rear Brake Line Removal:
Installation:
Brake Caliper Removal and Installation
Removal:
Installation:
Brake Pedal Removal and Installation
Removal:
Installation:
Park Brake Cable Removal and Installation
Removal:
Installation:
Park Brake Lever Removal and Installation
Removal:
Installation:
Miscellaneous Repair
Component Location
Summary of References
Seat and Seat Support Components
Fuel System Components
Fuel System Components
Coolant System Components
Repair
Summary of References
Specifications
Wheel Removal and Installation
Removal:
Installation:
Hood Latch Removal and Installation
Removal:
Installation:
Hood Removal and Installation
Removal:
Installation:
Remove and Install Front Grille
Removal:
Installation:
Remove and Install Front Fender
Removal:
Installation:
Dash Panel Removal and Installation
Removal:
Installation:
Remove and Install Headlight
Removal:
Installation:
Remove and Install Center Console
Remove and Install Transaxle Control Lever Housing
Seat Removal and Installation
Removal:
Installation:
Occupant Protective Structure Removal and Installation
Removal
Installation
Seat Base Cover Removal and Installation
Removal:
Installation:
Seat Adjuster Removal and Installation
Removal:
Installation:
Fuel Tank Removal and Installation
Removal:
Installation:
Remove and Install Cargo Box
Removal:
Installation:
Remove and Install Cargo Box Side
Cargo Box Side Removal
Cargo Box Side Installation
Rear Shock Absorber Removal and Installation
Removal:
Installation:
Front Bumper/Skid Plate Removal and Installation
Removal:
Installation:
Battery Removal and Installation
Removal
Installation
Drain and Flush Cooling System
Draining Cooling System
Flushing Cooling System
Remove and Install Radiator
Removal:
Installation:
Remove and Install Cooling Fan
Removal:
Installation:
Radiator Fill and Bleed Procedure
Filling and Bleeding Cooling System
Adjust Doors and Door Catch/Locking Bolts
Soft Doors:
Hard Doors
Engine Operation, Tests, and Adjustments
Component Location
Component Location
Theory of Operation
Cooling System Theory of Operation
Function
Theory of Operation
Lubrication System Theory of Operation
Theory of Operation
Fuel System Theory of Operation
Air System Theory of Operation
Function:
Theory of Operation:
Diagnosis
Engine Troubleshooting and Diagnostics
Engine Oil Diagnostics
Excessive Fuel Consumption
Incorrect Manifold Pressure
Low Engine Compression
Engine Starting Problem
Engine Operation Poor
Coolant Temperature Abnormal
Coolant in Oil or Oil in Coolant
Diagnostics
Tests and Adjustments
Summary of References
Essential or Recommended Tools
Service Equipment and Tools
Other Material
Specifications
Test Air Restriction Indicator
Reason:
Procedure (Normal Operation):
Results:
Procedure (Simulated Excess Restriction):
Results:
Adjust Fast Idle Speed
Reason:
Equipment:
Procedure:
Results:
Adjust Slow Idle
Reason:
Equipment:
Procedure:
Results:
Adjust Throttle Cable
Reason:
Equipment:
Procedure
To Adjust Cable:
Reason:
Equipment:
Adjust Valve Clearance
Reason:
Equipment:
Procedure:
Check Valve Lift
Reason:
Equipment:
Procedure:
Results:
Test Cylinder Compression
Reason:
Equipment:
Procedure:
Results:
Adjust Water Pump/Alternator Drive Belt
Reason:
Equipment:
Procedure:
Results:
Test Thermostat
Reason:
Equipment:
Procedure:
Results:
Test Radiator Bubble
Reason:
Equipment:
Procedure:
Results:
Test Cooling System Pressure
Reason:
Equipment:
Procedure:
Results:
Test Radiator Cap Pressure
Reason:
Equipment:
Procedure:
Results:
Test Engine Oil Pressure
Reason:
Equipment:
Procedure:
Results:
Test Fuel Injection System
Reason:
Equipment:
Procedure:
Results:
Test Fuel Injection Nozzle
Reason:
Equipment:
Connections:
Procedure 1:
Results:
Procedure 2:
Results:
Procedure 3:
Results:
Adjust Injection Pump Timing
Check Injection Pump Static Timing
Reason:
Equipment:
Procedure:
Results:
Bleed Fuel System Air
Reason:
Procedure:
Test Fuel Transfer Pump Flow
Reason:
Equipment:
Procedure:
Results:
Test Fuel Transfer Pump Pressure
Reason:
Equipment:
Procedure:
Results:
Electrical Operation, Tests, and Adjustments
Component Location
Summary of References
Main Wiring Harness Components (Non-EEC)
Main Wiring Harness Components (EEC)
Theory of Operation (Non – EEC)
Summary of References
Power Circuit Operation (Non-EEC)
Cranking Circuit Operation (Non-EEC)
Seat Belt Circuit Operation (Non-EEC)
Charging Circuit Operation (Non-EEC)
Function:
Operating Conditions:
Theory of Operation:
Fuel Shutoff Circuit Operation (Non-EEC)
Glow Plug Circuit Operation (Non-EEC)
4WD Clutch Circuit Operation (Non-EEC)
Engine Oil Pressure Light Circuit Operation (Non-EEC)
Function:
Operating Conditions:
Theory of Operation:
Hour Meter Circuit Operation (Non-EEC)
Function:
Operating Conditions:
Theory of Operation:
Cooling Fan and Temperature Light Circuit Operation (Non-EEC)
Function:
Operating Conditions:
Theory of Operation—Cooling Fan:
Theory of Operation—Engine Temperature Light:
Headlight Circuit Operation (Non-EEC)
Function:
Operating Conditions:
Theory of Operation:
Park Brake Circuit Operation (Non-EEC)
Function:
Operating Conditions:
Theory of Operation:
Accessory Power Circuit Operation (Non-EEC)
Function:
Operating Conditions:
Theory of Operation:
Theory of Operation (EEC)
Summary of References
Power Circuit Operation (EEC)
Power Circuit Schematic
Power Circuit Schematic
Charging and Tachometer Circuit Operation (EEC)
Seat Belt Circuit Operation (EEC)
Park Brake Light and Warning Buzzer Circuit Operation (EEC)
Cranking and Glow Plug Circuit Operation (EEC)
Cranking, Glow Plugs, Fuel Schematic (1 of 2)
Cranking, Glow Plugs, Fuel Gauge Schematic (2 of 2)
4WD and Speedometer Circuit Operation (EEC)
Engine Cooling Circuit Operation (EEC)
Light Circuit Operation (EEC)
Homologation Circuit Operation (EEC)
Discretionary Switched Power Circuit Operation (EEC)
CAN Bus Circuit Operation (EEC)
Diagnostics (Non – EEC)
Power Circuit Diagnosis
Cranking Circuit Diagnosis
Seat Belt Circuit Diagnosis
Charging Circuit Diagnosis
Fuel Shutoff Circuit Diagnosis
Glow Plug Circuit Diagnosis
4WD Circuit Diagnosis
Engine Oil Pressure Light Diagnosis
Hour Meter Circuit Diagnosis
Cooling Fan and Temperature Light Circuit Diagnosis
Headlight Circuit Diagnosis
Park Brake Circuit Diagnosis
Vehicle Control Unit/Relay Module (VCU) Operation
Schematics
Summary of References
Main Schematic (Non-EEC)
Main Schematic (Non-EEC) 2 of 4
Main Schematic (Non-EEC) 3 of 4
Main Schematic (Non-EEC) 4 of 4
Main Schematic (EEC)
Main Schematic (EEC) 2 of 6
Main Schematic (EEC) 3 of 6
Main Schematic (EEC) 4 of 6
Main Schematic (EEC) 5 of 6
Main Schematic (EEC) 6 of 6
Schematics, Kits
Summary of References
Lights Wiring Schematic, AM140950
Adventure Light Wiring Schematic, AM146377
Turn Signal with Flasher Schematic, AM145664
Canopy Wiring Schematic, AM143139
Roof Work Lights Wiring Schematic, AM146905
Roof Work Light Wiring Schematic, AM144192
Beacon Light Wiring Schematic, AM146422
Horn Wiring Schematic, VGA10902
Horn Wiring Schematic, VGA10903
Backup Alarm Wiring Schematic, AM144181
Rear Lights Wiring Schematic, AM146376
Winch Schematic
Receiver Winch Schematic
Homologation Front Wiring Schematic, AM147613
Homologation Jumper Wiring Schematic, AUC12396
Homologation Dash Wiring Schematic, AM147614
Homologation Rear Wiring Schematic, AM148772
Cargo Box Lift Wiring Schematic, AM136637
Brake Light Wiring Schematic, VGA12026
Deluxe Signal Light Wiring Schematic, AM142893
Deluxe Light Harness Schematic, AM147610
Switch Bank Wiring Schematic, AM140972
Headlight Jumper Wiring Schematic, AM147740
Connector Information
Summary of References
C2 Box Lift Switch Connector
C3 Key Switch Connector
C4 Alternator Connector
C5 Front Attachment Connector
C6 Front Power Connector
C7 Headlight Switch Connector
C8 Hour Meter Connector
C9 Box Lift Connector
C10 Rear Power Connector
C11 Seat Belt Switch Connector
C12 Neutral Switch Connector
C14 Front Lighting Connector
C15 Left Headlight
C17 Right Headlight
C20 Rear Lighting Connector
C23 Coolant Temp Sender
C29 Fuel Shutoff Connector
C34 4WD Switch Connector
C35 4WD Solenoid Connector
C38 Accessory Outlet Connector
C40 Service Brake Switch Connector
C49 VCU Connector
C50 VCU Connector
C52 Start Solenoid Connector
C89 Fuse Holder
C90 Accessory Outlet Connector
C96 Option Lights Connector
C97 Park Brake Light Diode Connector
C100 Mid Attachment Unswitched Power Connector
DC-22 Fuel Solenoid Diode Connector
T4 Engine Oil Pressure Switch Connector
T9 Park Brake Switch Connector
T10 Park Brake Switch Connector
T12 Engine Coolant Temperature Switch Connector
Connector Information (EEC)
Summary of References
B3 Fuel Level Sensor Connector
E1 Left Tail Light Connector
E2 Right Tail Light Connector
E3 Front Attachment Connector
E4 Glow Plug Connector
E5 4WD Solenoid Connector
E14 Dash Accessory Outlet
E15 Center Accessory Outlet
E28 Left Headlight
E29 Right Headlight
E30 Left Turn Signal Connector
F50 Load Center
F50 Load Center S2
F54 Fuse Holder
G2 Alternator Connector
H2 Buzzer
J1 Instrument Cluster Connector
J2 Instrument Cluster Connector
J5-1 EPAS Control Connector
M1 Radiator Fan Connector
N03-1 Cab Solenoid Connector
N03-2 Cab Solenoid Connector
N03-3 Cab Solenoid Connector
R1 CAN Terminator Connector
S1 Key Switch Connector
S2 Box Lift Switch Connector
S4 Neutral Switch Connector
S5 Reverse Switch Connector
S16 Throttle Switch Connector
S19-1 Park Brake Switch Connector
S19-2 Park Brake Switch Connector
S20 4WD Switch Connector
S21 Seat Belt Switch Connector
S26 Low Oil Connector
S27 Supervisor Mode Switch Connector
S29 Service Brake Switch Connector
S40 Headlight Switch Connector
S41 Coolant Temp Sensor Connector
S48 Radiator Temperature Switch Connector
X-C04 Start Solenoid Connector
X4 Diagnostic Connector
X7 Speed Sensor Connector
X9 Box Lift Attachment Connector
X10 Rear Attachment Connector
X13 Battery Connection
X14-1 Winch Module Power Connector
X14-2 Winch Module Control Connector
X15 Fuel Shutoff Solenoid Connector
X18-A Front Attachment Connector
X20 Brake Float Switch Connector
X22 Marker Jumper Connector
X23 CAN Bus Port Connector
X31 Cab Power Connector
X44 Jumper-Supervisor Mode Connector
V03 Fuel Shut-off Solenoid Diode Connector
V13-1 Winch Solenoid Connector
V13-2 Winch Solenoid Connector
Tests and Adjustments
Summary of References
Service Equipment and Tools
Other Material
Specifications
Ground Circuit Test
Reason:
Equipment:
Ohmmeter Procedure:
Voltmeter Procedure:
Results:
Clean Battery
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:
Starting Motor Solenoid Test
Reason:
Equipment:
Procedure:
Results:
Key Switch Test
Park Brake Switch Test
Reason:
Equipment:
Procedure
Results:
Headlight Switch Test
Work Light Switch Test
Beacon Light Switch Test
4WD Switch Test
4WD Solenoid Test
Reason:
Equipment:
Procedure:
Results:
Brake Lights Switch Test
Reason:
Equipment:
Procedure:
Results:
Neutral Start Switch Test
Reason:
Equipment:
Procedure:
Results:
Fuse Test
Reason:
Equipment:
Procedure:
Results:
Diode Test
Reason:
Equipment:
Procedure:
Results:
Relay Test (Discrete)
Reason:
Procedure:
Relay Test
Results:
Radiator Coolant Temperature Switch Test
Reason
Procedure
Results:
Engine Coolant Temperature Switch Test
Reason
Procedure
Results:
Bulb Test
Reason:
Equipment:
Procedure:
Results:
Raise/Lower Switch Test
Fuel Shutoff Solenoid Test
Reason
Equipment:
Procedure
Results
Engine Oil Pressure Switch Test
Reason:
Equipment:
Procedure:
Glow Plug Test
Reason:
Equipment:
Procedure:
Results:
Seat Belt Switch Test
Reason:
Equipment:
Procedure:
Results:
Brake Float Switch Test
Reason
Equipment:
Procedure
Wiggle Test
Terminal Test
Warning Alarm Test
Reason:
Equipment:
Procedure:
Results:
Control Unit Operation, Tests and Adjustments
Theory of Operation
Summary of References
CAN Bus Message Structure
CAN Bus Operation
CAN Trace
Approved Software for Control Units
Erroneous Diagnostic Trouble Codes
Diagnostic Trouble Codes Overview
SPN.FMI Codes
Failure Modes:
Engine Speed and Tachometer Function
Load Dump Operation
Low Voltage Indicator
Fuel Level Display
Low Fuel Warning
Brake MIL Operation (Homologated Only)
Engine Hour Operation
Engine Oil Pressure Monitor Operation
Parked Rollaway Alarm
Park Brake Indicator
Power On Self Test Operation (POST)
Seat Belt Indicator
Engine Coolant Temperature
Engine RPM Bar Gauge Operation
Odometer Operation
4WD Operation
Accessing Diagnostic Trouble Codes
Park Brake Drive Through Operation
Parked Drive Away Operation
Exit Lighting Operation
Signal Lighting Operation
ICC System Settings Menu
System Menu Settings
Reading ICC On-Board DTCs
Troubleshooting Electronic Controllers
Problems Due to Specific Operating Conditions:
Problems Due to Intermittent Electrical Failures:
Problems Due to Control Unit Failures:
Charging Circuit Failure Logic
Diagnostic Trouble Codes, ICC
ICC Quick Reference
ICC 000084.00— Wheel-Based Vehicle Speed
ICC 000110.00— Engine Coolant Temperature High
ICC 000168.00— Battery Potential / Power Input
ICC 000168.01— Battery Potential / Power Input
ICC 000629.12— Control Unit
ICC 000629.13— Control Unit
ICC 000639.12— Primary Vehicle Network
ICC 000639.14— Primary Vehicle Network
ICC 000676.03— Engine Glow Plug Relay
ICC 000676.04— Engine Glow Plug Relay
ICC 000677.03— Engine Start Solenoid Relay
ICC 000677.04— Engine Start Solenoid Relay
ICC 000677.14— Engine Start Solenoid Relay
ICC 000677.31— Engine Start Solenoid Relay
ICC 000920.03— Audible Alarm
ICC 000920.04— Audible Alarm
ICC 001071.03— Cooling Fan Driver Output
ICC 001071.04— Cooling Fan Driver Output
ICC 003353.03— Alternator State
ICC 003353.04— Alternator State
ICC 516124.03— Engine Fuel Hold Actuator Driver
ICC 516124.04— Engine Fuel Hold Actuator Driver
ICC 516125.03— Engine Fuel Pull-In Actuator Relay Driver
ICC 516125.04— Engine Fuel Pull-In Actuator Relay Driver
ICC 516182.03— 4WD Circuit
ICC 516182.04— 4WD Circuit
ICC 517289.07— Service Brake Pressure Consolidated
ICC 520542.03— CAN Network High Line-Test Voltage
ICC 520543.04— CAN Network Low Line-Test Voltage
ICC 520870.31— Non-Volatile Memory Zone 1
ICC 520871.31— Non-Volatile Memory Zone 2
ICC 520872.31— Non-Volatile Memory Zone 3
ICC 520873.31— Non-Volatile Memory Zone 4
ICC 520874.31— Non-Volatile Memory Zone 5
ICC 520875.31— Non-Volatile Memory Zone 6
ICC 520876.31— Non-Volatile Memory Zone 7
ICC 523910.31— ICC Data Memory
ICC 524265.31— ICC Diagnostic Mode
Service ADVISOR Readings
Summary of References
ICC Readings
Tests and Adjustments
Summary of References
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
Verification Procedure
Power Train Operation, Tests, and Adjustments
Component Location
Summary of References
Power Train Components
Transaxle Control Components
Drive Clutch Components
Driven Clutch
Shift Linkage Components
Differential Lock Linkage Components
Transaxle Input Components
Transaxle Gear Components
Differential Components
Rear Axle Components
Front Drive Gear Box Components
4WD Driveline Components
EMFWD Front Differential Components
Theory of Operation
Summary of References
Power Transfer Operation
Drive Clutch:
Driven Clutch:
Transaxle:
Differential Lock:
Mechanical Four Wheel Drive (MFWD):
Drive Clutch Operation
Clutch Operation
Theory of Operation:
Engagement RPM, Minimum Load, Low Output Speed (E):
High Engine RPM, Light Load, High Output Speed (F):
High Engine RPM, Increasing Load, Lower Output Speed:
EMFWD Operation
Function:
Operation:
Diagnostics
Diagnostic Check Points:
Tests and Adjustments
Summary of References
Essential or Recommended Tools
Specifications
Transaxle Shift Adjustments
Procedure:
Differential Lock Adjustments
Purpose:
Procedure
Results:
EMFWD Ring and Pinion Backlash Adjustment
Procedure:
Drive to Secondary (Driven) Clutch Adjustment
Checking Drive Belt
Steering and Brake Operation, Tests, and Adjustments
Component Location
Summary of References
Steering System
Brake System
Brake System Components
Park Brake System
Theory of Operation
Steering System Operation
Function:
Theory of Operation
Brake System Operation
Function:
Theory of Operation:
Diagnostics
Steering Diagnosis
Steering Symptoms
Brake Pedal
Hydraulic Brakes Checks
Brakes Will Not Engage or Show Poor Response
Brake Effort Excessive
Wheel Brakes Will Not Release
Brake Noisy or Chattering
Excessive Brake Pad Wear
Brake Pedal Travel Excessive
Brakes Pull Left or Right
Pedal Feels Hard With Little Travel
Park Brake Will Not Engage or Hold
Park Brake Will Not Release
Tests and Adjustments
Summary of References
Other Material
Specifications
Toe-Out Adjustment
Procedure:
Adjustment Procedure:
Check Brake Fluid Level
Adjust Master Cylinder Rod
Bleed Brakes
Bleed Master Cylinder
Burnish Brakes
Park Brake Adjustment
Service Tools
Service Tools and Kits
Essential or Recommended Tools
Service Equipment and Tools
Other Material
Page Number
Section 10
Group 10
Group 20
Group 30
Group 40
Section 20
Group 10
Section 30
Group 10
Group 20
Group 30
Group 40
Section 40
Group 10
Section 50
Group 10
Section 60
Group 10
Section 70
Group 10
Group 20
Section 220
Group 10
Group 20
Group 30
Group 40
Section 230
Group 10
Group 20
Group 25
Group 30
Group 40
Group 50
Group 60
Group 65
Group 70
Section 240
Group 10
Group 20
Group 30
Group 40
Section 250
Group 10
Group 20
Group 30
Group 40
Section 260
Group 10
Group 20
Group 30
Group 40
Section 299
Group 10