John Deere XUV590i and XUV590i S4 Gator Utility Vehicle (S.N. 010001-) Diagnostic Technical Manual TM143219 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
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
Load Center Wire Table, Non-EPAS
Load Center Wire Table, EPAS
Main Wiring Harness, Non—EPAS (2—Pass)
Harness, Non—EPAS (2—Pass) Page 2 of 5
Harness, Non—EPAS (2—Pass) Page 3 of 5
Harness, Non—EPAS (2—Pass) Page 4 of 5
Harness, Non—EPAS (2—Pass) Page 5 of 5
Main Wiring Harness, Non—EPAS (4—Pass)
Harness, Non—EPAS (4—Pass) Page 2 of 5
Harness, Non—EPAS (4—Pass) Page 3 of 5
Harness, Non—EPAS (4—Pass) Page 4 of 5
Harness, Non—EPAS (4—Pass) Page 5 of 5
Main Wiring Harness Color Codes, Non—EPAS
Main Wiring Harness Splices, Non—EPAS
Main Wiring Harness, EPAS (2—Pass)
Harness, EPAS (2—Pass) Page 2 of 5
Harness, EPAS (2—Pass) Page 3 of 5
Harness, EPAS (2—Pass) Page 4 of 5
Harness, EPAS (2—Pass) Page 5 of 5
Main Wiring Harness, EPAS (4—Pass)
Harness, EPAS (4—Pass) Page 2 of 5
Harness, EPAS (4—Pass) Page 3 of 5
Harness, EPAS (4—Pass) Page 4 of 5
Harness, EPAS (4—Pass) Page 5 of 5
Main Wiring Harness Color Codes, EPAS
Main Wiring Harness Splices, EPAS
Main Wiring Harness Terminal Tables
Engine Wiring Harness
Engine Wiring Harness (2 of 2)
Engine Wiring Harness Color Codes
Engine Wiring Harness Splices
Engine Speed Buffer Wiring Harness
Keyswitch Adapter Harness
Wiring Harnesses, Kits
Summary of References
Horn Wiring Harness, VGA10903
Backup Alarm Wiring Harness, AM140893
Lights Wiring Harness, AM140950
Lights Wiring Harness, AM137558
Lights Wiring Harness, AM146377
Headlight Jumper Wiring Harness, AM147740
Homologation Wiring Harness, AM145979
Homologation Harness, AM145979 (2 of 5)
Homologation Harness, AM145979 (3 of 5)
Homologation Harness, AM145979 (4 of 5)
Homologation Harness, AM145979 (5 of 5)
Homologation Wiring Harness Color Codes, AM145979
Homologation Wiring Harness Splices, AM145979
Load Center, Homologation Harness
Cab Power Splitter Wiring Harness, AM140972
Canopy Wiring Harness, AM143139
Roof Work Lights Wiring Harness, AM146905
Trailer Connector Wiring Harness
Winch Main Wiring Harness, AM144137
Winch Control Wiring Harness, AM142263
Power Train Repair
Transmission
Summary of References
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
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
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
Remove Steering Wheel
Install Steering Wheel
Remove Steering Knuckle
Install Steering Knuckle
Remove Front Coil Over Shock Absorber
Install Front Coil Over Shock Absorber
Remove Rear 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 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
Specifications
Remove Brake Caliper
Install Brake Caliper
Remove Brake Pad
Install Brake Pad
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
Remove and Install Wheels
Hood, Cargo Box, and Bumper
Summary of References
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
Drain Coolant System
Fill and Bleed Coolant System
Remove Radiator
Install Radiator
Remove Radiator Fan
Install Radiator Fan
Operator ` s Station Repair
Operator ` s Station and Seat
Summary of References
Remove Seat
Install Seat
Remove Transmission Control Lever Housing
Install Transmission Control Lever Housing
Remove Under Hood Tray
Install Under Hood Tray
Remove Dashboard
Install Dashboard
Remove Dashboard Back Panel
Install Dashboard Back Panel
Remove and Install Side Panels (2-Pass)
Remove
Install
Remove and Install Side Panels (4-Pass)
Remove
Install
Remove and Install Seat Closeout Panels (2-Pass)
Remove
Install
Remove and Install Seat Closeout Panels (4-Pass)
Remove
Install
Remove Floor Panel (2-Pass)
Install Floor Panel (2-Pass)
Remove Floor Panel (4-Pass)
Install Floor Panel (4-Pass)
Remove Seat Base Frame (2-Pass)
Install Seat Base Frame (2-Pass)
Remove Seat Base Frame (4-Pass)
Install Seat Base Frame (4-Pass)
Occupant Protective Structure (OPS)
Summary of References
Remove Operator Protective Structure (OPS) (2-Pass)
Install Operator Protective Structure (OPS) (2-Pass)
Remove Operator Protective Structure (OPS) (4-Pass)
Install Operator Protective Structure (OPS) (4-Pass)
Remove Seat Belts (OPS) (2-Pass)
Install Seat Belts (OPS) (2-Pass)
Remove Seat Belts (OPS) (4-Pass)
Install Seat Belts (OPS) (4-Pass)
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
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
Display Panel Signal Locations, Non—EPAS
Display Panel Signal Locations, EPAS
Speed Sensor Component Location
Main Wiring Harness Component Location (2-Pass)
Main Wiring Harness Component Location (4-Pass)
Engine 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 4)
Power Circuit Schematic (2 of 4)
Power Circuit Schematic (3 of 4)
Power Circuit Schematic (4 of 4)
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:
Malfunction Indicator Light (MIL) Operation
Function:
Operating Conditions:
Theory of Operation:
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 Locations and Identification
Control Unit Messaging Errors
Approved Software for Control Units
Erroneous Diagnostic Trouble Codes
Diagnostic Trouble Codes Overview
SPN.FMI Codes
Failure Modes:
Electronic Power Assist Steering (EPAS)
Fuel Gauge Logic
Speedometer and Ground Speed Logic
Engine Speed and Tachometer Function
Tachometer Logic
Starter Lockout
Temperature Warning Lamp Logic
Temperature Gauge Logic
Supervisor Mode
Schematics
Summary of References
Main Electrical Schematic, Non-EPAS
Main Schematic, Non-EPAS (2 of 7)
Main Schematic, Non-EPAS (3 of 7)
Main Schematic, Non-EPAS (4 of 7)
Main Schematic, Non-EPAS (5 of 7)
Main Schematic, Non-EPAS (6 of 7)
Main Schematic, Non-EPAS (7 of 7)
Main Electrical Schematic, EPAS
Main Schematic, EPAS (2 of 7)
Main Schematic, EPAS (3 of 7)
Main Schematic, EPAS (4 of 7)
Main Schematic, EPAS (5 of 7)
Main Schematic, EPAS (6 of 7)
Main Schematic, EPAS (7 of 7)
Engine Schematic
Engine Schematic (2 of 3)
Engine Schematic (3 of 3)
Schematics, Kits
Summary of References
Backup Alarm Schematic
Lights Wiring Schematic, AM140950
Lights Wiring Schematic, AM137558
Lights Wiring Schematic, AM146377
Homologation Electrical Schematic, AM141868
Sheet 2
Sheet 3
Homologation Electrical Schematic, AM145979
Homologation Schematic 2/2
Canopy Wiring Schematic, AM143139
Roof Work Lights Wiring Schematic, AM146905
Horn Wiring Schematic, VGA10903
Winch Schematic
Tests and Adjustments
Summary of References
Specifications
Common Circuit Tests
Ground Circuit Test
Reason:
Ohmmeter Procedure:
Voltmeter Procedure:
Results:
Charge Battery
Equipment:
Inspection:
Battery Charging:
Determining Battery State of Charge:
Load Test Battery
Results
Regulated Voltage Test
Reason:
Procedure:
Results:
Regulated Amperage Test
Reason:
Equipment:
Procedure:
Results:
Spark Test
Reason:
Equipment:
Procedure:
Results:
Key Switch Test
Brake Switch Test
Headlight Switch Test (2 Position) (AM142313)
Headlight Switch Test (2 Position) (AM147340)
Light Switch Test (3 Position) (AM147343)
Hazard Lights Switch Test (AM147346)
Turn Signal Lights Switch Test (AM147344)
Horn Switch Test (AM147527)
Neutral Switch Test
Results
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
Display Panel Replacement Programming
Odometer, Trip, and Hour Meter Modes
Clock and Unit Set Programming
Display Panel Tire Size Programming
Verification Procedure
Wiggle Test
Terminal Test
Speed Sensor Test
Reason:
Equipment:
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
Diagnostic Trouble Codes, EPAS
CMX DTC Quick Reference
CMX 000084.00— Speed Signal Exceeds Maximum
CMX 000084.08— Speed Signal Missing
CMX 000084.09— CAN Speed Information Not Received
CMX 000084.10— Speed Plausibility
CMX 000084.19— CAN Speed Message Contains Error
CMX 000084.31— Speed Circuit
CMX 000168.03— System Overvoltage
CMX 000168.04— System Undervoltage
CMX 000190.00— Engine rpm Signal Exceeds Maximum
CMX 000190.08— Engine rpm Signal Missing
CMX 000190.09— Engine rpm CAN Information Not Received
CMX 000190.10— Engine rpm Speed Plausibility
CMX 000190.19— Engine rpm Message Contains Error Value
CMX 000628.12— EEPROM Read-Write Error
CMX 000630.13— EEPROM CRC Error
CMX 520192.06— Over Current
CMX 520193.05— Current Error
CMX 520194.31— Torque Sensor Range
CMX 520195.31— Torque Sensor Linearity
CMX 520196.12— Encoder SPI
CMX 520196.31— Encoder Variance Fault
CMX 520197.00— Temperature Lockout
CMX 520197.16— Temperature Warning
CMX 520198.31— Ignition Timeout Fault
CMX 520199.31— Manufacturer CRC Error
CMX 520200.04— Gate Drive Voltage Low
CMX 520201.31— CAN Bus Error
CMX 520202.31— Dual Signal Loss
CMX 524032.31— Load Fail
CMX 524033.31— Application CRC Error
CMX 524034.31— Boot Counter Exceeded
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
Service ADVISOR Readings
Summary of References
EPAS Readings
Engine Readings
Connector Information
Summary of References
C-1 Display Panel Connector
C-2 Display Panel Connector
C-3 Key Switch Connector
C-4 Radiator Fan Connector
C-5 and C-6 Headlight Connector
C-8 EPAS Connector
C-9 Diagnostic Connector
C-10 Light Switch Connector
C-11 Box Lift Switch Connector
C-12 Supervisor Mode Connector
C-14 Front Attachment Connector
C-15 Power Port Connector
C-16 Front Power Connector
C-17 Brake Switch Connector
C-18 Fuse Holder
C-19 Box Lift Connector
C-20 Main Harness to Engine Harness Connector
C-21 Main Harness to Engine Harness Connector
C-22 EPAS Connector
C-23 Cab Solenoid Power Connector
C-24 Cab Solenoid Ground Connector
C-25 Rear Lights Connector
C-26 Switch Bank Power Connector
C-27 Seat Belt Switch Connector
C-28 Rear Power Connector
C-29 Park Brake Switch Connector
C-30 Fuse Holder, EPAS
C-32 Rear Power Connector
C-33 Fuel Pump Connector
C-34 Fuel Level Sensor Connector
C-35 CAN Terminator Connector
C-37 Turn Signal 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 Harness to Main Harness Connector
CE-17 Engine Harness to Main Harness Connector
CE-18 Diagnostic Connector
HMC-1 Turn Signal Connector
HMC-2 Right Front Marker Connector
HMC-3 Right Front Turn Connector
HMC-4 Right Headlight Connector
HMC-5 Left Headlight Connector
HMC-6 Left Front Turn Connector
HMC-7 Left Front Marker Connector
HMC-8 Power Main Harness Connector
HMC-9 Power Main Harness Connector
HMC-10 Power Main Harness Connector
HMC-11 Power Main Harness Connector
HMC-12 Light Switch Connector
HMC-13 Diode Connector
HMC-14 Turn Signal Switch Connector
HMC-15 Hazard Switch Connector
HMC-17 High Beam Switch Connector
HMC-18 Relay Connector
HMC-19 Flasher Connector
HMC-22 Radiator Fan Out Connector
HMC-23 Radiator Fan In Connector
HMC-24 Right High Beam Connector
HMC-25 Left High Beam Connector
HMC-27 Left Brake/Turn/Tail Connector
HMC-28 License Plate Light Connector
HMC-29 Right Brake/Turn/Tail Connector
HMC-30 Trailer Brake Connector
HMC-31 Trailer Left Marker/Turn Connector
HMC-32 Trailer Right Marker/Ground/Turn Connector
HMC-33 Brake Signal Connector
HMC-36 License Plate Light Connector
HMC-38 Rear Fog Light Connector
HMC-39 Horn Switch Connector
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
Diagnosis, Tests, and Adjustments
Summary of References
Adjust Transmission Shift
Adjust 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
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
Group 20
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
Group 10
Group 20
Section 220
Group 10
Group 20
Group 30
Section 230
Group 10
Group 20
Group 30
Group 31
Group 40
Group 50
Group 55
Group 60
Group 70
Section 240
Group 10
Group 20
Group 30
Section 250
Group 10
Group 20
Group 30
Group 40
Section 299
Group 10