NUMBER: GROUP: DATE: November 12, 2005 SUBJECT: OVERVIEW: MODELS: SYMPTOM/CONDITION: REV A. Electrical

Transcription

1 NUMBER: GROUP: REV A Electrical DATE: November 12, 2005 This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without written permission of DaimlerChrysler Corporation. THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN , DATED JULY 15, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES TO THE PART SECTION OF THIS BULLETIN. SUBJECT: Transmission In Limp-In Mode Or MIL On Due To PCM Ground Wire OVERVIEW: This bulletin involves inspecting the C4 (or D ) connector at the Powertrain Control Module (PCM) for presence of moisture, and if necessary, replacing either the two ground wires or the C4 connector. MODELS: 2005 (KJ) Liberty/Cherokee NOTE: This bulletin applies to vehicle equipped with a 3.7L engine and a 42RLE automatic transmission (sales code EKG and DG6 respectively) and built prior to April 18, 2005 (MDH 0418XX). SYMPTOM/CONDITION: The customer may notice while driving that the automatic transmission has entered into Limp-In mode (2nd gear). The customer may experience a Malfunction Indicator Lamp (MIL) illumination. This condition may be intermittent. Further diagnostic investigation by the technician may reveal that the MIL is the result of Diagnostic Trouble Codes (DTC s) that are transmission related and may be one of the following: P Transmission Temperature Sensor Intermittent P Output Speed Sensor Error P0755-2/4 Solenoid Circuit P OD Solenoid Circuit P UD Solenoid Circuit P LR Pressure Switch Sense Circuit P0846-2/4 Pressure Switch Sense Circuit P Fault Immediately After Shift P Speed Sensor Ground Error This condition may be due to water entering the PCM ground wires at the ground ring terminal. Water may track internally in the ground wire and deposit moisture inside the C4 Form TSB-003 Rev. 1.07

2 REV A -2- connector (green) at the PCM. The source of the water may be a partially unseated plastic push pin used to secure the cowl grill to the cowl panel. DIAGNOSIS: 1. Using a scan tool (DRBIII ) determine if one or more of the above DTC s are present: 2. Turn the ignition switch to the OFF position. 3. Disconnect and isolate the negative battery cable from the battery. 4. Remove the C4 connector (green color code) from the Powertrain Control Module (PCM) and inspect the connection for the presence of moisture. 5. If only moisture is present in the C4 connector without evidence of terminal corrosion, then replace only the PCM ground wire in the Repair Procedure. 6. If moisture and evidence of terminal corrosion is present in the C4 connector, then replace the PCM C4 connector in the Repair Procedure. PARTS REQUIRED: NOTE: Harness repair kits are not expected to be available until approximately August 17, Qty. Part No. Description AR (1) ** AA Kit, Ground Wire Lead Repair (includes: ground wire, AR (1) ** ** AA ** ** Nut, Ground ** NPN Electrical Tape NPN Solder - Rosin Core plastic tie wraps, and C4 connector plastic cover) Kit, PCM D Connector Repair (includes: populated C4 connector w/ground wire, wire splice bands, heat shrink tubes w/adhesive, plastic tie wraps, and C4 connector plastic cover) SPECIAL TOOLS / EQUIPMENT REQUIRED: 6680 Special Tool - Terminal Pin Removal AA Wire Splice Band Crimp Tool (part of the Mopar Harness/Connector Repair Kit) Heat Gun Soldering Tool CH6000A Scan Tool (DRBIII ) CH7000/7001 J1962 Cable with red DRBIII connector

3 REV A REPAIR PROCEDURE: Perform This Procedure To Replace The PCM Ground Wire Only: 1. If not already performed, turn the ignition switch to the off position. Remove and isolate the negative battery cable from the battery. 2. Remove and discard the old ground nut used to attach the ground wire ring terminal to the vehicle body (Fig. 1). FIGURE 1 - RING TERMINAL AND PUSH PIN 1 Cowl Grill 2 Old Ring Terminal - Without Shrink Wrap Around Wire Crimp 3 Ring Terminal Wire Crimp - Positioned Towards Left Fender And PCM (3 o clock position) 4 Ground Stud And Nut 5 Plastic Push Pin - Must Be Fully Seated To Grill And Body 3. Remove the C4 connector (38-way) from the PCM (if not already removed). 4. Remove the plastic cover used to protect the wires from the back of the C4 connector 5. Locate the two ground wires and terminals (pins #12 and #13) in the C4 connector (Fig. 2). Form TSB-003 Rev. 1.07

4 REV A -4- FIGURE 2-C4 CONNECTOR AND GROUND WIRES 1 PCM Connector With Plastic Cover- Typical 2 C4 PCM Connector Without Plastic Cover 3 C4 Terminal Pin Wires #12 and #13 4 Battery Positive Cables 5 Tape Applied To PCM Connector - Typical 6. Release the red latch on the C4 connector used to secure the connector wire terminals (Fig. 3). 7. Insert the terminal pin removal tool into pin #12 cavity and remove pin #12 ground wire terminal from the C4 connector. 8. Insert the terminal pin removal tool into pin #13 cavity and remove pin #13 ground wire terminal from the C4 connector. 9. Cut and tape back, so as to isolate, the old PCM ground wires at the PCM and ground stud. 10. Install the two new ground wire terminals into cavities #12 and #13 of the C4 connector. Either terminal can go into either cavity. 11. Lock the red latch on the C4 connector to secure the connector wire terminals. 12. Install the new plastic cover to the back of the C4 connector. 13. Tape the C4 connector wires to the new plastic cover. 14. Clean the connection between the PCM and the C4 connector of any moisture.

5 REV A 15. Route the new ground wire along the engine compartment harness, and then to its body ground stud. 1 C4 Terminal Pins #12 and #13 2 Special Tool Terminal Pin Removal 3 C4 PCM Connector 4 Electrical Tape 5 Plastic Cover - PCM Connector 6 Release Latch - Terminal Pin FIGURE 3 - TERMINAL REMOVAL 16. Without the ground ring terminal in place, install the new ground nut to vehicle body ground stud. Tighten the nut to 14.7 Nm (130 in. lbs.). Remove the new ground nut from the ground stud. 17. Install the new ground wire ring terminal to the vehicle body ground stud. Position the wire crimp section of the ground ring terminal so that when fully tightened the wire crimp when viewed is pointing to the 3 o clock position (towards the left fender) (Fig. 1). 18. Install the new ground nut and tighten the nut to 14.7 Nm (130 in. lbs.). 19. Verify that the seal used to seal the C4 connector to PCM is positioned correctly. 20. Install the C4 connector to the PCM. 21. Secure the ground wire to the engine compartment harness with plastic tie wraps. 22. Partially remove the left side of the cowl edge weather-strip seal and verify that the left cowl grill push pin is fully seated. Install the cowl grill weather-strip seal (Fig. 1). Form TSB-003 Rev. 1.07

6 REV A Verify proper wiring repair. 24. Check all transmission electrical connections for moisture. Clean connections as required. 25. Connect the negative battery cable to the battery. Set the clock to the correct time. 26. Using the scan tool (DRBIII ) erase any DTC s that may be present. 27. Verify correct transmission operation. Perform This Procedure To Replace The PCM C4 Connector With New Ground Wire: 1. If not already performed, turn the ignition switch to the off position. Remove and isolate the negative battery cable from the battery. 2. Remove and discard the old ground nut used to attach the ground wire ring terminal to the vehicle body (Fig. 1). 3. Cut and tape back, so as to isolate, the old ground wires at the ground stud. 4. Remove the C4 connector (38-way) from the PCM (if not already removed). 5. Remove the old plastic cover used to protect the wires from the back of the C4 connector 6. To prevent error, each C4 connector wire should be cut, spliced, and shrink wrapped one wire at a time. When wires are cut from the OLD C4 connector make sure that the wires are cut as close to the back of the old C4 connector as possible. This will allow for wire splices to be staggered along the electrical wire harness (preferred) versus all splices occurring at the same location in the wire harness. The original convolute will be reused. Each wire in the C4 connector is color coded to match the wires from the wire harness. 7. Repairing one wire at a time, cut and trim the wire ends on the new C4 connector wire and on the original harness wire. Slide the heat shrink wrap sleeve onto the wire. Using a splice band and crimping tool splice the wire ends together. Solder the splice. Using a heat gun position (center) the shrink wrap sleeve over the wire splice and apply heat to the shrink wrap sleeve. If necessary, refer to detailed splice procedures available on DealerCONNECT under the Service Info tab - 8-Electrical / Wiring Diagram Information / Wire / Standard Procedure / Wire Splicing (Fig. 4). 1 TOOL CRIMPING WIRE SPLICE BAND FIGURE 4 - CRIMPING TOOL 8. Complete the wire splice process for the remaining C4 connector wires.

7 REV A 9. Verify that the red latch on the C4 connector used to secure the connector wire terminals is in its locked position. 10. Install the new plastic cover to the back of the C4 connector. 11. Tape the C4 connector wires to the new plastic cover. 12. Tape the wire harness from the C4 connector and install original convolute tubing over repaired harness. 13. Clean the connection between the PCM and the C4 connector of any moisture. 14. Route the new ground wire along the engine compartment harness, and then to its body ground stud. 15. Without the ground ring terminal in place, install the new ground nut to vehicle body ground stud. Tighten the nut to 14.7 Nm (130 in. lbs.). Remove the new ground nut from the ground stud. 16. Install the new ground wire ring terminal to the vehicle body ground stud. Position the wire crimp section of the ground ring terminal so that when fully tightened the wire crimp when viewed is pointing to the 3 o clock position (towards the left fender) (Fig. 1). 17. Install the new ground nut and tighten the nut to 14.7 Nm (130 in. lbs.). 18. Verify that the seal used to seal the C4 connector to PCM connection is positioned correctly. 19. Install the C4 connector to the PCM. 20. Secure the ground wire to the engine compartment harness with plastic tie wraps. 21. Partially remove the left side of the cowl edge weather-strip seal and verify that the left cowl grill push pin is fully seated. Install the cowl edge weather-strip seal (Fig. 1). 22. Verify proper wiring repair. 23. Check all transmission electrical connections for moisture. Clean connections as required. 24. Connect the negative battery cable to the battery. Set the clock to the correct time. 25. Using the scan tool (DRBIII ) erase any DTC s that may be present. 26. Verify correct transmission operation. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Labor Operation Description No: Inspect / Replace Ground Wire At Powertrain Control Module Inspect / Replace Ground Wire And PCM Connector At Powertrain Control Module Amount 0.4 Hrs. 1.5 Hrs. Form TSB-003 Rev. 1.07

8 REV A -8- FAILURE CODE: 3T Terminals Corroded