Polaris Ranger 700 4×4 Crew 2009 Factory Service Repair Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:352
DOWNLOADABLE:YES
FILE TYPE:PDF
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
SAMPLE PAGE FROM THE MANUAL:
Polaris Ranger 700 4×4 Crew 2009 Factory Service Repair Manual
Periodic Maintenance Overview
Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Pure Polaris parts available from your Polaris dealer.
NOTE: Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.
TABLE OF CONTENTS:
Polaris Ranger 700 4×4 Crew 2009 Factory Service Repair Manual
9921885_Chapter_01.pdf.......................................................... 1
GENERAL INFORMATION......................................................... 1
MODEL INFORMATION....................................................... 2
Model Identification................................................ 2
Engine Designation Number........................................... 2
VIN Identification.................................................. 2
Engine Serial Number Location....................................... 2
Vehicle Identification Number (VIN) Location........................ 3
Transmission I.D. Number Location................................... 3
VEHICLE DIMENSIONS...................................................... 4
RANGER 4x4 CREW / 6X6 (Height and Width)............................ 4
RANGER 6X6 (Length and Wheel Base).................................. 5
RANGER 4x4 CREW (Length and Wheel Base)............................. 5
GENERAL SPECIFICATIONS.................................................. 6
MODEL: 2009 RANGER 4X4 CREW......................................... 6
MODEL: 2009 RANGER 4X4 CREW......................................... 7
MODEL: 2009 RANGER 6X6.............................................. 8
MODEL: 2009 RANGER 6X6.............................................. 9
VEHICLE INFORMATION..................................................... 10
Publication Numbers................................................. 10
Paint Codes......................................................... 10
Replacement Keys.................................................... 10
SPECIAL TOOLS........................................................... 10
MISC. SPECIFICATIONS AND CHARTS......................................... 11
Conversion Table.................................................... 11
Standard Torque Specifications...................................... 12
SAE Tap / Drill Sizes............................................... 13
Metric Tap / Drill Sizes............................................ 13
Decimal Equivalents................................................. 13
Glossary of Terms................................................... 14
9921885_Chapter_02.............................................................. 15
MAINTENANCE................................................................. 15
PERIODIC MAINTENANCE CHART.............................................. 17
Periodic Maintenance Overview....................................... 17
Break-In Period..................................................... 17
Maintenance Chart Key............................................... 17
Pre-Ride - 25 Hour Maintenance Interval............................. 18
50 - 100 Hour Maintenance Interval.................................. 19
100 - 300 Hour Maintenance Interval................................. 20
SERVICE PRODUCTS AND LUBES.............................................. 21
Polaris Lubricants, Maintenance and Service Products................ 21
MAINTENANCE REFERENCES.................................................. 22
Maintenance References, Continued................................... 23
GENERAL VEHICLE INSPECTION AND MAINTENANCE.............................. 24
Pre-Ride / Daily Inspection......................................... 24
Frame, Nuts, Bolts, and Fasteners................................... 24
Shift Linkage Inspection / Adjustment............................... 24
FUEL SYSTEM AND AIR INTAKE.............................................. 25
Fuel System......................................................... 25
Fuel Lines.......................................................... 25
Fuel Filter......................................................... 25
Vent Lines.......................................................... 25
Throttle Pedal Inspection........................................... 25
Throttle Freeplay Adjustment........................................ 26
Air Filter Service.................................................. 26
Air Intake Inspection............................................... 27
ENGINE.................................................................. 28
Compression and Leakdown Test....................................... 28
Breather Hose Inspection............................................ 28
Engine Oil Level.................................................... 28
Engine Oil and Filter Change........................................ 29
Exhaust Pipe........................................................ 30
TRANSMISSION AND GEARCASES.............................................. 31
Transmission Lubrication............................................ 31
Front Gearcase Lubrication.......................................... 32
Middle Gearcase Lubrication (6x6)................................... 33
Rear Gearcase Lubrication (4x4 CREW)................................ 34
Rear Gearcase Lubrication (6x6)..................................... 35
COOLING SYSTEM.......................................................... 36
Liquid Cooling System Overview...................................... 36
Coolant Level Inspection............................................ 36
Radiator Coolant Level Inspection................................... 37
Coolant Strength / Type............................................. 37
Cooling System Pressure Test........................................ 37
Cooling System Hoses................................................ 37
Radiator............................................................ 38
Coolant Drain / Radiator Removal.................................... 38
FINAL DRIVE / WHEEL AND TIRE............................................ 39
Wheel and Hub Torque Table.......................................... 39
CV Shaft Boot Inspection............................................ 39
Wheel Removal....................................................... 39
Wheel Installation.................................................. 39
Tire Inspection..................................................... 40
Tire Pressure....................................................... 40
ELECTRICAL AND IGNITION SYSTEM.......................................... 40
Battery Maintenance................................................. 40
Battery Fluid Level (Conventional Battery).......................... 41
Battery Removal..................................................... 41
Battery Installation................................................ 41
Battery Storage..................................................... 41
Battery Charging.................................................... 41
Spark Plug Service.................................................. 42
Engine To Frame Ground.............................................. 42
STEERING AND SUSPENSION................................................. 43
Steering............................................................ 43
Tie Rod End / Steering Inspection................................... 43
Wheel Toe Alignment Inspection...................................... 43
Toe Adjustment...................................................... 44
Front Suspension.................................................... 44
Rear Suspension..................................................... 45
Rear Suspension Adjustment (4x4 CREW)............................... 45
Rear Spring Adjustment.............................................. 45
BRAKE SYSTEM............................................................ 46
Brake Fluid Inspection.............................................. 46
Brake Hose and Fitting Inspection................................... 46
Brake Pad / Disc Inspection......................................... 46
Parking Brake Cable Adjustment...................................... 46
Parking Brake Pad Inspection........................................ 47
9921885_Chapter_03.............................................................. 49
ENGINE...................................................................... 49
ENGINE SPECIFICATIONS................................................... 50
Crankcase Exploded Views............................................ 50
Engine Fastener Torque Patterns..................................... 57
Torque Specifications............................................... 58
700 EFI Engine Service Specifications............................... 59
Special Tools....................................................... 61
GENERAL ENGINE SERVICE.................................................. 61
Accessible Components............................................... 61
Piston Identification............................................... 61
Cooling System Specifications....................................... 61
Cooling System Pressure Test........................................ 62
Cooling System Exploded View........................................ 63
Cooling System Bleeding Procedure................................... 63
Valve Cover Removal - 6x6 Models (Engine Installed)................. 65
Engine Removal...................................................... 66
Engine Installation Notes........................................... 67
Engine Lubrication Specifications................................... 68
Oil Pressure Test................................................... 68
Oil Flow Chart...................................................... 69
ENGINE DISASSEMBLY AND INSPECTION....................................... 70
Cylinder Head Assembly Exploded View................................ 70
Rocker Arms......................................................... 71
Push Rods........................................................... 71
Cylinder Head Removal .............................................. 71
Cylinder Head Inspection............................................ 72
Cylinder Head Warp.................................................. 72
Valve Seal / Spring Service (On Engine)............................. 72
Cylinder Head Disassembly........................................... 73
Valve Inspection.................................................... 74
Combustion Chamber.................................................. 75
Valve Seat Reconditioning........................................... 75
Cylinder Head Reassembly............................................ 77
Valve Sealing Test.................................................. 78
Cylinder Removal.................................................... 78
Valve Lifter Removal / Inspection................................... 78
Piston Removal...................................................... 79
Cylinder Inspection................................................. 80
Cylinder Hone Selection And Honing Procedure........................ 81
Honing To Deglaze................................................... 81
Cleaning the Cylinder After Honing.................................. 81
Piston-to-Cylinder Clearance........................................ 82
Piston / Rod Inspection............................................. 82
Piston Ring Installed Gap........................................... 83
Starter Drive Bendix Removal / Inspection .......................... 83
Flywheel / Stator Removal / Inspection.............................. 84
Engine Crankcase Disassembly / Inspection........................... 84
Camshaft Inspection................................................. 92
ENGINE REASSEMBLY....................................................... 93
Crankcase Reassembly................................................ 93
Flywheel / Stator Installation......................................102
Cylinder Head Reassembly............................................103
Oil Pump Priming....................................................105
Engine Break-In.....................................................105
TROUBLESHOOTING.........................................................106
Engine..............................................................106
Cooling System......................................................107
9921885_Chapter_04..............................................................109
ELECTRONIC FUEL INJECTION...................................................109
GENERAL INFORMATION.....................................................110
Special Tools.......................................................110
EFI Service Notes...................................................113
Fuel Tank Exploded View.............................................114
EFI System Exploded View............................................115
EFI System Component Locations......................................116
Fuel Lines - Quick Connect Removal / Installation...................117
ELECTRONIC FUEL INJECTION...............................................118
Principal Components................................................118
EFI Operation Overview..............................................118
Initial Priming / Starting Procedure................................118
ELECTRONIC CONTROL UNIT (ECU)...........................................119
Operation Overview..................................................119
ECU Service.........................................................119
ECU Replacement.....................................................119
FUEL PUMP...............................................................120
Operation Overview..................................................120
Fuel Sender Test....................................................120
Fuel Pump Test......................................................120
Fuel Pump / Tank Assembly Replacement...............................121
FUEL PRESSURE REGULATOR.................................................122
Operation Overview..................................................122
Fuel Pressure Regulator Test........................................122
Fuel Pressure Regulator Replacement.................................122
FUEL INJECTORS..........................................................123
Operation Overview..................................................123
Fuel Injector Service...............................................123
Fuel Injector Replacement...........................................123
CRANKSHAFT POSITION SENSOR (CPS)........................................124
Operation Overview..................................................124
CPS Test............................................................124
CPS Replacement.....................................................124
TEMPERATURE / BAROMETRIC AIR PRESSURE SENSOR (T-BAP)....................125
Operation Overview..................................................125
T-BAP Test..........................................................125
T-BAP Replacement...................................................125
THROTTLE POSITION SENSOR (TPS)..........................................125
Operation Overview..................................................125
TPS Tester / Regulator..............................................125
Checking TPS Reading................................................127
TPS Adjustment......................................................127
TPS Replacement.....................................................128
ENGINE COOLANT TEMPERATURE SENSOR (ECT).................................128
Operation Overview..................................................128
ECT Sensor Test.....................................................128
ECT Sensor Replacement..............................................128
IGNITION COIL...........................................................129
Operation Overview..................................................129
Ignition Coil Tests.................................................129
Ignition Coil / HT Lead Replacement.................................129
GENERAL TROUBLESHOOTING.................................................130
Diagnostic “Blink Codes”............................................130
EFI Troubleshooting.................................................131
EFI SYSTEM BREAK-OUT DIAGRAMS...........................................132
Fuel Injector Circuit (PTO).........................................132
Fuel Injector Circuit (MAG).........................................132
Crankshaft Position Sensor (CPS) Circuit............................133
Fuel Pump Circuit...................................................133
Engine Coolant Temperature Sensor (ECT) ............................134
Temperature Overheat Indicator Lamp Circuit.........................134
Throttle Position Sensor (TPS) Circuit..............................135
Air Temperature / Barometric Air Pressure Sensor (T-BAP) Circuit....135
Diagnostic Connector Circuit........................................136
Diagnostic Indicator Lamp Circuit...................................136
9921885_Chapter_05..............................................................137
BODY / STEERING / SUSPENSION................................................137
TORQUE SPECIFICATIONS...................................................138
SPECIAL TOOLS...........................................................138
BODY COMPONENT REMOVAL..................................................139
Removal Procedures..................................................139
Lower Body, Floor and Fenders (4x4 CREW)............................140
Lower Body, Floor and Fenders (6x6).................................141
Hood / Dash Components..............................................142
Dash Instruments and Controls.......................................143
CAB FRAME...............................................................144
Assembly / Removal (6x6)............................................144
Assembly / Removal (4x4 CREW).......................................145
SEAT / HEAD REST........................................................146
Seat Back / Head Rests..............................................146
CHASSIS / MAIN FRAME (4X4 CREW).........................................147
Exploded View.......................................................147
CHASSIS / MAIN FRAME (6X6)..............................................148
Exploded View.......................................................148
STEERING ASSEMBLY.......................................................149
Exploded View.......................................................149
STEERING AND SUSPENSION.................................................150
Exploded View.......................................................150
FRONT A-ARM.............................................................151
Replacement.........................................................151
FRONT STRUT.............................................................152
Exploded View.......................................................152
Front Strut Cartridge Replacement...................................153
Ball Joint Replacement..............................................153
MID AXLE A-ARM (6X6)....................................................154
Replacement.........................................................154
REAR A-ARM (4X4 CREW)...................................................155
Replacement.........................................................155
REAR STABILIZER BAR (4X4 CREW)..........................................157
Removal / Installation..............................................157
SWING ARM (6X6).........................................................158
Removal.............................................................158
Installation........................................................158
REAR DRIVE AXLE AND SWING ARM EXPLODED VIEW (6X6).......................159
REAR CARGO BOX..........................................................160
Cargo Box - Panels..................................................160
Cargo Box - Tailgate / Box Support..................................161
Box Removal.........................................................162
Box Installation....................................................162
STORAGE BOX (4X4 CREW)..................................................163
Removal.............................................................163
Installation........................................................163
DECAL REPLACEMENT.......................................................163
9921885_Chapter_06..............................................................165
CLUTCHING...................................................................165
SPECIAL TOOLS AND SUPPLIES..............................................166
TORQUE SPECIFICATIONS...................................................166
PVT System Fastener Torques.........................................166
PVT SYSTEM OVERVIEW.....................................................166
General Operation...................................................166
Drive Clutch Operation..............................................166
Driven Clutch Operation.............................................167
PVT Break-In (Drive Belt / Clutches)................................167
Maintenance / Inspection............................................167
Overheating / Diagnosis.............................................168
PVT SYSTEM SERVICE......................................................169
PVT Sealing, Guard, and Ducting Components..........................169
Disassembly.........................................................169
Assembly............................................................170
DRIVE BELT..............................................................171
Belt Removal........................................................171
Belt Inspection.....................................................172
Belt Installation...................................................172
PVT Break-In (Drive Belt / Clutches)................................172
CLUTCH ALIGNMENT........................................................172
Clutch Alignment Tool Use...........................................172
CLUTCH CENTER DISTANCE..................................................173
DRIVE CLUTCH SERVICE....................................................174
Spring Specifications...............................................174
Shift Weights.......................................................175
Exploded View.......................................................176
Clutch Disassembly..................................................176
Spider Removal......................................................177
Roller, Pin, and Thrust Washer Inspection...........................178
Button To Tower Clearance Inspection................................178
Shift Weight Inspection.............................................178
Bearing Inspection..................................................179
Clutch Inspection...................................................179
Moveable Sheave Bushing Inspection..................................180
Bushing Service.....................................................181
Clutch Assembly.....................................................183
DRIVEN CLUTCH SERVICE...................................................184
Exploded View.......................................................184
Clutch Disassembly / Inspection.....................................184
Clutch Assembly.....................................................186
TROUBLESHOOTING.........................................................187
9921885_Chapter_07..............................................................189
FINAL DRIVE.................................................................189
SPECIAL TOOLS...........................................................191
TORQUE SPECIFICATIONS...................................................191
Wheel, Hub, and Spindle Torque Table................................191
FRONT HUB...............................................................191
Hub Removal / Inspection............................................191
Hubstrut Bearing Replacement........................................192
Hub Installation....................................................193
Front Hub Exploded View.............................................194
FRONT DRIVE SHAFT.......................................................195
Removal.............................................................195
Drive Shaft / CV Joint Handling Tips................................196
Outer CV Joint / Boot Replacement...................................196
Inner Plunging Joint / Boot Replacement.............................198
Exploded View.......................................................199
Installation........................................................199
FRONT PROPSHAFT.........................................................200
6x6 Removal.........................................................200
4x4 CREW Removal....................................................200
Front Propshaft Components..........................................200
PROPSHAFT U-JOINT SERVICE...............................................201
Disassembly.........................................................201
Assembly............................................................201
FRONT GEARCASE / CENTRALIZED HILLIARD...................................203
Centralized Hilliard Exploded View..................................203
All Wheel Drive Operation...........................................204
AWD Diagnosis.......................................................205
Gearcase Removal....................................................206
Gearcase Disassembly / Inspection...................................207
Gearcase Reassembly / Inspection....................................209
Backlash Pad (Thrust Pad) Adjustment................................211
Gearcase Installation...............................................212
MID DRIVE HUB / BEARING CARRIER (6X6)...................................212
Removal.............................................................212
Hub Disassembly.....................................................213
Hub Assembly........................................................213
Hub Installation....................................................214
Mid Drive Exploded View.............................................215
MID DRIVE SHAFT (6X6)...................................................215
Removal.............................................................215
Disassembly / Assembly..............................................215
Installation........................................................216
MID PROPSHAFT (6X6).....................................................216
Removal.............................................................216
MID DRIVE GEARCASE (6X6)................................................217
Gearcase Removal....................................................217
Gearcase Disassembly................................................218
Gearcase Assembly...................................................220
Gearcase Installation...............................................223
Mid Gearcase Exploded...............................................224
REAR HUB / BEARING CARRIER (4X4)........................................225
Hub Inspection......................................................225
Hub Removal.........................................................225
Hub Disassembly.....................................................226
Hub Assembly........................................................226
Hub Installation....................................................227
Exploded View.......................................................228
REAR DRIVE SHAFT (4X4 CREW).............................................229
Removal.............................................................229
Outer CV Joint / Boot Replacement...................................229
Inner Plunging Joint / Boot Replacement.............................232
Drive Shaft Exploded View...........................................234
Installation........................................................235
REAR PROPSHAFT (4X4 CREW)...............................................236
Removal.............................................................236
Installation........................................................236
REAR GEARCASE (4X4 CREW)................................................237
General Operation...................................................237
Operation Modes.....................................................238
Gearcase Removal....................................................239
Gearcase Disassembly................................................239
Rear Gearcase Assembly..............................................242
Rear Gearcase Installation..........................................244
Rear Gearcase Exploded View (4x4 CREW)..............................245
REAR AXLE / GEARCASE SERVICE (6X6)......................................246
Rear Axle Removal...................................................246
Axle Tube Removal...................................................247
Axle Tube Bearing Replacement.......................................248
Gearcase Disassembly / Inspection...................................248
Gearcase Assembly...................................................249
Gearcase / Axle Installation........................................250
Rear Gearcase Exploded View (6x6)...................................253
9921885_Chapter_08..............................................................255
TRANSMISSION................................................................255
TORQUE SPECIFICATIONS...................................................256
SHIFT LEVER.............................................................256
Removal.............................................................256
Installation........................................................256
SHIFT LINKAGE...........................................................256
Inspection..........................................................256
Adjustment..........................................................257
TRANSMISSION SERVICE....................................................257
Transmission Removal................................................257
Transmission Disassembly............................................259
Transmission Assembly...............................................264
Transmission Installation...........................................268
TROUBLESHOOTING.........................................................269
Troubleshooting Checklist...........................................269
TRANSMISSION EXPLODED VIEW..............................................270
Exploded View.......................................................270
9921885_Chapter_09..............................................................273
BRAKES......................................................................273
GENERAL SPECIFICATIONS..................................................274
TORQUE SPECIFICATIONS...................................................274
SPECIAL TOOLS...........................................................274
BRAKE SYSTEM SERVICE NOTES..............................................275
BRAKE NOISE TROUBLESHOOTING.............................................275
HYDRAULIC BRAKE SYSTEM OPERATION........................................276
BRAKE SYSTEM EXPLODED VIEW..............................................277
6x6.................................................................277
4x4 CREW............................................................277
MASTER CYLINDER.........................................................278
Removal.............................................................278
Installation........................................................278
FOOT BRAKE PEDAL........................................................278
Pedal Removal.......................................................278
Pedal Installation..................................................278
BRAKE BLEEDING / FLUID CHANGE...........................................279
PARKING BRAKE...........................................................280
Exploded View (4x4 CREW)............................................280
Exploded View (6x6).................................................281
Inspection..........................................................282
Cable Tension Adjustment............................................282
PARKING BRAKE CALIPER SERVICE...........................................283
Exploded View.......................................................283
Caliper Removal.....................................................283
Caliper Disassembly / Inspection....................................284
New Brake Pad Installation..........................................285
Caliper Installation................................................285
PARKING BRAKE DISC SERVICE..............................................285
Disc Inspection / Removal...........................................285
FRONT BRAKE PADS........................................................286
Pad Removal.........................................................286
Pad Inspection......................................................286
Pad Assembly / Installation.........................................287
Brake Burnishing Procedure..........................................287
FRONT CALIPER SERVICE...................................................288
Caliper Exploded View...............................................288
Caliper Removal ....................................................288
Caliper Disassembly.................................................289
Caliper Inspection..................................................290
Caliper Assembly....................................................290
Caliper Installation................................................291
FRONT BRAKE DISC........................................................292
Disc Inspection.....................................................292
Disc Replacement....................................................292
REAR BRAKE PADS (6X6)...................................................293
Pad Removal.........................................................293
Pad Inspection......................................................293
Pad Installation....................................................294
REAR BRAKE PADS (4X4 CREW)..............................................294
Pad Removal.........................................................294
Pad Inspection......................................................295
Pad Assembly / Installation.........................................295
Brake Burnishing Procedure..........................................296
REAR CALIPER SERVICE (6X6)..............................................297
Rear Caliper Exploded View..........................................297
Caliper Removal.....................................................297
Caliper Disassembly.................................................298
Caliper Inspection..................................................298
Caliper Assembly....................................................299
Caliper Installation................................................299
REAR CALIPER SERVICE (4X4 CREW).........................................300
Rear Caliper Exploded View..........................................300
Caliper Removal ....................................................300
Caliper Disassembly.................................................301
Caliper Inspection..................................................302
Caliper Assembly....................................................302
Caliper Installation................................................303
REAR BRAKE DISC.........................................................304
Disc Inspection.....................................................304
Disc Replacement....................................................304
TROUBLESHOOTING.........................................................305
Brakes Squeal / Poor Brake Performance..............................305
Pedal Vibration.....................................................305
Caliper Overheats (Brakes Drag).....................................305
Brakes Lock.........................................................305
9921885_Chapter_10..............................................................307
ELECTRICAL..................................................................307
GENERAL INFORMATION.....................................................309
Special Tools.......................................................309
Electrical Service Notes............................................309
Under-Hood Components...............................................309
SWITCHES / CONTROLS.....................................................310
Headlight Switch....................................................310
AWD / 2WD / TURF Switch (4x4 CREW)..................................310
Differential Solenoid (4x4 CREW)....................................310
Brake Light Switch..................................................311
Parking Brake Switch................................................312
INSTRUMENT CLUSTER......................................................313
Overview............................................................313
Rider Information Display...........................................313
Standard Display Modes..............................................314
Diagnostic Display Mode.............................................314
Viewing Diagnostic Codes............................................316
Instrument Cluster Removal..........................................317
Instrument Cluster Installation.....................................317
INSTRUMENT CLUSTER TROUBLESHOOTING TESTS................................318
Test 1 - No All Wheel Drive.........................................318
TEST 2 - No Display.................................................319
TEST 3 - Wheel Speed Sensor.........................................319
TEST 4 - No AWD Hub Safety Limiter..................................320
TEST 5 - Fuel Gauge Display Not Working ............................321
TEST 6 - Shift Indicator Not Working (Transmission Switch)..........321
ALL WHEEL DRIVE (AWD) COIL..............................................322
Operation Overview..................................................322
Diagnosing System Failures..........................................322
GEAR POSITION INDICATOR SWITCH..........................................322
Test Diagram........................................................322
HEADLIGHTS..............................................................323
Headlight Adjustment................................................323
Headlight Bulb Replacement..........................................323
Headlight Housing Removal...........................................323
Headlight Housing Installation......................................324
TAIL LIGHT / BRAKE LIGHT................................................324
Lamp Replacement....................................................324
COOLING SYSTEM..........................................................325
Cooling System Break-Out Diagram....................................325
Fan Control Circuit Operation.......................................326
Fan Control Circuit Bypass Test.....................................326
Coolant Temperature Sensor..........................................326
EFI DIAGNOSTICS.........................................................326
EFI Component Testing...............................................326
FUEL SENDER.............................................................326
Testing.............................................................326
RELAYS..................................................................327
Operation...........................................................327
FUSES / CIRCUIT BREAKER.................................................328
Operation...........................................................328
CHARGING SYSTEM.........................................................329
Current Draw - Key Off..............................................329
Charging System “Break Even” Test...................................329
Charging System Alternator Tests....................................330
Charging System Testing Flow Chart..................................331
BATTERY SERVICE.........................................................332
Battery Terminals / Bolts...........................................332
Battery Terminal Block..............................................332
Battery Activation..................................................332
Battery Inspection..................................................333
Battery Removal / Installation......................................333
Battery Testing.....................................................333
OCV - Open Circuit Voltage Test.....................................333
Specific Gravity Test...............................................334
Load Test...........................................................334
Off Season Storage..................................................334
Charging Procedure..................................................334
STARTER SYSTEM..........................................................335
Troubleshooting.....................................................335
Voltage Drop Test...................................................335
Starter Motor Removal / Disassembly ................................335
Brush Inspection / Replacement......................................336
Armature Testing....................................................337
Starter Reassembly / Installation...................................337
Starter Drive.......................................................338
Starter Solenoid Bench Test.........................................339
Starter Solenoid Operation..........................................339
Starter Exploded View...............................................340
STARTING SYSTEM TESTING FLOW CHART......................................341
Condition: Starter fails to turn over the engine. ..................341
ELECTRIC BOX LIFT ACTUATOR..............................................342
DIAGNOSIS (if equipped).............................................342
ELECTRICAL BREAK-OUT DIAGRAMS...........................................343
Starting Circuit....................................................343
Key-On Power Circuit................................................343
Transmission Switch Circuit.........................................344
AWD Circuit.........................................................344
Speed Sensor Circuit................................................345
Charging System Circuit.............................................345
Cooling Fan Circuit.................................................346
Fuel Display / Fuel Pump Circuit....................................346
9921885_Wire_Diagrams...........................................................347
PLEASE NOTE:
- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
- No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
- Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
- So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com
Brendan Danny –
very good and correct