'

1998 Chevrolet Camara

and Pontiac Firebird
Service Manual
Volume 3
This manual provides information on the diagnosis, the service procedures, the adjustmonlh.
and the specifications for the 1998 Chevrolet Camara and Pontiac Firebird. This is the 11oco1111
edition of the 1998 Chevrolet Camara and Pontiac Firebird Service Manual. This manual
contains new and updated information that will help you diagnose and service vehicles. If you
are in the possession of the early edition of this manual GMP/98-F Volumes 1, 2, and 3 pleaso
DISCARD it because the information is outdated.
Information on transmission unit repair (overhaul) can be found in the 1998
Transmission/Transaxle/Transfer Case Unit Repair Manual (TURM), GMPT/98-TURM, available
separately. The TURM manual contains information on automatic and manual transmissions,
including the fluid flow and circuit description information.
The technicians who understand the material in this manual and in the appropriate Dealer
Service Bulletins better serve the vehicle owners.
When this manual refers to a brand name, a part number, or a specific tool, you may use an
equivalent product in place of the recommended item. All information, illustrations, and
specifications in this manual are based on the latest product information available at the time of
publication approval. General Motors reserves the right to make changes at any time without
notice.

TABLE OF CONTENTS
Volume 1

Volume 2

Preface ................................................................ 1

Preface ................................................................ 1

Cautions and Notices

.. .. ... . .. .. .. .. . .. ... . .. .. .. .. .. .. .. . .. . 3

Cautions and Notices

.. .. .... .. . . .. .. .. .. ... .. . . .. ... .. . .. . . .. 3

General Information ....................................... 0-1

Steering ............................................................ 2-1

General Information ......................................... 0-3

Maintenance and Lubrication . .. .. . .. .. . .. .. . .. .. ... .. 0-33
Vibration Diagnosis and Correction ................ 0-45

Power Steering System ................................... 2-3

Steering Wheel and Column - Tilt ................. 2-51

HVAC ................................................................ 1-1

HVAC System - Manual

.................................. 1-3

Body and Accessories ...... .. .. ...... ..... ... ... .. .. ... 8-1
Lighting Systems ........................................... 8-15
Wipers/Washer Systems .............................. 8-161
Entertainment .............................................. 8-195
Wiring Systems ............................................ 8-282
Body Control System .. ... ... ... .. .. ... ... .. . .. ... ... .. . 8-425
Instrument Panel, Gauges and Console ....... 8-467
Keyless Entry .............................................. 8-545
Horns .......................................................... 8-560
Theft Deterrent ............................................ 8-569
Cruise Control ............................................. 8-601
Retained Accessory Power .......................... 8-640
Exterior Trim ............................................... 8-647
Waterleaks .................................................. 8-658
Air/Wind Noise ............................................ 8-665
Squeaks and Rattles ................................... 8-667
Stationary Windows ..................................... 8-683
Bumpers ..................................................... 8-712
Body Front End ........................................... 8-734
Doors .......................................................... 8-771
Roof ............................................................ 8-825
Seats .. . .. .. ... . .. ... . .. . ... .... .... .. .. ..... ... ... .. .. ... ... .. 8-896
Interior Trim ................................................ 8-939
Body Rear End ........................................... 8-955
Plastic Panel Information and Repair ........... 8-987
Paint/Coatings ........................................... 8-1014
Frame and Underbody ............................... 8-1022
Collision Repair ......................................... 8-1080

Restraints ......................................................... 9-1

Seat Belts .. .. .. .. . .. .. .. ... .... ... .. .. ..... . ... .. ... .. ... .... ... 9-3
SIR ............................................................... 9-20

INDEX ........................................................INDEX-1

Suspension ................... ...... ....... ................. ..... 3-1

Suspension General Diagnosis ........................ 3-3
Wheel Alignment ............................................. 3-7
Front Suspension .......................................... 3-12
Rear Suspension . .. .. .. . . ... .. .. .. .. . . ... .. .. .. .. . .. .. .. .. . 3-43
Tires and Wheels .......................................... 3-58

Driveline/Axle .................................................. 4-1

Propeller Shaft ................................................ 4-3
Rear Drive Axle ............................................ 4-23

Brakes .............................................................. 5-1

Hydraulic Brakes ............................................. 5-5
Disc Brakes . . .. .. ... .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. . .. . ... ... . 5-68
Park Brake .................................................... 5-92
Anti lock Brake System ................................ 5-108

INDEX ........................................................ INDEX-1

Volume 3
Preface ................................................................ 1
Cautions and Notices

.. . .. .. .. .. . .. .. .. . .. .. .. .. . . .. .. .. . . . .. . 3

Engine .............................................................. 6-1

Engine
Engine
Engine
Engine
Engine
Engine
Engine

Mechanical - 3.8L .............................. 6-13

Mechanical - 5.7L ............................ 6-229
Cooling ............................................ 6-580
Electrical ......................................... 6-665
Controls - 3.8L ................................ 6-725
Controls - 5.7L .............................. 6-1247
Exhaust ......................................... 6-1900

Transmissionffransaxle ................................ 7-1

Manual Transmission - M49 ............................ 7-5
Manual Transmission - MM6 ......................... 7-28
Automatic Transmission - 4L60-E .................. 7-56
Clutch

.. .. . ... .. . .. .. .. .. ... .. .. . . ... .. .. .. . .. .. .. .. .. .. . .. . ... 7-359

INDEX ........................................................ INDEX-1

Preface

Table of Contents

- 1

Cautions and Notices

Cautions and Notices .........................................3

Definition of Caution, Notice, and Important ...... 3

ABS Handling Caution ......................................3
Battery Disconnect Caution ............................... 3
Brake Dust Caution ..........................................3
Brake Fluid Caution ......................................... .4
Clutch Dust Caution ......................................... .4
Electric Coolant Fan Caution ........................... .4
Fuel and EVAP Pipe Caution ........................... .4
Fuel Gauge Leak Caution ................................ .4
Fuel Pipe Fitting Caution ................................. .4
Fuel Storage Caution ....................................... .4
Gasoline/Gasoline Vapors Caution ................... .4
Lower 0-Ring Removal Caution ....................... .4
Moving Parts and Hot Surfaces Caution ........... 4
Relieving Fuel Pressure Caution ...................... .4
Road Test Caution .......................................... .4
Safety Glasses and Compressed Air Caution .... 5
Safety Goggles and Fuel Caution ..................... 5
Seat Belt Replacement Caution ........................ 5
SIR Caution ......................................................5
SIR Handling Caution ....................................... 5

SIR lnflator Module Disposal Caution ................ 5

SIR lnflator Module Handling and Storage
Caution .........................................................5
SIR Special Tool Caution ..................................5
Vehicle Lifting Caution ......................................5
Window Removal Caution .................................5
Window Retention Caution ................................5
Work Stall Test Caution .................................... 6
Defective Scan Tool Notice ...............................6
Fastener Notice ................................................ 6
Fuel Pressure Notice ........................................6
Handling ESD Sensitive Parts Notice ................ 6
Handling IAC Valve Notice ...............................7
Ignition OFF When Disconnecting Battery
Notice ...........................................................7
Latched DTC 81018, 81024 Notice
(SDM-RSD) ...................................................7
Nylon Fuel Lines Notice ....................................7
OBDII System Description Notice ...................... 7
PCM and ESD Notice .......................................7
Servicing and Replacing Seat Belts Notice ....... 7

2 -

Preface

Table of Contents

BLANK

Preface

Cautions and Notices

- 3

Cautions and Notices

)

Definition of Caution, Notice, and

Important
The diagnosis and repair procedures in the GM
Service Manual contain both general and specific
Cautions, Notices, and lmportants. GM is dedicated to
the presentation of service information that helps
the technician to diagnose and repair the systems
necessary for the proper operation of the vehicle,
however, certain procedures may present a hazard to
the technician if they are not followed in the
recommended manner. Cautions, Notices, and
lmportants are elements designed to prevent these
hazards, however, not all hazards can be foreseen.
This information is placed at strategic locations within
the service manual. This information is designed to
prevent the following from occurring:
Serious bodily injury to the technician
Damage to the vehicle
Unnecessary vehicle repairs
Unnecessary component replacement
Improper repair or replacement of vehicle
components. Any caution or notice that appears in
general information is referenced from the
individual service categories.

CAUTION Defined
When encountering a CAUTION, you will be asked to
take a necessary action or not to take a prohibited
action. If a CAUTION is not heeded, the following
consequences may occur:
Serious bodily injury to the technician
Serious bodily injury to other technicians in the
workplace area
Serious bodily injury to the driver and/or
passenger(s) of the vehicle, if the vehicle has
been improperly repaired

NOTICE Defined
Notices call special attention to a necessary action or
to a prohibited action. If a NOTICE is not heeded,
the following consequences may occur:
Damage to the vehicle
Unnecessary vehicle repairs
Unnecessary component replacement
Improper operation or performance of the system
or component under repair
Damage to any systems or components which are
dependent upon the proper operation of the
system or component under repair
Improper operation or performance of any
systems or components which are dependent
upon the proper operation or performance of the
system or component under repair
Damage to fasteners, basic tools, or special tools
The leakage of coolant, lubricant, or other vital
fluids

IMPORTANT Defined
IMPORTANT statements emphasize a necessary
characteristic of a diagnostic or repair procedure.
IMPORTANT statements are designed to do
the following:
Clarify a procedure
Present additional information for accomplishing a
procedure
Give insight into the reason or reasons for
performing a procedure in the manner
recommended
Present information that will help to accomplish a
procedure in a more effective manner
Present information that gives the technician the
benefit of past experience in accomplishing a
procedure with greater ease

ABS Handling Caution

Caution: Certain components in the Antilock Brake
System (ABS) are not intended to be serviced
individually. Attempting to remove or disconnect
certain system components may result in personal
injury and/or improper system operation. Only
those components with approved removal
and installation procedures should be serviced.

Battery Disconnect Caution

Caution: Before servicing any electrical
component, the ignition key must be in the OFF or
LOCK position and all electrical loads must be
OFF, unless instructed otherwise in these
procedures. If a tool or equipment could easily
come in contact with a live exposed electrical
terminal, also disconnect the negative battery
cable. Failure to follow these precautions
may cause personal injury and/or damage to the
vehicle or its components.

Brake Dust Caution

Caution: Avoid taking the following actions when
you service wheel brake parts:
Do not grind brake linings.
Do not sand brake linings.
Do not clean wheel brake parts with a dry
brush or with compressed air.
Some models or aftermarket brake parts may
contain asbestos fibers which can become
airborne in dust. Breathing dust with asbestos
fibers may cause serious bodily harm. Use a
water-dampened cloth in order to remove any dust
on brake parts. Equipment is available
commercially in order to perform this washing
function. These wet methods prevent fibers from
becoming airborne.

4 -

Cautions and Notices

Pretace

Brake Fluid Caution

Fuel Pipe Fitting Caution

Caution: Brake fluid may be irritating to the skin

or eyes. In case of contact, take the following
actions:

Caution: Always apply a few drops of clean engine

oil to the male pipe ends before connecting fuel
pipe fittings in order to reduce the risk of fire and
personal injury.
This will ensure proper reconnection and prevent
a possible fuel leak.
During normal operation, the 0-rings located in
the female connector will swell and may prevent
proper reconnection if not lubricated.

Eye contact-rinse eyes thoroughly with water.

Skin contact-wash skin with soap and water.

Clutch Dust Caution

Caution: When servicing clutch parts, do not
create dust by grinding or sanding the clutch disc
or by cleaning parts with a dry brush or with
compressed air. A water-dampened cloth-NOT
SOAKED-should be used. The clutch disc
contains asbestos fibers which can become
airborne if dust is created during servicing.
Breathing dust containing asbestos fibers may
cause serious bodily harm.

Electric Coolant Fan Caution

Caution: An electric fan under the hood can start
up even when the engine is not running and
can injure you. Keep hands, clothing and tools
away fromany underhood electric fan.

Fuel and EVAP Pipe Caution

Caution: In order to reduce the risk of fire and
personal injury observe the following items:
Replace all nylon fuel pipes that are nicked,
scratched or damaged during installation,
do not attempt to repair the sections of
the nylon fuel pipes
Do not hammer directly on the fuel harness
body clips when installing new fuel pipes.
Damage to the nylon pipes may result
in a fuel leak.
Always cover nylon vapor pipes with a wet
towel before using a torch near them. Also,
never expose the vehicle to temperatures
higher than 115C (239F) for more than one
hour, or more than 90C (194F) for any
extended period.
Apply a few drops of clean engine oil to the
male pipe ends before connecting fuel pipe
fittings. This will ensure proper reconnection
and prevent a possible fuel leak. (During
normal operation, the 0-rings located in the
female connector will swell and may prevent
proper reconnection if not lubricated.)

Fuel Gauge Leak Caution

Caution: Wrap a shop towel around the fuel
pressure connection in order to reduce the risk of
fire and personal injury. The towel will absorb
any fuel leakage that occurs during the connection
of the fuel pressure gauge. Place the towel in an
approved container when the connection of
the fuel pressure gauge is complete.

Fuel Storage Caution

Caution: Do not drain the fuel into an open
container. Never store the fuel in an open
container due to the possibility of a fire or an
explosion.

Gasoline/Gasoline Vapors Caution

Caution: Gasoline or gasoline vapors are highly
flammable. A fire could occur if an ignition source
is present. Never drain or store gasoline or
diesel fuel in an open container, due to the
possibility of fire or explosion. Have a dry chemical
(Class BJ fire extinguisher nearby.

Lower 0-Ring Removal Caution

Caution: Verify that the lower (small) 0-ring of
each injector does not remain in the lower
manifold in order to reduce the risk of fire and
personal injury.
If the 0-ring is not removed with the injector, the
replacement injector with new 0-rings will not seat
properly in the injector socket. Improper seating
could cause a fuel leak.

Moving Parts and Hot Surfaces Caution

Caution: While working around a running engine,
avoid contact with moving parts and hot surfaces
to prevent possible bodily injury.

Relieving Fuel Pressure Caution

Caution: Relieve the fuel system pressure before
servicing fuel system components in order to
reduce the risk of fire and personal injury.
After relieving the system pressure, a small
amount of fuel may be released when servicing
the fuel lines or connections. In order to reduce the
chance of personal injury, cover the regulator
and the fuel line fittings with a shop towel before
disconnecting. This will catch any fuel that
may leak out. Place the towel in an approved
container when the disconnection is complete.

Road Test Caution

Caution: Road test a vehicle under safe conditions
and while obeying all traffic laws. Do not attempt
any maneuvers that could jeopardize vehicle
control. Failure to adhere to these precautions
could lead to serious personal injury.

Preface

Cautions and Notices

- 5

Safety Glasses and Compressed Air

Caution

SIR lnflator Module Handling and Storage

Caution

Caution: Wear safety glasses when using

compressed air in order to prevent eye injury.

Caution: When you are carrying an undeptoyed

inflator module:

Safety Goggles and Fuel Caution

Caution: Always wear safety goggles when
working with fuel in order to protect the eyes from
fuel splash.

Seat Belt Replacement Caution

Caution: To help avoid personal injury from
unrepaired crash damage to a restraint system:
Replace each seat belt system worn during
a crash unless the crash was minor.
Perform the seat belt check for each seat belt
system. Replace the seat belt system if there
is any doubt about the condition of system
components.

SIR Caution
Caution: This vehicle has a Supplemental Inflatable
Restraint (SIR) System. Refer to SIR Component
Views in order to determine whether you are
performing service on or near the SIR components
or the SIR wiring. When you are performing
service on or near the SIR components or the SIR
wiring, refer to Repair Instructions in SIR. Failure
to follow the CAUTIONS could cause air bag
deployment, personal injury, or unnecessary SIR
system repairs.

SIR Handling Caution

Caution: When you are performing service on or
near the SIR components or the SIR wiring,
you must disable the SIR system. Refer to
Disabling the SIR System. Failure to follow the
correct procedure could cause air bag deployment,
personal injury, or unnecessary SIR system
repairs.

SIR lnflator Module Disposal Caution

Caution: In order to prevent accidental deployment
of the air bag which could cause personal injury,
do not dispose of an undeptoyed inflator module
as normal shop waste. The undeptoyed inflator
module contains substances that could cause
severe illness or personal injury if the seated
container is damaged during disposal. Use the
following deployment procedures to safety dispose
of an undeployed inflator module. Failure to
dispose of an inflator module as instructed may
be a violation of federal, state, province,
or Joel laws.

Do not carry the inflator module by the wires

or connector on the inflator module
Make sure the bag opening points away
from you
When you are storing an undeptoyed inflator
module, make sure the bag opening points away
from the surface on which the inflator module
rests. When you are storing a steering column, do
not rest the column with the bag opening facing
down and the column vertical. Provide free
space for the air bag to expand in case of an
accidental deployment. Otherwise, personal injury
may result.
I

SIR Special Tool Caution

Caution: In order to avoid deploying the air bag
when troubleshooting the SIR system, use only the
equipment specified in this manual and the
instructions given in this manual. Failure to use
the specified equipment as instructed could cause
air bag deployment, personal injury to you or
someone else, or unnecessary SIR system repairs.

Vehicle Lifting Caution

Caution: To avoid any vehicle damage, serious
personal injury or death when components
are removed from the vehicle and the vehicle is
supported by a hoist, perform the following steps:
Chain the vehicle to the hoist at the same end
as the components that are being removed.
Support the vehicle at the opposite end from
which the components are being removed.

Window Removal Caution

Caution: When working with any type of glass, use
approved safety glasses and gloves to reduce
the chance of personal injury.

Window Retention Caution

Caution: When replacing stationary windows,
Urethane Adhesive Kit GM PIN 12346392, or
a urethane adhesive system meeting GM
Specification GM3651M, must be used to maintain
original installation integrity. Failure to use the
urethane adhesive kit will result in poor retention
of the window which may allow unrestrained
occupants to be ejected from the vehicle resulting
in per13onat injury.

6 -

Preface

Cautions and Notices

Work Stall Test Caution

Fastener Notice

Caution: One or more of the following guidelines

may apply when performing specific required tests
in the work stall:

Notice: Use the correct fastener in the correct

location. Replacement fasteners must be the correct
part number for that application. Fasteners requiring
replacement or fasteners requiring the use of
thread locking compound or sealant are identified in
the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These coatings affect
fastener torque and joint clamping force and may
damage the fastener. Use the correct tightening
sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

When a test requires spinning the drive

wheels with the vehicle jacked up, adhere to
the following precautions:
- Do not exceed 56 km/h (35 mph) when
spinning one drive wheel with the
other drive wheel stopped. This limit is
necessary because the speedometer
indicates only one-half the actual vehicle
speed under these conditions. Personal
injury may result from excessive
wheel spinning.
If al/ of the drive wheels are spinning at
the same speed, do not exceed 112 km/h
(70 mph). Personal injury may result
from excessive wheel spinning.
All persons should stay clear of the
rotating components and the balance
weight areas in order to avoid possible
personal injury.
- When running an engine in the repair stall
for an extended period of time, use care
not to overheat the engine and the
transmission.
When a test requires jacking up the vehicle
and running with the wheels and brake
rotors removed, adhere to the following
precautions:
- Support the suspension of all drive
wheels at normal ride height.
- Do not apply the brake with the brake
rotors removed.
- Do not place the transmission in PARK
with the drive wheels still spinning.
- Turn Off the ignition in order to stop the
powertrain components from spinning.

Defective Scan Tool Notice

Notice: Do not use a scan tool that displays faulty
data. Report the scan tool problem to the
manufacturer. Use of a faulty scan tool can result in
misdiagnosis and unnecessary parts replacement.

Fuel Pressure Notice

Notice: Do not allow the fuel pressure to exceed the
specified value because damage to the fuel
pressure regulator or the fuel pressure gauge may
result.

Handling ESD Sensitive Parts Notice

Notice: Electrostatic discharge (ESD) can damage
many solid-state electrical components. ESD
susceptible components may or may not be labeled
with the ESD symbol. Handle all electrical components
carefully. Use the following precautions in order to
avoid ESD damage:
Touch a .metal ground point in order to remove
your body's static charge before servicing any
electronic component; especially after sliding
across the vehicle seat.
Do not touch exposed terminals. Terminals may
connect to circuits susceptible the ESD damage.
Do not allow tools to contact exposed terminals
when servicing connectors.
Do not remove components from their protective
packaging until required to do so.
Avoid the following actions unless required by the
diagnostic procedure:
- Jumpering or grounding of the components
or connectors.
- Connecting test equipment probes to
components or connectors. Connect
the ground lead first when using test probes.
Ground the protective packaging of any
component before opening. Do not rest solid-state
components on metal workbenches, or on top
of TVs, radios, or other electrical devices.

Preface

Cautions and Notices

- 7

Handling IAC Valve Notice

PCM and ESD Notice

Notice: If the IAC valve has been in service: DO NOT

push or pull on the IAC valve pintle. The force
required to move the pintle may damage the threads
on the worm drive. Also, DO NOT soak the IAC
valve in any liquid cleaner or solvent, as damage may
result.

Notice: Do not touch the connector pins or soldered

components on the circuit board in order to prevent
possible electrostatic discharge (ESD) damage to
the PCM.

Servicing and Replacing Seat Belts Notice

Ignition OFF When Disconnecting Battery
Notice
Notice: Always turn the ignition OFF when connecting
or disconnecting battery cables, battery chargers, or
jumper cables. Failing to do so may damage the
Powertrain Control Module (PCM) or other electronic
components.

Latched DTC 81018, 81024 Notice

(SDM-RSD)
Notice: When DTC 81018 or 81024 has been set it is
necessary to replace the inflatable restraint Sensing
and Diagnostic Module (SDM). Setting DTC 81018 or
81024 will also cause DTC 81071 to set. When a
scan tool clear codes command is issued and
the malfunction is no longer present, DTC 81018 or
81024 and DTC 81071 will remain current. Make sure
that thf:l short to ground condition is repaired prior
to installing a replacement SDM to avoid
damaging the SDM.

Notice: To prevent possible seat belt damage, refer

to the following items before servicing or replacing lap
and shoulder belts, including single loop belt
systems:
Lap and shoulder belts will be serviced as follows:
- Replace only the part in question.
- All belts need to be serviced as a set to
assure the belt components are from
the same supplier.
- Do not intermix standard and deluxe belts on
front or rear seats.
- All attachment hardware must be replaced,
not reused.
Keep sharp edges and damaging objects away
from belts.
Avoid bending or damaging any portion of the belt
buckle or latch plate.

Nylon Fuel Lines Notice

Do not bleach or dye belt or strap webbing. Clean

with a mild soap solution and water.

Notice: Do not attempt to straighten any kinked nylon

fuel lines. Replace any kinked nylon fuel feed or
return pipes in order to prevent damage to the vehicle.

When installing lap or shoulder belt anchor bolts,

start the bolts by hand to ensure that the bolts
are threaded straight.

08011 System Description Notice

Notice: The 08D II symbol is used on the circuit
diagrams in order to alert the technician that the circuit
is essential for proper 08D II emission control
circuit operation. Any circuit which, if it fails causes the
Malfunction Indicator Lamp (MIL) to turn on, is
identified as an 08DII circuit.

Do not attempt repairs on lap or shoulder belt

retractor mechanisms to lap belt retractor
covers. Replace defective assemblies with new
service replacement parts.
Do not attempt to remove the seat belt retractor
cover. The cover and the long rivet securing
the cover to the retractor are not available
as service replacement parts.

Preface

8 - Cautions and Notices

BLANK

Table of Contents 6-1

Engine

Section 6

Engine
Engine Mechanical - 3.8L .............................6-13

Specifications ................................................ 6-13

Fastener Tightening Specifications ............... 6-13
Engine Mechanical Specifications ................. 6-14
GM SPO Group Numbers ............................ 6-17
Sealers, Adhesives, and Lubricants .............. 6-18
Diagnostic Information and Procedures ....... 6-18
Base Engine Misfire Diagnosis ..................... 6-18
Engine Compression Test ............................ 6-20
Engine Noise Diagnosis (Base Engine) ........ 6-20
Engine Noise Diagnosis (Valve Train) .......... 6-23
Oil Consumption Diagnosis .......................... 6-25
Oil Pressure Diagnosis and Testing ............. 6-25
Oil Leak Diagnosis ....................................... 6-26
Cylinder Leakage Test ................ : ................ 6-28
Drive Belt Diagnosis ....................................6-28
Disassembled Views .................................... 6-29
Repair Instructions ........................................ 6-34
Drive Belt Replacement ...............................6-34
Drive Belt Tensioner Replacement ............... 6-35
Engine Mount Inspection .............................. 6-36
Engine Mount Replacement ......................... 6-37
Oil Level Indicator and Tube Replacement ... 6-45
Intake Manifold Replacement (Upper) ........... 6-46
Intake Manifold Replacement (Lower) ........... 6-56
Exhaust Manifold Replacement (Left) ........... 6-57
Exhaust Manifold Replacement (Right) ......... 6-64
Valve Rocker Arm Cover
Replacement (L.:eft ) .................................. 6-70
Valve Rocker Arm Cover
Replacement (Right) ................................. 6-74
Valve Rocker Arm and Push Rod
Replacement ............................................6-77
Valve Stem Oil Seal and Valve Spring
Replacement ............................................6-79
Valve Lifter Replacement ............................. 6-82
Crankshaft Balancer Replacement ................ 6-83
Crankshaft Front Oil Seal Replacement ........ 6-86
Engine Front Cover Replacement ................ 6-86
Oil Pump Cover and Gear Set
Replacement ............................................ 6-96
Oil Filter Adapter and Valve Assembly
Replacement ............................................ 6-96
Timing Chain and Sprockets
Replacement ...........................................6-100
Camshaft Replacement ..............................6-101
Cylinder Head Replacement (Left) ..............6-103
Cylinder Head Replacement (Right) ........... 6-105

Oil Pan Replacement ................................. 6-107

Oil Pump Pipe and Screen Assembly
Replacement ...........................................6-113
Engine Flywheel Replacement .................... 6-114
Crankshaft Rear Oil Seal Replacement ...... 6-116
Crankshaft Rear Oil Seal and Housing
Replacement ............................... , ...........6-116
Engine Replacement .................................. 6-118
Engine Oil and Oil Filter Replacement ....... 6-151
Draining Fluids and Oil Filter Removal ....... 6-152
Engine Flywheel Removal
(Manual Transmission) ............................ 6-153
Engine Flywheel Removal
(Automatic Transmission) ........................ 6-153
Drive Belt Tensioner Removal (VIN K) ....... 6-154
Oil Level Indicator and Tube Removal ....... 6-154
Water Outlet Removal .............. : ................. 6-1q4
Water Pump Removal ................................ 6-155
Intake Manifold Removal (Upper) ...............6-155
Intake Manifold Removal (Lower) ............... 6-157
Exhaust Manifold Removal (Left Side) ... : .... 6-157
Exhaust Manifold Removal (Right Side) ..... 6-158
Valve Rocker Arm Cover Removal
(Left Side) ..............................................6-159
Valve Rocker Arm Cover Removal
(Right Side) ............................................6-160
Valve Rocker Arm and Push Rod
Removal .................................................6-160
Cylinder Head Removal .............................6-160
Valve Lifter Removal .................................. 6-161
Crankshaft Balancer Removal .................... 6-161
Crankshaft Front Oil Seal Removal ............ 6-162
Engine Front Cover Removal .....................6-162
Oil Filter Adapter Removal ......................... 6-163
Oil Pump Cover and Gear Set Removal .... 6-163
Timing Chain and Sprockets
Removal (VIN K) ................................ , ... 6-164
Camshaft Removal .....................................6-165
Balance Shaft Removal .............................. 6-165
Crankshaft Rear Oil Seal Removal .............6-166
Crankshaft Rear Oil Seal and Housing
Removal .................................................6-167
Oil Pan Removal ................. , ........... ,............ 6-167
Oil Pump Pipe and Screen
Assembly Removal ................................. 6-168
Piston, Connecting Rod, and Bearing
Removal .................................,................. 6-168
Crankshaft and Bearings Removal ...... ,., .... 6-169
Engine Block Plug Removal ....:................... 6-170

6-2

Table of Contents
Engine Block Clean and Inspect ................ 6-170
Cylinder Boring and Honing ....................... 6-172
Crankshaft and Bearings Clean
and Inspect ............................................ 6-173.
Crankshaft Balancer Clean and Inspect ...... 6-176
Engine Flywheel Clean and Inspect
(Automatic Transmission) ........................ 6-177
Engine Flywheel Clean and Inspect
(Manual Transmission) ............................ 6-177
Piston and Connecting Rod Disassemble ... 6-177
Piston, Connecting Rod and Bearings
Clean/Inspect ..........................................6-178
Piston Selection ......................................... 6-180
Piston and Connecting Rod Assemble ........ 6-182
Camshaft Bearing Removal ........................ 6-183
Camshaft and Bearings Clean
and Inspect .................................... :...... 6-184
Camshaft Bearing Installation ..................... 6-185
Timing Chain and Sprockets Clean
and Inspect (VIN K) ................................6-185
Valve Rocker Arm and Push Rods
Clean and Inspect ..................................6-186
Valve Lifters and Guides Clean
and Inspect ............................................6-186
Cylinder Head Disassemble ....................... 6-186
Cylinder Head Clean and Inspect ............... 6-187
Valve GuideReamingNalve and
Seat Grinding .........................................6-189
Cylinder Head Assemble ............................ 6-192
Oil Pump Clean and Inspect ......................6-193
Valve Rocker Arm Cover Clean
and Inspect ............................................6-194
Oil Pan Clean and Inspect ......................... 6-195
Intake Manifold Clean and
Inspect (Upper) .......................................6-195
Intake Manifold Clean and
Inspect (Lower) .......................................6-195
Exhaust Manifold Clean and Inspect .......... 6-196
Water Pump Clean and Inspect ................. 6-196
Engine Front Cover Clean and Inspect ...... 6-197
Balance Shaft Clean and Inspect ............... 6-197
Balance Shaft Bearing and/or Bushing
Removal .................................................6-197
Balance Shaft Bearing and/or Bushing
Installation ..............................................6-198
Service Prior to Assembly .......................... 6-198
Engine Block Plug Installation ............... ,.... 6-199
Crankshaft and Bearings Installation ........... 6-199
Piston, Connecting Rod, and Bearing
Installation ..............................................6-201
Oil Pump Pipe and Screen Assembly
Installation ..............................................6-202
Oil Pan Installation .....................................6-202
Camshaft Installation ..................................6-203
Balance Shaft Installation ........................... 6-203
Crankshaft Rear Oil Seal and Housing
Installation ..............................................6-205
Crankshaft Rear Oil Seal Installation .......... 6-206
Timing Chain and Sprockets
Installation (VIN K) ................................. 6-207

Engine
Oil Pump Cover and Gear Set
Installation .............................................. 6-208
Oil Filter Adapter Installation ...................... 6-208
Engine Front Cover Installation .................. 6-209
Crankshaft Front Oil Seal Installation ......... 6-210
Crankshaft Balancer Installation
(Automatic Transmission) ........................ 6-210
Crankshaft Balancer Installation
(Manual Transmission) ............................ 6-211
Valve Lifter Installation ...............................6-211
Cylinder Head Installation ........................... 6-212
Valve Rocker Arm and Push Rod
Installation ..............................................6-212
Valve Rocker Arm Cover Installation
(Left Side} ..............................................6-213
Valve Rocker Arm Cover Installation
(Right Side) ............................................6-213
Exhaust Manifold Installation (Left Side) ..... 6-213
Exhaust Manifold Installation (Right Side) ... 6-215
Intake Manifold Installation (Upper) ............ 6-216
Intake Manifold Installation (Lower) ............ 6-217
Water Pump Installation ............................. ,6-218
Water Outlet Installation ............................. 6-219
Oil Level Indicator and Tube Installation ..... 6-219
Drive Belt Tensioner Installation ................. 6-219
Engine Flywheel Installation
(Manual Transmission) ............................ 6-220
Engine Flywheel Installation
(Automatic Transmission) ........................ 6-220
Description and Operation .......................... 6-221
Engine Component Description .................. 6-221
Lubrication Description ............................... 6-222
Thread Repair ............................ '. ............... 6-223
Cleanliness and Care ................................. 6-223
Replacing Engine Gaskets ......................... 6-224
Use of RTV and Anaerobic Sealer ............. 6-224
Separating Parts ........................................6-225
Installation Precautions ............ ,................. 6-225
Tools and Equipment ................................. 6-225
Special Tools and Equipment ..................... 6-226

Engine Mechanical - 5.7L ...........................6-229

Specifications ..............................................6-229
Fastener Tightening Specifications ............. 6-229
Engine Mechanical Specifications ............... 6-231
GM SPO Group Numbers ..........................6-234
Sealers, Adhesives, and Lubricants ............ 6-236
Thread Repair Specifications ...................... 6-237
Diagnostic Information and Procedures ..... 6-250
Base Engine Misfire Diagnosis ................... 6-250
Engine Compression Test .......................... 6-252
Engine Noise Diagnosis .............................6-252
Valve Train Diagnosis ................................6-254
Oil Consumption Diagnosis ........................ 6-255
Oil Pressure Diagnosis and Testing ........... 6-256
Oil Leak Diagnosis .....................................6-256
Drive Belt Diagnosis ...................................6-258
Visual Identification .....................................6-259
Disassembled Views .................................. 6-259

Engine

\.l

Repair Instructions ...................................... 6-267

Drive Belt Replacement (Accessory) ........... 6-267
Drive Belt Replacement (A/C) .................... 6-269
Drive Belt Idler Pulley Replacement
(Accessory) .............................................6-270
Drive Belt Idler Pulley
Replacement (A/C) .................................6-271
Drive Belt Tensioner Replacement
(Accessory) .............................................6-272
Drive Belt Tensioner Replacement (A/C) .... 6-273
Engine Mount Replacement (Right Side) .... 6-274
Engine Mount Replacement (Left Side) ...... 6277
Intake Manifold Replacement ..................... 6-281
Vapor Vent Pipe Replacement ................... 6-296
Engine Valley Cover Replacement ............. 6-297
Valve Rocker Arm Cover Replacement
(Right Side) ............................................6-299
Valve Rocker Arm Cover Replacement
(Left Side) .............................................. 6-302
Valve Rocker Arm and Push Rod
Replacement ...........................................6-307
Valve Stem Oil Seal and Valve Spring
Replacement ...........................................6-308
Oil Level Indicator and Tube
Replacement ...........................................6-311
Exhaust Manifold Replacement
(Right Side) ............................................6-315
Exhaust Manifold Replacement
(Left Side) ..............................................6-321
Cylinder Head Replacement (Right Side) ... 6-328
Cylinder Head Replacement (Left Side) ...... 6-331
Valve Lifter Replacement ...........................6-339
Crankshaft Balancer Replacement .............. 6-339
Crankshaft Front Oil Seal Replacement ...... 6-346
Engine Front Cover Replacement ............... 6348
Crankshaft Rear Oil Seal Replacement ......6-357
Engine Rear Cover Replacement ............... 6-358
Oil Pan Replacement .................................6-360
Oil Pump, Pump Screen and Deflector
Replacement ........................................... 6-369
Timing Chain and Sprockets
Replacement ........................................... 6-370
Camshaft Replacement ..............................6-371
Engine Flywheel Replacement .................... 6-374
Engine Replacement ..................................6-376
Engine Oil and Oil Filter Change ............... 6-408
Draining Fluids and Oil Filter Removal ....... 6-409
Crankshaft Balancer Removal .................... 6-411
Engine Flywheel Removal .......................... 6-412
Oil Level Indicator and Tube Removal ....... 6-413
Exhaust Manifold Removal (Left Side) ........ 6-413
Exhaust Manifold Removal (Right Side) ..... 6-414
Water Pump Removal ................................6-416
Throttle Body Removal ...............................6-416
Fuel Rail and Injectors Removal ................ 6-417
Intake Manifold Removal ............................ 6-418
Vapor Vent Pipe Removal .......................... 6-421
Engine Valley Cover Removal .................... 6-421
Valve Rocker Arm Cover Removal
(Left Side) ..............................................6-422

Table of Contents

6-3

Valve Rocker Arm Cover Removal

(Right Side) ............................................6-423
Valve Rocker Arm and Push Rod
Removal .................................................6-424
Cylinder Head Removal (Left Side) ............ 6-425
Cylinder Head Removal (Right Side) .......... 6-426
Valve Lifter Removal ..................................6-427
Oil Filter, Adapter and Pan Cover
Removal .................................................6-428
Oil Pan Removal ........................................ 6-429
Engine Front Cover Removal ..................... 6-431
Engine Rear Cover Removal ...................... 6-431
Oil Pump, Pump Screen and Deflector
Removal .................................................6-432
Timing Chain and Sprockets Removal ........ 6-433
Camshaft Removal .....................................6-434
Piston, Connecting Rod, and
Bearing Removal ....................................6-435
Crankshaft and Bearings Removal ............. 6-437
Engine Block Plug Removal ....................... 6-440
Engine Block Clean and Inspect ................ 6-443
Cylinder Boring and Honing ....................... 6-444
Crankshaft and Bearings Clean and
Inspect (Cleaning and Inspection) ........... 6-446
Crankshaft and Bearings Clean and
Inspect
(Measuring Main Brg Clearance) ............. 6-456
Crankshaft and Bearings Clean and
Inspect (Conn. Rod Bearing
Clearance) .............................................. 6-460
Crankshaft Balancer Clean and Inspect ...... 6-462
Engine Flywheel Clean and Inspect ........... 6-462
Piston and Connecting Rod Disassemble ... 6-463
Piston, Connecting Rod and Bearings
Clean/Inspect (Piston and Pin) ................ 6-465
Piston, Connecting Rod and Bearings
Clean/Inspect (Connecting Rod and
Bearings) ................................................6-467
Piston, Connecting Rod and Bearings
Clean/Inspect (Measuring Piston Ring
End Gap) ...............................................6-470
Piston Selection .........................................6-470
Piston and Connecting Rod Assemble ........ 6-471
Camshaft Bearing Removal
(Removal Procedure) ..............................6-474
Camshaft Bearing Removal
(Tool Instructions) ...................................6-476
Camshaft and Bearings Clean
and Inspect ............................................6-478
Camshaft Bearing Installation ..................... 6-481
Timing Chain and Sprockets Clean
and Inspect ............................................6-482
Valve Rocker Arm and Push Rods
Clean and Inspect ..................................6-483
Valve Lifters and Guides Clean
and Inspect ............................................ 6-484
Cylinder Head Disassemble ....................... 6-485
Cylinder Head Clean and Inspect ............... 6-487
Valve Guide ReamingNalve and
Seat Grinding ......................................... 6-488

6-4

Table of Contents

Cylinder Head Assemble ............................ 6-493

Oil Pump Disassemble ...............................6-496
Oil Pump Clean and Inspect ...................... 6-498
Oil Pump Assemble ...................................6-500
Engine Front Cover Clean and Inspect ...... 6-502
Engine Rear Cover Clean and Inspect ....... 6-503
Engine Valley Cover Clean and Inspect ..... 6-503
Valve Rocker Arm Cover Clean and
Inspect ...................................................6-504
Oil Pan Clean and Inspect ......................... 6-506
Intake Manifold Clean and Inspect ............. 6-509
Exhaust Manifold Clean and Inspect .......... 6-512
Vapor Vent Pipe Clean and Inspect ........... 6-514
Water Pump Clean and Inspect ................. 6-514
Service Prior to Assembly .......................... 6-515
Engine Block Plug Installation .................... 6-515
Crankshaft and Bearings Installation ........... 6-518
Piston, Connecting Rod, and Bearing
Installation ..............................................6-521
Camshaft Installation ..................................6-523
Timing Chain and Sprockets Installation ..... 6-524
Oil Pump, Pump Screen and Deflector
Installation ..............................................6-526
Engine Rear Cover Installation ................... 6-527
Crankshaft Rear Oil Seal Installation .......... 6-530
Engine Front Cover Installation .................. 6-530
Crankshaft Front Oil Seal Installation ......... 6-533
Oil Pan Installation .....................................6-533
Oil Filter, Adapter, Pan Cover Installation ... 6-536
Valve Lifter Installation ...............................6-537
Cylinder Head Installation (Left Side) ......... 6-538
Cylinder Head Installation (Right Side) ....... 6-539
Valve Rocker Arm and Push Rod
Installation ..............................................6-541
Valve Rocker Arm Cover Installation
(Left Side) ..............................................6-543
Valve Rocker Arm Cover Installation
(Right Side) ............................................ 6-544
Engine Valley Cover Installation ................. 6-545
Vapor Vent Pipe Installation ....................... 6-546
Intake Manifold Installation ......................... 6-547
Fuel Rail and Injectors Installation .............. 6-551
Throttle Body Installation ............................ 6-551
Water Pump Installation ............................. 6-552
Exhaust Manifold Installation (Left Side) ..... 6-553
Exhaust Manifold Installation (Right Side) ... 6-554
Oil Level Indicator and Tube Installation ..... 6-556
Engine Flywheel Installation ....................... 6-556
Crankshaft Balancer Installation .................. 6-557
Engine Set-Up and Testing ........................ 6-559
Description and Operation .......................... 6-560
Engine Component Description .................. 6-560
New Product Information ............................ 6-561
Engine Identification ...................................6-562
Lubrication .................................................6-563
Thread Repair ............................................6-564
Cleanliness and Care .................................6-572
Replacing Engine Gaskets ......................... 6-573
Use of RTV and Anaerobic Sealer ............. 6-573

Engine
Separating Parts ........................................ 6-574
Tools and Equipment .................................6-574
Special Tools and Equipment ..................... 6-575

Engine Cooling .............................................6-580

Specifications ..............................................6-580
Fastener Tightening Specifications ............. 6-580
Engine Cooling System Specifications ........ 6-580
GM SPO Group Numbers .......................... 6-580
Schematic and Routing Diagrams .............. 6-581
Cooling System Schematic References ...... 6-581
Cooling System Schematic Icons ............... 6-581
Cooling Fan Schematics ............................ 6-582
Component Locator .....................................6-584
Cooling System Components ..................... 6-584
Cooling System Connector End Views ....... 6-585
Diagnostic Information and Procedures ..... 6-586
Engine Overheating ....................................6-586
Loss of Coolant .........................................6587
Thermostat Diagnosis .................................6-588
Engine Fails To Reach Normal
Operating Temp ...................................... 6-588
Coolant Concentration Testing .................... 6-589
Cooling System Leak Testing ..................... 6590
Pressure Cap Testing ................................ 6-591
Repair Instructions ......................................6-592
Draining and Filling Cooling System (V6) ... 6592
Draining and Filling Cooling System (VB) ... 6595
Flushing .....................................................6598
Radiator Cleaning ...................................... 6598
Coolant Recovery Reservoir
Replacement ...........................................6598
Coolant Recovery Pipe Replacement ......... 6602
Vapor Vent Pipe Replacement ................... 6-602
Radiator Hose Replacement - Inlet (V6) ..... 6603
Radiator Hose Replacement - Inlet (VB) ..... 6606
Radiator Hose Replacement Outlet (V6) ..............................................6609
Radiator Hose Replacement Outlet (VB) .............................................. 6-612
Throttle Body Heater Hose
Replacement - Inlet ................................6-614
Throttle Body Heater Hose
Replacement - Outlet .............................. 6-615
Cooling Fan Replacement - Electric ........... 6-616
Cooling Fan Motor Replacement Electric .............. , ....................................6-621
Cooling Fan Relay Replacement ................ 6-622
Thermostat Housing
Replacement (3.8L V6) ........................... 6-623
Thermostat Housing
Replacement (5.7L VB) ........................... 6-625
Thermostat Replacement (3.8L V6) ............ 6-627
Thermostat Replacement (5.7L VB) ............ 6-629
Radiator Support Replacement ................... 6-631
Water Pump Replacement (3.8L V6) .......... 6-634
Water Pump Replacement (5.7L VB) .......... 6-636
Coolant Level Sensor Replacement ............ 6-644
Engine Coolant Temperature Sensor
Replacement (3.8L V6) ........................... 6-645

Engine
Engine Coolant Temperature Sensor
Replacement (5.7L V8) ........................... 6-646
Drain Cock Replacement ............................ 6-646
Fan Shroud Replacement ........................... 6-647
Radiator Replacement ................................ 6-648
Radiator Air Baffle Assemblies and
Deflectors (Lower) ..................................6-652
Radiator Air Baffle Assemblies and
Deflectors (Upper) .................................. 6-653
Coolant Heater Replacement (3.8L V6) ...... 6-654
Coolant Heater Replacement (5.7L V8) ...... 6-655
Coolant Heater Cord
Replacement (3.8L V6) ........................... 6-657
Coolant Heater Cord
Replacement (5.7L V8) ........................... 6-658
Description and Operation .......................... 6-660
Cooling System Description ........................ 6-660
Coolant Recovery System Description ........6-660
Throttle Body Coolant System
Description .............................................6-660
Coolant Heater Description ......................... 6-660
Radiator Assembly Description ...................6-661
Pressure Cap Description ........................... 6-662
Engine Cooling Fan Description Electric ...................................................6-663
Cooling Fan Relay Description ................... 6-663
Water Pump Description ............................ 6-663
Thermostat Description ...............................6-663
Engine Coolant Temperature Sensor
Description .............................................6-663
Air Baffles and Seals Description ............... 6-663
Coolant Sensor Description ........................ 6-664
Coolant Description ....................................6-664
Special Tools and Equipment ..................... 6-664

Engine Electrical ..........................................6-665

Specifications ..............................................6-665
Fastener Tightening Specifications ............. 6-665
Battery Usage ............................................6-665
Battery Temperature vs Voltage Drop ........ 6-666
Starter Motor Usage ............... ,................... 6-666
Generator Usage .......................................6-666
GM SPO Group Numbers .......................... 6-666
Schematic and Routing Diagrams .............. 6-667
Engine Electrical Schematic References ..... 6-667
Engine Electrical Schematic Icons .............. 6-667
Starting and Charging Schematics .............. 6-668
Component Locator .....................................6-670
Engine Electrical Components .................... 6-670
Engine Electrical Connector End Views ...... 6-671
Diagnostic Information and Procedures ..... 6-671
Starting System Check ...............................6-671
Charging System Check ............................. 6-672
Starter Solenoid Does Not Click ................. 6-672
Engine Cranks/Cranks Slowly, but
Does Not Start .......................................6-67 4
Starter No Load Test ................................. 6-675
Battery Common Causes of Failure ............ 6-675
Battery Hydrometer Displays Dark or
Yellow Dot ..............................................6-676

Table of Contents

6-5

Battery (Parasitic) Load Test ...................... 6-676

Battery Is Undercharged or Overcharged ... 6-680
Generator Assembly Check ........................ 6-681
Spark Plug Visual Diagnosis ...................... 6-682
Spark Plug Wires Not Operating
Properly ..................................................6-684
Repair Instructions ......................................6-684
Starter Motor Replacement (3.8L V6) ......... 6-684
Starter Motor Replacement (5.7L V8) ......... 6-686
Starter Shield Replacement (3.8L V6) ........ 6-688
Battery Replacement ..................................6-689
Battery Charging ........................................6-691
Jump Starting in Case of Emergency ......... 6-692
Battery Negative Cable Disconnect/
Connect Procedure ................................. 6-693
Battery Cable Replacement (3.8L V6) ........ 6-695
Battery Cable Replacement (5.7L V8) ........ 6-700
Generator Bracket Replacement ................. 6-705
Generator Brace Replacement ................... 6-706
Generator Replacement (3.8L V6) .............. 6-707
Generator Replacement (5.7L V8) .............. 6-709
Spark Plug Wire Harness
Replacement (V6) ................................... 6-711
Spark Plug Wire Harness
Replacement (VS) ................................... 6-714
Spark Plug Replacement ............................ 6-715
Ignition Coil Replacement ........................... 6-716
Ignition Coil and ICM Replacement ............ 6-718
Description and Operation .......................... 6-720
Starting System Circuit Description ............. 6-720
Battery Description ..................................... 6-720
Charging System Description ..................... 6-721
Charging System Operation ....................... 6-722
Charging System Circuit Description ........... 6-722
Ignition System Description (V6) .. ,............. 6-722
Ignition System Description (V8) ................ 6-723
Special Tools and Equipment ..................... 6-724

Engine Controls - 3.8L ................................6-725

Specifications .............................. , ............... 6-725
Temperature vs Resistance ........................ 6-725
Fastener Tightening Specifications ............. 6-725
Engine Scan Tool Data List ....................... 6-726
Engine Scan Tool Data Definitions ............. 6-731
OTC List .....................................................6-736
Fuel System Specifications (VIN K) ............ 6-739
GM SPO Group Numbers .......................... 6-740
Schematic and Routing Diagrams .............. 6-741
Emission Hose Routing Diagram ................ 6-741
Engine Controls Schematic References ...... 6-742
Engine Controls Schematic Icons ............... 6-742
Engine Controls Schematics ....................... 6-743
Component Locator ............. : ....................... 6-758
Engine Controls Components ..................... 6-758
Engine Controls Component Views ............ 6-763
PCM Connector End Views ........................ 6-767
Engine Controls Connector End Views ....... 6-771
Diagnostic Information and Procedures ..... 6-778
A Powertrain On Board Diagnostic
(080) System Check .............................6-778

6-6

Table of Contents
No Malfunction Indicator Lamp ................... 6-780
Data Link Connector Diagnosis .................. 6-782
Engine Cranks but Does Not Run .............. 6-784
Fuel Pump Relay Circuit Diagnosis ............ 6-791
Fuel System Diagnosis .............................. 6-794
OTC P0101 Mass Air Flow (MAF) Sensor
Performance ........................................... 6-795
OTC P0102 Mass Air Flow (MAF) Sensor
Circuit Low Frequency ............................ 6-799
OTC P0103 Mass Air Flow (MAF) Sensor
Circuit High Frequency ........................... 6-802
OTC P0107 Manifold Absolute Pressure
(MAP) Sensor Circuit Low Voltage .......... 6-805
OTC P0108 Manifold Absolute Pressure
(MAP) Sensor Circuit High Voltage ......... 6-808
OTC P0112 Intake Air Temperature (IAT)
Sensor Circuit Low Voltage ..................... 6-811
OTC P0113 Intake Air Temperature (IAT)
Sensor Circuit High Voltage .................... 6-813
OTC P0117 Engine Coolant Temperature
(ECT) Sensor Circuit Low Voltage .......... 6-816
OTC P0118 Engine Coolant Temperature
(ECT) Sensor Circuit High Voltage .......... 6-818
OTC P0121 Throttle Position (TP) Sensor
Performance ...........................................6-821
OTC P0122 Throttle Position (TP) Sensor
Circuit Low Voltage .................................6-824
OTC P0123 Throttle Position (TP) Sensor
Circuit High Voltage ................................ 6-827
OTC P0125 Engine Coolant Temperature
ECT) Excessive Time to Closed
Loop Fuel Control ...................................6-830
OTC P0131 H02S Circuit Low Voltage
Bank 1 Sensor 1 ....................................6-833
OTC P0132 H02S Circuit High Voltage
Bank 1 Sensor 1 .................................... 6-836
OTC P0133 H02S Slow Response
Bank 1 Sensor 1 ....................................6-839
OTC P0134 H02S Circuit Insufficient
Activity Bank 1 Sensor ........................... 6-842
OTC P0135 H02S Heater Performance
Bank 1 Sensor 1 ....................................6-845
OTC P0143 H02S Circuit Low Voltage
Bank 1 Sensor 3 ....................................6-848
OTC P0144 H02S Circuit High Voltage
Bank 1 Sensor 3 ....................................6-851
OTC P0146 H02S Circuit Insufficient
. Activity Bank 1 Sensor 3 ........................ 6-854
OTC P0147 H02S Heater Performance
Bank 1 Sensor 3 .................................... 6-857
OTC P0151 H02S Circuit Low Voltage
Bank 2 Sensor 1 .................................... 6-860
OTC P0152 H02S Circuit High Voltage
Bank 2 Sensor 1 .................................... 6-863
OTC P0153 H02S Slow Response
Bank 2 Sensor 1 ....................................6-866
OTC P0154 H02S Circuit Insufficient
Activity Bank 2 Sensor 1 ........................ 6-869
OTC P0155 H02S Heater Performance
Bank 2 Sensor 1 ....................................6-872

Engine
DTC P0171 Fuel Trim System Lean
Bank 1 ...................................................6-876
DTC P0172 Fuel Trim System Rich
Bank 1 ...................................................6-880
DTC P0174 Fuel Trim System Lean
Bank 2 ................................................... 6-884
OTC P0175 Fuel Trim System Rich
Bank 2 ...................................................6-887
DTC P0201 Injector 1 Control Circuit .......... 6-890
DTC P0202 Injector 2 Control Circuit .......... 6-893
DTC P0203 Injector 3 Control Circuit .......... 6-896
DTC P0204 Injector 4 Control Circuit .......... 6-899
DTC P0205 Injector 5 Control Circuit .......... 6-902
DTC P0206 Injector 6 Control Circuit .......... 6-905
DTC P0230 Fuel Pump Relay Control
Circuit .....................................................6-908
OTC P0300 Engine Misfire Detected .......... 6-911
DTC P0325 Knock Sensor System ............. 6-916
DTC P0327 Knock Sensor (KS) Circuit ....... 6-918
DTC P0332 Knock Sensor 2 Circuit ........... 6-921
DTC P0336 18X Reference Signal Circuit ... 6-924
OTC P0341 Camshaft Position (CMP)
Sensor Performance ...............................6-927
DTC P0401 Exhaust Gas Recirculation
(EGR) Flow Insufficient ........................... 6-932
DTC P0403 Exhaust Gas Recirculation
(EGR) Solenoid Control Circuit ............... 6-934
DTC P0404 Exhaust Gas Recirculation
(EGR) Open Position Performance ......... 6-938
OTC P0405 Exhaust Gas Recirculation
(EGR) Position Sensor Circuit Low
Voltage ...................................................6-942
DTC P0420 Catalyst System Low
Efficiency ................................................6-946
DTC P0440 Evaporative Emission
(EVAP) System .......................................6-949
OTC P0442 Evaporative Emission (EVAP)
Control System Small Leak Detected ...... 6-954
DTC P0446 Evaporative Emission
(EVAP)
Vent System Performance ...................... 6-958
DTC P0452 Fuel Tank Pressure Sensor
Circuit Low Voltage ................................. 6-962
DTC P0453 Fuel Tank Pressure Sensor
Circuit High Voltage ................................ 6-965
OTC P0500 Vehicle Speed Sensor
(VSS) Circuit ..........................................6-968
DTC P0506 Idle Speed Low ....................... 6-970
DTC P0507 Idle Speed High ...................... 6-973
OTC P0530 Air Conditioning (A/C)
Refrigerant Pressure Sensor Circuit ........ 6-976
DTC P0560 System Voltage ....................... 6-979
DTC P0601 Control Module Read Only
Memory (ROM) .......................................6-982
OTC P0602 Control Module Not
Programmed ........................................... 6-983
DTC P0704 Clutch Switch Circuit ...............6-984
DTC P0705 Trans Range Switch Circuit ..... 6-987
DTC P0706 Trans Range Switch
Performance ...........................................6-991

Engine

DTC P1106 Manifold Absolute Pressure

(MAP) Sensor Circuit Intermittent High
Voltage ...................................................6-994
DTC P1107Manifold Absolute Pressure
(MAP) Sensor Circuit Intermittent Low
Voltage ................................................... 6-996
DTC P1111 Intake Air Temperature (IAT)
Sensor Circuit Intermittent High
Voltage ...................................................6-998
DTC P1112 Intake Air Temperature (IAT)
Sensor Circuit Intermittent Low
Voltage .................................................6-1000
DTC P1114 Engine Coolant Temperature
(ECT) Sensor Circuit Intermittent Low
Voltage .................................................6-1002
DTC P1115 Engine Coolant Temperature
(ECT) Sensor Circuit Intermittent High
Voltage .................................................6-1004
DTC P1121 Throttle Position (TP)
Sensor Circuit Intermittent High
Voltage ................................................. 6-1006
DTC P1122 Throttle Position (TP)
Sensor Circuit Intermittent Low Voltage .6-1008
DTC P1133 H02S Insufficient Switching
Bank 1 Sensor 1 ..................................6-101 O
DTC P1134 H02S Transition Time
Ratio Sensor 1 .....................................6-1013
DTC P1153 H02S Insufficient Switching
Bank 2 Sensor 1 ..................................6-1016
DTC P1154 H02S Transition Time
Ratio Bank 2 Sensor 1 .........................6-1019
DTC P1336 Crankshaft Position (CKP)
System Variation Not Learned ..............6-1022
DTC P1351 Ignition Coil Control Circuit
High Voltage .........................................6~1024
DTC P1352 Ignition Bypass Circuit
High Voltage .........................................6-1026
DTC P1361 Ignition Coil Control Circuit
Low Voltage .........................................6-1028
DTC P1362 Ignition Bypass Circuit
Low Voltage .........................................6-1031
DTC P1374 Crankshaft Position (CKP)
High to Low Resolution Frequency
Correlation ............................................6-1034
DTC P1380 Misfire Detected - Rough
Road Data Not Available ......................6-1037
DTC P1381 Misfire Detected - No
Communication with Brake Control
Module .................................................6-1038
DTC P1404 Exhaust Gas Recirculation
(EGR) Closed Position Performance ..... 6-1040
DTC P1441 Evaporative Emission
(EVAP) System Flow During
Non-Purge ............................................6-1043
DTC P1554 Cruise Control Feedback
Circuit ...................................................6-1047
DTC P1626 Theft Deterrent Fuel
Enable Signal Lost ................................6-1049
DTC P1629 Theft Deterrent Fuel
Enable Signal Not Received .................6-1052
DTC P1635 5 Volt Reference Circuit ........ 6-1054

Table of Contents

6-7

DT~ P1_639 5 Volt Reference (B)

Circuit ...................................................6-1058
DTC P1641 A/C Relay Control Circuit .... "'6-1060
DTC P1651 Fan 1 Relay Control Circuit ... 6-1066
DTC P1652 Fan 2 Relay Control Circuit ... 6-1070
DTC P1653 Fuel Level Output Control
Circuit ...................................................6-1074
DTC P1662 Cruise Control Inhibit
Control Circuit .......................................6-1077
DT~ P1_663 Generator Lamp Control
C1rcu1t ...................................................6-1080
DTC P1665 EVAP Vent Solenoid
Control Circuit .......................................6-1083
DTC P1671 MIL Control Circuit ................ 6-1086
DTC P1672 Low Engine Oil Level
Lamp Control CKT ................................6-1089
DTC P1676 EVAP Canister Purge
Solenoid Control CKT ........................... 6-1092
Intermittent Conditions ..............................6-1095
Hard Start ................................................6-1095
Surges/Chuggles ......................................6-1097
Lack of Power, Sluggishness, or
Sponginess ...........................................6-1099
Detonation/Spark Knock ........................... 6-1101
Hesitation, Sag, Stumble .......................... 6-1102
Cuts Out, Misses .....................................6-1104
Poor Fuel Economy ................................. 6-1106
Rough, Unstable, or Incorrect Idle and
Stalling .................................................6-1108
Dieseling, Run-On ....................................6-1110
Backfire ....................................................6-111 o
Restricted Exhaust System Check ............ 6-1112
Powertrain Control Module Diagnosis ....... 6-1113
PCM Controlled Warning Lamps
Diagnosis ..............................................6-1114
PCM Controlled A/C Circuit Diagnosis ...... 6-1118
Electric Cooling Fan Diagnosis ................. 6-1124
Engine Oil Level Sensor/Switch
Diagnosis ..............................................6-1133
Fuel System Pressure Test ......................6-1135
Fuel Injector Balance Test ........................ 6-1141
Fuel lnj Coil Test - ECT Between
10-35 Degrees C ..................................6-1144
Fuel lnj Coil Test - ECT Outside
10-35 Degrees C ..................................6-1146
Fuel Tank Leak Check ............................. 6-1148
Fuel Tank Vent Valve Diagnosis .............. 6-1148
Alcohol/Contaminants-in-Fuel Diagnosis .... 6-1148
EVAP Control System Diagnosis .............. 6-1149
Idle Air Control System Diagnosis ............ 6-1152
Repair Instructions ....................................6-1155
PCM ReplacemenVProgramming .............. 6-1155
CKP System Variation Learn Procedure ... 6-1157
ECT Sensor Replacement ........................ 6-1158
MAF Sensor Replacement ........................ 6-1159
MAP Sensor Replacement ....................... 6-1160
H02S Replacement ..................................6-1161
TP Sensor Replacement .......................... 6-1163
IAT Sensor Replacement ......................... 6-1165
IAC Valve Replacement ...........................6-1166

68

Table of ,Contents
Accelerator Controls Cable
Replacement ........................................ :.6-1169
Accelerator Controls Pedal
Replacement ................. : ....................... 6-1170
Throttle Body Assembly Replacement ...... 6-1171
Throttle .Body Air Inlet Screen
Replacement .........................................6-117 4
Fuel Pressure Relief Procedure ................. 6-1175
Quick Connect Fitting(s) Service
(Metal Collar) ........................................ 6-1175
Quick Connect Fitting(s) Service
(Plastic Collar) ......................................6~ 1178
In-Line Fuel Filter Replacement ................ 6-1181
Fuel Tank Draining Procedure .................. 6-1182
Fuel Tank Replacement ........................... 6-1183
Fuel Tank Vent Valve Replacement ......... 6-1188
Fuel Tank Pressure Sensor
Replacement .........................................6-1189
Fuel Sender Assembly Replacement ........ 6-1190
Fuel Sender Assembly Service ........... , .... ,6-1191
Fuel Pump Strainer Replacemeril ............. 6~ 1192
Fuel Level Sensor Replacement ............... 6-1193
Fuel Hose/Pipes Replacement
(Filter to Engine) ................ ; .................. 6-1194
Fuel Hose/Pipes Replacement
(Filter to Tank) :6-1200
Fuel Hose/Pipes Replacement
(Engine Compartment) .......................... 6-1201
Fuel System Cleaning .................... ,......... 6-1203
Fuel Rail Assembly Replacement ............. 6-1204
Fuel Pressure Regulator Replacement ...... 6-1206
Fuel Injector Replacement ........................ 6-1207
Fuel Pump Relay Replacement .... ,........... 6-1208
Engine Oil Pressure Sensor/Switch
Replacement .........................................6-1209
EVAP Canister Purge Solenoid Valve
Replacement ................................ , ........ 6-1209
EVAP Vent Valve Replacement ................. 6-1210
EVAP Canister Replacement .................... 6-1211
Ignition Control Module Replacement ....... 6-1212
Ignition Coil(s) Replacement ..................... 6-1212
Crankshaft Position Sensor
Replacement .........................................6-1213
Camshaft Position Sensor Replacement ... 6-1214
Knock Sensor Replacement .......... ; .......... 6-1215
EGR Valve Replacement .......................... 6-1217
Clutch Anticipate Switch Replacement ...... 6-1218
Crankcase Ventilation System
Inspection .............................................6-1219
Air Cleaner Element Replacement ............ 6-1219
Air Cleaner Intake Duct Replacement ....... 6-1220
Description and Operation ........................ 6-1221
Powertrain Control Module Description ..... 6-1221
Information Sensors/Switches
Description ................................. , .......... 6-1221
PCM Controlled Warning Lamps
Description ............................................6-1226
PCM Controlled Air Conditioning
Description ............................................6-1226

Engine
Engine Cooling Fan Description Electric ................................................. 6-1227
Fuel Supply Component Description ......... 6-1227
Fuel Metering Modes of Operation ........... 6-1231
Fuel Metering System Component
Description ............................................ 6-1232
EVAP Control System Operation
Description ...'......................................... 6-1234
Electronic Ignition System Description ...... 6-1236
Knock Sensor System Description ............ 6-1240
EGR System Description .......................... 6-1242
Crankcase Ventilation System
.
Description ............................................6-1243
Air Intake System Description ................... 6-1243
Special Tools and Equipment ................... 6-1244

Engine Controls - 5.7L .............................. 6-1247

Specifications ............................................6-1247
Temperature vs Resistance ...................... 6-1247
Fastener Tightening Specifications ............6-124 7
Engine Scan Tool Data List ..................... 6-1248
Engine Scfin Tool Data Definitions ........... 6-1251
OTC List ...................................................6-1256
Fuel System Specifications ....................... 6-1259
GM SPO Group Numbers ........................ 6-1260
Schematic and Routing Diagrams ............ 6-1261
Emission Hose Routing Diagram .............. 6-1261
Engine Controls Schematic References .... 6-1262
Engine Controls Schematic Icons ............. 6-1262
Engine Controls Schematics ..................... 6-1263
Component Locator ..... ,............................. 6-1281
Engine Controls Components ................... 6-1281
Engine Controls Component Views ........... 6-1286
PCM Connector End Views ...................... 6-1300
Engine Controls Connector End Views ..... 6-1304
Diagnostic Information and Procedures ... 6-1312
A Powertrain On Board Diagnostic
(OBD) System Check ............................ 6-1312
Data Link Connector Diagnosis ................ 6-1315
Engine Cranks but Does Not Run ............ 6-1318
Ignition Relay Diagnosis ........................... 6-1321
Fuel Pump Relay Circuit Diagnosis .......... 6-1324
Fuel System Diagnosis .............................6-1329
DTC P0101 Mass Air Flow (MAF)
Sensor Performance .............................6-1334
DTC P0102 Mass Air Flow (MAF)
Sensor Circuit Low Frequency .............. 6-1339
DTC P0103 Mass Air Flow (MAF)
Sensor Circuit High Frequency .............. 6-1344
DTC P0107 Manifold Absolute Pressure
(MAP) Sensor Circuit Low Voltage ........ 6-1348
DTC P0108 Manifold Absolute Pressure
(MAP) Sensor Circuit High Voltage ....... 6-1352
DTC P0112 Intake Air Temperature
(IAT) Sensor Circuit Low Voltage .......... 6-1356
DTC P0113 Intake Air Temperature
(IAT) Sensor Circuit High Voltage ......... 6-1359
DTC P0117 Engine Coolant Temperature
(ECT) Sensor Circuit Low Voltage ........ 6-1363

Engine
OTC P0118 Engine Coolant Tel)1perature
(ECT) Sensor Circuit High Voltage ........6-1366
OTC P0121 TP Sensor Circuit
Insufficient Activity ............ ;....................6-1370
OTC P0122 Throttle Position {TP)
Sensor Circuit Low Voltage ................... 6-1374
OTC P0123 Throttle Position, {TP)
Sensor Circuit High Voltage .................. 6-1378
OTC P0125 Engine Coolant Temperature
(ECT) Excessive Time to Closed
Loop Fuel Control .................................6-1382
OTC P0131 H02S Circuit Low Voltage
Bank 1 Sensor 1 ..................................6-1385
DTC P0132 H02S. Circuit High Voltage
Bank 1 Sensor 1 ., .................................6-1389
OTC P0133 H02S Slow Response
Bank 1 Sensor 1 ..................................6-1393
OTC P0134 H02S Circuit Insufficient
Activity Bank 1 Sensor .......................... 6-1397
DTC P0135 H02S Heater Performance
Bank 1 Sensor 1 ..................................6-1401
DTC P0137 H02S Circuit Low Voltage
Bank1 Sensor 2 ....................................6-1405
DTC P0138 H02S Circuit High Voltage
Bank 1 Sensor 2 ..................................6-1409
DTC P0140 H02S Circuit Insufficient
Activity Bank 1 Sensor 2 ......................6-1413
DTC P0141 H02S Heater Performance
Bank 1 Sensor 2 ..................................6-1417
DTC P0151 H02S Circuit Low Voltage
Bank 2 Sensor 1 .................................. 6-1421
DTC P0152 H02S Circuit High Voltage
Bank 2 Sensor 1 ........................... ,......6-1425
DTC P0153 H02S Slow Response
Bank 2 Sensor 1 ..................................6-1429
OTC P0154 H02S Circuit Insufficient
Activity Bank 2 Sensor 1 ...................... 6-1433
OTC P0155 H02S Heater Performance
Bank 2 Sensor 1 ..................................6-1437
OTC P0157 H02S Circuit Low Voltage
Bank 2 Sensor 2 ..................................6-1440
OTC P0158 H02S Circuit High Voltage
Bank 2 Sensor 2 ..................................6-1444
OTC P0160 H02S Circuit Insufficient
Activity Bank 2 Sensor 2 ...................... 6-1448
DTC P0161 H02S Heater Performance
Bank 2 Sensor 2 ..................................6-1452
DTC P0171 Fuel Trim System Lean
Bank 1 .................................................6-1456
DTC P0172 Fuel Trim System Rich
Bank 1 .................................................6-1459
DTC P0174 Fuel Trim System Lean
Bank 2 .................................................6-1462
DTC P0175 Fuel Trim System Rich
Bank 2 .................................................6-1465
DTC P0230 Fuel Pump Relay Control
Circuit ...................................................6-1468
DTC P0300 Engine Misfire Detected .........6-1472
DTC P0325 Knock Sensor System ........... 6-1478
DTC P0327 Knock Sensor (KS) 1
Circuit ...................................................6-1479

Table of Contents

6-9

DTC P0332 Knock Sensor Circuit Rear .... 6-1483

DTC P0335 Crankshaft Position (CKP)
Sensor Circuit .......................................6-1487
OTC P0336 Crankshaft Position (CKP)
Sensor Performance .............................6-1491
DTC P0341 Camshaft Position (CMP)
Sensor Performance ............................. 6-1494
DTC P0342 Camshaft Position (CMP)
Sensor Circuit Low Voltage ................... 6-1497
DTC P0343 Camshaft Position (CMP)
Sensor Circuit High Voltage .................. 6-1503
DTC P0351 Ignition Coil 1 Control
Circuit ...................................................6-1509
DTC P0352 Ignition Coil 2 Control
Circuit ...................................................6-1513
DTC P0353 Ignition Coil 3 Control
Circuit ................................................... 6-1517
DTC P0354 Ignition Coil 4 Control
Circuit ...................................................6-1521
OTC P0355 Ignition Coil 5 Control
Circuit ...................................................6-1525
OTC P0356 Ignition Coil 6 Control
Circuit ...................................................6-1529
DTC P0357 Ignition Coil 7 Control
Circuit ...................................................6-1533
OTC P0358 Ignition Coil 8 Control
Circuit ...................................................6-1537
DTC P0401 Exhaust Gas Recirculation
(EGR) Flow Insufficient .... , ....................6-1541
OTC P0404 Exhaust Gas Recirculation
(EGR) Open Position Performance ........ 6-1543
OTC P0405 Exhaust Gas Recirculation
(EGR) Position Sensor Circuit Low
Voltage .................................................6-1547
OTC P0410 Secondary Air Injection
(AIR) System ........................................6-1551
OTC P0412 Secondary Air Injection
(AIR) Solenoid Relay Control Circuit ..... 6-1557
OTC P0418 Secondary Air Injection
(AIR) Pump Relay Control Circuit .......... 6-1561
OTC P0420 Catalyst System Low
Efficiency Bank 1 .................................. 6-1565
OTC P0430 Catalyst System Low
Efficiency Bank 2 ..................................6-1567
DTC P0440 Evaporative Emission
(EVAP) System .....................................6-1569
DTC P0442 Evaporative Emission
(EVAP) Control System Small Leak
Detected ...............................................6-1574
OTC P0443 Evaporative Emission
(EVAP) Purge Solenoid Control
Circuit ...................................................6-1579
OTC P0446 Evaporative Emission
(EVAP) Vent System Performance ........ 6-1583
DTC P0449 Evaporative Emission
(EVAP) Vent Solenoid Control Circuit .... 6-1587
DTC P0452 Fuel Tank Pressure
Sensor Circuit Low Voltage ................... 6-1591
OTC P0453 Fuel Tank Pressure
Sensor Circuit High Voltage .................. 6-1596
DTC P0461 Fuel Level Sensor
Performance ......................................... 6-1600

6-10

Table of Contents

DTC P0462 Fuel Level Sensor

Circuit Low Voltage ............................... 6-1603
DTC P0463 Fuel Level Sensor Circuit
High Voltage .........................................6-1606
DTC P0480 Cooling Fan Relay 1
Control Circuit ....................................... 6-161 O
DTC P0481 Cooling Fan Relay 2 and 3
Control Circuit ....................................... 6-1613
OTC P0500 Vehicle Speed Sensor
(VSS) Circuit , ........................................ 6-1616
DTC P0506 Idle Speed Low ..................... 6-1619
DTC P0507 Idle Speed High .................... 6-1622
DTC P0530 Air Conditioning (A/C)
Refrigerant Pressure Sensor Circuit ...... 6-1625
DTC P0562 System Voltage Low .............. 6-1628
DTC P0563 System Voltage High ............. 6-1631
DTC P0601 Control Module Read Only
Memory (ROM) ..................................... 6-1633
DTC P0602 Control Module Not
Programmed ......................................... 6-1634
DTC P0604 Control Module Random
Access Memory (RAM) ......................... 6-1635
DTC P0608 Vehicle Speed Output
Circuit ................................................... 6-1636
DTC P0650 Malfunction Indicator Lamp
(MIL) Control Circuit .............................. 6-1639
DTC P0654 Engine Speed Output
Circuit ...................................................6-1642
DTC P0656 Fuel Level Output Circuit .......6-1645
DTC P0801 Reverse Inhibit Solenoid
Control Circuit ....................................... 6-1649
DTC P0803 Skip Shift Solenoid Control
Circuit ...................................................6-1653
DTC P0804 Skip Shift Lamp Control
Circuit ................................................... 6-1656
DTC P1111 Intake Air Temperature (IAT)
Sensor Circuit Intermittent High
Voltage ................................................. 6-1659
DTC P1112 Intake Air Temperature (IAT)
Sensor Circuit Intermittent Low
Voltage .................................................6-1662
DTC P1114 Engine Coolant Temperature
(ECT) Sensor Circuit Intermittent Low
Voltage ................................................. 6-1665
DTC P1115 Engine Coolant Temperature
(ECT) Sensor Circuit Intermittent High
Voltage ................................................. 6-1668
DTC P1121 Throttle Position (TP)
Sensor Circuit Intermittent High
Voltage .................................................6-1671
DTC P1122 Throttle Position (TP)
Sensor Circuit Intermittent Low
Voltage .................................................6-1674
DTC P1133 H02S Insufficient Switching
Bank 1 Sensor 1 ..................................6-1677
DTC P1134 H02S Transition Time Ratio
ank 1 Sensor 1 .................................... 6-1681
DTC P1153 H02S Insufficient Switching
ank 2 Sensor 1 .................................... 6-1685
DTC P1154 H02S Transition Time Ratio
Bank 2 Sensor 1 .................................. 6-1689

Engine
DTC P1258 Engine Coolant
Overtemperature - Protection Mode
Active ................................................... 6-1693
DTC P1336 Crankshaft Position (CKP)
System Variation Not Learned .............. 6-1695
DTC P1380 Misfire Detected - Rough
Road Data Not Available ...................... 6-1698
DTC P1404 EGR Exhaust Gas
Recirculation (EGR) Closed Position
Performance ......................................... 6-1699
DTC P1415 Secondary Air Injection
(AIR) System Bank 1 ............................ 6-1703
DTC P1416 Secondary Air Injection
(AIR) System Bank 2 ............................ 6-1706
DTC P1441 Evaporative Emission
(EVAP) System Flow During
Non-Purge ............................................6-1709
DTC P1539 Air Conditioning (A/C)
Clutch Feedback Circuit High Voltage ... 6-1711
DTC P1545 A/C Compressor Clutch
Relay Control Circuit ............................. 6-1714
DTC P1546 Air Conditioning (A/C)
Clutch Feedback Circuit Low Voltage .... 6-1718
DTC P1626 Theft Deterrent Fuel
Enable Signal Lost ................................6-1721
DTC P1635 5 Volt Reference 1 Circuit ..... 6-1724
DTC P1639 5 Volt Reference 2 Circuit ..... 6-1727
Symptoms ................................................ 6-1733
Hard Start ................................................6-1734
Surges/Chuggles ...................................... 6-1735
Lack of Power, Sluggishness, or
Sponginess ........................................... 6-1737
Detonation/Spark Knock ........................... 6-1738
Hesitation, Sag, Stumble .......................... 6-1739
Cuts Out, Misses ..................................... 6-1740
Poor Fuel Economy .................................6-1742
Rough, Unstable, or Incorrect Idle and
Stalling ................................................. 6-1744
Dieseling, Run-On .................................... 6-1746
Backfire .................................................... 6-1746
Restricted Exhaust System Check ............ 6-1749
A/C Request Circuit Diagnosis ................. 6-1750
A/C Refrigerant Pressure Sensor Circuit
Diagnosis .............................................. 6-1753
Electric Cooling Fan Diagnosis ................. 6-1756
PNP Switch Diagnosis .............................. 6-1763
Engine Oil Level Sensor/Switch
Diagnosis ..............................................6-1766
Low Engine Oil Level Indicator
Diagnosis ..............................................6-1769
Fuel Injector Balance Test ........................ 6-1771
Fuel lnj Coil Test - ECT Between
10-35 Degrees C .................................. 6-1774
Fuel lnj Coil Test - ECT Outside
10-35 Degrees C ..................................6-1776
Fuel Injector Circuit Diagnosis .................. 6-1778
Fuel Tank Leak Check ............................. 6-1781
Fuel Tank Vent Valve Diagnosis .............. 6-1781
Alcohol/Contaminants-in-Fuel Diagnosis .... 6-1781
Electronic Ignition System Diagnosis ........ 6-1782

Engine

\/

Inspection/Maintenance Status Reset

Procedures ...........................................6 1785
Repair Instructions ....................................6-1786
PCM Replacement/Programming .............. 6-1786
PCM Idle Learn Procedure ............... , ....... 6-1789
CKP System Variation Learn Procedure ... 6-1789
ECT Sensor Replacement ........................ 6-1790
MAF Sensor Replacement ........................6-1791
MAP Sensor Replacement ....................... 6-1792
H02S Replacement - Bank 1 ................... 6-1794
H02S Replacement - Bank 2 ................... 6-1797
TP Sensor Replacement .......................... 6-1800
IAT Sensor Replacement ......................... 6-1800
IAC Valve Replacement ........................... 6-1801
Accelerator Controls Cable
Replacement .........................................6-1802
Accelerator Controls Pedal
Replacement .........................................6-1804
Throttle Body Assembly Replacement ...... 6-1804
Fuel Pressure Relief Procedure ................ 6-1807
Quick Connect Fitting(s) Service
(Metal Collar) ........................................ 6-1808
Quick Connect Fitting(s) Service
(Plastic Collar) ......................................6-1811
In-Line Fuel Filter Replacement ................ 6-1813
Fuel Tank Draining Procedure .................. 6-1814
Fuel Tank Replacement ...........................6-1815
Fuel Tank Vent Valve Replacement ......... 6-1821
Fuel Tank Pressure Sensor
Replacement ......................................... 6-1822
Fuel Sender Assembly Replacement ........ 6-1823
Fuel Sender Assembly Service ................. 6-1824
Fuel Pulse Dampener Replacement ......... 6-1826
Fuel Hose/Pipes Replacement
(Chassis) ..............................................6-1826
Fuel Hose/Pipes Replacement
(Engine Compartment) .......................... 6-1832
Fuel Hose/Pipes Assembly
Replacement (Rear Pipes) .................... 6-1833
Fuel System Cleaning ..............................6-1835
Fuel Pressure Connection Valve
Replacement .........................................6-1836
Fuel Rail Assembly Replacement ............. 6-1836
Fuel Injector Replacement ........................ 6-1839
Fuel Pump Relay Replacement ................ 6-1841
EVAP Canister Purge Solenoid Valve
Replacement ......................................... 6-1842
EVAP Vent Valve Replacement ................ 6-1843
EVAP Canister Replacement .................... 6-1844
EVAP System Cleaning ............................ 6-1845
Crankshaft Position Sensor
Replacement .........................................6-1846
Camshaft Position Sensor Replacement ... 6-1848
Knock Sensor Replacement ..................... 6-1849
Secondary AIR Injection Pump
Replacement ......................................... 6-1850
AIR Check Valve/Pipe
Replacement - Bank 2 .......................... 6-1852
AIR Check Valve/Pipe
Replacement - Bank 1 .......................... 6-1853

Table of Contents 6-11

Secondary Air Injection Solenoid Relay
_Replacement .........................................6-1854
Secondary Air Injection Pump Relay
Replacement .......... : ..............................6-1854
Secondary Air lnj Bleed Valve Sol
Replacement ......................................... 6-1855
EGR Valve Replacement ....................... '. .. 6-1856
EGR Pipe Replacement ........................... 6-1857
EGR System Cleaning ............................. 6-1858
Air Cleaner Element Replacement ............ 6-1858
Air Cleaner Assembly Replacement .......... 6-1859
Engine Oil Life Monitor Reset
Procedure .............................................6-1861
Description and Operation ........................ 6-1862
Powertrain Control Module Description ..... 6-1862
Information Sensors/Switches
Description ............................................ 6-1869
PCM Controlled Air Conditioning
Description ............................................6-1876
Engine Cooling Fan Description Electric ................................................. 6-1876
Fuel Supply Component Description ......... 6-1877
Fuel Metering Modes of Operation ........... 6-1879
Fuel Metering System Component
Description ............................................6-1880
Short Term Fuel Trim Description ............. 6-1883
Long Term Fuel Trim Description ............. 6-1883
Speed Density System Description ........... 6-1883
EVAP Control System Operation
Description ............................................6-1884
Electronic Ignition System Description ...... 6-1886
Knock Sensor System Description ............ 6-1889
Secondary AIR Injection System
Description ............................................6-1890
EGR System Description .......................... 6-1892
Crankcase Ventilation System
Description ............................................6-1893
Air Intake System Description ................... 6-1895
Special Tools and Equipment ................... 6-1897

Engine Exhaust .......................................... 6-1900

Specifications ............................................6-1900
Fastener Tightening Specifications ............ 6-1900
GM SPO Group Numbers ........................ 6-1900
Diagnostic Information and Procedures ... 6-1900
Internal Muffler Rattles/Loss of Power ...... 6-1900
Exhaust Leakage .....................................6-1901
Exhaust Noise ..........................................6-1901
Repair Instructions .................................... 6-1902
Catalytic Converter Replacement .............. 6-1902
Oxidation Catalytic Converter
Replacement (Left) ..............................6-1905
Oxidation Catalytic Converter
Replacement (Right) ............................. 6-1908
Muffler Replacement .................................6-1913
Converter Hanger Assembly
Replacement (3.8L Automatic) .............. 6-1917
Converter Hanger Assembly
Replacement (5.7L Auto/Man) ............... 6-1919

6-12

Table of Contents

Converter Hanger Assembly

Replacement (3.8L Man) ..................... ;.6-1920
Exhaust Muffler Hangers
Replacement (3.8L V6) ......................... 6-1921
Exhaust Muffler Hangers
Replacement (5.7L V8) ......................... 6-1923
Converter Heat Shield Replacement ......... 6~1924

.Engine
Exhaust Heat Shield Replacement ...........6-1925
Exhaust Pipe and Muffler Heat Shields
Replacement .............................. .'.; ........ 6-1926
Description and Op,eration ......................... 6-1929
Exhaust System Description ..................... 6s 1929

Engine

Engine. M~chanical - 3.SL

Engine Mechanical

6-13

3.8L

Specifications
Fastener Tightening Specifications
Nm

Application

Lb Ft

10

Acceler?tor Control Cable Bracket Bolt

Lbln
89

Balance Shaft Retainer Bolt

30

22

Camshaft Position Sensor Bolt

10

89

..

74 + 90

11

22+ 70

Balance Shaft Gear Bolt

16 + 70

100 + 90

Camshaft Sprocket Bolt

..

15

Camshaft Thrust Plate Bolt

Connecting Rod Cap Bolt

27 + 50

20 + 50

Crankshaft Balancer Bolt (Automatic Transmission)

150 + 76

111 + 76

Crankshaft Balancer Bott (Manual Transmission)

150+ 114

111 + 114

Crankshaft Main Bearing Cap Bolt

40 + 110

30 + 110

15+ 45

11 + 45

30

22

Crankshaft Main Bearing Cap Bolt (Side)

""

Crankshaft Position Sensor Stud

..

15 + 50

11 + 50

50 +120

37 + 120

Drive Belt Tensioner Bracket Bolt

50

37

EGR Valve Adapter Nut

50

37

21

21

Crankshaft Rear Oil Seal Housing Bolt

Cylinder Head Bolt

EGR Valve Nut

'

..

29

EGRValve Outlet Pipe Bolt/Nut (Except Upper Intake

Manifold)

29

Engine Block Coolant Drain Plug

10
18

13

Engine.Coolant Temperature Sensor

25

18

. 15+50

11 + 50

.-

15 + 40

11 + 40

EGR Valve Wiring Harness Heat Shield Bolt/Nut

Engine Flywheel Bolt (New)

Engine Lift Bracket Bolt/Nut/Stud

30

22

Engine Mount Bracket Bolt

102

75

Engine Mount Nut, Lower

43

32

Engine Mount Nut, Upper

47

35

Engine Mount Strut Bolt

48

35

Engine Mount Strut Bracket Bolt at Engine, Left

50

37

Engine Mount Strut Bracket Bott at Engine, Right

50

37

Engine Mount Strut Bracket Bolt at Upper Radiator Support

28

21

48

'35

Engine Oil Ga.Uery Plug

30

22

Exhaust Crossover Bolt/Stud

20

15

Exhaust Manifolcl Bolt/Stud

30

22

Fuel lnjectorHa:il As$embly Nut

10

89

Fuel Injector Raj! Stud

25

18

30

22

37

. Engine Mount StrutNut -

Fuel Injector $,ightShielel Bracket Nut

..

..

Geherator Brace Bracket Bolt

50

Heated, O~ygen Sensor

42

31

ICM Bracket Stud

30

22

ICM Assembly Bolt/Nut

50

37

Lower Intake Manifold Bolt

15

11

..,

..

..

89

Engine Front Cover Bolt/Stud

'

..

5..14

Engine

Engine Mechanical - 3.8L

Fastener Tightening Specifications (cont'd)
Application

Lbln

Nm

Lb Ft

MAP Sensor Bracket Bolt

30

22

MAP Sensor Bolt

27

Oil Cooler Adapter Connector

50

37

Oil Filter Adapter Bolt

30

22

Oil Level Indicator Tube Nut

19

14

Oil Pan Bolt

14

125

Oil Pan Drain Plug

30

22

Oil Pump Cover Screw

11

98

Oil Pump Screen Bolt

15

11

Power Brake Booster Heat Shield Nut

20

15

15 + 45

11 + 45

30

22

10

89

16

Side Main Cap Bolt

Starter Motor Heat Shield Bolt
.Throttle Body Bolt/N1:1t
Throttle Body Support Bolt

10

Timing Chain Dampener Bolt

22

89

Refer to Procedure

Upper Intake Manifold Bolt

Valve.Lifter Guide Retainer Bolt
Valve Rocker Arm Bolt

30

22

15 + 90

11 + 90

Valve Rocker Arm Cover Bolt

10

89

Water Outlet Bolt

27

20

Water Pump Bolt

15 + 80

11 + 80

13

Water Pump Pulley Bolt

116

Engine Mechanical Specifications

Specification
Application

English

Metric

General Data
Engine Type

90 V-6

Displacement

231 cu in
3.8L (K)

Liter (VIN)

L36

RPO
Bore
Stroke

96.52 mm

3.8 in

86.36 mm

3.4 in
9.4:1

Compression Ratio

1-6-5-4-3-2

Firing Order
Lubrication System
Oil Capacity with Oil Filter Change

4.25 L

4.5 qt

Oil Capacity without Oil Filter Change

3.75 L

4 qt

414 kPa

60 psi min

Oil Pressure @ Operating Temperature (1850 RPM) Using

10W-30 Oil
'
Oil Filter Type

Throw Away Element and Can

Gear Pocket Depth

11.71-11.75 mm

0.461-0.4625 in

Gear Pocket Diameter

89.10-89.20 mm

3.508-3.512 in

Inner Gear Tip. Clearance

Outer Gear DiameterClearance

0.152 mm

0.006 in

0.203-0.381 mm

0.008-0.015 in

End Clearance

0.025-0.089 mm

0.001-0.0035 in

Valve-to-Bore Clearance..

0.038-0.076 mm

0.0015-0.003 in

Engine Mechanical - 3.8L

Engine

6-15

Engine Mechanical Specifications (cont'd)

Specification

Application

English

Metric

Type of Lubrication
Main Bearings

Pressure

Connecting Rods

Pressure

Piston Pins

Splash

Balance Shaft Bearing - Front

Splash

Balance Shaft Bushing - Rear

Pressure

Camshaft Bearings

Pressure

Timing Chain

Splash

Cylinder Walls

Splash

Oil Pump Type

Gerotor

Oil Pressure Sending Unit

Electrical

Oil Intake

Stationary

Oil Filter System

Full Flow

Cylinder Bore
96.5 mm

3.8 in

Out-Of-Round Maximum

0.0254 mm

0.001 in

Taper

0.0254 mm

0.001 in

0.010-0.051 mm

0.0004-0.0020 in

Diameter

Piston
Clearance (39 mm from Top of Piston)
Piston Ring Groove Depth
4.019-4.146 mm

0.158-0.163 in

2nd Compression

4.214-4.341 mm

0.0166,0.171 in

Oil Control

3.814-3.941 mm

0.150-0.155 in

Top Compression

Piston Ring End Gap

Top Compression

0.305-0.559 mm

0.012-0.022 in

2nd Compression

0.762-1.016 mm

0.030-0.040 in

Oil Control

0.254-0.762 mm

0.010-0.030 in

Piston Ring Side Clearance

Top Compression

0.033-0.079 mm

0.0013-0.0031 in

2nd Compression

0.033-0.079 mm

0.0013-0.0031 in

Oil Control

0.023-0.201 mm

0.0009-0.0079 in

Top Compression

1.176-1.197 mm

0.0463-0.0471

2nd Compression

1.476-1.497 mm

0.0581-0.0589

Oil Control

1.854-2.007 mm

0.073-0.079

Piston Ring Width

Piston Pin
21.9950-22.0000 mm

0.8659-0.8661 in

Clearance in Piston

0.0020-0.0130 mm

0.00008-0.00051 in

Fit-In-Rod (Clearance)

0.0066-0.0217 mm

0.0003-0.0009 in

Main Journal Diameter-All

63.470-63.495 mm

2.4988-2.4998 in

Rod Journal Diameter-All

57.1170-57.1475 mm

2.2487-2.2499 in

Main Journal Taper-Maximum

0.0076 mm

0.0003 in

Rod Journal Taper-Maximum

0.0076 mm

0.0003 in

Main Journal Out-of-Round-Maximum

0.0076 mm

0.0003 in

Rod Journal Out-of-Round-Maximum

0.0076 mm

0.0003 in

Main Bearing To Journal Clearance 1

0.0178-0.0406 mm

0.0007-0.0016 in

Diameter

Crankshaft

6-16

Engine

Engine Mechanical - 3.8L

Engine Mechanical Specifications (cont'd)
Specification
Metric

English

Main Bearing To Journal Clearance 2 and 3

0.0254-0.0508 mm

0.0010-0.0020 in

Main Bearing To Journal Clearance 4

0.0229-0.0457 mm

0.0009-0.0018 in

Rod Bearing Clearance

0.0127-0.0660 mm

0.0005-0.0026 in

0.076-0.276 mm

0.003-0.011 in

0.102-0.508 mm

0.004-0.0200 in

60.295-60.312 mm

2.37378-2.37 45 in

Application

Crankshaft End Play

Connecting Rod
Rod Side Clearance
Connecting Rod Large End Bore ID
Camshaft
Journal Diameter

47.655-46.858 mm

1.8462-1.8448 in

Bearing Inside Diameter 1 and 4

46.970-46.934 mm

1.8428-1.8492 in

Bearing Inside Diameter 2 and 3

Bearing-to-Journal Clearance

46.977-46.942 mm

1.8481-1.8495 in

0.041-0.119 mm

0.0016-0.0047 in

Intake Maximum Lobe Lift

6.55 mm

0.258 in

Exhaust Maximum Lobe Lift

6.48 mm

0.255 in

0.0-0.171 mm

0.0-0.0067 in

38.085-38.105 mm

1.4994-1.5002 in

0.0-0.026 mm

0.0-0.001 O in

0.0127-0.109 mm

0.0005-0.0043 in

0.050-0.125 mm

0.002-0.0049 in

Balance Shaft
End Play
Rear Journal Diameter
Radial Play-Front, Bearing Clearance
Rear Bearing To Journal Clearance
Drive Gear Lash
Bearing Bore Diameter-Front

51.973-51.999 mm

2.0462-2.0472 in

Bearing Bore Diameter-Rear, In Block

47.584-47.612 mm

1.8735-1.8745 in

Bearing Inside Diameter-Rear

38.118-38.194 mm

1.5007-1.5037 in

Valve System
Hydraulic

Lifter

1.6:1

Rocker Arm Ratio

Face Angle

45

Seat Angle

45

Minimum Margin

0.635 mm

0.025 in

Seat Runout-Maximum

0.050 mm

0.002 in

Seat Width-Intake

1.53-2.03 mm

0.060-0.080 in

Seat Width-Exhaust

2.29-2.79 mm

0.090-0.11 O in

Stem Height-All

49.15-50.17 mm

1.935-1.975 in

Stem Clearance-All

0.038-0.089 mm

0.0015-0.0032 in

49.78 mm

1.960 in

Valve Spring
Free Length
Load-Closed
Load-Open
Installed Height

334N@

75 lb@ 1.72 in

43.69 mm

228 lb @ 1.277 in

1014 N @ 32.4 mm

1.690-1. 720 in

42.93-44.45 mm

Approximate Number of Active Coils

4.48

Approximate Number of Total Coils

6.60

Flywheel
Runout-Maximum

0.38 mm

0.015 in

Engine Mechanical- 3;8L

Engine
GM SPO Group Numbers
Application
Automatic Transmission Engine Flywheel
Camshaft Bearing
Camshaft Timing Chain
Connecting Rod
Connecting Rod Bearing Kit
Crankshaft Balancer
Crankshaft Bearing Kit
Cylinder Head

GM SPO Group Number

0.666
0.539
0.724
0.603
0.616
0.659
0.096
0.269

Cylinder Head Gasket

N.S.

EGR Valve Gasket

3.680

Engine Block
Engine Camshaft
Engine Cooling Manifold
Engine Cooling Manifold Gasket
Engine Cooling Thermostat
Engine Crankshaft
Engine Front Cover
Engine Front Cover Gasket
Exhaust Manifold
Exhaust Manifold Gasket
Intake Manifold

N.S.

0.519
1.097
1.097
1.246
0.646
0.206
0.207
3.601
3.270
3.265

Intake Manifold Gasket

N.S.

Oil Filter

1.836
1.840
1.840
1.516
1.516
1.429
1.426
1.656
1.657
1.723
0.629
0,643
2.270
3.335
3.336
0.459
0.439
0.426
0.386
0.423
0.303
1.079
1.069
1.069

Oil Filter Adapter

Oil Filter Adapter Gasket
Oil Level Indicator
Oil Level Indicator Tube
Oil Pan Kit with Gasket
Oil Pan Reinforcement
Oil Pump Screen
Oil Pump Screen Gasket
Oil Pump Cover
Piston with Pin
Piston with Ring Kit
Spark Plug
Throttle Body
Throttle Body Gasket
Valve Lifter
Valve Lifter Guide
Valve Pushrod
Valve Rocker Arm Cover
Valve Rocker Arm Cover Gasket
Valve Spring
Water Pump Gasket
Water Pump Kit
Water Pump with Gasket

617

6-18

Engine

Engine Mechanical - 3.8L

Sealers, Adhesives, and Lubricants
Application

Type of Material

GM Part Number

Accelerator Control Cable Bracket Bolt Threads

Thread lock

12345382

Coolant Temperature Sensor Threads

Sealant

12346004

Crankshaft Position Sensor Bolt/Stud Threads

Thread lock

12345382

Crankshaft Side Main Bolt Threads

Threadlock

12345493

Engine Block Coolant Drain Plug Threads

Sealant

12346004

Engine Block Oil Gallery Plug Threads

Sealant

12346004

Engine Front Cover Bolt Threads

Sealant

12346004

Engine Oil

Oil-10W-30

12345616

Engine Oil Supplement

Lubricant

1052368

Exhaust Manifold Bolt and Stud Threads

Thread lock

12345493

Intake Manifold Bolt Threads (Lower)

Thread lock

12345382

Intake Manifold Coolant Pipe

Sealant

12345493

Intake Manifold to Engine Block Mating Surface

Sealant

12346286

Knock Sensor Threads

Sealant

12346004

Oil Filter Bypass Hole Plug Threads

Sealant

12346004

Oil Pan Bolt Threads

Threadlock

12345382

Oil Pressure Switch Threads

Sealant

12346004

Piston and Piston Pin

Oil-10W-30

12345616

Rear Crankshaft Main Bearing Cap

Sealant

1052942

Valve Lifter and Camshaft Prelube

Lubricant

12345501

Valve Rocker Arm Cover Bolt Threads

Threadlock

12345382

Valve Rocker Arm Bolt Threads

Thread lock

12345493

Diagnostic Information and Procedures

Base Engine Misfire Diagnosis
Checks

Action

Engine performance diagnosis procedures are covered in Engine Controls and should be consulted for diagnosis of any
Driveability, Emissions, or Malfunctioning Indicator Lamp (MIL) concerns.
The following diagnosis covers common concerns and possible causes.
When the proper diagnosis is made, the concern should be corrected by adjustment, repair or replacement as required.
Refer to the appropriate section of the service manual for each specific procedure.
This diagnostic table will assist in engine misfire diagnosis due to a mechanical concern such as a faulty engine camshaft,
worn or damaged bearings or bent valve pushrod.
This table will not isolate a crossed fuel injector wire, faulty fuel injector or any other driveability component failure that may
cause a misfire.
The Powertrain On-Board Diagnostic System checks must be performed first.
When using this table to make a Base Engine Misfire diagnosis, begin with the preliminary information below and then
proceed to the specific category.
Preliminary

1. Perform DTC P0300 before proceeding with Base Engine Misfire Diagnosis
information.
OTC P0300 will assist in determining which cylinder or cylinders are misfiring.
2. Perform a visual inspection of the following:
A loose or improperly installed engine flywheel or crankshaft balancer
Worn, damaged or misaligned accessory drive system components
3. Listen to the engine for any abnormal internal engine noises.
4. Inspect the engine for acceptable oil pressure.
5. Verify if the engine has excessive oil consumption.
6. Verify if the engine has excessive coolant consumption.
7. Perform a compression test on the engine.

Engine Mechanical - 3.SL

Engine

6-19

Base Engine Misfire Diagnosis (cont'd)

Checks

Action

Intake Manifold Leaks

An intake manifold that has a vacuum leak may cause a misfire.

Inspect for the following:
Improperly installed or damaged vacuum hoses
Faulty or improperly installed lower intake manifold and/or gaskets
Cracked or damaged lower intake manifold
Improperly installed MAP sensor
The sealing grommet of the MAP sensor should not be torn or damaged
Improperly installed throttle body or damaged gasket
Warped intake manifold
Warped or damaged cylinder head sealing surface

Coolant Consumption

Coolant consumption may or may not cause the engine to overheat.

Inspect for the following:
External coolant leaks
Faulty cylinder head gasket
Warped cylinder head
Cracked cylinder head
Damaged engine block

Oil Consumption

Oil consumption may or may not cause the engine to misfire.

1. Remove the spark plugs and inspect for an oil fouled spark plug.
2. Perform a cylinder compression test.
3. If the compression test indicates worn valves or valve guides, inspect the
following:
Worn, brittle, or improperly installed valve stem oil seals
Worn valve guides
Worn valve stems
Worn or burnt valves or valve seats
4. If the compression test indicates worn or damaged piston rings, inspect the
following:
Broken or improperly seated piston rings
Excessive piston ring end gap
Excessive cylinder bore wear or taper
Cylinder damage
Piston damage

Abnormal Internal Engine Noises

1. Start the engine and determine if the noise is timed to the engine camshaft
speed or the crankshaft speed.
2. Using a timing light, two knocks per flash is the crankshaft speed and one
knock per flash is the engine camshaft speed.
3. If the noise is timed to the engine camshaft speed, inspect the following:
Missing or loose valve train components
Worn or loose valve rocker arms
Worn or bent valve pushrods
Faulty valve springs
Bent or burnt valves
Worn engine camshaft lobes
Worn or damaged camshaft timing chain and/or sprockets
Important: A slight COLD knock or piston slapping noise could be considered
normal if not present after the engine has reached normal operating temperatures.
4. If the knock is timed to the crankshaft speed, inspect the following:

Worn crankshaft or connecting rod bearings

Piston or cylinder damage
Worn piston or piston pin
Faulty connecting rod
Excessive carbon build-up on the top of the piston

6-20

Engine

Engine Mechanical - 3.BL

Base Engine Misfire Diagnosis (cont'd)
Checks

No Abnormal Internal Engine Noise

Action

1. lnspe.ct for a worn or improperly installed camshaft timing chain and/or

sprockets.
2. Remove the valve rocker arm cover on the side of the engine with the cylinder
that is misfiring.

3. Inspect for the following:

Loose valve rocker arm studs

Bent valve push rods
Faulty valve springs
Faulty valve lifters (bleeding down)
Worn or improperly seated valves
Worn engine camshaft lobes

Engine Compression Test

10. The following are examples of the possible

Testing Procedure
Tools Required
J 38722 Compression Tester
A compression pressure test of the engine cylinders
determines the condition of the rings, the valves,
and the head gasket.

1. Run the engine until it reaches normal operating

temperature. The battery must be at or near full
charge.
2. Turn the engine OFF.
Important: Remove the Powertrain Control Module
(PCM) and the ignition fuses from the 1/P fuse
block. Refer to Engine Electrical.
3. Disable the ignition.
4. Disable the fuel systems.
5. Remove the spark plugs from all the cylinders.
6. Remove the air duct from the throttle body.
7. Block the throttle plate in the open position.
8. Measure the engine compression, using the .
following procedure:

8.1. Firmly install the compression gauge to the

spark plug hole.
8.2. Have an assistant crank the engine through
at least four compression strokes in the
testing cylinder.
8.3. Check and record the readings on the
gauge at each stroke.
8.4. Disconnect the gauge.
8.5. Repeat the compression test for each
cylinder.
9. Record the compression readings from all of the
cylinders.
The lowest reading should not be less than
70 percent of the highest reading.
No cylinder reading should be less
than 689 kPa (100 psi).

11.
12.
13.
14.
15.

measurements:
When the compression measurement is
normal, the compression builds up quickly and
evenly to the specified compression on
each cylinder.
When the compression is low on the first
stroke and tends to build up on the following
strokes, but does not reach the normal
compression, or if the compression improves
considerably with the addition of three
squirts of oil, the piston rings may be
the cause.
When the compression is low on the first
stroke and does not build up in the following
strokes, or the addition of oil does not affect the
compression, the valves may be the cause.
When the compression is low on two adjacent
cylinders, or coolant is present in the
crankcase, the head gasket may be the cause.
Remove the block from the throttle plate.
Install the air duct to the throttle body.
Install the spark plugs.
Install the Powertrain Control Module (PCM) fuse.
Install the ignition fuse to the 1/P fuse block.

Engine Noise Diagnosis (Base Engine)

Notice: Some engine noise is characteristic to
the design. Compare the sounds in other engines in
order to make sure that you are not trying to correct a
normal condition.
There are four steps to diagnosing engine noise.
They include:
- The type of noise
- Under which operating conditions it exists
- At what rate in the engine
- At what location in the engine
Compare the sounds in other engines to ensure
the noise is not a normal condition.
Remember, engine noise is generally
synchronized to either engine speed (caused by
the crankshaft, connecting rods or pistons) or
one-half engine speed (valve train noise). Try to
determine the rate at which the noise is occurring.

Engine
Main Bearing Noise

Damaged or worn main bearing noise is revealed

by dull thuds or knocks which happen on every
engine revolution. This noise is loudest when the
engine is under heavy load.
Excessive crankshaft end play is indicated by an
intermittent rap or knock sharper than a worn
main bearing.
The following are causes of main bearing noise:
- Low oil pump pressure
- Thin, diluted, or dirty oil and/or filter
- Excessive main bearing clearance
- Excessive crankshaft end play
- Out-of-round crankshaft journals
- Loose crankshaft pulley
- Loose flywheel or torque converter
- Loose main bearing cap
- Belt pilling

Connecting Rod Bearing Noise

A damaged or worn connecting rod bearing will
produce a knock under all speeds. During the early
stages of wear, connecting rod noise may be confused
with piston slap or loose piston pins. Connecting rod
knock noise increases in volume with engine
speed and is at its loudest on deceleration.
The following are causes of connecting rod
bearing noise:
Excessive bearing clearance
Worn crankshaft connecting rod journal
Thin, diluted, or dirty oil and/or filter
Low oil pressure
Crankshaft connecting rod journals out-of-round
Misaligned connecting rod
Connecting rod bolts not properly torqued
The wrong bearing inserts or misaligned
bearing half

Timing Gear or Chain and Sprocket Noise

Engines designed with timing gears, or those equipped
with a timing chain and sprockets, can produce
different noise. The most common noise is a high
frequency, light-knocking sound. This sound will
generally be the same in intensity whether the engine
is idling, operating at high speeds, or under load.
The following are causes of timing gear or chain and
sprocket noise:
Worn timing chain and/or gears
Misaligned gears
Excessive backlash
A damaged tooth
Gear or sprocket loose on the shaft
Too much end play in the camshaft or crankshaft

Engine Mechanical - 3.8L

6-21

Loose or improperly seated camshaft timing gears are

usually loudest when warm. They are speed sensitive
only. They are not load sensitive.
Cam gear noise will usually be evident at a warm idle
in neutral and sounds much like a loose timing chain.

Piston Noise
Piston pin, piston, and connecting rod noise are ha.rd
to separate. A loose piston pin, for example, causes
a sharp double knock usually heard when the engine is
idling, or during sudden acceleration then deceleration
of the engine. A piston pin that has been improperly
fitted will emit a light ticking noise that is more
noticeable with no load on the engine. Excessive
piston-to-cylinder bore clearance will cause a piston
slap noise. The noise is similar to a metallic knock, as
if the piston were slapping the cylinder wall during
its stroke. As with most engine noise, understanding
the cause of the noise will help you imagine what
the noise sounds like. An indication of piston slap is a
decrease in noise as the engine warms up. When
the engine is cold, the piston-to-bore clearance
is greater and piston slap will be louder. The following
are causes of piston noise:
Worn or loose piston pin or bushing
Improper pin fit
Excessive piston-to-cylinder bore clearance
Lack of lubrication
, Carbon deposits on top of the piston striking the
cylinder head
Worn or broken piston ring land
Broken or cracked piston
Misaligned connecting rods
Worn or damaged rings
Excessive ring land clearance
Insufficient ring-end gap clearance
Piston 180 degrees out of position
Incorrect skirt profiles

Rattle (Balance Shaft)

Balance shaft rattle sounds like a tinny, chattery rattle
or a knocking noise that seems to come from the
top rear of the engine. This noise is most pronounced
when the engine is hot, and is not affected by
engine load. An example would be dirt lodged in the
root between two gear teeth. Each time the root
between two balance shaft gear teeth meshes with a
cam gear tooth, the balance shaft is momentarily
forced upward. This pivots the shaft through the front
bearing, causing a downward force on the rear
bearing that eventually wears the rear bearing, causing
a rattle. The following are other factors that contribute
to balance shaft bearing rattle:
A tight link. on the timing chain
Damaged, broken, or dirty teeth on the balance
shaft gears
A worn timing chain tensioner
Misaligned rear balance shaft bushing

6-22

Engine Mechanical - 3.8L

Flywheel Noise
Notice: Converter bolts that are too long may dimple
the torque converter clutch apply surface and
cause a shudder condition.
A loose or cracked flywheel will produce an irregular
thud or click. To test for a loose or cracked flywheel,
operate the vehicle at approximately 32 km/h (20 mph)
and shut off the engine. If a thud is heard, the
flywheel may be loose or damaged. This type of thud
is loudest on deceleration. Loose torque
converter-to-flywheel or flywheel-to-crankshaft bolts
will resemble a bearing knock. This condition produces
several raps during quick acceleration on a
free-running engine. Depending on the idle
smoothness, when the transaxle is in gear, the noise
may or may not appear. Check the torque
converter-to-flywheel and the flywheel-to-crankshaft
bolts before attempting to investigate any
bearing-related knock.

Knocks Cold and Continues for 2 to 3 Minutes

Cold engine knock usually disappears when the
specific cylinder secondary ignition circuit is grounded
out. Cold engine piston knock which disappears
in 1.5 minutes should be considered acceptable.
Engine flywheel contacting the transmission
converter cover - reposition the
transmission converter cover.
Loose or broken crankshaft balancer or the drive
pulleys - tighten or replace the crankshaft
balancer or the drive pulleys as necessary.
Excessive piston-to-bore clearance - replace the
piston.
Bent connecting rod - replace the connecting rod.

Knocks at Idle Hot

Inspect the drive belt for wear. Check the tension
and/or replace as necessary.
Inspect the A/C compressor or generator bearing.
Replace or repair as necessary.
Inspect the valve train. Replace the parts as
necessary.
Inspect for improper oil viscosity. Install the proper
viscosity oil for the expected temperature. Refer
to Maintenance and Lubrication for the engine
oil specifications.
Inspect for excessive piston pin clearance.
Replace the piston and the pin as necessary.
Inspect the connecting rod alignment. Check and
replace the connecting rods as necessary.
Inspect for insufficient piston-to-bore clearance.
Hone the bore and fit the new piston.
Inspect the crankshaft balancer for looseness.
Tighten and/or replace the worn parts.
Ensure that the piston pin is not offset to the
wrong side. Properly install the piston.
Ensure that the camshaft drive gear backlash is
not excessive. The knock will also be heard on
a cold engine.

Engine
Knocks on Start-Up but Only Lasts a
Few Seconds
The following conditions may produce engine knocks
on initial start-up, but only last a few seconds:
Improper oil viscosity
- Install the proper oil viscosity for the
expected temperatures.
- Refer to Maintenance and Lubrication.
Lifter bleed down - clean, test, and replace the
lifter as necessary.
- When the engine is off, some valves will be
open. Spring pressure against the lifters will
tend to bleed the lifter down. Repair the
lifter only if the problem is consistent.
- Engines operated for only short periods
between start-ups may have lifter noise that
lasts for a few seconds. This is a normal
condition.
Excessive crankshaft end play - replace the
crankshaft thrust bearing.
Excessive front main bearing clearance - replace
the worn parts.
Timing chain tensioner malfunction - clean,
inspect and, replace the timing chain tensioner, if
required.

Heavy Knock Hot in Heavy Load Condition

Broken crankshaft balancer or pulley hub replace the parts as necessary.
Loose torque converter bolts - tighten the bolts.
The drive belt is too tight or nicked - replace
the drive belt as necessary.
The exhaust system is grounded - reposition the
exhaust system components as necessary.
The flywheel is cracked - replace the flywheel.
Excessive crankshaft main bearing clearance
- replace the crankshaft main bearings as
necessary.
Excessive connecting rod bearing clearance replace the connecting rod bearings as
necessary.

Light Knock Hot in Light Load Condition

Light knock hot may be caused by one or more of the
following conditions:
Loose torque converter bolts - tighten the torque
converter bolts.
Leak at the exhaust manifold - tighten the bolts
and replace the exhaust manifold gasket if
necessary.
Excessive connecting rod bearing clearance replace the connecting rod bearings as
necessary.
Detonation or spark knock, refer to Engine
Controls.

Engine Mechanical - 3.8L

Engine
Engine Noise Diagnosis (Valve Train)

Bent push rods

A light tapping at one-half engine speed, or any

varying frequency, can indicate a valve train problem.
These tapping noises increase with the engine
speed. Warm up the engine before attempting to judge
the valve train noise. This will bring all of the engine
components to a normal state of expansion. Run
the engine at various speeds and listen for engine
noise with the hood closed.

Dirty, stuck, or worn valve lifters

Caution: The following procedure is not

recommended on engines with stainless steel
exhaust manifolds because manifold temperature
will exceed the flash point of the oil causing a
fire with possible personal injury.
If the valve mechanism is abnormally noisy, remove
the valve rocker arm covers and use a stethoscope to
determine which valve train components are causing
the noise. The causes of the valve noise include
the following conditions:
Broken or weak valve springs
Sticking or warped valves

Worn push rods

6-23

Damaged or improperly machined camshaft lobes

Insufficient or poor oil supply to the valve train
(low oil pressure)
Excessive valve stem-to-guide clearance
Worn valve guides
Worn valve rocker arms
Broken valve rocker arm bolt
Loose or worn valve rocker arm attachments
Missing or improperly positioned lifter guides (roller
lifter engines)

Momentary Noise on Engine Startup

Action

Step

Yes

No

Repair as
required

No correction is
needed

Yes

No

Replace the
valve lifter

System OK

Value(s)

DEFINITION: Momentary noise when the engine is started, usually cold

This condition is normal. Oil drains from the valve lifters
which hold the valves open when the engine is not
running. The valve lifter needs a few seconds to fill with oil
after you start the engine.
Does the noise continue after a few seconds?

Intermittent Noise on Idle Only

Action

Step

Value(s)

DEFINITION: Intermittent noise on idle that disappears when engine speed increases

1. Disassemble the valve lifters.

2. Check the valve lifters for any dirt. Check the valve
lifters for a pitted or damaged check ball.
Are the valve lifters dirty or damaged?

Noise at Idle
Step

Action

Value(s)

Yes

No

Replace the
faulty lifter

No correction is
needed

DEFINITION: Noise at idle or with hot oil that quiets at higher engine speeds or with cold oil
1

Inspect the lifter for a high leakdown rate.

Does the lifter have a high leakdown rate?

6-24

Engine

Engine Mechanical - 3.SL

Noise at High Vehicle Speeds

Step

Value(s)

Action

Yes

No

Drain the oil to

the proper level

Go to Step 2

Add oil as
required

Go to Step 3

DEFINITION: Noise at high RPM only

Check for a high engine oil level. An oil level above the
FULL mark allows the crankshaft counterweights to churn
the oil into a foam. When the foam is pumped into the
lifters, the lifters become noisy since a solid column of oil
ensures the proper operation.
Is the oil level too high?

Check for a low engine oil level. An oil level below the
ADD mark allows the oil pump to pump air at high speeds.
This causes noisy valve lifters.
Is the oil level too low?

Check the oil pan.

Is the oil pan bent against the oil pump pickup?

Repair as
required

Go to Step 4

Check the oil pump screen.

Is the oil pump screen bent or loose?

Repair as
required

System OK

Yes

No

Repair as
necessary

Go to Step 2

Replace the
valve spring

System OK

Yes

No

Repair as
required

Go to Step 2

Replace the push

rod and valve
rocker arm

Go to Step 3

Replace the
push rod

Go to Step 4

Noise at Idle, Louder at High Engine Speed

Step

Value(s)

Action

DEFINITION: Noise at idle that gets louder as the engine. speed increases, up to 1500 RPM
This noise is not connected with lifter .malfunction. The
noise becomes noticeable at 1O to 15 mph LOW range, or
30 to 35 mph DRIVE range. The noise is described as
ticking sound. At idle, the sound may be entirely gone or
appear as a light ticking noise in one or more of the
valves. This noise is caused by one or more of the
following:
A badly worn or scuffed valve tip and rocker arm pad
Excessive valve stem-to-guide clearance
Excessive valve seat runout
An off-square valve spring
Excessive valve face runout
Are any components damaged or worn excessively?

The noise may be an off-square valve spring. Eliminate

this noise by rotating the valve spring and the valve.
1. Crank the engine until the noisy valve is off its seat.
2. Rotate the spring. This will also rotate the valve.
3. Repeat until the valve is quiet.
4. If correction is obtained, check for an off-square valve
spring.
Is the valve spring off-square more than 1.6 mm (1 /16 i11)?

Noise at any Engine Speed

Step

Action

Value(s)

DEFINITION: Noise at all engine RPM

Check for excessive valve lash. To check for valve lash,
turn the engine so the piston in the cylinder is on TDC of
the firing stroke. If valve lash is present, the push rod
moves freely up and down with the valve rocker arm held
against the valve.
Is the valve lash excessive?

Check for a worn push rod upper end ball.

Is the push rod upper end ball worn?

Check for a bent push rod.

Is the push rod bent?

Engine

Engine Mechanical - 3.8L

6-25

Noise at any Engine Speed (cont'd)

Step

Value(s)

Action

Yes

No

Go to Step 5

Replace the
push rod and
valve rocker arm

Check the lubrication system feed to the push rod and for
a properly lubricated push rod.
Are the push rod and feed system properly lubricated?

Check for a loose or damaged valve rocker arm.

Is the valve rocker arm loose or damaged?

Replace the
valve rocker arm

Go toStep 6

Replace the
camshaft and
valve lifters

Replace th.e
valve lifters as
necessary

If the push rod or the valve rocker arm does. not need to
be replaced, this indicates trouble in the valve lifter or the
camshaft.
Is the camshaft worn or damaged?

Oil Consumption Diagnosis

An engine that has excessive oil consumption uses
0.9L (1 qt) of oil, or more, within 2,000 mi (3 200 km).
The following list indicates the conditions and
corrections of excessive oil consumption:
An improperly read oil level indicator (dipstick)
- Inspect the oil level while the car is parked
on a level surface.
- Allow adequate drain-down time.
Improper oil viscosity
- Use the recommended SAE viscosity for
prevailing temperatures.
- Refer to Maintenance and Lubrication for the
proper oil viscosity specifications.
Continuous high-speed driving
Severe hauling, such as a trailer. This causes
decreased oil mileage.
A malfunctioning crankcase ventilation system
External oil leaks
- Tighten the bolts, as needed.
- Replace the gaskets and seals, as needed.
Worn or omitted valve guides and/or valve
stem seals
- Ream the guides.
- Install oversized service valves and/or new
valve stem seals.
Broken or worn piston rings
Improperly installed or unseated piston rings
Improperly installed or improperly fitted piston
Plugged cylinder head gasket oil drain holes
Damaged intake gaskets

Oil Pressure Diagnosis and Testing

Low or No Oil Pressure
The following can cause low or no oil pressure:
Low oil level - fill to the full mark on the oil level
indicator.
Slow idle speed
Incorrect or malfunctioning oil pressure switch replace the oil pressure switch.

Incorrect or malfunctioning oil pressure gauge replace the oil pressure gauge.
Improper oil viscosity or diluted oil
- Install oil of proper viscosity for expected
temperature.
- Install new oil if it is diluted.
The oil pump is worn or dirty - clean or replace
the oil pump.
The oil filter is plugged - replace the oil filter.
The oil pickup screen is loose or plugged replace the oil pickup screen.
A hole in the oil pickup tube - replace the oil
pickup tube.
Excessive bearing clearance - replace the
bearings.
Cracked, porous, or plugged oil galleries - repair
or replace the engine block.
The gallery plugs are missing or improperly
installed - install or repair as necessary.
The pressure regulator valve is stuck.
- Check the pressure regulator valve for
sticking in the bore.
- Check the bore for scoring and burrs.
The camshaft is worn or poorly machined replace the camshaft.
Worn valve guides - repair as needed.

Oil Pressure Testing

Tools Required
J 25087-C Oil Pressure Test Kit
If the vehicle has low oil pressure perform the
following tests.
1. Check the oil level.
2. Raise the vehicle and remove the oil filter.
3. Assemble the plunger valve in the large hole of
J 25087-C base and the hose in the small hole
of J 25087-C base. Connect the gauge to the end
of the hose.
4. Insert the flat side of the rubber plug in the
bypass valve without depressing the bypass valve
itself.
5. Install J 25087-C on the filter mounting pad.

6-26

Engine

Engine Mechanical - 3.8L

6. Start the engine and check the overall oil

pressure, the oil pressure switch, and for
noisy lifters. The engine should be at operating
temperature before checking the oil pressure. The
oil pressure should be approximately 414kPa
(60 psi) at 1850 rpm using 10W30 engine oil.
7. If adequate oil pressure is indicated, check the oil
pressure switch.

8. If a low reading is indicated, press the valve on

the tester base to isolate the oil pump and/or its
components from the lubricating system. An
adequate reading at this time indicates a good
pump and the previous low pressure was due to
worn bearings, etc. A low reading while pressing
the valve would indicate a faulty pump.

Oil Leak Diagnosis

Step

Action

Value(s)

Yes

No

DEFINITION: You can repair most fluid leaks by first visually locating the leak, repairing or replacing the component, or by
resealing the gasket surface. Once the leak is identified, determine the cause of the leak. Repair the cause of the leak as
well as the leak itself.
1. Operate the vehicle until it reaches normal operating
temperature.
2. Park the vehicle on a level surface, over a large
sheet of paper or other clean surface.
3. Wait (15 minutes).
4. Check for drippings.
Are drippings present?

Can you identify the type of fluid and the approximate

location of the leak?

1. Visually inspect the suspected area. Use a small

mirror to assist in looking at hard to see areas.
2. Check for leaks at the following locations:
Sealing surfaces
Fittings
Cracked or damaged components
Can you identify the type of fluid and the approximate
location of the leak?

1. Completely clean the entire engine and surrounding

components.
2. Operate the vehicle for several kilometers (miles) at
normal operating temperature and at varying speeds.
3. Park the vehicle on a level surface, over a large
sheet of paper or other clean surface.
4. Wait (15 minutes).
5. Identify the type of fluid, and the approximate location
of the leak.
Can you identify the type of fluid and the approximate
location of the leak?

1. Visually inspect the suspected area. Use a small

mirror to assist in looking at hard to see areas.
2. Check for leaks at the following locations:
Sealing surfaces
Fittings
Cracked or damaged components
Can you identify the type of fluid and the approximate
location of the leak?

Go to Step2

System OK

Go to Step 10

Go to Step 3

Go to Step 10

Go to Step 4

Go to Step 10

Go to Step 5

Go to Step 10

Go to Step 6

Engine

Engine Mechanical - 3.8L

6-27

Oil Leak Diagnosis (cont'd)

Action

Step

Value(s)

Yes

No

Go to Step 10

Go to Step 7

Go to Step 10

Go to Step 8

Go to Step 10

Go to Step 9

Go to Step 10

System OK

Go to Step 11

System OK

1. Completely clean the entire engine and surrounding

components.

2. Apply an aerosol-type powder (baby powder, foot

powder, etc.) to the suspected area.

3. Operate the vehicle for several kilometers (miles) at

normal operating temperature and at varying speeds.
4. Identify the type of fluid, and the approximate location
of the leak, from the discolorations in the powder
surface.
Can you identify the type of fluid and the approximate
location of the leak?

1. Visually inspect the suspected area. Use a small

mirror to assist in looking at hard to see areas.

2. Check for leaks at the following locations:

Sealing surfaces
Fittings

Cracked or damaged components

Can you identify the type of fluid and the approximate
location of the leak?

Use J 28428-E, Dye and Light Kit in order to identify the

type of fluid, and the approximate location of the leak.
Refer to the manufacturer's instructions when using
the tool.
Can you identify the type of fluid and the approximate
location of the leak?

1. Visually inspect the suspected area. Use a small

mirror to assist in looking at hard to see areas.

2. Check for leaks at the following locations:

9

Sealing surfaces
Fittings
Cracked or damaged components
Can you identify the type of fluid and the approximate
location of the leak?

1. Inspect the engine for mechanical damage. Special

attention should be shown to the following areas:
Higher than recommended fluid levels
Higher than recommended fluid pressures
Plugged or malfunctioning fluid filters or pressure
bypass valves
Plugged or malfunctioning engine ventilation
system

10

Improperly tightened or damaged fasteners

Cracked or porous components
Improper sealants or gaskets where required
Improper sealant or gasket installation
Damaged or worn gaskets or seals

Damaged or worn sealing surfaces

2. Inspect the engine for customer modifications.
Is there mechanical damage, or customer modifications to
the engine?

11

Repair or replace all damaged or modified components.

Does the engine stll leak oil?

Go to Step 1

6-28

Engine Mechanical - 3.8L

Cylinder Leakage Test

Testing Procedure
Tools Required
J 35667-A Cylinder Leakdown Tester

With the use of air pressure, a cylinder leakage test

will aid in the diagnosis. The cylinder leakage test may
be used in conjunction with the engine compression
test, to isolate the cause of leaking cylinders.
Caution: Refer to Battery Disconnect Caution in
Cautions and Notices.
1. Remove the battery ground (negative) cable.
2. Remove the spark plugs. Refer to Ignition System.
3. Install the J 35667-A.
4. Measure each cylinder on the compression
stroke, with both valves closed.
Important: It may be necessary to hold the crankshaft
balancer bolt, to prevent piston movement.

Engine
9. If air is heard from the crankcase system at the
crankcase (oil filler tube), perform the following
procedure:
Remove the piston from the suspect cylinder.
Inspect the piston and connecting rod
assembly. Refer to Piston, Connecting Rod
and Bearings Clean/Inspect.
Inspect the engine block. Refer to Engine
Block Cleanand Inspect.
10. If bubbles are found in the radiator, perform the
following procedure:
Remove both cylinder heads and inspect.
Refer to Cylinder Head Clean and Inspect.
Inspect the engine block. Refer to Engine Block
Clean and Inspect.
11 . Remove the J 35667-A.
12. Install the spark plugs. Refer to Ignition System.
13. Install the battery ground (negative) cable. Refer to
Battery.

5. Apply air pressure, using the J 35667-A. Refer to

the manufacturer's instructions:
6. Record the cylinder leakage readings for each
cylinder.
Important:
Normal cylinder leakage is from 12 to 18 percent.
Make a note of any cylinder with more leakage
than the other cylinders.
Any cylinder with 30 percent leakage or more
requires service.
7. Inspect the four primary areas, to properly
diagnose a leaking cylinder.
8. fair is heard from the intake or exhaust system,
perform the following procedure:
Remove the valve rocker arm cover of the
suspect cylinder head.
- Ensure that both valves are closed.
- Inspect the cylinder head for a broken valve
spring.
Remove the suspect cylinder head and
inspect. Refer to Cylinder Head Clean
and Inspect.

Drive Belt Diagnosis

Notice: Routine inspection of the belt may reveal
cracks in the belt ribs. These cracks will not impair the
belt performance. The belt should be replaced if the
belt slip occurs if a section of the belt ribs are missing.
A single sepentine drive belt is used to drive all
engine accessories. All belt driven accessories are
rigidly mounted with the belt tension maintained by a
spring loaded tensioner. The indicator on the
movable portion of the tensioner must be within the
limits of the marks of the stationary portion of the
tensioner. Any reading outside of these limits indicates
either a defective belt or tensioner.
Inspect the belt length scale on the drive belt tensioner
for proper installed length. If the belt length scale
does not indicate proper installed length, install a new
drive belt.

Engine

Engine Mechanical - 3.SL

6-29

Disassembled Views
Cylinder Head and Components
\

;..._
47

7
46

40
12

41

39

13

38

36

~>

37

)if'~---

34

35

32

tlP'"'
-

~
e ..

~
.

~
e

15
17

29
18
27

30-~

31

~19

~~tG
L

20

22

21

24

42439

Legend
Engine Lift Rear Bracket

(15)

(2) Generator Brace Bracket

(16)

(3) Generator Brace Bolt

(17)

(1)

(4) Valve Rocker Arm Bolts

(18)

(5) Valve Stem Keys

(19)

(6) Valve Stem Cap

(7) Valve Seal

(20)

(8) Valve Stern Spring

(22)

(9) Valve Rocker Arm Pivot Retainer

(23)

(21)

(10) Valve Rocker Arm

(24)

(11) Valve Lifter Guide

(25)

(12) Spark Plug

(26)

(13) Cylinder Head Gasket

(27)

(14)

Intake Valve

(28)

Engine Lift Front Bracket

Exhaust Manifold Heat Shield Nut
Exhaust Manifold Heat Shield
Exhaust Manifold Heat Shield Nut
Exhaust Manifold Heat Shield
Exhaust Manifold Heat Shield Nut
Exhaust Manifold (Left)
Exhaust Manifold Stud
Exhaust Manifold Gasket (Left)
EGR Valve Adapter Bolt
EGR Valve Adapter Nuts
EGR Valve Adapter
EGR Valve Outlet Pipe
EGR Valve Outlet Pipe Bolt

6-30

Engine

Engine Mechanical - 3.8L

(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)

EGR Valve
EGR Valve Gasket
Drive Belt Tensioner
Drive Belt Tensioner Bolt
Heated Oxygen Sensors
Exhaust Manifold Heat Shield
Exhaust Manifold Heat Shield Nut
Exhaust Manifold Stud
Exhaust Manifold (Right}
Exhaust Manifold Heat Shield Nut
Exhaust Manifold Heat Shield
Exhaust Manifold Heat Shield Nut
Exhaust Manifold Gasket (Right}

(42)
(43)
(44)
(45)
(46)
(47)
(48)
(49)
(50)
(51)
(52)
(53)

Intake Manifold Seal

Valve Lifter
Push rod
Lower Intake Manifold Gasket
Cylinder Head Gasket
Cylinder Head
Valve Rocker Arm Cover Gasket
Valve Rocker Arm Cover
Oil Fill Tube Seal
Oil Fill Cap
Oil Fill Cap Seal
Oil Fill Tube

(
\

Engine

Engine Mechanical - 3.8L

6-31

Crankshaft and Components

34

35

33
27

~./

30
23

22

~~
24

26

25

12
13

21

~0/J

I ..@
~
)

14

18

19

20
17

42447

Legend
(1) Crankshaft Balancer Key

(2) Crankshaft Upper Bearing

(3) Crankshaft Rear Oil Seal
(4) Engine Flywheel
(5) Flywheel Bolt
(6) Engine Crankshaft
(7) Crankshaft Main Bearing Cap
(8) Side Main Bearing Bolt
(9) Crankshaft Main Bearing Cap Bolt
(10) Crankshaft Lower Bearing
(11) Crankshaft Main Bearing Cap
(12) Oil Pan Drain Plug
(13) Oil Pan Drain Plug Gasket
(14) Oil Pan Gasket
(15) Engine Oil Pan
(16) Oil Pan Bolt
(17) Engine Oil Level Sensor
(18) Crankshaft Position Sensor Shield

(19) Crankshaft Balancer

(20) Crankshaft Balancer Washer
(21) Crankshaft Balancer Bolt
(22) Camshaft Position Sensor Bolt
(23) Camshaft Position Sensor
(24) Crankshaft Position Sensor
(25) Oil Pump Gear Set
(26) Oil Pump Cover
(27) Oil Pump Cover Bolt
(28) Crankshaft Front Oil Seal
(29) Water Pump Bolt
(30) Water Pump Pulley Bolt
(31) Water Pump Pulley
(32) Water Pump
(33) Water Pump Gasket
(34)
(35)

Engine Front Cover

Engine Front Cover Gasket

6-32

Engine

Engine Mechanical - 3.8L

Intake Manifolds and Components

10

11

~-

12

42450

Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)

Fuel Injector Rail Nuts

Fuel Injector Rail
Water Outlet Bolts
Water Outlet
Water Outlet Gasket
Thermostat
Thermostat Gasket
ICM Bracket Bolt
ICM Bracket

(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)

Upper Intake Manifold Gasket

Lower Intake Manifold
Coolant Temperature Sensor
Lower Intake Manifold Bolt
Throttle Body
Throttle Body Gasket
Upper Intake Manifold
Upper Intake Manifold Bolt
Vacuum Source Manifold

Engine Mechanical - 3.SL

Engine

6-33

Piston and Components

23

22

28

32

~29

11

30
31

1 9 / ~.15
@

16
18

17
42456

Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)

Piston Pin Retainer Clip

Piston Rings
Piston
Connecting Rod
Connecting Rod Bearings
Connecting Rod Cap
Connecting Rod Cap Bolt
Crankshaft Rear Oil Seal Housing Bolt
Crankshaft Rear Oil Seal Housing
Crankshaft Rear Oil Seal Housing Gasket
Oil Level Indicator
Oil Level Indicator Tube
Cylinder Head Location Hole Pin
ESC Knock Sensor
Engine Block
Oil Pump Screen Gasket
Oil Pump Screen
Oil Pump Screen Bolt
Engine Block Core Hole Plug
Engine Front Cover Pin
Engine Block Oil Gallery Plug
Oil Pressure Relief Valve Spring

(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)

Oil Pressure Relief Valve

Oil Filter Adapter Gasket
Oil Filter Adapter
Oil Filter Adapter Bolt
Camshaft Thrust Plate
Camshaft Thrust Plate Bolt
Timing Chain Dampener
Crankshaft Sprocket
Camshaft Sprocket Bolt
Timing Chain
Camshaft Position Sensor Magnet
Balance Shaft Drive Gear
Camshaft Key
Camshaft
Camshaft Bearings
Balance Shaft Bushing
Balance Shaft
Balance Shaft Gear
Balance Shaft Gear Bolt
Balance Shaft Gear Pin
Balance Shaft Retainer Bolt
Balance Shaft Retainer

6-34

Engine Mechanical - 3.SL

Engine

Repair Instructions
Drive Belt Replacement
Removal Procedure

1. Position a hex-head socket on the belt tensioner

pulley bolt.
2. Rotate the drive belt tensioner (2) clockwise to
relieve the tension on the drive belt ( 1).
3. Remove the drive belt (1) from the tensioner (2)
and pulleys.
4. Clean and inspect the belt surfaces of all the
pulleys.

41363

Installation Procedure
1. Route the drive belt (1) around the pulleys.
2. Position a hex-head socket on the belt tensioner
pulley bolt.
3. Rotate the drive belt tensioner (2) clockwise to
relieve the tension.
4. Install the drive belt (1) onto the drive belt
tensioner (2).
5. Inspect the drive belt (1) to ensure that the bolt is
properly aligned into the grooves of the pulleys.

41363

Engine

Engine Mechanical" - 3.8L

6-35

Drive Belt Tensioner Replacement

Removal Procedure
1. Drain the engine coolant. Refer to Draining and
Filling Cooling System (V6) in Engine Cooling.
2. Remove the drive belt. Refer to Drive Belt
Replacement.
3. Remove the generator. Refer to Generator
Replacement (3.BL V6) in Engine Electrical.
4. Remove the heater hoses from the drive belt
tensioner.

282933

5. Remove the drive belt tensioner bolts.

Important: The drive belt tensioner must be rotated if
it is difficult to remove. Pulling the tensioner from
the top may damage the engine front cover. If
necessary, break the plastic heater water bypass inlet
pipe to allow rotation of the drive belt tensioner and
replace the pipe during installation.
Remove the drive belt tensioner.

35804

Installation Procedure
1. Install the drive belt tensioner.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the drive belt tensioner bolts.
Tighten
Tighten the drive belt tensioner bolts to
50 Nm (37 lb ft).

35804

6~36

Engine:F\Sechanical - 3.8L
3. Install the heater hpses to thE:lidrive belt tension~t..
4. Install the generator. Refer to Generator
Replacement (3.BL V6) in Engine Electrical.
5. lhstall the drive belt. Refer to .Drive Belt
Replacement.
6. Refill the engine coolant. Refer to Draining artd
Filling Cooling System (V6) in Engine' Cooling.

282933

Engine Mount Inspection

Notice: Broken or deteriorated mounts can cause
misalignment and destructiorrnf certain drive
train components. When a single mount breaks, the
remaining mounts are subjected to abnormally
high stresses;
Notice: When raising or supporting ttie engine for any
reason, do not usea jack under the oil pan, any ,
sheet metal, or the crankshaft pulley. Lifting the engine
in an unapproved manner may cause component
damage.
1. Measure the engine movement at the engine
mounts in order to check for damage to the
rubber portions of the mount.
1.1. Apply the park brake.
1.2. Start the engine.
1.3. Firmly apply the primary brakes.
1.4. With an assistant observing engine
movement, slightly load the engine in
R (Reverse) and D (Drive). If the E:lngine. .
moves more than 24 mm (0.945 in) frcitrl' the
at rest position;in either direction, check
the engine mount attachment.
2. If the engine mount attachment is within
specification~. replace: the engine mount. Refer to
Engine Mount Replacement.
3. Replace the E1ngine mount aJso if. any of the
following conditions exist:
Heat check cracks cover the hard rubber
surface.
The rubber cushion is separated from the
metal plate of the mount.
There is a split through the rubber cushion.
4. If the mount is loose, lower the engine and tighten
the bolts or the nuts to the engine frame or the
bracket. Refer to Fastener Tightening
Specifications in HVAC Systems with A/C Manual.

(,

Engine

Engine Mechanical .. 3.8L

6-37

Engine Mount Replacement

Removal Procedure

')

Tools Required
J 28467-360 Universal Support Fixture
J 41044 Engine Support Adapters
J 28467-90 Engine Support Fixture Adapters

Notice: When raising or supporting the engine for any

reason, do not use a jack under the oil pan,
crankshaft balancer, or any sheet metal. Due to small
clearances between the oil pan and the oil pump
screen, jacking against the oil pan may cause it to be
bent against the pump screen, resulting in a
damaged oil pickup unit. Jacking against the
crankshaft balancer may also cause oil seal and/or
crankshaft bearing damage. Always use a J 28467-A
(Universal Support Fixture) along with J 41044
(Engine Support Adapters) when raising or supporting
the engine.
1. Remove the generator. Refer to Generator
Replacement (3.BL V6) in Engine Electrical;
2. Remove the ignition control module. Refer to
ignition Coil and ICM Replacement in Engine
Electrical.
3. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
4. Remove the 3-way catalytic converter. Refer to
Catalytic Converter Replacement in Engine
Exhaust.
5. Remove the right side engine mount through
bolt nut (2).
6. Remove the left side engine mount through
bolt nut (1).

50513

50520

\)

6-38

Engine Mechanical - 3.SL

Engine
7. Remove the transmission oil cooler pipe bracket
bolt and bracket.

46662

8. Remove the air conditioning compressor bolts.

282953

9. Remove the air conditioning compressor rear

bolts (2, 3).
10. Position the A/C compressor forward from the
bracket.
Do this in order to remove the engine mount
through bolt(s) without recovering the refrigerant.
11. Install the J 28467-90 to the strut tower bolts.
12. Install the J 28467-360 and the J 41044 to
the engine.
13. Raise the engine using the J 28467-360 and the
J 41044 slightly to relieve tension on the
through bolts.

365440

Engine

Engine Mechanical - 3.8L

6-39

14. Remove the right engine mount through bolt (1 ).

50513

15. Remove the left engine mount through bolt (2).

16. Raise the engine enough to remove the engine
mounts and engine mount brackets.

50520

17. Remove the right engine mount bolts (1) and the
right engine mount (2).

49837

6-40

Engine Mechanical - 3.SL

Engine
18. Remove the left engine mount bolts (1) and the
left engine mount (2).

50525

19. Remove the right engine mount bracket

bolts (1 and 2) and the right engine mount
bracket (3).

3
50517

20. Remove the positive cable from the engine

mount stud.
Remove the battery positive cable nut (2).
Remove the harness clamp from the stud.
Remove the RF (Radio Frequency)
ground strap.

211604

Engine

Engine Mechanical - 3.8L

6-41

21. Remove the left engine mount bracket bolts (3).

22. Remove the left engine mount bracket stud (2)

and the left engine mount bracket (1 ).

\
I

23. Visually inspect the rubber portions of the engine

mount for damage.

50546

Installation Procedure
1 . Install the left engine mount bracket (1) and
stud (2) to the engine block.

Notice: Refer to Fastener Notice in Cautions and

Notices.

2. Install the left engine mount bracket bolts (3).

Tighten
Tighten the left engine mount bracket bolts (3)
to 100 N-m (74 lb ft).
Tighten the left engine mount bracket stud (2)
to 87 N-m (64 lb ft).

50546

3. Install the positive cable to the engine mount

bracket stud.
Install the RF (Radio Frequency) ground strap.
Install the harness clamp to the stud.
Install the battery positive cable nut (2).

Tighten
Tighten the battery positive cable nut (2) to
25 N-m (18 lb ft).

211604

6-42

Engine Mechanical - 3.8L

Engine
4. Install the right engine mount bracket (3) and
bolts (1 and 2) to the engine block.

Tighten
Tighten the two engine mount bracket bolts (1)
to 100 N-m (74 lb ft).

Tighten the engine mount bracket bolt (2) to

50 N-m (37 lb ft).

50517

5. Install the left engine mount (2) and bolts (1) to

the crossmember.

Tighten
Tighten the left engine mount bolts (1) to
58 N-m (43 lb ft).

50525

6. Install the right engine mount (2) and bolts (1) to

the crossmember.

Tighten
Tighten the right engine mount bolts (2) to
58 N-m (43 lb ft).
7. Lower the engine using the J 28467-360 and the
J 41044 until the mount bracket and mount
through holes line up together.
8. Remove the J 28467-360 and the J 41044.
9. Remove the J 28467-90 from the strut tower bolts.

(
49837

Engine

Engine Mechanical - 3.SL

6-43

10. Install the left engine mount through bolt (2).

50520

11. Install the right engine mount through bolt (1).

50513

12. Position the A/C compressor rearward to the

bracket.
13. Install the air conditioning compressor rear
bolts (2, 3).

Tighten
Tighten the air conditioning compressor rear
bolts (2, 3) to 30 Nm (22 lb ft).

365440

6-44

Engine Mechanical - 3.SL

Engine
14. lnstaltthe air conditioning compressor bolts:
Tighten
Tighten the air conditioning compressor bolts to
50 N-m (37 lb ft).

282953

15. Install the transmission oil cooler pipe bracket

and bolt.
Tighten
Tighten the oil cooler pipe bracket bolt to
17 Nm (13 lb ft).

(~

46662

16. Install the left side engine mount through bolt

nut (1 ).
Tighten
Tighten the engine mount through bolt nut (1) to
80 Nm (59 lb ft).

50520

Engine

Engine Mechanical - 3.8L

6-45

17. Install the right side engine mount through bolt

nut (2).

Tighten
Tighten the engine mount through bolt nut (2) to
80 N-m (59 lb ft).

18. Install the 3-way catalytic converter. Refer to

Catalytic Converter Replacement in Engine
Exhaust.
19. Lower the vehicle.
20. Install the ignition control module. Refer to Ignition
Coil and ICM Replacement in Engine Electrical.
21. Install the generator. Refer to Generator
Replacement (3.BL V6) in Engine Electrical.

50513

Oil Level Indicator and Tube Replacement

Removal Procedure
1. Remove the oil level indicator (2) from the
indicator tube (1 ).

2. Remove the oil level indicator tube bolt (3).

3. Remove the oil level indicator tube (1) from the
engine block.

444130

Installation Procedure
1 . Replace the 0-ring seal if necessary.

2. Install the oil level indicator tube (1) to the

engine block.

Notice: Refer to Fastener Notice in Cautions and

Notices.
3. Install the oil level indicator tube bolt (3).

Tighten
Tighten the oil level indicator tube bolt (3) to
10 N-m (89 lb in).
4. Install the level indicator (2) to the indicator
tube (1 ).

444130

6-46

Engine Mechanical - 3.8L

Engine
Intake Manifold Replacement (Upper )
Removal Procedure
1. Disconnect the intake air temperature (IAT)
sensor electrical connector.

208554

2. Remove the air intake duct.

3. Remove the drive belt tensioner. Refer to Drive
Belt Tensioner Replacement.

208572

4. Disconnect the fuel pressure regulator vacuum

and EV AP emission canister purge harness (3)
from the following:
Manifold vacuum source (1)
Purge solenoid valve (2)
Fuel pressure regulator valve
5. Disconnect the manifold vacuum source electrical
connector.

444131

Engine

Engine Mechanical - 3.8L

6-47

6. Remove the manifold vacuum source screws.

7. Remove the manifold vacuum source from the
upper intake manifold.
8. Disconnect the canister purge solenoid valve
electrical connector and hose.
9. Remove the evaporative emissions canister purge
solenoid valve.
10. Remove the idle air control (IAC) valve from the
upper intake manifold. Refer to JAG Valve
Replacement in Engine Controls-3.8L.
11. Relieve the fuel pressure. Refer to Fuel Pressure
Relief Procedure in Engine Controls-3.8l.

36629

12. Disconnect the fuel feed pipe (1) from the fuel rail.
13. Disconnect the fuel return pipe (2) from the
fuel rail.
14. Disconnect the EVAP pipe (6) at the engine.

215517

15. Remove the cruise control and accelerator control

cables from the throttle body and bracket.

296581

6-48

Engine Mechanical - 3.8L

Engine
16. Remove the accelerator control cable bracket
bolts (1) and bracket (2).
17. Remove the ignition control module. Refer to
Ignition Coil and ICM Replacement in Engine
Electrical.

444135

18. Remove the brake booster vacuum hose (2) from

the intake manifold fitting (1).

439407

19. Remove the generator brace bolts,

20. Remove the generator brace from the lower
intake manifold.

50376

Engine

Engine Mechanical - 3.8L

6-49

21. Disconnect the idle air control (IAC) valve

electrical connector.

155466

22. Disconnect the throttle position (TP) sensor

electrical connector.

178680

23. Disconnect the mass airflow (MAF) sensor

electrical connector.
24. Remove the wiring harness from the rosebud clips
at the fuel rail.

155464

6-50

Engine Mechanical - 3.8L

Engine
25. Remove the throttle body from the upper intake
manifold.
26. Remove the thermostat and thermostat housing.
Refer to Thermostat Replacement (3.BL V6) in
Engine Cooling.
27. Disconnect the fuel injector electrical connectors.

36624

Important: Clean the dirt out of the injector bores with

compressed air.

28. Remove the fuel rail nuts.

29. Remove the fuel rail.

36631

30. Remove the upper intake manifold bolts.

31. Remove the upper intake manifold.
32. Remove the upper intake manifold gasket.

36634

Engine Mechanical - 3.8L

Engine

6-51

Installation Procedure
\

1. Install the upper intake manifold gasket.

2. Install the upper intake manifold.

36634

Notice: Refer to Fastener Notice in Cautions and

Notices.

3. Install the upper intake manifold bolts.

Tighten
3.1. Tighten in sequence the vertical intake
manifold bolts (1-10) to 15 N-m (11 lb ft).
3.2. Tighten the two water outlet bolts (11) to
27 N-m (20 lb ft).
3.3. Tighten the side bolts (12, 13) to
30 Nm (22 lb ft).

10

12
11

50287

4. Perform the following to install the fuel rail to the

upper intake manifold:
4.1. Using clean engine oil, lubricate the fuel
injector 0-rings.
4.2. Install the injectors into the bores of the
manifold.
4.3. Carefully press the fuel rail down with the
palms of both hands until the injectors are
fully seated.
5. Install the fuel rail nuts.

Tighten
Tighten the fuel rail nuts to 8.5 Nm (75 lb in).
6. Connect the fuel injector electrical connectors.
7. Install the thermostat and thermostat housing.
Refer to Thermostat Replacement (3.BL V6) in
Engine Cooling.
36631

6-52

Engine Mechanical - 3.8L

Engine
8. Install the throttle body to the upper intake
manifold studs.
9. Install the throttle body bolt and nuts.
Tighten
Tighten the throttle body bolt to
1O N-m (89 lb in).
Tighten the throttle body nuts to
1O N-m (89 lb in).
10. Install the wiring harness to the rosebud clips on
the fuel rail.

36624

11 . Connect the mass airflow (MAF) sensor electrical

connector.

155464

12. Connect the throttle position (TP} sensor electrical

connector.

~
178680

Engine

Engine Mechanical - 3.8L

6-53

13. Connect the idle air control (IAC) valve electrical

connector.
\

'

155466

14. Install the generator brace to the upper intake

manifold.

15. Install the generator brace bolts.

Tighten
Tighten the generator brace bolts to
25 N-m (18 lb ft).

50376

16. Install the brake booster vacuum hose (2) to the

intake manifold fitting (1).
17. Install the ignition e;:ontrol module. Refer to Ignition
Coil and ICM Replacement in Engine E.lectrical.

439407

6-54

Engine

Engine Mechanical - 3.SL

18. Install the accelerator control cable bracket (2)

and bracket bolts ( 1) .
Tighten
Tighten the accelerator control cable bracket
bolts (1) to 16 Nm (12 lb ft).

444135

19. Install the accelerator control and cruise control

cables to the throttle body and bracket.

296581

20.
21.
22.
23.

Connect the EVAP pipe (6) at the engine.

Connect the fuel return pipe (2) to the fuel rail.
Connect the fuel feed pipe (1) to the fuel rail.
Install the idle air control (IAC) valve to the upper
intake manifold. Refer to JAG Valve Replacement
in Engine Controls-3.SL.
24. Install the evaporative emissions canister purge
solenoid valve.
25. Connect the canister purge solenoid valve
electrical connector and hose.

\.

215517

Engine

Engine Mechanical - 3.SL

6-55

26. Install the manifold vacuum source to the upper

intake manifold.

27. Install the manifold vacuum source screws.

)

Tighten
Tighten the manifold vacuum source screws to
IO N-m (89 lb in).
28. Connect the manifold vacuum source electrical
connector.

36629

29. Connect the fuel pressure regulator vacuum and

EVAP emission canister purge harness (3) to the
following:
Manifold vacuum source (1)
Purge solenoid valve (2)
Fuel pressure regulator valve
30. Install the drive belt tensioner. Refer to Drive Belt
Tensioner Replacement.

444131

31. Install the air intake duct.

208572

6-56

Engine Mechanical - 3.BL

Engine
32. Connect the intake air temperature (IAT) sensor
electrical connector.

208554

Intake Manifold Replacement {Lower )

Removal Procedure
Important: Remove the upper intake manifold in order
to uncover hidden bolts on the front and left rear
corners of the lower intake manifold.
1. Remove the upper intake manifold. Refer to
Intake Manifold Replacement (Upper).
2. Remove the engine coolant temperature sensor.
Refer to ECT Sensor Replacement in Engine
Control - 3.8L.
3. Remove the lower intake manifold bolts.
4. Remove the lower intake manifold.
5. Remove the lower intake manifold gaskets
and seals.

(
\

50046

Installation Procedure
1. Apply GM P/N 12345336 or equivalent to both the
front and rear intake manifold seals.
2. Install the intake manifold gaskets and seals.
3. Install the lower intake manifold.
4. Install the lower intake manifold bolts.
Important: The two lower intake manifold bolts are
located under the upper intake manifold. They must be
installed before the upper intake manifold.

5. Apply GM P/N 12345493 or equivalent thread lock

compound to the bolt threads before installing.

(
50046

Engine

Engine Mechanical - 3.8L

6-57

Notice: Refer to Fastener Notice in Cautions and

Notices.
6. Torque the lower intake bolts to specifications.
Tighten
Tighten the lower manifold bolts in sequence as
shown to 15 N-m (11 lb ft).
7. Install the engine coolant temperature sensor.
Refer to ECT Sensor Replacement in Engine
Control - 3.8L.
8. Install the upper intake manifold. Refer to Intake
Manifold Replacement (Upper).

50288

Exhaust Manifold Replacement (Left )

Removal Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Remove the 3-way catalytic converter. Refer to
Catalytic Converter Replacement in Engine
Exhaust.
3. Disconnect the secondary lock on the electrical
connector.
4. Disconnect the wiring harness connector (1) from
the oxygen sensor electrical connector.
5. Remove the oxygen sensor connector from the
spark plug wire harness bracket.

439775

6. Remove the oxygen sensor from the exhaust

manifold.

6-58

Engine

Engine Mechanical - 3.8L

7. Disconnect the numbers 1, 3 and 5 spark plug

wires from the spark plugs.

211645

8. Remove numbers 3 and 5 spark plugs from the

cylinder head.

14824

9. Remove the two rear exhaust manifold studs and

nut from the exhaust manifold.
10. Lower the vehicle.

36635

Engine

Engine Mechanical - 3.8L

6-59

11. Disconnect the EGA valve electrical connector.

221704

12. Remove the Exhaust Gas Recirculation (EGA)

valve adapter nuts (5).
13. Remove the EGA valve adapter bolt (4) from the
exhaust manifold (2).
14. Remove the EGA valve adapter (3) from the
cylinder head studs (6) and exhaust manifold (2).

36618

15. Remove the number 1 spark plug from the

cylinder head.

14824

6.-60

Engine Mechanical - 3.SL

Engine
16. Remove the. exhaust manifold heat shield nuts.

17. Remove the exhaust manifold heat shields from

the exhaust manifold.

50755

18. Remove the,twofront exhaust manifold studs and

nut from the exhaust manifold. ,
19. Remove the left exhaust manifold and gasket
from the cylinder head.

20. Remove the heat i;,hield studs from the exhaust

manifold, i.f necessary.

36635

Installation. Procedure
1. Install the heat shield studs to the exhaust
manifold, if necessary.

2. Install the left exhaust manifold gasket and

manifold to the cylinder head studs.
Notice: Refer to Fastener Notice in Cautions and
Notices.

3. Install the two front exhaust manifold studs and

nut to the exhaust manifold.

Tighten
Tighten
15 N-m
Tighten
18 N-m

36635

the two front exhaust manifold studs to

(11 lb ft).
the exhaust manifold nut to
(13 lbft).

Engine Mechanical - 3.8L

Eng.ine

6-61

4. Install the exhaust manifold heat shields to the

exhaust manifold.
5. lnstallthe exhaust manifold heat shield nuts.

Tighten
Tighten the exhaust manifold heat shield nuts to
10 N-m (89 lb in).

50755

6. Install the number 1 spark plug to the

cylinder head.

Tighten
Tighten the number 1 spark plug to .
27 Nm (20 lb ft).

14824

7. Install the EGR valve adapter (3) to the cylinder

head studs (6) and exhaust manifold (2).
8. Install the EGR valve adapter bolt (4) to the
exhaust manifold {2).

9. Install the EGR valve adapter nuts (5).

Tighten
Tighten
50 N-m
Tighten
25N-m

the EGR valve adapter nuts (5) to

(37 lb ft).
the EGR valve adapter bolt (4) to
(181bft).

36618

6-62

Engine

Engine Mechanical - 3.SL

10. Connect the EGA valve electrical connector.

11. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

221704

12. Install the two rear exhaust manifold studs and

nut to the exhaust manifold.

Tighten
Tighten
15 Nm
Tighten
18 N-m

the two rear exhaust manifold studs to

(11 lb ft).
the exhaust manifold nut to
(13 lb ft).

36635

13. Install numbers 3 and 5 spark plugs to the

cylinder head.

Tighten
Tighten numbers 3 and 5 spark plugs to
27 Nm (20 lb ft).

14824

Engine

Engine Mechanical - 3.8L

6-63

14. Connect the numbers 1, 3 and 5 spark plug wires

to the spark plugs.

211645

15. Install the oxygen sensor to the exhaust manifold.

Tighten
Tighten the oxygen sensor to 42 N-m (31 lb ft).

439800

16. Install the oxygen sensor connector (1) to the

spark plug wire harness bracket.
17. Connect the oxygen sensor electrical connector.
18. Connect the secondary lock on the electrical
connector.
19. Install the 3-way catalytic converter. Refer to
Catalytic Converter Replacement in Engine
Exhaust.
20. Lower the vehicle.

439775

6-64

Engine Mechanical - 3.SL

Engine
Exhaust Manifold Replacement (Right)
Removal Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Remove the 3-way catalytic converter. Refer 10
Catalytic Converter Replacement in Engine
Exhaust.
3. Disconnect the secondary lock on the electrical
connector.
4. Disconnect the oxygen sensor electrical
connector (3).

439410

5. Remove the oxygen sensor connector rosebud

from the engine left bracket.
6. Remove the oxygen sensor from the exhaust
manifold.

440850

7. Disconnect the numbers 4 and 6 spark plug wires

from the spark plugs.

(
211642

Engine

Engine Mechanical - 3.SL

6-65

8. Remove the number 6 spark plug from the

cylinder head.
\

14824

9. Remove the two rear exhaust manifold studs and

nut from the exhaust manifold,
10. Lower the vehicle.

36652

11. Disconnect the number 2 spark plug wire from the

spark plug.

211642

6-66

Engine

Engine Mechanical - 3.SL

12. Remove the numbers 2 and 4 spark plugs from

the cylinder head.

14824

13. Remove the exhaust manifold heat shield nuts.

14. Remove the exhaust manifold heat shields from
the exhaust manifold.

36638

15. Remove the two front exhaust manifold studs and

nut from the exhaust manifold.
16. Remove the right exhaust manifold and gasket
from the cylinder head.
17. Remove the heat shield studs from the exhaust
manifold, if necessary.

36652

Engine Mechanical - 3.SL

Engine

6-67

Installation Procedure
1. Install the heat shield studs to the exhaust
manifold, if necessary.
2. Install the right exhaust manifold gasket and
manifold to the cylinder head studs.

Notice: Refer to Fastener Notice in Cautions and

Notices.
3. Install the two front exhaust manifold studs and
nut to the exhaust manifold.
Tighten
Tighten
15 N,m
Tighten
18 N,m

the two front exhaust manifold studs to

(11 lb ft).
the exhaust manifold nut to
(13 lb ft).

36652

4. Install the exhaust manifold heat shields to the

exhaust manifold.

5. Install the exhaust manifold heat shield nuts.

Tighten
Tighten the exhaust manifold heat shield nuts to
10 N,m (89 lb in).

36638

6. Install the numbers 2 and 4 spark plugs to the

cylinder head.

Tighten
Tighten the numbers 2 and 4 spark plugs to
27 Nm (20 lb ft).

14824

6-68

Engine Mechanical - 3.8L

Engine
7. Connect the number 2 spark plug wire to the
spark plug.
8. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

(,

211642

9. Install the two rear exhaust manifold studs and

nut to the exhaust manifold.
Tighten

Tighten the two rear exhaust manifold studs to

15 Nm (11 lb ft).
Tighten the exhaust manifold nut to
18 Nm (13 lb ft).

36652

10. Install the number 6 spark plug to the

cylinder head.
Tighten
Tighten the number 6 spark plug to
27 Nm (20 lb ft).

(
14824

Engine

Engine Mechanical - 3.8L

6-69

11 . Connect the numbers 4 and 6 spark plug wires to

the spark plugs.

\
I

211642

12. Install the oxygen sensor to the exhaust manifold.

Tighten
Tighten the oxygen sensor to 42 Nm (31 lb ft).
13. Connect the oxygen sensor connector rosebud to
the engine left bracket.

440850

14. Connect the oxygen sensor electrical

connector (3).
15. Connect the secondary lock on the electrical
connector.
16. Install the 3-way catalytic converter. Refer to
Catalytic Converter Replacement in Engine
Exhaust.
17. Lower the vehicle.

439410

6-70

Engine Mechanical - 3.SL

Engine
Valve Rocker Arm Cover
Replacement (Left )
Removal Procedure
1. Remove the ignition coil module. Refer to Ignition
Coil and ICM Replacement in Engine Electrical.
2. Remove the Exhaust Gas Recirculation (EGA)
valve outlet pipe bolt from the upper intake.
3. Remove the EGR valve outlet pipe nut from the
EGR valve adapter.
4. Remove the EGR valve outlet pipe.

470217

5. Disconnect the EGR valve electrical connector.

221704

6. Remove the EGR valve adapter nuts (5).

7. Remove the EGR valve adapter bolt (4).
8. Remove the EGR valve adapter (3) from the
cylinder head studs (6).

36618

Engine

Engine Mechanical - 3.8L

6-71

9. Remove the engine lift bracket (1) from the

cylinder head studs.

444137

10. Remove the top ignition control module

bracket bolt.
11. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
12. Remove the bottom two ignition control module
bracket bolts (2).
13. Lower the vehicle.
14. Remove the ignition control module bracket (1).

444138

15. Loosen the valve rocker arm cover bolts.

16. Remove the valve rocker arm cover (1) and
gasket.
17. Remove the valve rocker arm cover gasket from
the cover.
18. Clean the following items:
The valve rocker arm cover
The cylinder head gasket surface
The valve rocker arm cover bolts

37442

6-72

Engine Mechanical - 3.8L

Engine
Installation Procedure
1. Apply GM P/N 12345493 thread lock adhesive or
equivalent to the valve rocker cover bolt threads.
2. Install the valve rocker arm cover (1) and gasket.
Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Tighten the valve rocker arm cover bolts.
Tighten
Tighten the valve rocker arm cover bolts to
1O N,m (89 lb in).

37442

4. Install the ignition control module bracket (1 ).

5. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
6. Install the bottom two ignition control module
bracket bolts (2).

Tighten
Tighten the bottom two ignition control module
bracket bolts to 50 Nm (37 lb ft).
7. Lower the vehicle.
8. Install the top ignition control module bracket bolt.
Tighten
Tighten the top ignition control module bracket
bolt to 50 N-m (37 lb ft).

444138

9. Install the engine lift bracket (1) to the cylinder

head studs.

444137

Engine

Engine Mechanical - 3.8L

6-73

10. Install the EGR valve adapter (3) to the cylinder

head studs (6).
11. Install the EGR valve adapter nuts (5).

Tighten
Tighten the EGR valve adapter nuts (5) to
50 N-m (37 lb ft).
12. Install the EGR valve adapter bolt (4).
Tighten
Tighten the EGR valve adapter bolt (4) to
25 N-m (18 lb ft).

36618

13. Connect the EGR valve electrical connector.

\
I

221704

14. Install the EGR valve outlet pipe.

15. Install the EGR valve outlet pipe nut to the EGR
valve adapter.
16. Install the EGR valve outlet pipe bolt to the upper
intake.

Tighten
Tighten the EGR valve outlet pipe nut to
29 N-m (21 lb ft).
Tighten the EGR valve outlet pipe bolt to
29 N-m (21 lb ft).
17. Install the ignition coil module. Refer to Ignition
Coil and ICM Replacement in Engine Electrical.

470217

6-74

Engine Mechanical - 3.SL

Engine
Valve Rocker Arm Cover
Replacement (Right)
Removal Procedure
1. Remove the drive belt. Refer to Drive Belt
Replacement.
2. Remove the generator. Refer to Generator
Replacement (3.BL V6).
3. Disconnect the canister purge solenoid
tubes (2, 5) from the solenoid (1).
4. Remove the canister purge solenoid (1) from the
mounting bracket.

187246

5. Remove the spark plug wiring harness from the

clip and reposition the harness.
6. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

52978

7. Remove the right rear engine lift bracket stud (2)

and bolt (1 ).
8. Lower the vehicle.

52977

Engine

Engine Mechanical - 3.8L

6-75

9. Loosen the valve rocker arm cover bolts.

10. Remove the valve rocker arm cover and gasket.
11. Remove the valve rocker arm cover gasket
from the cover.

63414

12. Remove the oil fill cap. Remove the oil fill tube, if
necessary.
13. Clean the following items:
The valve rocker arm cover
The cylinder head gasket surface
The valve rocker arm cover bolts

49878

Installation Procedure
1. Install the oil fill tube. Install the oil fill cap, if
necessary.

49878

6-76

Engine

Engine Mechanical - 3.8L

2. Apply GM P/N 12345493 thread lock adhesive or

equivalent to the valve rocker cover bolt threads.
3. Install the valve rocker arm cover and gasket.
Notice: Refer to Fastener Notice in Cautions
and Notices.
4. Tighten the valve rocker arm cover bolts.

Tighten
Tighten the valve rocker arm cover bolts to
1O Nm (89 lb in).
5. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

63414

6. Install the right rear engine lift bracket (3), stud (2)
and bolt (1 ).
Tighten
Tighten the right rear engine lift bracket stud (2)
and bolt (1) to 50 Nm (37 lb ft).
7. Lower the vehicle.

52977

8. Remove the spark plug wiring harness from the

clip and reposition the harness.

(
52978

Engine

Engine Mechanical - 3.8L

6-77

9. Install the canister purge solenoid (1) to the

mounting bracket.
1O. Connect the canister purge solenoid tubes (2, 5)
to the solenoid (1 ).
11. Install the generator. Refer to Generator
Replacement (3.BL V6).
12. Install the drive belt. Refer to Drive Belt
Replacement.

187246

Valve Rocker Arm and Push Rod

Replacement
Removal Procedure
1. Remove the rocker arm covers. Refer to Valve
Rocker Arm Cover Replacement (Left) or Valve
Rocker Arm Cover Replacement (Right).

Important: Place the valve rocker arms and pushrods

in a rack so they can be reinstalled in the same
locations from which they were removed.
2. Remove the valve rocker arm bolts (2).
3. Remove the valve rocker arms (1 ).

439879

4. Remove the valve rocker arm retainer (1 ).

439870

6-78

Engine Mechanical - 3.8L

Engine
5. Remove the pushrods (1 ).

439864

Installation Procedure
1

Tools Required
J 36660 Torque Angle Meter
Important: When installing valve rocker arms and
pushrods, coat the bearing surfaces with prelube GM
P/N 12345501 or equivalent. Install these components
in the locations from which they were removed.
1. Install the pushrods (1 ).

439864

2. Install the valve rocker arm retainer (1).

439870

Engine

Engine Mechanical - 3.8L

6-79

3. Install the valve rocker arms (1 ).

4. Apply GM P/N 12345493 or equivalent thread lock
adhesive to the valve rocker arm bolt threads.

Notice: Refer to Fastener Notice in Cautions and

Notices.

Notice: Refer to Permanently Stretching Bolt Notice in

Cautions and Notices.
5. Install the valve rocker arm bolts (2).
Tighten
Tighten the valve rocker arm bolts (2) to
15 N-m (11 lb ft) + 90 degrees using J 36660.
6. Install the rocker arm covers. Refer to Valve
Rocker Arm Cover Replacement (Left) or
Valve Rocker Arm Cover Replacement (Right).

439879

Valve Stem Oil Seal and Valve Spring

Replacement
Removal Procedure
Tools Required
J 23590 Spark Plug Port Adapter
J 38606 Valve Spring Compressor
1. Remove the valve rocker arm cover(s). Refer to
Valve Rocker Arm Cover Replacement (Left)
and/or Valve Rocker Arm Cover
Replacement (Right).
Important: Rotate the engine so that the piston in the
cylinder being worked on is at top dead center
before removing the valve locks. This will eliminate the
possibility of the valve accidentally falling inside the
cylinder.
2. Remove the rocker arm and push rod. Refer to
Valve Rocker Arm and Push Rod Replacement.
3. Remove the spark plug. Refer to Spark
Plug Replacement.
4. Install the J 23590 to the spark plug port and
apply compressed air in order to hold the
valves closed.

190565

6-80

Engine Mechanical - 3.SL

Engine
5. Install the J 38606 on the valve spring.

J 38606

190566

6. Compress the valve spring using the J 38606.

7. Remove the valve locks.
8. Remove the valve spring and cap.

190527

9. Remove the valve stem oil seal.

10. Inspect the valve spring for bent, cracked or
broken parts. Replace it if damaged. Refer to
Cylinder Head Clean and Inspect.

190567

Engine

Engine Mechanical - 3.SL

6-81

Installation Procedure
Tools Required
J41512Valve Guide Installation Tool
J 38606 Valve Spring Compressor
J 23590 Spark Plug Port Adapter
1. Place the oil seal over the stem until the seal
begins to contact the valve guide.

Notice: Use hand pressure only when installing the

valve stem oil seal using the J 41512. Using too much
force may cause damage to the oil seal and possibly
lead to excessive oil consumption.
Important: The color of the replacement seal may not
be the same color as the original seal. Install the
seals in their correct location based on GM part and
package description. Ensure that the seal is fully
seated on the valve guide.
2. Push the valve stem oil seal over the valve guide
using the J 41512 until the tool bottoms on the
valve spring seat.
3. Install the J 38606 on the valve spring.

190568

J 38606

190566

4.
5.
6.
7.

Compress the valve spring using the J 38606.

Install the valve spring and cap.
Install the valve locks.
Release the valve spring.

J 38606

190527

6-82

Engine Mechanical - 3.SL

Engine
Important: Ensure that the valve locks are seated.
8. Release the air pressure, and remove
the J 23590.
9. Install the spark plug. Refer to Spark Plug
Replacement in Engine Electrical.
10. Install the push rod and rocker arm. Refer to
Valve Rocker Arm and Push Rod Replacement.
11. Install the valve rocker arm cover(s). Refer to
Valve Rocker Arm Cover Replacement (Left)
and/or Valve Rocker Arm Cover
Replacement (Right).

190565

Valve Lifter Replacement

Removal Procedure
1. Remove the lower intake manifold. Refer to Intake
2.

3.
4.
5.

Manifold Replacement (Lower).

Remove the valve rocker arms and the pushrods.
Refer to Valve Rocker Arm and Push Rod
Replacement.
Loosen the valve lifter guide bolts.
Remove the valve lifter guide (1 ).
Remove the valve lifters (2).

41374

Installation Procedure
Important: Coat the valve lifters with prelube, GM
P/N 12345501 or equivalent prior to installation.
1. Install the valve lifters (1 ).
2. Install the valve lifter guide (2).

Notice: Refer to Fastener Notice in Cautions and

Notices.
3. Tighten the valve lifter guide bolts.
Tighten
Tighten the valve lifter guide bolts to
30 N-m (22 lb ft).
4. Install the lower intake manifold. Refer to Intake
Manifold Replacement (Lower).
5. Install the valve rocker arms and pushrods. Refer
to Valve Rocker Arm and Push Rod
Replacement.
41374

Engine

Engine Mechanical - 3.8L

6-83

Crankshaft Balancer Replacement

Removal Procedure

Tools Required
J 38197 Crankshaft Balancer Puller
J 37096 Flywheel Holding Tool
1. Remove the drive belt. Refer to Drive Belt
Replacement.
2. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
3. Remove the starter motor. Refer to Starter Motor
Replacement (3.BL V6) in Engine Electrical.
4. If equipped with the M49 manual transmission,
remove the following components:
5. Remove the transmission brace bolts (2, 3).
6. Remove the transmission brace (1 ).
349561

7. Remove the flywheel housing inspection cover

bolts (2).
8. Remove the flywheel housing inspection cover (3).
9. If equipped with the 4L60-E automatic
transmission, remove the torque converter
cover. Refer to Torque Converter Cover
Replacement (VB) in Automatic
Transmission - 4L60-E.

349560

10. Use the J 37096 in order to hold the flywheel.

309963

6..S4

Engine Mechanical 3.8L

Engine
11. Remove the:crankshaft balancer bolt ('1) from the:
balancer (2).

12. Remove the key (3) from the crankshaft.

440746

13. Remove the crankshaft balancer using

the J 38197.
13.1. Invert theJ 38197-2 so the leg of the.tool
is f,1;1cing away from the crankshaft

balancer.
13.2. Install the silver bolts J 38197-4 to the
crankshaft balancer.
13.3. Remove J 38197-1\J 38197-2, 'and
J 38197-4 from the crankshaft balancer.

J 38197

313955

Installation Procedure
Tools Required
J 36660 Torque Angle Meter
1. Lubricate the seal surface of the crankshaft
balancer with engine oil.
2. Install the crankshaft balancer (2).
3. Align the key slot in the balancer (2) to the key
slot in the crankshaft.
4. Install the key (3).

Notice: Refer to Fastener Notice in Cautions and

Notices.
5. Install the crankshaft balancer bolt (1 ).

313955

Tighten
Tighten the balancer bolt to 150 N-m (111 lb ft).
Use the J 36660 to torque the crankshaft balancer
bolt an additional 114 degrees.
6. Remove the J 36660.

Engine

Engine Mechanical - 3.8L

5...55

7. If equipped with the 4L60-E automatic:

transmission, install the torque converter
cover. Refer to Torque Converter Cover
Replacement (V8) in Automatic
Transmission -4L60-E.
8. If equipped with the M49 manual transmission,
install the following components:
9. Install the flywheel housing inspection cover (3).
10. Install the flywheel housing inspection cover
bolts (2).
Tighten
Tighten the flywheel housing inspection cover
bolts (2) to 48 N-m (35 lb ft).

349560

11. Install the transmission. brace (1 ).

12. Install the transniission brace bolts (2, 3).
Tighten

Tighten the brace bolts (3) to the engine block

to 28 Nm (21 lb ft).
Tighten the brace bolts (2) to the transmission
to 50 N-m (37 lb ft).
13. Install the starter motor. Refer to Starter Motor
Replacement (3.BL V6) in Engine Electrical.
14. Lower the vehicle.
15. Install the drive belt. Refer to Drive Belt
Replacement.

349561

6-86

Engine Mechanical - 3.8L

Engine
Crankshaft Front Oil Seal Replacement
Removal Procedure
1. Remove the crankshaft balancer. Refer to
Crankshaft Balancer Replacement.
2. Pry out the crankshaft front oil seal using a
screwdriver. Use care in order to avoid damage to
.the seal bore or seal contact surfaces.

50499

Installation Procedure
Tools Required
J 35354 Seal Installer
1. Install the crankshaft front oil seal. Use the
J 35354 and a soft faced hammer.
2. Remove the J 35354.
3. Coat the outside seal surface of the crankshaft
balancer with GM PIN 1052497 or equivalent.
4. Install the crankshaft balancer. Refer to Crankshaft
Balancer Replacement.

J 35354

36662

Engine Front Cover Replacement

Removal Procedure
Tools Required
J 25034-C Power Steering Pump Pulley Remover
1. Drain the engine oil.
2. Drain the engine coolant. Refer to Draining and
Filling Cooling System (V6) in Engine Cooling.
3. Disconnect the intake air temperature (IAT) sensor
electrical connector.

208554

Engine

Engine Mechanical - 3.8L

6-87

4. Remove the air intake duct.

5. Loosen the coolant pump pulley bolts.
6. Remove the drive belt tensioner. Refer to Drive
Belt Tensioner Replacement.

208572

7. Use the J 25034-C to remove the power steering

pump pulley.

354410

8. Place a drain pan under the power steering

pump (1).
9. Disconnect the inlet hose (3) from the power
steering pump (1).
10. Reposition the hose clamp on the return line (2).
11. Disconnect the reservoir hose return line (2)
from the power steering pump (1 ).

)
/

354420

6-88

Engine Mechanical - 3.8L

Engine
12. Remove the power steering pump nuts (3).
13. Remove the power steering pump (1 ).
14. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
15. Remove the crankshaft balancer. Refer to
Crankshaft Balancer Replacement.

290569

16. Disconnect the crankshaft position sensor

electrical connector.
17. Remove the crankshaft position sensor shield.

440841

18.
19.
20.
21.

Remove the crankshaft position sensor studs.

Remove the crankshaft position sensor.
Remove the oil pan to front cover bolts.
Loosen the oil pan bolts, to drop the oil pan
slightly in order to add clearance for the front
cover installation.
22. Lower the vehicle.

(
187288

Engine

Engine Mechanical - 3.8L

6-89

23. Remove the coolant pump pulley bolts.

24. Remove the coolant pump pulley.

221711

25. Remove the radiator outlet hose from the

front cover.

50509

26. Remove the engine front cover studs and

bolts (1 ).
27. Remove the engine front cover (2),

50504

6-90

Engine

Engine Mechanical - 3.8L

28. Remove the engine front cover gasket from the

engine block.

440843

29. Remove the coolant pump bolts (1 ).

30. Remove the coolant pump (2).
31. Remove the coolant pump gasket (3) from the
front cover (4).

11687

32. If replacing the front cover (1 ), disassemble the

following parts:
32.1. Oil pump gear set (2)
32.2. Camshaft sensor (3)
32.3. Oil filter adapter (5) and gasket
32.4. Oil pressure relief valve (6) and spring
33. Clean the engine front cover and the engine block
gasket surfaces.

3
445496

Engine

Engine Mechanical - 3.8L

6-91

Installation Procedure

Tools Required
J 36660 Torque Angle Meter
J 35354 Seal Installer
J 25033-C Power Steering Pump Pulley Installer
1. If replacing the front cover (1 ), assemble
the following parts:
1.1 . Oil pump gear set (2)
1.2. Camshaft sensor (3)
1.3. Oil filter adapter (5) and new gasket
1.4. Oil pressure relief valve (6) and spring
2. Install a new crankshaft front oil seal (4)

3
445496

3. Install the crankshaft front oil seal to the front

cover using the J 35354 and a soft faced hammer.

J 35354

J~-

36662

4. Install the coolant pump gasket (3) to the front

cover (4).
5. Install the coolant pump (2).

Notice: Refer to Fastener Notice in Cautions and

Notices.
6. Install the coolant pump bolts (1 ).
Tighten
Tighten the coolant pump bolts (1) to
15 N-m (11 lb ft). Using J 36660 tighten the
coolant pump bolts (1) an additional 80 degrees.

11687

6~92

Engine Mechanical - 3.8L

Engine
7. Install the engine front cover gasket to the
engine block.

440843

8. Install the engine front cover (2) ..

9. Align the cogs on the crankshaft sprocket with the
cogs on the oil pump in the engine front cover.

50504

10. Apply sealant GM P/N 12346004 or equivalent to

the engine front cover bolts (1) and stud (2).
11. Install the engine front cover bolts (1) and
stud (2).

Tighten
Tighten the front cover bolts (1) and studs to
20 Nm (15 lb ft). Using J 36660 tighten the front
cover bolts (1) and stud (2) an additional
40 degrees.

445603

Engine

Engine Mechanical - 3.SL

6-93

12. Install the radiator outlet hose to the front cover.

50509

13. Install the coolant pump pulley.

14. Install the coolant pump pulley bolts.
Tighten
Tighten the coolant pump pulley bolts to
13 N-m (115 lb in).
15. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
16. Install the oil pan to front cover bolts.

17. Tighten the loose oil pan bolts.

Tighten
Tighten the oil pan bolts to 14 N-m (10 lb ft).

221711

18. Install the crankshaft position sensor.

19. Apply sealant GM P/N 12346004 or equivalent to
the crankshaft position sensor studs.
20. Install the crankshaft position sensor studs.
Tighten
Tighten the crankshaft position sensor studs to
20 N-m (15 lb ft). Using J 36660 tighten the sensor
studs an additional 40 degrees.

~o

187288

6-94

Engine Mechanical - 3.8L

Engine
21. Install the crankshaft position sensor shield.
22. Connect the crankshaft position sensor electrical
connector.
23. Install the crankshaft balancer. Refer to Crankshaft
Balancer Replacement.

24. Lower the vehicle.

440841

25. Install the power steering pump (1 ).

26. Install the power steering pump nuts (3).

Tighten
Tighten the power steering pump nuts to
30 N-m (23 lb ft).

290569

27. Connect the reservoir hose return line (2) to the

power steering pump (1 ).
28. Position the return line (2) hose clamp in the
correct location.
29. Connect the inlet hose (3) to the power steering
pump (1).

Tighten
Tighten the inlet hose (3) fitting to
28 N-m (21 lb ft).

2
354420

Engine

Engine Mechanical - 3.8l. 6-95

30. Use the J 25033-C to install the power steering

pump pulley.
31. Remove the J 25033-C.
32. Install the drive belt tensioner. Refer to Drive Belt
Tensioner Replacement.

354410

33. Install the air intake duct.

208572

34. Connect the intake air temperature (IAT) sensor

electrical connector.
35. Refill the engine oil.
36. Refill the engine coolant. Refer to Draining and
Filling Cooling System (V6) in Engine Cooling.

208554

6'!-96

Engine

Engine Mechanical - 3.8L

Oil Pump Cover and Gear Set
Replacement
Removal Procedure

1 . Remove the engine front cover. Refer to Engine

Front Cover Replacement.
2. Remove the oil pump cover attaching screws.
3. Remove the oil pump cover.
4. Remove the oil pump gear set.
5. Inspect the oil pump gear set and housing. Refer
to Oil Pump Clean and Inspect.

153600

Installation Procedure
1. Lubricate the oil pump gears with petroleum jelly.
2. Install the oil pump gear set.
3. Pack the oil pump cavity with petroleum jelly.
4. Install the oil pump cover.
Notice: Refer to Fastener Notice in Cautions and
Notices.
5. Install the oil pump cover screws.
Tighten
Tighten the oil pump cover screws to
11 N-m (98 lb in).
6. Install the engine front cover. Refer to Engine
Front Cover Replacement.

153600

Oil Filter Adapter and Valve Assembly

Replacement
Removal Procedure

''

1. Remove the drive belt. Refer to Drive Belt

Replacement.
2. Remove the engine ground strap bolt (1) and
ground strap (2).
3. Disconnect the air conditioning compressor
electrical connector (3).
4. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
5. Drain the engine oil.
6. Remove the air conditioning compressor mounting
bracket. Refer to Compressor Mounting Bracket
Replacement (3.BL) in HVAC Systems with
A/C - Manual.

445688

Engine Mee hanical - 3.SL

Engine
sensor electrical
7. Disconnect the oil pressure
connecto,r (2).

\)

a.

Remove the oil pressu re sensor; .

9 _ Remove the oil filter.

6-97

6-98

Engine Mechanical - 3.8L

Engine
10. Remove the oil filter adapter bolts (3).
11. Remove the oil filter adapter (2) and gasket (1).
12. Remove the pressure relief valve (4) and
spring (5).
13. Clean the parts in a suitable solvent. Dry the parts.
14. Clean all of the gasket sealing surfaces.
15. Inspect the following areas:
The oil pressure relief valve (4) and the valve
bore for burrs
The spring (5) for loss of tension, replace the
spring if you are in doubt

440844

Installation Procedure
Tools Required

J 36660 Torque Angle Meter

1. Install the pressure relief valve (4) and spring (5).
2. Install the oil filter adapter (2) and gasket (1 ).
Notice: Refer to Fastener Notice in Cautions
and Notices.
3. Install the oil filter adapter bolts (3).
Tighten
Tighten the oil filter adapter bolts (3) to
15 Nm (11 lb ft). Using J 36660 tighten the oil
filter adapter bolts (3) an additional 50 degrees.

440844

4. Install a new oil filter.

Tighten
Tighten the oil filter to 30 Nm (22 lb ft).

440847

Engine

Engine Mee h anical - 3.S L

5. Install the oil press ure sensor.

Tighten the oil. pressure sensor to
Tghten
1~N-m (121bft).

\;

6. Connect the

oil pressure sensor electrical

mounting

connector (2;.oonditioning com\'.;~i~~~g Bracket

7. bracke
Install ~h~!;er
Co,:nprevsJg
Systems with
t 1toBL)
in H

Replacemen

a.

I'3

A/C _ Manual.
Lower the vehicle.

. conditioning
. co mpressor electrical
Connect the air
I

9. connector (3)..
ound strap (2) and bolt (1 .
10. Insta II the engine gr
Tighten
. ground strap bolt to
Ti hten the engine
11

2f Nm (18 lb ft).
Ier to Drive Belt
Install the drive belt. Re

. Replacement.

011 .
12. Refill the engine

6-99

6-100

Engine Mechanical - 3.8L

Engine
Timing Chain and Sprockets Replacement
Removal Procedure
1. Remove the engine front cover. Refer to Engine
Front Cover Replacement.
2. Align the timing marks (2) on the sprocket (1, 3)
so that they are as close together as possible.
3. Remove the timing chain dampener.

550171

4. Remove the camshaft sprocket bolt.

5. Remove the timing chain (1) and camshaft
sprocket (2).

550112

Important: If crankshaft sprocket does not come off

easily, a light blow on the edge of the sprocket (with a
plastic mallet) should dislodge the sprocket.
6. Remove the crankshaft sprocket (3).
7. Clean the timing chain.
8. Clean the sprockets.
9. Inspect all the components for wear or damage.
10. If the balance shaft timing has been disturbed.
Refer to Balance Shaft Installation.
11 . Use the following steps if the pistons have been
moved in the engine:
11.1. Turn the crankshaft in order to set the
number one piston is at top dead center.
11.2. With the sprocket installed, turn the
camshaft in order to have the timing
mark straight down.

Engine

Engine Mechanical - 3.SL

6-101

Installation Procedure

Tools Required
J 36660 Torque Angle Meter
1. Install the timing chain (1) onto the
sprockets (2, 3) with the timing marks in their
closest together position.
2. Install the timing chain (1) and sprockets (2, 3).
Notice: Refer to Fastener Notice in Cautions and
Notices.
.
.

3. Install the camshaft sprocket bolt.

Tighten
Tighten the camshaft sprocket bolt to
: .
100 N-m (74 lb ft). Using J 36660 tighten the
camshaft sprocket bolt an additional 90 degrees.
4. Install the timing chain dampener.
5. Install the timing chain dampener bolt.
Tighten
Tighten the dampener bolt to 22 N-m (16 lb ft).

550172

Important: Rotate the engine two revolutions and

check the timing marks. Ensure the marks are aligned.
6. Install the engine front cover. Refer to Engine
Front Cover Replacement

Camshaft Replacement
Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant
Recovery and Recharging in HVAC Systems
with A/C - Manual.
2. Remove the radiator with the A/C condenser.
Refer to Radiator Replacement in Engine
Cooling.
3. Remove the valve lifters. Refer to Valve Lifter
Replacement.
4. Remove the timing chain and sprockets. Refer to
Timing Chain and Sprockets Replacement.
5. Remove the balance shaft gear (2) from the
camshaft (1 ).

441129

\)

6-102

Engine Mechanical - 3.SL

Engine
6. Remove the camshaft thrust plate bolts (1 ).

7. Remove the camshaft thrust plate (2).

8. Remove the camshaft key (3).

Notice: All camshaft journals are the same diameter,

so care must be used in removing or installing the
camshaft to avoid damage to the camshaft bearings.
9. Use the following procedure to remove the
camshaft (4):
9.1. Install three 5/16-18 x 4 in bolts in the
camshaft bolt holes.
9.2. Carefully rotate and pull the camshaft out.
10. Inspect the camshaft and bearings. Refer to
Camshaft and Bearings Clean and Inspect.

35815

Installation Procedure
1. Coat the camshaft with prelube GM P/N 12345501
or equivalent before installation.
2. Install the camshaft (4).
3. Install the camshaft key (3).
4. Install the camshaft thrust plate (2).

Notice: Refer to Fastener Notice in Cautions and

Notices.
5. Install the camshaft thrust plate bolts (1 ).

Tighten
Tighten the camshaft thrust plate bolts to
15 N-m (11 lb ft).

35815

6. Install the balance shaft drive gear (2) to the

camshaft (1 ).

(
441129

Engine

Engine Mechanical - 3.SL

6-103

7. Align the timing marks (2) on the balance shaft

gear (1) and the balance shaft drive gear (3).
8. Install the timing chain and sprockets. Refer to
Timing Chain and Sprockets Replacement.
9. Install the valve lifters. Refer to Valve Lifter
Replacement.
1o. Install the radiator with the A/C condenser. Refer
to Radiator Replacement in Engine Cooling.
11. Recharge the refrigerant. Refer to Refrigerant
Recovery and Recharging in HVAC Systems
with A/C - Manual.

441151

Cylinder Head Replacement (Left)

Removal Procedure
1. Drain the coolant. Refer to Draining and Filling
Cooling System (V6) in Engine Cooling.
2. Remove the lower intake manifold. Refer to Intake
Manifold Replacement (Lower).
3. Remove the left exhaust manifold. Refer to
Exhaust Manifold Replacement (Left).
4. Remove the valve rocker arms and pushrods.
Refer to Valve Rocker Arm and Push Rod
Replacement.
5. Remove the cylinder head bolts (1 ).
6. Remove the left cylinder head (2).

441261

7. Remove the left cylinder head gasket (1).

8. Clean and inspect the cylinder head. Refer to
Cylinder Head Clean and Inspect.

441262

6-104

Engine Mechanical - 3.SL

Engine
Installation Procedure
Tools Required .
J 36660 Torque Angle Meter
Important: The arrow on the; gasket must point to the
front of the engine. Failure to install the gasket
properly wi.11 cause gasket failure and possible engine
failure.

1. Install a new left cylinder head:gasket (1) to the

alignment pins (2).
.
.

441262

2. Install the left cylinder head (2).

Notice: Refer to Permanently Stretching Bolt Notice in

Cautions and Notices.

3. Install the cylinder head bolts (1,.

441261

Notice: Refer to Fastener Notice in Cautions and

Notices.

4. Tighten the cylinder head bolts following the given

sequence.

Tighten
Tighten the cylinder head bolts to 50 Nm (37 lb ft)
in sequence. Using J 36660 tighten the cylinder
head bolts an additional 120 degrees.
5. Install the valve rocker arms and pushrods. Refer
to Valve Rocker Arm and Push Rod
Replacement.
6. Install the left exhaust manifold. Refer to Exhaust
Manifold Replacement (Left).

38826

Engine

Engine Mechanical - 3.SL

6-105

7. Install the lower intake manifold. Refer to Intake

Manifold Replacement (Lower)
8. Refill the engine coolant. Refer to Draining and
Filling Cooling System (V6) in Engine Cooling.
9. Change the engine oil and filter. Refer to Engine
Oil and Oil Filter Replacement.

Cylinder Head Replacement (Right )

Removal Procedure
1. Drain the coolant. Refer to Draining and Filling
Cooling System (V6) in Engine Cooling.
2. Remove the lower intake manifold. Refer to Intake
Manifold Replacement (Lower).
3. Remove the right exhaust manifold. Refer to
Exhaust Manifold Replacement (Right).
4. Remove the valve rocker arms and the pushrods.
Refer to Valve Rocker Arm and Push Rod
Replacement
5. Remove the cylinder head bolts (1 ).
6. Remove the right cylinder head (3).

441261

7. Remove the right cylinder head gasket (3).

8. Clean and inspect the cylinder head. Refer to
Cylinder Head Clean and Inspect.

441262

6-106

Engine Mechanical - 3.SL

Engine
Installation Procedure
Tools Required
J 36660 Torque Angle Meter
Important: The arrow on the gasket must point to the
front of the engine. Failure to install the gasket
properly will cause gasket failure and possible engine
damage.
1. Install a new right cylinder head gasket (3) to the
alignment pins (2).

441262

2. Install the right cylinder head (3).

Notice: Refer to Permanently Stretching Bolt Notice in
Cautions and Notices.
3. Install the cylinder head bolts (1 ).

441261

Notice: Refer to Fastener Notice in Cautions and

Notices.

4. Tighten the cylinder head bolts following the given

sequence.
Tighten
Tighten the cylinder head bolts to 50 N-m (37 lb ft)
in sequence. Using J 36660 tighten the cylinder
head bolts an additional 120 degrees.
5. Install the pushrods and the valve rocker arms.
Refer to Valve Rocker Arm and Push Rod
Replacement.
6. Install the right exhaust manifold. Refer to
Exhaust Manifold Replacement (Right).

@
~

G)

38826

Engine

Engine Mechanical - 3.8L

6-107

7. Install the lower intake manifold. Refer to Intake

Manifold Replacement (Lower).

8. Refill the engine coolant. Refer to Draining and

Filling Cooling System (V6) in Engine Cooling.
9. Change the engine oil and filter. Refer to Engine
Oil and Oil Filter Replacement.

Oil Pan Replacement

Removal Procedure
J 28467-360 Universal Support Fixture
J 41044 Engine Support Adapters
J 28467-90 Engine Support Fixture Adapters
1. Install the J 28467-360 and J 41044 to the vehicle.
2. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
3. Drain the engine oil.
4. Remove the right side engine mount (2) to cradle
bolts (1 ).

49837

5. Remove the left side engine mount (2) to cradle

bolts (1 ).

50525

6-108

Engine

Engine Mechanical -3!8L

6. Remove the right and left lower shock bolts.

220629

7. Remove the intermediate steering shaft bolt from

the rack and pinion.
8. Support the engine cradle with appropriate
equipment.

220630

9. Disconnect the oil level sensor electrical

connector (1 ).

440880

Engine

Engine Mechanical - 3.SL

6-109

Notice: Remove the oil level sensor, ,located in the oil

pan, before the oil pan is removed. The sensor may
be damaged if the oil pan is removed first.
10. Remove the oil level sensor from the oil pan.
11. Remove the starter motor. Refer to Starter Motor
Replacement (3.BL V6) in Engine Electrical.

441263

12. Remove the front crossm~mber.b.olts.

220632

13. Remove the oil pan bolts ft).

14. Remove the oil pari,(2): Lower. the rear of the oil
pan while rotating it outward.

441269

6-110

Engine Mechanical - 3.SL

Engine
15. Remove the oil pan gasket.
16. Clean the oil pan gasket surfaces.

441265

Installation Procedure
1. Install the oil pan gasket.

441265

2. Install the oil pan (2).

Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Install the oil pan bolts (1 ).

Tighten
Tighten the oil pan bolts to 14 N-m (10 lb ft).

441269

Engine

Engine Mechanical - 3.8L

6-111

4. Install the front crossmember bolts.

Tighten

\
)

Tighten the upper four crossmember bolts to

125 N,m (92 lb ft).
Tighten the lower two crossmember bolts to
145 Nm (107 lb ft).
5. Install the starter motor. Refer to Starter Motor
Replacement (3.BL V6) in Engine Electrical.

~
220632

Notice: Install the oil level sensor, located in the oil

pan, after the oil pan is installed. The sensor may be
damaged if the oil level sensor is installed first.
6. Install the oil level sensor to the oil pan.
Tighten
Tighten the oil level sensor to 20 Nm (15 lb ft).

441263

7. Connect the oil level sensor electrical

connector (1 ).
8. Remove the equipment used to support the
engine cradle.

440880

6-.112

Engine

Engine Mechanical - 3.SL

9. Install the intermediate steering shaft from the

rack and pinion.
Tighten
Tighten the intermediate shaft bolt to
47 N-.m (35 lb ft).

220630

1o. Install the right and left lower shock bolts.

Tighten
Tighten the shock bolts to 65 N-m (48 lb ft).

220629

11. Install the left side engine mount (2) to cradle

bolts (1 ).
Tighten
Tighten the left side engine mount to cradle
bolts (1) to 58 N-m (43 lb ft).

50525

Engine

Engine Mechanical "'.

a~sL

6-113

12. Install the right side engine mount (2) to cradle

bolts (1 ).

Tighten
Tighten the right side engine mount to cradle
bolts (1) to 58 N-m (43 lb ft).

13. Lower the vehicle.

14. Remove the J 28467-360 and J 41044 from the
vehicle.
15. Change the engine oil and filter. Refer to Engine
Oil and Oil Filter Replacement.

49837

Oil Pump Pipe and Screen Assembly

Replacemen.t
Removal Procedure
1. Remove the oil pan. Refer to Oil Pan
2.
3.
4.

5.
6.

Replacement.
Remove the oil pump screen bolts (2).
Remove the oil pump screen (1 ).
Remove the oil pump screen gasket (3)
Clean the screen and housing with solvent and
blow dry with compressed air.
Clean the gasket mating surfaces on the pipe
flange and cylinder block.

441270

Installation Procedure
1. Install the oil pump screen gasket (3).
2. Install the oil pump screen (1).

Notice: Refer to Fastener Notice in Cautions and

Notices.
3. Install the oil pump screen bolts (2).
Tighten
Tighten the oil pump screen bolts (2) to
15 N-m (11 lb ft).
4. Install the oil pan. Refer to Oil Pan Replacement.

441270

6-114

Engine

Engine Mechanical - 3.SL

Engine Flywheel Replacement
Removal Procedure

Tools Required
J 37096 Flywheel Holding Tool
1. If equipped with a manual transmission remove
the clutch pressure plate and driven disc. Refer
to Clutch Pressure Plate and Clutch Driven
Plate (3.BL) in Clutch.
2. Remove the automatic transmission, if equipped.
Refer to Transmission Replacement (3.BL) in
Automatic Transmission - 4L60-E.
3. Use J 37096 to hold the flywheel to loosen the
flywheel bolts.
4. If equipped with a manual transmission, remove
the flywheel bolts (1 ).

309963

5. If equipped with the manual transmission, remove

the following components:
5.1. Remove the flywheel bolts (1 ).
5.2. Remove the flywheel (2).

441112

6. If equipped with a automatic transmission, remove

the following components:
6.1. Remove the flywheel bolts (1 ).
6.2. Remove the flywheel (2).

441271

Engine

Engine Mechanical - 3.8L

6-115

Installation Procedure
Tools Required
J 37096 Flywheel Holding Tool
J 36660 Torque Angle Meter
1. If equipped with a automatic transmission, install
the following components:
1.1. Install the flywheel (2).
1.2. Install the flywheel bolts (1) finger tight.

441271

2. If equipped with a manual transmission, install the

following components:
2.1. Install the flywheel (2).
2.2. Install the flywheel bolts (1) finger tight.

441112

3. Use J 37096 to hold the flywheel when tightening

the flywheel bolts.

Notice: Refer to Fastener Notice in Cautions and

Notices.
4. Tighten the flywheel bolts.

Tighten
Tighten the flywheel bolts to 15 Nm (11 lb ft).
Using J 36660 torque the flywheel bolts an
additional 50 degrees.
5. Install the automatic transmission, if equipped.
Refer to Transmission Replacement (3.BL) .in
Automatic Transmission - 4L60-E.
6. If equipped with a manual transmission, install the
clutch pressure plate and driven disc. Refer to
Clutch Pressure Plate and Clutch Driven
Plate (3.BL) in Clutch.

309963

6-116

Engine Mechanical - 3.SL

Engine
Crankshaft Rear Oil Seal Replacement
Removal Procedure
1 . Remove the flywheel. Refer to Engine Flywheel
Replacement.
Important: Do not nick the crankshaft sealing surface
when removing the seal.

2. Remove the crankshaft rear oil seal.

2.1. Insert a screwdriver or similar tool through
the dust lip at an angle.
2.2. Pry the seal out by moving the handle of
the tool towards the end of crankshaft.
2.3. Repeat as necessary around the seal.

26129

Installation P,rocedure
Tools Required
J 38196 Rear Main Oil Seal Installer
1. Coat the new seal entirely with engine oil.

J 38196

2. Install the seal onto the J 38196.

3. Install the J 38196 onto the rear of the crankshaft.
4. Tighten the screws snugly in order to ensure
that the seal will be installed squarely over the
crankshaft.
5. Tighten the wing nut on the J 38196, until it
bottoms.
6. Remove the J 38196 from the crankshaft.
7. Install the flywheel. Refer to Engine Flywheel
Replacement.

37747

Crankshaft Rear Oil Seal and Housing

Replacement
Removal Procedure
1 . Remove the engine flywheel. Refer to Engine
Flywheel Replacement.
2. Loosen all .of the oil pan bolts,
3. Remov~ the crankshaft rear oil s.eal housing bolts.
4. Remove the crankshaft rear oil seal housing.
5. Remove the rear oil seal housing gasket.
Important: Make sure not to damage the crankshaft
OD surface with any tool.
6. Remove the oil seal from the housing.
7. Clean the gasket surfaces of the oil seal housing
and the engine block.

153604

Engine

Engine Mechanical - 3.8L

6-117

8. Inspect the ID of the oil seal housing bore.

Replace the crankshaft rear oil seal hoLJsing
as required.
9. Inspect the crankshaft for nicks or burrs on the.
surface that contacts the seal. Repair or replace
the crankshaft as required. Refer to Crankshaft
and Bearings Removal.

Installation Procedure
Tools Required
J 36660 Torque Angle Meter
J 41349 Crankshaft Rear OilSeal Aligning Tool
Notice: Do not use sealers or adhesives on rear main
oil seal housing gasket. Use of sealer$ or adhesives
on this gasket may cause oil leaks. '
1. Install the crankshaft rear oil seal housing gasket
over the bolts for alignment.
Important: The plastic inserts in the crankshaft rear
oil seal housing are used to aid assembly only.
The inserts are not required for service.
2. Install the crankshaft rear oil seal housing.
Hand tighten the crankshaft rear oil seal
housing bolts.

Notice: Sealability of the rear main oil seal depends

on the correct alignment of the rear main oil seal
housing and the oil pan. Incorrect alignment
may cause oil leaks.
3. Apply engine oil to both sides of the J 41349.
4. Install the J 41349 over the crankshaft. Twist the
tool to aid in sliding the tool over the crankshaft.
5. Place a straight edge on the engine block oil pan
flange and the crankshaft rear oil seal housing
flange. Use a feeler gage to ensure there is
no more than 0.004 in step on each side. Rotate
the crankshaft rear oil seal housing to make
the step equal on each side. Replace the
crankshaft rear oil seal if the rotation does not
make the step equal.

153604

J 41349

Notice: Refer to Fastener Notice in Cautions and

Notices.
6. Tighten the crankshaft rear oil seal housing bplts ..
Tighten
Tighten the crankshaft rear oil seal housing bolts
to 15 N-m (11 lb ft). Using J 36660 to tighten
the bolts an additional 50 degrees.
7. Remove the J 41349.

8. Recheck the step height on each side to ensure

the crankshaft rear oil seal housing did not move.
If the step height is beyond specification,
reinstall the crankshaft rear oil seal housing and
measure the step again. Replace the crankshaft
rear oil seal housing if the clearance is still beyond
specification.
9. Tighten the oil pan bolts.

Tighten
Tighten the oil pan bolts to 14 Nm (10 lb ft).
10. Install the engine flywheel. Refer to Engine
Flywheel Replacement.

153603

6-118

Engine Mechanical - 3.8L

Engine
Engine Replacement
Removal Procedure
Tools Required
J 39580 Engine Support Table
J 36221 Hydraulic Clutch Line Separator
J 39549 Ball Joint !Tie Rod Separator
J 21366 Converter Holding Strap

Caution: Refer to Battery Disconnect Caution in

Cautions and Notices.
1 .. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnect/Connect
Procedure in Engine Electrical.

208241

2. Disconnect the posiUve battery cable.

(
\

211587

3. Disconnect the intake air temperature (IAT)

sensor electrical connector.

208554

Engine

4. Remove the air intake duct

5. Recover the refrigerant. Refer to Refrigerant
Recovery and Recharging in HVAC Systems
with A/C-Manual.
6. Relieve the fuel pressure. Refer to Fuel Pressure
Relief Procedure in Engine Controls-3.SL.
7. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
8. Drain the engine oil.
9. Remove the front wheels. Refer to Wheel Removal
in Tires and Wheels.
10. Drain the engine coolant. Refer to Draining and
Filling Cooling System (V6) in Engine Cooling.
11. Remove the 3-way catalytic converter. Refer to
Catalytic Converter Replacement in Engine
Exhaust.
12. Drain the transmission fluid, if equipped with a
manual transmission.
13. Remove the propeller shaft. Refer to Propeller
Shaft Replacement - One Piece or Propeller
Shaft Replacement - Two Piece in Propeller Shaft.
Remove
the torque arm. Refer to Torque
14.
Arm Replacement in Rear Suspension.
15. Remove the starter motor. Refer to Starter Motor
Replacement (3.BL V6) in Engine Electrical.
16. On vehicles equipped with a automatic
transmission, unsnap the transmission range
selector lever cable from the range selector lever
at the transmission.

Engine Mechanical - 3.SL

6-119

208572

208264

6-120

Engine

Engine Mechanical - 3.8L

17. Remove the retainer from the range selector

lever cable.

341079

18. Remove the range selector lever cable from the

qable bracket.

208276

19. On vehicles equipped with a manual transmission,

disconnect the clutch actuator cylinder line from
the actuator cylinder using J 36221.
20. Remove the left side front air deflector.
21. Remove the stabilizer bar bracket bolts.
22. Remove the stabilizer bar brackets.

43255

Engine

Engine Mechanical - 3.SL

6-121

23. Remove the steering gear coupling shield.

24. Remove the intermediate steering shaft bolt and
shaft from the rack.

220630

25. Remove the wiring harness ground bolt and

RF (Radio Frequency) ground strap and cruise
control ground lead from the front rail.
26. Disconnect the knock sensors electrical
connectors.

346034

27. Disconnect thewheel speed sensors electrical

connectors.

\
346036

6-122

Engine Mechanical - 3.8L

Engine
28. Remove the A/C compressor and condenser
hose bolt.
29. Discard the 0-ring.

365423

30. Remove the A/C compressor and condenser hose

nut at the condenser.
31. Discard the 0-ring.

365450

32. Remove the front fuel pipe heat shield nuts (1 ).

33. Remove the front fuel pipe heat shield (2).
34. Disconnect the brake lines from the brake
pipe clip.
35. Lower the vehicle.

7~

173551

Engine
36. Remove the engine wiring harness ground
bolt (1 ).
37. Remove the engine ground.

Engine Mechanical - 3.SL

1

6-123

445688

38. Remove the A/C compressor and condenser hose

bolt at the accumulator.
39. Discard the 0-ring.

282936

40. Remove the heater hoses from the drive belt

tensioner.

282933

6.-124

Engine Mechanical~ 3.8L

Engine
41. Disconnect the fuel feed pipe (1) from the fuel rail.
42. Disconnect the fuel return pipe (2) from the
fuel rail.
43. Disconnect the EVAP pipe (6) at the engine.

215517

44. Remove the cruise control and accelerator control

cables from the throttle body and bracket.

296581

45. Remove the accelerator control cable bracket

bolts (1) and bracket (2).

444135

Engine

Engine Mechanical - 3.8L

6-125

46. Remove the inlet hose from the water outlet.

221680

47. Remove the outlet hos.e from the water pump.

221689

48. Remove the brake booster vacuum hose (2) from

the intake manifold fitting (1 ).
49. Remove the front two brake pipes from the brake
modulator.

439407

6-126

Engine

Engine Mechanical - 3.8L

50. Disconnect the secondary captured locks.

51. Disconnect the forward lamp harness from the
engine harness.
52. Disconnect the engine harness vacuum tube from
the bottom of the vacuum check valve.

346047

53. Disconnect the powertrain control module (PCM)

connectors.
54. Remove the PCM from the vehicle.
55. Remove the right side insulator panel.
56. Remove the hinge pillar trim panel.

346043

57. Disconnect the engine wiring harness from the

instrument panel wiring harness.

346039

Engine

Engine Mechanical - 3.SL

6-127

58. Remove the engine wire harness through the front

of dash. Place the harness on top of the engine.
59. Remove the floor shift control, if equipped. Refer
to Floor Shift Control Replacement in Automatic
Transmssion-4L60E.
60. Remove the transmission control, if equipped.
Refer to Control Assembly in Manual
Transmission-M49.
61. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

346041

62. Remove the right and left lower shock bolts from
the lower control arms.
63. Remove the cotter pins and nuts from the left and
right upper ball joints.
64. Using J 39549 separate the upper control arms
from the steering knuckles.
65. Support both steering knuckles.
66. Position the J 39580 below the vehicle.
67. Lower the vehicle.
68. Lay the engine wire harness on top of the engine.

220629

69. Remove the front crossmember bolts.

220632

6-128

Engine Mechanical - 3.SL

Engine
70. Remove the transmission support bolts.
71. Raise the vehicle and remove the engine and
transmission from the vehicle.
72. Secure the crossmember to the J 39580.

208587

73. Position a hex-head socket on the belt tensioner

pulley bolt.
74. Rotate the drive belt tensioner (2) clockwise to
relieve the tension on the drive belt (1 ).
75. Remove the drive belt (1) from the tensioner (2)
and pulleys.

41363

76. Remove the A/C compressor rear bolts (2, 3).

77. Remove the A/C compressor rear bracket
stud (1 ).
78. Remove the A/C compressor rear bracket.

365440

i
\

Engine

Engine Mechanical - 3.8L

6-129

79. Remove the A/C compressor bolts.

80. Remove the A/C compressor.

282953

81. Remove the drive belt tensioner bolts.

82. Remove the drive belt tensioner.

35804

83. Remove the power steering pump nuts (3).

84. Reposition the power steering pump to
crossmember.

290569

6-130

Engine Mechanical - 3.8L

Engine
85. Disconnect the generator electrical connector.

---- \ ----

211637

86. Remove the positive cable nut from the generator

terminal.
87. Remove the generator from the engine.
88. Install a lifting devise to the engine.

43670

89. Remove the right engine mount bracket

bolts (1, 2) and the right engine mount bracket (3).

50517

Engine Mechanical - 3.8L

Engine

'\
.I

a. 131

90. Remove the left engine mount bracket bolts (3).

91. Remove the left engine mount bracket stud (2)
and the left engine mount bracket (1).
92. With the aide of an assistant, raise the engine
and transmission from the crossmember.
93. If equipped with the automatic transmission
remove the following:

50546

94. Right side transmission support brace

bolts (1, 2, 3).
95. Right side transmission support nut (6).
96. Right side transmission support (4).

208574

97. Left side transmission support brace bolts (3, 5).

98. Left side transmission support nut (1).
99. Left side transmission support (4).
100. Remove the torque converter cover (2).

208577

6-132

Engine Mechanical - 3.8L

Engine
101. Remove the flywheel to torque converter bolts.
102. If equipped with the man'ual transmission remove
the following:

208580

103. Right srde transmission support bolts (3, 4).

104. Right side transmission support (1).

448855

105. Left side.transmission support bolts (2, 3).

106. Left side transmission support (1 ).
107. Disconnect the electrical connectors from the
transmission.

349561

Engine

Engine Mechanical - 3.SL

6-133

108. For the automatic transmission, remove the

transmission to engine bolts and nut.
109. Separate the transmission from the engine.
110. Attach the J 21366 the transmission.

208594

111. For the manual transmission, remove the

flywheel housing to engine bolts (1, 2) and
nuts (3).
112. Separate the flywheel housing from the engine.

441492

113. For the manual transmission, remove the

pressure plate bolts (1).
114. Remove the pressure plate (2) and the clutch
disc (6) from the flywheel (5).

6
441865

6-134

Engine Mechanical - 3.8L

Engine
115. For the automatic transmission, remove the
flywheel bolts (1) and flywheel (2).

441271

116. For the manual transmission, remove the

flywheel bolts ( 1) and flywheel (2).
117. Install the engine to a engine stand.

441112

Installation Procedure
Tools Required
J 36660 Torque Angle Meter
1. Install engine lifting devise and remove engine
from stand.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. For the manual transmission, install the
flywheel (2) and flywheel bolts (1).

Tighten
Tighten the flywheel bolts (1) to 15 N-m (11 lb ft).
Using J 36660 tighten the flywheel bolts an
additional 50 degrees.

441112

Engine

Engine Mechanical - 3.8L

6-135

3. For the automatic transmission, install the

flywheel (2) and flywheel bolts (1 ).

Tighten
Tighten the flywheel bolts (1) to 15 N-m (11 lb ft).
Using J 36660 tighten the flywheel bolts. an
additional 50 degrees.
4. For the manual transmission, install the clutch
disc and pressure plate to the flywheel.
5. Install the pressure plate bolts.
Tighten
Tighten the pressure plate bolts to 20 N-m
(15 lb ft). Using J 36660 tighten the pressure plate
bolts an additional 45 degrees.
6. Align the flywheel housing to the engine.

441271

7. For the manual transmission, install the flywheel

housing to engine bolts (1, 2) and nuts (3).
Tighten
Tighten the flywheel housing to engine bolts (1, 2)
and nuts (3) to 95 N-m (70 lb ft).
8. if P.quipped with a automatic transmission remove
the J 21366 from the transmission.

441492

6-136

Engine Mechanical - 3.SL

Engine
9. For the automatic transmission, install the
transmission to engine bolts and nut.
Tighten
Tighten the transmission to engine bolts and nut
to 95 N-m (70 lb ft).
10. Connect the electrical connectors to the
transmission.
11 . If equipped with the manual transmission install
the following:

208594

12. Left side transmission support (1).

13. Left side transmission support brace bolts (2, 3).
Tighten
Tighten the left side transmission support
brace bolts (2) to 50 N-m (37 lb ft).
Tighten the left side transmission support
brace bolts (3) to 28 N-m (21 lb ft).

349561

14. Right side transmission support (1).

15. Right side transmission support brace bolts (3, 4).
Tighten
Tighten the right side transmission support brace
bolts (3, 4) to 50 N-m (37 lb ft).
16. If equipped with the automatic transmission install
the following:

448855

Engine

Engine Mechanical - 3.SL

6-137

17. Install the torque converter to flywheel bolts.

Tighten
Tighten the torque converter to flywheel bolts to
63 N,m (47 lb ft).

208580

18. Install the torque converter cover (2).

19. Left side transmission support(<!!-).
20. Left side transmission support bolts (3, 5).
21. Left side transmission support nut (1 ):

Tighten
Tighten the left side transmission support
bolts (3) to 8.5 Nm (75 lb in).
Tighten the left side transmission support
bolts (5) to 28 Nm (21 lb ft).
Tighten the left side support nut (1) to
80 Nm (59 lb ft).

4
208577

22. Right side transmission support (4).

23. Right side transmission support brace
bolts (1, 2, 3).

24. Right side transmission support nut (6).

Tighten
Tighten the right side transmission support
brace bolts (1) to 8.5 Nm (75 lb in).
Tighten the right side transmission support
bolts (2, 3) to 50 N,m (37 lb ft).
Tighten the right side support nut (6) to
80 Nm (59 lb ft).
25. With the aide of an assistant, lower the engine
and transmission to the crossmember.

208574

6-138

Engine Mechanical - 3.8L

Engine
26. Install the left engine mount bracket (1) and
mount bracket stud (2).
27. Install the left engine mount bracket bolts (3).

Tighten
Tighten the left engine mount bracket bolts (3)
to 100 N-m (74 lb ft).
Tighten the left engine mount bracket stud (2)
to 87 N-m (64 lb ft).

50546

28. Install the right engine mount bracket (3) and the
engine mount bracket bolts (1, 2).

Tighten
Tighten the two right engine mount bracket
bolts (1) to 100 N-m (74 lb ft).
Tighten the right engine mount bracket bolt (2)
to 50 N-m (37 lb ft).
29. Remove the lifting devise from the engine.

50517

30. Install the generator to the engine.

31. Install the positive cable nut to the generator
terminal.

Tighten
Tighten the positive cable nut to generator
terminal to 22 N-m (16 lb ft)

\.

43670

Engine
32. Connect the generator electrical connector.

Engine Mechanical - 3.SL

---

6-139

---

211637

33. Install the power steering pump.

34. Install the power steering pump nuts (3).

Tighten
Tighten the power steering nuts (3) to
30 N-m (22 lb ft).

290569

35. Install the drive belt tensioner.

36. Install the drive belt tensioner bolts.
Tighten
Tighten the drive belt tensioner bolts to
50 N-m (37 lb ft).

35804

6-140

Engine

Engine Mechanical - 3.8L

37. Install the A/C compressor.
38. Install the A/C compressor bolts.
Tighten
Tighten the A/C compressor bolts to
50 N,m (37 lb ft).

\.

282953

39. Install the A/C compressor rear bracket.

40. Install the A/C compressor rear bracket stud (1).

41. Install the A/C compressor rear bolts (2, 3).

Tighten
Tighten the A/C compressor rear bracket
stud (1) to 50 Nm (37 lb ft).
Tighten the A/C compressor rear bolts (2, 3) to
30 Nm (22 lb ft).

(
\

365440

42. Route the drive belt (1) around the pulleys.

43. Position a hex-head socket on the belt tensioner
pulley bolt.
44. Rotate the drive belt tensioner (2) clockwise to
relieve the tension on the drive belt (1 ).
45. Install the drive belt (1) onto the tensioner (2).
46. Remove the crossmember to the J 39580 security
straps.
47. Lower the vehicle and install the engine and
transmission to the vehicle.
48. Align the crossmember to the vehicle body.

\.

41363

Engine

Engine Mechanical - 3.SL

6-141

49. Install the front crossmember bolts.

Tighten
Tighten the upper four cradle bolts to
125 N-m (92 lb ft).
Tighten the lower two cradle bolts to
145 N-m (107 lb ft).

t
220632

50. Install the transmission support bolts.

51.

52.
53.
54.

Tighten
Tighten the transmission support bolts to
57 N-m (42 lb ft).
Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
Remove the J 39580 from below the vehicle.
Remove the supports from both steering knuckles.
Connect the ball stud to the steering knuckle.

208587

55. Install the nuts and cotter pins to the left and right
upper ball joints.
Tighten
Tighten the upper ball joint nuts to
53 N-m (39 lb ft).
56. Install the right and left lower shock bolts to the
lower control arms.
Tighten
Tighten the shock bolts to 65 N-m (48 lb ft).
57. Lower the vehicle.
58. Install the transmission control, if equipped. Refer
to Control Assembly in Manual Transmission-M49.
59. Install the floor shift control, if equipped. Refer to
Floor Shift Control Replacement in Automatic
Transmssion-4L60E.

220629

6-142

Engine Mechanical - 3.8L

Engine
60. Install the engine wire harness through the front
of dash.

346041

61. Connect the engine wiring harness to the

instrument panel wiring harness.
62. Install the hinge pillar trim panel.
63. Install the right side insulator panel.

346039

64. Install the PCM to the vehicle.

65. Connect the powertrain control module (PCM)
connectors.

346043

Engine

Engine Mechanical - 3.SL

6-143

66. Connect the engine harness vacuum tube from

the bottom of the vacuum check valve.
67. Connect the forward lamp harness from the
engine harness.
68. Connect the secondary captured locks.
69. Install the front two brake pipes to the brake
modulator.

346047

70. Install the brake booster vacuum hose (2) to the

intake manifold fitting (1 ).

439407

71. install the outlet hose to the water pump.

221689

6-144

Engine Mechanical - 3.8L

Engine
72. Install the inlet hose to the water outlet.

221680

73. Install the accelerator control cable bracket (2)

and bolts (1 ).
Tighten
Tighten the accelerator control cable bracket
bolts (1) to 16 Nm {12 lb ft).

444135

74. Install the accelerator control and cruise control

cables to the throttle body and bracket.

296581

Engine

Engine Mechanical - 3.8L

6-145

75. Connect the EVAP pipe (6) at the engine.

76. Connect the fuel return pipe (2) to the fuel rail.
77. Connect the fuel feed pipe (1} to the fuel rail.

215517

78. Install the heater hoses to the drive belt tensioner.

282933

79. Install a new 0-ring.

80. Install the A/C compressor and condenser hose

bolt at the accumulator.
Tighten
Tighten the A/C compressor and condenser hose
bolt at the accumulator to 48 Nm (36 lb ft}.

282936

6-146

Engine Mechanical - 3.SL

Engine
81. Install the engine ground.
82. Install the engine wiring harness ground bolt (1 ).

Tighten
Tighten the engine wiring harness ground bolt (1)
to 25 N-m (18 lb ft).

83. Raise and suitably support the vehicle. Refer to

Lifting and Jacking the Vehicle in General
Information.
84. Connect the brake lines to the brake pipe clip.

445688

85. Install the front fuel pipe heat shield (2).

86. Install the front fuel pipe heat shield nuts (1 ).
Tighten
Tighten the front fuel pipe heat shield nuts (1) to
5 N,m (44 lb in).

7~

173551

87. Install a new 0-ring.

88. Install the A/C compressor and condenser hose
nut at the condenser.
Tighten
Tighten the A/C compressor and condenser hose
nut at the condenser to 16 Nm (12 lb ft).

365450

Engine

Engine Mechanical - 3.SL

6-147

89. Install a new 0-ring.

90. Install the A/C compressor and condenser
hose bolt.

Tighten
Tighten the A/C compressor and condenser hose
bolt to 33 N-m (24 lb ft).

365423

91. Connect the wheel speed sensors electrical

connectors.

92. Connect the knock sensors electrical connectors.

\
)

346036

93. Install the RF (Radio Frequency) ground strap,

cruise control ground lead and wiring harness
ground bolt to the front rail.

Tighten
Tighten the wiring harness ground bolt to
12 N-m (106 lb in).

346034

6-148

Engine Mechanical - 3.BL

Engine
94. Install the intermediate steering shaft and bolt to
the rack.
Tighten
Tighten the intermediate shaft bolt to
47 N-m (35 lb ft).

95. Install the steering gear coupling shield.

96. Install the stabilizer bar brackets.
97. Install the stabilizer bar bracket bolts.
Tighten
Tighten the stabilizer bar bolts to 55 N-m (41 lb ft).
98. Install the left side front air deflector.

220630

99. On vehicles equipped with a manual transmission,

connect the clutch actuator cylinder line to the
actuator cylinder.

43255

100. On vehicles equipped with a automatic

transmission, Install the range selector lever
cable to the cable bracket.

208276

Engine

Engine Mechanical - .3.BL

6-1'49

101. Install the retainer to the range selector

lever cable.

"1]
I

341079

102. Snap the transmission range selector lever cable

to the range selector lever at the transmission.
103. Install the starter motor. Refer to Starter Motor
Replacement (3.BL V6) in Engine Electrical.
104. Install the torque arm. Refer to Torque Arm
Replacement in Rear Suspension.
105. Install the propeller shaft. Refer to. Propeller
Shaft Replacement - One Piece or Propeller
Shaft Replacement - Two Piece in
Propeller Shaft.
106. Install the 3-way catalytic converter. Refer to
Catalytic Converter Replacement in Engine
Exhaust.
107. Install the front wheels. Refer to Wheel
Installation in Tires and Wheels.
108. Lower the vehicle.

208264

109. Install the air intake duct.

208572

6-150

Engine Mechanical - 3.8L

Engine
110. Connect the intake air temperature (IAT) sensor
electrical connector.

208554

111.
112.
113.
114.

Connect the positive battery cable.

Refill the engine oil.
Refill the transmission fluid.
Refill the engine coolant. Refer to Draining and
Filling Cooling System (V6) in Engine Cooling.
115. Recharge the refrigerant. Refer to Refrigerant
Recovery and Recharging in HVAC Systems
with A/C-Manual.
116. Bleed the brakes. Refer to Hydraulic Brake
System Bleeding (Manual Bleed) or Hydraulic
Brake System Bleeding (Pressure Bleed)
in Hydraulic Brakes.
117. Bleed the clutch hydraulic system. Refer to
Hydraulic Clutch Bleeding in Clutch.

211587

118. Connect the negative battery cable. Refer to

Battery Negative Cable Disconnect/Connect
Procedure in Engine Electrical.

208241

Engine

Engine Mechanical - 3.SL

6-151

Engine Oil and Oil Filter Replacement

Removal Procedure
\

1. Raise and suitably support the vehicle. Refer to

Lifting and Jacking the Vehicle in General
Information.
2. Position the oil drain pan under the engine oil
drain plug.
3. Remove the engine oil drain plug.
4. Clean and inspect the engine oil drain plug,
replace if necessary.
5. Clean and inspect the engine oil drain plug
sealing surface on the oil pan, repair or replace oil
pan if necessary. Refer to Oil Pan Replacement.

190564

6. Remove the oil filter.

7. Clean and inspect the oil filter sealing area on the
oil filter adapter, repair or replace the oil filter
adapter if necessary. Refer to Oil Filter Adapter
and Valve Assembly Replacement.

440847

Installation Procedure
1. Lightly oil the replacement oil filter gasket with
clean oil and install the new oil filter.

Notice: Refer to Fastener Notice in Cautions and

Notices.
2. Install the new oil filter.
Tighten
Tighten the new oil filter to 30 Nm (22 lb ft).

@l)___

440847

6-152

Engine Mechanical .. 3.8L

Engine
3. Install the engin~ oil drain plug.
Tighten
Tighten the engine oil drain plug to
30 N,m (22 lb ft).
.

190564

4. Remove the oil drain pan.

5. Lower the vehicle.
6. Fill the engine with new engine oil. Refer to
Approximate Fluid Capacities and Fluid and
Lubricant Recommendations in Maintenance and
Lubrication.
7. Start the engine.
8. Inspect for oil leaks after engine start up.
9. Turn off the engine and allow the oil a few minutes
to drain back into the oil pan.
10. Remove the oil level indicator from the oil
indicator tube.
11 . Clean off the indicator end of the oil level indicator
with a clean paper towel or cloth.
12. Install the oil level indicator into the oil level
indicator tube until the oil level indicator handle
contacts the top of 1he oil level indicator tube.
13. Again, remove the oil level indicator from the oil
level indicatortube keeping the tip of the oil level
indicator down.
14. Check the level of the engine oil on the oil level
indicator.
15. If necessary, readjust the oil level by adding or
draining the engine oil.

(
I

Draining Fluids and Oil Filter Removal

Draining the Engine
1. Remove the oil drain plug.
2. Drain the engine oil.
3. Remove the oil filter.

192725

Engine

Engine Mechanical - 3.8L

6-153

4. Remove the coolant drain plugs.

5. Drain the coolant.

\I

211914

Engine Flywheel Removal

(Manual Transmission)
1. Remove the flywheel bolts. Discard the bolts.
2. Remove the flywheel.
3. Inspect the flywheel for damage. If the flywheel is
damaged, replace the flywheel.
4. Inspect the crankshaft and flywheel mating
surfaces for burrs. If necessary, replace the
flywheel.

....

.,~

'~

192727

Engine Flywheel Removal

(Automatic Transmission)
1. Remove the flywheel bolts. Discard the bolts.
2. Remove the flywheel.
3. Inspect the flywheel for damage. If the flywheel is
damaged, replace the flywheel.
4. Inspect the crankshaft and flywheel mating
surfaces for burrs. If necessary, replace the
flywheel.

36665

6-154

Engine

Engine Mechanical - 3.8L

Drive Belt Tensioner Removal (VIN K)

1. Remove the drive belt tensioner bolts.
2. Remove the drive belt tensioner.

36693

Oil Level Indicator and Tube Removal

1. Remove the oil level indicator bolt.
2. Remove the oil level indicator.

36615

Water Outlet Removal

1.
2.
3.
4.

36621

Remove
Remove
Remove
Remove

the
the
the
the

water outlet bolts.

water outlet.
water outlet gasket.
thermostat.

Engine Mechanical - 3.8L

Engine

6-155

Water Pump Removal

1. Remove the water pump pulley bolts.
2. Remove the water pump pulley.

36596

3. Remove the water pump bolts.

4. Remove the water pump.
5. Remove the water pump gasket.

36600

Intake Manifold Removal (Upper)

1.
2.
3.
4.

Remove the
Remove the
Remove the
Remove the
manifold.

right spark plug wires.

manifold vacuum source.
EGR outlet pipe bolt and nut.
EGR outlet pipe from the intake

36609

6-156

Engine Mechanical - 3.8L

Engine
Notice: The two bolts which fasten the lower intake
manifold to the cylinder head are accessible only after
the upper intake is removed. The bolts are located
in the right front and left rear corners of the lower
intake manifold. Remove the upper intake manifold to
service the lower intake.

5. Remove the throttle body nuts and bolt.

6. Remove the throttle body.
7. Remove the throttle body gasket.

36624

8. Remove the fuel injectior rail nuts.

9. Remove the fuel injector rail.

36631

10. Remove the upper intake manifold bolts.

11. Remove the upper intak~ manifo~.
12. Remove the upper intake manifold gasket.

36634

Engine

Engine Mechanical - 3.8L

6-157

Intake Manifold Removal (Lower)

1. Remove the lower intake manifold bolts.

Notice: The two bolts which fasten the lower intake

manifold to the cylinder head are accessible only after
the upper intake is removed. The bolts are located
in the right front and left,rear corners of the lower
intake manifold. Remove the upper intake manifold to
service the lower intake.
2. Remove the lower intake manifold.
3. Remove the lower intake manifold gasket.

50046

Exhaust Manifold Removal (Left Side)

1. Disconnect the left heated oxygen sensor,
electrical connector from the wire support bracket.
2. Remove the left heated oxygen sensor.

192720

3. Remove the exhaust manifold heatshield.nuts.

4. Remove the exhaust manifold heats.hield!:i.

..

50755

6-158

Engine

Engine Mechanical - 3.8L

Important: When removing the EGA inlet tube from

the left exhaust manifold, inspect the pipe for leaks
during installation. Replace the EGA adapter
if the pipe leaks.

5. Remove the EGA inlet pipe bolt and nuts.

6. Remove the EGA inlet pipe from the exhaust
manifold.

36618

7. Remove the exhaust manifold nuts.

8. Remove the exhaust manifold.
9. Remove the exhaust manifold gasket.

36635

Exhaust Manifold Removal (Right Side)

1. Remove the right heated oxygen sensor electrical
connector from the lift bracket.
2. Remove the right heated oxygen sensor.

192721

Engine

Engine Mechanical - 3.SL

6-159

3. Remove the exhaust manifold heat shield nuts.

4. Remove the exhaust manifold heat shields.

36638

5. Remove the exhaust manifold nuts.

6. Remove the exhaust manifold.
7. Remove the exhaust manifold gasket.

36652

Valve Rocker Arm Cover Removal

(Left Side)
1. Remove the valve rocker arm cover bolts.
2. Remove the valve rocker arm cover.

35819

6-160

Engine Mechanical - 3.8L

Engine
Valve Rocker Arm Cover Removal
(Right Side)
1. Remove the valve rocker arm cover bolts.
2. Remove the valve rocker arm cover.

63414

Valve Rocker Arm and Push Rod Removal

1. Remove the valve rocker arm bolts.
2. Remove the valve rocker arm.
3. Remove the push rods.

35840

Cylinder Head Removal

1.
2.
3.
4.

35842

Remove the cylinder head bolts.

Discard the cylinder head bolts.
Remove the cylinder head.
Remove the cylinder head gasket.

Engine

Engine Mechanical - 3.8L

6-161

Valve Lifter Removal

1. Remove the valve guide retainer bolts.

2. Remove the valve guide retainers.

3. Remove the valve lifters.

41374

Crankshaft Balancer Removal

Tools Required
J 37096 Flywheel Holding Tool
J 38197 Crankshaft Balancer Puller
1. Use J 37096 to hold the flywheel.
2. Remove the crankshaft balancer bolt.

26141

3. Use the J 38197to remove the crankshaft

balancer.

Important: Do not separate the crankshaft pulley from

the crankshaft balancer. Service the crankshaft
pulley and the crankshaft balancer as an assembly.
3.1 . Invert J 38197-2 so the leg of the tool is
facing away from the crankshaft balancer.
3.2. Install the silver screws J 38197-4 to the
crankshaft balancer.
3.3. Turn J 38197-1 to remove the crankshaft
balancer from the crankshaft.
3.4. Remove J 38197-1, J 38197-2, and
J 38197-4 from the crankshaft balancer.

J 38197

36659

6-162

Engine Mechanical - 3.8L

Engine
Crankshaft Front Oil Seal Removal
Important: Do not damage the seal bore or the
contact surfaces.
Use a screwdriver to pry out the crankshaft front
oil seal.

26135

Engine Front Cover Removal

1. Remove the crankshaft position sensor shield.

35844

2. Remove the crankshaft position sensor studs.

3. Remove the crankshaft position sensor.
4. Remove the bolts connecting the oil pan to the
engine front cover.

36589

Engine Mechanical - 3.SL

Engine

6-163

5. Remove the engine front cover bolts and stud.

6. Remove the engine front cover.
7. Remove the engine front cover gasket.

189850

Oil Filter Adapter Removal

1. Remove the
front cover.
2. Remove the
3. Remove the
4. Remove the
5. Remove the

oil filter adapter bolts from the engine

oil
oil
oil
oil

filter adapter.
filter adapter gasket.
pressure relief valve.
pressure relief valve spring.

36655

Oil Pump Cover and Gear Set Removal

1. Remove the oil pump cover screws.
2. Remove the oil pump cover.
3. Remove the oil pump gears.

26160

6-164

Engine Mechanical - 3.SL

Engine
Timing Chain and Sprockets
Removal (VINK)
1. Align the timing marks on the sprockets.

192708

2. Remove the timing chain dampener.

154523

3.
4.
5.
6.

192716

Remove
Remove
Remove
Remove

the
the
the
the

camshaft sprocket bolt.

camshaft sprocket.
timing chain.
crankshaft sprocket.

Engine

Engine Mechanical - 3.8L

6-165

7. Remove the balance shaft drive gear.

\
/

154519

Camshaft Removal
1. Remove the camshaft thrust plate screws.
2. Remove the camshaft thrust plate.
3. Remove the camshaft. Carefully rotate and pull
the camshaft out of the camshaft bearings.

35815

Balance Shaft Removal

Tools Required
J 6125-18 Slide Hammer
1. Remove the balance shaft driven gear bolt.
2. Remove the balance shaft driven gear.

154521

6-166

Engine Mechanical - 3.8L

Engine
3. Remove the balance shaft retainer bolts.
4. Remove the balance shaft retainer.

42237

5. Use J 6125-18 to remove the balance shaft.

J 6125-18

36705

Crankshaft Rear Oil Seal Removal

Important: Do not damage the crankshaft or the
crankshaft rear oil seal housing.
Pry the crankshaft rear oil seal out with a screwdriver.

26129

Engine

Engine Mechanical - 3.8L

6-167

Crankshaft Rear Oil Seal and Housing

Removal
1. Remove the crankshaft rear oil seal housing bolts.
The bolts may remain in the crankshaft rear oil
seal housing.
2. Remove the crankshaft rear oil seal housing.

26125

Oil Pan Removal

Notice: Remove the oil level sensor, located in the oil
pan, before the oil pan is removed. The sensor
may be damaged if the oil pan is removed first.
1. Remove the oil level sensor.

35861

2. Remove the oil pan bolts.

3. Remove the oil pan.
4. Remove the oil pan gasket.

44775

6-168

Engine Mechanical - 3.8L

Engine
Oil Pump Pipe and Screen
Assembly Removal
1. Remove the oil pump pipe and screen
assembly bolts.
2. Remove the oil pump pipe and screen assembly.
3. Remove the oil pump pipe and screen assembly
gasket.
4. Use solvent to clean the oil pump pipe and
screen.

26202

Piston, Connecting Rod, and Bearing

Removal
Tools Required
J 41507 Connecting Rod Assembly Guide
1. Mark the connecting rod cap and the connecting
rod for proper installation.
2. Remove the connecting rod bolts.
3. Remove the connecting rod cap.

38153

4. Install J 41507to the connecting rod. Hand

tighten the tool to the connecting rod.
5. Use hand pressure on J 41507 to push the
connecting rod towards the top of the cylinder.
Important: Remove any carbon or ridge at the top of
the cylinder bore to avoid damaging the piston ring
lands. Mark the piston with the number of the cylinder
from which it was removed. Mark the piston as to
what is the front for proper reassembly.
6. Remove the piston, the connecting rod, and the
connecting rod bearings.

38180

Engine

Engine Mechanical - 3.8L

6-169

Crankshaft and Bearings Removal

')

Tools Required
J6125-18 Slide Hammer
J41348 Main Bearing Cap Puller
Important: This engine has side bolts on all of the
main caps except the rear cap. These bolts must be
removed to service the caps.
1. Remove the crankshaft main bearing cap
side bolts.
2. Remove the crankshaft main bearing cap bolts.

35863

Notice: Main bearing caps are press fit. Remove the

caps carefully for service. J 41348 has been designed
to work with J 6125-B in order to prevent damage
to the bearing and cap. J 41348 MUST be installed
properly into the bolt holes of the caps and J 6125-B
attached to J 41348 in order to properly remove
the main cap without damaging the bearing or the
cap. Any deviation from this procedure may cause
damage to the cap and the bearing and may result in
future engine damage.

J 6125-18

Notice: Refer to Fastener Notice in Cautions and

Notices.
3. Install J 41348 into the crankshaft main bearing
cap bolt holes.
Tighten
Tighten the bolts on J 41348 to 12 N-m (100 lb in).
4. Install J 6125-18 to J 41348.
5. Use J 6125-1 B to remove the crankshaft main
bearing cap.
6. Remove the crankshaft.

36704

35863

6-170

Engine Mechanical - 3.8L

Engine
Engine Block Plug Removal
1. Remove the threaded coolant jacket plugs.

192728

2. Remove the remaining plugs using the following

procedure.
2.1. Obtain a suitable self-threading screw.
2.2. Drill a hole into the plug.
2.3. Install the self-threading screw.
2.4. Use the screw to pry out the plug.

26198

Engine Block Clean and Inspect

Tools Required
J 8087 Cylinder Bore Checking Gauge
J 8001 Dial Indicator Set
1. Clean the sealing material from the gasket mating
surfaces.
2. Boil the engine block in caustic solution.
3. Flush the engine block with clean water or steam.
4. Clean the oil passages.
5. Clean the blind holes.
6. Spray the cylinder bores and the machined
surfaces with engine oil.
7. Inspect the threaded holes. Clean the holes with a
tap. If necessary, drill out the holes and install
thread inserts. Refer to Thread Repair.
5272

Engine

Engine Mechanical - 3.8L

6-171

8. Use a straight edge and a feeler gage to check

the deck surface for flatness. Carefully machine
minor irregularities. Replace the block if more
than 0.254 mm (0.01 O in) must be removed.
9. Inspect the oil pan rail for nicks. Inspect the front
cover attaching area for nicks. Use a flat mill file
to remove any nicks.
10. Inspect the mating surfaces of the
transmission case.

Notice: A broken flywheel may result if the

transmission case mating surface is not flat.
11 . Use the following procedure to measure the
engine block flange runout at the six mounting bolt
hole bosses:
11.1. Temporarily install the crankshaft. Measure
the crankshaft flange runout.
11 .2. Hold the gauge plate flat against the
crankshaft flange.
11.3. Place J 8001 on the transmission mounting
bolt hole boss. Set the indicator to 0.
11 .4. Record the readings obtained from
all of the bolt hole bosses. The
measurements should not vary more
than 0.254 mm (0.010 in).
11.5. Recheck the crankshaft flange
runout if the readings vary more
than 0.254 mm (0.010 in).
12. Inspect the crankshaft main bearing bores. Use
J 8087 to measure the bearing bore concentricity
and alignment at the following locations:
The camshaft
The crankshaft

J 8001

38648

(j

Important: Recondition the engine block with the

crankshaft main bearing caps and the crankshaft main
bearing cap side bolts installed and tightened to
specification.
13. Ensure that the crankshaft main bearing caps are
installed correctly. The arrows should point toward
the front of the engine.
14. Replace the engine block if the bores are out of
specification.

38663

6-172

Engine Mechanical - 3.8L

Engine
15. Use J 8087 to inspect the cylinder bores. Inspect
for the following items:

J 8087

Wear
Taper
Run-out
Ridging

Important: If the bore is worn beyond the limits; refit

the bore with oversized pistons. Select the smallest
available oversize piston. Refer to Piston Selection.
16. Leave sufficient material to allow honing when
fitting the piston.

38662

Cylinder Boring and Honing

Boring Procedure
1. Before honing or boring, measure all of the new
pistons. Select the smallest piston for the piston
fitting. Slightly varied pistons in a set may provide
correction, if the first piston is too loosely fitted.
2. Before using any type of boring bar, file the top of
the engine block to remove any dirt or burrs. If the
cylinder block is not straight, the boring bar may
be tilted, causing the bored cylinder wall to
have incorrect right angles to the crankshaft.
3. Carefully follow the instructions furnished by the
manufacturer regarding use of equipment.
4. Install all crankshaft main bearing caps to
specification when boring cylinders. Cover or tape
the crankshaft bearings and other internal parts
to. protect these parts during the boring or honing
operation.
5. Leave 0.03 mm (0.001 in) on the diameter for
finish honing when performing the final cut with
a boring bar. Carefully perform the honing
and boring operation to maintain the specified
clearances between pistons, rings, and
cylinder bores.

Honing Procedure
1. Follow the manufacturer's recommendations for
use, cleaning, and lubrication when honing the
cylinders. Use only clean, sharp stones of
the proper grade for the amount of material to be
removed. Dull, dirty stones cut unevenly and
generate excessive heat. When using coarse or
medium-grade stones, leave sufficient metal so all
stone marks may be removed with the fine
stones used for finishing to provide the proper
clearance.
2. During the honing operation, thoroughly clean the
cylinder bore. Check for the correct piston fit.

Engine

Engine Mechanical - 3.SL

6-173

3. Make full strokes in the cylinder to eliminate taper.

Repeatedly check the measurement at the top,
the middle, and the bottom of the cylinder bore.
\

Notice: Handle the pistons with care. Do not force the

pistons through the cylinder until you hone the
cylinder to the correct size. The piston can be distorted
through careless handling.

Important: The finish marks should be clean but not

sharp. The finish marks should be free from
imbedded particles and torn or folded metal.
4. When finish honing a cylinder bore to fit a piston,
move the hone up and down at a sufficient speed
to obtain a fine and uniform surface finish in a
cross hatch pattern.
5. Determine the finish hone cylinder measurement
by measuring the piston to be installed, and by
adding the average of the clearance specification.
Measure the block and the piston at normal
room temperature.
6. True up the refinished cylinder bores. Final hone
each cylinder bore to remove all stone or
cutter marks.
7. After final honing and before the piston is checked
for fit, clean the bores with hot water and
detergent. Scrub the bores with a stiff bristle
brush and rinse the bores thoroughly with
hot water. Do not allow any abrasive material to
remain in the cylinder bores. This abrasive
material will wear the new rings, the cylinder
bores, and the bearings lubricated by the
contaminated oil. After washing dry the bore.
8. Permanently mark the piston for the cylinder to
which the piston has been fitted.
9. Apply clean engine oil to each bore to prevent
rusting.

Crankshaft and Bearings Clean

and Inspect
Cleaning and Inspection
Tools Required
J 36660 Torque Angle Meter
J 8087 Cylinder Bore Checking Gauge
1. Clean the crankshaft of the following elements:

Oil
Sludge
Carbon
2. Inspect the crankshaft oil passages for
obstructions.
3. Inspect the crankshaft keyway for nicks or wear.
4. Inspect the crankshaft threads.

~~

~~
~~
26122

6-174

Engine

Engine Mechanical - 3.8L

Important: If cracks, severe gouges or burned spots

are found, the crankshaft must be replaced. Slight
roughness may be removed with a fine polishing cloth
soaked in clean engine oil. Burrs may be removed
with a fine oil stone.
5. Inspect the crankshaft bearing journals and the
crankshaft thrust surfaces for the following
conditions:
Cracks
Chips
Gouges
Roughness
Grooves
Overheating (discoloration)
6. Inspect the corresponding crankshaft bearings for
embedded foreign material and determine the
source.

Important: Note the location of the crankshaft main

bearing high spots. If they are not in line, the
crankshaft is bent and must be replaced.
7. Inspect the crankshaft bearings for uneven
side-to-side wear. This may indicate a bent
crankshaft or a tapered bearing journal.
Important: The crankshaft bearings are of the
precision insert type. The crankshaft bearings are
available in standard and various undersizes.

0
0

0
0
50027

Notice: Do not scrape, shim, or file bearing inserts. If

the bearing surface of the insert is touched with
bare fingers, the skin oil and acids will etch the bearing
surface.
8. Inspect the outer surfaces of the crankshaft
bearings for the following conditions:
Wear - surface wear indicates either movement
of the insert or high spots in the surrounding
material (spot wear).
Overheating or discoloration
Looseness or rotation indicated by flattened
tangs and wear grooves
9. Inspect the thrust surfaces of the main thrust
bearing for the following conditions:
Wear
Grooving (Grooves are caused by irregularities
of the crankshaft thrust surface.)

Engine
Important: If crankshaft bearing failure is due to other
than normal wear, investigate the cause. Inspect the
crankshaft or connecting rod bearing bores.
1O. Using the J 8087 inspect the connecting rod
bearing bores or crankshaft main bearing
bores using the following procedure:
10.1. Tighten the bearing cap to specification.
10.2. Measure the bearing bore using J 8087 for
taper and out-of-round.
10.3. No taper or out-of-round should exist.

Engine Mechanical - 3.8L

6-175

(j

38663

Bearing Selection
Measure the bearing clearance to determine the
correct replacement bearing insert size. There are two
methods to measure bearing clearance. Method A
gives more reliable results and is preferred.
Method A yields measurement from which the
bearing clearance can be computed.
Method B yields the bearing clearance directly.
Method B does not give any indication of
bearing run-out.
Method A
Important: Do not mix inserts of different nominal size
in the same bearing bore.

1. Measure the crankshaft bearing journal diameter

with a micrometer in several places, 90 degrees
apart. Average the measurements.
2. Measure the crankshaft bearing journal taper and
run out.
3. Install the crankshaft bearing inserts. Tighten the
bearing cap bolts to specification.
4. Measure the connecting rod inside diameter in the
same direction as the length of the rod with an
inside micrometer.
5. Measure the crankshaft main bearing inside
diameter with an inside micrometer.
6. Select a set of bearing inserts that will produce
the desired clearance.
7. If the specified clearances cannot be met, the
crankshaft journals must be reconditioned and
undersized bearing inserts installed.

5265

6-176

Engine

Engine Mechanical - 3.8L

Method B

Important: Do not mix inserts of different nominal size

in the same bearing bore.
1. Clean the used bearing inserts.
2. Install the used bearing inserts.
3. Place a piece of gaging plastic across the entire
bearing width.
4. Install the bearing caps.

Notice: In order to prevent the possibility of cylinder

block or crankshaft bearing cap damage, the
crankshaft bearing caps are tapped into the cylinder
block cavity using a brass, lead, or a leather mallet
before the attaching bolts are installed. Do not
use attaching bolts to pull the crankshaft bearing caps
into the seats. Failure to use this process may
damage a cylinder block or a bearing cap.
5. Install the bearing cap bolts to specification.
498 1

Important: Do not rotate the crankshaft.

6. Remove the bearing cap, leaving the gaging
plastic in place. It does not matter whether the
gaging plastic adheres to the journal or to the
bearing cap.
7. Measure the gaging plastic at its widest point with
the scale printed on the gaging plastic package.
8. Remove the gaging plastic.
9. Select a set of bearing inserts that will produce
the desired clearance.

Crankshaft Balancer Clean and Inspect

Inspect the crankshaft balancer for damage.
Inspect the outside of the crankshaft balancer
mounting shaft for grooves.
Replace the crankshaft balancer if grooves are
present and appear to be causing an oil leak.

187020

Engine

Engine Mechanical - 3.SL 6-177

Engine Flywheel Clean and Inspect

{Automatic Transmission)

Clean the flywheel.

Inspect the engine flywheel for damage and
cracks.
Inspect the engine flywheel ring gear for
damaged teeth.
Replace the flywheel if any damage is found.

187014

Engine Flywheel Clean and Inspect

{Manual Transmission)
Clean the flywheel.
Inspect the engine flywheel for damage and
cracks.
Inspect the engine flywheel ring gear for
damaged teeth.
Replace the flywheel if any damage is found.

427582

Piston and Connecting Rod Disassemble

Caution: Handle the piston carefully. Worn piston
rings are sharp and may cause bodily injury.
1. Remove the piston rings. Use a suitable tool to
expand the rings. Piston rings must not be
reused.

4977

6-178

Engine

Engine Mechanical - 3.8L

Important: Two retainers hold the piston pins in

place. Reuse the retainers if they are not damaged.
Ensure the piston pin is not damaged.

2. Remove the piston pin retaining clips.

3. Remove the piston pin.

35866

Piston, Connecting Rod and Bearings

Clean/Inspect
Caution: Bodily injury may occur if the carburetor
cleaning fluid is exposed to the skin or if the
fumes are inhaled.
1. Clean the sludge and carbon from the following
components:
The piston
The piston pin
The connecting rod
Notice: Do not cut the ring groove with a file or a
rough edged tool. Good performance and durability
depends on the straightness and smoothness of
the ring groove.
2. Clean the piston ring grooves of all carbon.

35866

Important: Do not scrape the piston skirt. Do not mark

or score the sides of the ring groove.
3. Soak the piston pin in carburetor cleaning solution
to remove varnish.

Engine

Engine Mechanical - 3.SL

6-179

4. Use the following procedure to inspect the

connecting rod for bending or twisting.
4.1. Install the connecting rod cap and bolts.
Tighten to specifications.
4.2. Place the connecting rod assembly on a
checking fixture and check for bending or
twisting.
4.3. Replace the connecting rod if bent more
than 0.127 mm (0.010 in).
4.4. Check new connecting rods before use.

156169

5. Inspect the outside of the connecting rod bearing

and the inside diameter of the connecting rod
bearing joumal for wear indicating high spots.

156167

6. Check the connecting rod cap bolts for stretch

(compare to known good bolt). (1) is a stretched
bolt, (2) is a new or good bolt.

~-f~'~~--L{l~l(~ltIT~O~ll~~l~!{!~!m
2

~-~-(~~_.......((~[((~(({~((~(~~(~!(.-!{(D

187037

6-180

Engine Mechanical - 3.SL

Engine
7. Inspect the piston for the following conditions:
Scoring of the skirt (2)
Cracks
Broken ring groove lands
. Wear (1)
8. Inspect the upper end of the connecting rod for
scoring.
9. Inspect the piston pin area.for the follovying
conditions:
Scoring (3)
Galling caused by improper installation (3)
Fit in the connecting rod and piston

3
156168

Piston Selection
1 . Measure the piston diameter. Remove the piston
pin to measure the piston for size arid taper.
2. Replace the piston with a standard or an oversized
piston if the piston is damaged.

4988

Important: Consider both the piston condition and the

cylinder bore condition when fitting the pistons.
Production and service pistons have the same nominal
weight. Production and service pistons can be
intermixed without affecting the engine balance. If
necessary, fit used pistons to any cylinder of the
engine. Ensure that the pistons are in good condition.
3. Measure the cylinder bore. If the cylinder bore
is worn beyond specifications, rebore the
cylinder bore. Use the following procedure to
hone the cylinder bore to the correct size:
3.1. Select a piston.
3.2. Hone the cylinder bore to obtain the
recommended clearance.
3..3. Scrub the cylinder bore and the piston with
soap and water. Remove all foreign
material. Dry the cylinder bore. Rub clean
engine oil into the cylinder bore.

Engine

4. Use the following procedure to measure

piston-to-cylinder bore .clearance:
4.1. Measure the cylinder bore with a
telescoping gauge. If the cylinder bore is
damaged, rebore or hone the cylinder bore
to size.
4.2. Subtract the piston diameter from the
cylinder bore diameter to determine the
piston-to-bore clearance.
4.3. Compare the piston-to-bore clearance with
the specifications to determine if the
clearance is within the acceptable range.
5. If the used piston is not within the acceptable
clearance range, check the service piston sizes
to determine if a new piston can be selected.
Service pistons are available in standard
and 0.508 mm (0.020 in) oversize.
6. If the cylinder bore needs reconditioning, measure
the new piston diameter and hone the cylinder
bore to the correct clearance.
7. Select a new piston. Mark the piston to identify
the corresponding cylinder.
8. Select a set of new piston rings.
9. Place each ring, one at a time, into the
corresponding cylinder.
10. Place the piston for that cylinder, upside' down
(top of the piston pushing on the ring). Push the
ring down to the bottom of the ring. travel.
11. Remove the piston.

Engine Mechanical .. 3.SL 6-181

4987

4967

6-182

Engine Mechanical 3.SL

Engine
12. Measure the ring gap.
13. If the ring gap is not within an acceptable
specification range, increase the ring gap. Do this
by filing any excess material from the ends of
the ring.

4968

14. Measure the piston ring side clearance

(compression rings).
Notice: Do not cut the ring groove with a file or a
rough edged tool. Good performance and durability
depends on the straightness and smoothness of
the ring groove.
15. Use the following procedure to measure piston
compression ring side clearance:
15.1. Roll the piston ring around the groove.
15.2. Measure the side clearance.
15.3. If the ring is too tight, check for nicks
or burrs.
Use emery cloth to remove burrs.
15.4. Determine if the ring is within
specifications. If necessary, replace
the ring.

22934

Piston and Connecting Rod Assemble

1. Coat the piston pin with oil.
2. Install one piston pin retainer into the retaining
groove.
3. Install the connecting rod and piston pin. The
connecting rod can be installed in either
direction. Push the piston pin in until it bottoms
against the installed piston pin retainer.
4. Install the second piston pin retainer.
5. Ensure the piston pin moves freely.

Important: To provide an effective compression seal,

the ring gaps must be staggered.

35866

Engine Mechanical - 3.8L

Engine

6-183

Notice: Use a piston ring expander to install the

piston rings. The rings may be damaged if expanded
more than necessary.

\I

6. Install the following components of the bottom ring

assembly (oil control ring):
6.1. The expander
6.2. The lower oil control ring
6.3. The upper oil control ring

4977

7. Install the middle ring (compression ring) with the

manufacturer's mark facing up.
8. Install the top ring (compression ring).

4967

Camshaft Bearing Removal

Tools Required
J 33049 Camshaft Bearing Remover/Installer
1. Select the expander assembly and driving washer.
2. Assemble J 33049.

15~

t14 ~1
tJ--13

a-12

@)-""'

00--11

4~3

rm @sO)

@]})

@!
10

@.ID
8

@(
66100

6-184

Engine

Engine. Mechanical - 3.SL

3. Drive out the camshaft bearings.

35815

Camshaft and Bearings Clean and Inspect

Tools Required
J 7872 Magnetic Base Indicator Set
1. Measure the camshaft journals with a micrometer.
If the camshaft journals are not within
specifications, replace the camshaft. Refer to
Engine Mechanical Specifications.

35212

2. Measure the camshaft runout using J 7872.

2.1. Mount the camshaft in V-blocks between
centers.
2.2. Use J 7872 to check the intermediate
camshaft journal.
3. If the runout exceeds specifications, the camshaft
is bent and should be replaced. Refer to Engine
Mechanical Specifications.

J 7872

35211

Engine Mechanical - 3.SL

Engine

6-185

Camshaft Bearing Installation

i
I

Tools Required
J 33049 Camshaft Bearing Installer
1. Select the camshaft bearings.

35815

2. Use the following procedure to install the camshaft

bearings:
2.1. Assemble J 33049 according to the
manufacturer's instructions.
2.2. Place the bearing on the tool.

15~

Notice: Severe engine damage may result if the oil

holes are not correctly aligned.
2.3. Index the bearing oil holes with the engine
block oil passages.

10

66100

Timing Chain and Sprockets Clean and

Inspect {VIN K)
1. Inspect the timing chain and sprockets for
damage.
2. Inspect the timing chain for overall in and out
movement. Movement should not exceed
25 mm (1 in).
3. Inspect the sprockets for wear.

192708

6-186

Engine Mechanical - 3.8L

Engine
Valve Rocker Arm and Push Rods Clean
and Inspect
Inspect the valve rocker arms and balls at the
mating surfaces. These surfaces should be
smooth and free of scoring or other damage.
Inspect the valve rocker arm pushrod sockets and
valve stem mating surfaces. These surfaces
should be smooth with no scoring or
exceptional wear.
Inspect the valve pushrods for scored ends
or bends.

(,

187061

Valve Lifters and Guides Clean

and Inspect
1. Keep the valve lifters in order so they can be
installed in their original position.
Important: When new valve lifters are installed, coat
the valve lifters with camshaft and lifter prelube
GM P/N 1052365 (or equivalent).
2. Inspect the following areas of the valve lifters:
The retaining clip (1)
The push rod socket for wear (2)
The valve lifter body for wear and scuffing (3)
The valve lifter bore for wear
The valve lifter roller assembly for wear (4)
The valve lifter roller pin for damage (5)
The oil hole for plugging (6)
3. Inspect the valve lifter guides for cracks or
damage.

178485

Cylinder Head Disassemble

Tools Required
J 38606 Valve Spring Compressor
Important: During disassembly, ensure the valve train
components are kept together and identified so they
can be reinstalled in their original locations and
with the same mating surfaces as when removed.
1. Use J 38606 to compress the valve spring.

187057

Engine

Engine Mechanical - 3.SL

6187

2. Remove the valve keys.

3. Remove the valve cap and spring.
4. Remove the valve stem oil seal by prying up on
the bottom.

42226

Cylinder Head Clean and Inspect

Tools Required
J 9666 Valve Spring Tester
1. Inspect the cylinder head gasket and the mating
surfaces for leaks, corrosion, and blowby.
2. If the gasket failed, determine the cause. Gasket
failure is caused by the following conditions:
Improper installation
A loose or warped cylinder head
Missing dowel pins
3. Clean the cylinder head of all foreign material. Do
not use a motorized wire brush on any gasket
sealing surface.
4. Clean the threaded holes.
5. Inspect the cylinder head for cracks typically
between the valve seats and inside of the
exhaust ports.
26157

Important: Do not attempt to weld the cylinder head.

If the cylinder head is damaged, replace the

cylinder head.

6. Inspect the cylinder head deck for corrosion.

5.. 1aa

Engine Mechanical - 3.8L

Engine
7. Inspect the following locations for flatness:
The cylinder head deck
The intake manifold mating surface
The exhaust manifold mating surface
8. Recondition the surfaces by parallel grinding.
Replace the cylinder head if more than 0.254 mm
(0.010 in) is removed.

36712

9. Measure the height from the deck surface to the

~
l) . :
10.
11.
12.
13.
14.

cast pads. Do this to determine if the cylinder

head has sufficient deck surface thickness
to resurface.
New cylinder heads measure from
1.372-1.676 mm (0.054-0.066 in). If the cylinder
head does not meet the minimum thickness
after resurfacing, replace the cylinder head.
Inspect all of the threaded holes for damage.
Repair the threaded holes, if necessary.
Inspect the valve seating surfaces.
Inspect the cooling jacket plugs.
Inspect the valve guides for wear. Clean the valve
guides.
Inspect the valve seats for excessive wear and
hot spots.

36714

15. Inspect the valve springs expanded height.

16. Inspect the valve spring ends. If the valve spring
ends,are not parallel, the' valve spring is bent.
Replace the bent valve spring.

63468

Engine

17. Using the J 9666 test the valve spring load. It the
valve spring load is below specification, replace
the valve spring.
18. Inspect the valve spring seating surface of the
valve spring retainers tor wear or gouging. If the
seating surface is damaged, replace the valve
spring retainers.
19. Use the following procedure to measure the valve
seat concentricity:
19.1. Lift the valve off its seat.
19.2. Apply a dab of blue dye to the valve face.
19.3. Seat and rotate the valve.
The blue dye traces transferred to the valve
seat are an indication of concentricity of
the valve seat.
20. Use the following procedure to measure the valve
runout:
20.1. Clean off the blue dye.
20.2. Apply blue dye to the valve seat.
20.3. Seat and rotate the valve.
The traces of blue dye transferred to the
valve indicates valve runout.
20.4. Recondition the valve seat or valve face, it
needed.

Engine Mechanical - 3.SL

6-189

4960

Valve Guide ReamingNalve and

Seat Grinding
\

Tools Required
J 8001 Dial Indicator Set
1. Recondition the valve seats by grinding. Use an
oscillating type valve seat grinder. Follow the
grinder manufacturer's instructions. If the valve
seat is too wide after grinding, use a 20 degree
stone or a 70 degree stone in order to narrow the
valve seat. The 20 degree stone will lower the
seat. The 70 degree stone will raise the seat.
Replace or recondition the valves it the seats are
reconditioned.
2. After grinding the valves, measure the valve
margin. Replace the valve it less than the
minimum recommended specification.

Notice: Clean the valve guides before reaming.

Packing of chips or carbon may result in the reamer
jamming into the valve guide or broken reamer flutes.
3. Clean any foreign material from the valves.
Use a wire brush to remove carbon. Do not
scratch the valve stem. Soak the valves in
carburetor cleaning fluid to remove varnish.
4. Use a suitable tool to clean the valve guides.
5. Follow the grinder manufacturer's instructions.
Ensure that the new surface is perpendicular to
the valve stem.

4955

6-190

Engine

Engine Mechanical - 3.SL

6. Inspect the valve key grooves for chipped or worn

lands (5). Replace the valve if the valve key
groove is damaged.
7. Inspect the valve stem tip for wear (6).
Reco.ndition the valve stem tip by grinding.
8. Inspect the valve stem for burrs and
scratches (4). Use an oil stone to remove burrs
and minor scratches.
9. Inspect the valve stem for straightness (3). Use
V blocks to inspect the valve head for bending or
distortion. Replace any bent or distorted valves.
10. Inspect the valve face for grooving (1, 2). If the
groove is so deep that refacing the valve face
would result in a knife edge, replace the valve.

5
6
156174

11. Inspect the valve face for burning, pitting, or

cracking (1, 2, 3, 4). If pieces of the valve face
are broken off, inspect the corresponding
piston and cylinder head area for damage.

156173

12. Measure the valve movement:

12.1. Insert the valve into the guide.
12.2. Lift the valve 2 mm (1/8 in) off of the seat.
12.3. Move the valve from side to side.
12.4. Use J 8001 to measure the amount of
movement.

40076

Engine

Engine Mechanical - 3.8L

6-191

Important: Clean the valve guide before reaming to

avoid breaking the reamer flutes. Do not push down
on the reamer.

13. Ream the valve guides for oversize valves if the

clearance exceeds the specifications.
14. Ream the valve guide bores for the oversize
valves.
15. Recondition the valve seats after reaming the
valve guide bores or installing the new valve
guides.

40073

16. Inspect the valve stem for straightness. Use

V blocks to inspect the valve head for bending or
distortion. Replace any bent or distorted valves.
It is essential that the valve guide bores
are free of carbon or dirt to ensure the proper
centering of the pilot in the guide.
The valve seats should be concentric to
within 0.05 mm (0.031 in) total indicator
reading.
Reface pitted valves on a valve refacing
machine to ensure the correct relationship
between the valve head and the valve stem.
Replace the valve if the valve stem is
warped (2), or if the valve stem shows signs of
excessive wear.
Inspect the valve key area (1) for damage and
carbon build up.
Replace the valve if the edge of the head is
less than 0.79 mm (0.031 in) thick after
grinding.
Use the manufacturer's recommendations of
equipment for the proper results.

156172

5.:.192

Engine Mechanical - 3.SL

Engine
Cylinder Head Assemble
Tools Required
J 38606 Valve Spring Compressor
J 42863 Valve Seal Installer
1. Install the valves .. The valves are available in
standard size and 0.015 in oversize.
Be sure to use oversize valve seals if oversize
valves are used.
Important: Use hand pressure only when installing
the valve seal using J 42863. Using to much force may
cause damage to the oil seal and possibly lead to
excessive oil consumption.
2. Place the valve stem oil seal over the valve stem
so the seal begins to contact the valve guide.
3. Use J 42863 to push the valve stem oil seal over
the valve guide.
40071

4. Use J 38606 to install the valve spring and the

valve cap.
5. Install the valve keys.
6. Use the following procedure to measure the valve
stem helght: .
6.1. Place the valve in the guide. Hold the valve
in the closed position.

6.2. Use a valve stem height gauge to measure

the valve stem height.
6.3. The measurement should be
49-50 mm (1.93-1.97 in).

154517

Important: Grinding the valves increases the valve

stem height and the valve spring installed height. Add
shims to correct the valve spring installed height.

7. U$e the following procedure to measure the valve

spring installed height:
7.1. Place the valve in the valve guide.
7.2. Install the valve spring cap and the valve
cap keys.
7.3. Seat the valve spring retainer by pulling up.
7.4. Use a steel machinists' rule to measure
the distance from the spring seat to the
bottom of the valve spring cap.
7.5. The measurement should be
42-44 mm (1.69-1.75 in).
If the measurement is not within
specifications add shims under the valve
spring.
40072

Engine

Engine Mechanical- 3.8L

6-193

Oil Pump Clean and Inspect

1. Use a suitable solvent to clean the oil pump.

2. Remove all old gasket material from the engine
front cover and from the engine block.
3. Inspect the oil pump cover and the engine front
cover for the following damage:
Cracks
Scoring
Porous or damaged casting
Damaged threads
Excessive wear
4. Inspect the pressure regulator valve for the
following damage:
Scoring
Sticking in the bore
Burrs
Foreign material
5. Inspect the pressure regulator spring for loss of
tension or bending. Replace the pressure
regulator spring if damaged.
6. Inspect the oil pump gears for the folfowing
conditions:
Chipping
Galling
Scoring
Excessive wear
7. Measure the inner oil pump gear tip clearance.

26160

38819

6-194

Engine Mechanical - a~sL

Engine
8. Measure the outer oil pump gear diameter
clearance.

38820

9. Measure the oil pump gear end clearance.

10. Measure the pressure regulator valve-to-bore
clearance.

36663

Valve Rocker Arm Cover Clean

and Inspect
Clean the valve rocker arm cover mating surface.
Clean the valve rocker arm cover. Remove all
the sludge and the oil deposits.
Inspect the valve rocker arm cover for damage.
Replace the valve rocker arm cover if any
damage is found.

187054

Engine

Engine Mechanical - 3.BL

6-195

Oil Pan Clean and Inspect

Clean the oil pan mating surface.
Clean the oil pan. Remove all the sludge and the
oil deposits.
Inspect the threads for the oil level sensor and the
engine oil drain plug.
Inspect the oil pan for dents or distortion.
Repair or replace the oil pan as necessary.

35861

Intake Manifold Clean and Inspect (Upper)

Clean the upper intake manifold mating surfaces.

Clean the upper intake manifold.
Inspect the upper intake manifold for damage.
Replace the upper intake manifold as necessary.

187078

Intake Manifold Clean and Inspect (Lower)

Clean the lower intake manifold mating surfaces.

Clean the lower intake manifold.
Inspect the threaded holes for damage.
Inspect the lower intake manifold for damage or
nicks in the mating surfaces.
Replace or repair the lower intake manifold as
necessary.

187073

6-196

Engine Mechanical - 3.8L

Engine
Exhaust Manifold Clean and Inspect
1. Clean the exhaust manifold mating surfaces.
2. Olean the exhaust manifold.
3. Inspect the exhaust manifold mating surfaces for
damage.

187068

4. Inspect the exhaust manifold flange for

straightness, using a straight edge and a
feeler guage.
5. If the exhaust manifold flange is warped more
than 0.05 mm (0.002 in) replace the exhaust
manifold.

187027

Water Pump Clean and Inspect

187022

Clean the water pump mating surface.

Clean the water pump.
Inspect the water pump shaft for looseness.
Inspect the water pump vanes for damage.
Inspect the water pump mating surfaces for nicks.
Repair or replace the water pump as necessary.

Engine

Engine Mechanical- 3.SL

6-197

Engine Front Cover Clean and Inspect

Clean the engine front cover mating surface.

Clean the engine front cover.
Inspect the engine front cover threaded holes.
Inspect the engine front cover for damage.
Inspect the engine front cover mating surfaces
for nicks.
Repair or replace the engine front cover as
necessary.

189850

Balance Shaft Clean and Inspect

1. Clean the balance shaft.
2. Inspect the balance shaft bearing/bushing journals
for excessive wear.
3. Inspect the balance shaft driven gear and the
balance shaft drive gear for nicks and burrs.
4. Inspect the balance shaft retainer for damage.
5. Inspect the balance shaft threads for damage.
6. Repair or replace the balance shaft components
as necessary.

42237

Balance Shaft Bearing and/or Bushing

Removal
Tools Required
J 36995 Balance Shaft Bearing Remover/Installer
1. Use J 36995 to remove the balance shaft. bearing.
2. Use J 36995 to remove the balance shaft
bushing. It may take a considerable amount
of force to loosen the bushing from the block bore.

J 36995

36706

6-198

Engine Mechanical - 3.SL

Engine
Balance Shaft Bearing and/or Bushing
Installation
Tools Required
J 21465-13 Drive Handle Extension
J 36995 Balance Shaft Bearing Remover/Installer
1. Dip the balance shaft bushing in clean engine oil.
Important: The J 36995 installs the balance shaft
bushing to the correct depth. The balance shaft
bushing is properly installed when J 36995 fully
contacts the balance shaft bore or the engine
block/transaxle mounting flange.
2. Use the balance shaft bushing installers to install
the balance shaft bushing.
3. Remove J 36995.

J 36995

36707

4. Dip the balance shaft bearing into clean engine oil.

5. Use J 21465-13 and J 36995 to install the balance
shaft bearing into the engine block.

566836

Service Prior to Assembly

Dirt will cause premature wear of the rebuilt engine.
Clean all of the components. Use the proper tools
in order to measure components when inspecting for
excessive wear. Repair or replace the components
that are not within the manufacturers specification.
When components are reinstalled into an engine,
return the components to their original location,
position, and direction. During assembly, lubricate all
of the moving parts with clean engine oil or engine
assembly lubricant (unless otherwise specified). This
will provide initial lubrication when the engine is
first started.

Engine

Engine Mechanical - 3.8L

6-199

Engine Block Plug Installation

\

Notice: Refer to Fastener Notice in Cautions and

Notices.
1. Install the threaded oil jacket plugs.

Tighten
Tighten the oil jacket plugs to 30 N,m (22 lb ft).

192728

2. Install the remaining oil gallery plugs using GM

P/N 12346004 sealant or equivalent.

26198

Crankshaft and Bearings Installation

Tools Required
J 36660 Torque Angle Meter
1. Install the lower crankshaft main bearings.
2. Install the crankshaft. Lubricate the crankshaft to
crankshaft main bearing contact areas with engine
oil or engine assembly lubricant.
3. Install the upper crankshaft main bearings.

~~-1
.[J~t55
C7j

:,, '
~

35863

6-200

Engine Mechanical - 3.SL

Engine
Notice: In order to prevent the possibility of cylind~r
block or crankshaft bearing cap damage, the
crankshaft bearing caps are tapped into the cylinder
block cavity using a brass, tead, or a leather mallet
before the attaching bolts are installed. Do not
use attaching bolts to pull the crankshaft bear1ng caps
into the seats. Failure to use this process may
damage a cylinder block or a bearing cap.

(',

4. Install the crankshaft main bearing caps. Use

GM P/N 1052942 sealer at the number 4
crankshaft main bearing cap to the engine block
surface.
Notice: Refer to Permanently Stretching Bolt Notice in
Cautions and Notices.

26153

Notice: Refer to Fastener Notice in Cautions and

Notices.
5. Install the crankshaft main bearing cap bolts. Start
the crankshaft main bearing cap bolts by hand.
Ensure the bottom of the crankshaft main bearing
cap is parallel to the bottom of the channel.
Tighten
Tighten the crankshaft main bearing cap bolts
in equal increments. Do not completely
tighten one bolt at a time to prevent the cap
from being cocked.
Tighten the bolts to 70 N-m (52 lb ft) to fully
seat the crankshaft main bearing caps.
Loosen the bolts 360 degrees
counterclockwise.

Tighten the bolts to 20 N-m (15 lb ft),

then 40 degrees (30 lb ft).
Use J 36660 to tighten the bolts in steps:
35 degrees + 35 degrees + 40 degrees for a
total of 11 O degrees.
6. Install the side main bolts. Apply
GM P/N 12345493 or equivalent to the side
main bolts.
Tighten
Tighten the side crankshaft main bearing cap
bolts to 15 N-m (11 lb ft). Use ,J 36660 to tighten
the bolts an additional 45 degrees.

Engine

Engine Mechanical - 3.SL

6-201

Piston, Connecting Rod, and Bearing

Installation

Tools Required
J 36660 Torque Angle Meter
J 8037 Piston Ring Compressor
J 41507 Connecting Rod Guide
1. Position the crankshaft so the connecting rod
journal is opposite the piston and connecting
rod assembly being installed. This will aid in the
installation of the connecting rod assembly.
2. Lubricate the cylinder wall with engine oil.
3. Install the connecting rod bearing inserts.
4. Lubricate the connecting rod bearing insert surface
with engine oil.
5. Install J 41507to the connecting rod. Hand
tighten the tool to the connecting rod.
6. Install J 8037 to the piston.

J 41507

38180

Notice: Guide the lower connecting rod end carefully

to avoid damaging the crankshaft journal.; ..
7. Use J 8037 to compress the piston rings for
installation of the piston and connecting rod
assembly.
8. Install the piston and connecting rod assembly
into the engine.
Important: Ensure the arrow on top of the piston or
the markings made during removal face towards
the front of the engine or a~e in the ~ame location as
when removed.
9. Use J 41507to pull the connecting rod into place.
10. Remove J 41507.

J 8037

5159

11. Install the connecting rod bearing cap.

Notice: Refer to Permanently Stretching Bolt Notice in
Cautions and Notices.
Notice: Refer to Fastener Notice in Cautions and
Notices.
12. Install the connecting rod bearing cap bolts.
Tighten
Tighten the connecting rod bearing cap bolts to
27 N-m (20 lb ft) + 50 degrees using J 36660.
13. Pry the connecting rod back and forth and check
for binding. If necessary loosen and retighten the
connecting rod bearing cap.

38153

6-202

Engine

Engine Mechanical - 3.SL

14. Measure the connecting rod side clearance.

5163

Oil Pump Pipe and Screen Assembly

Installation
1. Install the oil pump pipe and screen assembly
gasket.
Important: The oil pan gasket must be installed
before the oil pump pipe and screen assembly.

2. Install the oil pan gasket.

3. Install the oil pump pipe and screen assembly.
Notice: Refer to Fastener Notice in Cautions and
Notices.
4. Install the oil pump pipe and screen
assembly bolts.
Tighten
Tighten the bolts to 15 N-m (11 lb ft).

26202

Oil Pan Installation

1. Install the oil pan gasket to the oil pan flange.
2. Install the oil pan.
3. Install the oil pan bolts.
Tighten
Tighten the bolts to 14 N-m (125 lb in).
Notice: Refer to Fastener Notice in Cautions and
Notices.

44775

Engine

Engine Mechanical - 3.SL

6-203

Notice: Install the oil level sensor, located tn the oil

pan, after the oil pan is installed. Th13 sensor may be
damaged if the oil level sensor is installed first.
\

4. Install the oil level sensor.

Tighten
Tighten the oil level sensor to 20 Nm (15 lb ft).

35861

Camshaft Installation
1. Coat the camshaft with prelube GM P/N 12345507
or equivalent.
2. Install the camshaft.
3. Install the camshaft thrust plate.
Notice: Refer to Fastener Notice in Cautions and
Notices.

4. Install the camshaft thrust plate bolts.

)

Tighten
Tighten the bolts to 15 Nm (11 lb ft).

35815

Balance Shaft Installation

Tools Required
J 8001 Dial Indicator
J 21465-13 Drive Handle Extension
J 36660 Torque Angle Meter
J 36996 Balance Shaft Installer
1. Use J 21465-13 and J 36996 to install the balance
shaft into the engine block.

J 36996

36710

6~2.04

Engine

Engine Mechanical - 3.SL

2. Install the balance shaft bearing retainer.

Notice: Refer to Fastener Notice in Cautions and

Notices.
3. Install the balance shaft bearing retainer bolts.
Tighten
Tighten the balance shaft retainer bolts to
30 N-m (22 lb ft).

42237

4. Install the balance shaft driven gear.

Notice: Refer to Permanently $tretching Bolt Notice in
Cautions and Notices.
5. Install the balance shaft driven gear bolt.
Tighten
Tighten the balance shaft driven gear bolt to
22 N-m (16 lb ft). Use J 36660 to tighten the bolt
an additional 70 degrees.

154521

6. Using J 8001 measure. the balance shaft end play.

End play must not exceed 0.028 mm (0.008 in).

38470

Engine

7. Using J 8001 measure the balance shaft radial

play at the rear. Radial play must be
between 0.0127-0.119 mm (0.0005-0.0047 in).
8. Install the balance shaft drive gear.
9. Install the camshaft sprocket.
10. Turn the camshaft so the timing mark on the
camshaft sprocket is straight down.
11. Remove the camshaft sprocket and balance shaft
drive gear.
12. Turn the balance shaft so the timing mark on the
balance shaft driven gear points straight down.
13. Install the balance shaft drive gear.
14. Align the marks on the balance shaft driven gear
and the balance shaft drive gear. Do this. by
turning the balance shaft.
15. Turn the crankshaft so the number one piston is
at top dead center.
16. Install the timing chain.
17. Install the camshaft sprocket.
18. Using J 8001 measure the gear lash at four
places. Measure every quarter turn. Gear lash
must be between 0.050-0.127 mm
(0.002-0.005 in).

Engine Mechanical - 3.SL

6-205

J 8001

38472

38477

Crankshaft Rear Oil Seal and Housing

Installation
Tools Required
J 36660 Torque Angle Meter
J 41349 Crankshaft Rear Oil Seal Aligning Tool
1. Clean the gasket from the crankshaft rear oil seal
housing.
2. Clean the crankshaft rear oil seal housing.
3. Inspect the crankshaft rear oil seal housing for
damage.

Notice: Do not use sealers or adhesives on rear main

oil seal housing gasket. Use of sealers or adhesives
on this gasket may cause oil leaks.
4. Install the crankshaft rear oil seal housing gasket
over the bolts for alignment.
26125

6-206

Engine Mechanical - 3.8L

Engine
Important: The plastic inserts in the crankshaft rear
oil seal housing are used to aid assembly only.
The inserts are not required for service.
5. Install the crankshaft rear oil seal housing. Hand
tighten the crankshaft rear oil seal housing bolts.

\.

Notice: Sealability of the rear main oil seal depends

on the correct alignment of the rear main oil seal
housing and the oil pan. Incorrect alignment
may cause oil leaks.
6. Apply engine oil to both sides of J 41349.
7. Install J 41349 over the crankshaft. Twist the tool
to aid in sliding the tool over the crankshaft.
8. Place a straight edge on the engine block oil pan
flange and the crankshaft rear oil seal housing
flange. Use a feeler gage to ensure there is
no more than 0.004 in step on each side. Rotate
the crankshaft rearoil seal housing to make
the step equal on each side. Replace the
crankshaft rear oil seal housing if the rotation
does not make the step equal.
Notice: Refer to Fastener Notice in Cautions and
Notices.
.

9. Tighten the crankshaft rear oil seal housing bolts.

44779

Tighten
Tighten the crankshaft rear oil seal housing bolts
to 15 N-m (11 lb ft). Use J 36660 to tighten the
bolts an additional 50 degrees.
10. Remove J 41349.
11 . Recheck the step height on each side to ensure
the crankshaft rear oil seal housing did not move.
If the step height is beyond specification,
reinstall the crankshaft rear oil seal housing and
measure the step again. Replace the crankshaft
rear oil seal housing if the clearance is still beyond
specification.

Crankshaft Rear Oil Seal Installation

Tools Required
J 38196 Crankshaft Rear Oil Seal Installer
1. Apply engine oil to the inside diameter and the
outside diameter of the crankshaft rear oil seal.
2. Slide the crankshaft rear oil seal over the mandrel
until the back bottoms squarely against the collar
of the tool.

26129

Engine

Engine Mechanical - 3.BL

6-207

3. Use the following procedure to install the seal:

'l

Notice: Refer to Fastener Notice in Cautions and

Notices.
3.1 . Attach J 38196 to the crankshaft by hand or
tighten attaching screws to 5 N-m (54 lb in).
3.2. Turn the T handle of J 38196 so the collar
pushes the crankshaft rear oil seal into the
bore. Turn the handle until the tool is
bottomed out. Ensure the crankshaft rear oil
seal is seated properly.
3.3. Loosen the T handle of J 38196 until it
comes to a stop.
3.4. Remove the attaching screws.

J 38196

37747

Timing Chain and Sprockets

Installation (VIN K)
Tools Required
J 36660 Torque Angle Meter
1. Install the timing chain on the sprockets. Align the
timing marks.

192708

2. Install the timing chain, the crankshaft sprocket,

and the camshaft sprocket.
Notice: Refer to Permanently Stretching Bolt Notice in
Cautions and Notices.
Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Install the camshaft sprocket bolt.

Tighten
Tighten the camshaft sprocket bolt to
100 N-m (74 lb ft). Use J 36660 to tighten the
camshaft sprocket bolt an additional 90 degrees.

192716

6-208

Engine

Engine Mechanical - 3.8L

4. Install the timing chain dampener.

154523

Oil Pump Cover and Gear Set Installation

1. Lubricate the oil pump gears with petroleum jelly.

2. Install the oil pump gears.

3. Pack the oil pump cavity with petroleum jelly.
4. Install the oil pump cover.
Notice: Refer to Fastener Notice in Cautions and
Notices.
5. Install the oil pump cover screws.
Tighten
Tighten the screws to 11 Nm (98 lb in).

26160

Oil Filter Adapter Installation

1. Install the oil pressure relief valve spring into the
engine front cover.
2. Install the oil pressure relief valve into the engine
front cover.
3. Install a new oil filter adapter gasket.
4. Install the oil filter adapter.
Notice: Refer to Fastener Notice in Cautions and
Notices.
5. Install the oil filter adapter bolts.
Tighten
Tighten the oil filter adapter bolts to
15 Nm + 50 (11 lb ft+ 50).

36655

Engine

Engine Mechanical - 3.8L

6-209

Engine Front Cover Installation

Tools Required
J 36660 Torque Angle Meter
1. Install the engine front cover gasket.
2. Install the engine front cover.

Align the cogs on the crankshaft sprocket with the

cogs on the oil pump in the engine front cover.
3. Apply sealant GM P/N 12346004 or equivalent to
the engine front cover bolt threads.
4. Install the engine front cover bolts.
Tighten
Tighten the engine front cover bolts to
15 Nm (11 lb ft). Use J 36660 to tighten the
engine front cover bolts an additional 40 degrees.

Notice: Refer to Fastener Notice in Cautions

and Notices.
5. Install the oil pan to engine front cover bolts.

189850

Tighten
Tighten the oil pan bolts to 14 Nm (125 lb in).
6. Install the oil filter.
Tighten
Tighten the oil filter to 19 N-m (14 lb ft).

7. Install the crankshaft position sensor.

Tighten
Tighten the crankshaft position sensor studs to
30 Nm (22 lb ft).

36589

6-21 O Engine Mechanical - 3.SL

Engine
8. Install the crankshaft position sensor shield.

35844

Crankshaft Front Oil Seal Installation

Tools Required
J 35354 Seal Installer
1. Coat the inside diameter of the crankshaft front oil
seal with lubricant GM P/N 10522497 or
equivalent.
2. Use J 35354 and a soft faced hammer to install
the crankshaft front oil seal.
3. Remove J 35354.

J 35354

36662

Crankshaft Balancer Installation

(Automatic Transmission)
Tools Required
J 37096 Flywheel Holding Tool
J 36660 Torque Angle Meter
1. Lubricate the seal surface of the crankshaft
balancer with engine oil.
2. Install the crankshaft balancer.
3. Use J 37096 to hold the flywheel.

26141

Engine

Engine Mechanical - 3.8L

6-211

Notice: This bolt is designed to permanently stretch

when tightened. The correct part number fastener must
be used to replace this type of fastener. Do not use
a bolt that is stronger in this application. If the correct
bolt is not used, the parts will not be tightened
correctly. The system or the components may be
damaged.
4. Install the crankshaft balancer bolt.
Tighten
Tighten the crankshaft balancer bolt to
150 N-m (111 lb ft). Use J 36660 to tighten the
crankshaft balancer bolt an additional 76 degrees.
Notice: Refer to Fastener Notice in General
Information.

Crankshaft Balancer Installation

(Manual Transmission)
Tools Required
J 37096 Flywheel Holding Tool
J 36660 Torque Angle Meter
1. Lubricate the seal surface of the crankshaft
balancer with engine oil.
2. Install the crankshaft balancer.
3. Use J 37096 to hold the flywheel.

Notice: This bolt is designed to permanently stretch

when tightened. The correct part number fastener must
be used to replace this type of fastener. Do not use
a bolt that is stronger in this application. If the correct
bolt is not used, the parts will not be tightened
correctly. The system or the components may be
damaged.
4. Install the crankshaft balancer bolt.
Tighten
Tighten the crankshaft balancer bolt to
150 N-m (111 lb ft). Use J 36660 to tighten
the crankshaft balancer bolt an additional
114 degrees.

192730

Notice: Refer to Fastener Notice in General

Information.

Valve Lifter Installation

1. Dip the valve lifters in prelube GM P/N 12345501
or equivalent.
2. Install the valve lifters.
3. Install the valve lifter guides.

Notice: Refer to Fastener Notice in Cautions and

Notices.
4. Install the valve lifter guide bolts.
Tighten
Tighten the valve lifter guide bolts to
30 N-m (22 lb ft).

41374

6-212

Engine Mechanical - 3.SL

Engine
Cylinder Head Installation
Tools Required
J 36660 Torque Angle Meter
1. Install the cylinder head gasket. Ensure the
arrows point towards the front of the engine.
The left cylinder head gasket has the letter
L stamped next to the arrow.
Notice: Refer to Permanently Stretching Bolt Notice in
Cautions and Notices.
2. Install the cylinder head.

35842

Notice: Refer to Fastener Notice in Cautions and

Notices.
3. Install new cylinder head bolts.

Tighten
Tighten the cylinder head bolts to 50 Nm (37 lb ft)
in sequence.
Use J 36660 to rotate each cylinder head bolt
120 degrees in sequence.
Use J 36660 to rotate the four center cylinder
head bolts an additional 30 degrees in
sequence.

38826

Valve Rocker Arm and Push Rod

Installation
Tools Required
J 36660 Torque Angle Meter
1. Install the push rods.
2. Install the push rod guide plates.
3. Install the valve rocker arms.
Notice: Refer to Permanently Stretching Bolt Notice in
Cautions and Notices.
4. Apply GM P/N 12345493 threadlocker or
equivalent to the valve rocker arm bolt threads.
Notice: Refer to Fastener Notice in Cautions and
Notices.
5. Install the valve rocker arm bolts.
Tighten
Tighten the valve rocker arm bolts to
15 N-m (11 lb ft) + 90 degrees using J 36660.
35840

Engine

Engine Mechanical - 3.8L

6-21.3

Valve Rocker Arm Cover Installation

(Lett Side)

\I

1. Install the valve rocker arm cover.

2. Apply GM P/N 12345382 threadlocker or
equivalent to threads.

Notice: Refer to Fastener Notice in Cautions and

Notices.
3. Install the valve rocker arm cover bolts.
Tighten
Tighten the valve rocker arm cover bolts to
10 N-m (89 lb in).

35819

Valve Rocker Arm Cover Installation

(Right Side)
1 . Install the valve rocker arm cover.
2. Apply GM P/N 12345382 threadlocker or
equivalent to the threads.

Notice: Refer to Fastener Notice in C~utions and

Notices.
3. Install the valve rocker arm cover bolts.
)

Tighten
Tighten the valve rocker arm cover bolts to
10 Nm (89 lb in).

63414

Exhaust Manifold Installation (Left Side)

1 . Install the exhaust manifold gasket to the
cylinder head.
2. Install the exhaust manifold to the cylinder head.

Notice: Refer to Fastener Notice in Cautionsand

Notices.
3. Install the exhaust manifold nuts.

Tighten
Tighten the nuts 18 N-m (13 lb ft).

36635

6-214

Engine

Engine Mechanical - 3.8L

4. Install the exhaust manifold heat shield.

5. Install the exhaust manifold heat shield nuts.

Tighten
Tighten the nuts to 9 Nm (80 lb in).

50755

Important: Inspect the EGR inlet pipe for leaks.

Replace the EGR adapter if the pipe leaks.

6. Install the EGR inlet pipe to the exhaust manifold.

7. Install the EGR inlet pipe bolt and nuts.
Tighten
Tighten the nuts to 50 N,m (36 lb ft) and the bolt
to 25 Nm (18 lb ft).

36618

8. Install the left heated oxygen sensor into the

exhaust manifold.

Tighten
Tighten the sensor to 42 Nm (31 lb ft).
9. Connect the heated oxygen electrical connector to
the support bracket.

192720

Engine

Engine Mechanical 3.8L

6-215

Exhaust Manifold Installation (Right Side)

1. Install the exhaust manifold gasket to the
cylinder head.
2. Install the exhaust manifold to the cylinder head.

Notice: Refer to Fastener Notice in Cautions and

Notices.
3. Install the exhaust manifold nuts.
Tighten
Tighten the nuts to 18 N-m (13 lb ft).

36652

4. Install the exhaust manifold heat shields.

5. Install the exhaust manifold heat shield nuts.
Tighten
Tighten the heat shield nuts to 9 Nm (80 lb in).

36638

6. Install the right heated oxygen sensor into the

exhaust manifold.
7. Install the heated oxygen sensor electrical
connector to the lift bracket.
Tighten
Tighten the heated oxygen sensor to
42 N-m (31 lb ft).

192721

6-216

Engine

Engine Mechanical - 3.8L

Intake Manifold Installation (Upper)
1. Install the upper intake manifold gasket.
2. Install the upper intake manifold.
3. Install the water outlet.

36634

4. Install the upper intake manifold bolts.

Tighten
Tighten the vertical bolts in sequence to
15 Nm (11 lb ft).,
Tighten the two water outlet bolts in sequence
to 27 N-m (20 lb ft).
Tighten the side bolts in sequence to
30 Nm (22 lb ft).

11

50287

5. Install the fuel injector rail.

6. Install the fuel injector rail nuts.
Tighten
Tighten the fuel injector rail nuts to
10 Nm (89 lb in).

36631

Engine

Engine Mechanical - 3.8L

6-217

7. Install the throttle body gasket.

8. Install the throttle body.
9. Install the throttle body nuts and bolt.

Tighten
Tighten the throttle body nuts and bolt to
10 N-m (89 lb in).

36624

10. Install the EGR outlet pipe to the intake' manifold.

Tighten
Tighten the EGR outlet pipe bolt to
25 N-m (18 lb ft) and the nut to 29 N-m (21 lb ft).
11. Install the manifold vacuum source.

36609

Intake Manifold Installation (Lower)

1. Install the lower intake manifold gasket.
2. Install the lower intake manifold.
3. Apply GM P/N 12345382 threadlocker or
equivalent on the threads.

50046

6-218

Engine Mechanical - 3.8L

Engine
Notice: Refer to Fastener Notice in Cautions and
Notices.
4. Install the lower intake manifold bolts.
Tighten
Tighten the bolts to 15 Nm (11 lb ft).

'

50288

Water Pump Installation

Tools Required

J 36660 Torque Angle Meter

1. Install the water pump gasket.
2. Install the water pump.
Notice: Refer to Fastener Notice in Cautions and
Notices.

3. Install the water pump bolts.

Tighten
Tighten the water pump bolts to 15 N,m (11 lb ft).
Use J 36660 to tighten the bolt an additional
80 degrees.

187022

4. Install the water pump pulley.

5. Install the water pump pulley bolts.
Tighten
Tighten the water pump pulley bolts to
13 N-m (116 lb in).

36596

Engine

Engine Mechanical - 3.8L

6-219

Water Outlet Installation

1. Install the thermostat.

2. Install the water outlet gasket.
3. Install the water outlet.
Notice: Refer to Fastener Notice in Cautions and
Notices.
4. Install the water outlet bolts.

Tighten
Tighten the water outlet bolts to 27 N-m (20 lb ft).

36621

Oil Level Indicator and Tube Installation

1. Install the oil level indicator tube.

Lubricate the 0-ring with engine oil and make

sure it is in place.
Make sure the assembly is fully seated in the
engine block.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the oil level indicator tube bolt.

Tighten
Tighten the bolt to 10 N-m (89 lb in).

36615

Drive Belt Tensioner Installation

1. Install the drive belt tensioner.
2. Install the heater water bypass inlet pipe to the
lower intake manifold and to the tensioner.
Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Install the tensioner bolts.

Tighten
Tighten the bolts to 50 N-m (37 lb ft).

36693

6"-220

Engine Mechanical - 3.SL

Engine
Engine Flywheel Installation
(Manual Transmission)
Tools Required
J 36660 Torque Angle Meter
1. Install the flywheel.

Notice: Refer to Fastener Notice in Cautions and

Notices.
2. Install the new flywheel bolts.
Tighten
Tighten the bolts to 15 N-m (11 lb ft). Use J 36660
to tighten the bolts an additional 50 degrees.

192727

Engine Flywheel Installation

(Automatic Transmission)
T6ols Required
J,36660 Torque Angle Meter
i. Install the flywheel.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the new flywheel bolts.
Tighten
Tighten the bolts to 15 Nm (11 lb ft). Use the
J 36660 to tighten the bolts an additional
50 degrees.

36665

Engine

Engine Mechanical - 3.SL

6-221

Description and Operation

Engine Component Description
Engine Construction

Starting at the front of the engine, the cylinders of the

left bank are numbered 1-3-5 and the cylinders of
the right bank are numbered 2-4-6. The crankshaft is
supported in the engine block by four bearings. The
crankshaft is counterbalanced by the flywheel,
the crankshaft balancer, and the weights cast into the
crankshaft. Additional counterbalancing is obtained
from the balance shaft which rides in the engine block
above the camshaft and is driven by the camshaft.
All 3800 engines are even-firing, the cylinders
fire at equal 120 degree intervals of crankshaft rotation'.
The location of the crankshaft journals has been
offset by 30 degrees to fire the cylinders at 120 degree
intervals of crankshaft rotation. The camshaft lobes
and timing also reflect the 120 degree intervals.
The even firing crankshaft provides an equal interval
of 120 degrees between ignition of each of the
cylinders throughout the firing order. The firing order is
1-6-5-4-3-2. The aluminum alloy pistons have
slipper skirts and are cam turned. Four drilled holes or
casted slots in the oil ring grooves permit drain
back of the oil collected by the oil ring. The camshaft
is supported by four bearings in the engine block
and is driven by the crankshaft through sprockets and
a timing chain. The cylinder heads are cast iron
and incorporate integral valve stem guides. Right and
left cylinder heads are identical and are
interchangeable, but it is good practice to reinstall the
cylinder heads on the side from which they are
removed. The intake manifold is bolted to the inner
faces of both cylinder heads so it connects with all
inlet ports.

Each exhaust and intake valve has a valve spring to

insure positive seating throughout the operating speed
range. The valve rocker arms for each bank of the
cylinders pivot on pedestals bolted to the cylinder
head. Hydraulic roller valve lifters and tubular push
rods are used to operate overhead rocker arms
and valves of both banks of the cylinders from a single
camshaft. This system requires no lash adjustment
at the time of assembly or service.
In addition to its normal function of a cam follower,
each valve lifter also serves as an automatic adjuster
which maintains zero lash in the valve train under
all operating conditions. By eliminating all lash in the
valve train and also providing a cushion of oil to absorb
operating shocks, the valve lifter promotes quiet
valve operation. It also eliminates the need for periodic
valve adjustment to compensate for wear of parts.
Oil is supplied to the valve lifter through a hole in the
side of the valve lifter body which indexes with a
groove and a hole in the valve lifter plunger. Oil is then
metered past the oil metering valve in the valve
lifter, through the push rods to the valve rocker arms.
When the valve lifter begins to move up the
camshaft lobe, the check ball is held against its seat
in the plunger by the check ball spring which traps the
oil in the base of the valve lifter body below the
plunger.
The plunger and the valve lifter body then raise as a
unit, pushing up the push rod to open the valve.
The force of the valve spring which is exerted on the
plunger through the valve rocker arm and push
rod, causes a slight amount of leakage between the
plunger and the valve lifter body. This leakage allows a
slow escape of trapped oil in the base of the valve
lifter body. As the valve lifter rolls down the other side
of the camshaft lobe and reaches the base circle or
valve closed position, the plunger spring quickly moves
the plunger back (up) to its original position. This
movement causes the check ball to open against the
ball spring, and any oil inside the plunger is drawn
into the base of the valve lifter. This restores the valve
lifter to the zero lash.

6-222

Engine Mechanical - 3.BL

Engine

Lubrication Description

44529

The engine lubrication system is of the force-feed

type. The oil is supplied under full pressure to
the crankshaft, connecting rods, valve lifters, camshaft,
and rear balance shaft bearing. A controlled volume
of oil is supplied to the valve rocker arms and
push rods. All other moving parts are lubricated by
gravity flow or splash. The engine oil is stored in the
lower crankcase (oil pan) which is filled through a
filler opening in the valve rocker arm cover. A
removable oil level indicator, on the left side of the
engine block, is provided to check the oil level. The oil
pump is located in the engine front cover and is
driven by the crankshaft. It is a gerotor-style pump
which is a combination of a gear and a rotor pump. It
is connected by a passage in the cylinder block to
an oil screen and pipe assembly. The screen is
submerged in the oil supply and has ample volume for
all operating conditions. If the screen becomes
clogged, oil may be drawn into the system through the

oil pressure relief valve in the oil filter adapter. Oil is

drawn into the pump through the screen and pipe
assembly, and a passage in the crankcase, connecting
to the passages in the engine front cover. Oil is
discharged from the oil pump to the oil filter adapter.
The oil filter adapter consists of an oil filter bypass
valve and a nipple for installation of an oil filter. The
spring-loaded oil pressure relief valve, located in
the engine front cover, limits the oil pressure. The oil
filter bypass valve opens when the oil filter is
restricted to approximately 68.95 kPa (1 O psi) of
pressure difference between the oil filter inlet and
discharge. The oil will then bypass the oil filter
and channel unfiltered oil directly to the main oil
galleries of the engine. A full-flow oil filter is externally
mounted to the oil filter adapter on the lower right
front side of the engine. If the filter element becomes
restricted, not allowing engine oil to pass through,
a spring-loaded bypass valve opens.

Engine

Engine Mechanical - 3.SL

6-223

The main oil galleries run the full length of the engine
block and cut into the valve lifter guide holes to
supply oil at full pressure to the valve lifters. Holes,
drilled from the crankshaft bearings to the main
oil gallery, intersect the camshaft bearing bores to
supply oil to the cam bearings.
Oil is transfered from the crankshaft bearings to the
connecting rod bearings through holes drilled in
the crankshaft. Pistons, piston pins, and cylinder walls
are lubricated by oil splash from the crankshaft and
connecting rods.
Each valve rocker arm and valve is supplied with oil
through the tubular push rod. The oil comes from
the inside of the valve lifter passing around the
metering valve and through a hole in the push rod
seat. Oil from the push rod passes through a hole in
the push rod seat, and emerges on top of the push rod
seat boss.

Thread Repair

4963

General purpose thread repair kits are available

commercially.

8. Screw the thread insert onto the mandrel of the

thread insert installer. Engage the tang of the
thread insert onto the end of the mandrel.
Important: The thread insert should be flush to 1 turn
below the surface.
9. Lubricate the thread insert with clean engine oil
(except when installing in aluminum) and install
the thread insert.

10. If the tang of the thread insert does not break off
when backing out the thread insert installer, break
off the tang using a drift punch.

Cleanliness and Care

4962

Caution: Refer to Safety Glasses Caution in

Cautions and Notices.
Important: Refer to the thread repair kit
manufacturer's instructions regarding the size of the
drill and which tap to use.

Always avoid any buildup of chips. Back out the tap

every few turns and remove the chips.
1. Determine the size, the pitch, and the depth of the
damaged thread.
2. Adjust the stop collars on the cutting tool as
needed. Tap the stop collars to the required depth.
3. Drill out the damaged thread.
4. Remove the chips.
5. Apply clean engine oil to the top thread.
6. Use the tap in order to cut new thread.
7. Clean the thread.

An automobile engine is a combination of many of the

following surfaces:
Machined
Honed
Polished
Lapped
The tolerances of these surfaces are measured in the
ten-thousandths of an inch. When you service any
internal engine part, cleanliness and care are
important. Apply a liberal coating of engine oil to the
friction areas during assembly in order to protect
and lubricate the surfaces on initial operation.
Throughout this section, practice proper cleaning and
protection procedures to the machined surfaces
and to the friction areas.
Notice: Engine damage may result if an abrasive
paper, pad, or motorized wire brush is used to clean
any engine gasket surfaces.
Whenever you remove the valve train components,
keep the components in order. Follow this procedure in
order to install the components in the same locations
and with the same mating surfaces as when
removed.

6-224

Engine

Engine Mechanical - ~.SL

Caution: Refer to Battery Disconnect Caution in

Cautions and Notices.
Disconnect the negative battery cables before you
perform any major work on the engine. For more
information on the disconnection of the battery, refer
to Engine Electrical.

Replacing Engine Gaskets

1 . Do not reuse any gasket unless otherwise
specified. Reusable gaskets will be identified in the
service procedure. Do not apply sealant to any
gasket or sealing surface unless called out in the
service procedure.
2. Use a rubber mallet in order to separate
components. Bump the part sideways in order to
loosen the components. Perform the bumping
at the bends or at the reinforced areas in order to
prevent the distortion of components.
Important: Do not use any other method or technique
in order to remove the gasket material from a
components.

Do not use the following items in order to clean the

gasket surfaces:
Abrasive pads
Sand paper
Power tools
These methods of cleaning may damage the
component.
Abrasive pads also produce a fine grit that the oil filter
cannot remove from the oil. This grit is abrasive
and may cause internal engine damage.
3. Remove all of the gasket and the sealing material
from the component using a plastic or a wood
scraper. Do not gouge or scrape the sealing
surfaces.
Important: Do not allow the sealant to enter any blind
threaded holes. The sealant may cause the following
conditions:
Prevent you from properly seating the bolt
Cause damage when you tighten the bolt
4. When assembling components, use only the
sealant specified in the service procedure.
Ensure that the sealing surfaces are clean and
free of debris or oil. When applying sealant
to a component, apply a bead size as specified in
the service procedure.
5. Tighten the bolts to the specifications.

Use of RTV and Anaerobic Sealer

The following 2 types of sealer are commonly used in
engines:
The RTV sealer
The anaerobic gasket eliminator sealer
Follow the service procedure instructions. Use the
correct sealer in the proper place in order to prevent
oil leaks. Do not interchange the 2 types of sealers.
Use the sealer recommended in the service procedure.

Applying RTV Sealer

Do not use the room temperature vulcanizing
(RTV) sealant in areas where extreme
temperatures are expected. These areas include
the following locations:
- The exhaust manifold
- The head gasket
- The other surfaces where gasket eliminator
is specified
Use a rubber mallet in order to separate the
components sealed with RTV sealant. Bump the
part sideways in order to shear the RTV sealer.
Perform the bumping at the bends or the
reinforced areas in order to prevent distortion of
the components. The RTV sealant is weaker
in shear (lateral) strength than in tensile (vertical)
strength.
Important: Do not use any other method or technique
in order to remove the gasket material from a
component.
Do not use the following items in order to clean
the gasket surfaces:
- Abrasive pads
- Sand Paper
- Power tools
These methods of cleaning may damage the part.
Abrasive pads also produce a fine grit that the oil filter
cannot remove from the oil. This grit is abrasive
and may cause internal engine damage.
Remove all of the gasket material from the
component using a plastic or a wood scraper. Use
Loctite brand gasket remover P/N 4MA or the
equivalent. Follow all of the safety
recommendations and the directions that are on
the container.
Important: Do not allow the sealer to enter the blind
threaded holes. The sealer may cause the following
conditions:
- Prevent you from properly seating the bolt
- Cause damage when you tighten the bolt
Apply the RTV sealant to a clean surface. Use a
bead size as specified in the procedure. Apply
the bead to the inside of any bolt holes.
Assemble the components while the RTV sealant
is still wet (within 3 minutes). Do not wait for the
RTV sealant to skin over.
Important: Do not overtighten the bolts.
Tighten the bolts to specifications.

Engine

\I

Engine Mechanical - 3.SL

6-225

Applying Anaerobic Sealer

Installation Precautions

The anaerobic gasket eliminator hardens in the

absence of air. This type of sealer is used where
2 rigid parts (such as castings) are assembled
together. When 2 rigid parts are disassembled and no
sealer or gasket is readily noticeable, the parts
were probably assembled using a gasket eliminator.

Caution: Before removing or installing any

electrical unit, or when a tool or equipment could
easily come in contact with "live" or "hot all
the times" exposed electrical terminals, disconnect
the negative battery cable to help prevent
personal injury and/or damage to the vehicle or
components. Unless instructed otherwise, the
ignition switch must be in the OFF or LOCK
position.

Important: Do not use any other method or technique

in order to remove the gasket material from a
component.

Do not use the following items in order to clean the

gasket surfaces:
Abrasive pads
Sand paper
Power tools
These methods of cleaning may damage the part.
Abrasive pads also produce a fine grit that the oil filter
cannot remove from the oil. This grit is abrasive
and may cause internal engine damage.
Remove all of the gasket material from the
component using a plastic or a wood scraper. Use
Loctite brand gasket remover P/N 4MA or the
equivalent. Follow all of the safety
recommendations and the directions that are on
the container.
Apply a continuous bead of the gasket eliminator
to 1 flange. Clean and dry any surfaces that you
will reseal.
Important: Anaerobic sealed joints that are partially
torqued and allowed to cure more than 5 minutes may
result in incorrect shimming and sealing of the joint.

Do not allow the sealer to enter the blind

threaded holes. The sealer may cause the
following conditions:
- Prevent you from properly seating the bolt
- Cause damage when you tighten the bolt
Spread the sealer evenly in order to get a uniform
coating on the sealing surface.
Tighten the bolts to the specifications.
Remove the excess sealer from the outside of
the joint.

Separating Parts
The components of an internal combustion engine
develop wear patterns with their mating components.
During disassembly of the engine, parts should be
separated and kept in order so they may be reinstalled
in the same location from which they were removed.

Notice: The following information on engine service

should be noted carefully, as it is important in
preventing damage and contributing to reliable engine
performance.
When raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the
small clearance between the oil pan and the oil pump
screen, jacking against the oil pan may cause the
oil pan to be bent against the oil pump screen resulting
in a damaged oil pump screen or oil pump pipe.
Any time the throttle body or air induction tube is
removed, the intake opening should be covered. This
will protect against the accidental entrance of
foreign material which could follow the intake passage
into the cylinder and cause extensive damage when
the engine is started.

Tools and Equipment

Work in a clean and well-lit area. '7iave the following
components available before you begin to work:
A suitable parts cleaning tank
A compressed air supply
Trays, in order to keep the parts and the fasteners
organized
An adequate set of hand tools
An approved engine repair stand will prevent personal
injury or damage to the engine components. The
special tools are designed in order to quickly
and safely accomplish the operations for which the
tools are intended. Using the tools will minimize
possible damage to the engine components. Precision
measuring tools are required for the inspection of
certain critical components. Torque wrenches
are needed for the correct assembly of various parts.

6-226

Engine Mechanical - 3.8L

Special Tools and Equipment

Illustration

Engine
Tool Number/Description

Illustration

Tool Number/Description

J 8520
Dial Indicator Adapter

J 6125-18
Slide Hammer

3408
4865

J 9666
Valve Spring Tester

J 7872
Magnetic Base Indicator Set

5112

2014

J 21465-13
Drive Handle Extension

J 8001
Dial Indicator Set

3400

2014

J 22794
Spark Plug Port Adapter

J 8037
Universal Piston Ring
Compressor

26998
3403

J 28428-E
J 8087

High Intensity Black Light

Cylinder Bore
Checking Gauge

62292
5110

Engine

Engine Mechanical - 3.SL

Illustration

Tool Number/Description

Illustration

Tool Number/Description

J 28467-A
Engine Support Fixture

36154

6-227

J 36462
Engine Support Adapter Leg

52324

~ ~
~ ~

J 28467-90
Engine Support Fixture
Adapter

J 36660
Torque Angle Meter

~
50408

3413

J 33049
Camshaft Bearing
Remover/Installer Set

5118

J 35667-A

Cylinder Leakdown Tester

62295

J 36995
Balance Shaft Bearing
Remover/Installer

J 35354
Seal Installer

37773

38285

J 35953

J 36996

Engine Support Foot

Modification

50410

Balance Shaft Installer

3411

6-228

Engine

Engine Mechanical - 3.SL

Illustration

Tool Number/Description

Tool Number/Description

Illustration

(
J 41044

J 37096
Flywheel Holding Tool

Engine Support Adapter

220634

37623

J 38196

J 41348

Crankshaft Rear Oil Seal

Installer

Main Bearing Cap Puller

38515

38068

J 41349

J 38197

Crankshaft Rear Oil Seal

Housing Alignment Tool

Crankshaft Balancer Puller

49848

13547

J 38606

J 41507

Valve Spring Compressor

Connecting Rod Guide

38090

49850

62293

J 38722

J 42863

Compression Tester

Valve Seal Installer

223541

Engine Mechanical - 5. 7L

Engine

Engine Mechanical - 5.7L

J

Specifications
Fastener Tightening Specifications
Application

Nm

Lbln

Accelerator Control Cable Bracket Bolts

10

89

Air Conditioning Compressor Bolts

50

37

Air Conditioning Compressor Bracket Bolts

50

37

Air Conditioning Idler Pulley Bolt

50

37

Air Conditioning Tensioner Bolt

25

18

Air Injection Reaction (AIR) Pipe-to-Exhaust Manifold Bolts

20

15

Camshaft Retainer Bolts

25

18

Camshaft Sensor Bolt

25

18

Camshaft Sprocket Bolts

35

26

Catalytic Converter Nut

25

18

Connecting Rod Bolts (First Pass)

20

15

Connecting Rod Bolts (Final Pass)

60 degrees

Coolant Temperature Gauge Sensor

20

15

Crankshaft Balancer Bolt (Installation Pass-to Ensure the

Balancer is Completely Installed)

330

240

Crankshaft Balancer Bolt (First Pass-Install a NEW Bolt After

the Installation Pass and Tighten as Described in the First
and Final Passes)

50

37

Crankshaft Balancer Bolt (Final Pass)

Lb Ft

Crankshaft Bearing Cap Bolts (Inner Bolts-First Pass in

Sequence)

140 degrees
20

Crankshaft Bearing Cap Bolts (Inner Bolts-Final Pass in

Sequence)

15

80 degrees

Crankshaft Bearing Cap Side Bolts

25

18

Crankshaft Bearing Cap Studs (Outer Studs-First Pass in

Sequence)

20

15

Crankshaft Bearing Cap Studs (Outer Studs-Final Pass in

Sequence)
Crankshaft Oil Deflector Nuts

53 degrees
25

18

Crankshaft Position Sensor Bolt

25

18

Cylinder Head Bolts (First Pass all M11 Bolts in Sequence)

30

22

Cylinder Head Bolts (Second Pass all M11 Bolts in

Sequence)

90 degrees

Cylinder Head Bolts (Final Pass all M11 Bolts in Sequence Excluding the Medium Length Bolts at the Front and Rear of
Each Cylinder Head)

90 degrees

Cylinder Head Bolts (Final Pass M11 Medium Length Bolts at

Front and Rear of Each Cylinder Head in Sequence)

50 degrees

Cylinder Head Bolts (MB Inner Bolts in Sequence)

30

22

Cylinder Head Coolant Plug

20

15

Cylinder Head Core Hole Plug

20

15

Drive Belt Idler Pulley Bolt

50

37

Drive Belt Tensioner Bolts

50

37

Engine Block Coolant Drain Plugs

60

44

Engine Block Heater

40

30

Engine Block Oil Gallery Plugs

60

44

Engine Crossmember Bolts (Large)

145

107

6-229

5.;230

Engine Mechanical - 5.7L

Engine

Fastener Tightening Specifications (cont'd)

N,m

Lb Ft

Engine Crossmember Bolts (Small)

125

92

Engine Flywheel Bolts (First Pass)

20

15

Application

Lbln

Engine Flywheel Bolts (Second Pass)

50

37

Engine Flywheel Bolts (Final Pass)

100

74

Engine Flywheel-to-Torque Converter Bolt

60

44

Engine Front Cover Bolts

25

18

Engine Mount Heat Shield Nuts

10

89

Engine Mount Stud-to-Engine Block

50

37

Engine Mount Through Bolts

95

70

Engine Mount Through Bolt Nuts

80

59

Engine Mount-to-Engine Block Bolts

50

37

Engine Rear Cover Bolts

25

18

Engine Service Lift Bracket M10 Bolts

50

37

Engine Service Lift Bracket M8 Bolt

25

18

Engine Valley Cover Bolts

25

18

Exhaust Gas Recirculation (EGR) Valve Bolts (First Pass)

10

89

EGR Valve Bolts (Final Pass)

30

22

EGR Valve Pipe-to-Cylinder Head Bolts

50

37

EGR Valve Pipe-to-Exhaust Manifold Bolts

30

22

EGR Valve Pipe-to-Intake Manifold Bolt

10

89

Exhaust Manifold Bolts (First Pass)

15

11

Exhaust Manifold Bolts (Final Pass)

25

18

Exhaust Manifold Pipe Nuts

35

26

Front Shock-to-Engine Crossmember Bolt

65

48

Fuel Injection Fuel Rail Bolts

10

89

Generator Bracket Bolts

50

37

Generator Rear Bracket-to-Engine Block Bolt

25

18

Generator Rear Bracket-to-Generator Bolt

25

18

Ground Strap Bolt (at Rear of Cylinder Head)

50

37

Ignition Coil Bolts

12

106

Ignition Coil Wire Harness Connector Bolts

12

106

Intake Manifold Bolts (First Pass in Sequence)

44

Intake Manifold Bolts (Final Pass in Sequence)

10

89

Knock Sensors

20

15

Oil Filter

30

22

Oil Filter Fitting

55

40

Oil Level Indicator Tube Bolt

25

18

Oil Level Sensor

13

115
106
106
106

Oil Pan Baffle Bolts

12

Oil Pan Closeout Cover Bolt (Left Side)

12

Oil Pan Closeout Cover Bolt (Right Side)

12

Oil Pan Drain Plug

25

18

Oil Pan M8 Bolts (Oil Pan-to-Engine Block and Oil

Pan-to-Front Cover)

25

18

Oil Pan M6 Bolts (Oil Pan-to-Rear Cover)

12

Oil Pressure Sensor

20

15

Oil Pump-to-Engine Block Bolts

25

18

Oil Pump Cover Bolts

12

106

106

(
I

Engine

Engine Mechanical - 5.7L

6-231

Fastener Tightening Specifications (cont'd)

N,m

Application

Lb Ft

Lbln

Oil Pump Relief Valve Plug

12

106

Oil Pump Screen Nuts

25

18

Oil Pump Screen-to-Oil Pump Bolt

12
12

106

Oil Transfer Cover Bolts

Oxygen Sensor

42

31

Positive Crankcase Ventilation (PCV) System Strap Nut (at

right front vapor vent pipe stud)

12

106

Power Steering Pump Bolts

25

18

106
-

Power Steering Pump Brace Bolts

25

18

Power Steering Pump Bracket Bolts

50

37

Spark Plugs (Cylinder Head-New)

20

15

Spark Plugs (all Subsequent Installations)

15

11

Starter Motor Bolts

50

37

Throttle Body Bolts

12

106

Transmission Bellhousing Bolt

47

35

Valve Lifter Guide Bolts

12

106

Valve Rocker Arm Bolts

30

22

Valve Rocker Arm Cover Bolts

12

106

Vapor Vent Pipe Bolts

12

106

Water Inlet Housing Bolts

15

11

Water Pump Bolts (First Pass)

15

11

Water Pump Bolts (Final Pass)

30

22

Water Pump Cover Bolts

15

11

Water Pump Pulley Bolts (First Pass)

10

89

Water Pump Pulley Bolts (Final Pass)

25

18

Engine Mechani.cal Specifications

Specification
Application

Metric

English

General Data
VB

Engine Type
Displacement

5.7L-5665 cc

346 CID

Bore

99.0 mm

3.898 in

Stroke

92.0 mm

3.622 in

Compression Ratio

10.1 :1

Firing Order
Spark Plug Gap

1-8-7-2-6-5-4-3
1.524 mm

0.06 in

4.7 Liters

5.0 Quarts

Lubrication System
Oil Capacity (without Oil Filter Change)
Oil Capacity (with Oil Filter Change)
Oil Pressure (Minimum-Hot)

Oil Type

5.2 Liters

5.5 Quarts

41 kPa at 1,000
engine RPM
124 kPa at 2,000
engine RPM
165 kPa at 4,000
engine RPM

6 psig at 1,000
engine RPM
18 psig at 2,000
engine RPM
24 psig at 4,000
engine RPM
5W-30

6-232

Engine Mechanical - 5.7L

Engine

Engine Mechanical Specifications (cont'd)

Specification
Application

Metric

English

0.025-0.305 mm
54.99-55.04 mm
0.025 mm
7.43 mm

0.001-0.012 in

Camshaft Lobe Lift (Exhaust)

7.43 mm

0.292 in

Camshaft Runout (Measured at the Intermediate Journals)

0.05 mm

0.002 in

56.505-56.525 mm

2.224-2.225 in

0.004 mm
0.008 mm

0.00015 in

Camshaft
Camshaft End Play
Camshaft Journal Diameter
Camshaft Journal Diameter Out-of-Round
Camshaft Lobe Lift (Intake)

2.164-2.166 in
0.001 in
0.292 in

Connecting Rod
Connecting Rod Bearing Bore Diameter
Connecting Rod Bearing Bore Out-of-Round (Production)
Connecting Rod Bearing Bore Out-of-Round (Service Limit)
Connecting Rod Bearing Clearance (Production)
Connecting Rod Bearing Clearance (Service Limit)
Connecting Rod Side Clearance

0.015-0.063 mm
O.Q15-0.076 mm
Q.11-0.51 mm

0.0003 in
0.0006-0.00248 in
0.0006-0.003 in
0.00433-0.02 in

Crankshaft
Crankshaft Bearing Clearance (Production)
Crankshaft Connecting Rod Journal Diameter (Production)
Crankshaft Connecting Rod Journal Diameter (Service Limit)
Crankshaft Connecting Rod Journal Taper (Production)

Crankshaft Connecting Rod Journal Taper (Service Limit)

Crankshaft Connecting Rod Journal Out-of-Round (Production)
Crankshaft Connecting Rod Journal Out-of-Round (Service Limit)
Crankshaft End Play
Crankshaft Main Journal Diameter (Production)
Crankshaft Main Journal Diameter (Service Limit)
Crankshaft .Main Journai Out-of-Round (Production)
Crankshaft Main Journal Out-of-Round (Service Limit)
Crankshaft Main Journal Taper (Production)
Crankshaft Main Journal Taper (Service Limit)
Crankshaft Reluctor Ring Runout (Measured 1.0 mm (0.04 in) Below
the Tooth Diameter)

0.018-0.054 mm
53.318-53.338 mm

0.0007-0.00212 in
2.0991-2.0999 in
2.0987 in

53.308 mm
0.005 mm (Maximum
for 1/2 of the Journal

0.0002 in (Maximum for

1/2 of the Journal

Length)

Length)

0.02 mm (Maximum)
0.005 mm
0.01 mm

0.00078 in (Maximum)
0.002 in

0.04-0.2 mm
64.993-65.007 mm
64.993 mm (Minimum)
0.003 mm
0.008 mm
0.01 mm
0.02 mm

0.00039 in
0.0015-0.0078 in
2.558-2.559 in
2.558 in (Minimum)
0.000118 in
0.00031 in
0.00039 in
0.00078 in

0.25 mm

0.01 in

0.05 mm (Maximum)

0.002 in (Maximum)

0.025 mm
26.14-26.22 mm
26.2 mm (Maximum)

0.001 in
1.029-1.032 in
1.0315 in (Maximum)

99.0-99.018 mm
0.018 mm (Maximum)

3.897-3.898 in
0.0007 in (Maximum)

Cylinder Head Engine Block Deck Flatness (Measured within a

152.4 mm (6.0 in) area)

0.11 mm

0.004 in

Cylinder Head Engine Block Deck Flatness (Measuring the Overall

Length of the Cylinder Head)

0.22 mm

0.008 in

0.22 mm
0.22 mm

0.008 in
0.008 in

120.2 mm (Minimum)

4.732 in (Minimum)

Crankshaft Runout (at Rear Flange)

Crankshaft Thrust Wall Runout
Crankshaft Thrust Wall Width (Production)
Crankshaft Thrust Wall Width (Service)
Cylinder Bore
Cylinder Bore Diameter
Cylinder Bore Taper Thrust Side
Cylinder Head

_Cylinder Head Exhaust Manifold Deck Flatness

Cylinder Head Intake Manifold Deck Flatness
Cylinder Head Height (Measured from the Cylinder Head Deck to the
Valve Rocker Arm Cover Seal Surface)

Engine

Engine Mechanical - 5.7L

6-233

Engine Mechanical Specifications (cont'd)

Specification
Application

Metric

English

55.063-55.088 mm

2.168-2.169 in

Engine Block Cylinder Head Deck Surface Flatness (Measured within a

152.4 mm (6.0 in) area)

0.08 mm

0.003 in

Engine Block Cylinder Head Deck Surface Flatness (Measuring the

Overall Length of the Block Deck)

0.22 mm

0.008 in

234.57-234.82 mm

9.235-9.245 in

69.871-69.889 mm

2.75-2.751 in

0.5 mm

0.02 in

21.417-21.443 mm

0.843-0.844 in

0.5mm

0.02 in

Oil Pan to Rear of Engine Block Alignment (at Transmission

Bellhousing Mounting Surface)

0.0-0.25 mm
(Maximum)

O.O-O.D1 in (Maximum)

Front Cover Alignment (at Oil Pan Surface)

0.0-0.5 mm

0.0-0.02 in

Rear Cover Alignment (at Oil Pan Surface)

0.0-0.5 mm

0.0-0.02 in

98.964-98.982 mm

3.8962-3.8969 mm

O.D18 mm

0.0007 in

Engine Block
Camshaft Bearing Bore Diameter

Engine Block Cylinder Head Deck Height (Measuring from the

Centerline of Crankshaft to the Deck Face)
Main Bearing Bore Diameter (Production)
Main Bearing Bore Out-of-Round
Valve Lifter Bore Diameter (Production)
Intake Manifold
Intake Manifold Cylinder Head Deck Flatness (Measured at Gasket
Sealing Surfaces)
Oil Pan and Front/Rear Cover Alignment

Piston
Piston Outside Diameter (at Size Point)
Piston Out-of-Round (Service Limit)

Piston to Bore Clearance (Production)

0.018-0.054 mm

0.0007-0.00212 in

Piston to Bore Clearance (Service Limit)

0.018-0.054 mm
(Maximum)

0.0007-0.00212 in
(Maximum)

Piston Pin Clearance to Piston Bore (Production)

0.01-0.02 mm

0.0004-0.00078 in

Piston Pin Clearance to Piston Bore (Service Limit)

0.01-0.02 mm
(Maximum)

0.0004-0.00078 in
(Maximum)

Piston Pin

Piston Pin Diameter

23.997-24.0 mm

0.9447-0.9448 in

Piston Pin Fit in Connecting Rod

0.02-0.043 mm
(Interference)

0.00078-0.00169 in
(Interference)

Piston Compression Ring End Gap (Production-Top) (Measured in

Cylinder Bore)

0.23-0.38 mm

0.009-0.0149 in

Piston Compression Ring End Gap (Production-2nd) (Measured in

Cylinder Bore)

0.44-0.64 mm

0.0173-0.0251 in

Piston Oil Ring End Gap (Production) (Measured in Cylinder Bore)

0.18-0.69 mm

0.007-0.0271 in

Piston Compression Ring End Gap (Service-Top) (Measured in

Cylinder Bore)

0.23-0.38 mm
(Maximum)

0.009-0.0149 in
(Maximum)

Piston Compression Ring End Gap (Service-2nd) (Measured in

Cylinder Bore)

0.44-0.64 mm
(Maximum)

0.0173-0.0251 in
(Maximum)

Piston Oil Ring End Gap (Service Limit) (Measured in Cylinder Bore)

0.18-0.69 mm
(Maximum)

0.007-0.0271 in
(Maximum)

Piston Compression Ring Groove Clearance (Production-Top)

0.04-0.085 mm

0.00157-0.003346 in

Piston Compression Ring Groove Clearance (Production-2nd)

0.04-0.08 mm

0.00157-0.003149 in

Piston Rings

Piston Oil Ring Groove Clearance (Production)

0.01-0.22 mm

0.0004-0.00866 in

Piston Compression Ring Groove Clearance (Service-Top)

0.04-0.085 mm
(Maximum)

0.00157-0.003346 in
(Maximum)

Piston Compression Ring Groove Clearance (Service-2nd)

0.04-0.08 mm
(Maximum)

0.00157-0.003149 in
(Maximum)

6-234

Engine Mechanical - 5.7L

Engine

Engine Mechanical Specifications (cont'd)

Specification
Application

Piston Oil Ring Groove Clearance (Service Limit)

Metric

English

0.01-0.22 mm

0.0004-0.00866 in

(Maximum)

(Maximum)

Valve System

45 degrees

Valve Face Angle

Valve Guide Installed Height (Measured from the Cylinder Head
Spring Seat Surface to the Top of the Valve Guide)

17.32 mm

0.682 in

Net Lash-No Adjustment

Valve Lash
Valve Lift (Exhaust)

12.15 mm
11.99 mm

Valve Lift (Intake)

Valve Lifter

0.479 in
0.472 in
Hydraulic Roller

Valve Margin

0.05 in (Minimum)

1.25 mm (Minimum)
1.70:1

Valve Rocker Arm Ratio

46 degrees
0.05 mm (Maximum)
0.002 in (Maximum)
0.07 in
1.78 mm

Valve Seat Angle

Valve Seat Runout
Valve Seat Width (Exhaust)
Valve Seat Width (Intake)

1.02 mm
52.9 mm

Valve Spring Free Length

Valve Spring Installed Height (Exhaust)
Valve Spring Installed Height (Intake)
Valve Spring Pressure (Closed)
Valve Spring Pressure (Open)
Valve Stem Clearance (Production-Exhaust)

0.04 in
2.08 in
1.8 in
1.8 in

45.75 mm
45.75 mm
340 N at 45. 75 mm
980 N at 33.55 mm

76 lb at 1.8 in
220 lb at 1.32 in

0.025-0.066 mm

0.001-0.0026 in

Valve Stem Clearance (Production-Intake)

0.025-0.066 mm

0.001-0.0026 in

Valve Stem Clearance (Service-Exhaust)

0.093 mm (Maximum)

0.0037 in (Maximum)

Valve Stem Clearance (Service-Intake)

0.093 mm (Maximum)

0.0037 in (Maximum)

Valve Stem Diameter (Production)

Valve Stem Diameter (Service)

7.955-7.976 mm

0.313-0.314 in

7.95 mm (Minimum)

0.313 in (Minimum)

18.1-19.1 mm

0.712-0.752 in

Valve Stem Oil Seal Installed Height (Measured from the Valve Spring
Shim to Top Edge of Seal Body)

GM SPO Group Numbers

Application

Camshaft
Camshaft Bearing
Camshaft Timing Chain
Connecting Rod

GM SPO Group Number

0.519
0.539
0.724

Coolant Radiator

0.603
0.616
1.219

Crankshaft

0.646

Crankshaft Balancer

0.659
0.096
0.649
1.430

Connecting Rod Bearing Kit

Crankshaft Bearing Kit

Crankshaft Transmission Pilot Bearing
Crankshaft Oil Deflector
Crankshaft Front Oil Seal
Crankshaft Rear Oil Seal
Cylinder Head
Cylinder Head Gasket
Engine Block

0.213
0.137
0.269
0.289
N.S.

l.

Engine

Engine Mechanical - 5.7L

6-235

GM SPO Group Numbers (cont'd)

Application

')

\
I

GM SPO Group Number

Engine Cooling Thermostat

1.246

Engine Front Cover

0.206

Engine Front Cover Gasket

0.207

Engine Flywheel (Automatic Transmission)

0.666

Engine Flywheel (Manual Transmission)

0.666

Engine Rear Cover

0.137

Engine Rear Cover Gasket

0.137

Exhaust Manifold

3.601

Exhaust Manifold Gasket

3.27

Ignition Coil

2.17

Intake Manifold

3.265

Intake Manifold Gasket

3.270

Oil Filter

1.836

Oil Level Indicator

1.516

Oil Level Indicator Tube

1.516

Oil Pan

1.426

Oil Pan Gasket

1.429

Oil Pump

1.652

Oil Pump Screen

1.656

Oil Pan Cover

1.426

Oil Pan Cover Gasket

1.429

Piston with Pin

0.629

Piston with Ring Kit

0.643

Radiator Fan Shroud

1.277

Spark Plug

2.270

Starter Motor

2.041

Throttle Body

3.335

Throttle Body Gasket

3.336

Valley Cover

3.265

Valley Cover Gasket

3.270

Valve Lifter

0.459

Valve Lifter Guide

0.439

Valve Pushrod

0.426

Valve Rocker Arm

0.333

Valve Rocker Arm Cover

0.386

Valve Rocker Arm Cover Gasket

0.423

Valve Rocker Arm Support

0.429

Valve Spring

0.303

Valve Spring Shim

0.303

Valve Stem Oil Seal

0.308

Vapor Vent Pipe

0.1097

Vapor Vent Pipe Gasket

0.1097

Water Pump Gasket

1.079

Water Pump with Gasket

1.069

6-236

Engine Mechanical - 5.7L

Engine

Sealers, Adhesives, and Lubricants

Application

Type of Material

GM Part Number

Coolant Sensor Threads

Sealant

12346004

Cylinder Head Core Hole Plugs

Thread lock

12345382

Cylinder Head Expansion Plugs

Threadlock

12345382

Cylinder Head MB Bolt Threads

Threadlock

12345382

Engine Block Front Oil Gallery Plug

Thread lock

12345382

Engine Block Plug Sealing Washers

Sealant

12346004

Engine Flywheel Bolt Threads

Threadlock

12345382

Engine Oil (FN Car)

5W-30 Oil

12345610

Engine Oil (Y Car)

5W-30 Synthetic Oil

12345885

Engine Oil Supplement

Lubricant

12345795

Exhaust Manifold Bolt Threads

Thread lock

12345493

Fuel Rail Bolt Threads

Threadlock

12345382

Ignition Coil and Bracket Assembly Bolts

Thread lock

12345382

Intake Manifold Bolt Threads

Thread lock

12345382

Oil Pan Surface at Front and Rear Covers

Sealant

12378190

Oil Pressure Sensor Threads

Sealant

12346004

Engine

Engine Mechanical - 5.7L

6-237

Thread Repair Specifications

Engine Block-Front View

16
17

14

19.
64583

Hole

Thread
Size
M8

1-6

x 1.25

x 1.5

x 1.5

x 1.25

10

x 1.5

11-13

x 1.25

14

x 1.25

15

x 1.25

16

x 1.25

17-27

x 1.25

M10
M10
M8
M10
M8
M8
M8
M8
M8

Driver

Drill Depth
(Maximum)
mm (in)

Tap Depth
(Maximum)
mm (in)

Insert

Drill

Counterbore
Tool

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

J 42385-215

J 42385-211

J 42385-212

J 42385-213

J 42385-214

25.0 (0.984)

19.5 (0.767)

J 42385-215

J 42385-211

J 42385-212

J 42385-213

J 42385-214

32.5 (1.28)

25.0 (0.984)

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

J 42385-215

J 42385-211

J 42385-212

J 42385-213

J 42385-214

Thru

Thru

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

Thru

18.0 (0.708)

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

Thru

18.0 (0.708)

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17 .5 (0.688)

Tap

6-238

Engine Mechanical - 5.7L

Engine

Engine Block-Rear View

3

15

12

11

10

(
64590

Hole
1
2-4
5-6
7-13
14-16
17-18

Thread
Size
M10
x 1.5
MB

x 1.25
M10

x 1.5
MB

x 1.25
M10

x 1.5
MB

x 1.25

Driver

Drill Depth
(Maximum)
mm (in)

Tap Depth
(Maximum)
mm (in)

Insert

Drill

Counterbore
Tool

J 42385-215

J 42385-211

J 42385-212

J 42385-213

J 42385-214

27.0 (1.06)

21.5 (0.846)

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688}

J 42385-215

J 42385-211

J 42385-212

J 42385-213

J 42385-214

27.0 (1.06)

21.5 (0.846)

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

J 42385-215

J 42385-211

J 42385-212

J 42385-213

J 42385-214

27.0 (1.06)

21.5 (0.846)

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17 .5 (0.688)

Tap

Engine Mechanical'! 5.7L

Engine

6-239

Engine Block-Left Side View

19

18 17

16

15

13

14

12
64602

Hole

Thread
Size
M8

x 1.25

2-3

x 2.0

x 1.25
M6 x 1.0

5
6-7

M11
M8

M11
x 2.0
M8

x 1.25

x 2.0

10

x 2.0

11

x 1.5

12-17

M11
M11
M16
M10

x 1.5

Driver

Drill Depth
(Maximum)
mm (in)

Tap Depth
(Maximum)
mm (in)

J 42385-208

J 42385-209

26.5 (1.04)

19.0 (0.784)

J 42385-106

J 42385-107

124.0 (4.88)

115.0 (4.52)

Insert

Drill

Counterbore
Tool

J 42385-210

J 42385-206

J 42385-207

J 42385-108

J 42385-105

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

26.5 (1.04)

19.0 (0.784)

J 42385-205

J 42385-201

J 42385-202

J 42385-203

J 42385-204

22.5 (0.885)

16.0 (0.629)

J 42385-108

J 42385-105

J 42385-106

J 42385-107

124.0 (4.88)

115.0 (4.52)

J 42385-210

J 42385-206

J 42385-208

J 42385-209

26.5 (1.04)

19.0 (0.784)

J 42385-108

J 42385-105

J 42385-106

J 42385-107

69.0 (2.72)

60.0 (2.36)

J 42385-108

J 42385-105

J 42385-106

J 42385-107

124.0 (4.88)

115.0 (4.52)

J 42385-215

J 42385-211

J 42385-207

J 42385-212

Tap

J 42385-213

J 42385-214

29.0 (1.14)

23.0 (0.905)

6-240

Hole

Engine

Engine Mechanical - 5. 7L

Thread
Size

Insert

Drill

Counterbore
Tool

Tap

18

M28
x 1.25

19-20

M8
x 1.25

J 42385-210

J 42385-206

21

M16
x 1.5

22

M10
x 1.5

J 42385-215

J 42385-211

J 42385-212

J 42385-213

23

M11
x 2.0

J 42385-108

J 42385-105

24

M11
x 2.0

J 42385-108

J 42385-105

25

M8
x 1.25

J 42385-210

J 42385-206

26-27

M11
x 2.0

J 42385-108

J 42385-105

28

M6 x 1.0

J 42385-205

J.42385-201

29

M8
x 1.25

J 42385-210

J 42385-206

J 42385-207

J 42385-208

Driver

J 42385-209

Drill Depth
(Maximum)
mm (in)

Tap Depth
(Maximum)
mm (in) '

21.0 (0.826}

16.0 (0.629)

J 42385-214

27.0 (1.06)

21.5 (0.846)

J 42385-106

J 42385-107

124.0 (4.88)

115.0 (4.52)

J 42385-106

J 42385-107

69.0 (2.72)

60.0 (2.36)

J 42385-208

J 42385-209

26.5 (1.04)

19.0 (0.784)

J 42385-106

J 42385-107

124.0 (4.88)

115.0 (4.52)

J 42385-202

J 42385-203

J 42385-204

22.5 (0.885)

16.0 (0.629)

J 42385-207

J 42385-208

J 42385-209

26.5 (1.04)

19.0 (0.784)

J 42385-207

Bolt holes 2, 3, 6, 7, 10, 23, 26, and 27 have a 85 mm (3.34 in) counterbore included in the 124.0 mm (4.88 in)
drill depth.
Bolt holes 9 and 24 have a 30 mm (1.18 in) counterbore included in the 69.0 mm (2.72 in) drill depth. Use sleeve
J 42385-315 with the drill and tap.

Engine Mechanical - 5.7L 6-241

Engine
Engine Block-Right Side View

)
64579

Hole

Thread
Size

Insert

Drill

Counterbore
Tool

J 42385-207

Driver

Drill Depth
(Maximum)
mm (in)

Tap Depth
(Maximum)
mm (in)

J 42385-208

J 42385-209

26.5 (1.04)

19.0 (0.784)

J 42385-106

J 42385-107

124.0 (4.88)

115.0 (4,52)

Tap

M8
x 1.25

J 42385-210

J 42385-206

2-3

M11
x 2.0

J 42385-108

J 42385-105

M8
x 1.25

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

26.5 (1.04)

19.0 (0.784)

M6 x 1.0

J 42385-205

J 42385-201

J 42385-202

J 42385-203

J 42385-204

22.5 (0.885)

15.0 (0.590)

6-7

M11
x 2.0

J 42385-108

J 42385-105

J 42385-106

J 42385-107

124.0 (4.88)

115.0 (4.52)

MB
x 1.25

J 42385-210

J 42385-206

J 42385-208

J 42385-209

26.5 (1.04)

19.0 (0.784)

M11
x 2.0

J 42385-108

J 42385-105

J 42385-106

J 42385-107

69.0 (2.72)

60.0 (2.36)

10

M11
x 2.0

J 42385-108

J 42385-105

J 42385-106

J 42385-107

124.0 (4.88)

115.0 (4.52)

11-14

M10
x 1.5

J 42385-215

J 42385-211

J 42385-213

J 42385-214

27.0 (1.06)

21.5 (0.846)

J 42385-207

J 42385-212

6-242

Hole

Engine Mechanical - ~.7L

Thread
Size
M10

15-19

x 1.5

20

x 1.5

21

x 1.25

22

x 2.0

23

x 2.0

24
25-26
27
28

M16
M8
M11
M11
M8

x 1.25
M11

x 2.0
M6 x 1.0
M8
x 1.25

Insert

Engine

Drill

Counterbore
Tool

Tap

J 423'85-211

J 42385-212

J 42385-213

Driver

Drill Depth
(Maximum)
mm (in)

Tap Depth
(Maximum)
mm (in)

J 42385-214

29.0 (1.14)

23.0 (0.905)

J42385-215

J 42385-210

J 42385-206

J 42385-108

J 4238.5-105

J 42385-108

J 42385-105

J 42385-210

J 42385-206

J 42385-108

J 42385-105

J 42385-205

J 42385-201

J 42385-210

J 42385-206

Bolt holes 2, 3, 6, 7, 10, 22, 25, and 26 have

drill depth.

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

J 42385-106

J 42385-107

124.0 (4.88)

115.0 (4.52)

J 42385-106

J 42385-107

69.0 (2.72)

60.0 (2.36)

J 42385-208

J 42385-209

26.5 (1.04)

19.0 (0.784)

J 42385-106

J 42385-107

124.0 (4.88)

115.0 (4.52)

J 42385-202

J 42385-203

J 42385-204

22.5 (0.885)

15.0 (0.590)

J 42385-207

J 42385-208

J 42385-209

26.5 (1.04)

19.0 (0.784)

J 42385-207

J 42385-207
-

a 85 mm (3.34 in) counterbore included in the 124.0 mm (4.88 in)

Bolt holes 9 and 23 have a 30 mm (1.18 in).counterbore included in the 69.0 mm (2.72 in) drill depth. Use sleeve
J 42385-315 with the drill and tap.

Engine

Engine Mechanical - 5.. 7L

6-243

Engine Block-Bottom View

25

24 23 22 21 20

19

18

16 15

17

64655

Hole
1

Thread
Size
M10
x 2.0
M10

x 2.0

x 1.25

x 2.0

x 2.0

x 1.5

N/A

x 1.25

x 2.0

10-11

x 2.0

12

x 2.0

M8
M10
M10
M16

M8
M10
M10
M10

Tap

Driver

Drill Depth
(Maximum)
mm (in)

J 42385-102

J 42385-103

31.0 (1.22)

25.5 (1.0)

J 42385-102

J 42385-103

53.5 (2.10)

44.0 (1.73)

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17 .5 (0.688)

J 42385-101

J 42385-102

J 42385-103

31.0 (1.22)

25.5 (1.0)

J 42385-101

J 42385-102

J 42385-103

53.5 (2.10)

44.0 (1.73)

N/A

Insert

Drill

J 42385-104

J 42385-101

J 42385-104

J 42385-101

J 42385-210

J 42385-206

J 42385-104
J 42385-104

J 42385-210

J 42385-206

J 42385-104

J 42385-101

J 42385-104
J 42385-104

Counterbore
Tool

J 42385-207

Tap Depth
(Maximum)
mm (in)

J 42385-208

J 42385-209

22.5 (0.885)

17 .5 (0.688)

J 42385-102

J 42385-103

31.0 (1.22)

25.5 (1.0)

J 42385-101

J 42385-102

J 42385-103

53.5 (2.10)

44.0 (1.73)

J 42385-101

J 42385-102

J 42385-103

31.0 (1.22}

25.5 (1.0)

6-244

Hole

13-14

Engine

Engine Mechanical - 5,7L

Thread
Size

M10
x 1.5
M8

15

x 1.25

16

x 1.5

17

x 2.0

18

x 2.0

19

x 1.25

20

x 2.0

21

x 2.0

22

x 1.25

23

x 2.0

24

x 2.0

25-26

x 1.25

27

x 2.0

28-29

x 2.0

30

x 2.0

31
32

x 1.25

33

x 1.25

34

x 2.0

35

x 2.0

36

x 1.25

M16

Insert

Drill

J 42385-215

J 42385-101

J 42385-210

J 42385-206

Tap

Driver

Drill Depth
(Maximum)
mm (in)

J 42385-213

J 42385-214

42.5 (1.67)

37.0 (1.45)

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

Counterbore
Tool

Tap Depth
(Maximum)
mm (in)

J 42385-104

J 42385-101

J 42385-102

J 42385-103

53.5 (2.10)

44.0 (1.73)

J 42385-104

J 42385-101

J 42385-102

J 42385-103

31.0 (1.22)

25.5 (1.0)

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

J 42385-104

J 42385-101

J 42385-102

J 42385-103

53.5 (2.10)

44.0 (1.73)

J 42385-104

J 42385-101

J 42385-102

J 42385-103

31.0 (1.22)

25.5 (1.0)

J 42385-210

J 42385-206

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

J 42385-104

J 42385-101

J 42385-102

J 42385-103

31.0 (1.22)

25.5 (1.0)

J 42385-104

J 42385-101

J 42385-102

J 42385-103

53.5 (2.10)

44.0 (1.73)

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

J 42385-104

J 42385-101

J 42385-102

J 42385-103

31.0 (1.22)

25.5 (1.0)

J 42385-104

J 42385-101

J 42385-102

J 42385-103

53.5 (2.10)

44.0 (1.73)

J 42385-104

J 42385-101

J 42385-102

J 42385-103

31.0 (1.22)

25.5 (1.0)

x 1.25

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

M28

M10
M10
M8
M10
M10
M8
M10
M10
M8
M10
M10
M10
M8

M8
M10
M10
M8

J 42385-207

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

J 42385-104

J 42385-101

J 42385-102

J 42385-103

53.5 (2.10)

44.0 (1.73)

J 42385-104

J 42385-101

J 42385-102

J 42385-103

31.0 (1.22)

25.5 (1.0)

J 42385-210

J 42385-206

J 42385-208

J 42385-209

22.5 (0.885)

17.5 (0.688)

J 42385-207

Bolt holes 2, 5, 10, 11, 18, 21, 24, 28, 29, and 34 have a 20.5 mm (0.807 in) counterbore included in the 53.5 mm
(2.1 O in) drill depth.
Bolt holes 1, 4, 9, 12, 17, 20, 23, 27, 30, and 35 have a 1.5 mm (0.059 in) counterbore included in the 31.0 mm (1.22 in)
drill depth. Use sleeve J 42385-316 with the drill and tap.
Bolt holes 13 and 14 have a 11.5 mm (0.452 in) counterbore included in the 42.5 mm (1.67 in) drill depth. Use sleeve
J 42385-311 with the drill and tap.

Engine

Engine Mechanical - 5.7L

6-245

Engine Block-Top View

14

11

10

7
64573

Hole

Thread
Size
MB

1-4

x 1.25

x 1.5

6-7

x 1.25

x 1.5

9-10

x 1.25

11

x 1.5

12-14

x 1.25

M16
MB
M10
MB
M10
MB

Driver

Drill Depth
(Maximum)
mm (in)

Tap Depth
(Maximum)
mm (in)

J 42385-209

26.5 (1.04)

19.0 (0.784)

Insert

Drill

Counterbore
Tool

J 42385-210

J 42385-206

J 42385-207

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

26.5 (1.04)

19.0 (0.784)

J 42385-216

J 42385-211

J 42385-212

J 42385-213

J 42385-214

22.5 (0.885)

17 .0 (0.669)

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

26.5 (1.04)

19.0 (0.784)

J 42385-216

J 42385-211

J 42385-212

J 42385-213

J 42385-214

22.5 (0.885)

17.0 (0.669)

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

26.5 (1.04)

19.0 (0.784)

Tap

J 42385-208

6-246

Engine

Engine Mechanical - 5. 7L

Cylinder Head-Top View

12

11

10

64486

Hole
1-2
3
4-5
6
7
8-12
13
14
15

Thread
Size
M8

x 1.25
M6 x 1.0
MB

x 1.25
M6 x 1.0
M8

x 1.25
M6 x 1.0
M8

x 1.25
M6 x 1.0
M8

x 1.25

Driver

Drill Depth
(Maximum)
mm (in)

Tap Depth
(Maximum)
mm (in)

Insert

Drill

Counterbore
Tool

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

26.5 (1.04)

19.0 (0.784)

J 42385-205

J 42385-201

J 42385-202

J 42385-203

J 42385-204

22.0 (0.866)

18.0 (0.708)

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

26.5 (1.04)

19.0 (0.784)

J 42385-205

J 42385-201

J 42385-202

J 42385-203

J 42385-204

22.0 (0.866)

18.0 (0.708)

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

26.5 (1.04)

19.0 (0.784)

J 42385-205

J 42385-201

J 42385-202

J 42385-203

J 42385-204

22.0 (0.866)

18.0 (0.708)

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

26.5 (1.04)

19.0 (0.784)

J 42385-205

J 42385-201

J 42385-202

J 42385-203

J 42385-204

22.0 (0.866)

18.0 (0.708)

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

26.5 (1.04)

19.0 (0.784)

Tap

Engine

Engine Mechanical - 5.7L

6-247

Cylinder Head-End View

6~

~1

3
64503

Hole

Thread
Size

M10
x 1.5

N/A

x 1.5

M10

N/A

5-6

M10
x 1.5

Insert

Drill

Counterbore
Tool

J 42385-215

J 42385-211

J 42385-212

J 42385-215

J 42385-211

J 42385-215

J 42385-211

J 42385-212

J 42385-212

Tap

J 42385-213

J 42385-213
-

J 42385-213

Driver

Drill Depth
(Maximum)
mm (in)

Tap Depth
(Maximum)
mm (in)

J 42385-214

28.0 (1.10)

20.0 (0.787)

J 42385-214

28.0 (1.10)

20.0 (0.787)

J 42385-214

28.0 (1.10)

20.0 (0.787)

6-248

Engine

Engine Mechanical - 5.7L

Cylinder Head-Exhaust Manifold Deck View

4
64555

Hole
1-2
3

Thread
Size
M10
x 1.5
MB

x 1.25

Driver

Drill Depth
(Maximum)
mm (in)

Tap Depth
(Maximum)
mm (in)

Insert

Drill

Counterbore
Tool

J 42385-215

J 42385-211

J 42385-212

J 42385-213

J 42385-214

28.0 (1.10)

20.0 (0.787)

J 42385-210

J 42385-206

J 42385-207

J 42385-208

J 42385-209

21.0 (0.826)

16.0 (0.629)

J 42385-210

J 42385-206

M14
x 1.25

MB
x 1.25

M14
x 1.25

7-8

MB
x 1.25

J 42385-210

J 42385-206

M14
x 1.25

10

MB
x 1.25

11

J 42385-210

J 42385-206

M14
x 1.25

12

MB
x 1.25

J 42385-210

J 42385-206

13

M12
x 1.5

14-15

M10
x 1.5

J 42385-215

J 42385-211

J. 42385-207
-

J 42385-207
-

J 42385-207
-

J 42385-207
-

J 42385-212

Tap

J 42385-208
-

J 42385-209

J 42385-208

J 42385-209

J 42385-208

J 42385-209

J 42385-208

J 42385-209

J 42385-213

J 42385-214

21.0 (0.826)
-

21.0 (0.826)
-

21.0 (0.826)
-

21.0 (0.826)
-

28.0 (1.10)

16.0 (0.629)
-

16.0 (0.629)

16.0 (0.629)
-

16.0 (0.629)
-

20.0 (0.787)

Engine Mechanical - 5.7L

Engine

6-249

Cylinder Head-Intake Manifold Deck View

1

64557

Hole

Thread
Size

1-2

M6 x 1.0

3-4

M6 x 1.0

5-7

M6 x 1.0

Insert

Drill

Counterbore
Tool

J 42385-205
J 42385-205
J 42385-205

J 42385-201
J 42385-201
J 42385-201

J 42385-202
J 42385-202
J 42385-202

Tap

Driver

J 42385-203
J 42385-203
J 42385-203

J 42385-204
J 42385-204
J 42385-204

Drill Depth
(Maximum)
mm (in)

Tap Depth
(Maximum)
mm (in)

Thru

Thru

22.5 (0.885)

15.0 (0.688)

Thru

Thru

6-250

Engine Mechanical - 5.7L

Engine

Diagnostic Information and Procedures

Base Engine Misfire Diagnosis
Checks

Action

Engine performance diagnosis procedures are covered in Engine Controls and should be consulted for diagnosis of any
Driveability, Emissions, or Malfunctioning Indicator Lamp (MIL) concerns.
The following diagnosis covers common concerns and possible causes.
When the proper diagnosis is made, the concern should be corrected by adjustment, repair or replacement as required.
Refer to the appropriate section of the service manual tot each specific procedure.
This diagnostic table will assist in engine misfire diagnosis due to a mechanical concern such as a faulty camshaft, worn or

damaged bearings or bent pushrod.

This table will not isolate a crossed injector wire, faulty injector or any 0U1er driveability component failure that may cause a
misfire.
The Powertrain On-Board Diagnostic System checks must be performed first.
When using this table to make a Base Engine Misfire diagnosis, begin with the preliminary information below and then

proceed to the specific category.

Preliminary

1. Perform OTC P0300 before proceeding with Base Engine Misfire Diagnosis
information.
OTC P0300 will assist in determining which cylinder or cylinders are misfiring.
2. Perform a visual inspection for the following:
A loose or improperly installed engine flywheel or crankshaft balancer
Worn, damaged, or misaligned accessory drive system components
3. Listen to the engine for any abnormal internal engine noises.
4. lnspecUhe engine for acceptable oil pressure.
Refer to Oil Pressure Diagnosis and Testing.
5. Verify if the engine has excessive oil consumption.
6. Verlfy if the engine has coolant consumption.
7. Perform a compression test on the engine.
Refer to Engine Compression Test.

Intake Manifold Leaks

An intake manifold that has a vacuum leak may cause a misfire.

Inspect for the following:
Improperly installed or damaged vacuum hoses
Faulty or improperly installed intake manifold and/or gaskets
Loose Exhaust Gas Recirculaton (EGR) valve pipe or damaged or missing
0-ring seal
Cracked or damaged intake manifold
Inspect the areas between the intake runners.
Improperly installed or damaged Manifold Absolute Pressure (MAP) sensor
housing (located at the rear of the intake manifold)
Improperly installed or damaged MAP sensor housing 0-ring seal
Improperly installed MAP sensor or vacuum hoses
The sealing grommet of the MAP sensor should not be torn or damaged.
Improperly installed throttle body or damaged gasket
A loose EGR valve pipe assembly or damaged or missing 0-ring seal
Warped intake manifold
Warped or damaged cylinder head sealing surface

Coolant Consumption

Coolant consumption may or may not cause the engine to overheat.

Inspect for the following:
External coolant leaks
Faulty cylinder head gasket
Warped cylinder head
Cracked cylinder head
Damaged engine block

Engine

Engine Mechanical - 5.7L

6-251

Base Engine Misfire Diagnosis (cont'd)

Checks

Oil Consumption

Action

1. Oil consumption may or may not cause the engine to misfire.

2. Remove the spark plugs and inspect for an oil fouled spark plug.
3. Perform a cylinder compression test.
Refer to Engine Compression Test.
4. If the compression test indicates worn valves or valve guides, inspect for the
following:
Worn valve guides
Worn valve stems
Worn or burnt valves or valve seats
Worn, brittle, or improperly installed valve stem oil seals
5. If the compression test indicates worn or damaged piston rings, inspect the
following:

Abnormal Internal Engine Noises

Broken or improperly seated piston rings

Excessive piston ring end gap
Excessive cylinder bore wear or taper
Cylinder damage
Piston damage

1. With the engine running try and determine if the noise is timed to camshaft
speed or crankshaft speed.

2. Using a timing light, two knocks per flash is crankshaft speed and one knock
per flash is camshaft speed.

3. If the noise is timed to camshaft speed, inspect the following:

Missing or loose valve train components
Worn or loose valve rocker arms
Worn or bent pushrods
Faulty valve springs
Bent or burnt valves
Worn camshaft lobes
Worn or damaged timing chain and/or sprockets
Important: A slight COLD knock or piston slapping noise could be considered
normal if not present after the engine has reached normal operating temperatures.
4. If the knock is timed to crankshaft speed, inspect the following:
Worn crankshaft main or connecting rod bearings
Piston or cylinder damage
Worn piston or piston pin

Damaged or faulty connecting rod

Excessive carbon build-up on the top of the piston
No Abnormal Internal Engine Noise

1. Inspect for a worn or improperly installed timing chain and/or sprockets.

2. Remove the valve rocker arm cover on the side of the engine with the cylinder
that is misfiring.

3. Inspect for the following:

Loose valve rocker arm bolts

Bent push rods
Faulty valve springs
Faulty valve lifters (bleeding down)
Worn or improperly seated valves
Worn camshaft lobes

6-252

Engine Mechanical - 5.7L

Engine

Engine Compression Test

1. Charge the battery if the battery is not fully
charged.
2. Disable the ignition system.
3. Disable the fuel injection system.
4. Remove all the spark plugs.
5. Block the throttle plate wide open.
6. Start with the compression gauge at zero, and
crank the engine through four compression
strokes (four puffs).
7. Make the compression check for each cylinder.
Record the reading.
8. If a cylinder has low compression, inject
approximately 15 ml (one tablespoon) of engine
oil into the combustion chamber through the spark
plug hole.
Recheck the compression and record the reading.

9. The minimum compression in any one cylinder

should not be less than 70 percent of the highest
cylinder. No cylinder should read less
than 690 kPa (100 psi). For example, if the
highest pressure in any one cylinder is 1035 kPa
(150 psi), the lowest allowable pressure for
any other cylinder would be 725 kPa (105 psi).
(1035 x 70% = 725) (150 x 70% = 105).
Normal - Compression builds up quickly and
evenly to the specified compression for each
cylinder.
Piston Rings Leaking - Compression is low
on the first stroke. Compression then builds
up with the following strokes but does not
reach normal. Compression improves
considerably when you add oil.
Valves Leaking - Compression is low on the
first stroke. Compression usually does not
build up on the following strokes. Compression
does not improve much when you add oil.
If two adjacent cylinders have lower than
normal compression and injecting oil into
the cylinders does not increase the
compression, the cause may be a head gasket
leaking between the cylinders.

Engine Noise Diagnosis

Symptom

Cause

There are four steps to diagnosing engine noise. You must determine the following:
The type of noise
For example, is the noise a light rattle/tapping or a low rumble/knocking?
The exact operating condition under which the noise exists
Note factors such as the ambient temperature, the amount of engine warm-up time, the engine temperature, engine
RPMs, and other specifics.
At what rate the noise occurs., and at what location in the engine
Remember, engine noises are generally synchronized to either engine speed (crankshaft, flywheel, connecting rods,
balancer, or pistons and related components) or one-half engine speed (valve train noise such as rocker arms, valve
lifters, and timing chain). Try to determine the rate at which the noise is occurring.
Compare the engine sounds to other engines and make sure you are not trying to correct a normal condition.
Noise on Start-Up but Only Lasts a
Few Seconds

Improper oil viscosity. Install the recommended oil viscosity for the expected
temperatures.
Incorrect oil filter without the anti-drainback feature
Worn or dirty valve lifters
Excessive piston to bore clearance
Excessive piston pin to piston clearance
Excessive crankshaft bearing clearance

Knocks Cold and Continues for

1 to 2 Minutes

Loose or broken crankshaft balancer or accessory drive components

Excessive piston to bore clearance
A cold piston knock which disappears in 1.5 minutes should be considered
acceptable.
A cold engine knock usually disappears when the specific cylinders secondary
ignition circuit is grounded out.

Intermittent Noise on Idle,

Disappearing When Engine Speed is
Increased

Improper oil viscosity. Install the recommended oil viscosity for the expected
temperatures.
Lower than specified oil pressure
Install an oil pressure gauge and measure the engine oil pressure.
Dirty or worn valve lifter

Engine

Engine Mechanical - 5.7L

5...253

Engine Noise Diagnosis (cont'd)

Symptom

Valve Train Noise (Rattle/Tapping)

Cause

The following conditions may cause valve train noise:

Lower than specified oil pressure
Worn or faulty oil pump

Knocks at Idle Hot

(Rumble/Knocking)

Loose oil pump-to-engine block b.olts

Loose valve rocker arm attachments
Worn valve rocker arm bearings
Worn valve rocker arm and/or pushrod
Broken valve spring
Sticking valves
Worn, dirty, or faulty valve lifters
Worn camshaft lifter lobes
Worn valve guides or valve stems
Bent, broken, or damaged timing chain sprocket teeth

The following conditions may cause a knocking noise:

Malfunctioning accessory drive system components
Loose or broken crankshaft balancer
Loose prop shaft hub or clamp (Corvette only)
Detonation or spark knock
Check for proper operation of the cooling, knock, and ignition control
components.

Exhaust System Noise and/or

Leakage

Refer to diagnostic information in Engine Controls.

Excessive connecting rod bearing clearance
Excessive piston pin to bore clearance
Bent connecting rod
Excessive crankshaft main or thrust bearing clearance
Loose torque converter bolts
Cracked or damaged flywheel
Exhaust leak at the manifold

Exhaust system noise and/or leakage may be caused by the following conditions:
Improperly installed or misaligned exhaust system components
A cracked or broken exhaust manifold
Damaged or worn gaskets and/or seals
Burned or rusted out exhaust system components
A broken or loose exhaust clamp and/or bracket

Engine

6-254 Engine Mechanical - 5.7l

Valve Train Diagnosis
Symptom

Cause

A light tapping noise at one-half englne speed, or any varying frequency, may indicate a valve train problem.
These tapping noises will typically increase with engine speed.
Before attempting to diagnose valve train noise, check for the proper oil level and thoroughly warm up the engine.
By doing this you will bring all engine components to a normal state of expansion.
While sitting in the drivers seat, run the engine at various speeds and listen for any abnormal engine noise.
The Causes of Valve Train Noise
May Include the Following Conditions:

Low engine oil pressure

Worn or faulty oil pump

A loose or plugged oil pump screen
Loose valve rocker arm attachments (causing excessive valve lash)
Worn or damaged valve rocker arm bearings
Worn valve rocker arm and/or pushrod

Broken valve spring

Sticking valves
Valve lifters worn, dirty, or faulty
Broken valve lifter guide
Camshaft valve lifter lobes worn
Worn valve guides or valve stems
Worn or damaged valve keys
Bent pushrods
Excessive play in the camshaft timing chain
Bent, broken, or damaged timing chain sprocket teeth

Diagnostic Table
Step

Action

Value(s)

Yes

No

Go to Step 2

System OK

Drain the oil to

the proper level.
System OK

Go to Step 3

Add oil as
required.
System OK

Go to Step 4

Go to Step 7

Go to Step 5

Repair as
required.
System OK

Go to Step 6

Repair as
required.
System OK

Go to Step 10

DEFINITION: A light tapping noise at one half engine speed, or any varying frequency.
1

Is there valve train noise?

Check for a high engine oil level. A engine with the oil
level above the FULL mark allows the crankshaft
counterweights to churn the oil into foam. When foamy oil
is pumped into the lifters, the lifters become noisy. A solid
column of oil ensures proper lifter operation.
Is the oil level too high?

Check for a low engine oil level. A engine with the oil level
below the ADD mark may allow the oil pump to pump air
at high engine RPM's.
Is the oil level too low?

Check for proper engine oil pressure. Refer to Engine

Mechanical Specifications and Oil Pressure Diagnosis and
Testing.

Is the engine oil pressure within specifications?

1. Check the oil pump screen for damage or a loose fit
to the oil pump.

2. Inspect for a missing or damaged oil pump screen

0-ring seal.
Is the oil pump screen loose or is the screen or 0-ring
seal damaged?
Check for a damaged oil pump or loose mounting bolts
Refer to Oil Pump Clean and Inspect
Is the oil pump damaged or are the fasteners loose?

Engine Mechanical - 5.7L

Engine

6-255

Diagnostic Table (cont'd)

Action

Step

Are components worn or damaged?

Yes

No

Replace the
components as
required.
System OK

Go to Step B

Value(s)

Remove and inspect the valve lifters, rocker arms, and

pushrods. Refer to Valve Rocker Arm and Push Rods
Clean and Inspect and Valve Lifters and Guides Clean and
Inspect.

Perform a camshaft lobe lift test. Refer to Camshaft and

Bearings Clean and Inspect

Go to Step 9

Replace the
camshaft and
valve lifters.
System OK

Replace the
components as
required.
System OK

Go to Step 10

Replace the
components as
required.

System OK

Camshaft is OK

Is the test within Engine Mechanical Specifications ?

10

Remove the engine front cover and inspect the timing

chain and sprockets for excessive wear or damage.
Refer to Timing Chain and Sprockets Clean and Inspect
Are the components worn or damaged?
Perform a complete disassembly of the engine and inspect
all components.
Are the components worn or damaged?

Oil Consumption Diagnosis

Checks

Causes

Excessive oil consumption (not due to leaks) is the use of 0.95 liters (1.0 qt) or more of engine oil within 2 414 kilometers
(1,500 miles).
The causes of excessive oil consumption may include the following conditions:
Preliminary

External oil leaks

Refer to oil leak diagnosis.
Incorrect oil level or improper reading of the oil level indicator
With the vehicle on a level surface, run the engine for a few minutes, allow
adequate drain down time (2-3 minutes) and check for the correct engine
oil level.
Improper oil viscosity
Refer to the vehicle owners manual and use the recommended SAE grade and
viscosity for the prevailing temperatures.
Continuous high speed driving and/or severe usage
Crankcase ventilation system restrictions or malfunctioning components
Worn valve guides and/or valve stems
Worn or improperly installed valve stem oil seals
Piston rings broken, worn, not seated properly
Allow adequate time for the rings to seat.
Replace worn piston rings as necessary.
Piston and rings improperly installed or miss-fitted to the cylinder bore

'\

6-256

Engine

Engine Mechanical - 5.. 7L

Oil Pressure Diagnosis and Testing

Tools Required
J 21867 Pressure Gauge and Hose Assembly
J 42907 Oil Pressure Testing Tool

416607

1. With the vehicle on a level surface, run the

vehicle for a few minutes, allow adequate
drain down time (2-3 minutes) and measure for a
low oil level.

2. If required, add the recommended grade engine

oil and fill the crankcase until the oil level
measures full on the oil level indicator.
3. Run the engine briefly (10-15) seconds and verify
low or no oil pressure on the vehicle gauge
or light.
4. Listen for a noisy valve train or a knocking noise.

5. Inspect for the following:

Oil dilutedby water or glycol (anti freeze)
Foamy oil
6. Remove the oil filter and install the J 42907.
7. Install J 21867 or equivalent to the J 42907.
8. Run the engine and measure the engine oil
pressure.
9. Compare the readings to Engine Mechanical
Specifications.
1O. If the engine oil pressure is below specifications,
inspect the engine for one or more of the following:
Oil pump worn or dirty
Refer to Oil Pump Clean and Inspect.
Oil pump-to-engine block bolts loose
Refer to Oil Pump, Pump Screen and Deflector
Installation.
Oil pump screen loose, plugged, or damaged
Oil pump screen 0-ring seal missing or
damaged
Malfunctioning oil pump pressure
regulator valve
Excessive bearing clearance
Cracked, porous, or restricted oil galleries
Oil gallery plugs missing or incorrectly installed
Refer to Engine Block Plug Installation.
Broken valve lifters
Repair as necessary
11. If the oil pressure reading on the J 21867 or
equivalent is within specifications, inspect for
the following:
Plugged or incorrect oil filter and/or
malfunctioning oil bypass valve
Malfunctioning oil pressure gauge or sensor
Repair as necessary

Oil Leak Diagnosis

Step

Action

Value(s)

Yes

No

DEFINITION: You can repair most fluid leaks by first visually locating the leak, repairing or replacing the component, or by
resealing the gasket surface. Once the leak is identified, determine the cause of the leak. Repair the cause of the leak as
well as the leak itself.

1. Operate the vehicle until it reaches normal operating

temperature.
2. Park the vehicle on a level surface, over a large
sheet of paper or other clean surface.
3. Wait (15 minutes).
4. Check for drippings.
Are drippings present?

Can you identify the type of fluid and the approximate

location of the leak?

Go to Step 2

System OK

Go to Step 10

Go to Step 3

Engine Mechanical - 5.7L

Engine

6-257

Oil Leak Diagnosis (cont'd)

Step

Action

Value(s)

1. Visually inspect the suspected area. Use a small

mirror to assist in looking at hard to see areas.
2. Check for leaks at the following locations:
Sealing surfaces
Fittings
Cracked or damaged components
Can you identify the type of fluid and the approximate
location of the leak?

1. Completely clean the entire engine and surrounding

components.
2. Operate the vehicle for several kilometers (miles) at
normal operating temperature and at varying speeds.
3. Park the vehicle on a level surface, over a large
sheet of paper or other clean surface.
4. Wait (15 minutes).
5. Identify the type of fluid, and the approximate location
of the leak.
Can you identify the type of fluid and the approximate
location of the leak?

Yes

No

Go to Step 10

Go to Step 4

Go to Step 10

Go to Steps

Go to Step 10

Go to Step 6

Go to Step 10

Go to Step 7

Go to Step 10

Go to Step 8

Go to Step 10

Go to Step 9

1. Visually inspect the suspected area. Use a small

mirror to assist in looking at hard to see areas.
2. Check for leaks at the following locations:
5

Sealing surfaces
Fittings
Cracked or damaged components
Can you identify the type of fluid and the approximate
location of the leak?
1. Completely clean the entire engine and surrounding
components.
2. Apply an aerosol-type powder (baby powder, foot
powder, etc.) to the suspected area.
3. Operate the vehicle for several kilometers (miles) at
normal operating temperature and at varying speeds.
4. Identify the type of fluid, and the approximate location
of the leak, from the discolorations in the powder
surface.
Can you identify the type of fluid and the approximate
location of the leak?
1. Visually inspect the suspected area. Use a small
mirror to assist in looking at hard to see areas.
2. Check for leaks at the following locations:
Sealing surfaces
Fittings
Cracked or damaged components
Can you identify the type of fluid and the approximate
location of the leak?

Use J 28428-E, Dye and Light Kit in order to identify the

type of fluid, and the approximate location of the leak.
Refer to the manufacturer's instructions when using
the tool.
Can you identify the type of fluid and the approximate
location of the leak?

6-258

Engine Mechanical - 5. 7L

Engine

Oil Leak Diagnosis (cont'd)

Step

10

11

Action

Value(s)

1. Visually inspect the suspected area. Use a small

mirror to assist in looking at hard to see areas.
2. Check for leaks at the following locations:
Sealing surfaces
Fittings
Cracked or damaged components
Can you identify the type of fluid and the approximate
location of the leak?

1. Inspect the engine for mechanical damage. Special

attention should be shown to the following areas:
Higher than recommended fluid levels
Higher than recommended fluid pressures
Plugged or malfunctioning fluid filters or pressure
bypass valves
Plugged or malfunctioning engine ventilation
system
Improperly tightened or damaged fasteners
Cracked or porous components
Improper sealants or gaskets where required
Improper sealant or gasket installation
Damaged or worn gaskets or seals
Damaged or worn sealing surfaces
2. Inspect the engine for customer modifications.
Is there mechanical damage, or customer modifications to
the engine?

Repair or replace all damaged or modified components.

Does the engine stll leak oil?

Drive Belt Diagnosis

Definitions
The following are symptomatic noises of the accessory
drive belt system:

1. Chirping:

A high pitched noise that is usually heard once

per revolution of a pulley or a belt.
It is most common on cold, damp mornings.
Verify this condition by squirting water onto the
belt. The noise will momentarily stop.
2. Squeal:
A loud screeching noise that is caused by a
slipping belt (this is unusual for a multiple
ribbed belt).
The noise occurs when a heavy load is applied
to the belt, such as an air conditioning
compressor engagement, snapping the throttle,
or slipping on a seized pulley.

Yes

No

Go to Step 10

System OK

Go to Step 11

System OK

Go to Step 1

3. Knocking:
A low pitch tapping noise caused by belt
misalignment.
This noise occurs on cold start-up at idle.
4. Whine: A high pitched continuous noise that may
be caused by a failed component bearing.
5. Faint Cycle Rumbling: A low frequency noise
heard once per revolution of the belt.
6. Pilling:
The random accumulation of rubber dust in the
bottom of the multi-ribbed belt grooves.

A small amount of pilling is normal.

Operation of the drive belt system will not be
effected unless the buildup exceeds one
third (1/3) of the belt groove depth.
Multiple ribbed, accessory drive belts wear evenly with
their pulleys. Unusual wear indicates a correction is
needed. The following diagnostic tables will aid
in diagnosing drive belt system problems.

Engine Mechanical - 5.7L

Engine

6-259

Visual Identification
Disassembled Views

Intake Manifold/Upper Engine

19'-y
17

16

9v
178456

Legend

\
I

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)

Fuel Rail Bolt

Fuel Rail (with Injectors)
Fuel Rail Stop Bracket
Throttle Body Gasket
Intake Manifold Bolt
Intake Manifold Gaskets
Intake Manifold
Throttle Body
Throttle Body Bolt
Valley Cover Gasket

(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)

Valley Cover
Valley Cover Bolt
Knock Sensor Oil Seal
Knock Sensor
Knock Sensor Wire Harness
Vapor Vent Tube Hose
Vapor Vent Tube
Vapor Vent Tube Gasket
Vapor Vent Pipe Bolt

6-260

Engine

Engine Mechanical - 5.7L

Cylinder Head/Upper Engine
20

21~

y23

,24

3
4~5

J-6
7

10

9
,---14

~13

178452

Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)

Valve Stem Keys

Valve Spring Cap
Valve Spring
Valve Stem Oil Seal
Valve Spring Shim
Valve
Exhaust Manifold Gasket
Cylinder Head
Coolant Temperature Sensor
Exhaust Manifold
Exhaust Manifold Bolts
Push rod

(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)

Valve Rocker Arm

Valve Rocker Arm Bolt
Valve Rocker Arm Pivot Support
Cylinder Head Gasket
Valve Rocker Arm Cover Gasket
Oil Fill Tube
Oil Fill Tube Cap
Valve Rocker Arm Cover Assembly
Vapor Vent Valve Grommet
Cylinder Head Bolt (Short)
Cylinder Head Bolt (Medium)
Cylinder Head Bolt (Long)

Engine

12

14

16

11

178453

Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)

Oil Level Indicator Tube Bolt

Oil Level Indicator Tube
Oil Lever Indicator Tube 0-ring Seal
Valve Lifter Guide Bolt
Valve Lifter Guide
Valve Lifters
Engine Block
Crankshaft Rear Oil Seal
Engine Rear Cover Bolt
Engine Rear Cover
Engine Rear Cover Gasket

(12)
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)

Crankshaft Sprocket
Camshaft Timing Chain
Oil Pump Assembly
Oil Pump Assembly Bolt
Engine Front Cover Gasket
Engine Front Cover
Crankshaft Front Oil Seal
Crankshaft Balancer
Crankshaft Balancer Bolt
Engine Front Cover Bolt
Camshaft

6-262
(23)
(24)
(25)
(26)
(27)
(28)

Engine Mechanical - 5.7L

Camshaft Retainer
Camshaft Retainer Bolt
Camshaft Sprocket
Camshaft Sprocket Locating Pin
Camshaft Sprocket Bolt
Water Pump Pulley Bolt

Engine
(29)
(30)
(31)
(32)
(33)
(34)

Camshaft Bearings
Water Pump Pulley
Water Pump
Water Pump Bolt
Water Pump Gaskets
Oil Level Indicator

Engine

Engine Mechanical - 5.7L

6~263

Lower Engine Assembly

0--

24

e--21

27

22

20

19

178454

Legend

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
( 11)
(12)
(13)
(14)
(15)
(16)

Camshaft Position Sensor Bolt

Camshaft Position Sensor
Oil Pressure Sensor
Engine Block
Piston Rings
Piston and Connecting Rod Assembly
Connecting Rod Bearings
Connecting Rod Cap
Connecting Rod Bolt
Crankshaft Oil Deflector
Engine Flywheel (Manual Transmission)
Engine Flywheel (Automatic Transmission)
Engine Flywheel Bolt
Oil Pan Gasket
Oil Pan
Oil Pan Cover Gasket

(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)

Oil Pan Cover

Oil Pan Cover Bolt
Oil Pan Closeout Cover Bolt (Left Side)
Oil Pan Closeout Cover (Left Side)
Oil Filter Adapter
Oil Filter
Oil Level Sensor
Oil Pan Closeout Cover (Right Side)
Oil Pan Closeout Cover Bolt (Right Side)
Crankshaft Bearing Cap Side Bolt
Crankshaft Bearing Caps
Crankshaft Bearing Cap Studs
Crankshaft Bearing Cap Bolts
Crankshaft Bearing
Crankshaft Thrust Bearing
Crankshaft

6-264 Engine Mechanical - 5; 7L

(33)
(34)
(35)
(36)

Crankshaft Sprocket Key

Engine Block Front Oil Gallery Plug
Clutch PilotBearing
Oil Pump Screen Bolt

Engine
, (37) Oil Pump Screen
(38) Oil Pump Screen Nut
(39) Oil Pump Screen 0-Ring

Engine Mechanical - 5.7L

Engine
Cylinder Head Assembly (Aluminum)

64108

Legend

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)

Cylinder Head
Valve Stem Keys
Valve Spring Cap
Valve Spring
Valve Stem Oil Seal
Valve Spring Shim
Valve Guide
Cylinder Head Expansion Plugs
Exhaust Valve Seat
Exhaust Valve
Intake Valve Seat
Intake Valve

6-265

5..255

Engine Mechanical - s~7t.

Engine
Oil Pump Assembly

64190

Legend

(1)
(2)
(3)
(4)

Driven Gear
Oil Pump Housing
Pressure Relief Valve
Pressure Relief Valve Spring

(5)
(6)
(7)
(8)

Plug
Drive Gear
Cover Bolt
Cover

Engine

Engine Mechanical - 5.7L

6-267

Repair Instructions

Drive Belt Replacement (Accessory)

Removal Procedure
1. Disconnect the intake air temperature (IAT)
sensor electrical connector at the duct.
2. Disconnect the mass airflow (MAF) sensor
electrical connector at the duct.

208553

3. Remove the air intake duct from the throttle body

and the air cleaner box.

208569

6.,-268

Engine

Engine Mechanical~ 5.7L

4. Position a hex-head socket on the belt tensioner

pulley (1) bolt.
5. Rotate the driv~ belt tensioner clockwise to relieve
the tension on the ddve belt
6. Remove the drive belt from the tensioner and
pulleys;
7. Clean and inspeot the belt surfaces of all the
pulleys.

220580

Installation Procedure
1. Route the drive belt around the pulleys.
2. Position a hexahead socket on the belt tensioner
pulley (1) bolt.
3. Rotate the drive belt tensioner clockwise to relieve
the tension.
4. Inspect the drive belt to ensure that the belt is
properly aligned into the grooves of the pulleys.

220580

5. Install the air intake duct to the throttle body and

the air cleaner box.

208569

Engine

Engine Mechanical - 5.7L

6-269

6. Connect the mass airflow (MAF) sensor electrical

connector at the duct.
7. Connect the intake air temperature (IAT) sensor
electrical connector at the duct.

208553

Drive Belt Replacement (A/C)

Removal Procedure

1. Remove the accessory drive belt. Refer to Drive

Belt Replacement (Accessory).
2. Position a hex-head socket on the belt tensioner
pulley (1) bolt.
3. Rotate the air conditioning (A/C) drive belt
tensioner clockwise to relieve the tension on the
drive belt.
4. Remove the A/C drive belt from the crankshaft
balancer and A/C compressor.
5. Clean and inspect the A/C belt surfaces of the
balancer and compressor pulley.

220583

Installation Procedure
1. Route the A/C belt over the crankshaft balancer.
2. Rotate the A/C belt tensioner (1) clockwise to
relieve the tension.
3. Install the drive belt between the idler and around
the tensioner (1) and over the compressor pulley.
4. Inspect the drive belt to ensure that the belt
is properly aligned on all the pulleys.
5. Install the accessory drive belt. Refer to Drive Belt
Replacement (Accessory).

220583

6-270

Engine

Engine Mechanical - 5.7L

Drive Belt Idler Pulley Replacement
(Accessory)

Removal Procedure
1. Remove the drive belt. Refer to Drive Belt
Replacement (Accessory).

220580

2. Remove the drive belt idler pulley bolt.

3. Remove the drive belt idler pulley.

220582

Installation Procedure
1. Install the drive belt idler pulley.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the drive belt idler pulley bolt.
Tighten
Tighten the drive belt idler pulley bolt to
50 Nm (37 lb ft).

220582

Engine Mechanical - 5.7L

Engine
3. Install the drive belt. Refer to Drive Belt
Replacement (Accessory).

6-271

220580

Drive Belt Idler Pulley Replacement (A/C)

Removal Procedure
1. Remove the A/C drive belt. Refer to Drive Belt
Replacement (AIC)

220583

2. Remove the A/C drive belt idler pulley bolt (2).

3. Remove the A/C drive belt idler pulley (1).

3
220584

6-272

Engine Mechanical - 5. 7L

Engine
Installation Procedure
1. Install the A/C drive belt idler pulley (1 ).
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the A/C drive belt idler pulley bolt (2).

Tighten
Tighten the A/C drive belt idler pulley bolt (2) to
50 Nm (37 lb ft).

3
220584

3. Install the A/C drive belt. Refer to Drive Belt

Replacement (AIC).

220583

Drive Belt Tensioner Replacement

(Accessory)
Removal Procedure
1. Remove the drive belt. Refer to Drive Belt
Replacement (Accessory).
2. Remove the drive belt tensioner bolts.
3. Remove the drive belt tensioner.

(
220581

Engine

Engine Mechanical - 5.7L

6-273

Installation Procedure
1. Install the drive belt tensioner.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the drive belt tensioner bolts.

Tighten
Tighten the drive belt tensioner bolts to
50 N-m (37 lb ft).
3. Install the drive belt. Refer to Drive Belt
Replacement (Accessory).

220581

Drive Belt Tensioner Replacement (A/C)

Removal Procedure
1. Remove the A/C drive belt. Refer to Drive Belt
Replacement (AIC)

220583

2. Remove the A/C drive belt tensioner bolt (3).

3. Remove the A/C drive belt tensioner (4).

3
220584

6-274

Engine Mechanical - 5.7L

Engine
Installation Procedure
1. Install the A/C drive belt tensioner (4).

Notice: Refer to Fastener Notice in Cautions and

Notices.
2. Install the A/C drive belt tensioner bolt (3).

Tighten
Tighten the A/C drive belt tensioner bolt (3) to
25 Nm (18 lb ft).

3
220584

3. Install the A/C drive belt. Refer to Drive Belt

Replacement (A/C)

220583

Engine Mount Replacement (Right Side)

Removal Procedure
Tools Required
J 41044 Engine Support Adapters
J 42451 Engine Support Adapter Kit
J 28467-8 Universal Support Fixture
J 36462-A Engine Support Adapter Leg
Right Side
1. Support the engine using the J 42451,J 28467-8
and the J 36462-A.

487459

Engine

Engine Mechanical - !>.7L

6-275

Notice: When raising or supporting the engine for any

reason, do not use a jack under th.e oil pan, any
sheet metal, or the crankshaft pulley. Due to the small
clearance between the oil pan and the oil pump
screen, jacking against the oil pan may cause the pan
to be bent against the pump screen. This will result
in a damaged oil pickup unit.
2. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
3. Remove the starter motor. Refer to Starter Motor
Replacement (5.7L VB) in Engine Electrical.
4. Disconnect the low oil level sensor electrical
connector (1 ).
5. Remove the negative lead bolt (1) and lead (2)
from the engine block.

211595

6. Remove the engine mount bracket to

crossmember bolts.
7. Lower the vehicle.
8. Raise the right side of the engine with the support
fixture.
9. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

220585

\i

6-276

Engine

Engine Mechanical - 5. 7L

10. Remove the engine mount bracket to block bolts.

11 . Remove the engine mount from the vehicle.
12. Separate the upper and lower mount on
the bench.

220586

Installation Procedure
1. Loosely install the upper and lower mount
together on the bench.

2. Install the engine mount to the vehicle.

Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Install the engine mount bracket to block bolts.
Tighten
Tighten the engine mount bracket to block bolts to
50 N-m (37 lb ft).
4. Lower the vehicle.
5. Lower the right side of the engine.

6. Raise and suitably support the vehicle. Refer to

Lifting and Jacking the Vehicle in General
Information.

220586

7. Install the engine mount bracket to

crossmember bolts.
Tighten
Tighten the engine mount bracket to crossmember
bolts to 58 N-m (43 lb ft).
8. Tighten the engine mount through bolt and
mount nut.
Tighten
Tighten the through bolt to 95 N-m (70 lb ft).
Tighten the engine mount nut to
80 N-m (59 lb ft).

220585

,Engine

Engine Mechanical - 5.7L

6-277

9. Install the negative lead (2) and bolt (1) to the

engine block.

Tighten
Tighten the negative lead bolt (1) to the engine
block to 32 Nm (24 lb ft)

211595

10. Connect the low oil level sensor electrical

connector (1 ).

11. Install the starter motor. Refer to Starter Motor

Replacement (5.7L Vl1) in Engir1e, Electrical.
12. Lower the vehicle.

487459

Engine Mount Replacement (Left Side)

Removal Procedure
Tools Requied
J 41044 Engine Support Adapters
J 42451 Engine Support Adapter Kit
J 28467-8 Universal Support Fixture
J 36462-A Engine Support Adapter Leg
Notice: When raising or supporting the engine for any
reason, do not use a jack under the oil pan, any
sheet metal, or the crankshaft pulley. Due to the small
clearance between the oil pan and the oil pump
screen, jacking against the oil pan may cause the pan
to be bent against the pump screen. This will result
in a damaged oil pickup unit.
1. Disconnect the intake air temperature (IAT)
sensor electrical connector at the duct.
2. Disconnect the mass airflow (MAF) sensor
electrical connector at the duct.
208553

6-278

Engine Mechanical - 5.7L

Engine
3. Remove the air intake duct from the throttle body
and the air cleaner box.
4. Support the engine using the J 42451,J 28467-8,
and the J 36462-A.
5. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
6. Remove the left oxidation catalytic converter.
Refer to Oxidation Catalytic Converter
Replacement (Left) in Engine Exhaust.

208569

7. Remove the engine mount bracket to

crossmember bolts.
8. Lower the vehicle.
9. Raise the left side of the engine with the support
fixture.
10. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

220588

11. Remove the engine mount heat shield nuts.

12. Remove the engine mount heat shield.

220590

Engine

Engine Mechanical - 5.7L

6-279

13. Remove the engine mount bracket to block studs.

14. Remove the engine mount from the vehicle.

\}

15. Separate the upper and lower mount on

the bench.

220591

Installation Procedure
1. Loosely install the upper and lower mount
together on the bench.

2. Install the engine mount to the vehicle.

Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Install the engine mount bracket to block studs.

Tighten
Tighten the engine mount bracket to block studs
to 50 Nm (37 lb ft).

220591

4. Install the engine mount heat Shield.

5. Install the engine mount heat shield nuts.
Tighten
Tighten the engine mount heat shield nuts to
10 Nm (89 lb in).
6. Lower the vehicle.
7. Lower the right side of the engine.
8. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

220590

6-280

Engine Mechanical - 5.7L

Engine
9. Install the engine mount bracket to
crossmember bolts.
Tighten
Tighten the engine mount bracket to crossmember
bolts to 58 Nm (43 lb ft).
10. Tighten the engine mount through bolt and
mount nut.
Tighten
Tighten the through bolt to 95 Nm (70 lb ft).
Tighten the engine mount nut to
80 Nm (59 lb ft).
11. Install the left oxidation catalytic converter. Refer
to Oxidation Catalytic Converter Replacement
(Left) in Engine Exhaust.
12. Lower the vehicle.

220588

13. Install the air intake duct to the throttle body and
the air cleaner box.

208569

14. Connect the IAT sensor electrical connector.

15. Connect the MAF sensor electrical connector.

208553

Engine

Engine Mechanical - 5.7L

6-281

Intake Manifold Replacement

Removal Procedure
1. Drain the cooling system. Refer to Draining and
Filling Cooling System (VB) in Engine Cooling.
2. Raise the vehicle and support. Refer to Lifting and
Jacking the Vehicle in General Information
3. Remove the transmission fluid indicator tube bolt.
4. Lower the vehicle.
5. Relieve the fuel pressure. Refer to Fuel Pressure
Relief Procedure in Engine Controls - 5.7L.

Important: Cap the fittings and plug the holes when

separative fuel system components in order to prevent
dripping of fuel and/or dirt and other contaminants
from entering the fuel system.

208459

6. Disconnect the fuel lines from the fuel rail.

7. disconnect the fuel lirie from the fuel vapor
purge valve.

220597

8. Disconnect the.intake. air tempe~ature (IAT)

sensor connector at the air intake duct.
9. Disconnect the mass airflow (MAF) sensor
connector at the air intake duct.

208553

6-282

Engine Mechanical - 5.7L

Engine
10. Remove the air intake duct from the throttle body
and the air cleaner box.

208569

11. Disconnect the idle air control (IAC) valve

electrical connector from the throttle body.
12. Disconnect the throttle position sensor (TPS)
electrical connector from the throttle body.
13. Remove the accessory drive belt. Refer to Drive
Belt Replacement (Accessory).

220606

14. Disconnect the exhaust gas recirculation (EGR)

solenoid electrical connector.

220595

Engine

Engine Mechanical - 5.7L

6-283

15. Remove the EGR valve pipe and solenoid.

220596

16. Unsnap the cruise control cable from the throttle

lever, if equipped.
Push the cruise cable connector forward to
unsnap.
Unsnap the cable from the engine bracket.

220601

17. Remove the accelerator cable from the

throttler lever.

220602

6-284

Engine Mechanical - 5.7L

Engine
18. Remove the accelerator control cable and cruise
control servo bracket.

220603

19. Disconnect the right side fuel injector connectors.

220605

20. Disconnect the left side fuel injector connectors.

21. Remove the fuel rail. Refer to Fuel Rail Assembly
Replacement in Engine Controls - 5. 7L.

(
\

220608

Engine

Engine Mechanical - 5.7L

6-285

22. Disconnect the manifold absolute pressure (MAP)

sensor electrical connector.
23. Disconnect the vacuum hose from the vacuum
port on the MAP sensor housing.

220609

24. Disconnect the knock sensor connector (4).

25. Disconnect all the remaining electrical connections
from the intake manifold.

379365

26. Remove the knock sensor jumper wire from the

PCV hose.

220612

6-286

Engine

Engine Mechanical - 5.7L

27. Remove the PCV valve pipe from the PCV valve.

220598

28. Remove the PCV valve pipe from the

rocker cover.

220613

29. Remove the fresh air hose from the throttle body
and coil assembly.

220619

Engine

Engine Mechanical - 5.7L 6-287

30. Remove the engine coolant air bleed hose from

the throttle body.

220621

31. Remove the throttle body heater outlet hose from

the throttle body.

220620

32. Remove the EVAP canister purge tube.

\J

220615

6-288

Engine Mechanical - 5,7L

Engine
33. Remove the canister purge valve and bracket.

220617

34. Remove the intake manifold. Refer to Intake

Manifold Removal.
35. Remove the fuel rail stop bracket from the intake
manifold.

178557

Installation Procedure
1. Install the intake manifold. Refer to Intake
Manifold Removal.
2. Install the fuel rail stop bracket to the intake
manifold.

178557

Engine

Engine Mechanical - 5.7L

6.;289

3. l11staU the canister purge valve and bracket.

220617

4. Install the EVAP canister purge tube.

220615

5. Install the:,throttle body heater outlet hose to the

throttle body.

220620

6-290

Engine Mechanical - 5. 7L

Engine
6. Install the engine coolant air bleed. hose to the
throttle body.

220621

7. Install the fresh air hose to the throttle body and

coil assembly.

220619

8. Connect the PCV valve pipe to the rocker cover.

220613

Engine

Engine Mechanical - 5.7L

6-291

9. Connect the PCV valve pipe to the PCV valve.

220598

10. Connect the knock sensor jumper wire to the

PCV valve hose.

220612

11. Connect the knock sensor connector (4).

379365

6-292

Engine Mechanical - 5.7L

Engine
12. Connect the MAP sensor connector.
13. Connect the vacuum hose.

220609

14. Connect the left side fuel injector connectors.

220608

15. Connect the right side fuel injector connectors.

16. Connect all remaining electrical connectors to the
intake manifold.

220605

Engine

Engine Mechanical s~ 7L

6-293

Notice: Refer to Fastener Notice in. Cautions and

Notices.

\i

17. Install the accelerator control cable and cruise

control servo bracket.
Tighten
Tighten the accelerator control cable and cruise
control servo bracket nut to 10 N-m (89 lb in).

220603

18. Install the accelerator cab.le to the throttle lever.

220602

19. Install the cruise control cable to the. throttle lever,

if equipped.

220601

6-294

Engine Mechanical - 5. 7L

Engine
20. Install the EGA valve pipe.
Tighten
Tighten the EGA valve pipe to exhaust
manifold bolts to 25 Nm (18 lb ft).
Tighten the EGA valve pipe to cylinder head
bolt to 50 N-m (37 lb ft).
Tighten the EGA valve pipe to intake manifold
bolt to 12 N-m 106 lb in).

220596

21. Connect the EGA valve connector.

22. Install the accessory drive belt. Refer to Drive Belt
Replacement (Accessory).

220595

23. Connect the TPS sensor connector to the

throttle body.
24. Connect the IAC sensor connector to the
throttle body.

220606

Engine

Engine Mechanical - 5.7L

6-295

25. Install the air intake duct.

208569

26. Connect the MAF sensor connector at the

intake duct.
27. Connect the IAT sensor connector at the
intake duct.
28. Remove the fuel rail. Refer to Fuel Rail Assembly
Replacement in Engine Controls - 5.7L.

208553

29. Connect the fuel lines to the fuel rail.

30. Connect the fuel line to the fuel vapor purge valve.
31. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information

220597

6~296

Engine Mechanical - 5.7L

EngJne
32. Install the transmission fluid indicator bolt.
Tighten
Tighten the transmission fluid indicator tube bolt
to 50 N-m (37 lb ft).
33. Fill the cooling system. Refer to Draining and
Filling Cooling System (VB) in Engine Cooling.

208459

Vapor Vent Pipe Replacement

Removal Procedure
1. Remove the intake manifold. Refer to Intake
Manifold Replacement.

178557

2. Remove the vapor vent pipe. Refer to Vapor Vent

Pipe. Removal.

'

64139

Engine

Engine Mechanical - 5.7L

6-297

Installation Procedure
1. Install the vapor vent pipe. Refer to Vapor Vent
Pipe Installation.

64139

2. Install the intake manifold. Refer to Intake

Manifold Replacement.

178557

Engine Valley Cover Replacement

Removal Procedure
1. Remove the vapor vent pipe. Refer to Vapor Vent
Pipe Removal.

64139

6-298

Engine Mechanical - 5.7L

Engine
2. Remove the engine valley cover. Refer to Engine
Valley Cover Removal.

65048

Installation Procedure
1. Install the engine valley cover. Refer to Engine
Valley Cover Installation.

65048

2. Install the vapor vent pipe. Refer to Vapor Vent

Pipe Installation.

64139

Engine

Engine Mechanical - 5.7L

6-299

Valve Rocker Arm Cover Replacement

(Right Side)

Removal Procedure
1. Remove the Air Injection Reaction (AIR) hose
clamps and remove the hose.

178465

2. Remove the AIR pipe (with check valve), bolts

and gasket from the exhaust manifold.

178464

3. Disconnect the ignition coil harness main

connector.

211648

6-300

Engine

Engine Mechanical - 5.7L

4. Remove .the spar!:< plugnrJiresr

211641

5. Remove the right side valve rocker arm cover.

Refer to Valve Rocker Arm Cover Removal
(Right Side).

63205

Installation, Procedure
1. Install the right side valve rocker arm cover.
Refer to Valve Rocker Arm Cover Installation
(Right Side).

63205

Eng~ne

Engine Mechanical - 5.7L

6-301

2. Install the spark plug wires.

211641

3. Connect .the ignition coil harness main connector.

211648

Notice: Refer to Fastener Notice iri Cautions an<:!

Notices.
4. Install the AIR pipe (with check valve), bolts and
gasket to the exhaust manifold.
Tighten
Tighten the AIR pipe bolts to 20 N-m (15 lb ft).

178464

6-302

Engine

Engine Mechanical - 5.7L

5. Install the AIR hose and clamps.

178465

Valve Rocker Arm Cover Replacement

(Left Side)
Removal Procedure
1. Relieve the fuel system pressure using
Fuel Pressure Relief Procedure in Engine
Controls - 5.7L.
2. Remove the fuel lines from the vehicle.

220597

3. Remove 1he PCV hose from the PCV valve.

220598

Engine

Engine Mechanical - 5.7L

6-303

4. Disconnect the coil harness main connector.

211648

5. Remove the spark plug wires from the

ignition coils.
6. Remove the spark plug wires from the
spark plugs.

211641

7. Loosen the AIR hose clamps and remove

the hose.

178465

6-304

Engine

Engine Mechanical - 5. 7L

8. Remove the AIR pipe (with check valve), bolts

and gasket from the left exhaust manifold.

178463

9. Remove the PCV hose from the rocker arm cover.

220613

10. Remove the left side valve rocker arm cover.

Refer to Valve Rocker Arm Cover Removal
(Left Side).

63205

Engine

Engine Mechanical - 5.7L

5.;.305

Installation Procedure
1. Install the LH valve rocker arm cover. Refer to
Valve Rocker Arm Cover Installation (Left Side).

65890

2. Install the PCV hose to the rocker arm cover.

\
I

220613

Notice: Refer to Fastener Notice in Cautions and

Notices.
3. Install the AIR pipe (with check valve), bolts and
gasket to the left exhaust manifold.

Tighten
Tighten the AIR pipe bolts to 20 N-m (15 lb ft).

178463

6-306

Engine Mechanical - 5.7L

Engine
4. Install the AIR hose and clamps.

178465

5. Install the spark plug wires to the spark plugs.

6. Install the spark plug wires to the ignitions coils.

211641

7. Connect the coil harness main connector.

211648

Engine

Engine Mechanical - 5.7L

6-307

8. Install the PCV hose to the PCV valve.

220598

9. Install the fuel lines to the vehicle.

220597

Valve Rocker Arm and Push Rod

Replacement
Removal Procedure
1. Remove the valve rocker arm covers. Refer to
Valve Rocker Arm Cover Replacement (Right
Side) or Valve Rocker Arm Cover Replacement
(Left Side).
2. Remove the valve rocker arms, push rods, and
pedestals. Refer to Valve Rocker Arm and Push
Rod Removal.

()

0
10

63205

6-308

Engine

Engine Mechanical - 5.7L

Installation Procedure

1. Install the valve rocker arms, push rods, and

pedestals. Refer to Valve Rocker Arm and
Push Rod Installation.
2. Install the valve rocker arm covers. Refer to Valve
Rocker Arm Cover Replacement (Right Side} or
Valve Rocker Arm Cover Replacement
(Left Side).

63205

Valve Stem Oil Seal and Valve Spring

Replacement
Removal Procedure
Tools Required
J 22794 Spark Plug Port Adapter
J 38606 Valve Spring Compressor (Head-on)
J 42078 Valve Seal Installer
1. Remove the spark plugs from the cylinders to be
serviced.
2. Remove the valve rocker arms, pedestal, and
valve pushrods. Refer to Valve Rocker Arm
and Push Rod Removal.

14824

3. Install J 22794 Spark Plug Port ~dapter to the

spark plug hole.
4. Apply compressed air in order to retain the valves
in their closed position.

11517

Engine

Engine Mechanical - 5.7L

6-309

5. Compress the valve spring (4) using J 38606

Valve Spring Compressor (head on).
6. Remove the valve stem keys (2).
7. Release the valve spring compressor.
8. Remove the valve spring cap (3).
9. Remove the valve spring (4).
10. Remove the valve stem oil seal (5).

64108

)
Installation Procedure
Important: The valve stem oil seal alignment and
position on the valve guide is critical.
An improperly installed valve stem oil seal may lead to
excessive oil consumption, increased vehicle
emissions, or component damage.
1. Install the valve stem oil seal (5) onto the
guide (7).
1.1 . Lubricate the valve guide (7) and valve
stem (5) oil seal with clean engine oil.
1.2. Install the valve stem oil seal onto the valve
stem. Push the seal down until the seal
contacts the valve guide.
1.3. Push or lightly tap the J 42078 until the tool
bottoms against the valve spring shim (6).

'

63193

6-31 O Engine Mechanical - 5. 7L

Engine
2. Measure the valve stem oil seal for the properly
installed height.
There should be a 18.1-19.1 mm (0.712-0.752 in)
gap between the top edge of the oil seal body
and the shim spring seat surface.

18.1-19.1 mm

(0.712-0.752")

63158

3. Install the valve spring (4).

4. Install the valve spring cap (3).
5. Compress the valve spring (4) using the J 38606.
6. Install the valve stem keys (2).
6.1. Use grease to hold the keys (2) in place
and remove the J 38606.
6.2. Make sure the keys (2) seat properly in the
groove of the valve stem (10,12).
6.3. Tap the end to the valve stem (10, 12) with
a plastic faced hammer to seat the keys
(if necessary).

64108

Engine

Engine Mechanical - 5.7L

6-311

7. Remove the J 22794.

11517

Notice: Refer to Fastener Notice in Cautions and

Notices.
8. Install the spark plug.

Tighten
Tighten the spark plug to 15 Nm (11 lb ft).
9. Install the valve rocker arms, pedestal, and valve
pushrods. Refer to Valve Rocker Arm and Push
Rod Removal.

14824

Oil Level Indicator and Tube Replacement

Removal Procedure
1. Disconnect the secondary air injection (AIR) pump
hose from the check valve hose.

379369

6-312

Engine

Engine Mechanical - 5. 7L

2. Remove the AIR valve hose clamps and hose.

3. Remove the number 4 and 6 spark plugs wires.

346024

4. Remove the number 4 and 6 ignition coils from

the coil bracket.

65292

5. Remove the oil level indicator from the tub.e.

220593

Engine

Engine Mechanical - 5.7L 6-313

6. Remove the oil level indicator tube bolt.

7. Remove the indicator tube from the engine block.

8. Remove the 0-ring from the tube.

178459

Installation Procedure
1. Clean the indicator tube.
2. If the 0-ring seal is damaged, install a new 0-ring
to the tube.

3. Install the oil level indicator tube.

4. Rotate the tube into the proper position.
Notice: Refer to Fastener Notice in Cautions and
Notices.
5. Install the oil level indicator tube bolt.
Tighten
Tighten the oil level indicator tube bracket bolt to
25 N-m (18 lb ft).

178459

6. Install the indicator to the tube.

220593

6-314

Engine Mechanical - 5.7L

Engine
7. Install the number 4 and 6 ignition coils to the coil
bracket.
Tighten
Tighten the ignition coil bolts to 12 N-m (106 lb in).
8. Install the number 4 and 6 spark plug wires.

65292

9. Install the AIR valve hose and clamps.

346024

10. Connect the AIR pump hose to the check

valve hose.

379369

Engine

Engine Mechanical - 5.7L

6-315

Exhaust Manifold Replacement

(Right Side)
Removal Procedure
1. Remove the oil level indicator and tube. Refer to
Oil Level Indicator and Tube Replacement.
2. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
3. Remove the right exhaust manifold pipe nuts.
4. Lower the vehicle.

220594

5. Loosen the AIR hose clamps and remove

the hose.

178465

6. Remove the AIR pipe (with c;;heck valve), bolts

and gasket from the right exhaust manifold.

178464

5..315

Engine

Engine Mechanical .. 5.7L

7. Disconnectthe coil harness main connector.

211648

8. Remove the spark plug wires from the

ignition coils.
9. Remove the spark plug wires from the
spark plugs.

211641

10. Remove the spark plugs.

11 . Remove the valve rocker arm 'cover. Refer to
Valve Rocker Arm Cover Replacement
(Right Side).

14824

Engine

Engine Mechanical - 5.7L

6-317

12. Disconnect the EGA valve connector.

220595

13. Remove the EGA valve pipe.

')

220596

14. Remove the exhaust manifold, bolts and gasket.

15. Discard the gasket.

el
178460

6-318

Engine Mechanical - 5. 7L

Engine
Installation Procedure
1. Install a new gasket and the exhaust manifold.
Important: Do not apply sealant to the first three
threads of the bolts. Apply a 5 mm (0.20 in) wide band
of threadlock GM P/N 12345493 or equivalent to the
threads of the exhaust manifold bolts.

Notice: Refer to Fastener Notice in Cautions and

Notices.
2. Install the exhaust manifold bolts.
Tighten
Tighten the exhaust manifold bolts to
25 N-m (18 lb ft).

178460

3. Install the EGR valve pipe.

Tighten
Tighten the EGR valve pipe to exhaust
manifold bolts to 25 Nm (18 lb ft).
Tighten the EGR valve pipe to cylinder head
bolt to 50 Nm (37 lb ft).
Tighten the EGR valve pipe to intake manifold
bolt to 12 Nm (106 lb in).

220596

4. Connect the EGR valve connector.

5. Install the valve rocker arm cover. Refer t0 Valve
Rocker Arm Cover Replacement (Right Side).

(
220595

Engine

Engine Mechanical - 5.7L

6-319

6. Install the spark plugs.

Tighten
Tighten the spark plugs to 15 N-m (12 lb ft).

14824

7. Install the spark plug wires to the spark plugs.

8. Install the spark plug wires to the ignition coils.

211641

9. Connect the coil harness main connector.

)
211648

s~a20

Engine Mechanical - 5. 7L

Engine
10. Install the AIR pipe (with check valve), bolts and
gasket to the right exhaust manifold.
Tighten
Tighten the AIR pipe to exhaust manifold bolts to
20 N-m (15 lb ft).

\.

178464

11. Install the AfR hose and clamps.

12. Raise and suitably support the vehicle. Refer to.
Lifting and Jacking the Vehicle in General
Information.

178465

13. Install the right exhaust manifold pipe nuts.

Tighten
Tighten the right exhaust manifold pipe nuts to
35 Nm (26 lb ft).
14. Install the oil level indicator and tube. Refer to Oil
Level Indicator and Tube Replacement.
15. Lower the vehicle.

220594

Engine

Engine Mechanical - 5.7L

6-321

Exhaust Manifold Replacement (Left Side)

Removal Procedure
)

Tools Required
J 34730-tA Fuel Pressure Gauge
1. Relieve the fuel system pressure using
the J 34 730-1 A.
2. Remove the fuel lines from the vehicle.

220597

3. Remove the PCV hose from the rocker arm cover.

220613

4. Remove the spark plug wires from the

ignition coils.
5. Remove the spark plug wires from the
spark plugs.

211641

6-322

Engine Mechanical - 5.7L

Engine
6. Remove the spark plugs.

14824

7. Loosen the AIR hose clamps and remove

the hose.

178465

8. Remove the AIR pipe (with check valve}, bolts

and gasket from the left exhaust manifold.

178463

Engine

Engine Mechanical - 5.7L

6-323

9. Remove the coolant sensor from the left

cylinder head.
10. Remove the left side exhaust manifold bolts.
11. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

50974

12. Remove the oxygen sensor from the exhaust

manifold.

53269

13. Remove the exhaust manifold pipe nuts.

)
220599

6.324 .Engine Mechanical~ 5.7L

Engine
14. Remove the catalytic converter nuts.

220600

15. Remove the exhaust manifold .from the vehicle. '"-

(
\

178462

Installation Proc.edure
1. Install the exhaust manifold to the vehicle.
Notice: Refer to Fastener Notice in Cautions and
Notices.

(
\

178462

Engine

Engine Mechanical - 5.7L

6-325

2. Install the catalytic converter nuts.

Tighten
Tighten the catalytic converter nuts to
25 Nm (18 lb ft).

220600

3., Install the exhaust manifold pipe nuts.

Tighten
Tighten the exhaust manifold pipe nuts to
35 N-m (26 lb ft).
'

220599

4. Install the oxygen sensor tothe exhaust manifold.

Tighten
Tighten the oxygen sensor to 42 N,m (31 lb ft).

5. Lower the vehicle.

6. Install the left side exhaust manifold bolts.
Tighten
Tighten the exhaust manifold bolts to
25 Nm (18 lb ft).

53269

6-326

Engine Mechanical - 5.7L

Engine
7. lnstal the coolant sensor to the left cylinder head.

50974

8. Install the AIR pipe (with check valve), bolts and

gasket to the left exhaust manifold.
Tighten
Tighten the AIR pipe bolts 20 Nm (15 lb ft).

178463

9. Install the AIR hose and clamps.

178465

Engine

Engine Mechanical - 5.7L

6-327

10. Install the spark plugs.

Tighten
Tighten the spark plugs to 15 N-m (11 lb ft).

14824

11. Install the spark plug wires to the spark plugs.

12. Install the spark plug wires to the ignition coils.

211641

13. Install the PCV hose to the rocker arm cover.

220613

6-328

Engine Mechanical - 5.7L

Engine
14. Install the fuel lines to the vehicle.

220597

Cylinder Head Replacement (Right Side)

Removal Procedure
1. Remove the intake manifold. Refer to Intake
Manifold Replacement.

178557

2. Remove the vapor vent pipe from the engine.

Refer to Vapor Vent Pipe Replacement.

(
64139

Engine

Engine Mechanical - 5.7L

6-329

3. Remove the right side exhaust manifold. Refer to

Exhaust Manifold Replacement (Right Side).

178460

4. Remove the valve rocker arms, pedestals and

pushrods. Refer to Valve Rocker Arm and Push
Rod Replacement.

64171

5. Remove the right side cylinder head. Refer to

Cylinder Head Removal (Right Side).

100173

6-330

Engine

Engine Mechanical - 5.7L

Installation Procedure

1. Install the right side cylinder head. Refer to

Cylinder Head Installation (Right Side).

100173

2. Install the valve rocker arms, pedestals and

pushrods. Refer to Valve Rocker Arm and Push
Rod Replacement.

64171

3. Install the right side exhaust manifold. Refer to

Exhaust Manifold Replacement (Right Side).

,.

/
178460

Engine
4. Install the.vapor vent pipe from the engine. Refer
to Vapor Vent Pipe Replacement.
\

Engine Mechanical - 5.7L

6-331

'

64139

5. Install the intake manifold. Refer to Intake

Manifold Replacement.
6. Inspect for any leaks.

178557

Cylinder Head Replacement (Left Side)

Removal Procedure
Tools Required
J 25034-C Pulley Puller Remover
1. Remove the intake manifold. Refer to Intake
Manifold Replacement.

178557

6-332

Engine Mechanical - 5.7L

Engine
2. Remove the vapor vent pipe. Refer to Vapor Vent
Pipe Replacement.

64139

3. Remove the power steering pump pulley

using J 25034-C.

354410

4. Remove the power steering gear outlet hose (2)

from the reservoir (1 ).

450869

Engine Mechanical - 5.7L

Engine

6-333

5. Remove the power steering gear inlet hose (1)

from the pump (2).

450871

6. Remove the power steering pump.

220625

7. Remove the power steering pump bracket..

220627

6-334

Engine Mechanical - 5. 7L

Engine
8. Remove the valve rocker arm cover. Refer to
Valve Rocker Arm Cover Replacement
(Left Side).

63205

9. Remove the left side exhaust manifold. Refer to

Exhaust Manifold Replacement (Left Side).

178462

10. Remove the valve rocker arms, pedestal, and

valve pushrods. Refer to Valve Rocker Arm and
Push Rod Replacement.
11. Remove the ground wires and bolts from the rear
of the head.

64171

Engine

Engine Mechanical - 5.7L

6-335

12. Remove the left side cylinder head. Refer to

Cylinder Head Removal (Left Side).
\I
/

64878

Installation Procedure
Tools Required
J 25033-C Pulley Pump Installer
1. Install the left side cylinder head. Refer to
Cylinder Head Installation (Left Side)

Notice: Refer to Fastener Notice in Cautions and

Notices.
2. Install the ground wires and bolts to the rear of
the head.
Tighten
Tighten the ground bolt to 50 N-m (37 lb ft).

64878

3. Install the valve rocker arms, pedestal, and valve

pushrods. Refer to Valve Rocker Arm and Push
Rod Replacement.

64171

6-336

Engine Mechanical - 5.7L

Engine
4. Install the left side exhaust manifold. Refer to
Exhaust Manifold Replacement (Left Side).

178462

5. Install the valve rocker arm cover. Refer to Valve

Rocker Arm Cover Replacement (Left Side).

63205

6 .. install the power steering pump bracket.

Tighten
Tighten the steering pump brackets to
50 N-m (37 lb ft).

220627

Engine Mechanical - 5.7L

Engine

6-337

7. Install the power steering pump.

Tighten
Tighten the pump brace bolts to 25 N,m (18 lb ft).

220625

8. Install the power steering gear inlet hose (1) to

the pump (2).
Tighten
Tighten the power steering gear inlet hose (1)
fitting to 28 N-m (21 lb ft).

450871

9. Install the power steering gear outlet hose (2) to

the reservoir (1 ).

450869

6-338

Engine

Engine Mechanical - 5.7L

10. Install the power steering pump pulley using

the J 25033-C.

290557

11. Install the vapor vent pipe. Refer to Vapor Vent

Pipe Replacement.

64139

12. Install the intake manifold. Refer to Intake

Manifold Replacement.
13. Inspect for any leaks.

178557

Engine Mechanical - 5.7L

Engine

6-339

Valve Lifter Replacement

Removal Procedure
\

,,
J

Tools Required
J 3049-A Valve Lifter Remover
1. Remove the cylinder head. Refer to Cylinder
Head Replacement (Right Side) or Cylinder
Head Replacement (Left Side).
2. Remove the valve lifters. Refer to Valve Utter
Removal.

63230

Installation Procedure
1. Install the valve lifters. Refer to Valve Utter
Instal/a tion.
2. Install the cylinder head. Refer to Cylinder Head
Replacement (Right Side) or Cylinder Head
Replacement (Left Side).

63230

Crankshaft Balancer Replacement

Removal Procedure

Tools Required
J 41816 Crankshaft Balancer Remover

J 42386-A Flywheel Holding Tool

Important: The crankshaft balancer is balanced as an
individual component. It is not necessary to mark
the balancer position prior to removal. Do not reuse
the crankshaft balancer bolt. Install a NEW crankshaft
balancer bolt during final assembly.
1. Remove the drive belt. Refer to Drive Belt
Replacement (Accessory).

220580

6-340

Engine Mechanical - 5.7L

Engine
2. Remove the A/C drive belt. Refer to Drive Belt
Replacement (A/C).
3. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

220583

4. Remove the starter motor. Refer to Starter Motor

Replacement (5. 7L VB) in Engine Electrical.

211621

5. Remove the right closeout cover and bolt.

208464

Engine

Engine Mechanical - s~7L

6-341

6. Remove the transmission oil cooler lines from the

radiator.

208376

7. Remove the power steering cooler, if equipped

from the plastic support, if more room is needed.

221666

Important: Make sure that the teeth of the flywheel

holding tool mesh with the teeth of the engine flywheel.

Notice: Refer to Fastener Notice in Cautions and

Notices.
8. Install the J 42386-A and bolts.
Tighten
Tighten the J 42386-A bolts to 50 Nm (37 lb ft).

156162

6-342

Engine Mechanical - 5.7L

Engine
9. Remove the crankshaft balancer bolt.
Do not discard the crankshaft balancer bolt. The
balancer bolt will be used during the balancer
installation.

64275

10. Using the J 41816 and the J 41816 in order to

remove the crankshaft balancer.
11 . Remove the J 42386-A and bolts.

J 41816

156164

Installation Procedure
Tools Required
J 41665 Crankshaft Balancer and Sprocket
Installer
J 36660 Torque Angle Meter
J 42386-A Flywheel Holding Tool
Important: The crankshaft balancer installation and
bolt tightening involves a four stage tightening process.
The first pass ensures that the balancer is installed
completely onto the crankshaft. The second, third and
forth passes tighten the NEW bolt to the proper
torque.

The used crankshaft balancer bolt will be used only

during the first pass of the balancer installation
procedure. Install a NEW crankshaft balancer bolt and
tighten as described in the second, third and forth
passes of the balancer bolt tightening procedure.
156162

Engine

Engine Mechanical - 5.7L

6-343

1. Install the J 42386-A and bolts.

Use one M1-1.5 x 120 mm and one M10-1.5 x
45 mm tor proper tool operation.

'1

Tighten
Tighten the J 42386-A bolts to 50 N-m (37 lb ft).
Important: The balancer should be positioned onto
the end of the crankshaft as straight as possible prior
to tool installation.
2. Install the crankshaft balancer onto the end of the
crankshaft.

64275

3. Using J 41665 perform the following in order to

install the balancer:
3.1. Assemble the threaded rod, nut, washer
and installer.
Insert the smaller end of the installer into
the front of the balancer.
3.2. Use a wrench and hold the hex end of the
threaded rod.
3.3. Use a second wrench and rotate the
installation tool nut clockwise until the
balancer is started onto the crankshaft.
3.4. Remove the tool and reverse the
installation tool.
Position the larger end of the installer
against the front of the balancer.
3.5. Use a wrench and hold the hex end of the
threaded rod.
3.6. Use a second wrench and rotate the
installation tool nut clockwise until the
balancer is installed onto the crankshaft.
3.7. Remove the J 41665.
4. Install the USED crankshaft balancer bolt.
Tighten
Tighten the USED crankshaft balancer bolt to
330 N-m (240 lb ft).
5. Remove the USED crankshaft balancer bolt.

63187

6-344

Engine

Engine Mechanical - 5.7L

Important: The nose of the crankshaft should be

recessed 2.40-4.48 mm (0.094-0.176 in)

6. Measure for a correctly installed balancer.

If the balancer is not installed to the proper
dimensions, install the J 41665 and repeat the
installation procedure.

63245

7. Install the NEW crankshaft balancer bolt.

Tighten
7.1 . Tighten the crankshaft balancer bolt a first
pass to 50 N-m (37 lb ft).
7.2. Tighten the crankshaft balancer bolt a
second pass to 140 degrees using
the J 36660.
8. Remove the J 42386-A.

64275

9. Install the power steering cooler, if removed, to

the plastic support.

221666

Engine

Engine Mechanical - 5.7L

6-345

10. Install the transmission oil cooler lines to the

radiator.

Tighten
Tighten the oil cooler line connections to
27 N-m (20 lb ft).

208376

11. Install the right closeout cover and bolt.

Tighten
Tighten the closeout cover bolt to
12 N-m (106 lb in).

208464

12. Install the starter moto.r. Refer to StarlerMotor

Replacement (5. 7L VB) in Engine Electrical.
13. Lower the vehicle.

211621

6-346

Engine Mechanical - 5.7L

Engine
14. Install the A/C drive belt. Refer to Drive Belt
Replacement (A/C).

220583

15. Install the drive belt. Refer to Drive Belt

Replacement (Accessory).

220580

Crankshaft Front Oil Seal Replacement

Removal Procedure
1. Remove the crankshaft balancer. Refer to
Crankshaft Balancer Replacement.

64275

Engine

Engine Mechanical - 5.7L

6-347

2. Remove the front crankshaft oil seal.

220622

Installation Procedure
Tools Required
J 41478 Engin~ Front Cover Oil Seal Installer
Important: Do not lubricate the oil seal sealing
surface.

Do not reuse the crankshaft front oil seal.

1. Lubricate the outer edge of the oil seal with clean
engine oil.
2. Lubricate the front cover oil seal bore with clean
engine oil.
3. Install the crankshaft front oil seal onto the
J41478 guide.
4. Install the J 41478 threaded rod (with nut, washer,
guide, and oil seal) into the end of the crankshaft.
5. Use the J 41478 to install the oil seal into
the cover bore.
5. 1. Use a wrench and hold the hex on the
installer bolt.
5.2. Use a second wrench and rotate the
installer nut clockwise until the seal
bottoms in the cover bore.
5.3. Remove the J 41478.
5.4. Inspect the oil seal for proper installation.
The oil seal should be installed evenly and
completely into the front cover bore.

63177

6-348

Engine

Engine Mechanical - 5. 7L

6. Install the crankshaft balancer. Refer to Crankshaft

Balancer Replacement.

64275

Engine Front Cover Replacement

Removal Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Remove th~ electrical connectors from the. fan
shroud.
3. Drain the cooling system. Refer to Draining and
Filling Cooling System (VB) in Engine Cooling.
4. Drain the engine oil.
5. Lower the vehicle.

221692

6. Disconnect the intake air temperature (IAT) .

sensor electrical connector at the intake duct.
7. Disconnect the mass airflow (MAF} sensor
electrical connector at the ~ntake duct.

208553

Engine

Engine Mechanical - 5.7L

6-349

8. Remove the air intake duct.

9. Remove the air conditioning (A/C) drive belt.
Refer to Drive Belt Replacement (A/C).

208569

10. Remove the upper radiator hose from the

water pump.

221676

11. Remove the radiator hose:from the water intlet

housir;ig.

221671

6-350

Engine Mechanical - 5.7L

Engine
12. Remove the two heater hoses from the
water pump.

282934

13. Remove the upper radiator support.

221697

14. Remove the fan shroud.

15. Remove the drive belt tensioner. Refer to Drive
Belt Tensioner Replacement (Accessory).

41692

Engine

Engine Mechanical - 5.7L

6~351

16. Remove the overflow hose from the radiator.

221645

17. Remove the throttle body heater hose from the

radiator.
18. Remove the drive belt idler pulley. Refer to Drive
Belt Idler Pulley Replacement (Accessory).
19. Remove the water pump. Refer to Water Pump
Replacement (5. 7L VB) in Engine Cooling.
20. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

220620

21. Remove the crankshaft balancer. Refer to

Crankshaft Balancer Replacement.

64275

6-352

Engine

Engine Mechanical - 5.7L

22. Remove the oil pan-to-front cover bolts.

451709

23.
24.
25.
26.

Remove the engine front cover bolts.

Remove the front cover and gasket.
Remove the crankshaft oil seal from the cover.
Inspect for the following:
Gasket sealing surfaces fro excessive
scratches or gouging.
Cover-to-oil pan threaded bolt holes for
damaged threads or debris.
Crankshaft oil seal mounting bore for damage.
Oil pan gasket for damage.

64278

Installation Procedure
Tools Required
J 41476 Front and Rear Cover Alignment (Crankshaft
Oil Seal Area)
1. Apply a 5 mm (0.20 in) bead of sealant GM
P/N 12378190 or equivalent 20 mm (0.80 in)
long to the oil pan to engine block junction.

451898

\
'

Engine

Engine Mechanical - 5.7L

6-353

Important:
Do not reuse the crankshaft oil seal or the engine
front cover gasket.
All gasket surfaces should be free of oil or other
foreign material during assembly.

The crankshaft front oil seal MUST be centered in

relation to the crankshaft.
An improperly aligned front cover may cause
premature front oil seal wear and/or engine assembly
oil leaks.
2. Install a new crankshaft oil seal to the front cover.
3. Install the front cover gasket and cover.
4. Install the front cover bolts finger tight. Do not
overtighten.

64278

5. Install the J 41476.

Important: lign the tapered legs of the J 41476 with
the machined alignment surfaces on the front cover.
Notice: Refer to Fastener Notice in Cautions and
Notices.
Tighten
Tighten the oil pan-to-front cover bolts to
25 Nm (18 lb ft).
Tighten the engine front cover bolts to to
25 Nm (18 lb ft).
6. Remove the J 41476.
7. Install the crankshaft balancer. Refer to Crankshaft
Balancer Replacement.
8. Lower the vehicle.
9. Install the water pump. Refer to Water Pump
Replacement (5. 7L VB) in Engine Cooling.
10. Install the drive belt idler pulley. Refer to Drive
Belt Idler Pulley Replacement (Accessory).
451712

11. Install the throttle body heater hose to the

radiator.

220620

6-354

Engine

Engine Mechanical - 5.7L

12. Install the overflow hose to the radiator.

13. Install the drive belt tensioner. Refer to Drive Belt
Tensioner Replacement (Accessory).

221645

14. Install the fan shroud.

41692

15. Install the upper radiator support.

Tighten
Tighten the radiator supporVair cleaner bolts to
12 N-m (106 lb in).

\.
221697

Engine

Engine Mechanical - 5.7L

6-355

16. Install the lower radiator hose to the water inlet

housing.

221671

17. Install the upper radiator hose to the water pump.

18. Install the A/C drive belt. Refer to Drive Belt
Replacement (AIC).

221676

19. Install the two heater hoses to the water pump.

282934

6-356

Engine Mechanical - 5.7L

Engine
20. Install the air intake duct.

208569

21. Connect the MAF sensor electrical connector at

the intake duct.
22. Connect the IAT sensor electrical connector at the
intake duct.
23. Refill the engine oil.
24. Refill the cooling system. Refer to Draining and
Filling Cooling System (VB) in Engine Cooling.

208553

25. Install the electrical connectors to the tan shroud.

(
221692

Engine Mechanical - 5.7L

Engine

6-357

Crankshaft Rear Oil Seal Replacement

Removal Procedure
1. Remove the flywheel. Refer to Engine Flywheel
Replacement.

178458

2. Remove the crankshaft rear oil seal.

3. Gently pry the seal from the rear cover.

Installation Procedure
Tools Required
J 41479 Crankshaft Rear Oil Seal Installer

J 41479

Important:
Do not lubricate the oil seal inside diameter (ID)
or the crankshaft surface.
Do not reuse the crankshaft rear oil seal.

1 . Lubricate the outside diameter (OD) of the oil seal

with clean engine oil.
DO NOT allow oil or other lubricants to contact
the seal surface.
2. Lubricate the rear cover oil seal bore with clean
engine oil.
DO NOT allow oil or other lubricants to contact
the seal surface.
3. Install the J 41479 cone (2) and bolts onto the
rear of the crankshaft.
63200

6-358

Engine Mechanical - 5.7L

Engine
4. Tighten the bolts until snug. Do not overtighten.
5. Install the rear oil seal onto the tapered
cone (2) and push the seal to the rear cover bore.
6. Thread the J 41479 threaded rod into the tapered
cone (2) until the tool (1) contacts the oil seal.
7. Align the oil seal onto the tool (1).
8. Rotate the handle of the tool (1) clockwise until
the seal enters the rear cover and bottoms into
the bore.
9. Remove the J 41479.
10. Install the flywheel. Refer to Engine Flywheel
Replacement.

178458

Engine Rear Cover Replacement

Removal Procedure
1. Remove the flywheel. Refer to Engine Flywheel
Replacement.

178458

Engine Mee hanical -

Engine

cover-tos,nglne
the engine rear
.
2. Removbelts
ket
O
block

and gas
rear cover
er gasket.
3 Remove the
4. Discard the rear cov kshaft oil seal from
5. Remove the rear cran
. the cover.

Installation Pro~edurer; cover. Refer to Engine

h engine
1
t e Installation.
. Install
Rear Cover

Install the flywheel. Refer to Engine Flywheel

2. Replacement.

s.7L

6-359

6-360

Engine Mechanical - 5.7L

Engine
Oil Pan Replacement
Removal Procedure
Tools Required
J 41044 Engine Support .A:dapters
J 42451 Engine Support Adapter Kit
J 28467-8 Universal Support Fixture
J 36462-A Engine Support .A:dapter Leg

Important: DO NOT reuse the oil pan gasket. The

original oil pan gasket is retained and aligned to the oil
pan by rivets. When installing a new gasket, it is not
necessary to rivet the gasket to the oil pan.
1. Support the engine using J 41044, J 42451,
J 28467-8 and J 36462-A.
2. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
3. Remove the oil drain plug.
4. Drain the engine oil.
178475

5. Remove the oil filter.

(
I

178469

6. Remove the right side engine mount to

cradle bolts.

220585

Engine

Engine Mechanical - 5.7L

6-361

7. Remove the left side engine mount to cradle bolts.

220588

8. Remove the right and left lower shock bolts.

220629

9. Remove the intermediate steering shaft bolt.

10. Support the engine cradle using adjustable jack
stands.

220630

6-362

Engine Mechanical - 5. 7L

Engine
11 . Disconnect the oil level sensor connector, if
required.

220633

12. Remove the oil level sensor from the oil pan, if
required.
13. Remove the starter motor. Refer to Starter Motor
Replacement (5. 7L VB) in Engine Electrical.

178471

14. Remove the right side closeout and bolt.

208464

Engine

Engine Mechanical - 5.7L

6-363

15. Remove the left side closeout and bolt.

208478

16. Loosen the six cradle bolts three or four turns.

17. Lower the cradle slightly using the adjustable jack
stands.
18. It may be necessary to also raise the engine
using the engine support fixture.
19. Remove the bottom two transmission
bellhousing bolt.

220632

20. Remove the oil pan bolts (1 ).

21. Lower the oil pan, position the pan until it can be
removed from around the pickup screen.
Important: DO NOT allow foreign material to enter
the oil passages of the oil pan, cap or cover the
openings as required.
22. Use care not to gouge, score, or damage the oil
pan sealing surface.
23. Remove the oil pan gasket rivets and gasket from
the oil pan (2).
24. Discard the old gasket and rivets.

451962

6-364

Engine Mechanic.al - 5.7L

Engine
Installation Procedure
Important: The alignment of the structural oil pan is
critical. The rear bolt hole locations of the oil pan
provide mounting points for the transmission
bellhousing. To ensure the rigidity of the powertrain
and correct transmission alignment, it is important that
the rear of the block and the rear of the oil pan
must NEVER protrude beyond the engine block and
transmission bellhousing plane.
1. Apply a 5 mm (0.20 in) bead of sealant GM
P/N 12378190 or equivalent 20 mm (0.80 in)
long to the oil pan to engine block junction.
2. Apply the sealant directly onto the tabs of the
front cover gasket that protrudes into the oil
pan surface.

451897

3. Apply a 5 mm (0.20 in) bead of sealant GM

P/N 12378190 or equivalent 20 mm (0.80 in) long
to the oll pan to engine block junction.
4. Apply the sealant directly onto the tabs of the
front cover gasket that protrudes into the oil
pan surface.

451898

5. Pre-assemble the oil pan gasket to the pan (2).

Install the gasket onto the pan (2).
Install the oil pan bolts (1) to the pan through
the gasket.
6. Install the oil pan (2), gasket and bolts (1) to the
engine block
7. Snug the oil pan bolts finger tight. Do not
overtighten.

8, Install the two lower bellhousing bolts to position

the oil pan correctly.

451962

Engine

Engine Mechanical - 5.7L

6-365

Notice: Refer to Fastener Noticein Cautions and

Notices.
9. Snug the lower bellhousing bolts finger tight. Do
not overtighten.
Tighten
9.1. Tighten the oil pan-to-block and oil
pan-to-front cover bolts to 25 N-m (18 lb ft).

9.2. Tighten the oil pan-to-rear cover bolts to

12 N-m (106 lb in).
9.3. Tighten the bellhousing bolts to
50 N-m (37 lb ft).
10. Raise the engine cradle and/or if necessary, lower
the engine.
11 . Tighten the cradle bolts.
Tighten
Tighten the upper four cradle bolts to
125 Nm (92 lb ft).
Tighten the lower two cradle bolts to
145 N-m (107 lb ft).

220632

12. Install the left side closeout and bolt.

Tighten
Tighten the left side closeout bolt to
12 N-m (106 lb in).

208478

6-366

Engine

Engine Mechanical - 5.7L

13. Install the right side closeout and bolt.

Tighten
Tighten the right closeout bolt to
12 Nm (106 lb in).
14. Install the starter motor. Refer to Starter Motor
Replacement (5.7L VB) in Engine Electrical.

208464

15. Install the oil level sensor to the oil pan.

Tighten
Tighten the oil level sensor to 35 Nm (26 lb ft).

178471

16. Connect the oil level sensor electrical connector.

17. Remove the adjustable jack stands.

220633

Engine

Engine Mechanical - 5.7L

6-367

18. Connect the intermediate steering shaft bolt.

Tighten
Tighten the intermediate shaft bolt to
47 N-m (35 lb ft).

220630

19. Install the right and left lower shock bolts.

Tighten
Tighten the shock bolts to 65 N-m (48 lb ft).

220629

20. Install the left side engine mount cradle bolts.

Tighten
Tighten the engine mount to cradle bolts to
58 N-m (43 lb ft).

220588

6-368

Engine Mechanical - 5.7L

Engine
21. Install the right side engine mount cradle bolts.
Tighten
Tighten the right side engine mount cradle bolts
to 58 Nm (43 lb ft).

220585

22. Install the oil filter.

Tighten
Tighten the oil filter to 30 N-m (22 lb ft).

(
I

178469

23. Install the oil drain plug.

Tighten
Tighten the oil drain plug to 25 N-m (18 lb ft).
24. Lower the vehicle.

25. Remove the J 41044, J 42451, J 28467-8

and J 36462-A.
26. Refill the engine with oil.

178475

Engine

Engine Mechanical - 5.7L

6-369

Oil Pump, Pump Screen and Deflector

Replacement

Removal Procedure
1. Remove the engine front cover. Refer to Engine
Front Cover Replacement.

-~

64278

2. Remove the engine oil pan (2). Refer to Oil Pan

Replacement.
3. Remove the oil pump, pump screen and deflector.
Refer to Oil Pump, Pump Screen and Deflector
Removal.

451962

Installation Procedure
1. Install the oil pump, pump screen and deflector.
Refer to Oil Pump, Pump Screen and Deflector
Installation.
2. Install the engine oil pan (2). Refer to Oil Pan
Replacement.

451962

6-370

Engine Mechanical - 5.7L

Engine
3. Install the engine front cover. Refer to Engine
Front Cover Replacement.

64278

Timing Chain and Sprockets Replacement

Removal Procedure
1. Remove the oil pump. Refer to Oil Pump, Pump
Screen and Deflector Replacement.

64281

2. Remove the timing chain and sprocket. Refer to

Timing Chain and Sprockets Removal.

(
63263

Engine

Engine Mechanical - 5.7L

6-371

Installation Procedure
1. Install the timing chain and sprocket. Refer to
Timing Chain and Sprockets Installation.

63263

2. Install the oil pump. Refer to Oil Pump, Pump

Screen and Deflector Replacement.

64281

Camshaft Replacement
Removal Procedure
1. Remove the valve lifter guide and the valve lifters.
Refer to Valve Lifter Replacement.

63233

6-372

Engine

Engine Mechanical - 5.7L.

2. Remove the radiator. Refer to Radiator::
Replacement
in. Engir;,e
Cooling. '.
.
,,;
\

221724

3. Remove\the timing chain and sprocket. Refer to

Timing Chain and Sprockets Replacement.

63263

4. Remove the camshaft., Refer to C~rnshaft

Removal.

63212

Engine

Engine Mechanical - 5.7L

6-373

Installation P.rocedure
1. Install the camshaft. Refer to Camshaft
Installation.

l/

63212

2. Install the timing chain and sprocket. Refer to

Timing Chain and Sprockets Replacement.

63263

3. Install the radiator. Refer to Radiator Replacement

in Engine Cooling,

221724

6-374

Engine

Engine Mechanical - 5.7L

4. Remove the valve lifter guide and the valve lifters.

Refer to Valve Lifter Replacement.

63233

Engine Flywheel Replacement

Removal Procedure
1. Remove the automatic transmission, if equipped.
Refer to Transmission Replacement (5. 7L) in
Automatic Transmission-4L60E.

208590

2. Remove the automatic transmission flywheel.

Refer to Engine Flywheel Removal.

178458

Engine

Engine ,Mechanical - 5.7L

6-375

3. Remove the manual transmission, if equipped.

Refer to Transmission Replacement (Removal) in
Manual Transmission-MM6.
4. Remove the manual transmission flywheel. Refer
to Engine Flywheel Removal.

156166

Installation Procedure
1. Install the manual transmission flywheel. R~Jer to
Engine Flywheel Installation.

2. Install the manual transmission, if equipped. Refer

to Transmission Replacement (Installation) ln
Manual Transmission-MM6.

156166

3. Install the automatic transmission flywheel. Refer

to Engine Flywheel Installation.

178458

6-376

Engine Mechanical - 5.7L

Engine
4. Install the automatic transmission, if equipped.
Refer to Transmission Replacement (5. 7L) in
Automatic Transmission-4L60E.

208590

Engine Replacement
Removal Procedure
Tools Required
J 39580 Engine Support Table
J 36221 Hydraulic Clutch Line Separator
J 39549 Ball Joint!Tie Rod Separator
J 21366 Converter Holding Strap
J 39411 Flywheel Holding Tool

Caution: Refer to Battery Disconnect Caution in

Cautions and Notices.
1. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnect/Connect
Procedure in Engine Electrical.

208241

2. Disconnect the positive battery cable.

211587

Engine

Engine Mechanical - 5.7L

6~377

3. Disconnect the intake .air temperature (IAT)

sensor electrical connector.
4. Disconnect the mass airflow (MAF) sensor
electrical connector.

208553

5. Remove the air intake duct resonator.

6. Recover the refrigerant. Refer to Refrigerant
Recovery and Recharging in HVAC Systems
with A/C-Manual.
7. Relieve the fuel pressure. Refer to Fuel Pressure
Relief Procedure in Engine Controls-5.7L.
8. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
9. Drain the engine oil.
10. Remove the front wheels. Refer to Wheel Removal
in Tires and Wheels.
11. Drain the engine coolant. Refer to Draining and
Filling Cooling System (VB) in Engine Cooling.
12. Remove the right side oxidation catalytic
converter. Refer to Oxidation Catalytic Converter
Replacement (Right) in Engine Exhaust.
13. Drain the transmission fluid, if equipped with a
manual transmission.
14. Remove the propeller shaft. Refer to. Propeller
Shaft Replacement - One Piece in Propeller Shaft.
Remove
the torque arm. Refer to Torque
15.
Arm Replacement in Rear Suspension.
16. Remove the starter motor. Refer to Starter Motor
Replacement (5.7L VB) in Engine Electrical.

208569

6-378

Engine Mechanical -5.7L

Engine
17. On vehicles equipped with a automatic
transmission, unsnap the transmission range
selector lever cable from the range selector lever
at the transmission.

208264

18. Remove the retainer from the range selector

lever cable.

~
I

341079

19. Remove the range selector lever cable from the

cable bracket.

208276

Engine

\)

Engine Mechanical - 5. 7L

6-379

20. On vehicles equipped with a manual transmission,

disconnect the clutch actuator cylinder line from
the actuator cylinder using J 36221.
21. Remove the left side front air deflector.
22. Remove the stabilizer bar bracket bolts.
23. Remove the stabilizer bar brackets.

43255

24. Remove the intermediate steering shaft bolt and

shaft from the rack.

220630

25. Remove the wiring harness ground bolt and RF

(Radio Frequency) ground strap and cruise
control ground lead from the front rail.

346034

6-380

Engine Mechanical r 5.7L

Engine
26. Disconnect the wheel .speed sensors electrical
connectors.

\
346036

27. Remove the air conditioning (A/C) compressor

and condenser hose bolt.
28. Discard the 0-ring.

365448

29. Removethe A/C compressor and condenser hose

nut at the condenser.
30. Discard the 0-ring.

365450

Engine

Engine Mechanical - 5.7L

6-381

31. Remove the front fuel pipe heat shield nuts (1).
32. Remove the front fuel pipe heat shield (2).
33. Disconnect the brake lines from the brake
pipe clip.
34. Lower the vehicle.

7~

173551

35. Remove the A/C compressor and condenser hose

bolt at the accumulator.
36. Discard the 0-ring.

282941

37. Remove the inlet and outlet heater hoses frorri the
water pump.
37.1. Squeeze the hose clamp together with
pliers.
37.2. Slide the hose clamp away from the water

pump fitting.
37.3. Gently twist and pun the heater hose from
the water pump fitting.

282934

6-382

Engine Mechanical - 5.7L

Engine
38. Disconnect the fuel feed pipe from the fuel rail.
39. Disconnect the fuel return pipe from the fuel rail.

220597

40. Remove the cruise control cable from the

throttle lever.

220601

Caution: In order to avoid possible injury or

vehicle damage, always replace the accelerator
control cable with a NEW cable whenever you
remove the engine from the vehicle.
In order to avoid cruise control cable damage,
position the cable out of the way while you remove
or install the engine. Do not pry or lean against
the cruise control cable and do not kink the cable.
You must replace a damaged cable.
41 . Remove the accelerator control cable from the
throttle lever.
42. Unsnap and remove the accelerator and cruise
control cable from the throttle body bracket.

220602

Engine

Engine Mechanical - 5.7L

6-383

43. Remove the cruise control and accelerator control

cables from the servo adjuster, if equipped.

296567

44. Remove the inlet hose from the water pump.

221676

45. Remove the outlet hose from the water outlet.

221671

6-384

Engine

Engine Mechanical - 5.7L

46. Remove the brake booster vacuum hose:

47. Remove the front two brake pipes from the brake
pressure modulator valve.

222997

48. Disconnect the secondary captured locks.

49. Disconnect the forward lamp harness from the
engine harness.
50. Disconnect the engine harness vacuum tube from
the bottom of the vacuum check valve.

346047

51. Disconnect the powertrain control module '(PCM)

connectors.
52. Remove the PCM from the vehicle.
53. Remove the right side insulator panel.
54. Remove the hinge pillar trim panel.

346043

Engine

Engine Mechanical - 5.7L

6-385

55. Disconnect the engine wiring harness from the

instrument panel wiring harness.

346039

56. Remove the engine wire harness through the front

of dash. Place the harness on top of the engine ..
57. Remove the floor shift control, if equipped. Refer
to Floor Shift Control Replacement in Automatic
Transmission-4L60E.
58. Remove the transmission control, if equipped.
Refer to Control Assembly in Manual
Transmission-MM6.
59. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

346041

60. Remove the right and left lower shock bolts from
the lower control arms.
61. Remove the cotter pins and nuts from the left and
right upper ball joints.
62. Using J 39549 separate the upper control arms
from the steering knuckles.
63. Support both steering knuckles.
64. Position the J 39580 below the vehicle.
65. Lower the vehicle.
66. Lay the engine wire harness on top of the engine.

220629

6-386

Engine

Engine Mechanical - 5.7L

67. Remove the front crossmember bolts.

~
220632

68. Remove the transmission support bolts.

69. Raise the vehicle and remove the engine and
transmission from the vehicle.
70. Secure the crossmember to the J 39580.

208587

71. Position a hex-head socket on the belt tensioner

pulley (1) bolt.
72. Rotate the drive belt tensioner clockwise to relieve
the tension on the drive belt.
73. Remove the drive belt from the tensioner and
pulleys.

220580

Engine

\).

Engine Mechanical - 5.7L

6-387

74. Position a hex-head socket on the belt tensioner

pulley (1) bolt.
75. Rotate the air conditioning (A/C) drive belt
tensioner clockwise to relieve the tension on the
drive belt.
76. Remove the A/C drive belt from the crankshaft
balancer and A/C compressor.

220583

77. Disconnect the A/C compressor electrical

connector.

365446

78. Remove the A/C compressor bolts.

79. Remove the A/C compressor.

282955

6-388

Engine Mechanical - 5.7L

Engine
80. Remove the power steering pump bolts (4) and
pump brace (3).
81. Remove the power steering pump (1) from the
bracket (2).
82. Reposition the power steering pump to the
crossmember.

290570

83. Disconnect the generator electrical connector (3).

211624

84. Remove the positive cable nut from the generator.

85. Remove the positive cable from the generator.
86. Install a lifting devise to the engine.

211599

Engine

Engine Mechanical - 5.7:t.

6-389

87. Remove the right side engine mount bracket to

block bolts and bracket.

220586

88. Remove the engine mount heat shield nuts.

89. Remove the engine mount heat shield.

'\
I

220590

90. Remove the left side engine mount bracket to

block studs and bracket.
91. With the aide of an assistant, raise the engine
and transmission from the crossmember.
92. Disconnect the electrical connectors from the
transmission.
93. If equipped with an automatic transmission
perform the following:

220591

6-390

Engine

Engine Mechanical - 5.7L

94. Remove the left side transmission closeout

and bolt.

208478

95. Remove the right side transmission closeout

and bolt.

208464

96. Remove the flywheel to torque converter bolts.

208580

Engine

Engine Mechanical - 5.7L

6-391

97. Remove the transmission to engine bolts.

98. Separate the transmission from the engine.
99. Attach the J 21366 to the transmission.
100. If equipped with a manual transmission perform
the following:

208590

101. Remove the flywheel housing to engine bolts (2).

102. Separate the flywheel housing from the engine.

210528

103. Remove the pressure plate bolts (4).

104. Remove the pressure plate (3) and clutch
disc (2) from the flywheel (1 ).
105. Install the engine to a engine stand.
106. Remove the engine lifting devise.

441863

6-392

Engine

Engine Mechanical - 5.7L

Installation Procedure

Tools Required
J 38836 Pilot Bushing Installer/Clutch Alignment Arbor
1. Install the engine lifting devise.
2. Remove the engine from the engine stand.
3. If equipped with a manual transmission perform
the following:
4. Install the clutch disc and pressure plate to the
flywheel.
5. Install the pressure plate bolts finger tight.
6. Using the J 38836 to align the clutch disc splines
with the pilot bearing.

J 38836
71488

Notice: Refer to Fastener Notice in Cautions and

Notices.

7. Tighten the clutch pressure plate bolts.

Tighten
Tighten the clutch pressure plate bolts in
sequence (as shown) and evenly over
3 increments with the fourth increment to
70 Nm (52 lb ft).
8. Remove the J 38836.

5
71490

9. Install the flywheel housing to engine bolts (2).

Tighten
Tighten the flywheel housing to engine bolts (2) to
50 N-m (37 lb ft).
10. If equipped with an automatic transmission
perform the following:

210528

Engine

Engine Mechanical - 5. 7L

6-393

11. Remove the J 21366 from the transmission.

12. Install the transmission to engine bolts.
Tighten
Tighten the transmission to engine bolts to
50 Nm (37 lb ft).

208590

13. Install the flywheel to torque converter bolts.

Tighten
Tighten the flywheel to torque converter bolts to
60 N-m (44 lb ft).

208580

14. Install the right side transmission closeout

and bolt.
Tighten
Tighten the right side closeout bolt to
12 N-m (106 lb in).

208464

6-394

Engine Mechanical - 5.7L

Engine
15. Install the left side transmission closeout and bolt.
Tighten
Tighten the left side closeout bolt to
12 N-m (106 lb in).

16. Connect the electrical connectors to the

transmission.
17. With the aide of an assistant, lower the engine
and transmission to the crossmember.

208478

18. Install the left side engine mount bracket

and studs.
Tighten
Tighten the engine mount bracket studs to
50 Nm (37 lb ft).

220591

19. Install the engine mount heat shield.

20. Install the engine mount heat shield nuts.
Tighten
Tighten the engine mount heat shield nuts to
10 N-m {89 lb in).

220590

Engine

Engine Mechanical - 5.7L

6-395

21. Install the right side engine mount bracket

and bolts.

\!

Tighten
Tighten the engine mount bracket bolts to
50 Nm (37 lb ft).
22. Remove the lifting devise from the engine.

220586

23. Install the positive cable to the generator.

24. Install the positive cable nut to the generator.
Tighten
Tighten the positive cable nut to the generator to
22 Nm (16 lb ft).

211599

25. Connect the generator electrical connector (3).

211624

6-396

Engine Mechanical - 5.7L

Engine
26. Position the powe.r stee:ring pump to the engine.
27. Install the power steering pump (1) to the
bracket (2).
28. Install.the powe.r steering pump, brace (3) and
bolts (4).

Tighten
Tighten the power steering pump bolts (4) to
25 N,m (18 lb ft).

290570

29. Install the A/C compressor.

30. Install the .A/C.compressor bolts;
Tighten
Tighten the A/G compressor bolts to
50 N-m (37 lb ft).

282955

31. Connect the A/C compressor.electrical connector.

365446

Engine

Engine Mechanical - 5.7L

6-397

32. Route the A/C belt over the crankshaft balancer.

33. Rotate the A/C drive belt tensioner (1) clockwise
to relieve the tension.
34. Install the drive belt between the .idler and around
the. tensioner (1) and overt.he compressor pulley.

220583

35. Route the drive belt around the pulleys.

36. Position. a hex-head socket on the belt tensioner.
pulley (1) bolt.
37. Rotate the drive belt tensioner clockwi&e to relieve
tension.
38. Install the drive belt around the te.nsioners.
39. Remove the straps from the crossmember to
the J 39580.

40. Lower the vehicle and install the engine and

. transmission. to the vehicle.

220580

41. Install the transmission support bolts.

Tighten
Tighten the transmission support bolts to
90 N-m (66 lb ft).

I
208587

6-398

Engine Mechanical - 5.7L

Engine
42. Install the front crossmember bolts.

43.

44.
45.
46.
47.

220632

Tighten
Tighten the upper four crossmember bolts to
125 N-m (92 lb ft).
Tighten the lower two crossmember bolts to
145 N-m (107 lb ft).
Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
Remove the J 39580 from below the vehicle.
Remove the support from both steering knuckles.
Install the upper control arm ball studs to the
steering knuckles.
Install the upper control arm nuts to the left and
right upper ball joints.

Tighten
Tighten the upper control arm nuts to
53 N-m (39 lb ft).
48. Install the cotter pins to the upper control
arm nuts.
49. Install the right and left lower shock bolts to the
lower control arms.
Tighten
Tighten the shock bolts to 65 N-m (48 lb ft).
50. Lower the vehicle.
51. Install the transmission control, if equipped. Refer
to Control Assembly in Manual
Transmission-MM6.
52. Install the floor shift control, if equipped. Refer to
Floor Shift Control Replacement in Automatic
Transmission-4L60E.

220629

Engine

Engine Mechanical - 5.7L

6-399

53. Install the engine wire harness through the front

of dash.

346041

54. Connect the engine wiring harness to the

instrument panel wiring harness.
55. Install the hinge pillar trim panel.
56. Install the right side insulator panel.
57. Install the PCM to the vehicle.

346039

58. Connect the powertrain control module (PCM)

connectors.
Tighten
Tighten the PCM connector bolts to
8 N-m (71 lb in).

346043

6-400

Engine

Engine Mechanical - 5.7L

59; Connect the;engine harness vacuum tube to the

bottom of the vacuum check valve.
60. Connect the forward lamp harness to the engine
harness.
61. Connect the secondary captured locks.
62. Install the front two brake pipes to the brake
pressure modulator valve.

346047

63. Install the brake booster vacuum hose.

222997

64. Install the outlet hose to the water outlet.

221671

Engine

Engine Mechanical - 5.7L

5..:401

65. Install the inlet hose to the water pump.

221676

66. Install the cruise control and accelerator control

cables to the servo adjuster, if equipped.

296567

67. Install the accelerator and cruise control cable to

the throttle body bracket.
68. Install the accelerator control cable to the
throttle lever.

220602

6-402

Engine Mechanical.,. 5.7L

Engine
69. Install the ,cruise control cable to the throttle lever.

220601

70. Connect the fuel feed pipe to the fuel rail.

71 . Connect the fuel return pipe to the fuel rail.

220597

72. Install the inlet.and outlet heater hoses to the

water pump.

282934

Engine

Engine Mechanical - 5.7L 6-403

73. Install a new 0-ring.

74. Install the A/C compressor and condenser hose
bolt at the accumulator.

Tighten
Tighten the A/C compressor and condenser hose
bolt at the accumulator to 16 N-m (12 lb ft).
75. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

282941

76. Connect the brake lines to the brake pipe clip.

77. Install the front fuel pipe heat shield (2).
78. Install the front fuel pipe heat shield nuts (1).

Tighten
Tighten the front fuel pipe heat shield nuts (1) to
5 N-m (44 lb in).

7~

173551

79. Install a new 0-ring.

80. Install the A/C compressor and condenser hose
nut at the condenser.

Tighten
Tighten the A/C compressor and condenser hose
nut at the condenser to 16 N-m (12 lb ft).

365450

6-404

Engine Mechanical - 5.7L

Engine
81. Install a new 0-ring.
82. Install the A/C compressor and condenser
hose bolt.
Tighten
Tighten the A/C compressor and condenser hose
bolt to 33 Nm (24 lb ft).

365448

83. Connect the wheel speed sensors electrical

connectors.

\
346036

84. Install the RF (Radio Frequency) ground strap

and cruise control ground lead from the front rail.
85. Install the wiring harness ground bolt.
Tighten
Tighten the wiring harness ground bolt to
12 Nm {106 lb in).

346034

Engine

Engine Mechanical - 5.7L

6-405

86. Install the intermediate steering shaft and shaft

bolt to the rack.
Tighten
Tighten the intermediate steering shaft bolt to
47 N-m (35 lb ft).
87. Install the stabilizer bar brackets.
88. Install the stabilizer bar bracket bolts.
Tighten
Tighten the stabilizer bar bracket bolts to
55 Nm (41 lb ft).
89. Install the left side front air deflector.

220630

90. On vehicles equipped with a manual transmission,

connect the clutch actuator cylinder line to the
actuator cylinder.

43255

91. On vehicles equipped with a automatic

transmission, install the range selector lever cable
to the cable bracket.

)
208276

6-406

Engine Mechanical - 5. 7L

Engine
92. Install the retainer to the range selector
lever cable.

~
I

341079

93. Snap the transmission range selector lever cable

94.
95.
96.
97.

98.
99.

to the range selector lever at the transmission.

Install the starter motor. Refer to Starter Motor
Replacement (5.7L VB) in Engine Electrical.
Install the torque arm. Refer to Torque Arm
Replacement in Rear Suspension.
Install the propeller shaft. Refer to Propeller Shaft
Replacement - One Piece in Propeller Shaft.
Install the right side oxidation catalytic converter.
Refer to Oxidation Catalytic Converter
Replacement (Right) in Engine Exhaust.
Install the front wheels. Refer to Wheel Installation
in Tires and Wheels.
Lower the vehicle.

208264

100. Install the air intake duct resonator.

(
208569

Engine

Engine Mechanical - 5.7L

6-407

101. Connect the intake air temperature (IAT) sensor

electrical connector.
102. Connect the mass airflow (MAF) sensor electrical
connector.

208553

103.
104.
105.
106.

Connect the positive battery cable.

Refill the engine oil.
Refill the transmission fluid.
Refill the engine coolant. Refer to Draining and
Filling Cooling System (VB) in Engine Cooling.
107. Recharge the refrigerant. Refer to Refrigerant
Recovery and Recharging in HVAC Systems
with A/C-Manual.
108. Bleed the brakes. Refer to Hydraulic Brake
System Bleeding (Manual Bleed) or Hydraulic
Brake System Bleeding (Pressure Bleed)
in Hydraulic Brakes.
109. Bleed the clutch hydraulic system. Refer to
Hydraulic Clutch Bleeding in Clutch.

211587

110. Connect the negative battery cable. Refer to

Battery Negative Cable Disconnect/Connect
Procedure in Engine Electrical.

208241

6-408

Engine Mechanical - 5. 7L

Engine
Engine Oil and Oil, Filter Change
Removal Procedure
1. Open the hood.
2. Remove the oil fill cap.
3. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
4. Remove the oil pan drain plug and drain the
engine oil.
5. Wipe the excess oil from the drain hole and plug.

178475

6. Remove the oil filter from the engine block.

Important: Check the old oil filter to ensure that the
filter seal is not left on the engine block.
7. Wipe the excess oil from the oil filter mounting.

178469

Installation Procedure
1. Install the oil fitter to the engine block.
Notice: Refer to Fastener Notice in Cautions and
Notices.

Tighten
Tighten the oil filter to 30 Nm (22 lb ft).

178469

Engine

Engine Mechanical - 5.7L

6-409

2. Install the drain plug to the oil pan.

Tighten
Tighten the oil drain plug to 25 Nm (18 lb ft).
3. Lower the vehicle.
4. Fill the crankcase with oil.
5. Close the hood.

178475

Draining Fluids and Oil Filter Removal

Tools Required
J 41712 Oil Pressure Sensor Socket
Important: In order to completely drain the oil from
the oil pan internal baffling, the bottom of the oil
pan must be level during the oil drain procedure.
1. Remove the oil pan drain plug and allow the oil
to drain.

178475

2. Remove the engine oil filter.

178469

6-410

E .

En gme

Mechanical - 5.7L

3. Remove the . h
ngme
I and allow
rigthe
t rear
en
pug
coolan~1tnedblo_ck
coolant drain
o rain.

63164

4. Remo_ve the left front en .

plug (1f applicable) and 11ine block coolant drain
a ow the coolant to drain.

63165

5. Remove th e engine
bl
applicable) and allow t~ck coolant heater (if
e coolant to drain.

65332

Engine

Engine Mechanical - 5.7L

6-411

6. Use the J 41712 or equivalent in order to remove

the oil pressur sensor (if required).

J 41712

178483

Crankshaft Balancer Removal

Tools Required

J 41816 Crankshaft Balancer Remover

J 41816-2 Crankshaft End Protector
J 42386-A Flywheel Holding Tool
Important: Do not reuse the crankshaft balancer bolt.
Install a NEW crankshaft balancer bolt during final
assembly.

Notice: Refer to Fastener Notice in Cautions and

Notices.
Important: Make sure that the teeth of the flywheel
holding tool mesh with the teeth of the engine flywheel.
1. Install the J 42386-A and bolts.
Use one M10-1.5 x 120 mm and one M10-1.5 x
45 mm bolt for proper tool operation.
Tighten
Tighten the J 42386-A bolts to 50 N-m (37 lb ft).
2. Remove the crankshaft balancer bolt.

J 42386-.A

260126

Do not discard the crankshaft balancer bolt. The

balancer bolt will be used during the balancer
installation procedure.

)
260154

6-412

Engine Mechanical - 5.7L

Engine
3., JUse the J 41816 and the J 41816-2 in order to
remove the c.rc;inkshaft balancer.
4. Remove the J 42386-A and bolts.

J 41816

156164

Engine Flywheel Removal

Important: Note the position and direction of the
engine flywheel before removal. The flywheel does not
use a locating pin for alignment and will not initially
seat against the crankshaft flange, but will be
pulled onto the crankshaft by the engine flywheel
bolts. This. procedure requires a three stage tightening
process.
1. Remove the engine flywheel bolts.
2. Remove the automatic transmission engine
flywheel (if applicable).

178458

3. Remove the manual transmission engine flywheel

(if applicable).

156166

Engine

Engine Mechanical - 5.7L

6-413

Oil Level Indicator and Tube Removal

1. Remove the oil level indicator from the tube.

2. Remove the oil level indicator tube bolt from the
cylinder head.
3. Remove the oil level indicator tube from the
engine block.
Important: Inspect the 0-ring seal for cuts or damage.
The 0-ring seal may be reused if not cut or damaged.
4. Remove the 0-ring seal from the tube
(if required).

178459

Exhaust Manifold Removal (Left Side)

1. Loosen the Air Injection Reaction (AIR) hose
clamps and remove the hose assembly.

178465

lmportarit: Qo not remove. ttle ctleck va,tve fror:r:i the

AIR pipe unless service is required.

2. Remove the AIR pipe (with check valve), bolts

and gasket from the left exhaust manifold.
3. Rerriove the spark plug wires from the
spark plugs.
Do not remove the spark plug wires from the
ignition coils unless required.

178463

6-414

Engine Mechanical - 5.7L

Engine
Important: Do not remove the oxygen sensor from
the manifold unless service is required.

4. Remove the oxygen sensor from the manifold

(if required).

(.
.

222952

5. Remove the exhaust manifold, bolts and gasket,

6. Discard the gasket.

178462

Exhaust Manifold Removal (Right Side)

Important: Do not remove the Exhaust Gas
Recirculation (EGR) valve from the pipe assembly
unless service is required.
1. Remove the EGR valve, gasket, and bolts.

178487

Engine

Engine Mechanical - 5.7L

6-415

2. Remove the EGR valve pipe bolt from the intake

manifold.
3. Remove the EGR valve pipe bolts and gasket
from the exhaust manifold.
4. Remove the EGR valve pipe bolts from the
cylinder head.
5. Remove the EGR valve pipe assembly.
With mild force, pull the EGR valve pipe from the
intake manifold.
6. Remove the 0-ring seal from the EGR valve pipe
assembly.
7. Discard the exhaust manifold gasket and
0-ring seal.

178489

Important: Do not remove the check valve from the

Air Injection Reaction (AIR) pipe unless service is
required.
8. Remove the AIR pipe (with check valve), bolts
and gasket from the right exhaust manifold.

178464

9. Remove the spark plug wires from the

spark plugs.
Do not remove the spark plug wires from the
ignition coils unless required.

Important: Do not remove the oxygen sensor from

the manifold unless service is required.
10. Remove the oxygen sensor from the manifold.
11. Remove the exhaust manifold, bolts, and gasket.
12. Discard the gasket.

/
178460

6-416

Engine Mechanical - 5.7L

Engine
Water Pump Removal
1. Remove the water pump pulley bolts.
2. Remove the water pump pulley.

74081

3. ,Remove the water.pump bolts.

4. Remove the water pump and gaskets.
5. Discard the water pump gaskets.

63204

Throttle Body Removal

Important: The intake manifold, throttle body, fuel
injection rail, and fuel injectors may be removed as an
assembly. If not servicing the individual components,
remove the manifold as a complete assembly.
1. Remove the electrical wire harness connectors
from the throttle body.
2. Remove the vapor vent pipe hose and clamp.
3. Remove the throttle body bolts.
4. Remove the throttle body.

222051

Engine

Engine Mechanical - 5.7L

6-417

5. Remove the throttle body gasket (1).

Important: DO NOT reuse the throttle body gasket.
Install a NEW gasket during assembly.
6. Discard the g?sket.

490580

Fuel Rail and Injectors 'Removal

Important: The intake manifold, throttle body, fuel
injection rail and fuel injectors may be removed as an
assembly. If not servicing the individual components,
remove the intake manifold as a complete assembly.

Caution: The fuel rail stop bracket must be

installed onto the engine assembly. The stop
bracket serves as a protective shield for the fuel
rail in the event of a vehicle frontal crash. If
the fuel rail stop bracket is not installed and the
vehicle is involved in a frontal crash, fuel could be
sprayed possibly causing a fire and personal
injury from burns.
1. Remove the fuel rail bolts.
Important: Do not separate the fuel injectors from the
fuel rail unless component service is required.
Use cleanliness and care when handling the fuel
system components.
Do not allow dirt or debris to enter the fuel injectors or
fuel rail components, cap ends as necessary.
2. Remove the fuel rail (with injectors), lifting evenly
from both sides of the fuel rail until all the injectors
have left their bores.

222050

6-418

Engine

Engine Mechanical - 5.7L

Intake Manifold Removal

Important: The intake manifold, throttle body, fuel

injection rail, and fuel injectors may be removed as an
assembly. If not servicing the individual components,
remove the manifold as a complete assembly.
1. Remove the Manifold Absolute Pressure (MAP)
sensor (if required).

58838

2. DisconnecUhe knock.sensor wire harness

connector (1) from the fuel rail stop bracket (2).

490736

3. Remove the Positive Crankcase Ventilation (PCV)

valve pipe from the left rocker cover (if required).

379366

Engine

Engine Mechanical - 5.7L 6-419

4. Remove the PCV valve pipe strap nut.

5. Remove the PCV valve pipe from the right rocker
cover and intake manifold.

379367

Caution: The fuel rail stop bracket must be

installed onto the engine assembly. The stop
bracket serves as a protective shield for the fuel
rail in the event of a vehicle frontal crash. If
the fuel rail stop bracket is not installed and the
vehicle is involved in a frontal crash, fuel could be
sprayed possibly causing a fire and personal
injury from burns.
6. Remove the intake manifold bolts (1) and fuel rail
stop bracket (2).

490927

6-420

Engine

Engine 'Me'ehanical .. s~7L

7. Remove the vapor vent pipe clamp and hose from

the throttle body.
8. Remove the intake manifold.

178557

9. Remove the intake manifold-to-cylinder head

gaskets (1) .
10. Discard the gaskets.

490579

11. Remove the throttle cable bracket (2) and bolt (1)
from the manifold (if required).

(
490573

Engine

Engine Mechanical..; 5.7L

6-421

Vapor Vent Pipe Removal

1. Disconnect the knock sensor wire harness

retaining clips from the tube.
2. Remove the vapor vent pipe hose and clamp.
3. Remove the vapor vent pipe bolts.
4. Remove the vapor vent pipe and gaskets.

64139

5. Remove the gaskets from the pipe.

6. Discard the vapor vent pipe gaskets.

64262

Engine Valley Cover Removal

1. Remove the knock sensor wire harness.

54608

6-422

Engine Mechanical - 5.7L

Engine
2. Remove the knock sensors.

54612

3. Remove the valley cover bolts.

4. Remove the valley cover and gasket.
5. Discard the valley cover gasket.

65048

Valve Rocker Arm Cover Removal

(Left Side)
Important: Do not remove the ignition coils from the
valve rocker arm cover unless required.

Do not remove the vent valve grommet from the cover

unless service is required.
If the vent valve grommet has been removed from the
cover, a NEW grommet must be installed.
1. Remove the crankcase vent vacuum tube from
the grommet.
2. Remove the valve rocker arm cover bolts.
3. Remove the valve rocker arm cover.

63205

Engine

Engine Mechanical- 5.7L

6-423

4. Remove the crankcase vent valve grommet from

the left cover (if required).
5. Discard the vent valve grommet. .

63244

6. Remove the ignition coil wire harness (if required).

7. Remove the ignition coils and bolts from the cover
(if required).
8. Remove the gasket and bolt grommets from,
the cover.
9. Discard the gasket. The bolt grommets,may be
reused if not damaged.

65292

Valve Rocker Arm Cover Removal

(Right Side)
Important: Do not remove the ignition coils from the
valve rocker arm cover unless required.
.

Do not remove the 9il fill tube from the cover unless
service is required.
If the oil fill tube has' been removed from the cover,
install a NEW tube during assembly.
1. Remove the valve rocker arm cover bolts.
2. Remove the valve rocker arm cover.

63205

6-424

Engine Mechanical - 5.7L

Engine
3. Remove the oil fill cap from the oil fill tube.
4. Remove the oil fill tube (if required).
5. Discard the oil fill tube.

64263

6. Remove the gasket and bolt grommets from

the cover.
7. Remove the ignition coil wire harness (if required).
8. Remove the ignition coils and bolts (if required).
9. Discard the gasket. The bolt grommets may
be reused if not damaged.

65290

Valve Rocker Arm and Push Rod Removal

Important: Place valve rocker arms, valve pushrods,
and pivot support, in a rack so that they can be
installed in the same location from which they were
removed.
1. Remove the valve rocker arm bolts.
2. Remove the valve rocker arms.

64171

Engine

Engine Mechanical - 5.7L

6-425

3. Remove the valve rocker arm pivot support.

64178

4. Remove the pushrods.

64266

Cylinder Head Removal (Left Side)

1. Remove the spark plugs from the cylinder head.
Important: The M11 cylinder head bolts are NOT
reuseable. Install NEW M11 cylinder head bolts during
assembly.
2. Remove the cylinder head bolts.

Notice: After removal, place the cylinder head on two

wood blocks to prevent damage.
3. Remove the cylinder head.

64878

6-426

Engine Mechanical - 5.7L

Engine
4. Remove the gasket.
5. Discard the gasket.
6. Discard the M11 cylinder head bolts.

63169

Cylinder Head Removal (Right Side)

1. Remove the spark plugs from the cylinder head.
Important: The M11 cylinder head bolts are NOT
reuseable. Install NEW M11 cylinder head bolts during
assembly.

2. Remove the cylinder head bolts.

Notice: After removal, place the cylinder head on two
wood blocks to prevent damage.
3. Remove the cylinder head.

100173

4. Remove the gasket.

5. Discard the gasket.
6. Discard the M11 cylinder head bolts.

63170

Engine

Engine Mechanical - 5.7L

6-427

Valve Lifter Removal

)

Tools Required
J 3049-A Valve Lifter Remover
1. Remove the valve lifter guide bolts (1 ).
2. Remove the valve lifters and guide.

63230

Important: Some valve lifters may be stuck in their

bores because of gum or varnish deposits.

3. Use the J 3049-A or equivalent in order to remove

the valve lifters (if required).

31350

4. Remove the valve lifters from the guide.

5. Organize or mark the components so that they
can be installed in the same location from which
they were removed.
Refer to Separating Parts.

)
63233

6-428

Engine Mechanical - 5.7L

Engine
Oil Filter, Adapter and Pan Cover Removal
1. Remove the oil filter.

178469

2. Remove the oil pan cover, bolts, and gasket.

3. Discard the gasket.

178471

4. Remove the oil filter fitting (1) and bypass

valve (2) (if required).

(
490699

Engine

Engine Mechanical - 5.7L

6-429

Oil Pan Removal

Important: The original oil pan gasket is retained and

aligned to the oil pan by rivets. When installing a
new gasket, it is not necessary to install new oil pan
gasket rivets.

DO NOT reuse the oil pan gasket. When installing the

oil pan, install a NEW oil pan gasket.
It is not necessary to remove the oil level sensor prior
to oil pan removal. Remove the oil level sensor if
service is required.
1. Remove the left closeout cover and bolt.

178477

2. Remove the right closeout cover and bolt.

178480

3. Remove the oil level sensor from the oil pan

(if required).

178467

6-430

Engine Mechanical - 5.7L

Engine
4. Remove the oil pan bolts.
5. Remove the oil pan.

178558

Important: DO NOT allow foreign material to enter

the oil passages of the oil pan, cap or cover the
openings as required.

6. Drill (3) out the oil pan retaining rivets (2)

(if required).
7. Discard the gasket and rivets.

384699

8. Remove the oil pan baffle bolts and baffle

(if required).

178491

Engine

Engine Mechanical - 5.7L

6-431

Engine Front Cover Removal

1. Remove the front cover bolts.
2. Remove the front cover and gasket.
3. Discard the front cover gasket.

_,41)

64278

4. Remove the ;erankshaft front oil seal (1) from

the cover.

490689

Engine Rear Cover Removal

1. Remove the rear cover bolts.
2. Remove the rear cover and gasket.
3. Discard the rear cover gasket.

)
64282

6-432

Engine Mechanical- 5.7L

.Engi,ne
4. Remove the crankshaft rear oil seal (1) from
the cover.

490692

Oil Pump, Pump Screen and Deflector

Removal
1.
2.
3.
4.

Remove the oil pump screen bolt and nuts.

Remove the oil pump screen with 0-ring seal.
Remove the 0-ring seal from the pump screen.
Discard the 0-ring seal.

64268

5. Remove the remaining crankshaft oil

deflector nuts.
6. Remove the crankshaft oil deflector.

64270

Engine

Engine Mechanical - 5.7L

6-433

7. Remove the oil pump bolts ..

Important: Do not allow dirt or debris to enter the oil

pump assembly, cap ends as necessary.
8. Remove the oil pump.

Timing Chain and Sprockets Removal

Tools Required
J 8433 I J 21427-01 Pulley Puller
J 41816-2 Crankshaft Pilot
J 41558 Crankshaft Sprocket Remover

Notice: Do not turn the crankshaft assembly after the

timing chain has been removed in order to prevent
damage to the piston assemblies or the valves.
1. Remove the camshaft sprocket bolts.
2. Remove the camshaft sprocket and timing chain.

63263

3. Use the J 8433 I J 21427-01, the JA1816-?:; and

the J 41558 in order to remove the crankshaft
sprocket.

J 8433-1
63189

6-434

Engine

Engine Mechanical - 5.7L

4. Remove the crankshaft sprocket.

156150

5. Remove the crankshaft sprocket key (if required).

156149

Camshaft Removal
1. Remove the camshaft sensor bolt and the sensor.

260128

Engine

Engine.Mechanical - 5.7L

6-435

2. Remove the camshaft retainer bolts and the

retainer.

63211

Notice: All camshaft journals are the same diameter,

so care must be used in removing or installing the
camshaft to avoid damage to the camshaft bearings.

3. Remove the camshaft.

3.1. Install the three M8-1.25 x 100 mm bolts in
the camshaft front bolt holes.
3.2. Using the bolts as a handle, carefully rotate
and pull the camshaft out of the
engine block.
3.3. Remove the bolts from the front of the
camshaft.

63212

Piston, Connecting Rod, and

Bearing Removal
Tools Required

J 41556 Connecting Rod Guide

J 24270 Cylinder Ring Ridge Remover
Important: The connecting rods and the bearing caps
are NOT interchangeable.
1. Use the J 24270 in order to remove the cylinder
bore ring ridge (if required).
1.1 . Turn the crankshaft until the piston is at the
bottom of the stroke.
1.2. Place a cloth on top of the piston.
1.3. Use the J 24270 or equivalent in order to
remove cylinder ring ridge.

J 24270
11497

6-436

Engine Mechanical - 5.7L

Engine
1A Turn the crankshaft so the piston is at the
top of the stroke.
1.5. Remove the cloth.
1.6. Remove the cutting debris from the cylinder
and piston.

Important: Using a paint stick or etching tool, place

matchmarks or numbers on the connecting rods and
the connecting rod caps. The connecting rods and
caps MUST be assembled to their original position and
direction.

A stamping mark on the side of the connecting rod at

the crank journal may effect component geometry.
Mark the top of the piston to the specific cylinder bore.
2. Remove the connecting rod bolts.
Important: Mark, sort, or organize the connecting rod
bearings so they may be installed to their original
position and location.
3. Remove the connecting rod cap.
Refer to Separating Parts.

53223

4. Install the J 41556 to the connecting rod.

J 41556

63186

Engine Mechanical - 5.7L

Engine

6-437

5. Use a hammer and tap lightly on the end of the

J 41556 in order to remove the piston and
connecting rod assembly from the cylinder bore.
\

(P~.
z::,~

,,

-;;,:!! ~

JL~'o
~,'
~
::;,,' $
-

wd1

~~
64285

6. Upon removal of the piston and connecting rod

assembly, assemble the connecting rod cap and
bolts onto the matching connecting rod.

53223

Crankshaft and Bearings Removal

Tools Required
J41818 Crankshaft Bearing Cap Remover

J6125-1B Slide Hammer

Important: The crankshaft bearing caps are machined
with the engine block for the proper clearances.
Mark Dr identify each crankshaft bearing cap location
and direction before removal. The crankshaft
bearing caps MUST be installed to their original
position and direction.

Do not reuse the bearing cap MB side bolts.

\
!

Remove the bearing cap MB side bolts prior to cap

removal.
1. Remove the crankshaft position sensor bolt.
2. Remove the crankshaft position sensor.
55322

6-438

Engine Mechanical - 5.7L

Engine
3. Remove the crankshaft bearing cap MB side bolts.
4. Remove the bearing cap M10 bolts and studs.
Note the M1 O stud locations.
(
\

156155

Notice: Refer to Fastener Notice in Cautions and

Notices.

5. Install the J 41818.

Tighten
Tighten the J 41818 bolts to 11 N-m (100 lb in).
6. Install the J 6125-18 to the J 41818 in order to
remove the crankshaft bearing caps.

63188

7. Remove the bearing caps.

156152

Engine

Engine Mechanical - 5.7L

6-439

8. Remove the crankshaft.

156151

Important: Use care when handling the crankshaft.

Avoid damage to the crankshaft position sensor
reluctor ring teeth. Nicks, burrs or other damage to the
teeth may effect On-Board Diagnostics (OBD) II
system performance.

9. Lay the crankshaft onto two wooden V-blocks or

other protective surface.

156153

10. Remove the crankshaft bearings from the bearing

caps and the engine block.
11. Mark, sort, or organize the crankshaft bearings so
they may be installed to their original position and
location.
Refer to Separating Parts.

64293

6-440

Engine

Engine Mechanical - 5.7L

Engine Block Plug Removal
Tools Required
J 41712 Oil Pressure Sensor Socket

J 41712

Important: Do not remove the engine block front oil

gallery plug unless service is required.

If the front oil gallery plug is removed for service, a

NEW oil gallery plug must be installed.
1. Remove the oil pressure sensor (if not previously
removed) using the J 41712 or equivalent.

178483

2. Remove the engine block right rear coolant plug.

63164

3. Remove the engine block coolant heater

(if applicable).

65332

Engine

Engine Mechanical - 5.7L

6-441

4. Remove the engine block left front coolant plug

(if applicable).

63165

5. Remove the engine block left front oil gallery plug.

63167

6. Remove the engine block left rear oil gallery plug.

7. Inspect the block plug sealing washers.
If the block plug and heater sealing washers are
not damaged, they may be used during assembly.

64923

6-442

Engine Mechanical - 5.7L

Engine
8 ... Remove the engine block rear oil gallery plug.
9. Inspect the 0-ring seal of the rear oil gallery plug.
If the 0-ring seal is not cut or damaged, the plug
and 0-ring seal may be use during assembly.

63228

Important: Remove the front oil gallery plug only if

service is required.

If the front oil gallery plug is removed, a NEW oil

gallery plug must be installed.

10. Remove the engine block front oil gallery plug.

64295

Engine

Engine Mechanical - 5.7L

6-443

Engine Block Clean and Inspect

1. Clean the following areas:
\
)

J8087

Notice: Do not use a caustic solution to clean the

aluminum engine block.
Important: When cleaning an engine block in a
thermal type oven, do not exceed 450F (232C).
The engine block in the solvent, remove all
sludge, dirt, or debris
Refer to Cleanliness and Care.

Caution: Wear safety glasses in order to avoid eye

damage.
Dry the block with compressed air.
The gasket surfaces
Refer to Replacing Engine Gaskets.
The coolant passages
The oil galleries
The main bearing caps
The engine block cylinder head bolt holes for
threadlocking material
Thread repair driver tool J 42385-107 may be
used to clean the threads of old threadlocking
material.
2. Inspect the following areas:
The cylinder walls for excessive scratches,
gouging, or ring ridge
The coolant jacket for cracks
The valve lifter bores for excessive scoring
or wear
The crankshaft bearing webs for cracks
The gasket sealing surfaces for excessive
scratches or gouging
Refer to Replacing Engine Gaskets.
The oil galleries for restrictions
All threaded bolt holes for damage
3. Measure the following areas:
The cylinder bores for taper
The cylinder bores for excessive ring ridge at
the top of the cylinder

Measuring Cylinder Taper

1. Adjust the micrometer to 96.0 mm (3.78 in).

4974

6-444

Engine Mechanical - 5. 7L

Engine
2. Insert the bore gauge into the micrometer and
zero the bore gauge dial.
3. Use a bore gauge and measure the cylinder bore.
for taper.

Slide the bore gauge up and down throughout the

length of the cylinder bore. Check the bore
both parallel and perpendicular to the centerline of
the crankshaft.
Recondition cylinders with less than 0.018 mm
(0.0007 in) wear or taper with a hone.
Cylinders with more than 0.018 mm (0.0007 in)
wear or taper must be fitted with an oversize
piston.

4972

Cylinder Boring and Honing

Boring Procedure
1. A 0.25 mm (0.01 in) oversize service piston and
piston ring set are available for the LS1 engine.
Important: Do not bore the cylinder liners on tl'\e LS1
engine:
2. It is recommended to hone the cylinder to achieve
proper fit for the oversize piston.
Refer to the Cylinder Honing information for the
proper honing procedure.

Honing Procedure

186747

1. When honing the cylinders, follow the

manufacturer's reco.mmendations for equipment
use, cleaning, and lubrication. Use only clean,
sharp stones of theproper grade for the amount
of material you remove. Dull, dirty stones cut
unevenly and generate excessive heat. Do
not hone to final clearance with a coarse or
medium-grade stone. Leave sufficient metal so
that all stone marks may be removed with
fine-grade stones. Perform final honing with a
fine-grade stone, honing the cylinder to the proper
clearance.
2. During the honing operation, thoroughly clean the
cylinder bore. Repeatedly check the cylinder bore
for fit with the selected piston.
All measurements of the piston or the cylinder
bore should be made with the components
at normal room temperature.
3. When honing a cylinder for fit to an oversize
piston, first perform the preliminary honing
with a 100 grit stone.
4. Perform final cylinder honing with a 240 grit stone
and obtain a 45 degree cross hatch pattern.
A 240 grit stone is preferred for final honing. If a
240 grit stone is not available, a 220 grit stone
may be used as a substitute.

Engine

Engine Mechanical - 5.7L

6-445

5. When honing to eliminate taper in the GYlinder,

make full strokes the complete length of the bor~.
Repeatedly check the measurement at the
top, the middle, and the bottom of the bore.
6. The finish marks should be clean but not sharp,
The finish marks should also be free from
imbedded particles and tqrn or folded metal.
7. By measuring the selected piston at the sizing
point arid by adding the average of the clearance
specification, you can determine the final
cylinder honing dimension required.
8. When finished, the reconditioned cylinder bores
should have less than or meet the specified
out-of-round and taper requirements.
9. After final honing and before the piston is checked
for fit, clean the cylinder bores with hot water and
detergent. Scrub the bores with a stiff bristle
brush and rinse the bores thoroughly with
hot water. Do not allow any abrasive material to
remain in the cylinder bores. This abrasive
material may cause premature wear of the new
piston rings and the cylinder bores. Abrasive
material will also contaminate the engine oil and
may cause premature wear of the bearings.
After washing the cylinder bore, dry the bore with
a clean rag.
10. Perform final measurements of the piston and the
cylinder bore.
11. Permanently mark the top of the piston for the
specific cylinder to which it has been fitted.
12. Apply clean engine oil to each cylinder b.ore in
order to prevent rusting.

Deglazing Procedure
Using a ball typ~ or self centering honing tool, deglaze
the cylinder bore lightly. Deglazing should be done
only to remove any deposits that may have formed.
Use a 240 grit stone of silicone carbide or equivalent
material when preforming the deglazing procedure.
A 240 grit stone is preferred for final honing. If a
240 grit stone is not available, a 220 grit stone may be
used as a substitute.

490757

6-446

Engine Mechanical - 5.7L

Engine
Crankshaft and Bearings Clean and
Inspect (Cleaning and Inspection)
Cleaning Procedure
Important: Use care when handling the crankshaft.
Avoid damage to the bearing surfaces or the lobes of
the crankshaft position reluctor ring. Damage to the
teeth of the crankshaft position reluctor ring may effect
On-Board Diagnostics (OBD) II system performance.
1. Remove the clutch pilot bearing.

63195

(
2. Clean the crankshaft with solvent.
3. Thoroughly clean all oil passages and inspect for
restrictions or burrs.
Caution: Wear safety glasses in order to avoid eye
damage.
4. Dry the crankshaft with compressed air.

156153

Engine

Engine Mechanical - 5.7L

6-447

Inspection Procedure

Tools Required
J 7872 Magnetic Base Dial Indicator Set
J 36660 Torque Angle Meter
Important: Use care when handling the crankshaft.
Avoid damage to the bearing surfaces or the lobes of
the crankshaft position reluctor ring. Damage to the
teeth of the crankshaft position reluctor ring may effect
On-Board Diagnostic (OBD) II system performance.
Important: The reluctor ring teeth should not
have imperfections on the rising or falling edges.

Imperfections of the reluctor ring teeth may effect OBD

II system performance.
1. Perform a visual inspection of the crankshaft for
damage.
2. Inspect the crankshaft position reluctor ring lobes
for damage.
156153

3. Inspect the crankshaft journals for wear (1).

Journals should be.. smooth with no signs of
scoring, wear, or damage.
4. Inspect the crankshaft journals for grooves or

scoring (2).
5. Inspect the crankshaft journals for scratc.hes or
wear (3).
6. Inspect the crankshaft journals for pitting or
imbe.dded bearing material (4).

156170

7. Inspect the crankshaft key (1), keyway (2), and

threaded hole (3) for damage.

)
188090

6-448

Engine Mechanical - 5. 7L

Engine
8. Measure the crankpins for the out-of-round.
9. Measure the crankpins for taper.

35207

10. Measure the crankshaft runout.

Using wooden V blocks, support the crankshaft on
the front and rear journals.

11. Use the J 7872 in order to measure the crankshaft

runout at the front and rear intermediate journals.
12. Use the J 7872 in order to measure the runout of
the crankshaft rear flange.
13. Use the J 7872 in order to measure the runout of
the crankshaft position reluctor ring. Reluctor ring
runout should be measured 1.0 mm (0.03937 in)
below the ring teeth.
A reluctor ring with runout in excess of 0.25 mm
(0.010 in), must be replaced.

J7872
35210

Engine

Engine Mechanical -5.7L

6-449

Important: A loose or damaged crankshaft oil gallery

plug must be replaced.

14. Inspect the rear crankshaft oil gallery plug for a

loose fit or leaking.

63238

)
15. Install a new clutch pilot bearing.
A properly installed clutch pilot bearing will be
installed until flush to the face of the crankshaft.

63195

6-450

Engine Mechanical - 5.7L

Engine
16. Install a 5/8 in washer (1) onto the J 38836 or
equivalent.
The washer serves as a stop against the
crankshaft face and will assist in installing the
bearing to the proper depth.
17. Install the new pilot bearing onto the tool.
18. Install the NEW pilot bearing into the crankshaft.

J 38836

(
\

2
260131

19. Inspect crankshaft bearings for craters or pockets.

Flattened sections on the bearing halves also
indicate fatigue.

52051

20. Inspect the crankshaft bearings for excessive

scoring or discoloration.
21. Inspect the crankshaft bearings for dirt or debris
imbedded into the bearing material.

52053

Engine

Engine Mechanical - 5.7L

6-451

22. Inspect the crankshaft bearings for improper

seating indicated by bright, polished sections of
the bearing.
If the lower half of the bearing is worn or
damaged, both upper and lower halves should be
replaced.
Generally, if the lower half is suitable for use, the
upper half should also be suitable for use.

52056

Measuring Main Bearing Clearance

Important: The crankshaft main bearings are a
precision insert type. Main bearing caps are machined
with the engine block for proper clearance and
cannot be shimmed or filed for bearing fit. If the
clearances are found to be excessive, new bearings
and/or engine block and cap repair or replacement
may be required.

Do not rotate the crankshaft while gauging plastic is

between the crankshaft journal and the bearing
surface.
The crankshaft bearing clearances are critical.
Excessive bearing clearance may effect crankshaft
position sensor signals and may effect On-Board
Diagnostics (OBD) II system operation.
Tools Required
J 41818 Crankshaft Bearing Cap Remover
J 6125-18 Slide Hammer
J 36660 Torque Angle Meter

Important: Remove the bearing cap side bolts prior to

cap removal.
1. Remove the bearing cap MB side bolts.

156155

6-452

Engine Mechanical~ 5.7L

Engine
2. Remove the bearing cap M10 bolts and studs.

156152

Notice: Refer to Fastener Notice in Cautions and

Notices.

3; Install the J 41818 to the bearing cap.

Tighten
Tighten the J 41818 bolts.to 11 Nm (100 lb in).
4. Install the J 6125-18 to the J 41818 in order to
remove the bearing cap.

63188

5. Remove the bearing cap and lower bearing.

64293

Engine

Engine Mechanical - 5.7L

6-453

6. Install gauging plastic onto the crankshaft journal.

Install the gauging plastic the full width of
crankshaft bearing journal.

(
4980

7. Install the bearing, bearing cap, bolts and studs.

Tighten
7.1. Tighten the inner bolts (1-10) a first pass in
sequence to 20 N,m (15 lb ft).
7.2. Tighten the inner bolts (1-10) a final
pass in sequence to 80 degrees using
the J 36660.
7.3. Tighten the outer studs (11-20) a first pass
in sequence to 20 N,m (15 lb ft).
7.4. Tighten the outer studs (11-20) a final
pass in sequence to 53 degrees using
the J 36660.
7.5. Tighten the side cap bolts to
25 N,m (18 lb ft).

19
9

10

20

Tighten the bolt on one side of the bearing

cap and then tighten the bolt on the
opposite side of the same bearing cap.
63214

Important: Remove the bearing cap side bolts prior to

cap removal.
8. Remove the bearing cap MB side bolts.

156155

6-454

Engine Mechanical - 5.7L

Engine
9. Remove the bearing cap bolts and studs.

156152

10. Use the J 41818 and the J 6125-18 in order to

remove the bearing cap.

63188

11. Measure the gauging plastic at its widest area

using the scale supplied with the plastic
gauging kit.
If the gauging plastic shows irregularity in the
journal exceeding 0.025 mm (0.001 in),
remove the crankshaft and measure the journal
with a micrometer.
If the bearing clearance is greater
than 0.054 mm (0.00212 in), select and install
an undersized bearing set, and measure
the clearance with gauging plastic.
If clearance cannot be brought to
specifications, replace the crankshaft or grind
the crankshaft for use with the next
undersized bearing.

4981

Engine Mechanical - 5.7L

Engine

\
/

6-455

12. Measure the crankshaft end play.

12.1. Thrust the crankshaft forward or rearward.
12.2. Insert a feeler gauge between the
center crankshaft bearing and the
bearing surface of the crankshaft and
measure the bearing clearance.
The proper crankshaft end play clearance is
0.04-0.2 mm (0.0015-0.0078 in).
12.3. If the bearing clearance is not within
specifications:
Inspect the thrust surfaces for nicks,
gouges or raised metal. Minor
imperfections may be removed with a
fine stone.
Replace the thrust bearings and
measure the end play.
If the correct measurements cannot be
obtained, repair the crankshaft thrust
surfaces or replace the crankshaft.
64316

Measuring Connecting Rod Bearing Clearance

Tools Required

J 36660 Torque Angle Meter

Important: Connecting rod bearings are a precision
insert type. Connecting rods are of a powdered
metal design and cannot be shimmed or filed for
bearing fit. If clearances are found to be excessive, a
new bearing and/or connecting rod are required.

Do not rotate the crankshaft while gauging plastic is

between the crankshaft journal and the bearing
surface.
1. Remove the bearing cap, bearing half and bolts.

53223

2. Install the gauging plastic onto the connecting rod

bearing journal. Install the gauging plastic the full
width of the journal.

(
4980

6-456

Engine Mechanical - 5. 7L

Engine
Notice: Refer to Fastener Notice in Cautions and
Notices.

3. Install the bearing cap, bearing, and bolts.

Tighten
3.1 . Connecting rod bolts first pass to
20 Nm (15 lb ft).
3.2. Connecting rod bolts final pass to
60 degrees using the J 36660.
4. Remove the bearing cap, bearing, and bolts.

53223

5. Measure the gauging plastic at its widest area

using the scale supplied with the plastic
gauging kit.
The connecting rod bearing clearance should be
0.015-0.076 mm (0.0006-0.003 in).

4981

Crankshaft and Bearings Clean and

Inspect (Measuring Main Brg Clearance)
Measuring Main Bearing Clearance
Important: The crankshaft main bearings are a
precision insert type. Main bearing caps are machined
with the engine block for proper clearance and
cannot be shimmed or filed for bearing fit. If the
clearances are found to be excessive, new bearings
and/or engine block and cap repair or replacement
may be required.

Do not rotate the crankshaft while gauging plastic is

between the crankshaft journal and the bearing
surface.

156155

Engine

Engine Mechanical - 5.7L

6-457

The crankshaft bearing clearances are critical.

Excessive bearing clearance may effect crankshaft
position sensor signals and may effect On-Board
Diagnostics (OBD) II system operation.
Tools Required
J 41818 Crankshaft Bearing Cap Remover
J6125-1B Slide Hammer
J 36660 Torque Angle Meter
Important: Remove the bearing cap side bolts prior to
cap removal.
1. Remove the bearing cap MB side bolts.
2. Remove the bearing cap M10 bolts and studs.

156152

Notice: Refer to Fastener Notice in Cautions and

Notices.

3. Install the J 41818 to the bearing cap.

Tighten
Tighten the J 41818 bolts to 11 Nm (100 lb in).
4. Install the J 6125-18 to the J 41818 in order to
remove the bearing cap.

63188

6-458

Engine Mechanical - 5.7L

Engine
5. Remove the bearing cap and lower bearing.

64293

6. Install gauging plastic onto the crankshaft journal.

Install the gauging plastic the full width of
crankshaft bearing journal.

(
4980

7. Install the bearing, bearing cap, bolts and studs.

Tighten

7.1. Tighten the inner bolts (1-10) a first pass in

sequence to 20 Nm (15 lb ft).
7.2. Tighten the inner bolts (1-10) a final
pass in sequence to 80 degrees using
the J 36660.
7.3. Tighten the outer studs (11-20) a first pass
in sequence to 20 Nm (15 lb ft).
7.4. Tighten the outer studs (11-20) a final
pass in sequence to 53 degrees using
the J 36660.
7.5. Tighten the side cap bolts to
25 N-m (18 lb ft).
Tighten the bolt on one side of the bearing
cap and then tighten the bolt on the
opposite side of the same bearing cap.

19

10
20

63214

Engine

Engine Mechanical - 5.7L

6-459

Important: Remove the bearing cap side bolts prior to

cap removal.

8. Remove the bearing cap M8 side bolts.

156155

9. Remove the bearing cap bolts and studs.

156152

10. Use the J 41818 and the J 6125-18 in order to

remove the bearing cap.

63188

6-460

Engine Mechanical - 5.7L

Engine
11. Measure the gauging plastic at its widest area
using the scale supplied with the plastic
gauging kit.
If the gauging plastic shows irregularity in the
journal exceeding 0.025 mm (0.001 in),
remove the crankshaft and measure the journal
with a micrometer.
If the bearing clearance is greater
than 0.054 mm (0.00212 in), select and install
an undersized bearing set, and measure
the clearance with gauging plastic.
If clearance cannot be brought to
specifications, replace the crankshaft or grind
the crankshaft for use with the next
undersized bearing.

4981

12. Measure the crankshaft end play.

12.1. Thrust the crankshaft forward or rearward.
12.2. Insert a feeler gauge between the
center crankshaft bearing and the
bearing surface of the crankshaft and
measure the bearing clearance.
The proper crankshaft end play clearance is
0.04-0.2 mm (0.0015-0.0078 in).
12.3. If the bearing clearance is not within
specifications:
Inspect the thrust surfaces for nicks,
gouges or raised metal. Minor
imperfections may be removed with a
fine stone.
Replace the thrust bearings and
measure the end play.
If the correct measurements cannot be
obtained, repair the crankshaft thrust
surfaces or replace the crankshaft.
64316

Crankshaft and Bearings Clean and

Inspect (Conn. Rod Bearing Clearance)
Measuring Connecting Rod Bearing Clearance
Tools Required
J 36660 Torque Angle Meter
Important: Connecting rod bearings are a precision
insert type. Connecting rods are of a powdered
metal design and cannot be shimmed or filed for
bearing fit. If clearances are found to be excessive, a
new bearing and/or connecting rod are required.

Do not rotate the crankshaft while gauging plastic is

between the crankshaft journal and the bearing
surface.
1. Remove the bearing cap, bearing half and bolts.

53223

Engine Mechanical - 5.7L

Engine

6-461

2. Install the gauging plastic onto the connecting rod

bearing journal. Install the gauging plastic the full
width of the journal.
\

(
4980

Notice: Refer to Fastener Notice in Cautions and

Notices.

3. Install the bearing cap, bearing, and bolts.

Tighten

3.1. Connecting rod bolts first pass to

20 Nm (15 lb ft}.
3.2. Connecting rod bolts final pass to
60 degrees using the J 36660.
4. Remove the bearing cap, bearing, and bolts.

53223

5. Measure the gauging plastic at its widest area

using the scale supplied with the plastic
gauging kit.
The connecting rod bearing clearance should be
0.015-0.076 mm (0.0006-0.003 in).

0
l
!

4981

6-462

Engine

Engine Mechanical - 5.7L

Crankshaft Balancer Clean and Inspect

1. Clean the crankshaft balancer in solvent.
2. Clean the belt grooves of all dirt or debris with a
wire brush.
3. Dry the crankshaft balancer with compressed air.
4. Inspect the crankshaft balancer for the following:
Worn, grooved, or damaged hub seal surface
A crankshaft balancer hub seal surface with
excessive scoring, grooves, rust or other
damage must be replaced.
Minor imperfections on the hub seal surface
may be removed with polishing compound
or fine grade emery cloth.

260155

(
1

Important: In order for the belt to track properly, the

belt grooves should be free of all dirt or debris.
Dirty or damaged belt grooves
The balancer belt grooves should be free of
any nicks, gouges, or other damage that
may not allow the belt to track properly.
Minor imperfections may be removed with a
fine file.
Wom, chunking or deteriorated rubber between
the hub and pulley

Engine Flywheel Clean and Inspect

1. Clean the flywheel in solvent.
2. Dry the flywheel with compressed air.
3. Inspect the manual transmission flywheel for
loose or improperly installed balance weights
(if applicable).
A properly installed balance weight should be
installed until flush or below flush with the face of
the flywheel.

64126

Engine Mechanical - 5.7L

Engine

6-463

4. Inspect the manual transmission flywheel for the

following:
Pitted surfaces (1)
Grooves or scoring (2)
Rusted surface (3)
Damaged ring gear teeth (4)
Loose or improperly positioned ring gear
The ring gear has an interference fit onto the
flywheel and should be positioned completely
against the flange of the flywheel.
Missing, bent, or damaged pressure plate
locating pins
The two locating pins are installed into the
flywheel and spaced 170 degrees apart.

188086

5. Inspect the automatic transmission flywheel tor

the following:
Damaged ring gear teeth
Stress cracks around the flywheel-to-crankshaft
bolt hole locations
Important: Do not attempt to repair the welded areas
that retain the ring gear to the flywheel plate. Install
a new flywheel.
Welded areas that retain the ring gear onto the
flywheel tor cracking

178458

Piston and Connecting Rod Disassemble

Tools Required
J 24086-C Piston Pin Remover/Installer
J 24086-1 Piston Pin Remover/Installer Base
1. Using piston ring pliers, remove the piston rings
from the piston.

490763

6-464

Engine

Engine Mechanical - 5. 7L

2. Install fork insert J. 24086-920 into fixture

J 24086-10 Piston Pin Remover/Installer Base.

;J 24086-10

533475

3. Install the piston and connecting rod assembly

onto J 24086-10.
4. Install the J 24086-107 into the piston pin
and J 24086-88A through the fixture and
into J 24086-107.

J 24086-88A

'1

533478

Notice: After the installer hub bottoms on the support

assembly, do not exceed 35 000 kPa (5,000 psi)
pressure, this could cause damage to the tool.

J 24086-88A

5. Press the piston pin from the piston and

connecting rod assembly.
6. The piston and pin are a matched set and are not
to be serviced separately. Mark, sort or organize
the piston and the matching piston pin.
Refer to Separating Parts.

533480

Engine

Engine Mechanical - 5.7L

6-465

Piston, Connecting Rod and Bearings

Clean/Inspect (Piston and Pin)

Important: Replace the pistons and the pins that are

.

damaged or show signs of excessive wear..

The piston and the pin are a matched set. .If service is
required, replace the piston and the pin as an
assembly.
Do not wire brush any part of the piston.
1. Clean the varnish from the piston and the pin with
cleaning solvent.
2. Dry the piston and the pin with compressed air.

64180

3. Clean the piston ring grooves with a suitable ring

groove cleaning tool.
4. Clean the oil lubrication holes and slots.

4977

5. Inspect the piston and the pin for the following:

Cracks in the piston ring lands, the piston skirt,
or the pin bosses
Piston ring grooves for nicks, burrs, or warpage
which may cause the piston ring to bind
MINOR imperfections may be removed from
the piston with a fine file.
Scuffed or damaged skirts (2)
Eroded areas at the top of the piston (1)
Scoring to the piston pin bore (3) or the
piston pin

3
156168

6-466

Engine Mechanical - 5.7L

Engine
Important: Measurements of components should be '
taken with the components at normal room

temperature.

6. Measure the. piston ring-to-pistqn ring groove side

clearance.
6.1. Insert the edge of the piston ring into the
piston ring groove.
6.2. Roll the piston ring completely around the
piston.
If binding is caused by a distorted piston
ring groove, MINOR ring groove
imperfections may be removed with a
fine file.
If binding is caused by a distorted piston
ring, replace the piston ring.

4969

7. Measure the piston ring side clearance with a

feeler gauge.
8. If side clearance is not within specifications, try
another piston ring set.
9. The proper piston ring-to-piston ring groove side
clearance is:
The top compression ring side clearance is
0.04-0.085 mm (0.00157-0.003346 in).
The second compression ring side clearance is
0.04-0.08 mm (0.00157-0.003149}.
The oil control ring side clearance is
0.01-0.22 mm (0.0004-0.00866).
10. If proper piston ring-to-piston ring groove side
clearance cannot be achieved, replace the
piston and pin assembly.

(.

22934

11. To determine piston pin-to-bore clearance, use a

micrometer and measure the piston pin.

(
4976

Engine

Engine Mechanical .. 5.7L

6-467

12. To determine piston pin-to-bore clearance, use an

inside micrometer and measure the piston
pin bore.
)

Important: The piston and pin are a matched set. If

the clearance is not within specifications, replace
the piston and pin as an assembly.
13. To determine the proper piston pin-to-bore
clearance, subtract the piston pin diameter
from the piston pin bore diameter.
The proper piston pin-to-bore clearance is
0.01-0.02 mm (0.0004-0.00078).

4975

14. Measure the piston for out-of-round.

14.1. With the micrometer at a right angle to the
piston, measure the piston at 11 mm
(0.433 in) from the bottom of the skirt.
14.2. Measure the piston at two different points
and compare the readings.
14.3. If the piston is more than 0.018 mm
(0.0007 in) out-of-round, replace the
piston and pin as an assembly.

188016

Piston, Connecting Rod and Bearings

Clean/Inspect (Connecting Rod and
Bearings)
Important: The powdered metal connecting rod and
cap are machined for the proper clearances. The
conriecting rod and the cap must be used as
an assembly with no repair or modifications to either
mating surface.

Do not attempt to repair the connecting rod or the cap

mating surfaces. If service is required, the connecting
rod and the cap must be replaced as an assembly.
1. Clean the connecting rod and the cap in solvent.

64180

6-468

Engine

Engine Mechanical - 5.7L

Important: Replace the connecting rod if the bolt hole

threads are damaged. Do not attempt to repair the
bolt hole threads of the connecting rod.
2. Clean the connecting rod threaded bolts hol8$.
Caution: Wear safety glasses in order to avoid eye
damage.
3. Dry the' connecting rod with compressed air.
4. Inspect the connecting rod for the following:
Twisting
Nicks or gouging in the bearing bore
Damage to the bearing locating slots in the
bearing bore
Proper fit of the connecting rod and the cap
mating surfaces

156169

5. Measure the connecting rod bearing bore for

out-of-round.
If the measurement exceeds 0.008 mm
(0.0003 in), replace the connecting rod assembly.

156167

Englne

Engine Mechanical - 5.7L

6-469

6. Inspect the connecting rod bearings for craters or

poc;kets ..Flattened se.ctions on the bearing halves
also indicate fatigue.

52051

7. Inspect the connecting rod bearings tor exce$sive

scoring or discoloration.
.
8. Inspect the connecting rod bearings for dirt or
debris imbedded into the bearing tTiateriaL

52053

9. Inspect the connecting rod .:bearings for improper

seating indicated by bright, polished sections of
ttie bearing.

52056

6-470

Engine Mechanical - 5.7L

Engine
Piston, Connecting Rod and Bearings
Clean/Inspect (Measuring Piston Ring
End Gap)
Important: Do not attempt to file the end of the piston
ring for fit in the cylinder bore.
Important: Measure the piston ring in the cylinder in
which the piston ring will be used.
1. Place the piston ring into the cylinder bore.
2. Push the piston ring into the bore 6.5 mm (0.25 in)
below the piston ring travel area.
3. Insert a feeler gauge and measure the piston ring
end gap.
The proper top compression ring end gap is
0.23-0.38 mm (0.009-0.0149 in).
The proper second compression ring end gap
is 0.44-0.64 mm (0.0173-0.0251 in).
The proper oil control ring end gap is
0.18-0.69 mm (0.007-0.0271 in).
4968

Piston Selection
Important: Measurements of au components should
be taken with the components at normal room
temperature.

For proper piston fit, the engine block cylinder bores

must not have excessive wear or taper.
A used piston and pin set may be reinstalled if, after
cleaning and inspection, they are within specifications.
1. Inspect the engine block cylinder bore for
scoring or other damage.
2. Inspect the piston and the piston pin.
Refer to Piston, Connecting Rod and Bearings
Clean/Inspect (Piston and Pin).
3. With a micrometer or caliper at a right angle to
the piston, measure the piston 11 mm (0.433 in)
from the bottom of the skirt.
4. Record the piston diameter.
188016

5. Adjust the micrometer to the recorded piston

diameter.
6. Insert the bore gauge into the micrometer and
zero the bore gauge dial.

J 8087

4974

Engine

Engine Mechanical - 5.7L

6-471

7. Use a bore gauge and measure the cylinder bore

diameter. Measure at a point 64 mm (25 in) from
the top of the cylinder bore.
8. Record the cylinder bore diameter.
9. Subtract the piston diameter from the cylinder
bore diameter in order to determine piston-to-bore
clearance.
The proper piston-to-bore clearance should be
between 0.018-0.054 mm (0.0007-0.00212 in).
10. If the proper clearance cannot be obtained, select
another piston and measure for the clearances.
If the proper fit cannot be obtained, the cylinder
bore may require honing for an oversize piston or
block replacement.
11. When the piston-to-cylinder bore clearance is
within specifications, permanently mark the top
of the piston for installation to the proper cylinder.
Refer to Separating Parts.
4972

Piston and Connecting Rod Assemble

Tools Required
J 24086-C Piston Pin Remover/Installer Set
J 24086-10 Piston Pin Remover/Installer Base
J 24086-9 Adjustable Installer

))

Important: Assemble the piston for the specific

cylinder with the connecting rod for the corresponding
crankshaft journal.

The piston and connecting rod MUST be assembled

properly.
1. Install fork insert J 24086-920 into fixture
J24086-10 Piston Pin Remover/Installer Base.

J 24086-10

533475

Caution: Avoid contact with HOT components.

Wear safety glasses and protective gloves to
avoid personal fnjury.
Notice: Applying excessive heat to the connecting rod
may damage or distort the rod. Rod temperature
SHOULD NOT exceed 315C (600F). At this
temperature the end of the connecting rod will turn a
straw color upon visual inspection.
2. Use a torch and apply MILD heat to the pin end
of the connecting rod.
Mild heating of the connecting rod will ease in
piston and pin assembly.
3. With the piston and connecting rod properly
assembled, both the flat flange area of the
connecting rod and the alignment mark on the top
of the piston will be facing the front of the
engine.
63227

6-472

Engine Mechanical - 5.7L

Engine
4. Assemble the piston, connecting rod and adapter
J 24086-16A and install onto fixture J 24086-10.

J 24086-16A

533488

5. Adjust installation pin J 24086-9,to 1-8.

J 24086-9

533486

Notice:After tn'e installer hdb bottoms on the sui;>port,

assembly, do not exceed 35 000 kPa (5,000 psi)
pressure, this could cause damage to the todl.
6. lr\sertpin J 24086-9 through fixture J 24086-10
and to the piston pin.
7. Press pin J 24086-9 until the installer bottoms on
fixture j 24086-10.
,
. .

533483

Engine

Engine Mechanical - 5.7L

6-473

8. Measure the piston (J ), pin (3), and cormecting, ::"'

rod (2) for proper assembly, .
,
8.1 . Place the piston and connecting rod
assembly onto a table or other flat
surface.
Lay the flat top .of the piston ( 1) onto the.
table surface.

8.2. Slide the connecting rod (2) and pin (3) to

one s;de .and hold firmly agajnst the .inside
of the pi,ston q).

8.3. Measure the pin (3) for proper installation.

A properly installedpistonpin should
protrude 1.27 mm (0.05 in) from the side of
the. piston. .

63156

Important: When installing the piston rings onto the

piston, use a ring expanding plier type tool. Do not roll
the piston rings into the grooves of the piston.
Use caution and care to expand the piston rings only
slightly larger than the Outside Diameter (OD) of
the piston.
9. Using piston ring pliers, install the piston rings
onto the piston.
9.1. Install the oil control ring spacer in the
groove.
9.2 .. Install the lower. oil ce>11trol.ring ..
The oil control rings do l)Ot have c;1..diqiple
or orientation mark and. m,c;1.y be installed ,
in either direction.
'

9.3. Install the upper oil control rrng.
9.4. Stagger the three oil control ring encl g~ps
a minimum of 90 degrees.
9.5. Using.piston ring pliers, install the lower
compres.sion .ring ..
The lower compression ring, has a dimple. Qf
orient.ation mark. and must face the top of.
the piston.
9.6. Using piston ring pliers, install the upper
compression ring.
The upper compression ring does not have
a dimple or orientation mark and may be
installed in either direction.
9.7. Stagger the compression ring end gaps a
minimum of 25 mm (1.0 in).

490763

6-474

Engine

Engine Mechanical- s~7L

Camshaft Bearing Removal
(Removal Procedure)
Tools Required
J 33049 Camshaft Bearing Remover/Installer

Important: A loose camshaft bearing may be caused

by an enlarged, out of round or damaged engine
block bearing bore.
,
1. Prior to bearirig removal, inspect the. camshaft
bearings for loose fit in the engine block
bearing bores;
Refer to Camshaft and Bearings Clean and
Inspect.
2. Repair or replace the components as required.

63163

15~

t14 ~1
lJ---13
a-12

3. Select the expanding driver (4-8) and

washer (2 or 3) from the tool information.
4. Assemble the tool.

00-11 4@r'3
OD~

@:O)
~

10

(ID.

9, .... 8

@ID
66100

5. Insert the tool through the front of the engine

block and into the bearing.
6. Tighten the expander assembly (15} nu~ until snug.
7. Push the guid~ cone (1) into the front camshaft
bearing to align the tooL .
8. Drive the bearing from the block bore.

Important: To remove the front camshaft bearing,

operate the tool from the rear of the block using the
guide cone (1) in the rear camshaft bearing bore.
9. Repeat the above procedures to remove
the remaining bearings.

J 33049
63219

Engine Mechanical - 5.7L

Engine
Tool Usage Information
Bearing, Expander, and Expander Driver
Information
The tool consists of a guide cone (1 ), driving
washers (2 or 3), expander bearing drivers (4-8),
driver bars (9 or 10), expander jaws (11 ),
expander sleeve (12), expander cone (13),
expander shaft (14), and expander assembly (15).
Expander bearing driver number one inside
diameter is 28.575-37.465 nim (1.125-1.475 in)
and is used with the expander assembly and
the small washer.
Expander bearing driver number two inside
diameter is 37.465-43.18 mm (1.475-1.7 in) and
is used with number one expanding driver and
the small washer.
Expander bearing driver number three inside
diameter is 43.18-48.895 mm (1.7-1.925 in) and
is used with number two expanding driver and
the large washer.
Expander bearing driver number four inside
diameter is 48.895-54.61 mm (1.925-2.15 in) and
is used with number three expanding driver
and the large washer.
Expander bearing driver number five
inside diameter is 54.61-60.325 mm
{2.150-2.375 in) and is used with number four
expanding driver and the large washer.
Expander bearing driver number six inside
diameter is 60.325-68.326 mm (2.375-2.69 in)
and is used with number five expanding driver and
the large washer.

15~

6-475

r14 Qy1
tJ---13

ey12
~
00--11 4 0))--'3

DD

@sO)

10

g@J
(IDT
66100

Tool Assembly and Operation

1. Select the proper expanding driver and washer
from the expanding driver and washer information.
Important: To install or remove the expanding driver,
always push on or pull from the ends.
Pressure on the outside diameter may cause a bind
against the rubber expanding sleeve.
2. Place the expanding driver onto the expander
assembly.
3. Check to insure that the separation lines between
the segments of the expanding driver align with
the separation lines of the expander assembly.
4. Place the guide cone over the driving ba.r (with
the small end of the cone facing the driver
assembly).
5. Place the driving washer over the threaded
portion of the expander assembly.
,
6. Screw the expander assembly (with driving
washer) onto the driving bar.
It may be necessary to install the driver bar
extension for removal of the inner bearings.

64183

6-476

Engine Mechanical - 5.7L

Engine
7. Insert the tool into a inner camshaft bearing and
tighten until sn,ug.
Operate the tool from the front or rear of the
engine block.
. .
On some engine blocks the nut on the expander
assembly is inaccessible except from either end. In
this case you must use a socket an.d extension, to
enlarge and reduce the expander assembly.
8. Slide the nylon cone into.the front or rear camshaft
bearing (this willproperly align the tool).
9. Drive the bearing out of or into the engine block.
10. Repeat the procedure for the additional inner
bearings.
11. For the two end bearings (front and rear), remove
the nylon cone and driver bar extension.
12. Drive the bearings out of or into the engine block.

J 33049
63219

15~

t-14 ~1
tJ---13

e,-12

Camshaft Bearing Removal (Tool

Instructions)
Tool Usage Information

Bearing, Expander, and Expander Driver

Information

00-11' 4@r"3
DO~

@:to
~

10

\.

(llID
.8

@ID
66100

The tool consists of a guide cone (1 ), driving

washers (2 or 3), expander bearing drivers (4-8),
driver bars (9 or 10), expander jaws (11 ),
expander sleeve (12), .expander cone (13), :
expander shaft (14), and expander assembly (15).
Expander bearing driver number one inside
diameter is 28.575-37.465 mm (1. 125-1.475 in)
and is used with the expander assembly and
the small washer.
Expander bearing driver number two inside
diameter is 37.465-43.18 mm (1.475-1.7 in) and
is used with number one expanding driver and
the small washer.
Expander bearing driver number three inside
diameter is 43.18-48.895 mm (1.7-1.925 in) and
is used with number two expanding driver and
the large washer.

Engine

Engine Mechanical - 5.7L

6-477

Expander bearing driver number four inside

diameter is 48.895-54.61 mm (1.925-2.15 in) and
is used with number three expanding driver
and the large washer.
Expander bearing driver number five
inside diameter is 54.61-60.325 mm
(2.150-2.375 in) and is used with number four
expanding driver and the large washer.
Expander bearing driver number six inside
diameter is 60.325-68.326 mm (2.375-2.69 in)
and is used with number five expanding driver and
the large washer.
Tool Assembly and Operation
1. Select the proper expanding driver and washer
from the expanding driver and washer information.
Important: To install or remove the expanding driver,
always push on or pull from the ends.

Pressure on the outside diameter may cause a bind

against the rubber expanding sleeve.
2. Place the expanding driv~r.onto the .expander

assembly.
3. Check to insure that the separation lines between
the segments of the expan(.ling driver align with
the separation lines of the expander assembly.
4. Place the guide cone over the driving bar (with
the small end of the cone facing the driver

assembly).
5. Place the driving washer over the threaded
portion of the expander assembly.
6. Screw the expander assembly (with driving
washer) onto the driving bar.
It may be necessary to install the driver bar
extension for removal of the inner bearings.
7. Insert the tool into a ihner camshaft bearing and
tighten until snug.
Operate the tool from the front or rear of the
engine block.
On some engine blocks the nut on the expander
assembly is inaccessible except from either
end. In this case you must.use a socket.and
extension to enlarge and reduce the expander
assembly.
8. Slide the nylon cone into the front or rear camshaft
bearing (this will properly align the tool).
9. Drive the bearing out of or into the engine block.
10. Repeat the procedure for the additional inner
bearings.

64183

6-478

Engine Mechanical - 5~ 7L

Engine
11. Forthe two end bearings (front and rear), remove
the nylon cone and driver bar extension.
12. Drive the bearings out of or into the engine block.

J 33049
63219

Camshaft and Bearings Clean and Inspect

Tools Required
J 7872 Magnetic Base Dial Indicator Set
J 8520 Camshaft Lobe Lift Indicator

1. Clean the components in solvent.

3
188095

Caution: Wear safety glasses in order to avoid eye

damage.
2. Dry the components with compressed air.
3. Inspect the camshaft bearing journals (1) for
scoring or excessive wear.
4. Inspect the camshaft yalve lifter lobes (2) for
scoring or excessive wear.
5. Inspect the threaded bolt holes (3) in the front of
the camshaft for damaged threads or <;iebris.
6. Inspect the car:nshaft sprocket pin (4) for damage.
7. Inspect the camshaft position reluctor ring for
nicks or damage.
8. Inspect the camshaft retainer plate for wear or a
damaged sealing gasket.
If the camshaft retainer plate sealing gasket is not
cut or damaged, it may be reused.

63211

Engine

Engine Mechanical ... 5.7L

6-479

9. Inspect the camshaft bearings for proper fit in the

1o.

engine block. The camshaft bearings have an

interference fit to the engine block and should not
be loose in their engine block bearing bores.
Inspect the camshaft bearings for excessive wear
or scoring.
Bearings with excessive scoring or wear must be
replaced.

63163

11 . Measure the camshaft journals for wear and

out-of-r9und with a micrometer.
A camshaft with bearing journals that measure
more than 0.025 mm (0.0010 in) out-of-round,
must be replaced.
A camshaft with bearing journal diameters that
measure less that 54.99 mm (2.164 in), must
be replaced.

35212

12. Measure the camshaft lobes for wear with a

micrometer.
A camshaft with an intake lobe that measures
46.20 mm (1.8190 in) or less, must be
replaced.
A camshaft with an exhaust lobe that measures
46.37 mm (1.8255 in) or le~s. must be
replaced.

260130

6-480

Engine Mechanical - 5~71J

Engine
13. Measure the cam~haft runbut.
13.1. Mountthe camshaft in wooden V~blocks or
between centers ot'la fixture.
13.2. Check the runout of the intermediate
camshaft t>earing journals using'
the J 7872.
,

13.3. If camshaft runout exceeds 0.05 mm

(0.002 in), the camshaft is bent and
should be replaced.

J7872

64297

Measuring Cams,haft Lobe Lift

Important: Measuring camshaft lobe lift is a procedure
used to determine if the camshafHobes have worn.
This test is to be performed prior to engine
disassembly and with the camshaft and valve train
cc;,mponents . installed in the engin0o,.

1. rv1Jasure camshaft lbbe{ iiri using J 8520.

1.1. Remove the valve rocker arms and bolts
1.2. Install the dial indicator mounting stud

64967

into the valve rocker arm bolt hole.

1.3. Assemble the components of the J 8520
and position onto the stud.
1.4. Position the shaft of the dial indicator onto
the end of the pushrod.
1.5. Rotate the face of the dial indicator to zero.
1.6. Slowly rotate the crankshaft clockwise
until the dial indicator obtains its highest
and lowest readings.
1.7. Compare the total lift shown to
specifications.
The proper lobe lift for the
Carnaro/Firebirdintake lobes is
'"''7.43nim (0.292 in).
The proper lobe lift for the
Camaro/Fii'ebird exhaust lobes is
7.43 mm (0.292 iH}.'
The proper lobe lift for the Corvette
intake lobes is 7.04 mm (0.277 in).
The proper lobe lift for the Corvette
exhaust lobes is 7.13 mm (0.281 in).
1.8. Remove the tool.
2. Compare measurements to specifications.
If the readings are not within specifications,
remove the camshaft. Inspect and/or replace
components as required.

Engine Mechanical - 5.7L

Engine

6-481

Camshaft Bearing Installation

\
I

Tools Required
J 33049 Camshaft Bearing Remover/Installer

Aloose camshaft beciring may be caused

by an enlarged, out of round or damaged engine
block bearing bore.
1. Prior to bearing removal, inspect the camshaft
bearings for loose fit in the engine block
bearing bores.
2. Repair or replace the components as required.

Important:

63163

3. Select the expanding driver (4-8).and

washer (2 or 3) from the tool usage information.
4. Assemble the tool.

15~

10

66100

5. Insert the tool through the front of the engine

block and to the p,earing bore.
6. Install the new bearing onto the tool.
7. Tighten the expander assembly nut until snug.
8. Push the guide cone into the front camshaft
bearing to align the tool.
9. Properly align the oil hole in the bearing with the
oil gallery in the engine block.
10. Drive the bearing into the block bore.

)
/

Important: To install the front camshaft bearing,

operate the tool from the rear of the block using the
guide cone in the rear camshaft bearing bore.
11. Repeat the above procedures to install the
remaining bearings.
12. Check the installed bearing for proper alignment
of the oil gallery holes.

J 33049
63219

6-482

Engine Mechanical - 5.7L

Engine
Timing Chain and Sprockets Clean .
and Inspect
1. Clean the components with cleaning solvent.
Caution: Wear safety glasses in order to avoid eye
damage.
2. Dry the components with compressed air.
3. Inspect the timing chain for binding or wear.

156158

4. Inspect the camshaft and crankshaft sprockets for:

Worn teeth (1)
Damaged teeth (2)
Chipped teeth (3)
Worn 'valleys between the sprocket teeth

(
3

188097

5. Inspect the crankshaft sprocket keyway for wear.

6. Inspect the crankshaft sprocket oil pump drive
splines for wear.

156150

Engine

Engine Mechanical - 5.7L

6-483

Valve Rocker Arm and Push Rods Clean

and Inspect

Important: Parts that are to be reused must be

marked, sorted or organized for assembly.
1. Mark, sort, or organize the components for
assembly.
Refer to Separating Parts.
2. Clean the components with cleaning solvent.

Caution: Wear safety glasses in order to avoid eye

damage.
3. Dry the components with compressed air.
4. Inspect the valve rocker arms bearings for binding
or roughness.
5. Inspect the valve rocker arm pushrod sockets and
valve stem mating surfaces. T.hese surfaces
should be smooth with no scoring or
exceptional wear.
64171

6. Inspect the pushrods for worn or scored ends.

These surfaces should be smooth with no scoring
or exceptional wear.
7. Inspect the pushrods for bends. Roll the pushrod
on a flat surface to determine if the pushrod
is bent.
8. Inspect the pushrod oil passages for restrictions.

64266

9. Inspect the pivot supports for cracks, wear, or

other damage.

64178

6-484

Engine

Engine Mechanical~ 5.7L

Valve Lifters and Guides Clean
and Inspect

Important: Components that are to be reused must

be marked, sorted or organized for assembly.
1. Mark, sort, or organize the components for
assembly.
Refer to Separating Parts.
2. Clean the components in cleaning solvent.

118485

63233

Caution: Wear safety glasses in order to avoid eye

damage.
3. Dry the components with compressed air.
4. Inspect the vah1:e. lifters for the following:
Bent or broken clip (1)
Worn pushrod socket (2)
Scuffed .or vvorn sides (3)
If the valve lifter shows wear, in~pect the
engine block lifter bores for wear or damage.
Flat .spots on the roller (4)
Loose or damaged pin {5)
Plugged oil hole (6)
Worn or damaged roller bearing
The roller should rotate freely with no binding
or roughness.
5. Inspect the valve lifter'guides for the follow'ing:
For cracks or damage
Excessive wear in the lifter mounting bores

Engine Mechani,cah.. 5.7L

Er:agine

6-485

Cylinder Head Disassemble .

\

Tools Required
J 8062 Valve Spring Compressor
Important: Remove the spark plugs from the cyHnder
head with the components at room temperature.

Mark, organize, or sort the cylinder head components

for assembly. Return the components to their

original location during assembly.

Do not remove the cylinder head valve guides (7),
coolant core plugs (8), or valve seats (9), unless
service is required.
1. Remove the spark plugs from the cylinder heads.

12
64108

2. Use the J 8062 in order to compress the valve

spring (4).

64299

6-486

Engine Mechanical - 5.7L

Engine
3.
4.
5.
6.
7.
8.

Remove the valve stem keys (2).

Remove the valve spring cap (3).
Remove the valve spring (4).
Remove the valves (10 and 12).
Remove the valve stem oil seal (5).
Remove the valve spring shim (6).
Refer to Separating Parts.

64108

9. Remove the coolant sensor from the left cylinder

head (if required).

50974

Engine

Engine Mechanical - 5.7L

6-487

Cylinder Head Clean and Inspect

Cleaning Procedure
)

J8089

Tools Required
J 8089 Carbon Removing Brush
Important: When cleaning an cylinder head in a
thermal type oven, do not exceed 400 F (204 C).
1. Clean the following components:
Caution: Wear safety glasses in order to avoid eye
damage.

Important: Be careful not to scuff the chamber.

Use the J 8089 in order to remove the

carbon from the combustion chambers.

Gasket surfaces
Refer to Replacing Engine Gaskets.
Valve stems and heads on a buffing wheel
Bolt hole threads. Remove all dirt, debris, or
threadlocking material from the bolt holes.
2. Inspect the following:
2.1. The cylinder head (1) for cracks in the
exhaust ports and combustion chambers
2.2. The cylinder head for external cracks in the
water chambers
2.3. The gasket surfaces for excessive scratches
or gouging.
Refer to Replacing Engine Gaskets.
2.4. The bolt hole threads for debris or damaged
threads.
Refer to Thread Repair Specifications.

4957

64108

\,I

6-488

Engine

Engine Mechanical - 5.7L

3. Inspect the valve springs for squareness.

40075

4. Use the J 9666 in order to measure the valve

spring tension.
Replace the spring if the spring tension is less
than 310 N (70 lb) at 45.75 mm (1.80 in).

4960

Valve Guide ReamingNalve and

Seat Grinding
Valve Guide Reaming
Tools Required
J 37378-1 Valve Guide Reamer
Important: Excessive valve stem-to-guide clearance
may cause a noisy valve train, premature valve
stem oil seal wear, component damage, and/or
excessive engine oil consumption.

Insufficient valve stem-to-guide clearance will result in

noisy or sticking valves. Valves that are too tight
may disturb engine smoothness or lead to component
damage.

O'-'
65822

Engine

\!

Engjne Mechanical .. 5.7L

6-489

1. Measure the valve stem-to-guide clearance using

a dial indicator.
Valve stem-to-guide clearance may also be
obtained by using a micrometer to measure the
valve stem diameter and a ball type measuring
gauge to measure the guide bore.
2. A valve stem (1) and guide (2) with clearance in
excess of 0.093 mm (0.0037 in) must be repaired
or the components replaced.

156172

3. Inspect the valve stems for excessive scoring,

wear, or warpage.
A valve stem that has excessive
scoring (3 or 4) or wear (4 or 6) must be
replaced.
A valve guide that is worn and has excessive
stem-to-guide clearance should be reamed
and valves with oversize stems installed.
4. Measure the valve stem diameter. A valve stem
with a diameter less than 7.95 mm (0.313 in)
must be replaced. Position the tip of the
dial indicator at the top of the valve guide.
If the valve stem diameter is within specifications,
and the stem-to-guide clearance is excessive,
the valve guide must be. .reamed ov~rsize and a
valve with oversize stem installed.

156174

6-490

Engine Mechanical - 5.7L

Engine
5. Ream the valve guide using the J 37378-1.
6. Clean the guide bore of all metal shavings and
debris.

572270

7. Install the valve (2) (with oversize stem) into the

cylinder head (1 ).
8. Inspect the valve for the proper fit.
Move the valve back and forth in the guide. The
valve should move freely with no resistance
or drag.

572278

Valve and Seat Grinding

Important:
Reconditioning the valve seats is very important.
The seating of the valves must be perfect for
the engine to deliver optimum power and
performance. Several different types of equipment
are available for grinding valve seats.
Another important factor is the cooling of the valve
head. Good contact between the valve and the
seat will ensure that heat will be properly
dissipated.
The recommendations of the manufacturer of the
equipment should be followed carefully to obtain
the proper results. Regardless of what type of
equipment is used, it is essential that valve guide
bores be free from carbon or dirt to ensure
proper centering of the tool pilot in the guide.

5
6
156174

Engine

Engine Mechanical - 5.7L

6-491

Valves that are pitted must be refaced to the

proper angle. Valve stems that show excessive
wear, or valves that are warped excessively must
be replaced. When a valve head that is warped
excessively is refaced, a knife edge may be
ground on part or all of the valve head due to the
amount of metal that must be removed. Knife
edges lead to breakage, burning or pre-ignition
due to heat localizing on this knife edge. If
the edge of the valve head is less than 1.25 mm
(0.05 in) after grinding, replace the valve.
Several different types of equipment are available
for refacing valves. The recommendation of the
manufacturer of the equipment should be carefully
followed to obtain the proper results.
DO NOT reface intake valves. Intake valves with
excessive wear or damage MUST be replaced.
1. Inspect the valve for the following:
Burnt or eroded areas (1)
A worn margin (2)
A bent stem (3)
A worn or scored stem (4)
A worn key groove (5)
A worn stem tip (6)
Inspect
the valve face for the following:
2.
Worn or no margin (1 or 4)
Pitted surfaces (2)
Burnt or eroded areas (3)

1
3

156173

6-492

Engine Mechani'cal - 5~7L

Engine
3. Inspect the valve margin.
The exhaust Valve may be refaced if the margin is
greater than .1.25 mm (0.05 in) thick before
grihcling.

(,

p1tt~d

4. Reface
exhau.$t valves on a suitable valve
refacing machine.
.
5. Raplace the valve if the margin is less
than 1,25 mm (0.05 in) thick after grinding.
6 ..If the valve face has been ground, it may be
necessary to shirn the valve spring to obtain
.the .proper spring in$talleq neight. Refer to
Cylinder Head.Assemble.

c::::=::===~j_

4955

7. Inspect for a loose valve seat (9 or 11) in the

cylinder head (1). Thevalve seat has an
interference fit to the cylinder head.
8. Clean the valve guide (7) bores with a suitable
tool. Remove all carbon or dirt from the bores.
The valve guide must be clean for the seat
grinding tool to obtain proper res~lts.
9. Grind the valve seat.
the manufacturer of the
The recommendations
equipment should be followed carefully to
obtain the proper results. Regardless of what type
of equipment is used, it is essential that valve
guide bores be free from carbon or dirt to ensure
proper centering of the tool pilot in the guide.
10. Inspect the valve seats.
The valve seats should be concentric to
within 0.05 mm (0.0021 in) total indicator
reading.
If the valve seat has been ground, it may be
necessary to shim the valve spring to attain
the proper spring installed height.
Refer to Cylinder Head Assemble.

of

64108

Engine

Engine Mechanical - 5.7l

6-493

Cylinder Head Assemble

Tools Required
J 8062 Valve Spring Compressor
J 42078 Valve Stem Oil Seal Installer
1. Clean the cylinder head valve spring shim area.
Important: When reusing the valves and related
components, install the parts to their original location.
2. Install the valves (10 and 12) into the proper port.
Refer to Separating Parts.
3. Install the valve spring shim (6).

64108

Important: The valve stem oil seal alignment and

position on the valve guide is critical.

An improperly installed valve stem oil seal may lead to

excessive oil consumption, increased vehicle
emissions, or component damage.
4. Install the valve stem oil seal (5) onto the
guide (7).
4. 1. Lubricate the valve guide (7) and valve
stem (5) oil seal with clean engine oil.
4.2. Install the valve stem oil seal onto the valve
stem. Push the seal down until the seal
contacts the valve guide.
4.3. Use the J 42078 in order to install the valve
stem oil seal.
Push or lightly tap the tool until the tool
bottoms against the valve spring shim (6).
63193

6-494

Engine Mechanical - 5.7L

Engine
5. Measure the valve stem oil seal for the properly
installed height.

18.1-19.1 mm
(0. 712 - o. 752")

Specification
There should be a 18.1-19.1 mm (0.712-0.752 in)
gap between the top edge of the oil seal body
and the valve spring shim surface.

63158

6. Install the valve spring (4).

7. Install the valve spring cap (3).

64108

Engine

Engine Mechanical - 5.7L

6-495

8. Compress the valve spring (4) using the J 8062.

9. Install .the valve stem keys (2).
9.1. Use grease to hold the keys (2) in place
and remove the J 8062.
9.2. Make sure the keys (2) seat properly in the
groove of the valve stem (10 and 12).
9.3. Tap the end to the valve stem (10 and 12)
with a plastic faced hammer to seat the
keys (if necessary).

64299

10. Measure the valve spring installed height using

a ruler.
Measure from the machined surface of the
cylinder head to the top of the valve spring cap.
Specification
If the installed height exceeds 46.25 mm
(1.82 in), install a valve seat spring shim
of approximately 0.5 mm (0.020 in) thick.
Do not shim the valve spring to obtain less
than the specified height.
Do not assemble the components without a
spring shim on the cylinder head.
11. Install the remaining valves (10 and 12),
springs (4) and other components.

64315

12. Install sealant GM P/N 12346004 or equivalent to

the threads of the coolant sensor.

Notice: Refer to Fastener Notice in Cautions and

Notices.
13. Install the coolant sensor into the left cylinder
head (if required).
Tighten
Tighten the coolant senor to 20 N-m (15 lb ft).
14. Install sealant GM P/N 12345382 or equivalent to
the cylinder head core plug holes.
15. Install NEW cylinder head core plugs (if required).

50974

6i-'496

Engine Mechanical .. 5.7L

Engine
Oil Pump Disassemble
Important: The internal parts of the oil pump assembly
are not serviced separately (excluding the spring). If
the oil pump components are worn or damaged,
replace the oil pump as an assembly.
1. Remove'the oil pump cover bolts.

65055

2. Remove the oil pump cover.

65057

lmpQrtant: Mark or identify the gears for assemt:;>ty.

Refer to Separating Parts. ,

3. Remove thedrive gear.

65058

Engine

Engine Mechanical - 5.7L

6-497

4. Remove the driven gear.

65060

5. Remove the pressure relief valve plug.

.
I

~
65064

6. R~move the pressure relief valve spring.

65068

6~498

Engine

Engine Mechanical - 5. 7L
7. Remove the pressure relief valve.
8. Inspect the oil pump components.
Refer to Oil Pump Clean and Inspect.

65076

Oil Pump Clean and Inspect

Important: The internal parts of the oil pump assembly
are not serviced separately (excluding the spring). If
the oil pump components are worn or damaged,
replace the oil pump as an assembly.

The oil pump pipe and screen are to be serviced as

an assembly. Do not attempt to repair the wire
mesh portion of the pump and screen assembly.
1. Clean the parts in solvent.

65060

Caution: Wear safety glasses in order to avoid eye

damage.
2. Dry the parts with compressed air.
3. Inspect the oil pump housing and the cover for
cracks, excessive wear, scoring, or casting
imperfections.
4. Inspect the oil pump housing-to-engine block oil
gallery surface for scratches or gouging.
5. Inspect the oil pump housing for damaged bolt
hole threads.
6. Inspect the relief valve plug and plug bore for
damaged threads.
7. Inspect the oil pump internal oil passages for
restrictions .

~
65064

Engine

Engine Mechanical - 5.7L

6-499

8. Inspect the drive gear and driven gear for

chipping, galling or wear.
Minor burrs or imperfections on the gears may be
removed with a fine oil stone.

65060

9. Inspect the drive gear splines for excessive wear.

65058

10. Inspect the pressure relief valve and bore for

scoring or wear.
The valve must move freely in the bore with no
restrictions.

)
/

65076

6-500

Engine Mechanical - 5:7L

Engine
11. Inspect the .oil pump screen for debris or
restrictions.
12. Inspect the oil pump screen for broken or loose
wire mesh.

64268

Oil Pump Assemble

Important: Prior to assembling the oil pump, coat all
wear or internal surfaces with clean engine oil.
1. Install the driven gear into the pump housing.
Install the driven gear with the orientation mark
facing the pump cover.

-65060

2. Install the drive gear into the pump housing.

65058

Engine

Engine Mechanical - 5.7L

6-501

3. Install the oil pump cover.

'

;'

65057

Notice: Refer to Fastener Notice in Cautions and

Notices.

4. Install the pump cover bolts.

Tighten
Tighten the oil pump cover bolts to
12 N-m (106 lb in).

65055

5. Install the regulator valve.

65076

6-502

Engine Mechanical - 5.7L

Engine
6. Install a NEW regulator valve spring.

65068

7. Install the pressure relief valve plug.

Tighten
Tighten the pressure relief valve plug to
12 N-m (106 lb in).
8. Inspect the oil pump for smoothness of operation
by rotating the drive gear.

~
65064

Engine Front Cover Clean and Inspect

Important: Do not reuse the crankshaft oil seal. Install
a NEW crankshaft oil seal during assembly.

Do not reuse the front cover-to-engine block gasket.

Install a NEW gasket during assembly.
1. Remove the crankshaft oil seal (1) from the
front cover.
2. Clean the cover in solvent. Remove the sealant
from the cover oil pan surface.
Refer to Replacing Engine Gaskets.

Caution: Wear safety glasses in order to avoid eye

damage.
3. Dry the cover with compressed air.

490689

Engine

Engine:Mechanical - 5.7L

6-503

4. Inspect the gasket sealing surla.ces for excessive

scratches or gouging.
5. Inspect the cover-to-oil pan threaded bolt holes
for damaged threads or debris.

6. Inspect the crankshaft oil seal mounting bore for

damage.

Engine Rear Cover Clean and lnspect

Important: Do. not reuse the crankshaft oil seal. Install
a NEW crankshaft oil seal during as~embly.

Do n9t reuse the rear cover-to-engine block gasket.

lnst~U a NEW gasket during assembly.
1. Remove the crankshaft oil seal (1) from the
r~ar cover.
2. Clean the cover in solvent. Remove the sealant
from the,. cover oil pan surface.
Refer to Replacing Engine Gaskets.
Caution: Wear safety glasses in order to avoid eye
damage.
3. Dry the cover with compr'~ssed air.
4. Inspect the gasket sealing surfaces for excessive
scratches or gouging.
5. Inspect the cover-to-oil pan threaded bolt holes
for damaged threads or debris.
6. Inspect the crankshaft oil seal mounting bore for
damage.

490692

Engine Valley Cover Clean and Inspect

Important: Do not reuse the valley cover knock
sensor oil seals. Install NEW oil seals during assembly.

Do not reuse the valley cover gasket. Install a NEW

gasket during assembly.
1. Remove the knock sensor oil seals (1) from the
valley cover (2).
2. Clean the valley cover in solvent.

1~

Caution: Wear safety glasses in order to avoid eye

damage.
3. Dry the valley cover .with compressed air.
4. Inspect the gasket sealing surfaces for excessive
scratches or gouging.
Refer to Replacing Engine Gaskets.
5. Inspect the valley cover oil seal bores for
excessive scratches or gouging.
490851

6-504

Engine Mechanical - 5.7L

Engine
Valve Rocker Arm Cover Clean and
Inspect

65292

Important:
Do not reuse the valve rocker arm ce>yer ga$ket.
Install a NEW gasket during assembly.
Remove the ignition coils before cleaning the
cover in solvent. Do not submerge the ignition ,,
coils in solvent.
' Note the, location of the beauty cover mounting .
studs tor assembly.
'
Do not remove the oil fill tube or crankcase vent
valve grommett from the covers unless service
is required.
If the oil fill tube or crankcase vent valve groinmet
have been removed from the rocker arm covers,
install a NEW tube or grommett during assembly.
1. Remove the ignition coils, bolts and wire harness
from the left cover (if required).

2. Remove the ignition coils, bolts and wire harness

from the right cover (if required).

65290

3. Remove the oil fill cap and tube from the right
cover (if required).

64263

Engine

Engine Mechanical - 5.7L

6-505

4. Remove the crankcase vent valve grommet from

the left cover (if required).
5. Remove the gaskets from the covers.
6. Remove the cover mounting bolts (with
grommets).
Cover mounting bolts and grommets that are not
damaged may be reused during assembly.
7. Clean the covers in solvent.

63244

Caution: Wear safety glasses in order to avoid eye

'

damage.

8. Dry the covers with compressed air.

9. Inspect the ventilation system passages for
restrictions.
10. Inspect the gasket grooves for damage.
11. Inspect the coil mounting bosses threaded bolt
holes for damaged threads or debris.

65290

12. Inspect the oil. fill tube ano the crankcase vent
valve grommet for a loose fit or damage.

64263

6-506

Engine Mechanical - 5.7L

Engine
Oil Pan Clean and Inspect
Important:
Do not r~1,1se the oil pan cover gasket. Install a
NEW cover gasket during assembly.
Do not reuse the oil pan to engine block gasket.
lnst~II a NEW gasket during assembly.
When installing a NEW oil pan gasket, it is not
necessary to install the rivets that retain the
NEW gasket to the pan.
1. Remove the oil level sensor from the pan.

178467

2. Remove

the

oil pan cover; gasket, and bolts.

178471

3. Remove the oil pan drain plug and 0-ring seal.

.

'

'

178475

Engine

Engine Mechanical - 5.7L

6-507

4. Remove the oil pan baffle bolts and baffle.

178491

5. Drill out (3) the oil pan gasket retaining rivets (2)
(if required).
6. Remove the gasket (1) from the oil pan.
7. Clean the oil pan in solvent. Be sure to thoroughly
clean all of the oil passages and recesses of
the pan.
8. Clean the oil pan gasket surfaces. Refer to
Replacing Engine Gaskets.
Caution: Wear safety glasses in order to avoid eye
damage.
9. Dry the oil pan with compressed air.
10. Inspect the gasket sealing surfaces for excessive
scratches or gouging. Refer to Replacing Engine
Gaskets.

384699

11. Inspect the oil pan oil level sensor seal surface for
damage.
If the 0-ring seal of the sensor is not cut or
damaged, it may be reused.

)
178467

6-508

Engine Mechanical - 5.7L

Engine
12. Inspect the oil pan drain plug and threaded drain
hole for damaged threads.
The drain plug 0-ring seal may be reused if not
cut or damaged.

178475

13. Inspect the oil filter sealing surface for scratches

or gouging.
14. Inspect the oil passages for restrictions.

(
I

178469

15. Inspect the oil filter fitting (1) for a loose fit or
damaged threads.
16. Inspect the oil filter bypass valve (2) for proper
operation.
Lightly push the bypass valve into the bore. The
valve spring should reseat the valve to the
proper position.

490699

Engine

Engine Mechanical - 5.7L

6-509

Intake Manifold Clean and Inspect

Cleaning Procedure

Important: Do not reuse the intake

manifold-to-cylinder head sealing gaskets.
1. Remove the Manifold Absolute Pressure (MAP)
sensor from the rear of the intake (the MAP
sensor is to be reinstalled upon completion of the
cleaning and inspection procedures).
2. Inspect the sealing grommet on the MAP sensor.
The grommet should not be torn or damaged.

58838

3. Remove the throttle body and bolts.

222051

4. Remove the throttle body gasket (1 ).

5. Discard the gasket.

490580

6-510

Engine Mechanical - 5.7L

Engine
6. Remove the accelerator control cable bracket .(2)
and bolts (1) (if required).

490573

7. Remove the fuel rail with injectors.

Refer to Fuel Rail and Injectors Removal.

222050

8. Remove and discard the intake

manifold-to-cylinder head gaskets (1 ).

(
490579

Engine

Engine Mechanical - 5.7L

6-511

9. Clean the intake manifold in solvent.

Clean the intake manifold gasket grooves.
Clean the intake manifold vacuum passages at
the rear of the intake. >
Caution: Wear safety glasses in order to avoid eye
damage.
1Q. Ory the intake manifold with compressed ~ir.
11. Upon installation of the intake manifold, install
NEW manifold-to~cylinder head gaskets.

Inspection Procedure

1. Inspect the throttle body bolt inserts for looseness

. or damaged threads. . .
.

222051

2. Inspect the .fuel rail bolt 1nserts. for looseness or

damaged threads.
3. Inspect the intake manifold vacuum passages for
debris or restrictions.

)
222050

6-512

Engine Mechanical - 5.7L

Engine
Important: The rear Manifold Absolute Pressure
(MAP) sensor housing is reta)ned to th.e intake
manifold by push-in-place snap lock design.
.
.
'
The rear MAP sensor housing is sealed at th~ intake
manifold' by an 0-ring
seal.
:,

4. Inspect the rear MAP sensor housing.

58838

Inspect for damaged or broken vacuum fittings,

damaged MAP sensor mounting. bore, or
broken MAP sensor retaining tab.
Inspect the rear MAP sensor housing for
looseness or poor sealing to the intake
manifold. Repair or replace the components as
necessary.
5. Inspect the composite intake manifold assembly
for cracks or damage.
Inspect the areas between the intake runners.
6. Inspect all the gasket sealing surfaces and
grooves for cracking or damage.

7. Inspect the fuel injector boresfor excessive

scoring or damage.
8. Inspect the intake manifold cylinder head deck for
warpage.
8.1. Locate a straight edge across the intake
manifold cylinder head deck surface.
8.2. Insert a feeler gauge between the intake
manifold and the straight edge.
A intake manifold with warpage in excess of
0.5 mm (0.02 in), must be replaced.
9. Upon completion of inspection, install the MAP
sensor to the manifold.

222050

Exhaust .Manifold Clean and Inspect

Important:
Do not reuse the exhaust manifold-to-cylinder
head gaskets. Upon installation of the exhaust
manifold, install a NEW gasket. A improperly
installed gasket or leaking exhaust system may
effect On-Board Diagnostics (OBD) II system
performance.
Remove the oxygen sensor prior to cleaning the
manifold, do not submerge the oxygen sensor
in cleaning solvent.
1. Remove the oxygen sensor from the manifold.
2. Clean the exhaust manifold in solvent.

Caution: Wear safety glasses in order to avoid eye

damage.
3. Dry the exhaust manifold with compressed air.
178460

(
'

Engine

Engine Mechanical - 5.t'L

6-513

4. Inspect the, exhaust manifold Air Injection Reaction

(AIR) passages for restrictions.
5. lnspectthe AI.R flar'!g~ threaded bolt hol~s threads
for damage.

6 .. Inspect the AIR flange gasket surface for

excessive scratches. or gouging:
7. Inspect the exhaust manifold-to-cylinder head
gasket surface for excessive scratches or
gouging.
8. Inspect the right side manifold EGR flange sealing
surface for excessive scratches or gouging.
9. Inspect the right side manifold EGR flange bolt
hole threads for damage.
10. Inspect for a loose or damaged heat shield.
11 . insert new art here
Inspect the take down studs for damaged threads.

64015

12. Use a straight edge and a feeler gauge and

measure the exhaust manifold cylinder head deck
for warpage.
A exhaust manifold deck with warpage in excess
of 0.25 mm (0.010 in), may cause an exhaust
leak and may effect OBD II system performance ..
Exhaust manifolds not within specifications
must be replaced.

66607

6-.514

Engine Mechanical - 5.7L

Engine
Vapor Vent Pipe Clean and Inspect
Important: Do noJ reuse the vapor ventp.ipe gaskets.
Upon installation of U1e vapor vent pipe, install
NEW gaskets.
1. Remove the vapor vent pipe hose, clamps and
sealing gaskets from the tube.

64262

2. Clean the vapor vent pipe and hose in solvent.

'

Caution: Wear safety glasses in order to avoid eye

damage.
3. Dry the tube with compressed air.
4. Inspect the vapor vent pipe for damage or
restrictions.
5. Inspect the vapor vent pipe gasket and hose
sealing surfaces for damage.
6. Inspect the vapor vent pipe hose for restrictions,
cracking or wear.
The vapor vent pipe hose may be reused if not
damaged.

64139

Water Pump Clean and. Inspect

1. Remove the old gasket material from the water
pump sealing surfaces.
Refer to Replacing Engine Gaskets.
2. Clean all excess dirt and debris from the water
pump housing.
3. Inspect the water pump for the following:
Gasket sealing surfaces for excessive
scratches or gouging
Restrictions within the internal coolant
passages
Excessive side-to-side play in the pulley shaft
Leakage at the water outlet housing or rear
cover gasket
Leakage at the water pump vent hole
A stain around the vent hole is acceptable. If
leakage occurs (dripping) with the engine
running and the cooling system pressurized,
replace the water pump.
63204

Engine

Engine Mechanical - 5.7L

6-515

Service Prior to Assembly

Dirt or debris will cause premature wear of the

rebuilt engine. Clean all the components.
Refer to Cleanliness and Care.
Use the proper tools to measure components
when checking for excessive wear. Components
that are not within the manufacturers specifications
must be repaired or replaced.
When the components are reinstalled into an
engine, return the components to their original
location, position and direction.
Refer to Separating Parts.
During assembly, lubricate all the moving parts
with clean engine oil. This will provide initial
lubrication when the engine is first started.

Engine Block Plug Installation

Tools Required
J 41712 Oil Pressure Sensor Socket

Important:
Engine block plug (oil gallery and coolant) sealing
washers may be reused if not bent, scored or
otherwise damaged.

Apply the proper amount and type of seal.ant to

the sealing washer as recommended in thE1
service procedure.
1. Apply a 3.175 mm (0.125 in) bead of sealant
GM P/N 12346004 or equivalent to the engine
block coolant heater sealing washer (if applicable).
Refer to Sealers, Adhesives, and Lubricants.

Notice: Refer to Fastener Notice in Cautions and

Notices.
2. Install the engine block coolant heater to the
engine block (if applicable).

65332

Tighten
Tighten the block coolant heater to
40 N-m (30 lb ft).
3. Apply a 3.175 mm (0.125 in) bead of sealant
GM P/N 12346004 or equivalent to the engine
block left front coolant drain plug sealing washer
(if applicable).
4. Install the engine block left front coolant drain
plug (if applicable).
Tighten
Tighten the block left front coolant drain plug to
60 Nm (44 lb ft).

63165

6-516

Engine Mechanical - 5.7L

Engine
5. Apply a 3.175 mm (0.125 in) bead of sealant
GM P/N 12346004 or equivalent to the engine
block right rear coolant drain plug sealing washer.
6. Install the engine block right rear coolant
drain plug.

{
\

Tighten
Tighten the block right rear coolant drain plug to
60 N,m (44 lb ft).

63164

7. Apply a 3.175 mm (0.125 in) bead of sealant

GM P/N 12346004 or equivalent to the engine
block left front oil gallery plug sealing washer.

8. Install the engine block left front oil gallery plug.

Tighten
Tighten the block left front oil gallery plug to
60 N,m (44 lb ft).

,,

63167

9. Apply a 3.175 mm (0.125 in) bead of sealant

GM P/N 12346004 or equivalent to the. engine
block left rear oil gallery plug sealing washer.
10. Install the engine block left rear oil gallery plug.

Tighten
Tighten the block left rear oil gallery plug to
60 Nm (44 lb ft).

(
64923

Engine

Engine Mechanical - 5.7L

6-517

11. Inspect the engine block rear oil gallery plug and
0-ring seal. If the 0-ring seal on the plug is not
cut or damaged, the rear oil gallery plug may
be reused.
12. Lubricate the 0-ring seal with clean engine oil.
13. Install the block rear oil gallery plug into the
oil gallery bore 0.8-1.4 mm (0.0315-0.055 in)
below flush.

63228

Important: The engine block front oil gallery plug

should not be removed unless service is required.

14. Apply sealant GM P/N 12345382 or equivalent to

the sides of the NEW front oil gallery plug.

15. Install a NEW engine block front oil gallery plug

(if required). Install the front oil gallery plug into
the oil gallery bore 2.2-2.8 mm (0.0086-0.011 in)
below flush.

64295

6-518

Engine Mechanical - 5.7L

Engine
16. Apply sealant GM P/N 12346004 or equivalent to
the threads of the oil pressure sensor.
17. Use the J 41712 or equivalent in order to install
the oil pressure sensor.

J 41712

Tighten
Tighten the oil pressure sensor to
20 Nm (15 lb ft).

178483

Crankshaft and Bearings Installation

Tools Required
J 36660 Torque Angle Meter

64293

Important:
Crankshaft bearing clearances are critical.
Excessive crankshaft bearing clearance may effect
crankshaft position sensor signals and/or
On-Board Diagnostics (OBD) II system
performance.
Crankshaftbearing caps must be installed to the
proper location and direction.
When installing the crankshaft bearings, align the
locating tabs on the bearings with the locating
notches in the engine block journal bore and the
bearing cap.
Always install crankshaft bearings with their
machined partner. Do not file bearings or
mix bearing halves.
To prevent engine block oil leakage, install NEW
MS crankshaft bearing cap side bolts.
The crankshaft bearing cap MB side bolts have a
sealant patch applied to the bolt flange.
1. Install the crankshaft thrust bearings to the engine
block and center bearing cap.
2. Install the remaining crankshaft bearings to the
engine block and bearing caps.
3. Lubricate the bearing surfaces and crankshaft
journals with clean engine oil.

Engine

'

Engine Mechanical - 5.7L

6-519

Notice: To maintain proper crankshaft end play, .use

extreme care during crankshaft installation. Avoid
scoring or damaging the thrust bearing.
4. Install the crankshaft.

156151

Important: The bearing caps must be installed in the

proper location and direction.
5. Install the crankshaft bearing caps (with bearings)
into the engine block.
6. Start the M10 bolts and studs.
7. Tap the bearing caps into place with a
plastic-faced hammer.

156152

8. Install the NEW M8 bearing cap side bolts.

156155

6-520

Engine Mechanical - 5.7L

Engine
Notice: Refer to Fastener Notice in Cautions and
Notices.

9. Tighten the bearing cap bolts and studs.

Tighten
Tighten the inner M10 bearing cap bolts first pass
in sequence to 20 N-m (15 lb ft).
Important: To properly align the crankshaft thrust
bearings, the final thrust of the crankshaft MUST be in
the forward direction.
10. Using a plastic faced hammer, tap the crankshaft
rearward then forward to align the thrust bearings.

19

9
10

Tighten

20

63214

10.1. Tighten the inner M10 bolts final pass in

sequence 80 degrees using the J 36660.
10.2. Tighten the outer M10 bolts first pass in
sequence to 20 Nm (15 lb ft).
10.3. Tighten the outer M10 bolts final pass in
sequence 53 degrees using the J 36660.
10.4. Tighten the bearing cap side MB bolts to
25 Nm (18 lb ft).
Tighten the bolt on one side of the bearing
cap and then tighten the bolt on the
opposite side of the same bearing cap.
11. Install the crankshaft position sensor.
11.1. Inspect the crankshaft position sensor
0-ring seal. If the 0-ring seal is not cut or
damaged, it may be used.
11.2. Coat the 0-ring seal with clean engine oil.
11.3. Install the sensor. Align the notch in the
sensor retaining bracket with the bolt hole
in the block.
11.4. Install the sensor bolt.

Tighten
Tighten the crankshaft position sensor bolt
to 25 Nm (18 lb ft).

55322

Engine

Engine Mechanical - 5.7L

6-521

12. Measure the crankshaft end play.

12.1. Thrust the crankshaft forward or rearward.
12.2. Insert a feeler gauge between the
center crankshaft bearing and the
bearing surface of the crankshaft and
measure the bearing clearance.
The proper crankshaft end play clearance is
0.04-0.2 mm (0.0015-0.0078 in).
12.3. If the bearing clearance is not within
specifications, inspect the thrust surfaces
for nicks, gouges or raised metal.
Minor imperfections may be removed with
a fine stone.

64316

Piston, Connecting Rod, and Bearing

Installation
Tools Required
J 41556 Connecting Rod Guide
J 8037 Piston Ring Compressor

J 36660 Torque Angle Meter

Important: The piston and cylinder bore have been
measured and the bore has been sized for the proper
clearance. Install the piston and connecting rod
assembly into the proper cylinder bore.

The piston alignment mark MUST face the front of the

engine block.
1. Lightly lubricate the following components with
clean engine oil:
The piston
The piston rings
The cylinder bore
The bearing surfaces
2. Stagger the oil control ring end gaps a minimum
of 90 degrees.
3. Stagger the compression ring end gaps a
minimum of 25 mm (1.0 in).
4. Install the J 41556 to the connecting rod.
5. Install the J 8037 onto the piston and compress
the piston rings.

64180

6522

Engine Mechanical 5.7L

Engine
Important: The piston alignment mark MUST facing
the front of the engine block.
6. Install the piston and connecting rod assembly
into the pmper cylinder bore.
6.1. Hold the piston ring compressor firmly
against the engine block. Using a wooden
hammer handle, tightly tap the top of
the piston until all of the piston rings enter
the cylinder bore.
6.2. Use the J 41556 to guide the connecting
rod end onto the crankshaft journal.

63217

7. Remove the J 41556.

J 41556

63186

Notice: Refer to Fastener Notice in Cautions and

Notices.

Important: Position the connecting rod cap onto the

connecting rod property.
Align the flat side of the connecting rod with the flat
side of the rod cap.

8. Install the connecting rod cap, bearing and bolts.

Tighten
8.1. Tighten the bolts a first pass evenly to
20 Nm (15 lb ft).
8.2. Tighten the bolts a final pass to 60 degrees
using the J 36660.

(
53223

Engine

Engine Mechanical - 5.7L

6-523

9. Inspect the connecting rods for proper orientation

onto the crankshaft journal.
1O. With the pistons and connecting rods installed,
use a soft faced mallet and lightly tap each
connecting rod assembly parallel to the crankpin
to make sure that the rods have side clearance.
11. Measure the connecting rod side clearance using
a feeler gauge or a dial indicator. Connecting rod
side clearance should be within 0.11-0.51 mm
(0.0043-0.02 in).

63227

Camshaft Installation
Important: If camshaft replacement is required, the
valve lifters must also be replaced.
1. Lubricate the camshaft journals and the bearings
with clean engine oil.
2. Install three M8-1.25 x 100 mm (M8-1.25 x 4.0 in)
bolts into the camshaft front bolt holes.

Notice: All camshaft journals are the same diameter,

so care must be used in removing or installing the
camshaft to avoid damage to the camshaft bearings.
3. Using the bolts as a handle, carefully install
the camshaft into the engine block.

4. Remove the three bolts from the front of the

camshaft.

63212

Notice: Refer to Fastener Notice in Cautions and

Notices.
Important: Install the retainer plate with the sealing
gasket facing the engine block.

The gasket surface on the engine block should be

clean and free of dirt or debris.

5. Install the camshaft retainer and the bolts.

Tighten
Tighten the camshaft retainer bolts to
25 Nm (18 lb ft).
6. Inspect the camshaft sensor 0-ring seal. If the
0-ring seal is not cut or damaged, it may be
reused.
7. Lubricate the 0-ring seal with clean engine oil.

63211

6-524

Engine Mechanical - 5.7L

Engine
8. Install the camshaft sensor and bolt.

Tighten
Tighten the camshaft sensor bolt to
25 N-m (18 lb ft).

260128

Timing Chain and Sprockets Installation

Tools Required
J 41665 Crankshaft Balancer and Sprocket Installer
1. Install the key into the crankshaft keyway
(if previously removed).

156149

2. Tap the key (1) into the keyway until both ends of
the key bottom onto the crankshaft.

(
490871

Engine

Engine Mechanical - 5.7L

6-525

3. Install the crankshaft sprocket onto the front of the

crankshaft. Align the crankshaft key with the
crankshaft sprocket keyway.
\

156150

4. Use the J 41665 in order to install the crankshaft

sprocket.
Install the sprocket onto the crankshaft until fully
seated against the crankshaft flange.
5. Rotate the crankshaft sprocket until the alignment
mark is in the 12 o'clock position.

63199

Important:
Properly locate the camshaft sprocket locating pin
with the camshaft sprocket alignment hole.
The sprocket teeth and timing chain must mesh.

The camshaft and the crankshaft sprocket

alignment marks MUST be aligned properly.
Locate the camshaft sprocket alignment mark in
the 6 o'clock position.
6. Install the camshaft sprocket and timing chain.

63263

6~526

Engine Mechanical - 5.7L

Engine
7. If necessary, rotate the camshaft or crankshaft
sprockets in order to align the timing marks.
Notice: Refer to Fastener Notice in Cautions and
Notices.
8. Install the camshaft sprocket bolts.

Tighten
Tighten the camshaft sprocket bolts to
35 N,m (26 lb ft).

156158

Oil Pump, Pump Screen and Deflector

Installation
Important: Inspect the oil pump and engine block oil
gallery passages. These surfaces must be clear
and free of debris or restrictions.
1. Align the splined surfaces of the crankshaft
sprocket and the oil pump drive gear and
install the oil pump.
2. Install the oil pump onto the crankshaft sprocket
until the pump housing contacts the face of the
engine block.
Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Install the oil pump bolts.
Tighten
Tighten the oil pump bolts to 25 N-m (18 lb ft).
64281

4. Install the crankshaft oil deflector.

5. Lubricate a NEW oil pump screen 0-ring seal with
clean engine oil.
6. Install the NEW 0-ring seal onto the oil pump
screen.

64270

\.

Engine Mechanical - 5.7L

Engine

6-527

Important: Push the oil pump screen tube completely

into the oil pump prior to tightening the bolt.. Do not
allow the bolt to pull the tube into the pump.

)
/

Align the oil pump screen mounting brackets with the

correct crankshaft bearing cap studs.
7. Install the oil pump screen.

8. Install the oil pump screen bolt and the

deflector nuts.
Tighten
8. 1. Tighten
12 N-m
8.2. Tighten
25 N-m

the oil pump screen bolt to

(106 lb in).
the crankshaft oil deflector nuts to
(18 lb ft).

64268

Engine Rear Cover Installation

Tools Required
J 41480 Front/Rear Cover Alignment (Oil Pan
Surface)
J 41476 Front/Rear Cover Alignment (Crankshaft
Oil Seal Area)
Important:
Do not reuse the crankshaft rear oil seal or the
engine rear cover gasket.
Do not apply any type sealant to the rear cover
gasket (unless specified).
The special tools in this procedure are used to
properly align the engine rear cover at the oil
pan surface and to center the crankshaft
rear oil seal.
The crankshaft rear oil seal will be installed after
the rear cover has been installed and aligned.
Install the rear cover without the
crankshaft oil seal.
- The crankshaft rear oil seal MUST be
centered in relation to the crankshaft.

- The oil pan sealing surface at the rear cover

and engine block MUST be aligned within
specifications.
- An improperly aligned rear cover may cause
premature rear oil seal wear and/or engine
assembly oil leaks.
1. Inspect the rear oil gallery plug for proper
installation.

63228

6~528

Engine Mechanical - 5.7L

Engine
2. Install the rear cover gasket, rear cover and bolts.
3. Tighten the bolts finger tight. Do not overtighten.

64282

Notice: Refer to Fastener Notice in Cautions and

Notices.

Important: Start the J 41480 tool-to-rear cover bolts.

Do not tighten the bolts at this time.
4. Install the J 41480 and bolts.
Tighten
Tighten the tool-to-engine block bolts to
25 N-m (18 lb ft).

64204

Important: To properly align the rear cover, the

J 41476 must be installed onto the rear of the
crankshaft with the tool mounting bolts parallel to the
oil pan surface.

J 41480

5. Rotate the crankshaft until two opposing flywheel

bolt holes .are parallel to the oil pan surface.

J 41476
63243

Engine

Engine Mechanical - 5.7L

6-529

Important: The tapered legs of the. alignment tool

must enter the rear cover oil seal bore.

6. Install the J 41476 and bolts onto the rear of the

crankshaft.

Tighten
6.1. Tighten the tool mounting bolts until snug.
Do not overtighten.
6.2. Tighten the J 41480 tool-to-rear cover bolts
evenly to 12 Nm (106 lb in).
6.3. Tighten the rear cover bolts to
25 N,m (18 lb ft).
7. Remove the tools.

65286

8. Measure the oil pan surface for flatness (rear

cover-to-engine block).
8.1 . Place a straight edge onto the engine block
and rear cover oil pan sealing surfaces.
Avoid contact with the portion of the gasket
that protrudes into the oil pan surface.
8.2. Insert a feeler gauge between the rear
cover and the straight edge. The,cover
must be flush with the oil pan or no more
than 0.5 mm (0.02 ih} below flush.
9. If the rear cover-to-engine block oil pan. surface
alignment is not within specifications, repeat the
cover alignment procedure.
10. If the correct rear cover-to-engine block alignment
at the oil pan surface cannot be obtained, replace
the rear cover.

63240

6-530

Engine Mechanical - 5.7l

Engine
Crankshaft Rear Oil Seal Installation
Tools Required
J 41479 Crankshaft Rear Oil Seal Installer
Important:

Do not lubricate the oil seal inside diameter (ID)

or the crankshaft surface.
Do not reuse the crankshaft rear oil seal.
1. Lubricate the outside diameter (OD) of the oil
seal (1) with clean engine oil.
DO NOT allow oil or other lubricants to contact
the seal surface.
2. Lubricate the rear cover oil seal bore with clean
engine oil.
DO NOT allow oil or other lubricants to contact
the crankshaft surface.
490692

3. Install the J 41479 cone (2) and bolts onto the

rear of the crankshaft.
4. Tighten the bolts until snug. Do not overtighten.
5. Install the rear oil seal onto the tapered
cone (2) and push the seal to the rear cover bore.
6. Thread the J 41479 threaded rod into the tapered
cone until the tool (1) contacts the oil seal.
7. Align the oil seal ontOthe tool (1).
8. Rotate the ha.ndle of the tool (1) clockwise until
the seal enters the rear cover and bottoms into
the cover bore.
9. Remove the tool.

J 41479

63200

Engine Front Cover Installation

Tools Required

J 41480 Front/Rear Cover Alignment (Oil Pan

Surface)
J 41476 Front/Rear Cover Alignment (Crankshaft
Oil Seal Area)

64278

(\

Engine

Engine Mechanical - 5.7L

6+531

Important:
Do not reuse the crankshaft oil seal or the engine
front cover gasket.
Do not apply any type sealant to the front cover
gasket (unless specified).

The special tools in this procedure are used to

properly align the engine front cover at the oil
pan surface and to center the crankshaft
front oil seal.
- All gasket surfaces should be free of oil or
other foreign material during assembly.
The crankshaft front oil seal MUST be centered
in relation to the crankshaft.
- The oil pan sealing surface at the front cover
and engine block MUST be aligned within
specifications.
- An improperly aligned front cover may cause
premature front oil seal wear and/or engine
assembly oil leaks.
1. Install the front cover gasket, cover, and bolts
onto the engine.
2. Tighten the cover bolts finger tight. Do not
overtighten.

Notice: Refer to Fastener Notice in Cautions and

Notices.
Important: Start the tool-to-front cover bolts. Do not
tighten the bolts at this time.
3. Install the J 41480.
Tighten
Tighten the tool~to-engine block bolts to
25 Nm (18 lb ft).

63182

6-532

Engine Mechanical - 5.7L

Engine
Important: Align the tapered legs of the tool with the
machined alignment surfaces on the front cover.
4. Install the J 41476.
5. Install the crankshaft balancer bolt.

Tighten
5.1. Tighten the crankshaft balancer bolt by
hand until snug. Do not overtighten.
5.2. Tighten the J 41480.
5.3. Tighten the engine front cover bolts to
25 N-m (18 lb ft).
6. Remove the tools.

63185

7. Measure the oil pan surface flatness (front

cover-to-engine block).
7.1. Place a straight edge across the engine
block and front cover oil pan sealing
surfaces.
Avoid contact with the portion of the gasket
that protrudes into the oil pan surface.
7.2. Insert a feeler gauge between the front
cover and the straight edge tool. The
cover must be flush with the oil pan surface
or no more than 0.5 mm (0.02 in)
below flush.
8. If the front cover-to-engine block oil pan surface
alignment is not within specifications, repeat the
cover alignment procedure.
9. If the correct front cover-to-engine block alignment
cannot be obtained, replace the front cover.

0.0-0.Smm
(0.0 - 0.02")

63242

Engine

Engine Mechanical - 5.7L

6-533

Crankshaft Front Oil Seal Installation

Tools Required
J 41478 Crankshaft Front Oil Seal Installer
Important: Do not lubricate the oil seal sealing
surface.

Do not reuse the crankshaft front oil seal.

1. Lubricate the outer edge of the oil seal (1) with
clean engine oil.
2. Lubricate the front cover oil seal bore with clean
engine oil.

490689

3. Install the crankshaft front oil seal onto the

J 41478 guide.
4. Install the J 41478 threaded rod (with nut, washer,
guide, and oil seal) into the end of the crankshaft.
5. Use the J 41478 in order to install the oil seal into
the cover bore.
5. 1. Use a wrench and hold the hex on the
installer bolt.
5.2. Use a second wrench and rotate the
installer nut clockwise until the seal
bottoms in the cover bore.
5.3. Remove the tool.
5.4. Inspect the oil seal for proper installation.
The oil seal should be installed evenly and
completely into the front cover bore.

63177

Oil Pan Installation

Important: The alignment of the structural oil pan is
critical. The rear bolt hole locations of the oil pan
provide mounting points for the transmission housing.
To ensure the rigidity of the powertrain and correct
transmission alignment, it is important that the rear of
the block and the rear of the oil pan are flush or
even. The rear of the oil pan must NEVER protrude
beyond the engine block and transmission
housing plane.

Do NOT reuse the oil pan gasket.

It is not necessary to rivet the NEW gasket to the
oil pan.
It is not necessary to remove the oil level sensor prior
to oil pan installation.

178491

6-534

Engine Mechanical - 5.7L

Engine
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Install the oil pan baffle and bolts (if previously
removed).
Tighten
Tighten the oil pan baffle bolts to
12 N,m (106 lb in).
2. Apply a 5 mm (0.2 in) bead of sealant
GM P/N 12378190 or equivalent 20 mm (0.8 in)
long to the engine block. Apply the sealant directly
onto the tabs of the front cover gasket that
protrude into the oil pan surface. Refer to Sealers,
Adhesives, and Lubricants.

63176

3. Apply a 5 mm (0.2 in) bead of sealant

GM P/N 12378190 or equivalent 20 mm (0.8 in)
long to the engine block. Apply the sealant directly
onto the tabs of the rear cover gasket that
protrude into the oil pan surface. Refer to Sealers,
Adhesives, and Lubricants.

63175

Engine

Engine Mechanical- 5.7L

6-535

Important: Be sure to align the oil gallery passages in

the oil pan and engine block properly with the oil pan
gasket.

4. Preassemble the oil pan gasket to the pan.

4.1. Install the gasket onto the oil pan.
4.2. Install the oil pan bolts to the pan and
through the gasket.
5. Install the oil pan, gasket and bolts to the
engine block.
6. Tighten bolts finger tight. Do not overtighten.
7. Place a straight edge across the rear of the engine
block and the rear of the oil pan at the
transmission housing mounting surfaces.

178558

8. Align the oil pan until the rear of engine block and
rear of oil pan are flush or even.

Tighten
8.1. Tighten the oil pan-to-:block a.nd oil
pan-to-front cover bolts to 25 N-m (18 lb ft).
8.2. Tighten the oil pan-to-rear cover bolts to
12 Nm (106 lb in).
9. Measure the oil pan-to-engine block alignment.
9.1. Place a straight edge across the rear of
the engine block and rear of oil pan at the
transmission housing mounting surfaces.

Important: The rear of the oil pan must NEVER

protrude beyond the engine block and transmission
housing mounting surfaces.
9.2. Insert a feeler gauge between the straight
edge and the oil pan transmission housing
mounting surface and check to make
sure that there is no more than a 0.25 mm
(0.01 in) gap between the pan and
straight edge.
9.3. If the oil pan alignment is not within
specifications, remove the oil pan and
repeat the above procedure.

178474

6-536

Engine Mechanical - 5.7L

Engine
10. Install the oil level sensor.
Tighten
Tighten the oil level sensor to 13 Nm (115 lb in).

\.

178467

Oil Filter, Adapter,,Pan Cover Installation

Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Install a NEW oil pan cover gasket, the cover and

the bolts.

Tighten
Tighten the oil pan cover bolts to
12 N,m'(106 lb in).

2. Install the oil filter fitting (if required).

Tjght~n
Tighten the oil filter fitting to 55 N-m (40 lb ft).

178471

3. Lubricate the oil filter seal with clean engine oil.

4. Install th~ oil filter.
Tighten
Tighten the oil filter to 30 Nm (22 lb ft).

178469

Engine

Engine Mechanical - 5.7L

6-537

5. Install the oil pan drain plug.

Tighten
Tighten the oil pan drain plug to 25 N-m (18 lb ft).

178475

Valve lifter Installation

Important: When reusing valve lifters, install the lifters
to their original locations.

If camshaft replacement is required, the valve lifters

must also be replaced.
1. Lubricate. the valve lifters and engine block valve
lifter bores with clean engine oil.
2. Insert the valve lifters i.nto the lifter guides.
Align the flat area on the top of the lifter with the
flat area in the lifter guide bore. Push the lifter
completely into the guide bore.

63233

3. Install the valve lifters and guide assembly to the

engine block.

Notice: Refer to Fastener Notice in Cautions and

Notices.
4. Install the valve lifter guide bolt (1 ).
Tighten
Tighten the valve lifter guide bolt to
12 N-m (106 lb in).

)
63230

6-538

Engine Mechanical 5.7L

Engine
Cylinder Head Installation (Left Side)
Tools Required
J 36660 Torque Angle Meter
Important: Do not reuse the M11 cylinder head bolts.
Install NEW M11 cylinder head bolts during assembly.

Do not use any type sealant on the cylinder head

gasket (unless specified).
The cylinder head gaskets must be installed in the
proper direction and position.
Caution: Wear safety glasses in order to avoid eye
damage.

63235

Notice: Clean all dirt, debris, and coolant from the

engine block cylinder head bolt holes. Failure to
remove all foreign material may result in damaged
threads, improperly tightened fasteners or damage to
components.
1. Using a M11 x 2.0 cut thread tap, clean the
engine block head bolt hole threads.
2. Spray cleaner GM P/N.12346139, P/N 12377981,
or equivalent into the hole.
3. Clean the cylinder head bolt holes with

compressed air.
4. Check the cylinder head locating pins for proper
installation.
Important: When properly installed, the tab on the left
cylinder head gasket will be located left of center or
closer totne front of the engine.
5. Install the NEW left cylinder head gasket onto the
locating pins.

63169

Engine Mechanical- 5.7L

Engine

6-539

6. Install the cylinder head onto the locating pins and

the gasket.
7. Install the M11 cylinder head bolts.
8. Apply a 5 mm (0.20 in) band of threadlock
GM P/N 12345382 or equivalent to the threads of
the MB cylinder head bolts.
Refer to Sealers, Adhesives, and Lubricants.
9. Install the MB cylinder head bolts.

64878

Notice: Refer to Fastener Notice in Cautions and

Notices.

10. Tighten the cylinder head bolts.

Tighten
i0.1. Tighten the M11 cylinder head bolts a first
pass in sequence to 30 N-m (22 lb ft).
10.2. Tighten the M11 cylinder head bolts a
second pass in sequence to 90 degrees
using the J 36660.
10.3. Tighten the M11 cylinder head bolts
(1,2,3,4,5,6,7,8) to 90 degrees and the
M11 cylinder head bolts (9 and 10)
to 50 degrees a final pass in sequence to
using the J 36660.
i0.4. Tighten the MB cylinder head bolts
(11, 12, 13, 14, 15) to 30 N,m (22 lb ft).
Begin with the center bolt (11) and
alternating side-to-side, work outward
tightening all of the bolts.

15

13

11

12

14

64333

Cylinder Head Installation (Right Side)

Tools Required
J 36660 Torque Angle Meter
Important: Do not reuse the M11 cylinder head bolts.
Install NEW M11 cylinder head bolts during assembly.
Do not use any type sealant on the cylinder head
gasket (unless specified).
The cylinder head gaskets must be installed in the
proper direction and position.

63235

6-540

Engine

Engine Mechanical - 5.7L

Caution: Wear safety glasses in order to avoid eye

damage.
Notice: Clean all dirt, debris, and coolant from the
engine block cylinder head bolt holes. Failure to
remove all foreign material may result in damaged
threads, improperly tightened fasteners or damage to
components.
1. Using a M11 x 2.0 cut thread tap, clean the
engine block head bolt hole threads.
2. Spray cleaner GM P/N 12346139, P/N 12377981,
or equivalent into the hole.
3. Clean the cylinder head bolt holes with
compressed air.
4. Check the cylinder head locating pins for proper
installation.
Important: When properly installed, the tab on the
right cylinder head gasket will be located right of
center or closer to the front of the engine.
5. Install the NEW right cylinder head gasket onto
the locating pins.

'

63170

6. Install the cylinder head onto the locating pins and

the gasket.
7. Install the M11 cylinder head bolts.
8. Apply a 5 mm (0.20 in) band of threadlock
GM P/N 12345382 or equivalent to the threads of
the M8 cylinder head bolts.
Refer to Sealers, Adhesives, and Lubricants.
9. Install the M8 cylinder head bolts.

100173

Engine Mechanical - 5.7L

Engine

6-541

Notice: Refer to Fastener Notice in Cautions and

Notices.
10. Tighten the cylnder head bolts.
Tighten
10.1. Tighten the M11 cylinder head bolts a first
pass in sequence to 30 N,m (22 lb ft).
10.2. Tighten the M11 cylinder head bolts a
second pass in sequence to 90 degrees
using the J 36660.
10.3. Tighten the M11 cylinder head bolts
(1,2,3,4,5,6,7,8) to 90 degrees and the
M11 cylinder head bolts (9 and 10)
to 50 degrees a final pass in sequence to
using the J 36660.
10.4. Tighten the M8 cylinder head bolts
(11,12,13,14,15) to 30 Nm (22 lbft).
Begin with the center bolt (11) and
alternating side-to-side, work outward
tightening all of the bolts.

15

13

11

12

14

64333

Valve Rocker Arm and Push Rod

Installation
Important: When reusing the valve train components,
always install the components to the original location
and position.

Valve lash is net build, no valve adjustment is required.

1. Lubricate the valve rocker arms and pushrods
with clean engine oil.
2. Lubricate the flange of the valve rocker arm bolts
with clean engine oil.
Lubricate the flange or washer surface of the bolt
that will contact the valve rocker arm.
3. Install the valve rocker arm pivot support.

64178

Important: Make sure that the pushrods seat properly

to the valve lifter sockets.

4. Install the pushrods.

64266

6-542

Engine Mechanical - 5.7L

Engine
Important: Make sure that the pushrods seat properly
to the ends of the rocker arms.

DO NOT tighten the rocker arm bolts at this time.

5. Install the rocker arms and bolts.

64171

6. Rotate the crankshaft until number one piston is

at top dead center of compression stroke.
In this position, the crankshaft and camshaft
sprocket marks will be aligned, cylinder number
one rocker arms will be off lobe lift, and the
crankshaft sprocket key will be at the 1:30
position. While viewing from the rear of the engine,
the additional crankshaft pilot hole (non-threaded)
will be in the 10:30 position.
The engine firing order is 1,8,7,2,6,5,4,3.
Cylinders 1,3,5 and 7 are left bank.
Cylinders 2,4,6, and 8 are right bank.
Notice: Refer to Fastener Notice in Cautions and
Notices.
7. With the engine in the number one firing position,
tighten the following valve rocker arm bolts:
Tighten
156158

Tighten exhaust valve rocker arm bolts 1, 2, 7,

and 8 to 30 N-m (22 lb ft).
Tighten intake valve rocker arm bolts 1, 3, 4,
and 5 to 30 N-m (22 lb ft).
8. Rotate the crankshaft 360 degrees.
9. Tighten the following valve rocker arm bolts:
Tighten

Tighten exhaust valve rocker arm bolts 3, 4, 5,

and 6 to 30 Nm (22 lb ft).
Tighten intake valve rocker arm bolts 2, 6, 7,
and 8 to 30 N-m (22 lb ft).

Engine

Engine Mechanical - 5.7L

6-543

Valve Rocker Arm Cover Installation

(Left Side)
Important: All gasket surfaces should be free of oil or
other foreign material during assembly.

DO NOT reuse the valve rocker arm cover gasket.

DO NOT remove the ignition coils from the valve
rocker arm cover unless necessary.
The valve rocker arm cover bolt grommets m,w be
reused.
If the vapor vent grommet has been removec;I from the
valve rocker arm cover, install a NEW vapor vent
gourmet during assembly.
1. Lubricate the 0-ring seal of the NEW vapor vent
gourmet with clean engine oil.
2. Insert the NEW vapor vent grommet into the
rocker arm cover and rotate the grommet
clockwise until locked in the proper position.
3. Install a NEW cover gasket into the valve rocker
arm cover.
4. Install the cover bolts with grommets.

63244

Notice: Refer to Fastener Notice in Cautions and

Notices.
5. Install the valve rocker arm cover onto the
cylinder head.
Tighten
Tighten the valve rocker arm cover bolts to
12 N-m (106 lb in).

63205

6-544

Engine Mechanical - 5.7L

Engine
6. Install the ignition coils, studs, and bolts (if
applicable).
Tighten
Tighten the ignition coil studs and bolts to
12 Nm (106 tb in).
7. Install the ignition coil wire harness (if applicable).
8. Install the ignition coil wire harness connector
bolts (if applicable).

Tighten
Tighten the ignition coil wire harness connector
bolts to 12 N-m (106 lb in).
9. Install the crankcase ventilation hose.

65292

Valve Rocker Arm Cover Installation

(Right Side)
Important: All gasket surfaces should be free of oil or
other foreign material during assembly.

DO NOT reuse the valve rocker arm cover gasket.

DO NOT remove the ignition coils from the valve
rocker arm cover unless necessary.
The valve rocker arm cover bolt grommets may be
reused.

64263

If the oil fill tube has been removed from the valve
rocker arm cover, install a NEW oil fill tube during
assembly.
1. Lubricate the 0-ring seal of the NEW oil fill tube
with clean engine oil.
2. Insert the NEW oil fill tube into the rocker arm
cover and rotate the tube clockwise until locked
in the proper position.
3. Install the oil fill cap into the tube and rotate
clockwise until locked in the proper position.

Engine

Engine Mechanical - 5. 7L

6-545

4. Install a NEW gasket into the valve rocker

arm cover.
5. Install the cover bolts with grommets.
Notice: Refer to Fastener Notice in Cautions and
Notices.
6. Install the valve rocker arm cover onto the
cylinder head.

Tighten
Tighten the valve rocker arm cover bolts to
12 N-m (106 lb in).

63205

7. Install the ignition coils, studs, and bolts

(if applicable).
Tighten
Tighten the ignition coil studs and bolts to
12 N-m (106 lb in).
8. Install the ignition coil wire harness (if applicable).
9. Install the ignition coil wire harness connector
bolts (if applicable).

Tighten
Tighten the ignition coil wire harness connector
bolts to 12 N-m (106 lb in).
10. Install the crankcase ventilation hoses.

65290

Engine Valley Cover Installation

Important: All gasket surfaces should be free of oil or
other foreign material during assembly.
1. Install NEW knock sensor oil seals into the
valley cover.
Lubricate the seal surface with clean engine oil.
2. Install the valley cover and NEW gasket.
Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Install the valley cover bolts.

Tighten
Tighten the valley cover bolts to 25 N-m (18 lb ft).

1
I

65048

6-546

Engine Mechanical - 5. 7L

Engine
4. Install the knock sensors.
Tighten
Tighten the knock sensors to 20 Nm (15 lb ft).

54612

5. Install the knock sensor wire harness.

54608

Vapor Vent Pipe Installation

Important: Install the vapor vent pipe gaskets
properly onto the vapor vent pipe.

Position the gasket 0-ring seal onto the nipple portion

of the pipe.
1. Install.the gaskets onto the vapor vent pipe.

64262

Engine
Important: Route the knock sensor wire harness over
the top of the vapor vent pipe. The vapor vent pipe
and knock sensor wire harness should be installed in a
manner as to allow the removal of the wire harness
without requiring the removal of the vapor vent pipe.

Engine Mechanical - 5.7L

6-547

'

2. Install the vapor vent pipe and gaskets onto the

cylinder heads.

Notice: Refer to Fastener Notice in Cautions and

Notices.
3. Install the vapor vent pipe bolts.
Tighten
Tighten the vapor vent pipe bolts to
12 N-m (106 lb in).
4. Install the vapor vent hose and clamp onto the
vapor vent pipe.

64139

Intake Manifold Installation

Important: The intake manifold, throttle body, fuel
injection rail and fuel injectors may be removed as an
assembly. If not servicing the individual components,
install the intake manifold as a complete assembly.

1 . Install NEW intake manifold-to-cylinder head

gaskets ( 1) .

490579

2. Install the manifold to the engine.

178557

6-548

Engine

Engine Mechanical - 5. 7L

3. Apply threadlock GM P/N 12345382 or equivalent

to the threads of the intake manifold bolts (1).
Refer to Sealers, Adhesives, and Lubricants.

Caution: The fuel rail stop bracket must be

installed onto the engine assembly. The stop
bracket serves as a protective shield for the fuel
rail in the event of a vehicle frontal crash. If
the fuel rail stop bracket is not installed and the
vehicle is involved in a frontal crash, fuel could be
sprayed possibly causing a fire and personal
injury from burns.
4. Install the fuel rail stop bracket (2).

I\

490927

Notice: Refer to Fastener Notice in Cautions and

Notices.
5. Install the intake manifo.ld bolts.

Tighten
5.1. Tighten the intake manifold bolts a first
pass in sequence to 5 N-m (44 lb in).
5.2. Tighten the intake manifold bolts a final
pass in sequence to 10 N-m (89 lb in).

@)
@)
@)
@)
6
2
3 O 9
,,--~~o,..-~--..,o,,--~~

63222

6. Install the knock sensor wire harness

connector (1) onto the fuel rail stop bracket (2).

(
490736

Engine

Engine Mechanical - 5.7L

6-549

7. Install the Manifold Absolute Pressure (MAP)

sensor (if previously removed).

58838

8. Install the accelerator control cable bracket (2)

and bolts (1 ).

Tighten
Tighten the bracket bolts to 10 Nm (89 lb in).

490573

5..;550

Engine Mechanical - 5.7L

Engine
9. Install the Positive Crankcase Ventilation (PCV)
valve pipe to the right rocker cover and intake
manifold.
10. Install the PCV strap and nut onto the right front
vapor vent pipe stud.

Tighten
Tighten the PCV strap nut to 12 N-m (106 lb in).

379367

(
11. Install the PCV valve pipe to the left rocker cover.

379366

Engine

Engin~ Mechanical - 5.7L 6-551

Fuel Rail and Injectors Installation

Important: DO NOT reuse fuel injector 0-ring seals.

Install NEW fuel injector 0-ring seals during assembly.
1. Lubricate the NEW fuel injector 0-ring seals
with clean engine oil.
2. Install the 0-ring seals onto the fuel injectors.
3. Install the fuel rail (with fuel injectors) into
the intake manifold.
Press evenly on both sides of the fuel rail until all
of the injectors are seated in their bores.
4. Apply a 5 mm (0.2 in) band of threadlock
GM P/N 12345382 or equivalent to the threads of
the fuel rail bolts.
Refer to Sealers, Adhesives, and Lubricants.

Caution: The fuel rail stop bracket must be

installed onto the engine assembly. The stop
bracket serves as a protective shield for the fuel
rail in the event of a vehicle frontal crash. If
the fuel rail stop bracket is not installed and the
vehicle is involved in a frontal crash, fuel'could be
sprayed possibly causing a fire and personal
injury from burns.
Notice: Refer to Fastener Notice in Cautions and
Notices.

222050

5. Install the fuel rail bolts.

Tighten
Tighten the fuel rail bolts to 10 Nm (89 lb in).

Throttle Body Installation

Important: DO NOT reuse the throttle body gasket.
Install a NEW gasket during assembly.
1. Install the throttle body gasket (1) to the intake
manifold.

490580

6-552

Engine Mechanical~ 5.7L

Engine
Notice: Refer to Fastener Notice in Cautions and
Notices.

2. Install the throttle body and bolts.

Tighten
Tighten the throttle body bolts to
12 Nm (106 lb in) ..
3. Install the vapor vent hose and clamp.

222051

Water Pump lnstaltation

Notice: DO NOT use cooling system seal taos (or.
similar compounds) unless otherwise instructed. The
use of cooling system seal tabs (or similar compounds)
may restrict coolant flow through the passages of
'
the cooling system or the engine components.
Restricted coolant flow may cause engine overheating
and/or damage to the cooling system or .the engine
components/assembly.

Important: All gasket surfaces to be free of oil or

other foreign material during assembly.
1 . Install the water pump and NEW gaskets.
Not;ce: Refer to Fastener Notice in Cautions and
Notices.

2. Install the water pump bolts.

63204

Tighten
2.1. Tighten the water pump bolts first pass to
15 N-m (11 lb ft).

2.2. Tighten the water pump bolts final pass to

30 N,m (22 lb ft).

Engine

Engine Mechanical - 5.7L

6-553

3. Install the water pump pulley and bolts.

Tighten
3.1 . Tighten
pass to
3.2. Tighten
pass to

the water pump pulley bolts a first

1O N-m (89 lb in).
the water pump pulley bolts a final
25 N-m (18 lb ft).

74081

Exhaust Manifold Installation (Left Side)

Important: Tighten the exhaust manifold bolts as
specified in the service procedure. Improperly installed
and/or leaking exhaust manifold gaskets may effect
vehicle emissions and/or On-Board Diagnostic (OBD) II
system performance.

The cylinder head exhaust manifold bolt hole threads

must be clean and free of debris or threadlocking
material.
1. Apply a 5 mm (0.20 in) wide band of threadlock
GM P/N 12345493 or equivalent to the threads of
the exhaust manifold bolts.
Refer to Sealers, Adhesives, and Lubricants.
2. Install the exhaust manifold and NEW exhaust
manifold gasket.
Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Install the exhaust manifold bolts.

Tighten
3.1. Tighten the exhaust manifold bolts a first
pass to 15 N-m (11 lb ft). Tighten the
exhaust manifold bolts beginning with the
center two bolts. Alternate from side-to-side,
and work toward the outside bolts.
3.2. Tighten the exhaust manifold bolts a final
pass to 25 N-m (18 lb ft). Tighten the
exhaust manifold bolts beginning with the
center two bolts. Alternate from side-to-side,
and work toward the outside bolts.
4. Using a flat punch, bend over the exposed edge
of the .exhaust .manifold gasket at the rear of the
left cylinder head.

178462

6-554

Engine Mechanical - 5. 7L

Engine
5. Install the Air Injection Reaction (AIR) pipe (with
check valve), NEW gasket and bolts.
Tighten
Tighten the AIR pipe to exhaust manifold bolts to
20 Nm (15 lb in).
6. Install the oxygen sensor into the intake manifold.

(
\

Tighten
Tighten the oxygen sensor to 41 Nm (30 lb ft).

178463

Exhaust Manifold Installation (Right Side)

Important: Tighten the exhaust manifold bolts as
specified in the service procedure. Improperly installed
and/or leaking exhaust manifold gaskets may effect
vehicle emissions and/or On-Board Diagnostic (OBD) II
system performance.

The cylinder head exhaust manifold bolt hole threads

must be clean and free of debris or threadlocking
material.

178460

Do not reuse Exhaust Gas Recirculation (EGR) valve

and pipe gaskets or seals during assembly. Install
NEW gaskets and 0-ring seal.
1 . Apply a 5 mm (0.20 in) wide band of threadlock
GM P/N 12345493 or equivalent to the threads of
the exhaust manifold bolts.
Refer to Sealers, Adhesives, and Lubricants.
2. Install the exhaust manifold gasket and exhaust
manifold.
Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Install the exhaust manifold bolts.

Tighten

3.1. Tighten the exhaust manifold bolts first

pass to 15 N-m (11 lb ft). Tighten the
exhaust manifold bolts beginning with the
center two bolts. Alternate from side-to-side,
and work toward the outside bolts.
3.2. Tighten the exhaust manifold bolts final
pass to 25 N-m (18 lb ft). Tighten the
exhaust manifold bolts beginning with the
center two bolts. Alternate from side-to-side,
and work toward the outside bolts.
4. Using a flat punch, bend over the exposed edge
of the exhaust manifold gasket at the front of the
right cylinder head.

Engine

Engine Mechanical - 5.7L

6-555

5. Install the Air Injection Reaction (AIR) pipe (with

check valve), NEW gasket and bolts.
\

Tighten
Tighten the AIR pipe to exhaust manifold bolts to
25 Nm (18 lb ft).

178464

6. Install the AIR tubing and clamps.

7. Install the oxygen sensor into the intake manifold.

Tighten
Tighten the oxygen sensor to 41 Nm (30 lb ft).

178465

8. Apply a light coating of clean engine oil to a NEW

0-ring seal and install the seal onto the EGA
valve pipe.
9. Insert the EGA valve pipe into the intake manifold.
10. Start the EGR valve pipe to intake manifold bolt.
Do not tighten the bolt at this time.
11. Install the EGA valve pipe to cylinder head bolts.
Do not tighten the bolt at this time.
12. Install a NEW EGA valve pipe exhaust manifold
gasket and bolts.

Tighten
12.1. Tighten the EGA valve pipe to intake
manifold bolt to 10 Nm (89 lb in).
12.2. Tighten the EGR valve pipe to cylinder
head bolts to 50 N,m (37 lb ft).
12.3. Tighten the EGR valve pipe to exhaust
manifold bolts to 25 Nm (18 lb ft).
178489

6-556

Engine

Engine Mechanical - 5.7L

13. Install the EGR valve, a NEW gasket and bolts.

Tighten

13.1. Tighten the EGR valve bolts first pass to

10 N,m (89 lb in).
13.2. Tighten the EGR valve bolts final pass to
30 N,m (22 lb ft).

178487

Oil Level Indicator and Tube Installation

1. Inspect the 0-ring seal for cuts or damage. If the
oil level indicator tube 0-ring seal is not cut or
damaged, it may be reused.
2. Lubricate the 0-ring seal with clean engine oil.

3. Install the 0-ring seal onto the oil level

indicator tube.

4. Install the oil level indicator tube into the engine

block and rotate into proper position.
Notice: Refer to Fastener Notice in Cautions and
Notices.
5. Install the tube bolt to the right cylinder head.
Tighten
Tighten the oil level indicator tube bolt to
25 N,m (18 lb ft).
6. Install the oil level indicator into the tube.
178459

Engine Flywheel Installation

Important: Note the position and direction of the
engine flywheel before removal. The flywheel does not
use a locating pin for alignment and will not initially
seat against the crankshaft flange, but will be
pulled onto the crankshaft by the engine flywheel
bolts. This procedure requires a three stage tightening
process.
1. Install the manual transmission engine flywheel to
the crankshaft (if applicable).

156166

Engine

Engine Mechanical - 5.7L

6-557

2. Install the automatic transmission engine flywheel

to the crankshaft (if applicable).

178458

3. Apply threadlock GM P/N 12345382 or equivalent

to the threads of the flywheel bolts.
Notice: Refer to Fastener Notice in Cautions and
Notices.
4. Install the engine flywheel bolts.

Tighten

4.1. Tighten the engine flywheel bolts first pass

in sequence to 20 Nm (15 lb ft).
4.2. Tighten the engine flywheel bolts second
pass in sequence to 50 Nm (37 lb ft).
4.3. Tighten the engine flywheel bolts final pass
in sequence to 100 Nm (74 lb ft).

63174

Crankshaft Balancer Installation

Tools Required
J 41665 Crankshaft Balancer and Sprocket
Installer

J 36660 Torque Angle Meter

J 42386-A Flywheel Holding Tool
Important: The crankshaft balancer installation and
bolt tightening involves a four stage tightening process.
The first pass ensures that the balancer is installed
completely onto the crankshaft. The second, third and
fourth passes tighten the new bolt to the proper
torque.
The used crankshaft balancer bolt will be used only
during the first pass of the balancer installation
procedure. Install a NEW crankshaft balancer bolt and
tighten as described in the second, third and fourth
passes of the balancer bolt tightening procedure.

J 42386-A

260126

6-558

Engine Mechanical - 5.7L

Engine
Important: Make sure the teeth of the tool engage the
engine flywheel teeth.
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Install the J 42386-A and bolts.
Use one M10-1.5 x 120 mm and one M10-1.5 x
45 mm bolt for proper tool operation.

Tighten
Tighten the J 42386-A bolts to 50 Nm (37 lb ft).
Important: The balancer should be positioned onto
the end of the crankshaft as straight as possible prior
to tool installation.
2. Install the balancer onto the end of the crankshaft.

260154

63187

(
3. Use the J 41665 in order to install the balancer.
3.1. Assemble the threaded rod, nut, washer
and installer.
Insert the smaller end of the installer into
the front of the balancer.
3.2. Use a wrench and hold the hex end of the
threaded rod.
3.3. Use a second wrench and rotate the
installation tool nut clockwise until the
balancer is started onto crankshaft.
3.4. Remove and reverse the installation tool.
Position the larger end of the installer
against the front of the balancer.
3.5. Use a wrench and hold the hex end of the
threaded rod.
3.6. Use a second wrench and rotate the
installation tool nut clockwise until the
balancer is installed onto the crankshaft.
3.7. Remove the balancer installation tool.

Engine

Engine Mechanical - 5.7L

6-559

4. Install the used crankshaft balancer bolt.

Tighten
Tighten the crankshaft balancer bolt to
330 Nm (240 lb ft).
5. Remove the used crankshaft balancer bolt.
Important: The nose of the crankshaft should be
recessed 2.40-4.48 mm (0.094-0.176 in) into
the balancer bore.
6. Measure for a correctly installed balancer.
If the balancer is not installed to the proper
dimensions, install the J 41665 and repeat the
installation procedure.

63245

7. Install the NEW crankshaft balancer bolt.

Tighten
7.1. Tighten the crankshaft balanc~r bolt a first
pass to 50 N,m (37 lb ft).

7.2. Tighten the crankshaft balancer bolt a

second pass. to 140 degrees using
the J 36660.
8. Remove the J 42386-A.

260154

Engine Set-Up and, Testing

Important: After overhaul, the engine should be
tested before installation into the vehicle. If a suitable
test stand is not available, the following procedure
can be used after the engine is installed into the
vehicle.
1. Fill the crankcase with the proper quantity and
grade of engine oil.
2. Add engine oil supplement GM P/N 12345795 or
equivalent.
Refer to Sealers, Adhesives, and Lubricants.
3. Fill the cooling system with the proper quantity
and grade of coolant.
4. Disable the ignition system.
5. Crank the engine several times. Listen for any
unusual noises or evidence that parts are
binding.

6-560

Engine Mechanical - 5.7L

6. Start the engine and listen for unusual noises.

7. Check the vehicle oil pressure gauge or light and
confirm that the engine has acceptable oil
pressure.
If necessary, install an oil pressure gauge and
measure the engine oil pressure.

Engine
8. Run the engine speed at about 1000 RPM until
the engine has reached normal operating
temperature.
9. Listen for sticking lifters and other unusual noises.
10. Inspect for fuel, oil and/or coolant leaks while
the engine is running.
11. Perform a final inspection for the proper engine oil
and coolant levels.

Description and Operation

Engine Component Description

178450

The 1998 5.7 Liter V-8 engine is identified as RPO-LS1

and VIN-G.
Camshaft and Drive System
A billet steel one piece camshaft is supported by five
bearings pressed into the engine block. The
camshaft has a machined camshaft sensor reluctor
ring incorporated between the fourth and fifth bearing

journals. The camshaft timing sprocket is mounted to

the front of the camshaft and is driven by the
crankshaft sprocket through the camshaft timing chain.
The crankshaft sprocket is splined and drives the oil
pump driven gear. A retaining plate mounted to
the front of the engine block maintains camshaft
location.

Engine

Crankshaft
The crankshaft is cast nodular iron: The crankshaft is
supported by five crankshaft bearings. The bearings
are retained by crankshaft bearing caps which
are machiped with the engine block for the proper
alignment and clearance. The crankshaft journals are
undercut and rolled. The center main journal is the
thrust journal. A crankshaft position reluctor ring
is mounted at the rear of the crankshaft. The reluctor
ring is not servicea.ble separately.
Cylinder Heads
The cylinder head assembHes are cast .aluminum and
have pressed in place powdered metal valve guides
and valve seats. Passages for the vapor ventilation
system are at the front and rear of each cylinder head.
There are no exhaust gas passages within the
cylir,ider h.ead.

Engine Block
The engine block is a cam-in-block deep skirt .
90 degree V configuration with five crankshaft bearing
caps. The engine block is aluminum with cast in
place iron cylinder bore liners. The five crankshaft
bearing caps each have four vertical M10 and
two horizontal MB mounting bolts: The camshaft is
supported by five camshaft bearings pressed
into the block.
Exhaust Manifolds
The exhaust manifolds are one piece fabricated
stainless steel and are a double wall design. The
exhaust manifolds direct exhaust gasses from
the combustion chambers to the exhaust system.
Each manifold has a single inlet for the Air Injection
Reaction (AIR) system and the left exhaust manifold
has a threaded opening for installation of an
oxygen sensor. Exhaust system gasses are directed
from the right exhaust manifold through the Exhaust
Gas Recirculation (EGR) pipe assembly and valve to
the intake manifold. The EGR pipe asserr1bly is
retained to the exha':!St manifold by two bolts and
sealed at the exhaust manifold flange with a gasket.
Each manifold also has an externally mounted
heat shield that is retained by rivets.

Jntake Manifold
The intake manifold is a one piece composite design
that incorporates metal threaded inserts for mounting
the fuel rail, throttle cable bracket, throttle body,
and EGR inlet pipe. The intake manifold is sealed to
the cylinder heads by eight separate non-reuseable
silicone sealing gaskets which press into the grooves
of the intake housing. The cable actuated throttle
body assembly bolts to the front of the intake manifold.
The throttle body is sealed to the intake manifold by
a one piece push in place silicone gasket. The fuel rail
assembly with eight separate fuel injectors is retained
to the intake by four bolts. The injectors are seated
in their individual manifold bores with 0-ring seals to
provide sealing. A fuel rail stop bracket is retained
at the rear of the left fuel rail by the intake manifold
mounting bolts. A snap fit Manifold Absolute Pressure
(MAP) sensor housing is mounted at the rear of

Engine Mechanical .. 5.7L

6-561

the manifold and sealed by an 0-ring seal. The MAP

sensor is installed and retained to the MAP sensor
housing. An externally mounted Exhaust Gas
Recirculation (EGR) pipe assembly installs into the top
front of the intake manifold. The EGR pipe assembly
is sealed to the intake manifold by an 0-ring seal
and is retained to the manifold by one bolt There are
no coolant passages within the intake manifold.
Oil Pan
The structural oil pan is cast aluminum. Incorporated
into the design are the oil filter mounting boss,
drain plug opening, oil level sensor mounting bore,
and oil pan baffle. The oil pan cover and oil level
sensor mount to the side of the oil pan. The alignment
of the structural oil pan to the rear of the engine
block and transmission bell housing is critical.
Piston and Connecting Rod Assemblies
The pistons are cast aluminum. The pistons use two
compression rings and one oi'I control ring assembly.
The piston is a low friction, lightweight design with
a flat top and barrel shaped skirt. The piston pins are
chromium steel. They have a floating. fit in the
piston and are retained by a press fit in the connecting
rod. The connecting rods are powdered metal. The
connecting rods are fractured at the connecting
rod journal and then machined for the proper
clearance.,
Valve Rocker Arm Cover Assemblies
The valve rocker arm covers are cast aluminum and
use a pre-molded silicone gasket for sealing. Mounted
to each rocker cover are four individual ignition
coils. Incorporated into the covers are the oil fill tube,
the Positive Crankcase Ventilation (PCV) system
passages, and the engine fresh air passages.
Valve Train
Motion is transmitted from the camshaft through the
hydraulic roller valve lifters and tubular pushrods to the
roller type rocker arms. The valve lifter guides
position and retain the valve lifters. The valve rocker
arms for each bank of cylinders are mounted on
pedestals.(pivot supports). Each rocker arm is retained
on the pivot support and cylinder head by a bolt.
Valve lash is net build.

New Product Information

The purpose of New Product Information is to highlight
or indicate important product changes from the
previous model year.
Changes may include one or more of the
following items:
Torque values and/or fastener tightening strategies
Changed engine specifications
New sealants and/or adhesives
Disassembly and assembly procedure revi~ions
Engine mechanical diagnostic procedure revisions
New special tools required
A component comparison from the previous year

6-562

Engine Mechanical. - 5.7L

Torque Values and/or Fastener Tightening

Strategies
All fasteners and threaded holes on the LS1
engine utilize metric threads.
Cylinder head, connecting .rod, crankshaft
. balancer, and main bearing cap bolts now apply a
torque angle strategy.
Certain fasteners should not be reused. Bolts,
studs, or other fasteners that must be replaced will
be called out in the specific service procedure.
Refer to Fastener Tightening Specifications and
Thread Repair Specifications.

Changed Engine Specifications

Cylinder honing is permitted on the 1998 LS1
cylinder block.
A 0.25 mm (0.010 in) oversize piston and piston
ring set are available for service.
Refer to Engine Mechanical Specifications.

New Sealants and/or Adhesives

Threadlocking material is used on the fuel rail,
intake manifold, cylinder head M8, and exhaust
manifold bolt threads.
A pipe sealant type material is used on the engine
block coolant and oil gallery plugs, oil pressure
sensor threads, and engine block oil pan surface.

Engine
A Component Comparison from the Previous Year
The 1997 5. 7 liter LT1 engine has been replaced
by the new 5.7 liter LS1 engine.
Some of the new features include:
LT1 has a iron cylinder block. LS1 has an
alumin.um cylinder block with cast in place steel
liners.
LT1 has a cast aluminum one piece intake
manifold. LS1 has a composite one piece
design
LT1 crankshaft has two bolt main caps with
the thrust bearing in the number five journal.
The LS1 crankshaft has six bolt main caps with
the thrust bearing in the number three
journal.
LT1 ignition system includes one ignition coil.,
crankshaft sensor, and a distributor assembly.
LS1 ignition system includes a crankshaft
sensor, camshaft sensor, and eight individual
ignition coils.
LT1 has a stamped steel oil pan. LS1 has a
cast aluminum structural oil pan.
Refer to Disassembled Views and Engine
Component Description.

Engine Identification

Refer to Sealers, Adhesives, and Lubricants.

Disassembly and Assembly Procedure Revisions

Dowell pins align and position the LT1 front
cover and rear crankshaft oil seal housing to the
engine block.
The LS1 front and rear engine covers are
adjustable and must be aligned properly with the
oil pan surface and crankshaft assembly.
The LS1 oil pan is a structural member of the
powertrain and must be aligned properly with
the rear of the engine block and transmission
bellhousing.
Crankshaft balancer installation has a specific
procedure to ensure complete installation.

Engine Mechanical Diagnostic Procedure

Revisions
Base Engine Misfire, Valve Train, and other diagnostic
information is now provided in table form. Potential
or probable causes are supplied for each specific
concern.

New Special Tools Required

A variety of new tools have been developed to
assist in engine disassembly, assembly, and
on-vehicle service.
Refer to Special Tools.

63234

The 5.7 Litre LS1 engine has two locations where

information is stamped on the block to identify
the component. Location one is the primary stamping
location. Location two is the secondary stamping
location. Both stamping locations contain the engine
identification numbers.

Engine

Engine Mechanical - 5.7L

6-563

Lubrication
Lubrication Flow Schematic

t
<;:::l

u
63257

Engine lubrication is supplied by a gerotor type oil

pump assembly. The pump is mounted on the front of
the engine block and driven directly by the crankshaft
sprocket. The pump gears rotate and draw oil from
the oil pan sump through a pick-up screen and pipe.
The oil is pressurized as it passes through the
pump and is sent through the engine block oil galleries.
Contained within the oil pump assembly is a pressure
relief valve that maintains oil pressure within a
specified range. Pressurized oil is directed through the
lower gallery to the full flow oil filter where harmful
contaminants are removed. A bypass valve is
incorporated into the oil pan which will permit oil flow

in the event the filter becomes restricted. At the rear

of the block, oil is then directed to the upper main
oil galleries which are drilled just above the camshaft
assembly. From there oil is then directed to the
crankshaft and camshaft bearings. Oil that has entered
the upper main oil galleries also pressurizes the
valve lifter assemblies and is then pumped through
the pushrods to lubricate the valve rocker arms
and valve stems. Oil returning to the pan is directed
by the crankshaft oil deflector. Oil temperature,
pressure and crankcase level are each monitored by
individual sensors.

6-564

Engine Mechanical - 5.7L

Engine
Oil Pump Assembly

64190

Legend
(1)
(2)
(3)
(4)

Driven Gear
Oil Pump Housing
Pressure Relief Valve
Pressure Relief Valve Spring

. (5)
(6)
(7)
(8)

Thread Repair

Plug
Drive Gear
Cover Bolt
Cover

installed to the proper depth, the flange of the insert

will be seated against the counterbore of the
repaired hole.

General Thread Repair

Cautio.n: Wear safety glasses in order to avoid eye

damage.

Tools Required
J 42385-200 General Threads Kit

Important: The use of a cutting type fluid GM

P/N 1052864, WO 40, or equivalent is recommended

when performing the drilling, counterboring, and

tapping procedures.
Driver oil MUST be used on the installer driver tool.
The tool kits are designed for use with either a suitable
tap wrench or drill motor.

320675

The Time Sert thread repair process involves a solid,

thin walled, self-locking, carbon steel, bushing type
insert (1 ). During the bushing installation process, the
driver tool expands the bottom external threads of
the insert into the base material (2). This action
mechanically locks the insert in place. Also, when

Engine

Engine Mechanical - 5.7L

1

6-565
2

320670

1. Drill out the threads of the damaged hole (1 ).

320670

5. Using a tap wrench (2), tap the threads of the

drilled hole.

M6 inserts require a minimum drill depth of

15 mm (0.59 in).

M6 inserts require a minimum tap depth of

15 mm (0.59 in).

M8 inserts require a minimum drill depth of

20 mm (0.79 in).
M10 inserts require a minimum drill depth of
23.5 mm (0.93 in).
2. Using compressed air, clean out any chips.

M8 inserts require a minimum tap depth of

20 mm (0.79 in).
M1 O inserts require a minimum tap depth of
23.5 mm (0.93 in).
6. Using compressed air, clean out any chips.

7. Spray cleaner GM P/N 12346139, P/N 12377981,

or equivalent into the hole.
8. Using compressed air, clean any cutting oil and
chips out of the hole.

320672

3. Counterbore the hole to the full depth permitted

by the tool (1 ).

4. Using compressed air, clean out any chips.

313562

Important: Do not allow oil or other foreign material to

contact the outside diameter (OD) of the insert.
9. Lubricate the threads of the installer tool (2) with
the driver oil (1 ).

6-566

Engine Mechanical - 5.7L

Engine

'

'
313567

10. Install the insert (2) onto the driver tool (1).

320673

12. Install the insert (2) into the hole.

Install the insert until the flange of the insert
contacts the counterbored surface. Continue to
rotate the in.staller tool (1) through the insert.
The installer tool will tighten up before screwing
completely through the insert. This is acceptable.
You are forming the bottom threads of the
insert and mechanically locking the insert to the
base material threads.

(
2

313572

11. Apply threadlock Loctite277, J 42385-109 (1), or

equivalent to the insert OD threads (2).

320675

13. Inspect the insert for proper installation into

the hole.
A properly installed insert (1) will be either flush or
slightly below flush with the surface of the base
material (2).

Engine

Engine Mechanical - 5.7L

6-567

Cylinder Head Bolt Hole Thread Repair

Tools Required

J 42385-100 Cylinder Head/Main Bearing Bolt Kit

J 42385-300 Fixtures and Hardware Kit

313574

Caution: Wear safety glasses in order to avoid eye

damage.
Important: The use of a cutting type fluid GM
P/N 1052864, WD 40, or equivalent is recommended
when performing the drilling and tapping procedures.
Driver oil MUST be used on the installer driver tool.
The tool kits are designed for use with either a suitable
tap wrench or drill motor.

2. Install the fixture plate (3), bolts (1 ), and bushing

(2) onto the engine block deck.

Position the fixture plate and bushing over the

hole that is to be repaired (4).
313560

1. The cylinder head bolt hole thread repair kit

consists of the following items:
Drill (1)

~1

'

'

Tap (2)
Installer (3)
Sleeve (4)
Alignment Pin (5)
Bushing (6)
Bolts (7)
Fixture Plate (8)

313577

3. Position the alignment pin (1) through the bushing

and into the hole.
4. With the alignment pin in the desired hole, tighten
the fixture retaining bolts (2).
5. Remove the alignment pin from the hole.

6-568

Engine Mechanical - 5.7L

15

13

12

11

........

........

........

Engine

14

:J
309861

260150

6. Cylinder head bolt holes 1-8 are the deep holes

and will be drilled without the drill sleeve.
Cylinder head bolt holes 9 and 1O are the
shallower holes, drilling MUST be done with the
drill sleeve in place.

Important: During the reaming process, it is necessary

to repeatedly remove the drill and clean the chips
from the hole.

8. Drill out the threads of the damaged hole.

Drill the hole until the stop collar of the drill bit or
the sleeve contacts the bushing.
9. Using compressed air, clean out any chips.

'
313570

7. Install the sleeve (2) onto the drill (1) (if required).
320667

1O. Using a tap wrench, tap the threads of the

drilled hole.

Engine

Engine Mechanical - 5,7L

6-569

2
377637

11. In order to tap the new threads to the proper

depth, rotate the tap into the hole until the
marks (1 or 4) on the tap align with the top of the
drill bushing (3).
For the deeper cylinder head bolt holes '(1-8),
rotate the tap until the upper mark on the tap (4)
aligns with. the top of the drill bushing.

313562

Important: Do not allow oil or other foreign material to

contact the outside diameter (OD) of the insert.
16. Lubricate the threads of the installer tool (2) with
the driver oil (1 ).

For the shallower cylinder head bolt ..

holes (9 and 10), rotate the tap until the lower
mark on the tap (1) aligns with the top of the drill
bushing.
12. Remove the fixture plate (2), bushing (3),
and bolts.
13. Using compressed air, clean out any chips.
14. Spray cleaner GM P/N 12346139, P/N 12377981,
or equivalent into the hole.

'

15. Using compressed air, clean any cutting oil and

chips out of the hole.

'
313567

17. Install the insert (2) onto the driver tool (1).

6-570

Engine Mee hanical - 5.7L

Engine
. Cap Bolt Hole Thread Repair
Main

Too Is Required
C l"nder Head/Main Bearing
.
. Bolt Kit
J 42385-100 Y I
d Hardware Kit
J 42385-300 Fixtures an
--- I

J 42385-109 (1), or
ly threadlock ~ocrte
~ OD277,
threads (2 ).
equ1va1ent to the msee~_::.:~-------_
18. App_

tr

. kit consists
. cap bolt
The mam
. hole
s thread repair

1. of the following item .

Drill (1)

Tap (2)
Installer (3)
.
rt and driver (1) into the ho~e.
Install the mse
til the mark on th
19. Rotate the d~ivetrh~~e~~ surface of the
l"gns with
tool a '
k
screwing
engine bloc . I will tighten up belosreacceptable.
The installer too h the insert. This I f the
completely thro~~he bottom thre~dsi~sert to the
formmhanically
locking t e
You
.
rtare
and
mec
al
threads.
mse
base maten

Fixture Plate (4)

Long Bolts (5)
Short Bolts (6)
Alignment Pin (7)
Bushing (8)

Engine Mechanical - 5.7L

Engine

6-571

J 42385-306

377630

2. Install the fixture plate, bolt, and bushing, onto the

engine block.
Position the fixture plate and bushing over the
hole that is to be repaired.
3. Position the alignment pin in the desired hole and
tighten the fixture retaining bolts.

19

377637

6. Using a tap wrench, tap the threads of the

drilled hole.
In order to tap the new threads to the proper
depth, rotate the tap into the hole until the mark
on the tap aligns with the top of the bushing.
For the deeper main cap holes (1-10), rotate the
tap until the upper mark (4) on the tap aligns
with the top of the bushing (3).
For the shallower main cap holes (11-20), rotate
the tap until the lower mark (1) on the tap
aligns with top of the bushing (3).
7. Using compressed air, clean out any chips.
8. Spray cleaner GM P/N 12346139, or equivalent
into the hole.
9. Using compressed air, clean any cutting oil and
chips out of the hole.

9
10

20

63214

4. Drill out the damaged hole.

The outer bolt hole locations (11-20) have the
shallower counterbores. Use sleeve J 42385-316
with the drill.
Drill until the stop collar of the drill bit or the
sleeve contacts the bushing.

5. Using compressed air, clean out any chips.

313562

Important: Do not allow oil or other foreign material to

contact the outside diameter (OD) of the insert.
10. Lubricate the threads of the installer tool (2) with
the driver oil (1).

6-572

Engine ,Mechanical - 5. 7L

Engine

2
'

'
313567

11. Install the insert (2) onto the driver tool (1 ).

377635

Important: The fixture plate and bushing remains

installed onto the engine block during the insert
installation procedure.

13. Install the insert and driver (1) through the fixture
plate and bushing and into the hole.
Rotate the driver tool until the mark on the tool (3)
aligns with the top of the bushing (2).
The installer tool will tighten up before screwing
completely through the insert. This is acceptable.
You are forming the bottom threads of the
insert and mechanically locking the insert to the
base material threads.

Cleanliness and Care

Throughout this section, it should be understood
that proper cleaning and protection of machined
surfaces and friction areas is part of the repair
procedure. This is considered standard shop
practice even if not specifically stated.
313572

12. Apply threadlock Loctite 277, J 42385-109 (1), or

equivalent to the insert OD threads (2).

When any internal engine parts are serviced, care

and cleanliness is important.
When components are removed for service, they
should be marked, organized or retained in a
specific order for reassembly.
Refer to Separating Parts.
At the time of installation, components should be
installed in the same location and with the same
mating surface as when removed.
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces
with tolerances that are measured in millimeters or
thousandths of an inch. These surfaces should
be covered or protected to avoid component
damage.
A liberal coating of clean engine oil should be
applied to friction areas during assembly.
Proper lubrication will protect and lubricate friction
surfaces during initial operation.

Engine

)
I

Engine Mechanical - 5.7L

6-573

Replacing Engine Gaskets

Use of RTV and Anaerobic Sealer

Gasket Reuse and Applying Sealants

Pipe Joint Compound

Tools Required

Important: Three types of sealer are commonly used

in engines. These are RTV sealer, anaerobic gasket
eliminator sealer, and pipe joint compound. The correct
sealer and amount must be used in the proper location
to prevent oil leaks. DO NOT interchange the three
types of sealers. Use only the specific sealer or the
equivalent as recommended in the service procedure.

J 28410 Gasket Remover

Do not reuse any gasket unless specified.

Gaskets that can be reused will be identified in
the service procedure.
Do not apply sealant to any gasket or sealing
surface unless called out in the service
information.

Separating Components
Use a rubber mallet to separate components.
Bump the part sideways to loosen the
components.
Bumping should be done at bends or reinforced
areas to prevent distortion of parts.

Cleaning Gasket Surfaces

Remove all gasket and sealing material from the
part using the J 28410 or equivalent.
Care must be used to avoid gouging or scraping
the sealing surfaces.
Do not use any other method or technique to
remove sealant or gasket material from a part.
Do not use abrasive pads, sand paper, or power
tools to clean the gasket surfaces.
- These methods of cleaning can cause
damage to the component sealing surfaces.
- Abrasive pads also produce a fine grit
that the oil filter cannot remove from the oil.
- This grit is abrasive and has been known to
cause internal engine damage.

Assembling Components
When assembling components, use only the
sealant specified or equivalent in the service
procedure.
Sealing surfaces should be clean and free of
debris or oil.
Specific components such as crankshaft oil seals
or valve stem oil seals may require lubrication
during assembly.
Components requiring lubrication will be identified
in the service procedure.
When applying sealant to a component, apply the
amount specified in the service procedure.
Do not allow the sealant to enter into any blind
threaded holes, as it may prevent the bolt
from clamping properly or cause component
damage when tightened.
Tighten bolts to specifications. Do not overtighten.

Pipe joint compound is a pliable sealer that does

not completely harden. This type sealer is used
where two non-rigid parts (such as the oil pan and
the engine block) are assembled together.
Do not use pipe joint compound in areas where
extreme temperatures are expected. These areas
include: exhaust manifold, head gasket, or other
surfaces where gasket eliminator is specified.
Follow all safety recommendations and directions
that are on the container.
To remove the sealant or the gasket material, refer
to Replacing Engine Gaskets
Apply the pipe joint compound to a clean surface.
Use a bead size or quantity as specified in the
procedure. Run the bead to the inside of any bolt
holes. Do not allow the sealer to enter any blind
threaded holes, as it may prevent the bolt from
clamping properly or cause component damage
when the bolt is tightened.
Apply a continuous bead of pipe joint compound to
one sealing surface. Sealing surfaces to be
resealed must be clean and dry.
Tighten the bolts to specifications. Do not
overtighten.

RTV Sealer
Room Temperature Vulcanizing (RTV) sealant
hardens when exposed to air. This type sealer
is used where two non-rigid parts (such as
the intake manifold and the engine block) are
assembled together.
Do not use Room Temperature Vulcanizing (RTV)
sealant in areas where extreme temperatures are
expected. These areas include: exhaust
manifold, head gasket, or other surfaces where a
gasket eliminator is specified.
Follow all safety recommendations and directions
that are on the container.
To remove the sealant or the gasket material,
refer to Replacing Engine Gaskets
Apply RTV to a clean surface. Use a bead size as
specified in the procedure. Run the bead to the
inside of any bolt holes. Do not allow the sealer to
enter any blind threaded holes, as it may
prevent the bolt from clamping properly or cause
damage when the bolt is tightened.
Assemble components while RTV is still wet
(within 3 minutes). Do not wait for RTV to skin over.
Tighten bolts to specifications. Do not overtighten.

6-574

Engine Mechanical - 5.7L

Anaerobic Sealer
Anaerobic gasket eliminator hardens in the
absence of air. This type sealer is used where two
rigid parts (such as castings) are assembled
together. When two rigid parts are disassembled
and no sealer or gasket is readily noticeable,
the parts were probably assembled using a gasket
eliminator.
Follow all safety recommendations and directions
that are on the container.
To remove the sealant or the gasket material,
refer to Replacing Engine Gaskets
Apply a continuous bead of gasket eliminator to
one flange. Surfaces to be resealed must be
clean and dry.
Spread the sealer evenly with your finger to get a
uniform coating on the sealing surface.
Do not allow the sealer to enter any blind threaded
holes, as it may prevent the bolt from clamping
properly or cause damage when tightened.
Important: Anaerobic sealed joints that are partially
torqued and allowed to cure more than five minutes
may result in incorrect shimming and sealing
of the joint.
Do not allow the sealer to enter any blind threaded
holes, as it may prevent the bolt from seating properly
or cause damage when the bolt is tightened.
Tighten bolts to specifications. Do not overtighten.
After properly tightening the fasteners, remove
the excess sealer from the outside of the joint.

Separating Parts
Important: Many internal engine components will
develop specific wear patterns on their friction
surfaces.
When disassembling the engine, internal components
MUST be separated, marked, or organized in a
way to ensure reinstallation to their original location
and position.

Engine
Connecting rod to the crankshaft journal
Connecting rod to the bearing cap
A paint stick or etching/engraving type tool are
recommended. Stamping the connecting rod
or cap near the bearing bore may affect
component geometry.
Crankshaft main and connecting rod bearings
Camshaft and valve lifters
Valve lifters, guides, pushrods, pivot supports and
rocker arms
Valve to the valve guide
Valve spring and shim to the cylinder head
location
Engine block main bearing cap location and
direction
Oil pump drive and driven gears

Tools and Equipment

Special tools are listed and illustrated throughout this
section with a complete listing at the end of the
section. These tools (or their equivalents) are specially
designed to quickly and safely accomplish the
operations for which they are intended. The use of
these special tools will also minimize possible damage
to engine components. Some precision measuring
tools are required for inspection of certain critical
components. Torque wrenches and a torque angle
meter are necessary for the proper tightening of
various fasteners.
To properly service the engine assembly, the following
items should be readily available:
Approved eye protection and safety gloves
A clean, well-lit, work area
A suitable parts cleaning tank
A compressed air supply
Trays or storage containers to keep parts and
fasteners organized
An adequate set of hand tools
Approved engine repair stand
An approved engine lifting device that will
adequately support the weight of the components

Separate, mark, or organize the following components:

Piston and the piston pin
Piston to the specific cylinder bore
Piston rings to the piston

r\

Engine

Engine Mechanical - 5.7L

Special Tools and Equipment

Illustration

Illustration

6-575

Tool Number/ Description

Tool Number/ Description

)
J 8062
Valve Spring Compressor
(head off-vehicle)

J 3049-A
Valve Lifter Remover

3414
14487

J 8087
Cylinder Bore
Checking Gauge

J 6125-18
Slide Hammer

5110
4865

Engine

6-576 Engine Mechanical - 5.7L

Tool Number/. Description

Illustration

Illustration

Tool Number/ Description

J 25034-B
Power Steering Pump
Remover

J 9666
Valve Spring Tester

5112

675

J 22794
Spark Plug Port Adapter

26998

J 28410
Gasket Remover

54479

J 24086-C

J 28428-E

Piston PirlRemover/lnstaller

Leak Detector Kit

14495

62292

J 24270
Cylinder Ridge Remover

3412

676

J 28467-B
Universal Support Fixture

220640

J 25033-B

J 33049

Power Steering Pump

Installer

Camshaft Bearing
Remover/Installer

5118

Engine

Engine Mechanical - 5.7L 6-577

Illustration

Tool Number/ Description

Tool Number/ Description

Ulustration

)
J 38606
Valve Spring Compressor
(head on-vehicle)

J.34730-1A
Fuel Pressure Gauge

5389

40271

J 36462-A
Engine Support Adapter Leg

220642

J 38722
Compression Gauge

62293

J 36660
Torque Angle Meter

3413

J 39580
Engine Support Table

82341

J 37378-1
Valve Guide Reamer

J 39580-500
Engine Support Table Top

74284

J 38836
Pilot Bushing Installer/Clutch

J 41044
Engine Support Adapters

18093
220634

6-578

Engine Mechanical .. 5.7L

Illustration

Engine

Tool Number/ Description

J 41476

Illustration

Tool Number/ Description

J 41558

Front and Rear Cover

Alignment (at crankshaft
seal area)

64207

Crankshaft Sprocket
Remover

98060

J 41478
Crankshaft Front Oil Seal
Installer

64248

J 41665
Crankshaft Balancer and
Sprocket Installer

64240

J 41479

J 41712

Crankshaft Rear Oil Seal

Installer

64249

Oil Pressure Sensor Socket

9192

J 41480
J 41798

Front and Rear Cover

Alignment (at oil pan
surface)

64211

(}]))

()));})) 11

Engine Lifting Brackets

74283

J 41556

J 41816

Connecting Rod Guide

Crankshaft Balancer
Remover

(
64260

54474

Engine

Engine Mechanical - 5.7L

Illustration

Tool Number/ Description

Illustration

Tool Number/ Description

J 42385-200
Thread Repair Kit (General
Threads)

J 41816-2
Crankshaft End Protector

98058

54577

J 41818
Crankshaft Bearing Cap
Remover

J 42385-300
Thread Repair Kit (Fixtures
and Hardware)

38515

54577

J 42078

'

Valve Stem Oil Seal Installer

98042

91
JJJJ

J 42451
Engine Support Adapter Kit

220638

J 42386

J 42907

Flywheel Holding Tool

Oil Pressure Testing Tool

13545

54471

J 42385-100

J 43276
Clutch Pilot Bearing
Remover

Thread Repair Kit (Cylinder

Head/Main Bearing Bolt)

)
54577

6-579

355040

6-580

Engine Cooling

Engine

Engine Cooling
Specifications

(
Fastener Tightening Specifications
Application

Lb Ft

Nm

Lbln

Accelerator and Cruise Control Servo Cable Adjuster Bolt

7.5

Air Cleaner Bolt

12

106

Air Conditioning Condenser Tube Bolt

16

12

Air Conditioning Condenser Tube Nut

16

12

Coolant Heater Bolt (3.8L)

1.9

17

Coolant Heater (5.7L)

40

30

Coolant Pump Bolt (5.7L)

25

18

Coolant Pump Pulley Bolt (5.7L) - First Pass

10

89

Coolant Pump Pulley Bolt (5.7L) - Last Pass

25

18

Coolant Recovery Reservoir Bolt

12

106

Cooling Fan Motor Bolts

53

Drive Belt Tensioner Bolt

50

37

EGR Valve Outlet Pipe Bolt

29

21

EGR Valve Outlet Pipe Nut

29

21

Engine Coolant Temperature Sensor (3.8L)

25

18

Engine Coolant Temperature Sensor (5.7L)

29

21

Engine Block Coolant Drain Hole Plug (5.7L)

60

44

Knock Sensor (3.8L)

19

14

Air Lower Deflector Screw

10

89

Radiator Drain Cock

1.5

13

Transmission Oil Cooler Pipe Fittings at Radiator

27

20

Water Outlet Bolt (3.8L)

27

20

Water Outlet Bolt (5.7L)

15

11

Water Pump Bolt (3.8L)

15

11 + 80

Water Pump Pulley Bolt (3.8L)

13

66

115

Engine Cooling System Specifications

Application

Liters

11.8
11.6

I
I

14.5
14.3

I
I

Gallons

Quarts

I
I

12.5
12.3

I
I

15.3
15.1

3800 (VINK)

I
I

With Manual Transmission

With Automatic Transmission

5.7L (VIN G)

I
I

With Manual Transmission

With Automatic Transmission

GM SPO Group Numbers

Application

Cap, Radiator Filler

GM SPO Group Number

1.203

Deflectors, Radiator Air Baffles and

1.272

Driveshaft, Water Pump 5.7L (VIN P)

1.105

Hoses, Radiator Inlet and Outlet

1.173

Kit, Water Pump

1.069

Module, Engine Coolant Level Indicator 5.7L (VIN P)

1.203

Motor, Electric Engine Cooling Fan and

1.055

Engine

Engine Cooling

6-581

GM SPO Group Numbers {cont'd)

Application

GM SPO Group Number

Panel, Radiator Upper Mounting

1.270

Pipe, Engine Coolant Air Bleed 5.7L (VIN P)

1.097

Pump, Water

1.069

Radiator, Coolant

1.219

Reservoir, Coolant Recovery

1.240

Sensor, Engine Coolant Temperature

1.150

Thermostat, Engine Coolant

1.246

Schematic and Routing Diagrams

Cooling System Schematic Refer~nces
Section Number - Subsection
Name

Reference on Schematic
Fuse Block Details Cell 11

8 - Wiring Systems

Ground Distribution Cell 14

8 - Wiring Systems

Power Distribution Cell 1O

8 - Wiring Systems

Cooling System Schematic Icons

Icon

Icon Definition
Refer to ESD Notice in Cautions and Notices.

19384

Refer to OBD II Symbol Description Notice in Cautions and Notices.

19385

0,

Cooling Fan Schematics (Cooling Fans 3.8L)

~
I

L1

(RofAt All Times

COOL FAN
MaxiFuse

K1

Distribution
Cell 10

40A

J7

I, -

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mt u

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I Electrical
Center 1
1

FAN
M" "F se

JS

3 REDl402

Cell10

10A

Power

Distribution

-l~"~ -

----f---------,;.;-4 - - - IHot At AllTlmes I

U'I

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Fuse Block

/ , - -- ---+

Details

I I I~m
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Cell11

::,

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$179
0.35 ORN I 1640
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Underh<;>od ~~ [
Electrical I
Center 1 1
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- - - -

Ih

a"; __

Engine

~:ling
Relay1

-------

I I ,r

! B1 t

ll:1---Qr~~.
--,

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LT BLU 409

B_!.0

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J!C100

I:l..f ~:lay

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_________

___ -

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0.35 DK BLU 473

5 C1

--':"' ---.,
=~:
1. . f5~ay :~~~~f~
~-~------------------------------J~

Powertrain

r - - - - - - - - - - - - - - - - - - - - - - - - e1

... Control

j.

3 BLK 150
8113
Ground

Distribution
CeH 14

/ /

~ - - - - ..,

3 BLKl150

C2=CLEAR

H C100

___

~Right
Engine
M Cooling
Fan

3 GAY 532

0.35
DK BLU 473

0.35 DK GAN 335

----.,

3 WHT 504
8167
0.35 DK BLU 473 3 WHT 504

$166

Engine
Cooling
Fan

C4

Engine
Cooling
Fan
Relay2

0.35
DK BLU 473

Cooling

~ Left

0.35 DK GAN 1335

C6

B6

B9

\I

0.35 ORN I 1640

0.35 ORN I 1640

(PCM)

~G106

:::l

cc
:::l
193818

.~

~----,

CD

._/

'-./

m
:::,

Cooling Fan Schematics (Cooling Fans 5.7L)

r-

1
I

L1

K1

-?-------------

[Hof At AlfTimesJ
- - - - - - ;;,;;,- - 4- - - - - COOL FAN

MaxiFuse
40A

Distribution
Cell 10

Underhood

J7

COOLING FAN

J6

MiniFuse
10A

Electrical
Center 1

I
I

IL 0 c

I 111

jEsc

L-4-----------------+-------------J
I

3 RED I 402

0.35 ORN 1640

.... _____s_1s_s___________- - ' I ' - - - - - - - - - - - - - - - - - - - .

Fower
Distribution
Cell10

[B

$179

0.35 ORN I 1640

0.35 ORN I 1640

3 RED I 402

3REDI 402

3WHTI 504
0.35 ORN I 1640

.---

- - - - - - ... - - - - , Underhood
C4
I Electrical
.,.......,.-------""'2,......... Engine I Center 1
Cooling
I

88

B9

83

C3

C6

Engine
Cooling
Fan
Relay1

Fan
Relay2

;L;~~t~-------;G-:-1-;;; 035 r

_____ !4

C10

- -~ L

oi< BW

JJC100

r167

0.35 DK BLU 473 3 W':i 504

0.35
DKBLU I 473

Engi~e
Cooling

--aw~i 504 - - - ~

$166

Left

0.35 DK GRN I 335

73

I
I
I

~Right
Engine

Fan

Cooling

Fan

HJ C100

:::,

3 BLK I 150

0.35 DK GRN I 335

3BL: 1150

I C1

.------------

Cooling

I /
Fan
I ....f Relay1

..
I

____ ---------7----,
28

PCM
C1=RED

... Control

-:-

C2=BLU

C2

Powertrain
Fan Relay I Control
---T 2And3 I Module~
.t. Control I (PCM)
Cooling

______________ _

-;-

--------------J

.,._ ____ .I

:::,

$113

(D

0.35 DK BLU 1473

43

(C

'14.

Ground
Distribution
Cell 14

0
0

5?.

:::,

3BLK 150
G106

(C

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192886

6-584

Engine Cooling

Engine

Component Locator
Cooling System Components
Location

Name

Locator View

Engine Coolant Fans

Behind the radiator

Engine Coolant Fan

Relays

1n the underhood electrical center 1

'

Powertrain Control
Module (PCM)
(V6 VINK)

On the right side of the engine

compartment, rear of the yvheelhouse

Powertrain Control
Module (PCM)
(VB VIN G)
Underhood Electrical
Center 1

Connector End View

Cooling System
Connector End Views

Power and Grounding

Component Views

PCM Connector
End Views

On the right side of the engine

compartment, rear of the wheelhouse

Power and Grounding

Component Views

PCM Connector
End Views

On the Left front corner of the engine

compartment

Power and Grounding

Component Views

'

Engine to forward lamp harness, in the

engine compartment, above the right
wheelhouse

Harness Routing Views

G106

Attached to the top left side of the radiator

support

Harness Routing Views

8113

In the forward lamp harness approximately

7 cm (3 in) from the engine coolant
fans/cruise control

8166

Forward lamp harness, approximately

14 cm (6 in) from G105 breakout

8167

Forward lamp harness, approximately

7 cm (3 in) from electronic brake control
module (EBCM) breakout

8169

In the forward lamp harness,

approximately 6 cm (2 in) from the main
branch into the UH electrical center 1
breakout

C100 (10 cavities)

lnline Harness Connector

End Views

Engine

Engine Cooling

Cooling System Connector End Views

6-585

Right Engine Cooling Fan

Left Engine Cooling Fan

\J

--......

~0

~0 0~

0j
62489

62489

Connector Part
Information

Pin

Wire Color

1203-3769
2 Way F Metri-Pack
630 Series Pull to Seat (BLK)
Circuit
No.

Connector Part
Information

1203-3769
2 Way F Metri-Pack
630 Series Pull to Seat (BLK)

Pin

Wire Color.

Circuit
No.

BLK

150

Ground

WHT

504

Right Engine Cooling Fan

Motor Feed

Function

GAY

532

Cooling Fan Secondary

Motor Feed

LT BLU

409

Left Engine Cooling Fan

Motor Feed

Function

6-586

Engine

Engine Cooling

Diagnostic Information and Procedures

Engine Overheating

No
Value
Yes
Step
DEFINITION: Engine temperature lamp comes ON and stays ON, or the temperature gauge shows hot, or coolant overflows
from the reservoir onto the ground while the engine is running.
Check for a missing or damaged radiator upper baffle
and/or center air deflector.
1
Go to Step 2
Is the baffle or deflector missing or damaged?
Go to Step B

2
3

10
11
12

13

14

15

16

Action

Check for a loss of coolant.

Is there a loss of coolant?
Fill the system to the specified level.
Does the engine overheat?
Check for low coolant protection. Refer to Coolant
Concentration Testing
Is the coolant to the correct concentration?
Check for a loss of system pressure. Refer to Pressure
Cap Testing.
Is there a loss of system pressure?
Check for a faulty engine coolant temperature (ECT)
sensor. Refer to OTC P0117 Engine Coolant Temperature
(ECT) Sensor Circuit Low Voltage or OTC P0118 Engine
Coolant Temperature (ECT) Sensor Circuit High Voltage in
Engine Controls-3.BL. or OTC P0117 Engine Coolant
Temperature (ECT} Sensor Circuit Low Voltage or
OTC P011B Engine Coolant Temperature (ECT) Sensor
Circuit High Voltage in Engine Controls-5.7L.
Is the sensor operating properly?
Check for a damaged coolant recovery reservoir or a
leaking hose. Refer to Coolant Recovery Reservoir
Replacement.
Is the reservoir cracked or is the hose leaking?
Repair or install new parts as necessary, then retest.
Does the engine overheat?
Check for incorrect drive belt tension. Refer to Drive Belt
Replacement in Engine Mechanical-3.BL or Drive Belt
Replacement (Accessory) in Engine Mechanical-5.7L.
Is the belt to the correct tension?
Check for a damaged water pump driveshaft (5.7L Only).
Is the water pump driveshaft damaged or is the seal
leaking?
Check for obstructed radiator air flow or bent radiator fins.
Is the radiator air flow obstructed?
Check for blocked cooling system passages.
Are the cooling system passages blocked?
Check for an improper direction of inoperative cooling
fans. Refer to Cooling Fan Replacement - Electric.
are the cooling fans and motors operating correctly?
Check the thermostat. Refer to Thermostat Diagnosis.
Is the thermostat stuck in the closed position?
Replace the thermostat. Refer to Thermostat Replacement
(3.BL V6) for the 3.8L or Thermostat Replacement
(5.7L VB) for the 5.7L.
Does the engine overheat?
Check for a faulty water pump. Refer to Water Pump
Replacement (3.BL V6) for the 3.8L or Water Pump
Replacement (5.7L VB)
Are the impeller blades broken or eroded?

Go to Step 3

Go to Step 4

Go to Step 4

System OK

Go to Step 5

Go to Step B

Go to Step B

Go to Step 6

Go to Step 7

Go to Step B

Go to Step B

Go to Step 3

Go to Step B

System OK

Go to Step 10

Go to Step B

Go to Step B

Go to Step 11

Go to Step B

Go to Step 12

Go to Step B

Go to Step 13

Go to Step 14

Go to Step 8

Go to Step 15

Go to Step 16

Go to Step 16

System OK

Go to Step B

Go to Step 17

Engine

Engine Cooling

6-587

Engine Overheating (cont'd)

Step

Action

Value

17

Check the radiator cooling capacity.

is the proper sized radiator being used on the vehicle?

18

Consult the current pa~s catalog and replace the radiator.

Refer to Radiator Replacement.
Is t.he repair complete?

Yes

No

Go to Step 3

Go to Step 18
-

System OK

Loss of Coolant
Step

1
2

)
7

10

11
12

13

14
15
16

Action

Check for a leaking radiator. Refer to Co9/ing System

Leak Testing.
Is the radiator leaking?
Repair or install new parts as necessary.
Is the repair complete?
Check for a leaking heater core.
Refer to Cooling System Leak Testing.
Is the heater core leaking?
Check for a faulty radiator fill cap. Refer to Pressure Cap
Testing.
Is the cap operating properly?
Check for a leaking coolant recovery hose, a cranked
recovery reservoir. Refer to Coolant Recovery Reservoir
Replacement.
Is the reservoir or the hose leaking?
Check for any loose or damaged hoses or connections.
Are any hoses damaged or are any hose connections
leaking?
Check for a cracked thermostat housing or a leaking
thermostat seal. Refer to Thermostat Replacement
(3.BL V6) for 3.8L or Thermostat Replacement (5.7L VB)
for 5.7L.
Is the thermostat housing cracked or is there a seal leak?
Check for a cracked water pump or a leaking water pump
gasket.
Is the water pump cracked or is there a leaking gasket?
Check for a leaking water pump driveshaft seal
(5.7L Only).
Is the water pump shaft seal leaking?
Replace the water pump. Refer to Water Pump
Replacement (3.BL V6) for 3.8L or Water Pump
Replacement (5.7L VB) for 5.7L.
Is the repair complete?
Check for a leaking engine block coolant drain hole plug or
knock sensor.
Are any drain plugs or knock sensors leaking?
Check for any leaking cylinder head core plugs.
Are the cylinder head core plugs leaking?
Check for a leaking cylinder head gasket(s), vent(s) or a
cracked cylinder head.

Is the cylinder head gasket leaking or is the cylinder head

cracked?
Check for a cracked throttle body or a gasket leak.
Is the throttle body cracked or is there a gasket leak?
Check for a cracked engine block.
Is the engine block cracked?
Check for any porous castings.
Are the castings OK?

Value

Yes

No

Go to Step 2

Go to Step 3

System OK

Go to Step 2

Go to step 4

Go to Step 5

Go to Step 2

Go to Step 2

Go to Step 6

Go to Step 2

Go to Step 7

Go to Step 2

Go to Step 8

Go to Step 2

Go to Step 9

Go to Step 10

Go to step 11

System OK

Go to Step 11

Go to Step 2

Go to Step 12

Go to Step 2

Go to Step 13

Go to Step 2

Go to Step 14

Go to Step 2

Go to Step 15

Go to Step 2

Go to Step 16

System OK

6-588

Engine

Engine Cooling

Thermostat Diagnosis

Check the operation of the thermostat by hanging the

thermostat on a hook in a 33 percent glycol solution.

Thermostat Testing Procedure

In order to check if the thermostat valve is opening

properly, perform the following test:
1. Completely submerge the thermostat in the glycol
solution. The solution should be 11 C (22F)
above the temperature indicated on the
thermostat valve.
2. Thoroughly agitate the solution. Under these
conditions, the thermostat valve should open.
In order to check if the thermostat valve is closing
properly, perform the following test:
1. Completely submerge the thermostat in the glycol
solution. The solution should be 6C (10F) below
the temperature indicated on the thermostat valve.

2. Thoroughly agitate the solution. Under these

conditions, the thermostat valve should close
completely.

13758

Engine Fails To Reach Normal Operating Temp

Step

Action

Value(s)

Yes

No

System OK

Go to Step 2

System OK

Go to Step 3

Notice: When adding coolant, use DEX-COOL coolant. If

silicated coolant is added to the system, premature engine,
heater core or radiator corrosion may result. In addition,
the engine coolant will require change sooner-at
50,000 km (30,000 mi) or 24 months.

1. Check the level of the coolant in the coolant recovery

reservoir. The coolant level should be at the FULL
COLD mark.

2. Add engine coolant as necessary.

Does the engine reach normal operating
temperature now?

1. Check for a blockage in the coolant passages.

2. Flush the cooling system or flow check the radiator.
Refer to Flushing.
Does the engine reach normal operating
temperature now?

1. Check to see if the correct type of thermostat was

installed.

2. Check if the thermostat is stuck in the open position.

Refer to Engine Overheating.
3. If necessary, replace the thermostat.
On the 3800 (VIN K) engine, refer to Thermostat
Replacement (3.BL V6).
On the 5.7L (VIN P) engine, refer to Thermostat
Replacement (5. 7L VB)
Does the engine reach normal operating temperature?

System OK

Engine Cooling

Engine

6-589

Testing Procedure

Coolant Concentration Testing

Some coolant manufacturers mix other types of glycol
into their coolant formulations. Propylene glycol is
the most common new ingredient.
A hydrometer does not always provide a correct
measurement of freeze protection when anything other
than ethylene glycol and water is being tested. The
degree of inaccuracy varies depending on the
proportion of other glycols present in the coolant.
All new GM vehicles are produced with coolant that
can be accurately measured with a hydrometer;
however, when the type and quality of coolant being
measured is unknown, such as a customer vehicle that
has accumulated mileage, the use of the refractometer
is recommended.
Coolant testers J 23688 (Fahrenheit Scale) or J 26568
(Centigrade Scale) can be used to check the
antifreeze protection of the coolant, make sure the
refractometer markings are correct. Unless J 23688 or
J 26568 has a provision for temperature correction,
test the temperature at which J 23688 or J 26568
is calibrated. If the coolant is warmer or cooler, the
reading may be incorrect. Follow the manufacturer's
directions on using J 23688 or J 26568.

Cleaning The Instruments

Tools Required

J 23688 Coolant and Battery Fluid Tester

(Fahrenheit Scale)
J 26568 Coolant and Battery Fluid Tester
(Centigrade Scale)

13709

1. Release the clear plastic dropper, located on the

side of the J 23688 or J 26568 should be used to
draw the test sample.
2. Ensure that the dropper is free of any previous
sample before starting the testing procedure.
3. Dip the end of the plastic dropper into the coolant
without removing it from the tester. Be sure to
insert the tube slightly below the fluid level.
4. Press and release the bulb to draw a sample of
the coolant.

J 23688 or
J 26568

402834
13712

1. To clean, swing back the plastic sample cover

located at the slanted end of the J 23688
or J 26568.
2. Wipe clean both the prism and the bottom of the
sample cover.
3. Close the sample cover.

5. Bend the plastic tube around the J 23688 or

J 26568 so that the tip can be inserted in the
sample cover opening.
6. Eject a few drops of the coolant onto the
measuring prism by pressing the bulb. take
a reading.

6~590

Engine Cooling

Engine

7. The J 23688 or J 26568 are equipped with an

eyeguard that can be used in two positions.
When wearing eyeglasses, the eyeguard should
be folded back; when no eyewear is worn the
eyeguard should be extended. Proper positioning
of the eyeguard will help eliminate stray light
and improve image quality.

Important: The temperature scale is reversed from a

standard thermometer scale. Readings below
O degrees are on the upper half of the scale. The
scale is not visible until a sample is placed on
the prism. If the concentration of the solution tested is
greater than the limits of the scale, the shadow will
not be visible.

10. To obtain the best contrast between the light and

dark portions of the scale, tilt the J 23688 or
J 26568 toward a light source. If the edge between
the light and dark shadow is not sharp, the
measuring prism was not sufficiently clean and
dry or there was not enough fluid on the
measuring prism.

Calibrating Testers
The J 23688 and the J 26568 are factory calibrated
and sealed. The testers should not require adjustment.
If adjustment is required, do the following adjust
procedure:
1 . Make sure the temperature of the J 23688 and
the J 26568 is between 21 and 29 degrees
Centigrade (70 and 85 degrees Fahrenheit).

2. Using distilled water, take a reading.

3. If the reading departs from a O degrees Centigrade
(32 degrees Fahrenheit) reading on the scale,
perform the following:
3.1. Remove the sealant covering the screw.
3.2. Turn the screw in the direction necessary to
adjust the reading to the O degrees
Centigrade (32 degrees Fahrenheit) line.

Important: Never REMOVE the screw from the

J 23688 or J 26568.
3.3. Reseal the screw using silicone sealant.

Cooling System Leak Testing

Leak Testing (On Vehicle)

402832

8. To take a reading, point the J 23688 or J 26568

toward any light source and look into the
eyepiece.
80(83"'1

1.-too---

-iOIU"')

<i""I

-~%)
-20 (49%)

1.250--==--

-10(44%)

5(., ..l
O{SS%>
+&(34'%}

Tools Required

J 24460-01 Cooling System and Cap Pressure Tester

Caution: Under pressure, the temperature of
the solution in the radiator can be considerably
higher, without boiling. Removing the radiator cap
while the engine is hot (pressure is high}, will
cause the solution to boil instantaneously, with
explosive force. The solution will spew out
over the engine, fenders, and the person removing
the cap. Serious bodily injury may result.
Flammable antifreeze, such as alcohol, is not
recommended for use at any time. Flammable
antifreeze could cause a serious fire.

"+10(30'!4)

1.100

=---

Caution: In order to help avoid being burned, do

not remove the radiator cap while the engine
and the radiator are hot. Scalding fluid and steam
can be blown out under pressure if the cap is
removed too soon.

+:ZO (19%)

BATIERV
CHARGE

+25 (12%~

SPECIFlC

GRI\VrTY

PROPOVLENE

GLVCOL

"F

1. After the system has cooled, remove the

radiator/surge tank pressure cap.

FREEZE POINT

("" GlYCOL BYVOl.VME)

13713

9. The coolant freeze point reading is taken where

the dark and light portions of the scale meet.
Take the coolant reading on the right-hand scale.

Engine

Engine Cooling

6-591

)
I

J.24460-01

11658

2. Connect the cooling system tester J 24460-01 to

the radiator/ surge tank.
3. Apply normal system operating pressure. Do not
exceed 138 kPa (20 psi).

1375

6. Check the radiator/surge tank cap with J 24460-01

in order to ensure the cap maintains the correct
pressure.
7. If the pressure leaks during the pressure test,
mark the leak area so the leak can be located
once the radiator has been removed from
the vehicle.

Leak Testing (Off Vehicle)

1374

4. Watch the gauge needle for an indication of a

leak. Examine all cooling system connections
and components, including the radiator and the
heater core, for leaking coolant.
5. Tighten the hose connections or repair as
required.

Tools Required
J 24460-01 Cooling System and Cap Pressure Tester
Notice: Do not use boil-out tanks or any other tank
that has been used for copper or brass radiators. The
remaining solutions or chemicals in these tanks
could cause radiator failure.
1. Plug the inlet and outlet tubes. Make sure the
drain cock is closed.
2. Attach the J 24460-01 to the radiator.
3. Apply pressure to the radiator. Do not exceed
138 kPa (20 psi) of pressure.
4. Observe the gauge for any pressure loss.
5. Run water over the repair area and look for any
bubbles. If a large tank is available, the radiator
can be submerged in order to check for air
bubbles.

Pressure Cap Testing

Radiator Fill Cap Inspection
Check the cap for a weak spring washer or
damage to the gasket. If the spring washer
is weak, or damaged replace the cap.
Check the inner sealing surface of the radiator
neck for damage or debris.

6~592

Eng.ine Cooling

Engine

Radiator Cap Pressure Testing Procedure

Caution: As long as there is pressure in the

cooling system, the temperature can be
considerably higher than the boiling temperature
of the solution in the radiator without causing
the solution to boil. Removal of the pressure cap
while the engine is hot and pressure is high
will cause the solution to boil instantaneously possibly with explosive force - spewing the
solution over the engine, fenders and the person
removing the cap.

Tools Required

J 24460-01 Cooling System Pressure Tester

1. Clean the radiator fill cap.

1375

2. Install the cap on the J 24460-01.

3. In order to obtain the minrmum holding pressure,
slowly pump the J 24460-01.
If the cap fails to hold 83 kPa ( 12 psi) of
pressure, replace the cap.
If a new cap is installed, coat the gasket with
engine coolant.

Repair Instructions
Draining and Filling Cooling System (V6)
Draining Procedure
1. Park the VE;lhicle on a level surface.
2. Remove the coolant recovery reservoir fill cap.

456596

3. Remove the radiator pressure cap (1) from the

radiator (2).
3.1. Slowly rotate the pressure cap (1)
counterclockwise until the cap (1) reaches
the detent. Do not press down while
rotating the pressure cap (1 ).
3.2. Wait until any remaining pressure, indicated
by a hissing sound, is relieved.
3.3. After all the pressure is relieved, press
down on the pressure cap (1) and continue
to rotate the pressure cap (1)
counterclockwise.
Important: Recover and store used coolant in a used
coolant holding tank and submit the used coolant
for recycling on a regular basis. DO NOT pour used
coolant down the drain! Ethylene glycol antifreeze
is very toxic. Disposing of ethylene glycol into
the sewer system or ground water is both illegal and
ecologically unsound!
4. Place a drain pan under the radiator drain cock in
order to collect all the used coolant.

Engine Cooling

Engine

6-593

II~

l~

21707

457901

5. Open the radiator drain cock.

6. Place a shop towel under the bleed valve in order
to prevent coolant from splashing onto the EGR
valve outlet pipe.
7. Open the air bleed vent on top of the water outlet
two complete turns.
8. Place a drain pan under the engine block knock
sensors in order to collect the used coolant.

10. Remove both of the engine knock sensors. (left

side shown, right side similar)
11. Allow the cooling system to drain completely.

Filling Procedure
1. Remove, clean, and reinstall the coolant recovery
reservoir. Refer to Coolant Recovery Reservoir
Replacement.

457901
187243

9. Disconnect the knock sensor electrical connectors.

(left side shown, right side similar)

)
I

2. Close the radiator drain cock.

Notice: Refer to Fastener Notice in Cautions and
Notices.

6-594

3.

Engine Cooling

Install both the engine knock sensors.

Engine

70035

21707

5. Add two engine coolant supplement sealant

pellets, GM P/N 3634621 or equivalent into
the radiator.

Tighten
Tighten the knock sensors to 19 N-m (14 lb ft).
Tighten the radiator drain cock to
1.5 Nm (13 lb in).

Notice: When adding coolant, it is important that you

use GM Goodwrench DEX-COOL or HAVOLINE
DEX-COOL coolant. If Coolant other than
DEX-COOL or HAVOLINE DEX-COOL is added to
the system the engine coolant will require change
sooner-at 50 000 km (30,000 mi) or 24 months.
6. Slowly add a 50/50 mixture of GM Goodwrench
DEX-COOL or HAVOLINE DEX-COOL and clean
drinkable water to the radiator until the coolant
level is at the base of the radiator fill neck.
7. Close the air bleed vent when the bubbles
disappear and only the coolant is visible.
8. Fill the coolant recovery reservoir to the FULL
HOT mark with a 50/50 mixture of GM
Goodwrench DEX-COOL or HAVOLINE
DEX-COOL and clean, drinkable water.
9. Install the coolant recovery reservoir cap.
1O. Run the engine until the engine reaches normal
operating temperature. The radiator inlet hose will
become hot.

187243

4. Connect the knock sensor electrical connectors.

11. After the engine reaches normal operating

temperature, check for coolant leaks.
12. Wait for two minutes and recheck the level of the
coolant in the radiator.
13. If needed, add coolant to the radiator until the
coolant level reaches the bottom of the radiator
fill neck.

Engine

Engine Cooling

6-595

Draining and Filling Cooling System (VS)

Draining Procedure
1. Park the vehicle on a level surface.
2. Remove the coolant recovery reservoir fill cap.
Caution: As long as there is pressure in the
cooling system, the temperature can be
considerably higher than the boiling temperature
of the solution in the radiator without causing
the solution to boil. Removal of the pressure cap
while the engine is hot and pressure is high
will cause the solution to boil instantaneously possibly with explosive force - spewing the
solution over the engine, fenders and the person
removing the cap.

456596

14. Install the radiator pressure cap (1) to the

radiator (2).

456596

3. Remove the radiator pressure cap (1) from the

radiator (2).

2
456597

15. Ensure that the radiator cap (1) arrows point

toward the radiator overflow tube.

Slowly rotate the pressure cap (1)

counterclockwise until the cap (1) reaches the
detent. Do not press down while rotating
the pressure cap (1).
Wait until any remaining pressure, indicated by
a hissing sound, is relieved.
After all the pressure is relieved, press down
on the pressure cap (1) and continue to
rotate the pressure cap (1) counterclockwise.

Important: Recover and store used coolant in a used

coolant holding tank and submit the used coolant
for recycling on a regular basis. DO NOT pour used
coolant down the drain! Ethylene glycol antifreeze
is very toxic. Disposing of ethylene glycol into
the sewer system or ground water is both illegal and
ecologically unsound!

4. Place a drain pan under the radiator drain cock in

order to collect all the used coolant.

6-596

Engine Cooling

Engine

II~

l--

457901

5. Open the radiator drain cock.

457157

7. Remove the left side engine block drain hole plug.

8. Allow the cooling system to drain completely.

Filling Procedure
Notice: DO NOT use cooling system seal tabs (or
similar compounds) unless otherwise instructed. The
use of cooling system seal tabs (or similar compounds)
may restrict coolant flow through the passages of
the cooling system or the engine components.
Restricted coolant flow may cause engine overheating
and/or damage to the cooling system or the engine
components/assembly.

1. Remove, clean, and reinstall the coolant recovery

reservoir. Refer to Coolant Recovery Reservoir
Replacement.

457154

6. Remove the right side engine block drain

hole plug.

457157

2. Install the left side engine block drain hole plug.

Engine

Engine Cooling

6597

8. Run the engine until the engine reaches normal

operating temperature. The radiator inlet hose will
become hot.
9. After the engine reaches normal operating
temperature, check for coolant leaks.
10. Wait two minutes and recheck the level of the
coolant in the radiator.
11. If needed, add coolant to the radiator until the
coolant level reaches the bottom of the radiator
fill neck.

.>3. Remove the right side engi.ne block drain

hole plug.

456596

12. Install the radiator pressure cap (1) to the

radiator (2).

457901

Notice: Refer to Fastener Notice in Cautions and

Notices.

4. Close the radiator drain cock.

Tighten
Tighten the drain hole plugs to
60 Nm (44 lb ft).
Tighten the radiator drain cock to
1.5 Nm (13 lb in).
5. Slowly add a 50/50 mixture of GM Goodwrench
DEX-COOL or HAVOLINE DEX-COOL and clean
drinkable water to the radiator until' the coolant
level is at the base of the radiator fill neck.
6. Fill the coolant recovery reservoir to the FULL
HOT mark with a 50/50 mixture of GM
Goodwrench DEX-COOL or HAVOLINE
DEX-COOL and clean, drinkable water.
7. Install the coolant recovery reservoir cap.

2
456597

13. Ensure that the radiator cap (1) arrows point

toward the radiator overflow tube.

6-598

Engine Cooling

Engine
Flushing
1. Block the drive wheels.
Place the transmission in Park or Neutral.
Engage the park brake.
Start the engine.
Run the engine until the thermostat opens.
Shut off the engine.
Drain the cooling system. Refer to Draining and
Filling Cooling System (V6) or Draining and
Filling Cooling System (VB).
8. Follow the drain and fill procedure using ONLY
clean drinkable water, repeat if necessary, until
the fluid being drained,is colorless.
9. Fill the cooling system. Refer to Draining and
Filling Cooling System (V6) or Draining and
Filling Cooling System (VB).

2.
3.
4.
5.
6.
7.

Radiator Cleaning
Caution: NEVER spray water on a hot radiator. The
resulting steam could cause personal injury.
Notice: The radiator fins are necessary for good heat
transfer. Do not brush the fins. This may cause
damage to the fins, reducing heat transfer.
Important: Do not brush the radiator fins. The radiator
fins are necessary for good heat transfer. Brushing
damages the fins and reduces heat transfer.
Clean the front face of the radiator annually.
Clean the front face of the condenser.
Remove bugs, leaves, etc. by blowing compressed
air through the radiator.
Blow the air from the rear toward the front. If
compressed air is not available a water hose can
be used to force water through the radiator.
Us only cool water with the engine not running.

Coolant Recovery Reservoir Replacement

Removal Procedure
1. Remove the battery. Refer to Battery Replacement
in Engine Electrical.
2. Remove the coolant recovery reservoir hose from
the radiator.

221645

Engine

Engine Cooling

5;.599

3. Remove the accelerator and cruise control servo

cable bolts, if equipped.
4. Reposition the accelerator and cruise control
servo cable adjuster, if equipped.

221646

5. Remove the coolant recovery reservoir bolt.

221653

6. Remove the wiring harness rosebud clip from the

reservoir neck.
7. Remove the coolant recovery reservoir.

221650

6-600

Engine Cooling

Engine
8. Remove the coolant recovery reservoir hose and
grommet from the reservoir.
9. Clean the coolant recovery reservoir with soap
and water. Thoroughly rinse the reservoir.

221663

Installation Procedure
1. Install the coolant recovery reservoir hose and
grommet to the reservoir.
2. Install the coolant recovery reservoir.

221663

3. Install the wiring harness rosebud clip to the

reservoir neck.

221650

Engine

Engine Cooling

6-601

Notice: Refer to Fastener Notice in Cautions and

Notices.

4. Install the coolant recovery reservoir bolt

Tighten
Tighten.the coolant recovery.reservoir bolt to
12 N-m (106 lb in).

221653

5. Position the accelerator and cruise control servo

ca~le adjuster, if equipped.

6. Install the accelerator and cruise control servo

cable bolts, if equipped.

Tighten
Tighten the servo cable adjuster bolts to
7.5 N-m (66 lb in).

221646

7. Install the coolant recovery reservoirhose to the

radiator.
8. Install the battery. Refer to Battery Replacement
in Engine Electricat
9. Add engine coolantto the FULL COLD mark pn
the reservoir.

221645

6-602

Engine

Engine Cooling

Coolant Recovery Pipe Replacement

Removal Procedure
1. Remove the coolant recovery reservoir. Refer to
Coolant Recovery Reservoir Replacement.
2. Remove the coolant recovery hose from the

reservoir.

221663

Installation Procedure
1. Install the coolant recovery hose to the 'reservoir.
2. Install the coolant recovery reservoir. Refer to
Coolant Recovery Reservoir Replacement.

221663

Vapor Vent Pipe Replacement

'

Removal Procedure
1. Remove the intake manifold. Refer to
Intake Manifold Replacement in Engine

Mechanical - 5.7L.
2. Remove the vapor vent pipe. Refer to Vapor Vent
Pipe Removal in Engine Mechanical - 5.7L.

64139

Engine

Engine Cooling

6-603

Installation Procedure

1. Install the vapor vent pipe. Refer to Vapor Vent

Pipe Removal in Engine Mechanical - 5.7L.
2. Install the intake manifold. Refer to
Intake Manifold Replacement in Engine
Mechanical - 5.7L.

'

64139

Radiator Hose Replacement - Inlet (V6)

Removal Procedure
1. Drain the engine coolant. Refer to Draining and
Filling Cooling System (V6).
2. Disconnect the (IAT) intake air temperature
sensor electrical connector.

208554

3. Remove the air intake duct.

208572

6-604

Engine Cooling

Erigirie
4. Remove the inlet hose from the water outlet.

221680

5. Remove the inlet.hese from the radiator. .

221679

Installation Procedure
1. Install the inlet hose to the radiator.

221679

Engine

Engine Cooling 6-605

2. Install the inlet ho~e to the water outlet.

221680

3. Install the air intake duct.

208572

4. Connect the IAT sensor electrical connector.

5. Fill the engine coolant. Refer to Draining and
Filling Cooling System (V6).

208554

6-606

Engine Cooling

Engine
Radiator Hose Replacement - Inlet (VS)
Removal Procedure
1. Drain the engine coolant. Refer to Draining and
Filling Cooling System (VB).
2. Disconnect the (IAT) intake air temperature
sensor and (MAF) mass airflow sensor electrical
connectors.

208553

3. Remove the air intake duct.

208569

4. Remove the inlet hose (1) from the radiator.

349797

Engine

Engine Cooling

6-607

5. Remove the inlet hose from the power steering

cooler, if equipped.
6. Remove the inlet hose from the power steering
cooler to the water pump, if equipped.

221666

7. Remove the inlet hose from the water pump.

221676

Installation Procedure
1. Install the inlet hose to the water pump.

221676

6-608

Engine Cooling

Engine
2. Install the inlet hose to the power steering cooler,
if equipped.
3. Install the inlet hose to the power steering cooler
and the water pump, if equipped.

221666

4. Install the .inlet.hose (1) to the radiator:

349797

5. Install the air intake duct

208569

Engine

Engine Cooling

6-609

6. Connect the IAT sensor and the MAF sensor

electrical connectors.
7. Refill the coolant system. Heter to Draining and
Filling Cooling System (VB).

208553

Radiator Hose ,Replacement - Outlet (V6)

Removal Procedure
1. Drain the engine coolant. Refer to Draining and
Filling Cooling System (V6).
2. Disconnect the (IAT) intake air temperature
sensor electrical connector.

208554

3. Remove the air intake duct.

)
208572

6-61 O Engine Cooling

Engine
4. Remove the outlet hose from the water pump.
5. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

221689

6. Remove the outlet hose from the radiator.

7. Remove the hose support from the fan shroud.

221683

Installation Procedure
1. Install the outlet hose support to the fan shroud.
2. Install the outlet hose to the radiator.
3. Lower the vehicle.

221683

Engine

Engine Cooling 6-611

4. Install the outlet hose to the water pump.

221689

5. Install the air intake duct.

208572

6. Connect the IAT sensor electrical connector.

7. Refill the engine coolant. Refer to Draining and
Filling Cooling System (V6).

)
I

208554

6-61"2

~ngine Cooling
Radiator Hose Replacement - Outlet (VS)
Removal Procedure
1. Drain the engine coolant. Refer to Draining and
Filling Cooling System (VB).
2. Disconnect the (IAT) intake air temperature
sensor and the (MAF) mass airflow sensor
electrical connectors.

\.

208553

3. Remove the air intake duct.

208569

4. Remove the outlet hose from the water outlet.

5. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

(
I

221671

Engine

Engine Cooling 6-613

6. Remove the outlet hose from the radiator.

221675

Installation Procedure
1. Install the outlet hose to the radiator.
2. Lower the vehicle.

221675

3. Install the outlet hose to the water outlet.

221671

6-614

Engine Cooling

Engine
4. Install the air intake duct.

208569

5. Connect the IAT sensor and the MAF sensor

electrical connectors.
6. Refill the engine coolant. Refer to Draining and
Filling Cooling System (VB).

208553

Throttle Body Heater Hose

Replacement - Inlet
Removal Procedure
1. Drain the cooling system. Refer to Draining and
Filling Cooling System (VB).
2. Remove the throttle body heater inlet hose from
the throttle body.
3. Remove the throttle body inlet hose from the
vapor vent pipe.

220621

Engine

Engine Cooling

6-615

Installation Procedure
1. Install the throttle body inlet hose to the vapor
vent pipe.
2. Install the throttle body heater inlet hose to the
throttle body.
3. Refill the cooling system. Refer to Draining and
Filling Cooling System (VB).

220621

Throttle Body Heater Hose

Replacement - Outlet
Removal Procedure

1. Drain the cooling system. Refer to Draining and

Filling Cooling System (VB).
2. Remove the throttle body outlet hose from the
throttle body.
3. Remove the throttle body outlet hose from the
radiator.

220620

Installation Procedure
1. Install the throttle body outlet hose to the radiator.
2. Install the throttle body outlet hose to the
throttle body.
3. Fill the cooling system. Refer to Draining and
Filling Cooling System (VB).

)
/

220620

6-616

Engine

Engine Cooling
Cooling Fan Replacement - Electric
Removal Procedure

Caution: Keep hands, tools, and clothing away

from the electric engine coolant fans in order
to help prevent personal injury. These fans are
electric and can turn on whether or not the engine
is running. The fans can start automatically with
the ignition in the ON position.

1. Disconnect the electrical connectors from the

(IAT) intake air temperature sensor and (MAF)
mass airflow sensor, if equipped with the
5.7L (VIN G) engine.

208553

2. Remove the air intake duct, if equipped with the

5.7L (VIN G) engine.

(
\

208569

3. Disconnect the electrical connector from the (IAT)

intake air temperature sensor, if equipped with the
3800 (VIN K) engine.

(
\

208554

Engine

Engine Cooling

6~617

4. Remove the air intake duct, if equipped with the

3800 (VIN K) engine.

208572

5. Disconnect the rosebud clips from the fan

assembly.

211602

6. Disconnect the coolant fan electrical (',;

connectors
from the fan assembly.

221692

6-618

Engine Cooling

Engine
7. Remove the air cleaner assembly bolts.
8. Remove the air cleaner assembly.

221697

9. Remove the electric engine coolant fan. The fan

will slide off of the radiator.
10. Remove the fan blade nut.

41692

Caution: If a fan blade is bent or damaged in any

way, do not repair or reuse the damaged part.
Always replace a bent or damaged fan blade. Fan
blades that have been damaged can not be
assured of proper balance and could fail and fly
apart during subsequent use. This creates an
extremely dangerous situation.
The fan blades must remain in proper balance.
You cannot assure fan blade balance once a fan
blade has been bent or damaged. A fan blade
that is not in proper balance could fail and fly apart
during use, creating an extremely dangerous
situation.
11. Remove the fan blade.
12. Inspect for the following conditions:
Bent or cracked fan blades
Smoothness of the fan blade mating surfaces
Remove burrs or other imperfections as
necessary

Engine

Engine Cooling

6-619

Installation Procedure
1. Install the fan blade.
2. Install the fan blade nut.
3. Install the electric engine coolant fan. The fan will
slide into place on the radiator.

41692

4. Install the air cleaner assembly.

Notice: Refer to Fastener Notice in Cautions and

Notices.
5. Install the air cleaner assembly bolts.

Tighten
Tighten the air cleaner bolts to 12 N-m (106 lb in).

221697

6. Connect the coolant fan electrical connectors to

the fan assembly.

221692

6-620

Engine

Engine Cooling

7. Connect the rosebud clips to the fan assemb.ly., ..

211602

8. Install the air intake duct, if equipped with the

3800 (VIN K) engine.

208572

9. Connect the electrical connector to the IAT

sensor, if equipped with the 3800 (VIN K) engine.

(
208554

Engine

Engine, Cooling

6-621

10. Install the air intake duct, ,ff equipped with the
5.7L (VIN G) engine:

208569

11. Connect the electrical connectors to ,the IAT .,

sensor and the MAF sensor, if equipped with the
5.7L (VIN G) engine.

208553

Cooling Fan Motor Replacement - Electric

Removal Procedure
1. Remove the cooling fan. Refer to Cooling Fan

Replacement - Electric.
2. Remove the cooling fan bolts
3. Remove the cooling fan motor.

)
342295

6-622

Engine Cooling

Engine
Installation Procedure
1. Install the cooling fan motor.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the cooling fan motor bolts.

Tighten
Tighten the cooling fan motor bolts to
6 Nm (53 lb in).
3. Install the cooling fan. Refer to Cooling Fan
Replacement - Electric.

342295

Cooling Fan Relay Replacement

Removal Procedure
Caution: Refer to Battery Disconnect Caution in
Cautions and Notices.
1. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnect/Connect
Procedure in Engine Electrical.

(
\

208241

2. Remove the cover from the number 1 underhood

electrical center.
3. Remove the cooling fan relay from the underhood
electrical center.

401242

Engine

Engine Cooling

6-623

Installation Procedure

')

1. Install the cooling fan relay to the underhood

electrical center.
2. Install the cover to the number 1 underhood
electrical center.

401242

3. Connect the negative battery cable. Refer to

Battery Negative Cable Disconnect/Connect
Procedure in Engine Electrical.

208241

Thermostat Housing
Replacement (3.8L VG)
Removal Procedure
1. Open the radiator drain cock. Drain the engine
coolant from the radiator to a level below the
thermostat.

Notice: Refer to Fastener Notice in Cautions and

Notices.
2. Close the radiator drain cock.
Tighten
Tighten the radiator drain cock to
1.5 N-m (13 lb in).
3. Disconnect the exhaust gas recirculation (EGR)
valve electrical connector.

221704

6-624

Engine Cooling

Engine
4. Remove the EGR valve outlet pipe 'bolt from the
upper intake maAifold 1
5. Remove the EGR valve outlet pipe nut from the
EGR valve adapter.
6. Remove the EGR valve pipe.

470217

7. Loosen the hose clamp (3).

8. Remove the inlet hose (4) from the water
outlet (2).

9. Remove the water outlet bolts (1 ).

10. Remove the water outlet (2).
11. Remove the water outlet gasket (6).

11686

Installation Procedure
1. Install a new water outlet gasket (6).
2. Install the water outlet (2).
Notice: Refer to Fastener Notice in Cautions and
Notices.

3. Install the water outlet bolts (1).

Tighten
Tighten the water outlet bolts (1) to
27 N-m (20 lb ft).
4. Install the inlet hose (4) to the water outlet(2).
5. Install the hose clamp (3).

11686

Engine

Engine Cooling

6-625

6. Install the EGR valve pipe.

7. Install the EGR valve outlet pipe nut to the EGR

valve adapter.

Tighten
Tighten the EGR valve outlet pipe nut to
29 N-m (21 lb ft).

8. Install the EGR valve outlet pipe bolt to the upper

intake manifold.

Tighten
Tighten the EGR valve outlet pipe bolt to
29 Nm (21 lb ft).

470217

9. Disconnect the exhaust gas recirculation (EGR)

valve electrical connector.

221704

Thermostat Housing
Replacement (5. 7L VS)
Removal Procedure
1. Open the radiator drain cock. Drain the engine
coolant from the radiator to a level below the
thermostat.

Notice: Refer to Fastener Notice in Cautions and

Notices.

2. Close the radiator drain cock.

Tighten
Tighten the radiator drain cock to
1.5 N-m (13 lb in).

3. Remove the radiator outlet hose from the water

outlet.

221671

6-626

Engine Cooling

Engine
4. Remove the water outlet housing bolts.
5. Remove the water outlet and gasket.

221708

Installation Procedure
1. Thoroughly clean the water outlet and water pump
surfaces.
2. Install the water outlet and gasket.
3. Install the water outlet bolts.
Tighten
Tighten the water outlet bolts to 10 N,m (89 lb in).

221708

4. Install the radiator outlet hose to the water outlet.

5. Add engine coolant, if required.

(
'

221671

Engine

Engine Cooling

6-627

Thermostat Replacement (3.8L V6)

Removal Procedure

1. Open the radiator drain cock. Drain the engine

coolant from the radiator to a level below the
thermostat.

Notice: Refer to Fastener Notice in Cautions and

Notices.
2. Close the radiatordrain cock.

Tighten
Tighten the radiator drain cock to
1.5 Nm (13 lb in).
3. Disconnect the EGR valve electrical connector.

221704

4. Remove the EGR valve outlet pipe bolt from the

upper intake.
5. Remove the EGR valve outlet pipe nut from the
E(3R valve adapter.
6. Remove the EGR valve outlet pipe.

221706

7. Loosen the hose clamp (3).

8. Remove the inlet hose (4) from the water
outlet (2).
9. Remove the water outlet bolts (1).
10. Remove the water outlet (2).
11. Remove the water outlet gasket (6).
12. Remove the engine coolant thermostat (5).
13. Clean the gasket surfaces of the water outlet and
upper intake manifold.

)
11686

6-628 Engine Cooling

Engine
Installation Pro.cedure
1. Install the engine coolant thermo.stat (5) into the

upper intake manifold.

2. install a new water, outlet,gasket (6).

3. Install the water outlet (2).
4. Install the wat,er outlet bot~~ (1 ).

Tighten
Tighten the water outlet bolts (1) to
27 N,m (20 lb ft).
5. Install the inlet hose (4) to the water outlet (2).
6. Install the hose clamp (3).

11686

7. Install the EGR valve outlet pipe.

8. Install the EGR valve outlet pipe nut to the EGR
valve adapter ....
9. Install the EGR valve outlet pipe bolt to the upper
intake.

Tighten
Tighten the EGR valve outlet pipe bolt to the
upper intake to 29 N,m (21 lb ft).
Tighten the EGR valve outlet pipe nut to the
EGR valve adapter to 29 Nm (21 lb ft).
Add engine coolant.

221706

(
,

Notice: When adding coolant, use DEX-COOL

coolant. If silicated coolant is added to the system,
premature engine, heater core or radiator corrosion
may result. In addition, the engine coolant will
require change sooner-at 50,000 km (30,000 mi) or
24 months.
Start the engine.
After the engine reaches normal operating
temperature, inspect for coolant leaks.

(
\

Engine

Engine Cooling

6-629

Thermostat Replacement (5.7L VS)

Removal Procedure
1. Open th.e radiator drain. cock. Drain the engine
coolant from the radiator to a level below the
thermostat.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Close the radiator drain cock.

Tighten
Tighten the radiator drain cock to
1.5 Nm (13 lb in).
3. Reposition the radiator outlet hose clamp at the
thermostat housing.
4. Remove the radiator outlet hose from the
thermostat housing.

221671

5. Remove the thermostat housing bolts.

221708

6. Remove the thermostat housing and note position

of thermostat.
7. Remove the thermostat housing gasket.
8. Remove the thermostat.

221709

6-630

Engine Cooling

Engine
Installation Procedure
1. Thoroughly clean the thermostat housing and

water pump gasket surfaces.

2. Install the thermostat gasket with the taper up.
3. Install the thermostat.
4. Install the thermostat housing.

221709

5. Install the thermostat housing bolts.

Tighten
Tighten the thermostat housing bolts to
15 N-m (11 lb ft).

221708

6. Install the. radiator outlet hose to the thermostat

housing.
7. Position the radiator outlet hose clamp at the
thermostat housing.
8. Add engine coolant.
Notice: When adding coolant, use DEX-COOL
coolant. If silicated coolant is added to the system,
premature engine, heater core or radiator corrosion
may result. In addition, the engine coolant will
require change sooner-at 50,000 km (30,000 mi) or
24 months.
9. Start the engine.
10. After the engine reaches normal operating
temperature, inspect for coolant leaks.

221671

Engine

Engine Cooling

6~631

Radiator Support Replacement

Removal Procedure
\

1. Disconnect the electrical connectors from the

(IAT) intake air temperature sensor and (MAF)
mass airflow sensor, if equipped with the
5.7L (VIN G) engine.

208553

2. Remove the.air intake duct; if equipped with the

5.7L., (VIN G) engine.

208569

3. Disconnect the electrical .connector from the '{IAT)

intake air temperature sensor, if equipped with the
3800 (VIN K) engine.
.
.

)
I

208554

6-632

Engine Cooling

Engine
4. Remove the air intake duct, if equipped with the, '.
3800 (VIN K) engine.

208572

5. Remove the air cleaner assembly bolts.

6. Remove the air cleaner assembly I radiator
support.

221697

Installation Procedure
1. Install the air cleaner assembly I rad.iator support.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the air cleaner assembly bolts.

Tighten
Tighten the air cleaner bolts to 12 N-m (106 lb in).

(
221697

Engine

Engine Cooling

6-633

3. Install the air intake duct, if equipped with the

3800 (VIN K) engine.

208572

4. Connect the, electricat connector to the IAT

sensor, if equipped with the 3800 (VIN K) engine.

208554

5. Install the air intake duct, if equipped with the

5.7L (VIN G) engine.

)
208569

6-634

Engine Coo,ing

Engine
6. Connect the electrical connectors to the IAT.
sensor and the MAF sensor, if equipped with the
5.7L (VIN G) engine.

208553

Water' Pump Replacement {3.8L V6)

Removal Procedure
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Open the radiator drain cock. Drain the engine
coolant from the radiator to a level below the
thermostat.
Tighten
Tighten the radiator drain cock to
1.5 N-m (13 lb in).
2. Loosen the water pump pulley bolts.
3. Remove the serpentine drive belt. Refer to Drive
Belt Replacement in Engine Mechanical-3.8L.

221711

4. Remove the radiator inlet hose from the.

water pump.

221689

Engine

Engine Cooling

6-635

5. Remove the water pump pulley bolts.

6. Remove the water pump pulley.

221711

7.
8.
9.
10.

Remove the water pump bolts (1).

Remove the water pump (2).
Remove the water pump gasket (3).
Clean all of the gasket mating surfaces, including
the water pump bolts.

11687

Installation Procedure
Tools Required
J 36660 Torque Angle Meter
1. Install a new water pump gasket (3).
2. Install the water pump (2).
3. Install the water pump bolts (1 ).
Tighten
Tighten the water pump bolts (1) to 15 Nm
(11 lb ft ) plus an additional 80 degrees using
the J 36660.

)
11687

6-636

Engine Cooling

Engine
4. Connect the radiator inlet hose to the water pump.

221689

5. Install the water pump pulley.

6. Install the water pump pulley bolts.
Tighten
Tighten the water pump pulley bolts to
13 Nm (115 lb in).
7. Install the serpentine drive belt. Refer to Drive
Belt Replacement in Engine Mechanical-3.BL.
8. Add the engine coolant. Refer to Draining and
Filling Cooling System (3800 VIN K).
9. Start the engine. After the engine reaches normal
operating temperature, check for coolant leaks.

221711

Water Pump Replacement (5. 7L VS)

Removal Procedure
1 . Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Disconnect the coolant fan electrical connectors
from the fans.
3. Drain the cooling system. Refer to Draining and

Filling Coo/inf! System (VB).

4. Lower the vehicle.

221692

Engine

Engine Cooling

6-637

5. Disconnect the (IAT) intake air temperature

sensor and (MAF) mass airflow sensor electrical
connectors.

1
!

208553

6. Remove the air intake duct.

208569

7. Remove the outlet hose from the water outlet.

)
221671

6-638

Engine Cooling

Engine
8. Remove the inlet hose from the coolant pump.

221676

9. Remove the air cleaner assembly bolts.

10. Remove the air cleaner assembly I upper radiator
support.

221697

11. Remove the inlet hose (1) from the radiator.

349797

Engine

Engine Cooling

6-639

12. Remove the electric engine coolant fans.:,

13. Remove the air conditioning drive belt. Refer to
Drive Belt Replacement (AIC) in Engine
Mechanical-5. 7L.

41692

14. Remove the drive belt tensioner pulley from the

~oolant pump.
15. Remove the vent hose from the radiator.

220581

16. Remove the coolant pump pt.dley, bolts.

17. Remove the coolant pump pulley.

74081

6-640

Engine Cooling

Engine
18. Remove the coolant pump bolts.

221712

19. Remove the coolant pump.

20. Clean all gasket mating surfaces, including the
water pump bolts.
21. Transfer the thermostat from the old water pump
to the new pump.

221714

Installation Procedure
1. Install the coolant pump to the engine block,

221714

Engine

Engine Cooling

6-641

Notice: Refer to Fastener Notice in Cautions and

Notices.
\

2. Install the coolant pump bolts.

Tighten
Tighten the coolant pump bolts to
25 N,m (18 lb ft).

221712

3. Install the coolant pump pulley. ,

4. Install the coolant pump pulley bolts.
Tighten
Tighten the coolant pump pulley bolts the first
pass evenly to 10 N,m (89 lb in).

Tighten the coolant pump pulley bolts the final

pass to 25 Nm (18 lb ft).
5. Install the vent hose to the radiator.

74081

6. Install the drive belt tensioner to the coolant pump.

Tighten
Tighten the drive belt tensioner bolt to
50 Nm (37 lb ft).
7. Install the drive belts. Refer to Drive Belt
Replacement (AIC) in Engine Mechanical-5.7L.

)
220581

6-642

Engine Cooling

Engine
8. Install the ele~tric engine cooling fans.

41692

9. Install the inlet hose (1) to the radiator.

349797

1Q; Install the air cleaner assembly I upper radiator

support.
11. Install th,e air cleaner assembly bolts.
Tighten
Tighten the air cleanerbolts to 12 Nm (106 lb in).

221697

Engine

Engine Cooling

6-643

12. Install the inlet hose to the coolant pump.

221676

13. Install the outlet hose to the water outlet.

221671

14. Install the air intake duct.

)
208569

6-644

Eng.ine

Engine Cooling

15. Connect the IAT sensor and the MAF sensor

electrical connectors.

208553

16. Connect the coolant fan electrical connectors to

the fan assemblies.
17. Fill the cooling system. Refer to Draining and
Filling Cooling System (VB).

(
\

221692

Coolant Level Sensor Replacement

Removal Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Open the radiator drain cock. Drain the coolant
from the radiator to a level below the coolant
level indicator module.
3. Lower the vehicle.
4. Remove the battery. Refer to Battery Replacement
in Engine Electrical.
5. Disconnect the electrical connector at the module.
6. Remove the coolant level indicator module from
the radiator.

221716

Engine Cooling

Engine

6-645

Installation .Procedure

1. Install the module to the radiator.

1.1 . Apply lubricant to the 0-ring.
1 .2. Align the coolant indicator module to the
module port in the radiator.
1.3. Press the module probe into the radiator
module port housing until the retainer
spring snaps onto the port flange.

2. Connect the electrical connector at the module.

3. Install the battery. Refer to Battery Replacement in
Engine Electrical.

4. Refill the engine coolant. Refer to braining and

Filling Cooling System (VB).

221716

Engine Coolant Temperature Sensor

Replacement (3.8L VS)
Removal Procedure
Important: Care must b.e taken when handling the
engine coolant temperature (ECT) sensor, damage to
the sensor will affect proper operation of the fuel
injection system.
1. Drain the engine coolant. Refer to Draining and
Filling Cooling System (V6).
2. Disconnect the coolant temperature sensor (1)
electrical connector.

3. Remove the coolant temperature sensor (1 ).

444133

Installation Procedure
1. Coat the sensor threads with sealer GM
P/N 12346004 or equivalent.
2. Install the coolant temperature sensor (1) into the
engine.

Notice: Refer to Battery Disconnect Caution in

Cautions and Notices.
3. Tighten the coolant temperature sensor (1).

Tighten
Tighten the coolant temperature sensor (1) to
25 Nm (18 lb ft).
4. Connect the coolant temperature sensor (1)
electrical connector.
5. Refill the cooling system. Refer to Draining and
Filling Cooling System (V6).

444133

6-646

Engine

Engine Cooling

Engine Coolant Temperature Sensor

Replacement (5. 7L VS}
Removal Procedure
Important: Care must be taken when handling the
engine coolant temperature (ECT} sensor. Damage to
the sensor will affect proper operation of the fuel
injection system.
1. Drain the cooling system. Refer to Draining and
Filling Cooling System (VB).
2. Disconnect the coolant temperature sensor
electrical connector.
3. Remove the number 1 spark plug wire.
4. Remove the coolant temperature sensor.

50974

Installation Procedure
1. Coat the sensor threads with sealer GM
P/N 12346004 or equivalent.
2. Install the coolant temperature sensor.
Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Tighten the coolant temperature sensor.
Tighten
Tighten the coolant temperature sensor to
20 Nm (15 lb ft).
4. Install the number 1 spark plug wire.
5. Connect the coolant temperature sensor electrical
connector.
6. Refill the cooling system. Refer to Draining and
Filling Cooling System (VB).

50974

Drain Cock Replacement

Removal Procedure
1. Drain the engine coolant. Refer to Draining and
Filling Cooling System (V6) or Draining and
Filling Cooling System (VB).
2. Pull the radiator drain cock from the radiator body.
Squeeze the sides together with needle nose
pliers.
3. Clean and/or replace the seal and the drain cock
as necessary.

II~

l--

457901

Engine

(;ngine. Cooling

6-&47

Installation Procedure
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Install the drain cock to the radiator body.
Tighten
Tighten the radiator drain cock to
1.5 N-m (13 lb in).
2. Refill the engine cooling system. Refer to Draining
and Filling Cooling System (V6) or Draining and
Filling Cooling System (VB).

457901

Fan Shroud Replacement

Removal' Procedure
'
1. Remove the radiator UPP~r support:Hefer.to
Radiator Support Replacement.
2. Remove the fan shroud:
Move the fan shroud up in order to clear the
four mounts.
Move the fan shroud down in order to remove
it from the vehicle.

185073

3. Remove the cooling fan ~r.~ck~ts from the t1:1r:i.

shroud.

349792

6-648

Engine

Engine Cooling
Installation Procedure

1. Install the cooling fan brackets to the fan shroud.

349792

2. Install the fan shroud into the four retaining tabs

on the radiator.
3. Install the radiator upper support. Refer to
Radiator Support Replacement.

185073

Radiator Replacement
Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant
Recovery and Recharging in HVAC Systems
with A/C-Manual.
2. Drain the engine coolant. Refer to Draining and
Filling Cooling System (V6) or to Draining and
Filling Cooling System (VB).
3. Remove the radiator inlet hose. Refer to Radiator
Hose Replacement - Inlet (V6) or to Radiator
Hose Replacement - Inlet (VB).
4. Remove the radiator outlet hose. Refer to Radiator
Hose Replacement - Outlet (V6) or to Radiator
Hose Replacement - Outlet (VB).
5. Remove the upper air conditioning evaporator
tube bolt.
6. Remove the evaporator tube from the condenser.
221720

Engine

Engine Cooling

6649

7. Remove the upper oil cooler line from the radiator.

8. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
9. Remove the lower oil cooler line from the radiator.

208321

10. Remove the air conditioning condenser tube nut.

11 . Remove the condenser tube from the condenser.
12. Lower the vehicle.

221721

13. Remove the coolant recovery reservoir hose from

the radiator.
14. Remove the electric engine coolant fans. Refer to
Cooling Fan Replacement - Electric.
15. Remove the coolant level indicator module, if
equipped. Refer to Coolant Level Sensor
Replacement.

)
221645

6-650

Engine

Engine Cooling
16. Remove the radiator from the vehicle.

221724

17. Remove the condenser from the radiator.

221726

Installation Procedure
1. Install the condenser to the radiator.

221726

Engine

Engine Cooling

6-651

2. Install the radiator to the vehicle.

3. Install the coolant level indicator module, if
equipped. Refer to Coolant Level Sensor
Replacement.
4. Install the electric engine coolant fans. Refer to
Cooling Fan Replacement - Electric.

221724

5. Install the coolant recovery reservoir hose to the

radiator.

6. Raise and suitably support the vehicle. Refer to

Lifting and Jacking the Vehicle in General
Information.

221645

7. Install the condenser tube to the condenser.

Notice: Refer to Fastener Notice in Cautions and

Notices.
8. Install the air conditioning condenser tube nut.
Tighten
Tighten the condenser tube nut to
16 N-m (12 lbft).

221721

6652

Engine

Engine Cooling

9. Install the lower oil cooler line to the radiator.

Tighten
Tighten the lower oil cooler line to
27 N,m (20 lb ft).

10. Lower the vehicle.

11. Install the upper oil cooler line to the radiator.
Tighten
Tighten the upper oil cooler line to
27 N,m (20 lb ft).

208321

12. Install the evaporator tube to the condenser.

13. Install the upper air conditioning evaporator

tube bolt.

14.

15.

16.

17.

Tighten
Tighten the condenser tube bolt to
16 N,m (12 lb ft).
Install the radiator outlet hose. Refer to Radiator
Hose Replacement - Outlet (V6) or to Radiator
Hose Replacement - Outlet (VB).
Install the radiator inlet hose. Refer to Radiator
Hose Replacement - Inlet (V6) or to Radiator
Hose Replacement - Inlet (VB).
Drain the engine coolant. Refer to Draining and
Filling Cooling System (V6) or to Draining and
Filling Cooling System (VB).
Recharge the air conditioning system. Refer to
Refrigerant Recovery and Recharging in HVAC
Systems with A/C-Manual.

221720

Radiator Air Baffle Assemblies and

Deflectors (Lower)
Removal. Procedure
1. Remove the air lower deflector screws (3).
2. Remove the radiator air lower baffle retainers (4).
3. Remove the radiator air lower baffle (1).
4. Inspect for any component damage.

11689

Engine Cooling

Engine

6-653

Installation Procedure
1. Install the radiator air lower baffle (1 ).
\

2. Install the radiator air lower baffle retainers (4).

Notice: Refer to Fastener Notice Fastener Notice
in General Information.
3. Install the radiator air lower deflector screws (3).
Tighten
Tighten the air lower deflector screws to
10 N-m (89 lb in).

11689

Radiator Air Baffle Assemblies and

Deflectors (Upper)
Removal Procedure
1. Remove the radiator air upper baffle from the
retainers (3).
2. Remove the radiator air upper baffle (1) from the
radiator (2).

()
11690

Installation Procedure
1. Install the radiator air upper baffle (1) to the

radiator (2).
2. Install the radiator air upper baffle to the
retainers (3).

()

11690

6-654

Engine Cooling

Engine
Coolant Heater Replacement (3.8L V6)
Removal Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Drain the engine cooling system. Refer to Draining
and Filling Cooling System (V6).
3. Disconnect the electrical cord from the coolant
heater.

298431

4. Loosen the coolant heater bolt.

Important: When removing the engine coolant heater
from the engine block, be careful not to score the
machined surface of the plug hole.
5. Remove the coolant heater from the engine block.
6. Clean the engine coolant heater hole. Remove
any burrs, sealer, paint or other rough spots.

298427

Installation Procedure
Important: The heater element must not touch the
engine block inner wall in the installed position
or damage to the engine block and coolant heater
could result.
1. Apply a coat of engine coolant heater lubricant,
GM P/N 12345996 or equivalent, to the 0-ring
and walls of the coolant heater hole.
2. Install the coolant heater into the coolant hole
using the following steps:
Insert the heating element end of the heater
into the engine block.
Line up the heater with the plug hole and push
it straight into place.
Rotate the heater so that the center electrical
contact and bolt are in line horizontally.

298427

Engine

Engine Cooling

6-655

Notice: Refer to Fastener Notice in Cautions and

Notices.
3. Tighten the.,bolt so that the yoke presses against
the engine block inner wall.
Tighten
Tighten the coolant heater bolt to
1.9 Nm (17 lb in).
4. Connect the coolant heater electrical cord to the
heater.

5. Lower the vehicle.

6. Refill the engine cooling system. Refer to Draining
and Filling Cooling System (V6).

298431

Coolant Heater Replacement (5. 7L VS)

Removal Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
'
2. Drain the engine cooling system. Refe(to Draining
and Fiiiing Cooling System (VB).
3. Disconnect the electrical cord from the coolant
heater.
Important: When removing the engine coolant heater
from the engine block, be careful not to score the
machined surface of the plug hole ..

298433

6~656

Engine Cooling

Engine
4. Remove the coolant heater from the engine block.
5. Clean the engine coolant heater hole. Remove
any burrs, sealer, paint or other rough spots.

298428

Installation Procedure
Important: The heater element must not touch the
engine block inner wall in the installed position
or damage to the engine block and coolant heater
could result.
1. Apply a 3.175 mm (0.125 in) bead of sealant GM
P/N 12346004 or equivalent, to the engine block
coolant. heater sealing wash~r.
2. Finger start the coolant heater to the engine block.
Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Tighten the coolant heater.

Tighten
Tighten the coolant heater to 40 N-m (30 lb ft).

298428

4. Install the coolant heater electrical cord to the

heater.
5. Lower the vehicle.
6. Refill the engine cooling system. Refer to Draining
and Filling Cooling System (VB).

298433

Engine

Engine Cooling

6~657

Coolant Heater Cord

Replacement (3.SL V6)
Removal Procedure
1. Disconnect the heater cord from the block heater.
2. Route the block heater end of the cord under
the power steering rack lines.
3. Cut the heater cord strap at the power steering
reservoir.

298431

4. Cut the heater cord strap at the fuse block center.

5. Remove the heater cord from the v~hicle.

298430

6. Install the ,heater cord and a new strap to the fuse

block center.

)
298430

6-658

EAgine Cooling

Engine
7. Route the cord up under the power steering
rack lines.
8. Install a new heater cord strap .to the power
steering reservoir.

9. Connect the heater cord to the eoolant heater.

298431

Coolant Heater Cord

Replacement (5.7L VS)
Removal Procedure
1. Disconnect the heater cord from the block heater.
2. Cut the heater cord strap at the power
steering line.

298433

3. Cut the heater cord strap at the fuse blocK center.

4. Remove the heater cord from the vehicle.

298430

Engine

Engine Cooling

6-659

Installation Procedure

1. lnstal the heater cord to the vehicle.

2. Install the heater cord and a new strap to the fuse
block center.

298430

3. Install the heater cord and a new strap to the

power steering line.
4. Connect the heater cord to the coolant heater.

298433

6-660

Engine Cooling

Engine

Description and Operation

Cooling System Description
General Description
The cooling system consists of the following major
components:
The radiator
The coolant recovery reservoir ,
The cooling fans
The thermostat
The coolant pump
The vapor vent pipe
The engine coolant temperature (ECT) sensor
The transmission oil cooler
All related coolant hoses
The fan shroud
The fan motor/blade
The cooling systems function is to maintain an efficient
engine operating temperature during all speeds and
under all operating conditions. Cooling systems
are designed to remove about one-third (30 to 35
percent) of the heat producedinthe combustion
chambers by the burning of the air-fuel mixture. The
engine is very inefficient while cold. Therefore the
cooling system includes a device (thermostat)
that prevent normal cooling action during engine
warm-up. The thermostat allow the engine parts to
reach their normal operating temperatures more
quickly. This shortens the inefficient cold-operating
time. When the engine reaches its normal operating
temperature, the cooling system begins to function.
.The cooling system removes excess heat when
the engine is hot, and slowly or not at all when the
engine is cold or warming up.
The coolant absorbs heat as it passes through the
engine. Then the hot coolant flows through a radiator
in which the heat in the coolant is passed on to
the air that is flowing through the radiator. The cooled
coolant then flows back through the engine. This
circulation of the coolant continually removes heat from
the engine. The coolant is kept in circulation by the
coolant pump.
Water jackets are designed to keep the cylinder block
and cylinder head cool. The water jackets are open
spaces between the outside wall of the cylinder
and the inside of the cylinder block and head. The
coolant can circulate freely around the engine
hot spots. These hot spots include the following:
Valve guides
Valve seats
Upper parts of the cylinder walls
When the engine is running at normal temperature,
coolant flows into the block and through the water
jackets surrounding the cylinders. Vapor is vented off
through the vapor vent pipe. Then the coolant is
forced through the head gasket openings and into the
cylinder head water jackets. In the heads, the
coolant flows around the combustion chambers and
valve seat, picking up additional heat. From the heads,

the coolant flows through the upper hose into the

radiator. There, the coolant temperature is lowered,
and the coolant is drawn again into the engine by the
coolant pump. A separate coolant flow loop is
available from the coolant pump to the heater core
and back to the coolant pump to provide passenger
compartment heat and defrost. The coolant recovery
reservoir provides a coolant fill point. The reservoir
is translucent for coolant level viewing.

Coolant Recovery System Description

The cooling system has a separate plastic, translucent
coolant recovery reservoir. The reservoir, also called
a recovery tank or expansion tank, is partly filled
with coolant and is connected to the overflow tube on
the radiator fill neck to the reservoir by the overflow
tube. The coolant in the engine expands as the engine
heats up. Instead of dripping out the over flow tube
onto the g~ound and being lost from the cooling system
completely, the coolant flows into the reservoir.
When the engine cools,. a vacuum is created in the
cooling system. The vacuum siphons some of
the coolant back into the radiator from the reservoir. In
effect, a cooling system with a recovery reservoir is
a closed system. Coolant can flow back and forth
between the radiator and the reservoir. This occurs as
the coolant expands and contracts from heating
and cooling. Under normal conditions, no coolant
is lost.
An advantage to the use of a coolant recovery
reservoir is that it eliminates almost all air bubbles
from the cooling system. Coolant without bubbles
absorbs heat much better than coolant with bubbles in
it. Although the coolant level in the recovery reservoir
goes up and down, the radiator and cooling system
are kept full. This results in maximum cooling
efficiency.

Throttle Body Coolant System Description

The fuel injection system has coolant passages in
the throttle body. The coolant flow improves cold
driveability.

Coolant Heater Description

The engine coolant heater is used to heat the engine
coolant making it easier to start the engine in cold
climates. It is installed into the engine block at a water
jacket plug location. An engine coolant heater cord
is routed inside the engine compartment. The heater is
rated at 600 watts and uses a 110 volt ac power
supply.

Engine

Engine Cooling

6-661

Radiator Assembly Description

47015

The radiator is a heat exchanger that removes heat

from the coolant passing through it. The radiator holds
a large volume of coolant in close contact with a
large volume of air so that heat will transfer from the
coolant to the air. The radiator core is divided into two
separate compartments Coolant passes through
one, and air passes through the other. The aluminum
radiator core (1) is a crossflow tube and fin design.
A tube and fin radiator consists of a series of
tubes extending from side to side on the radiator core.
The tubes run from the inlet tank (4) to the outlet
tank (9). Fins are placed around the outside of
the tubes to improves heat transfer. Air passes
between the fins. As the air passes by, it absorbs heat
from the fins which have, in turn, absorbed heat
from the coolant.

In a typical radiator, there are five fins per inch.

Radiators used in vehicle that have factory installed
air conditioning have seven fins per inch. This provides
the additional cooling surface required to handle the
additional heat load imposed by air conditioning.
The inlet (4) and outlet (9) tanks are molded with high
temperature nylon-reinforced plastic. A high
temperature rubber gasket (2, 12) seals the tank
flange edge. The tanks are clamped to the core with
clinch tabs. The tabs are part of the aluminum
header at each end of the core (1 ). A plastic
serviceable drain cock (7) and rubber seal is used.
The integral transmission oil cooler (3) is housed inside
the outlet (4) tank. The cooler provides the automatic
transmission fluid cooling capacity. This maintains
a fairly constant fluid temperature under all operating
conditions.

6-662 Engine Cooling

Pressure Cap Description
Caution: Under pressure, the temperature of the
solution in the radiator can be considerably higher,
without boiling. Removing the radiator cap while
the engine is hot (pressure is high), will cause the
solution to boil instantaneously, with explosive

Engine
force. The solution will spew out over the engine,
fenders, and the person removing the cap.
Serious bodily injury may result. Flammable
antifreeze, such as alcohol, is not recommended
for use at any time. Flammable antifreeze could
cause a serious fire.

4~305

The cooling system is sealed and pressurized by a

radiator pressure cap. There are two advantages
to sealing and pressurizing the coolir:ig system:
Increased pressure raises the boiling point of the
coolant. This increases the efficiency of.the
cooling system.
Sealing the cooling system reduces coolant losses
from evaporation and permits the use of the
recovery reservoir.
As the pressure goes up, the boiling point goes up.
Therefore, the coolant can be safely run at a
temperature higher than 212 degrees F
(100 degrees C) without boiling. The higher the
coolant temperature, the greater the difference
between it and the outside air temperature. This
difference in temperature is what causes the cooling
system to work. The hotter the coolant, the faster
the heat moves from the radiator to the cooler passing
air. This means that the pressurized, sealed cooling
system can take heat away from the engine faster.
Therefore, the cooling system works more efficiently
when the coolant is under higher pressure.
However, the cooling system can be pressurized too
much. If the pressure in the system gets too high,
it can damage the radiator and blow off the hoses. To
prevent this the radiator cap has a pressure relief
valve. When the pressure gets too high, it raises the
valve so that the excess pressure can escape into the
recovery reservoir.

The radiator pressure cap also has a vacuum vent

valve. This valve protects the system from developing
a vacuum that could collapse the radiator. When
the engine is shut off and cools, the coolant volume is
reduced. Cold coolant takes up less space than hot
coolant As the temperature of the coolant drops,
a vacuum develops in the cooling system. To prevent
excessive vacuum from developing, the vacuum
valve opens to allow outside air or coolant from the
recovery reservoir to flow into the cooling system. This
relieves the vacuum that could otherwise cause
outside air pressure to collapse the radiator.
To install the radiator pressure cap, perform the
following:
1. Place the cap on the fill neck, the locking lugs on
the cap fit under the fill neck flange.
2. As the cap is turned, the cam locking surface of
the flange tightens the cap. It also preloads the
pressure relief valve spring.
To remove the radiator pressure cap, perform the
following:
1. Press down and slowly turn the cap back to the
safety stop.
2. Never remove the cap when the engine is hot.
Boiling coolant and steam can erupt from the
fill neck.

EngineCooUng

Engine

~663

Engine Cooling'F~n Description - Electric

The. coolingfans are located behind the radiator.
The cooling fans are driven by an electric motor. The
cooling fan motors both have five blades that are
each 312 mm (12.3 in) in diameter. One cooling fan
will start and run and then both cooling fans will
run depen9ing on the amount of cooling the
radiator needs.
The advantage of the electric fan is less power drain
on the engine and less fan noise;.Also, there is
no fan belt to inspect, adjust, or replace. This means
less cooling system maintenance.
The engine cooling fan relays provide the current
required for the motors based on a low current'signal
received from the PCM.
.

Cooling Fan Relay Description

The cooling fan relays are used to control the high

current ftow to power the cooling fan.motors. Both fans

operate together. When minimum cooling is requir~d,
the PCM energizes cooling fan relay #1 and both
fans operate at low speed, since the fans .are
connected in series through cooling fan relay #2 and
#3. When maximum cooling is required, the PCM
energizes all three cooling fan relays. The left fan 'is
still powered through cooling fan relay #1, but is
.now grounded through cooling fan #3. The right fan is
now powered directly through coolir,g fan relay #2i
and both fans operate at high speed: ...

Water .Pmp Description

The die-cast coolant pump :is a centrifugal vane
impeller type. The impeller turns on a steel shaft that
rotates in a permanently lubricated ball bearing.
The pump inlet connects to the bottom of the radiatoL
with the rubber radiator outJet hose. Coolant from
.the pump passes through the engine front cover, then
into the coolant passages ih the engine block in
order to absorb excess engine. heat.
i

Thermostat Description
The thermostat is a coolant flow Control component
that utilizes a temperature sensitive wax-pellet .
element (4). Its purpose is to close off the coolant
passage when the engine is cold. Now coolant
circulation is restricted, causing the engine to. reach
normal operating temperature more quickly. Also, after
warm-up, the thermostat keeps the engine running
at a higher temperature than it would without a
thermostat. The higher operating temperature
improves engine efficiency and reduces exhaust
emissions.

The thermostat performs the following functions:

Controls the flow of coolant through the radiator
Enables controlled engine warm-up
Assists in coolant temperature control

1370!>

T~e ':"ax pellet element (4) in the thermostat expands

with increasing temperatures, and contracts with
decreasing temperatures.
The element connects through a piston (1) to a

thermostat valve (2).

When the element is heated,' pressure is exerted
,against a rubber diaphragm (3) which forces the
thermostat valve to open. As the 'element is cooled
'
the contraction allows a spring (5Jto c:lose
the thermostat valve.
W.hilethe coolant is cold, the thermostat valve
remains closed. This prevents circulation of coolant
through the _radiator. At this point, coolant is only
allowed to circulate throughout the engine block and
he'.1ter core in order to allow the. engine to warm
quickly~ ..
. .

As the. engine warms,. the element expands and the
thermostat valve opens. This permits coolant to
flow through.the radiator, where the h,eat dissipates to
.
.
the at,:nosphere. .

Engine Coolant Temperature Sensor

Description
The engine coolanttemperature (ECT) sensor is a
variable resis~ance device. The ECT sensor resistance
determines thepositfon of the. temperature gaugi:3:
As the temperature increases 1 the ECT sensor
resistance decreases. This allpws for more current to
flow through the gauge, causing a higher temperature

reading.

Air Baffles and Seals Descri'ption

A deflector redirects air flow. o'eflectors are installed
under the vehicle and redirects the air fl6W beneath the
vehicle to flqw,through the cooling system. The
deflectors perforr:n .the following functions:
Reduce drag .
Prevent front end lift
Increase radiator cooling

6-664

Engine Cooling

Engine

Air baffles are used to direct air into the radiator and
A/C condenser. Air seals ensure that air passes
through, and does not bypass, the radiator and the
A/C condenser. A missing, damaged, or incorrectly
installed baffle or seal may cause the engine to
overheat.

Special Tools and Equipment

IHustration

Tool' Number/ Qescription

Coolant Sensor Description

J 2368~
Coolant Tester
(Fahrenheit Scale)

This sensor monitors the coolant level in the cooling

system and indicates if the coolant is low. This sensor
is located in the right front corner of the radiator.
1406

J 24460-01
Cooling System and Cap
Pressure Tester

1405

J 26568
Coolant Tester
(Celsius Scale)

221716

Coolant Description
This vehicle has a newly developed engine coolant.
GM Goodwrench DEX-COOL was developed to last
fro 240 000 km (150,000 mi) or 5 years, whichever
occurs first. Follow the instruction in Draining and
Filling Cooling System. Make sure only GM
Goodwrench DEX-COOL (silicate-free) or Havoline
DEX-COOL is used when coolant is added or
changed.

12869

J 36660

A 50/50 mixture of DEX-COOL and clean drinkable

water will provide the following protection:
Notice: Pure coolant can be added to raise the boiling
point of the coolant, but too much will affect the
freezing point. Do not use a. solution stronger
than 70 percent, as the freeze level rises rapidly after
this point. Pure coolant will freeze at -22C (-8F).
Give freezing protection down to -37C (-;34F).
Give boiling protection up to 129C (260F).
Protect against rust and corrosion.
Help maintain the proper engine temperature
Let the warning lights and gauges operate
correctly.

Torque Angle Meter

3413

Engine

Engine Electrical

6-665

Engine Electrical
\

Specifications
Fastener Tightening Specifications
Application
Battery Hold Down Retainer Bolt
Engine Lift Bracket to Control Module Bolt (V6)

"'m
18

Lb Ft
13

25

18

Generator Brace Bracket Bolt (V6)

50

37

Generator Mounting Bolt (V8)

50

37

Lb In.

Generator to Drive Belt Tensioner Lower Bolt (V6)

50

37

Generator to Drive Belt Tensioner Upper Bolt (V6)

30

22

Generator Rear Brace Bolt (V6)

25

18

Generator Brace Bolt (V6)

27

20

Ground Strap Bolt

12

106

Heated Oxygen Sensor

42

31

Ignition Coil Bolt (V8)

12

106

Ignition Control Module Bolt (V6)

2.5

22

Ignition Control Module Nut (V6)

30

22

15

11

..

Negative Battery Cable Bolt

Negative Cable Nut to Block Stud

22

16

Negative Cable to Engine Block Nut (V8)

32

24

Negative Cable to Wheelhouse Stud Nut

53

Positive Battery Cable Bolt

15

11

Positive Cable Clamp Nut to Block Stud (V6)

25

18

Positive Cable to Generator Nut

22

16

Positive Cable to Starter Motor Nut

10

89

Positive Cable Nut to Fuseblock Stud

14

10

Positive Cable to Starter Nut

10

89

Spark Plugs

20

15

Starter Motor Bolt (V6)

47

35

Starter Motor Bolt (V8)

50

37

Starter Motor Lead Nut

18

Starter Moto_r Stud

45

33

Starter Shield N_ut (V6)

10
10

89

Starter Shiel_d to Transmission Brac_e Bolt (V6)

Starter Shield to Engine Block Bolt (V6)

30

22

,<

Battery Usage
Description

Application
3800-V6 (VIN K)

674

Catalog Number
Cold Cranking Amperage (CCA)

690

Load Test (AMPS)

345

Replacement Model Number

758-84

Reserve Capacity Minutes

90
5.7L-V8 (VIN G)

Catalog Number

.,

670

Cold Cranking Amperage (CCA)

525

Load. Test (AMPS)

260

89

6-666

Engine

Engine Electrical
Battery Usage (cont'd)
Application

Description

Replacement Model Number

75-60

Reserve Capacity Minutes

90

Battery Tempt!rature vs Voltage Drop

Degrees Celsius (C)

Voltage

Degrees Fahrenheit (F)

Temperature vs Minimum Voltage

21
10 .
0
-10

70

9.6

50

9.4

. 32

9.1
8.8

14

-18

Below-18

Below O

..

8.5
8.0

Starter Motor Usage

Description

Application

No Load Test at 11.5 Volts

Starter Motor

PG-260

Current Draw (AMPS)

60-125

2900-3400

Pinion Speed (RPM)

0.25 mm (0.01 in)-4.06 (0.16 in)

Pinion Clearance
Starter Solenoid Switch
Hold-in Windings

5,15 Amps

Both Windings

30-50 Amps

Generator Usage
Description

Application

3.8L V6 (VIN K) and 5.7L VB (VIN G)

Engine

105

Rated Amperes
Type

CS-130D

GM SPO Group Numbers

Application
..

GM SPO Group Number

Battery Negative Cable

02.341

Battery Positive Cable

02.342

Crankshaft (CKP) Position Sensor

02.383

Distributor

02.361

Distributor Cap Kit

02.367

Distributor Wiring Harness

02.383

Electronic Ignition ControlModule (El ICM)

02.383

El ICM Heat Sink

02.383

Engine Wiring Harness

02.525

Generator

02.275

Generator Battery Terminal

02.313

Generator Brush Kit

02.291

Generator Capacitor

02.319

Generator Drive End Frame

02.305

Generator Fan

02.274

Generator Pulley

02.274

Generator Rear Inner Brace

02.277

Engine Electrical

Engine

6-667

GM SPO Group Numbers (cont'd)

Application

GM SPO Group Number

Generator Rear Outer Brace

02.277

Generator Rectifier Bridge

02.319

Generator Rotor

02.279

Generator Slip Ring End Frame

02.297

Generator Stator

02.310

Generator Valve Regulator

02.500

Ignition Coil

02.170

Ignition Coil Wiring Harness

02.240

Knock Sensor

02.383

Spark Plug

02.270

Spark Plug Wires #1-8

02.240

Spark Plug Wire Support

02.251

Spark Plug Wire Kit

02.239

Starter Motor

02.041

Starter Shield

02.042

Schematic and Routing Diagrams

Engine Electrical Schematic References
Section Number Subsection Name

Reference on Schematic
Fuse Block Details - Cell 11

8-Wiring

Instrument Cluster - Cell 81

8-Wiring

Ground Distribution - Cell 14

8-lnstrument Panel and Guages

Power Distribution - Cell 1O

8-Wiring

Engine Electrical Schematic Icons

Icon Definition

Icon
Notice: Refer to ESD Notice.

19384

Notice: Refer to 080 II Symbol Description Notice.

)
i

19385

Starting and Charging Schematics {Starting System)

r-----Power

- - - - ., Underhood
I Electrical
I Center 2

____

I Distribution
I ee1110

P100

BI

Swilci1

_____ ...

5RED 2
Power
Distribution
Cell10

5RED

----.- ---7---1
1

rf :
)

. __.__...
o 1,,

: Cell 10

'Neutral
1Position

Switch

Ace "!_

_ start :

Loe~--.. __ _...,.'Bulb
Test

I
I

~-------Off_ Run

I Switch
I

I
I

A C2

L------..1

Fl

0.35 DK GRN11433
C200D
A6 C200A

Generator
5RED

8 RED 1 (VIN K)
13 BLK 1 (VIN G)

19 RED 1

5YEL
5

0.5DKGRN 1433

- - - -er - - - - ., Underhood

--+----.. . .

-starter 1Electrical
Relay I Center 2
I
I
I

C102
5PPL 6

32 BLK 1 (VIN K)
19 RED 1 (VIN G)

Battery

m
:::,
cc

:::,
CD

m
ci
(')

-...
c;

'Ignition
I

~~:~ution

0:,

!!.

B C2

! Automatic !

E'J
r------,Park/

~
~
~

5RED 2

0.35 PPL/WHT11035

I
Clutch
I
Pedal
Position (CPP) I

K2

$183

AI

L------

...

0.8 PPL/WHT 1035

P100
0.8 PPL/WHT 1035
C200B
CS C200D

C2

- - - - - , Underhood
~!Fuse
I Electrical
so A
I Center 2

a,
I
a,
a,

Starter
Solenoid

5PPL 6

13 BLK 50
L--""

'

G101

32 BLK 50 (VIN K)
19 BLK 50 (VIN G)
G100
192808

~____/

m
:::,

Starting and Charging Schematics (Charging System)

!Loe I

IHot In RUN,BULB TEST Or START I

... - - - -

Battery ... - - ,
Junction 1
_I_ -+
Block I
I
L. -

G3

Power
Distribution
Cell10

...

...

Fuse ock
Details
Cell 11

19 RED 1

,1p

GAGES

I Fuse

Fuse 9
10A

________ ...
H3

cc
:::,

(I)

!Desc!

Block

H4

0.8 PNK 39
$206
0.35PNK 39
A5
... - - - - - - - - - - - - - - - - - - - - - - - - , Instrument
I
Instrument
I Cluster

+--------

Cluster
Cell 81

CHECK GAUGES
Indicator

~;s::!

I
I

4700
Indicator
Control

>

Voltage

1
I L ..-&

Generator
Status

I
I

.......:!

I
I

t
8 RED 1 (VIN Kl
13 BLK 1 (VIN G)

32BLK
19RED

P110
Starter

m
:::,

Solid State Regulator

cc
0.35 BRN 25

:::,

0.35 RED 225

(I)

Ground
Distribution
Cell14

32 BLK 50 (VIN Kl
19 BLK 50 (VIN G)

13 BLK 50

L - - "'

'

Field
(Rotor)

II

36 C1
... - - - - - - - - - - - - ,powertrain
Generator
Generator I Co
I
I
Terminal L
PCM
Status
ntro
I
Output
C1 = RED
I Module (PCM)
I
C2=BLU
I

61

C2

.. ____________ ., >

er
n
" 'I

!!.

G101

G100
192813

en
I

m
U)

6-670

Engine

Engine Electrical

Component Locator
Engine Electrical Components
Name

Battery
Body Control
Module (BCM)
Clutch Pedal Position
(CPP) Switch
Instrument Cluster
Park Neutral Position
Switch

Location

Locator View

In the right front of the engine

compartment

Power and Grounding

Component Views

Under the right side of the instrument

panel. near the blower motor

Body Control Module

Component Views

Mounted to the clutch pedal bracket

On the left side of the instrument panel

Instrument Cluster
Component Views

Under the console, on the base of the shift

control lever

Tilt Wheel/Column
Component Views

Connector End View

-

Body Control Module

Connector End Views
Engine Electrical
Connector End Views
Instrument Cluster
Connector End Views
-

Powertrain Control
Module (PCM)
(V6 VINK)

On the right side of the engine

compartment, rear of the wheelhouse

Power and Grounding

Component Views

PCM Connector
End Views

Powertrain Control
Module (PCM)
(V8 VIN G)

On the right side of the engine

compartment, rear of the wheelhouse

Power and Grounding

Component Views

PCM Connector
End Views

Underhood Electrical
Center 2

On the left front corner of the engine

compartment

Power and Grounding

Component Views

Engine to forward lamp harness, in the

engine compartment, above the right
wheelhouse

Harness Routing Views

lnline Harness Connector

End Views

C200A ( 17 cavities)

Forward lamp to instrument panel harness,

behind the left kick panel and steering
column

Harness Routing Views

lnline Harness Connector

End Views

C200B (18 cavities)

Forward lamp to instrument panel harness,

between the left kick panel and the
steering column

Harness Routing Views

lnline Harness Connector

End Views

C200D (48 cavities)

Part of the instrument panel harness,

between the left kick panel and the
steering column

Harness Routing Views

lnline Harness Connector

End Views

C220 (10 cavities)

Instrument panel to engine harness, under

the right side of the instrument panel,
behind the knee bolster

Harness Routing Views

lnline Harness Connector

End Views

G100 (V6 VIN K)

On the lower right side of the engine,

above the A/C compressor

Harness Routing Views

G100 (V8 VIN G)

On the lower right side of the engine,

above the starter solenoid

Harness Routing Views

G101

In the engine compartment, attached to

the front of the left wheelhouse

Harness Routing Views

P100

Left side in the dash panel, engine to the

passenger compartment

Harness Routing Views

P110

Right side in the dash panel, engine to the

passenger compartment

8183

In the forward lamp harness,

approximately 10 cm (4 in) from the UH
electrical center 1 breakout

8206

Instrument panel, at rear compartment lid

release relay breakout

C101 (1 O cavities)

'

Engine Electrical

Engine

6-671

Engine Electrical Connector End Views

Gen~rator
Clutch Pedal Position Switch

I l
......-

lJ []
I

i;;;;;;;;i

~[]@O@O@JFD

I
62443
73251

Connector Part
Information

1203-3711
2 Way F Metri-Pack
480 Series (BLU)

Connector Part
Information

Circuit
No.

Pin

Wire Color

1204-7950
4 Wa,y F Metri-Pack
150 Series (BLK)
Circuit
No.

Not used

Pin

Wir~color

PPUWHT

1035

Ignition Feed

RED

25

DKGRN

1433

Clutch Pedal Position

Switch Output

RED

225

Function

G-D

Function

(VIN K) Generator Status

Output
(VIN G) Generator Status
Output
Not used

Diagnostic Information and Proced\,lres

Starting System Check
Action

Step

Normal Result(s)

Visually inspect the battery

hydrometer.

Battery hydrometer displays a

green eye.

Refer to Battery Hydrometer Displays

DE1rk or Yellow Dot.

Visually inspect the battery cables.

Battery .cables are clean and tightly

connected.

Battery cables arE;l frayed or .not

tightly connected: Refer to Battery
Cable Replacement (5.7L VB) or
Battery Cable Replacement
(3.BL V6).

Inspect STRTR fuse, IGN f1,1se, and

GAGES fuse 9.

STRTR fuse, IGN fuse, and GAGES

fuse 9 are not open.

Repair source, of overload anct

replace STRTR fuse, IGN fuse, or
GAGES fuse 9.

Inspect all grounds.

All grounds are clean and tightly

connected.

Clean and tighten grounds.

Inspect starter motor and starter

solenoid.

Both starter motor and starter

solenoid are properly mounted and
starter solenoid terminals S an'd 8
a.re clean and tight.

Ensure proper mounting and clean

and tighten terminals.

Inspect the generator.

Generator drive belt is tight. The

generator connector and terminal are
clean and tight.

Adjust generator drive belt.

Clean and tighten connectors and
terminals.

Check gages indicator lamp turns on,

engine does not run.

Refer to fnstrment Cluster

System Check.

2
\

Abnormal Result(s)*

Move the ignition switch from the

OFF position to the RUN position.

--'

6672

Engine

Engine Electrical
Starting System Check {cont'd)

Step

Action

Normal Result(s)

Move the ignition switch to the start

position and then slowly release.

Starter motor runs, the engine starts,

and the check gages indicator lamp
turns off.

Refe'r to SECURITY Indicator Off,

Engine Does Not Crank in Theft
Deterrent, Engine Cranks/Cranks
Slowly, but Does Not Start, or
Instrument Cluster System Check.

Allow Engine to run for

approximately 5-7 minutes.
Measure voltage at the Battery
terminals.

Voltage reading of 13-16 volts.

Refer to Battery Is Undercharged or

Overcharged.

Abnormal Result(s)*

* Refer to the appropriate symptom diagnostic table for the applicable abnormal result.

Charging System Check

Step

Action

Abnormal Result(s)*

Normal Result(s)

Visually inspect the battery

hydrometer.

Battery hydrometer displays a

green eye.

Refer to Battery Hydrometer Displays

Dark or Yellow Dot.

Visually inspect the battery cables.

Battery cables are clean and tightly

cormected.

Battery cables are frayed or not

tightly connected. Refer to Battery
Cable Replacement (5.7L VB) or
Battery Cable Replacement
(3.BL V6).

2
,

'

Inspect STRTR fuse, IGN fuse, and

GAGES fuse 9.

STRTR fuse, IGN fuse, and GAGES

fuse 9 are not open.

Repair source of overload and

replace STRTR fuse, IGN fuse, or.
GAGES fuse 9.

Inspect all gmunds.

All grounds are clean and tightly

connected.

Clean and tighten grounds.

Inspect starter motor and starter

solenoid.

Both starter motor and starter

solenoid are properly mounted and
starter solenoid terminals S and B
are clean and tight.

Ensure proper mounting and clean

and tighten terminals.

Inspect the generator.

Generator drive belt is tight. The

generator connector and terminal are
clean and tight.
\-

Adjust generator drive belt.

Clean and tighten connectors and
terminals.

Move the ignition switch from the

OFF position to the RUN position.

Check gages indicator lamp turns on,

engine aoes not run.

Refer to Instrument Cluster

System Check.

Move the ignition switch to the start

position and then slowly release.

Starter motor runs, the engine starts,

and the check gages indicator lamp
turns off.

Refer to Starter Solenoid Does Not

Click, Engine Cranks/Cranks Slowly,
but Does Not Start, or Instrument
Cluster System Check.

Allow Engine to run for

approximately 5-7 minutes.
Measure voltage at the Battery
terminals.

Voltage reading of 13~ 16 volts.

Refer to Battery Is Undercharged or

Overcharged.

* Refer to the appropriate symptom diagnostic table for the applicable abnormal result

Starter Solenoid Does Not Click

Step

Action

1. Disconnect the theft deterrent relay.

2. Connect a test lamp between the theft deterrent relay
terminal A 1 and B+.

Value(s)

No

Go to Step 2

Refer to Vehicle
Theft Deterrent
(VTD) System
Check.

Go to Step 3

Go to Step 4

3. Turn the ignition switch to START.

Does the test lamp go on?
1. Connect a test lamp between the theft deterrent relay
C1 and ground.
2. Turn the ignition switch to START.
Does the test lamp go on?

Yet;

Engine

Engine Electrical

6-673

Starter Solenoid Does Not Click (cont'.d)

Step

Action

1. Connect
relay C2
2. Turn the
Does the test

a test lamp between the theft deterrent

and ground.
ignition switch to START.
lamp go on?

1. Check for an open or poor connection in circuit 5 or

power feed circuit 102.
2. Check for a poor connection at the ignition switch
connector ,C2.
3. If OK, replace the ignition switch.

Value(s)

Yes

No

Go to Step 5

Go to Step 6

Is the repair complete?

System OK

Important: Do not allow the starter to crank longer than

15 seconds. Damage to the starter may occur.

1. Attach a 30A fused jumper between the theft

deterrent relay terminals C1 and A2.
2. Place the transmission in PARK or NEUTRAL
(automatic) or press the clutch pedal (manual).
3. Turn the ignition switch to START.

Go to Step 7

Does the engine crank?

6
"

1. Check for an open in circuit 269 from the the.ft

deterrent relay terminal C2 to the transmission range
switch terminal F (automatic) or the clutch pedal
position switch terminal A (manual).
2. Check for a poor connection at the transmission
range switch (automatic) or the clutch pedal position
switch (manual).
.3. Check for an open in circuit 5 from the transmission
range switch terminal E (automatic) or the clutch
pedal position switch terminal B (manual) to 8223.
4. If OK, adjust or replace the transmission range
switch. Refer to Automatic Transmission On Vehicle
Service.
Is the repair complete

1. Check for a poor connection at the theft

deterrent relay.
2. If OK, replace the theft deterrent relay.
Is the repair complete?

1. With the fused jumper still connected, connect a test

lamp from the starter solenoid terminal S to ground.
2. Place the transmission in PARK or NEUTRAL
(automatic) or press the clutch pedal (manual).
3. Turn the ignition switch to START.
Does the test lamp go on?

Go to Step 8

System OK

System OK

Go to Step 9

Go to Step 10

1. Check for a poor connection at the starter solenoid

terminal S.

10

2. If OK, replace the starter. Refer to Starter Motor

Replacement (5.7L VB) or Starter Motor Replacement
(3.BL V6).
Is the repair complete?
Repair the open or poor connection in circuit 6 between
the theft deterrent relay and the starter solenoid.
Is the repair complete?

System OK

System OK

6..;674

Engihe,Electri~af

Engine

Engine Cranks/Cranks Slowly; but Does. Not: Start

Action

Step

Value(s)

1. The .battery is fully charged.

2. Turn the ignition switch to START.
3. Wait. 15 seconds and measure the voltage at the
batt~ry while cranking the engine.
..
Is the reading greater than the specified value?
Measure the voltage between the B- terminal and the
engine block while cranking the engine.
Is the reading greater than the specified value?
Load test the battery. Refer to Battery (Parasitic)
.,
Load Test.
Is the battery OK?

Yes

No

' ..

9.5V
'

Goto Step 2

Go to Step 3

,.

0.5V

.',

'

Go to Step 4

Go to Step 5

Go_to Step 6

'Go to Step 1 ..

..

Replace the negative battery cable. Refer to Battery Cable

Replacement (5. 7L VB) or Battery Cable Replacement
(3.BL V6);
Does the starter solenoid continue to click and the engine
to crank slowly or not at all?

'

Measure the voltage between the B+ terminal and the

starter solenoid terminal B while cranking the engine.
Is the reading greater than the specified value?

Repair or replace the starter motor. Refer to Starter Motor

Replacement (5.7L VB) or Starter Motor Replacemerlt
(3.BL V6).
Does the starter solenoid continue to click and the engine
to crank slowly or not at all?

Replace the battery. Refer to. Battery Replacement.

Does the starter solenoid continue to click and the engine
to crank slowly or not at all? .

Replace the positive battery cable. Refer to Battery Qal:Jle

Replacement (5.7L VB) or Battery Cable Replacement
(3.BL V6).
Is the repair complete?

'

Go. to Step, ,5

.System OK

Go to Step.S :'

Go

0.5V

..

to Step 6

Go to Step 7

System OK

. Go ;to Step B

System OK

'.
i

System OK

Engine 'Electrical

Engine
Starter No Load Test

1 . Remove the starter motor. Refer to Starter Motor

Replacement (3.BL V6) or Starter Motor
Replacement (5. 7L VB)

6-675

8. If the starter motor energizes and the pinion

rotates, then, while maintaining 1 O Volts on
the voltmeter, check the current draw on the
ammeter and the pinion speed on the RPM

indicator

2. Turn OFF the carbon pile.

Turn OFF the switch.

Compare the values to the starter.
specifications ta.ble. Refer to Starter Motor
Usage.

- If the current draw and the pinion speed
(RPM) are within the specifications, then
the starter motor is good.
- If the current draw or the pinion speed
(RPM) is not within the specifications, then
replace the starter motor. Refer to Starter
Motor Replacement (3.BL V6) or Starter
Motor Replacement (5. 7L VB).

Battery Common Causes of Failure

Battery Diagnosis
If the battery tests good but still fails to perform well,
the following are some of the more common causes:
105 2

Caution: Keep fingers, tools, and any other

objects away from the opening in the drive end
housing while making electrical connections. The
strong shifting action of the starter solenoid
can cause severe personal injury or damage to
components as the drive pinion moves into
the cranking positiqn.

A vehicle accessory was left on overnight.

The driving speeds have been slow with frequent

stops (stop-and-go driving).
The electrical load has exceeded the generator
output (particularly with tt,e addition of aftermarket
equipment).
Existing conditions in the charging system,
including the following possibilities:

3. Make connections as shown with the switch open.

- An electrical short

4. Close the switch.

- A slipping belt

5. Adjust the carbon pile in order to obtain 10 Volts.

- A bad generator .

6. Compare the readings of the current, the RPM,

and the voltage. Refer to Starter Motor Usage.

7. If the pinion does not shift into the cranking

position or the pinion does not rotate, then
turn OFF the switch immediately. Ensure that the
test electrical connections were properly made.
If so, then replace the starter motor. Refer
to Starter Motor Replacement (3.BL V6) or Starter
Motor Replacement (5. 7L VB).

The battery has not been properly maintained,

including the following situations:

- A failure to keep the terminals tight

- A failure to keep the terminals clean

- A loose battery hold-down
Power failure caused by an existing mechanical
condition in the electrical system, such as a
short or pinched wire.
The car is in storage for extended periods of time.
Extended cranking periods caused by! spark
plug fouling.
The hydrometer has been read incorrectly.
There has been an insufficient ampere-hour
charge rate for a discharged battery.

There is a burned out charge indicator bulb

causing a NO CHARGE condition.
There is a continuous current draw on the battery
through excessive parasitic drain.
The battery is old.

6-676

Engine Electrical

Engine

Battery Hydrometer Displays Dark or

Yellow Dot

4. A low electrolyte (5) level can be caused by any

of the following conditions:
Prolonged charging
An excessive charge
A broken case
Excessive battery tipping
5. When finding a battery in this condition it may
indicate high charging voltages caused by a
faulty charging system. The charging and electrical
systems should be checked.
6. If there is a cranking complaint, inspect for trouble
in the charging or electrical systems.
7. If a cranking complaint exists and is caused by
the battery, the battery should be replaced.

Battery (Parasitic) Load Test

Tools Required

J 38758 Parasitic Draw Test Switch

J 39200 Digital Multimeter

A Fused Jumper Wire
Caution: Refer to Battery Disconnect Caution in
Cautions and Notices.

405478

1. The battery has a built-in hydrometer (1 ).

The hydrometer lens provides a visual indication
of the condition of the electrolyte.
2. Tap lightly on the lens and observe the built-in
hydrometer (1).
3. Under normal operation, one of three color
conditions on the hydrometer (1) is possible:
Green ball visible (2).
This condition indicates a sufficient state of
electrolyte (5) charge (65 percent or above) for
normal charging system operation.
Dark lens (3) (Green ball not visible)
This condition indicates an insufficient state of
electrolyte (5) charge (below 65 percent).
Recharge the battery before further testing.

208241

1. Disconnect the negative battery cable. Refer to

Battery Negative Cable Disconnect/Connect
Procedure.

Clear lens (4) (Yellow lens)

This condition indicates that the electrolyte (5)
is low. The battery electrolyte (5) cannot be
refilled. Replace the battery.

Engine

Engine Electrical

6-&n

1
405483

405480

2. Install the male end of the J 38758 (1) to the

negative battery terminal.

5. Turn the test switch ON (1 ).

Notice: Do not turn the parasitic draw test switch to

the OFF position with the engine running. Damage will
occur to the vehicle's electrical system.
6. Road test the vehicle. Activate all accessories,
including the air conditioning system and radio.
7. Turn OFF the ignition switch. Remove the key.
Important: This allows the electronically timed
components to power down, preventing false parasitic
drain readings.

8. Wait 15 minutes before continuing the test.

405481

3. Turn the test switch OFF (1 ).

4. Connect the negative battery cable (2) to the
female end of the test switch.

405486

9. Connect the fused jumper wire (1) to the terminals

of the test switch.

10. If the fuse does not fail, the J 39200 can be

installed. A current of less than 1O amps is
present.

6;;.678

Engine Electrijcal

fingine

1
405490

405487

11. Turn the test switch ON (1 ).

15. Turn the test switch OFF (1 ). Current is now

flowing through the ammeter option of J 39200

12. Remove the fused jumper wire.

16. Wait one minute.

17. Wait until the current reading is 2 amps or less.

405488

13. Set the J 39200 to the 1OA ,Scale (1 ).

405495

'Important: If an ammeter other than the J 39200 is

used, ensure that the vehicle does not have a

,high current drain that would damage the ammeter
when connected to the circuit
14. Connect the J 39200 to the terminals (2) of the
test switch.

18. Turn the test switch to ON (1 ).

19. Switch the J 39200 from the 10A setting to the 2A
setting.

Engine

Engine Electrical

6679

27. To finelthe:source of the excessive load perform

the following: .
\

2~A
20A
5

,,

10J I

II

20A 11 15A
7
6

25A
4

I "2~A I

I I 2.sA.
I ~.oA.
11 . L.:::::::_j

*
I
DD'~~ DD~
10A
9

1sA
10

D-"_. . n21: Dj
1

405490

20. Turn the test switch to OFF (1 ).

21. Read the current in milliamps. This is the parasitic
drain value.
22. Note the battery reserve capacity. Refer to Battery
Usage.

.23. Divide the battery reserve capacity by 4, this will

be the parasitic drain number.
'
24. The parasitic drain number should not exceed %
of the battery's reserve capacity.
'
i25. If the parasitic drain number exceeds % of the
battery's reserve capacity go to step 27.

405498

27.1. Remove the courtesy lamp fuse. Note the

J 39200 reading.
27.2. If the parasitic loaq is still excessive start
. removing the remaining fuses.

27.3. Keep the courtesy lamp fuse out during

diagnosis, so the door can remain open.
Continue removing the, fus~s one at a time,
starting with the fuses that are hot all the
time. When the voltage drops across the J 39200,
note the last fuse removed. The current drain
comes from the circuit or circuits protected by
that fuse.
29. Repair the circuit and perform the parasitic load
test again to verify the repair.

2a:

405483

26. Turn the test switch ON (1 ).

Notice: The test switch must be in the ON position

when removing the fuses in order to maintain
continuity in the electrical system. This avoids
damaging the digital multimeter due to accidental
overloading, such as a door being opened to change
a fuse.

208241

30. Connect the negative battery cable. Refer to

Battery Negative Cable Disconnect/Connect
Procedure.

s;.aao

Engine Electrical

Engine
Battery Is Undercharged or Overcharged

Step

Action

Value(s)

1. Disconnect the generator connector.

2. Turn the ignition switch to RUN with the engine OFF.
3. Connect a voltmeter set at DC scale between the
generator connector terminal L (V8 VIN G) or
terminal ,,.B (V6 VIN K) and ground.
4: (V6 VIN K) Using a scan tool, command the
powertrain control module (PCM) to turn the
generator on.
Is .the reading greater than the specified value?

ov

Move the voltmeter lead from terminal L (V8 VIN G) or

terminal B (V6 VINK) to the generator BATT terminal.
Is the reading greater than specified value?

ov

1, (V8 VIN G) Check for an open or poor connection in

circuit 225 between the generator terminal L and the
instrument cluster terminal A 14.
2. Check for an open fuse 9 or circuit 39 to the
instrument cluster. (If fuse 9 or circuit 39 is open, the
instrument cluster will not operate correctly.)
3. If OK, replace the instrument cluster. Refer to IP
Cluster Replacement.
4. (V6 VIN K) Check for an open or poor connection in
circuit 25 between the generator connector terminal B
and the powertrain control module (PCM). If OK
refer toA Powerlrain On Board Diagnostic (080)
System Che<;;k.
Is the repair complete?

1. Connect the generator connector.

2. Run the eqgine at fast idle with all of the
accessories OFF.
3. Connect a voltmeter set at the DC scale across the
battery terminals.
Is the reading within the specified value?

Repair open in circuiU between the generator BATI

terminal and the battery.
Is the repair complete?

..

1. Load test the generator.

2. Replace the generator if necessary. Refer to
Generator Replacement (5.7L VB) or Generator
Replacement (3.BL V6).
3. If the generator is OK, perform the Parasitic load
Test. Refer t6 Battery (Parasitic) Load. Test.
Repair or replace the generator. Refer to Generator
Replacement (5.7L VB) or Generator Replacement
(3.BL V6)
Is the repair complete?

Yes

No

Go to Step 2

Go to Step3

Go to Step 4

Go to Steps

System OK

(
13.5-15.5 V

Go to Step 6

Go to Step 7

, System OK

System OK

'

Engine
Generator Assembly Check
On Vehicle Inspection Procedure
When the charging system is operating normally, the
voltmeter will read between 11-16 volts when the
engine is running. If the voltmeter operates abnormally,
or if an undercharged or overcharged battery
condition occurs, the following procedure may be used
to diagnosis the charging system.
An undercharged battery js often caused by
accessories being left oh OVEH't'light, or by a hood or
instrument panel compartni'ent lamp that stays on.
Noise from a generator may be ca.1Jsedby a .
loose drive pulley, loose mounting bolts, worn or dirty
bearings, faulty diode or faulty stator. A magnetic
whining noise may be heard from the CS-130D
generator. This is considered a normal condition.
To avoid damage to the electrical equipment, always
observe the following precautions:
Precautions

1. Do not reverse the connections to the generator.

2. Do not short across or ground any of the

terminals in the charging circuit, unless otherwise
directed by instructions.
3. Never disconnect the generator BAT terminal
while the generator is operating.

4. When connecting a battery charger or a booster

battery, follow the procedure in Jump Starting in
Case of Emergency
5. Do not attempt to disassemble CS-130D
generator. Damage to the generator could result.
Trouble in the charging system will show up as one or
more of the following conditions:
An abnormal voltmeter reading
An undercharged battery condition (with slow
cranking or a dark hydrometer)
An overcharged battery condition (with electrolyte
leaks or a yellow hydrometer). Refer to Battery
Hydrometer Displays Dark or Yellow Dot

Engine Electrical

6-681

Diagnosis
Tool Required
J 39200 Digital Multimeter
To diagnosis the CS-130D charging system, use the
following procedure.
1. Inspect the accessory drive belt for damage or
wear. Service or replace as necessary.
2. Inspect the wiring.
3. Check for an undercharged or overcharged
battery condition (voltage lower than 11 volts
or higher than 16 volts), refer to Battery Is
Undercharged or Overcharged
Detach the wiring harness connector from the
generator.
With the ignition switch in the ON position and
the engine not running, connect the J 39200
as a voltmeter from a ground to the L terminal
in the wiring harness connector. Connect
the F or the I terminal for the gauge equipped
vehicles. At least one terminal should have
battery voltage.
Zero volts indicates an open circuit between
the terminal and the battery. Connect as
required.
Reconnect the wiring harness connector to the
generator.
Important: Disconnect the negative battery cable
before removing or installing a series-type ammeter at
the generator battery terminal.
Install an ammeter at the generator output
terminal. With the load off, install a carbon pile
load test across the battery terminals. Start
the engine and run at 2500 RPM. Make sure
this is done at ambient temperature.
Measure the voltage across the battery, using
the J 39200 If the voltage is above 16 volts, ,
replace or repair the generator. Refer to
Generator Replacement (3.BL V6) or Generator
Replacement (5. 7L VB).
Turn on the accessories and place a load on
the battery with the carbon pile to obtain
maximum generator output. Maintain voltage at
13 volts or above. Use an ammeter to check
amperage. Compare output to amperage rating
in Generator Usage

6-682

Engine Electrical

Engine

Spark Plug Visual Diagnosis

Worn or dirty plugs give satisfactory operation at idling
speed, but under operating conditions they frequently
fail. Faulty plugs are indicated in a number of ways
poor fuel economy, power loss, loss of speed,
hard starting and general poor engine performance.
Spark plugs may also fail due to carbon fouling,
excessive plug gap, or broken insulators. Fouled plugs
are identified by black carbon deposits. The black
deposits are usually the result of slow-speed driving
and short runs where sufficient engine temperature is
seldom reached. Worn pistons, rings, faulty ignition,
over-rich air/fuel mixture and spark plugs which are too
cold will also result in carbon deposits. Excessive
gap wear, on plugs of low mileage usually indicated
the engine is operating at high speeds or loads
that are consistently greater than normal or that a plug
which is too hot is being used. Electrode wear may
also be the result of plug overheating due to
insufficient spark plug torque or too much spark plug
torque. An excessively lean air/fuel mixture will
also result in excessive electrode wear.
Broken insulator are usually the result of improper
installation or carelessness when regapping .the plug.
Broken upper insulators usually result from a poor
fitting wrench or an outside impact. The cracked
insulator may not show up right away, but will as soon.
as oil or moisture penetrates the crack. The crack

may not be visible. Broken lower insulators usually

result from carelessness when regapping and
generally are visible. This type of break may result
from the plug operating too hot, which may happen in
periods of high-speed operation or under heavy
loads. When regapping a spark plug, always make the
gap adjustment by bending the ground (side)
electrode. Spark plugs with broken insulators should
always by replaced.
Resistor type spark plugs with tapered seats are used.
No gasket is needed on these plugs. These spark
plugs are a High Efficiency (HE) spark plug that has a
fine wire electrode, nickel plated shell and a platinum
pad across from the electrode.
1. Normal service is a mixture of idling, low speed,
and high speed operation.

1053

Occasional high speed driving is essential to

good spark plug performance.
Increased combustion hea.t burns away excess
carbon deposits, which accumulate from
frequent idling or stop-and-go driving.
2. The heat resistant, insulating boot covers the
spark plug terminal.
The boot extends over a portion of the spark
plug insulator.
These boots prevent engine misfiring.
3. Corona discharge is a steady blue light appearing
(in darkness) around the insulator, just above the
shell crimp.
Do not mistake this for a shorted insulator.
This is visible evidence of a high-tension field.
This has no effect on ignition system
performance.
This discharge repels dust particles.
This leaves a clear ring on the insulator just
above the shell.

This is not evidence that combustion gases

are escaping.

Spark Plug Visual Diagnosis

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to Step 3

DEFINITION: A visual inspection of the spark plug firing end.

3
4

1. Remove the spark plug from the engine.

2. Note which cylinder the plug is from.
Do you see a brown to grayish tan deposit with a slight

electrode wear?
1. This is normal wear clean, regap and install the plug.
2. Tighten the plug, refer to Fastener Tightening
Specifications.
Is the repair complete?
Do you see dry, fluffy, black carbon deposits?
This indicates poor ignition output.
Is the ignition coil(s) to the spark plug connections OK?

1.524 mm
(0.060 in)

System OK

Go to Step 4

Go to Step 6
Go to Step 5

Engine Electrical

Engine

6-683

. Spark. Ptug Visual Diagnosis (cont'd)

Action

Step

5
6

Repair or install new parts as necessary.

Is the repair complete?
Do you see wet, oily deposits with very little
electrode wear?
1. This results from either the break-in of a new or
recently overhauled engine or from failed piston rings.
2. Degrease, gap and reinstall the spark plug.

Value(s)

10

11

Go to Step 7

Go to Step B

System OK

Go to Step 11

Go to Step 9

Go to Step 11

Go to Step 10

Go to Step 2

0.060 in

Do you see red, brown, yellow and/or white colored

coatings on the insulator?

These are the by-products of combustion.

Is the insulator heavily coated?

System OK

No

1.524 mm

Is the repair complete?

8

Yes

1. Gap and install new spark plug(s).

2. Tighten the spark plug, refer to Fastener Tightening
Specifications.
Is the repair complete?

1.524 mm
(0.060 in)

Are there heavy deJjosits of dark colored coatings,

especially on the side bf the plug facing the intake valve?

System OK

. Go to Step 12

Go to Step 13

This is the result of failed intake valve seats or)rom

excessive valve stem to valve guide clearances.
This may nofoccur in all cylinders.
Repair or install new parts as necessary.
Is the repair complets?

13

Is there a shiny, yellow glaze coating on the spark plug

insulator?

14

These are the melted by-products of combustion.

1. Avoid wide open throttle after long periods of low
speed operation.
2. Gap and install new spark plug(s). Refer to Fastener
Tightening Specifications.
Is the repair complete?

15

Are the insulator tips blistered or burned?

Are the electrodes badly eroded?

16

This is the result of overheating.

The spark plug heat range may be too hot.
The fuel octane rating may be to low for the application,
refer the customer to the Owner Manual for correct fuel
rating.
Is the plug heat range correct?

Check the torque value to ensure good spark plug seat

contact.
Are the spark plugs tightened according to specifications?
Refer to Fastener Tightening Specifications

~.

18

Check for a misfiring engine, refer to OTC P0230 Fuel

Pump Relay Control Circuit for V6 or OTC P0300 Engine
Misfire Detected for V8 in Engine Controls.
Is the vehicle operating properly?.

19

Check for a lean/rich fuel mixture, refer to Fuel System

Diagnosis for V6 or Fuel System Diagnosis for V8 in
Engine Controls.
Repair or install new parts as necessary.
Is the repair complete?

12

17

20

Gap and install the correct spark plug(s).

Is the repair complete?

System OK

Go to Step 14

1.524 mm
(0.060 in)

Go to Step 15

System OK

Go to Step 16

Go to Step 17

Go to Step 20

Go to Step 18

Go to Step 10

Go to Step 19

Go to Step 10

System OK

System OK

6-684

Engine

Engine Electrical

Spark Plug Wires Not Operating Properly

Inspection Procedure
1. Inspect the spark plug gap. Adjust as needed.
2. Inspect the spark plug wires for any obvious cuts,
burns, or damage. replace as needed.
3. With the engine ON, inspect for any arcing to
ground or other components. Replace the
wires as required.
4. Connect an ohmmeter to the end of each suspect
wire. If the meter reads over 30,000 ohms,
replace the wire.

Repair Instructions
Starter Motor . Replacement (3.8L V6)
Removal Procedure
Important: This vehicle was designed for starter
mounting without shims. However, if single or double
shims have been added to correct a noise or
engagement condition, reinstall the shims in their
original location to ensure proper pinion-to-flywheel
engagement.
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Remove the starter shield. Refer to Starter Shield
Replacement (3.BL V6).
3. Remove the starter motor bolt.
4. Remove the starter motor stud.
5. Lower the starter motor.
43571

6. Remove the positive cable to starter nut (1 ).

7. Remove the positive cable.

211604

Engine

Engine Electrical

6-685

8. Remove the starter motor lead nut from the

starter.
9. Remove the starter motor lead.
10. Remove the starter motor.

211623

Installation Procedure
1. Install the starter motor.
2. Install the starter motor lead to the starter.
3. Install the starter motor lead nut.

Notice: Refer to Fastener Notice in Cautions and

Notices.
Tighten
Tighten the starter motor lead nut to
2 N,m(17 lb in).

211623

4. Install the positive cable.

5. Install the positive cable to starter nut (1).
Tighten
Tighten the positive cable to starter nut (1) to
10 Nm (89 lb in).
6. Raise the starter motor.

211604

6-686

Engine

Engine Electrical
7. Install the starter motor bolt.
Tighten
The bolt to 47 N-m (35 lb ft).
8. Install the starter motor stud.

Tighten
The starter motor stud to 45 N-m (33 lb ft).

9. Install the starter shield. Refer to Starter Shield

Replacement (3.BL V6).

43571

Starter Motor Replacement (5. 7L VS)

Removal Procedure

Important: This vehicle was designed for starter

mounting without shims. However, if single or double
shims have been added to correct a noise or
engagement condition, reinstall the shims in their
original location to ensure proper pinion-to-flywheel
engagement.
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Remove the left side oxidation catalytic converter.
Refer to Oxidation Catalytic Converter
Replacement (Left)
in Engine Exhaust.
3. Remove the starter motor bolts.
4. Lower the starter motor.

~
211621

5. Remove the engine wiring harness starter

lead nut.

211617

Engine Electrical

Engine

6-687

6. Remove the positive battery cable to .starter motor

nut (3).

7. Remove the starter motor.

4
211595

Installation Procedure
Notice: Refer to Fastener Notice in Cautions and
Notices.

1. Install the starter motor.

2. Install the positive battery cable to starter motor

nut (3).

Tigh~en
Tighten the positive battery cable to starter motor
nut (3) to 10 Nm (89 lb in).

211595

3. Install the engine wiring harness starter lead nut .

Tighten
Tighten the engine wiring harness starter lead nut
to 2 N-m (18 lb in).
4. Raise the starter motor.

)
211617

6;.688

Engine Electrical

Engine
5. Install the starter motor bolts.

Tighten
Tighten the starter motor bolts to 50 N-m (37 lb ft).
6. Install the left side oxidation catalytic converter.
Refer to Oxidation Catalytic Converter
Replacement (Left) in Engine Exhaust.
7. Lower the vehicle.

211621

Starter Shield Replacement (3.8L V6}

Removal Procedure
1 . Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Remove the starter shield bolts (1, 3) and nut (2).

3. Remove the starter shield from the vehicle.

211622

Installation Procedure
1. Install the starter shield to the vehicle.
Notice: Refer
Notices.

to Fastener Notice in

Cautions and

2. Install the starter shield nut (2) and bolts (1, 3). '
Tighten
Tighten the starter shield nut (2) to
10 N-m (89 lb in).
Tighten the starter shield to transmission brace
bolt (3) to 10 N-m (89 lb in).
Tighten to starter shield to engine block
bolt (1) to 30 N-m (22 lb ft).
3. Lower the vehicle.

211622

Engine

Engine Electrical

6-689

Battery Replacement
Removal Procedure
Caution: Refer to Battery Disconnect Caution in

Cautions and Notices.

1. Disconnect the negative battery cable. Refer to

Battery Negative Cable Disconnect/Connect
Procedure.

208241

2. Disconnect the positive battery cable.

211587

3. Remove the battery hold down retainer bolt.

4. Remove the battery hold down retainer.
5. Remove the battery.

)
43660

5.;.590

Engine

Engine Electrical
Installation Procedure
1. Install the battery.

2. In.stall th13 battery hold. dowq retainer.

Notice: Refer to.Fastener Notice in Cautions and:..
Notices..
..
.
3. lnstalUhe battery hold dov,m retainer bolt.

Tighten
Tighten the battery hold down retainer bolt to
18 Nm (13 lb ft).

43660

4. Connect the positive battery cable.

Tighten
Tighten the positive battery cable to
15 N,m (11 lb ft).

211587

5. Connect the negative battery cable. Refer to

Battery N~gative .Cable Di$connect/Connect
Procedure.

208241

Engine
Battery Charging
Before Charging
Notice: Turn OFF the ignition when connecting or
disconnecting the battery cables, the. battery charger
or the jumper .cables. Failure to do so may damage the
PCM or other electronic components.

Important: Do not use the boost, the jump start or the

crank setting for prolonged charging of batte.ries if
the charger is equipped with these settings. Using any
of these settings for a prolonged period may cause
gassing or spewing of electrolyte through the
vent hole.
1. Ensure that the electrolyte and the plates are at
room temperature before charging the battery. An
extremely cold battery may not accept the
current for several hours after the charger is
started.
2. Always stop charging, or reduce the charging
rate, if either of the following conditions exists:
The battery temperature is 52C (125F)
or higher.
Electrolyte spews or gasses violently through
the vent holes.
3. Replace the battery when either of the following
conditions exist:
The hydrometer is clear or yellow.
The battery is frozen.

Charge Time Required

The time required to charge a battery will vary
depending on the following factors:
The size of the battery; A higher capacity battery
which is completely discharged requires more
time to charge than a smaller capacity battery.
The battery temperature; The colder the battery,
the more time it takes to charge.
The battery charger capacity (in Amperes); The
higher the charger amperage, the less time it
will take to charge the battery.
The battery state-of-charge; A completely
discharged battery requires more than twice as
much charge as a half-charged battery.

While Charging

Tools Required
GM PIN 12303040 Battery Terminal Adapters
1. Do not charge a battery with a green hydrometer
dot unless it has just been discharged, such as in
cranking.
2. When charging, the adapters should be snug
against the battery terminals to keep resistance
to a minimum.
3. Make sure all battery terminals are clean and tight.
Tighten
Tighten the battery side terminal adapters to
15 Nm (11 lb ft).

Engine Electrical

6~91

4. Best results occur when charging a battery tha.t is

at room temperature. A battery that is extremely
cold may not accept current for several hou~s.
5. Charge the battery until the hydrometer has a
green dot.

6. Inspect the battery every half hour after starting

the battery charger.
7. Tap the hydrometer lightly to dislodge any air
bubbles. The bubbles may cause a.false
indication.
8. After charging, load test the battery.

Charging Procedure
1. Measure the battery voltage:
Measure the voltage at the battery terminals
using a voltmeter.
A reading of less than 11 Volts indicates that
the charge current is low.
The battery will take longer fo accept a current

higher than 2 milliamps,

2. Set the battery charger on the highest setting.
3. If necessary, disable the polarity protection
circuitry:
This circuitry, available on most chargers,
prevents charging unless the charger leads are
properly connected to the battery terminals.
A completely discharged battery may not have
enough voltage to activate this circuitry, even
though the leads are properly connected,
implying that the battery will not accept
a charge.
Most chargers have an override or a bypass
function so that the charger will turn on and
charge a low voltage battery.
4. The required battery charge time varies according
to the voltage capabilities of the battery charger.
Replace the battery only if the charge current
is not measurable after the following charge times.
16 Volts or more - up to 4 hours
14-15.9 Volts - up to 8 hours
Less than 13.9 Volts - up to 16 hours
5. Reserve capacity rating:
The reserve capacity rating on the battery
label is the number of Ampere-hours of charge
required in order to produce the green
hydrometer dot.
For example, if the battery has a reserve
capacity rating of 90 (expressed in
Ampere-hours), the battery would be recharged
as follows:
- 1O Ampere charge x 9 hours =
90 Ampere hours
- 30 Ampere charge x 3 hours =
90 Ampere hours
If the green hydrometer dot is not visible after
an Ampere-hour charge equal to twice the
reserve capacity rating, replace the battery.
6. After charging, load test the battery. Refer to
Battery (Parasitic) Load Test.

6-692 . Engine Electrical

Engine
Jump Starting in Case of Emergency
Caution: Batteries produce explosive gasses.
Batteries contain corrosive acid. Batteries supply
levels of electrical current high enough to
cause burns. Therefore, to reduce the risk of
personal injury while working near a battery:
Always shield your eyes.
A void leaning over the battery whenever
possible.
Do not expose the battery to open flames or
sparks.
Do not allow battery acid to contact the eyes
or the skin.
- Flush any contacted areas with water
immediately and thoroughly.
- Get med/cal help.
Notice: Push starting the vehicle can, under some
conditions, cause damage to the catalytic converter
and an automatic transmission.

405500

This vehicle has a 12 Volt, negative ground electrical

system. Make sure the vehicle or equipment being
used to jump start the engine is also 12 Volt, negative
ground. Use of any other type of system will damage
the vehicle's electrical components.
1. The following procedure is a typical battery to
battery hookup for jump starting.
2. The booster battery (4) and the discharged
battery (3) should be treated carefully when using
jumper cables. Do not cause sparks;
3. Position the vehicle with the charged (booster)
battery (4) so that the jumper cables will reach.
Do not let the vehicles touch.
4. Attach the end of one jumper cable (6) to the
positive terminal of the booster battery (4).
5. Attach the other end of the same cable (2) to the
positive terminal of the discharged battery (3).
6. Attach one end of the second jumper cable (5) to
the negative terminal of the booster battery (4).

Caution: CAUTION: Do not connect a jumper cable

directly to the negative terminal of a discharged
battery to prevent sparking and possible explosion
of battery gases.
7. Attach the other end of the second jumper
cable (1) to a good engine ground (engine lift hook
or generator bracket) at the discharged battery (3).

Engine
8. Start the engine of the vehicle that is providing
the boost (4).
9. Start the engine of the vehicle with the discharged
battery (3).
10. Disconnect the negative jumper cable (1) from the
engine ground of the battery (3) that was boosted.
11. Remove the other end of the negative jumper
cable (5) from the booster battery (4).
12. Remove the positive jumper cable (60 from the
booster battery (4).

Engine Electrical
1

6-693
2

Important: Do not let the cable end touch any metal

while the other cable end is still connected.
13. Remove the positive jumper cable (2) from the
other battery (3).

405501

Battery Negative Cable

Disconnect/Connect Procedure
Removal Procedure

Caution: This vehicle has a Supplemental Inflatable

Restraint (SIR) System. Refer to SIR Component
Views in order to determine whether you are
performing service on or near the SIR components
or the SIR wiring. When you are performing
service on or near the SIR components or the SIR
wiring, refer to Repair Instructions in SIR. Failure
to follow the CAUTIONS could cause air bag
deployment, personal injury, or unnecessary SIR
system repairs.
Caution: Before servicing any electrical
component, the ignition key must be in the OFF or
LOCK position and all electrical loads must be
OFF, unless instructed otherwise in these
procedures. If a tool or equipment could easily
come in contact with a live exposed electrical
terminal, also disconnect the negative battery
cable. Failure to follow these precautions
may cause personal injury and/or damage to the
vehicle or its components.
1. Record all the vehicle preset radio stations.
2. Record the customers's radio Theftlock code (if
applicable).
3. Turn all the lamps and accessories off.
4. Turn the ignition switch to the OFF position (3).

341078

6-694

Engine Electrical

Engine
5. Disconnect the negative battery cable.

208241

Installation Procedure
Important: Clean any existing oxidation from the
contact face of the battery terminal and battery cable
using a wire brush before installing.
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Install the negative battery cable.

Tighten
Tighten the negative battery cable to
15 N-m (11 lb ft).
2. On V8 equipped vehicles, perform a PCM idle
learn procedure. Refer to PCM Idle Learn
Procedure in Engine Controls-5.7L.

208241

3. Turn .the ignition switch to the ACC position (1 ).

4. Unlock the Theftlock radio (if applicable). Refer
to Radio/Audio System Operation-Theftlock in
Entertainment.
5. Reprogram the radio stations to the previous
settings.

6. Set the clock to the current time.

7. Turn the ignition key to the LOCK position (2) and
remove the key.

(
341078

Engine

Engine Electrical

6-695

Battery Cable Replacement (3.8L VG)

Removal Procedure
)

Negative Cable
1. Remove the battery. Refer to Battery
Replacement.
2. Remove the battery negative cable nut.
3. Remove the ground lead from the
wheelhouse stud

211588

4. Remove the battery cable from the rosebud clip at

the accumulator !;>racket.

211593

5. Remove the negative battery cable nut from the

engine block stud.
6. Remove the negative battery cable from the
conduit.

)
43679

6-696

Engine Electrical

Engine
Positive Cable

1. Remove the battery. Refer to Battery

Replacement.
2. Remove the positive battery cable from the stud
on the fuseblock:

Open the positive cable cap.

Remove the positive cable nut.
Remove the positive lead from the stud.

211614

3. Remove the positive cable.from the generator:

Slide the boot down revealing the positive
terminal stud.
Remove the positive cable nut at the generator.
Remove the positive cable.
4. Remove the positive cable rosebud clip from the
engine lift bracket.

43670

5. Remove the positive cable rosebud clips from the

cooling fans.
6. Raise and suitably support the vehicle; Refer to
Lifting and Jacking the Vehicle in General
Information.

211607

,Engine

Engine Electrical

e.;.597

7. Remove the positive cable from the rosebud clip

at the power steering reservoir.

8. Remove the bolt and ground strap at tlie driver

)

side front rail.

211610

9. Remove the positive/negative cable from the

engine mount stud:
Remove the battery positive cable nut (2).
Remove the harness clamp from the stud.
Remove the RF (Radio Frequency)
ground strap.
10. Remove the starter shield. Refer to Starter Shield
Replacement (3.BL V6).
11 . Remove the positive cable from the start~r
solenoid:
Remove the cable to starter nut (1 ).
Remove the positive cable from the conduit.

211604

Installation Procedure
Positive Cable
1. Install the positive cable to the conduit.
2. Install the cable to starter nut (1).
Notice: Refer to Fastener Notice in Cautions and
Notices.

Tighten
Tighten the positive cable to starter nut (1) to
10 N,m (89 lb in).
3. Install the starter shield. Refer to Starter Shield
Replacement (3.BL V6).

)
211604

6-698

Engine Electrical

Engine
4. Install the positive/negative cable to the engine
mount stud:
Install the RF (Radio Frequency) ground strap.
Install the harness clamp to the stud.
Install the battery positive cable nut (2).

Tighten
Tighten the positive cable to block stud
nut (2) to 25 N-m (18 lb ft).
5. Install the bolt and ground strap at the driver side
front rail.
Tighten
Tighten the ground strap bolt to 12 N-m (106 lb in).
6. Connect the positive cable to the rosebud clip at
the power steering reservoir.
7. Lower the vehicle.

8. Install the positive cable rosebud clips to the

cooling fans.

(
'

Engine

Engine Electrical

6-699

9. Install the positive cable to the generator.

Install the positive cable to the stud.
Install the positive cable nut to the generator.

Tighten
Tighten the positive cable to generator nut
to 22 Nm (16 lb ft).
Slide the boot over the positive terminal stud.

43670

10. Install the positive battery cable to the stud on the

fuseblock:
Install the positive lead to the stud.
Install the positive battery cable nut.

Tighten.
Tighten the positive cable to fuseblock nut
to 14 Nm (10 lb ft).
Close the positive cable cap.
11. Install the battery. Refer to Battery Replacement.

211614

Negative Cable
1. Install the negative battery cable to the conduit.
2. Install the negative cable to the engine bloc~ stud.
3. Install the negative cable nut to the engine
block stud.

Tighten
Tighten the negative cable nut to engine block
stud to 22 N-m (16 lb ft).

)
43679

6-700

Engine

Engine Electrical

4. Install the battery cable to the rosebud clip on the

accumulator bracket.

211593

5. Install the ground lead to the wheelhouse stud.

6. Install the battery negative cable nut.
Tighten
Tighten the negative cable nut to 6 N-m (53 lb in).
7. Install the battery. Refer to Battery Replacement.

211588

Battery Cable Replacement (5.7L VS)

Removal Procedure
Negative Battery Cable
1. Remove the battery. Refer to Battery
Replacement.
2. Remove the battery negative cable nut.
3. Remove the ground lead from the
wheelhouse stud.

211588

Engine

Engine Electrical

6-701

4. Remove the battery cable from the rosebud clip at

the accumulator bracket.

211593

5. Remove the negative cable to engine block

bolt (1).
6. Remove the ground lead from the block.
7. Remove the negative battery cable from the
conduit.

4
211595

Positive Cable

1. Remove the battery. Refer to Battery

Replacement.
2. Remove the positive battery cable from the stud
on the fuseblock.
Open the positive cable cap.
Remove the positive battery cable nut.
Remove the positive lead from the stud.
3. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

)
211614

6-702

Engine Electrical

Engine
4. Remove the conduit rosebud clips from the
cooling fans.
5. Remove the bolt and ground strap at the driver
side front rail.

211602

6. Remove the positive cable from the generator.

Slide the boot down revealing the positive
terminal stud.
Remove the positive cable nut at the generator.
Remove the positive cable.

211599

7. Remove the positive cable to starter nut (3).

8. Remove the positive cable from the starter.
9. Remove the positive cable from the conduit.

4
211595

Engine

Engine Electrical

6-703

Installation Procedure
')

Positive Cable
1. Install the positive cable to the conduit.
2. Install the positive cable to the starter.
3. Install the positive cable to starter nut.

Notice: Refer to Fastener Notice in Cautions and

Notices.

Tighten
Tighten the positive cable to starter nut to
10 N-m (89 lb in).

165225

4. Install the positive cable to the generator:

Install the positive cable.
Install the positive cable nut.

Tighten
Tighten the positive cable nut to generator
to 22 N-m (16 lb ft).
Slide the boot over the positive terminal stud.
5. Install the ground strap and bolt at the driver side
front rail.
Tighten
Tighten the ground strap bolt to 12 N-m (106 lb in).

211599

6. Install the conduit rosebud clips to the

cooling fans.
7. Lower the vehicle.

211602

6-704

Engine Electrical

Engine
8. Install the positive cable into the clip:
Install the positive cable.
Snap the clip closed.
Lower the vehicle.

165219

9. Install the positive battery to the stud on the

fuseblock:
Install the positive lead to the stud.
Install the positive battery cable nut.

Tighten
Tighten the cable nut to 14 Nm (1 O lb ft).
Close the positive cable cap.
10. Install the battery. Refer to Battery Replacement.

211614

Negative Cable

1. Install the negative cable to the conduit.

2. Install the ground lead and negative cable to the
engine block bolt (1 ).
Tighten
Tighten the negative cable to engine block bolt (1)
to 32 Nm (24 lb ft).

211595

Engine

Engine Electrical

6-705

3. Install the battery cable to the rosebud clip at the

accumulator bracket.

211593

4. Install the ground lead to the wheelhouse stud.

5. Install the negative cable nut.
Tighten .
Tighten the negative cable nut to 6 Nm (53 lb in).
6. Install the battery. Refer to Battery Replacement.

211588

Generator Bracket Replacement

Removal Procedure
1. Remove generator rear brace. Refer to Generator
Brace Replacement.
2. Remove the fuel rail from the upper intake
manifold. Refer to Fuel Rail Assembly
Replacement in. Engine Controls-3.SL.
3. Remove the generator brace bracket bolts.
4. Remove the bracket from the vehicle.

165246

6-706

Engine Electrical

Engine
Installation Procedure
1. Install the bracket to the vehicle.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the generator brace bracket bolts.
Tighten
Tighten the brace bracket bolts to
50 N-m (37 lb ft).

3. Install the fuel rail to the upper intake manifold.

Refer to Fuel Rail Assembly Replacement in
Engine Controls-3.SL
4. Install the generator rear brace. Refer to
Generator Brace Replacement.

165246

Generator Brace Replacement

Removal Procedure
1. Remove the generator. Refer to Generator
Replacement (3.BL V6).
2. Remove the canister purge solenoid. Refer to

5~

EVAP Canister Purge Solenoid Valve

Replacement in Engine Controls-3.SL.
3. Remove the generator rear brace bolts (5).
4. Remove the generator rear brace (4) from the
vehicle.

165247

Installation Procedure
1. Install generator rear brace (4) to vehicle.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install generc1tor rear brace bolts.
Tighten
Tighten the generator rear brace bolts (5) to
25 Nm (18 lb ft).
3. Install the canister purge solenoid. Refer to EVAP
Canister Purge Solenoid Valve Replacement in
Engine Controls-3.SL.
4. Install the generator. Refer to Generator
Replacement (3.BL V6).

165247

Engine

Engine Electrical

5..707

Generator Replacement (3.SL V6)

Removal Procedure

1. Remove the accessory drive belt. Refer to Drive

Belt Replacement in Engine Mechanical-3.BL.
2. Disconnect the generator electrical connector.

----- \ ---

211637

3. Remove the positive cable nut from the generator

terminal.
4. Remove the canister purge solenoid. Refer to
EVAP Canister Purge Solenoid Valve
Replacement in Engine Controls-3.BL.

43670

5. Remove the generator rear brace bolt.

43656

6-708

Engine Electrical

Engine
6. Remove the generator bolts (1, 2).

7. Remove the generator from the drive belt

tensioner.

43850

Installation Procedure
1. Install the generator to the drive belt tensioner.
Notice: Refer to Fastener Notice in Cautions and
Notices.

2. Install the generator bolts (1, 2).

Tighten
Tighten the generator bolt (1) to
30 N-m (22 lb ft).
Tighten the generator bolt (2) to
50 N-m (37 lb ft).
3. Install the canister purge solenoid. Refer to EVAP
Canister Purge Solenoid Valve Replacement in
Engine Controls-3.BL.

43850

4. Install the generator brace bolt.

Tighten
Tighten the generator brace bolt to
30 Nm (22 lb ft).

43656

Engine

Engine Electrical

6-709

5. Install the positive cable nut on the generator

terminal.
Tighten
Tighten the positive cable nut to generator to
22 Nm (16 lb ft).

43670

6. Connect the generator electrical connector.

7. Install the accessory drive belt. Refer to Drive Belt
Replacement in Engine Mechanical-3.8L.

211637

Generator Replacement (5.7L VS)

Removal Procedure
1. Remove the accessory drive belt. Refer to Drive
Belt Replacement (Accessory) in Engine
Mechanical-5.?L.
2. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
3. Remove the generator rear bracket mounting bolt.

-~
2

211626

6-710

Engine Electrical

Engine
4. Remove the generator mounting bolts.

211628

5. Disconnect the generator electrical connector (3).

6. Remove the generator from the vehicle.

211624

Installation Procedure
1. Install the generator electrical connector.
2. Connect the generator electrical connector (3).

211624

Engine

Engine Electrical

6-711

Notice: Refer to Fastener Notice in Cautions and

Notices.
\

3. Install the generator mounting bolts.

Tighten
Tighten the generator mounting bolts to
50 N-m (37 lb ft).

211628

4. Install the generator rear bracket mounting bolt.

Tighten
Tighten the rear bracket mounting bolt to
25 N-m (18 lb ft).
5. Lower the vehicle

6. Install the accessory drive belt. Refer to Drive Belt

Replacement (Accessory) in Engine
Mechanical-5. 7L.

-~
2

211626

Spark Plug Wire Harness

Replacement (V6)
Removal Procedure
Right Bank
1. Turn the ignition to OFF (3) or to LOCK (2).
2. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

341078

6-712

Engine Electrical

Engine
3. Disconnect the number 4 and number 6 plug
wires from the spark plugs.
Notice: Twist the spark plug boot one-half turn in
order to release the boot. Pull on the spark plug boot
only. Do not pull on the spark plug wire or the wire
could be damaged.
4. Lower the vehicle.
5. Disconnect the number 2 plug wire from the
spark plug.

211645

6. Disconnect the even (2, 4, 6) spark plug wires

from the ignition coils.
7. Remove the spark plug wire harness.

43661

Left Bank

1. Disconnect the odd numbered plug wires (1, 3, 5)

from the ignition coils.
Notice: Twist the spark plug boot one-half turn in
order to release the boot. Pull on the spark plug boot
only. Do not pull on the spark plug wire or the wire
could be damaged.
2. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

43661

Engine

Engine Electrical

6~713

3. Remove the plug wires from the spark plugs.

4. Remove the spark plug wire harness from the
vehicle.

211642

Installation Procedure
Important: The lower tabs of the heat shield must
extend over the hex on the spark plug in order
to complete installation of the heat shield and the boot
on the spark plug.
Left Bank
1. Install the spark plug wire harness to the vehicle.
2. Install the spark plug wires to the spark plugs.
3. Lower the vehicle.

211642

4. Connect the odd numbered plug wires (1, 3, 5) to

the ignition coils.

)
43661

6-714

Engine Electrical

Engine
Right Bank

1. Install the spark plug wire harness.

2. Connect the even (2, 4, 6) spark plug wires to the
ignition coils.
3. Connect the number 2 plug wire from the
spark plug.
4. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

43661

5. Connect the number 4 and number 6 plug wires

from the spark plugs.
6. Lower. the vehicle.

211645

Spark Plug Wire Harness

Replacement (VS}
Removal Procedure
1. Disconnect the spark plug wire at each spark plug.
Twist each spark plug 1/2 turn.
Pull only on the boot in order to remove the
wire from each spark plug.
2. Disconnect the spark plug wire from the
ignition coil.
Twist each spark plug boot 1/2 turn.
Pull only on the boot in order to remove the
wires from the ignition coil.

211641

Engine

Engine E1ectrical

6-715

Installation Procedure
1 . Install the spark plug wires at the ignition coil.

2. Install the spark plug wire to each spark plug.

3. Inspect the wires for proper installation:
Push sideways on each boot in order to inspect
the seating.
Reinstall any loose boot.

211641

Spark Plug Replacement

Removal Procedure
1. Remove the spark plug wires. Refer to Spark Plug
Wire Harness Replacement (V6) or Spark Plug
Wire Harness Replacement (VB).
2. Remove the heated oxygen sensor from the right
oxidation catalytic c.onverter. (5. 7L Va only)

222954

3. Loosen each spar)< plug one or two t.urns.

4. Brush or air blast away any dirt from around the
spark plugs.
5. Remove the spark plugs one at a time and place
each plug in a tray marked with the corresponding
cylinder numbers.

)
14824

6-716

Engine Electrical

Engine
Installation Procedure
1. Properly position each spark plug washer.
2. Inspect each spark plug gap. Adjust each plug as
needed.

Specification
Spark plug gap: 1.524 mm (0.060 in).

3. Hand start the spark plugs in the corresponding

cylinders.

4. Tighten the spark plugs.

Notice: Refer to Fastener Notice in Cautions and
Notices.

Tighten
Tighten the spark plugs to 20 N,m (15 lb ft).

14824

5. Install the heated oxygen sensor to the right

oxidation catalytic converter. (5.7L VB only)

Tighten
Tighten the heated oxygen sensor to
42 N,m (31 lb ft).

6. Install the spark plug .wires. Refer to Spark Plug

Wire Harness Replacement (V6) or Spark Plug
Wire Harness Replacement (VB)

222954

Ignition Coil Replacement

Removal Procedure
1. Disconnect
the ignition
2. Disconnect
3. Disconnect

211648

the main electrical connector feeding

coils.
the ignition coil harness connector.
the spark plug wire at the ignition coil.

Engine ElectricaI 6-717

Engine

. ounting bolts.

move the ignition co~I m

4.
Re
5. Remove
the ignition coil.

----

65292

.
Procedure
Installation
..
ii

II the ignition
co .
. n Cautions and
1. Ins aRefer
Notice:
to Fastener Notice I
Notices.
. . coil moun t'in g bolts.
. tall the ignition
2. Ins
ts to
Tighten h Ignition
. . coil mounting bol
Tighten t e
. )
12 N-m (106 lb in.

. at the ignition
ector.coil.
park plug wire

3. Conne: :~: ~nition con_ harne~.:~ feeding the

4. Conne
ain electrical con
5 Connect t~e m
. ignition coils.

------------

211648

s. 718

Engine Electrical

Engine
Ignition Coil and ICM Replacement
Removal Procedure
1. Disconnect the control module electrical
connector bolt.
2. Remove the control module electrical connector
from the module.
3. Remove the spark plug wires from the ignition
control module.

211652

4. Remove the ignition control module nuts.

43664

5. Remove the engine lift bracket to control

module bolt.
6. Remove tt:ie ignition control module.

52979

Engine

Engine Electrical

6-719

Installation Procedure
1. Install the ignition control module.
)

Notice: Refer to Fastener Notice in Cautions and

Notices.
2. Install the ignition control module nuts.
Tighten
Tighten the ignition control module nuts to
30 N-m (22 lb ft).

43664

3. Install the engine lift bracket to control

module bolt.

Tighten
Tighten the engine lift bracket to control module
bolt to 25 N-m (18 lb ft).

52979

4. Connect the control module electrical connector.

5. Install the control module electrical connector bolt.
Tighten
Tighten the ignition control module bolt to
2.5 N-m (22 lb in).
6. Install the spark plug wires to the control module.

)
211652

6-720

Engine

Engine Electrical

Description and Operation

Starting System Circuit Description

Battery Description

Starter Circuit Operation

Caution: Batteries generate hydrogen gas which is

t;x!re1!1ely flammable and may explode violentfy
~f 1gmted by a spark or a flame. Battery acid ..
~s _extr mely c~rrosive and causes severe personal
m1ury if the acid comes into contact with the
skin- blindness if the acid comes into contact with
!h~ eyes. In order to avoid severe personal
m1ury, use extreme precaution when servicing the
battery or battery-related components.

When the ignition switch is moved to the ST ART

position, voltage is applied to the normally open
contacts of the starter relay. Voltage is also applied
through either the park neutral position switch
(automatic transmission) when in park or neutral or
the clutch pedal position switch (manual transmission)
when the clutch pedal is depressed, to the starter
relay coil. The body control module (BCM) energizes
th~ starter relay by grounding one side of the relay
coil only when the theft deterrent system has not been
activated.
When the starter relay is energized, the normally open
contacts close completing the circuit to the starter
solenoid. When the starter solenoid circuit is
completed, both the hold-in and pull-in windings are
energized. The circuit through the pull-in winding
is completed through the starter motor. The windings
work together magnetically to pull in and hold in
the plunger. The plunger moves the shift lever. This
action causes the drive assembly to rotate as it
engages the flywheel ring gear on the engine. At the
same time the plunger also closes the solenoid
switch contacts in the starter solenoid. Full battery
voltage is then applied directly to the starter motor and
it cranks the engine.
As soon as the solenoid switch contacts close, voltage
is no longer applied to the pull-in winding since
battery voltage is applied to both ends of the winding.
The hold-in winding remains energized and continues
to hold the plunger, the shift lever, and the drive
assembly solenoid switch contacts in place to continue
cranking the engine.
When the ignition switch is released from the START
position, battery voltage is removed from the two
windings. Voltage is applied through the motor
contacts and both windings to ground. However, the
direction of current flow through the windings is
reversed. The magnetic fields of the two windings now
oppose one another. The return spring, aided by
the opposing magnetic fields of the windings,
disengages the drive assembly which opens the
solenoid switch contacts. Once the contacts open, the.
starter circuit is turned off.

(
405476

A maintenance free battery is standard on all vehicles.

There are no vent plugs in the cover. The battery is
completely sealed except for two small vent holes
in the side. These vent holes allow the small amount
of gas that is produced in the battery to escape.
The battery consists of the following components:
Hydrometer lens (1)
Negative terminal (2)
Hold-down ramp (3)
PosiHve terminal (4)
Battery grids (5)
The battery has three functions in the electrical
system:
Provides electrical current when the vehicle's
electrical needs exceed the generator's output.
Stabilizes current surges in the charging system in
order to protect electrical systems.
Stores electrical energy for the starting system.
!he batt~ry specification label contains important
information about the following:
The test ratings
The original model number
The recommended replacement model number
The cold cranking Amps (CCA)

Engine

Engine Electrical

6-721

Battery Diagnosis
If the battery tests good but still fails to perform
satisfactorily, the following are some of the more
common caus.es:
A vehicle accessory was left on overnight.
The driving speeds have been slow with frequent
stops (stop-and-go driving).
The electrical load has exceeded the generator
output (particularly with the addition of aftermarket
equipment).
Existing conditions in the charging system,
including the following possibilities:
- An electrical short
, A slipping belt
- A badgenerator
- A bad generator voltage regulator
The battery has not been properly maintained,
including the following situation$:
- A failure to keep the terminals tight
- A failure to keep the terminals clean
- A loose battery hold-down
Existing mechanical conditions in the electrical
system, such as any short or pinched wires,
attributing to power failure.
The car is in storage for extended periods of time.
Plug fouling, causing extended cranking periods.
The hydrometer has been read incorrectly.
There has been an insufficient Ampere-hour
charge rate for a discharged battery.
There is a burned out charge indicator bulb
causing a NO CHARGE condition.
There is a continuous current draw on the battery

through excessive parasitic drain.

The battery is old.

Charging System Description

Tt;ie charging system consists of the following
components:
The battery
The generator (CS-1300)
A voltage regulator
Indicator lamp or voltmeter circuitry

405469

Model CS-series generators (1) feature a high ampere

output per pound of weight. The CS stands for
charging systems. The 130 is the measurement, in
millimeters, of the outside diameter of the stator
laminations and the D is for dual internal fans. The
delta stator, rectifier bridge, and the rotor with slip rings
and brushes, are electrically similar to other CS
series generators. The CS-1300 generator uses a
conventional pulley and dual internaHans to cool the
slip ring end frame, rectifier bridge and voltage
regulator.
The generator's rotor shaft (2) is rotated by the engine
drive belt.The rotor shaft rotates the generator's
rotor. The generator produces the electrical current
that charges the battery. The generator also pmvides
energy to the. vehicle's electrical systems when the
engine is running.

5.;722

Engine Electrical

Engine

Charging System Operation

the generator instead of, or in addition to, the

L terminal which must be stepped down. This S
terminal may be connected to an external voltage
source, such as voltage near the battery, for voltage
control. If the S terminal in not used, internal generator
voltage is used for control.
The CS-130D generator must be replaced,
DO NOT disassemble the CS-130D generator.

Charging System Circuit Description

Charging Circuit Operation

7
405471

The charging system provides voltage to the battery

and to the vehicle electrical systems. The generator's
voltage regulator controls the rotor's field current to
meet these needs.
Current flows (1) through the slip rings (8) to the rotor
winding (2) in order to create a magnetic field (3).
The engine-driven rotor (4) is rotated by the engine
within the stator (5). This rotation creates an
alternating current (AC) voltage in the stator
windings (6) The AC voltage goes to the rectifier
bridge (7). The rectifier bridge converts this AC voltage
to direct current (DC) voltage. The DC voltage is
delivered from the generator's output terminal to the
battery and the electrical systems through a fusible
link. The regulator grounds circuit 225 when the
charging system voltage is abnormal. This information
causes the PCM to ground circuit 25, which turns
on the charge indicator lamp.
The voltage regulator limits system voltage by
controlling the rotor field current. When the field current
is on, the regulator switches the rotor field on and
off at a fixed rate of about 400 cycles per second. By
varying the overall on/off time, correct average
field current for proper system voltage control is
maintained. At high speeds, the on time may be
1O percent and the off time may be 90 percent. At low
speeds, with high electrical loads, the on/off time
may be 90 percent and 1O percent respectively.
The voltage reads battery voltage when the engine is
not running and reads charging system voltage
when the engine is running. The normal indication
when the engine is running. The normal indication is
between 11 and 16 volts.
The generator uses only two connections - battery
positive and the L terminal, in addition to the ground
path through the generator bracket. Use of P, I, and
S terminals is optional. The P terminal is connected to
the stator and may be connected externally to a
tachometer or other devise. The I terminal can be
connected directly to battery voltage to power

The generator provides voltage to operate the vehicle's

electrical system and to charge the battery. A
magnetic field is created when current flows through
the rotor windings. This field rotates as the rotor
is driven by the engine, creating an AC voltage in the
stator windings. The AC voltage is then converted
to a DC voltage by a rectifier bridge. This DC voltage
is then supplied to the vehicle's electrical system
at the battery terminal.
The amount of output voltage is controlled by the
current supplied to the rotor. The regulator in
the generator uses digital techniques to control the
current supplied to the rotor. The rotor current is
a series of electrical pulses supplied by the regulator.
When the ignition switch is first placed in the RUN
position, the pulse width is very narrow. This causes
the rotor to produce a weak magnetic field. This
will produce a lower output voltage to the vehicle's
electrical system. Once the engine is running,
the regulator monitors the output voltage through an
internal wire and changes the pulse width accordingly.

Ignition System Description (V6)

Ignition System (3800 VIN K)
The 3800 {VIN K) electronic ignition system uses a
coil pack. For each two cylinders in the engine, the coil
pack uses one ignition coil. The ignition control
module {ICM) is mounted under the ignition coils. The
ICM performs ignition coil switching functions and
interacts with the powertrain control module (PCM) in
order to optimize ignition system operation.
The 3800 ignition system spark timing is controlled
electronically. The ICM controls the spark timing during
engine start-up. The ICM provides a back-up timing
system that will allow the engine to run in the event of
an open or ground in the ignition control circuit.
Once the engine starts and is running above 400 rpm,
the PCM takes over the spark timing and sends
signals to the ICM for ignition coil switching.
The electronic ignition system uses a waste spark
method of spark distribution. Each cylinder is paired
with its opposing cylinder in the firing order. One
cylinder on compression fires simultaneously with the
opposing cylinder on exhaust. The exhaust stroke
spark is referred to as the waste spark.

Engine

The spark plugs in the two opposing cylinders are

connected to the two secondary terminals of the same
ignition coil. The spark voltage appears at the center
electrode of one of the spark pl\Jgs and jumps the side
electrode. The spark voltage then passes through
the cylinder head to the other spark plug. At the
second spark plug, the spark j;~s from the side
electrode to the center electrodl..The spark then
completes the series circuit back to the ignition coil.
The high level of energy available from the ignition coil
fires both plugs simultaneously. Since the waste
spark requires very little voltage to fire, the coil output
voltage fires the cylinder that is on the compression
stroke.

Ignition System Description (VS)

Distributor Ignition (DI) System
The following are the primary components of the
distrioutor ignition (DI) system:
The ignition coil
The ICM
The distributor
The PCM
The PCM timing control circuits
The vacuum harness primary wiring
The vacuum harness secondary wiring
The spark plugs
The camshaft position (CMP) sensors
The crankshaft position (CKP) sensor
The distributor is mounted on the front cover behind
the water pump. The distributor directs the spark from
the ignition coil through a rotor to the proper spark
plug secondary wire. The spark plug secondary wire
connectors in the cap ease in the routing of the
spark plug wire harnesses. A cylinder number is
molded on each distributor cap next to each spark plug
secondary wire connector.
The distributor contains a signal disk and optical
camshaft position (CMP) sensors that send signals to
the PCM for timing control. The PCM controls all
ignition timing. There is no bypass mode built into the
ICM. One CMP sensor senses 360 equally spaced
slots in the signal disk in order to provide 720 signals
per camshaft revolution for high resolution timing
control. The second CMP sensor senses eight disk
slots of varying lengths, providing a low resolution
signal. This signal tells the PCM which of the spark
plugs is being fired.

Engine Electrical

6-723

The PCM determines if one of the timing inputs is not

being received by comparing the inputs. If the PCM
detects one timing pulse without detecting the
other, DTC 16 or DTC 36 will set. The following forces
are transferred between the PCM and the distributor
through a shielded harness on the terminal distributor
connectors:
The power for the optical CMP sensors
The system ground
The CMP sensor signals
The reference signals toggle between 0-5 volts as the
camshaft turns. Any of the following situations can
prevent the voltage from pulsing at the PCM:
1. An open circuit
2. A short to voltage
3. A short to ground
4. A defective sensor
The ignition coil and the ICM provide a spark to the
distributor, timed by the PCM signals. The ignition
switch provides the power for the following
components:
The ignition coil primary circuit
The ICM
The PCM combines the CMP information supplied by
the distributor with other system parameters. The
PCM then calculates the required spark advance. The
PCM signals the ICM. The ICM turns on the primary
circuit to the ignition coil by the following actions:
1. Grounding the primary circuit
2. Removing the ground in order to turn off the
primary circuit to the ignition coil
The high voltage induced in the ignition coil secondary
winding when the primary circuit current flow stops
becomes the spark voltage for the spark plug.
The spark voltage undergoes two deliveries, which
include:
1. The delivery to the distributor through the
secondary coil output wire
2. The delivery to the proper spark plug connector
by the distributor rotor
Refer to Distributor Ignition System Check in Engine
Controls.

6-724

Engine Electrical

Engine

Special Tools and Equipment

Tool Number/Description

Illustration

(
J 38758
Parasitic Draw Test
Switch Tool

3432

\\
J 39200
Digital Multimeter

3430

ST-1201
Battery Side Terminal
Adapters (Pair)

3431

Engine

Engine Controls - 3.8L

6-725

Engine Controls - 3.SL

'\)

Specifications

oc

Temperature vs Resistance
OF
OHMS

Temperature vs Resistance Values (Approximate)

212
194
176
158
140
122
113
104
95
86

100
90
80
70
60
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
-30
-40

177
241
332
467
667
973
1188
1459
1802
2238
2796
3520
4450

77

68
59
50
41
32
23
14

5670
7280
9420
12300
16180
21450
28680
52700
100700

5
-4
-22
-40

Fastener Tightening Specifications

Application
A/C Refrigerant Pressure Sensor

N,m

Lb Ft

Lbln

53
89

6
10
150
+114
20
25
20

111
+114
15
18
15

Exhaust Gas Recirculation Valve Adapter Bolt to Exhaust

Manifold

25

18

Exhaust Gas Recirculation Valve Adapter Nuts to

Cylinder Head

50

37

Exhaust Gas Recirculation Valve Nuts to EGR Valve Adapter

29

21

Exhaust Gas Recirculation Valve Outlet Pipe Bolt to Upper

Intake Manifold

25

18

Exhaust Gas Recirculation Valve Outlet Pipe Nut to EGR

Valve Adapter

29

21

30
4.5

22
-

Camshaft Position (CMP) Sensor Retaining Bolt

Crankshaft Balancer Bolt
Crankshaft Position (CKP) Sensor Bolts
Engine Coolant Temperature (ECT) Sensor
Engine Oil Level Switch

Fuel Filter Fitting

Fuel Pipe Front Clip Bolts

40

6-726

Engine

Engine Controls - 3.SL

Fastener Tightening Specifications (cont'd)
Application

N,m

Lb Ft

Spark Plug(s)

5.5
5
5
5
10
6.5
2.5
33
42
3
4-5
30
30
19
27

Throttle Body Retaining Nuts or Bolts

10

22
22
14
20
-

Throttle Position Sensor Attaching Screws

Fuel Pipe Rear Clip Bolt

Fuel Pipe Shield Bolt
Fuel Pipe Shield Nuts
Fuel Pipe Shield Studs
Fuel Rail Attaching Nuts or Bolts
Fuel Sender Assembly Attaching Nuts
Fuel Tank Fill Pipe Shield Bolt
Fuel Tank Retaining Strap Bolts
Heated Oxygen Sensor(s)
Idle Air Control Valve Attaching Screws
Ignition Coil to Ignition Control Module Screws
Ignition Control Module Assembly to Bracket Nuts
In-Pipe Fuel Filter Nut
Knock Sensor(s)

25
31
-

Lbln

49
44
44
44
89
58
22

27
40

89
18

Engine Scan Tool Data List

Use the Typical Scan Data Values table only after the
Powertrain On-Board Diagnostic System Check
has been completed, no DTCs were noted and you
have determined the on-board diagnostics are
functioning properly. Scan tool values from a properly
running engine may be used for comparison with
the engine you are diagnosing. The Typical Scan Data
values represent values that would be seen on a
normally running engine.
Important: A scan tool that displays faulty data should
not be used, and the problem should be reported to
the scan tool manufacturer. Use of a faulty scan
tool can result in misdiagnosis and unnecessary parts
replacement.

Only the parameters listed below are referred to in this

service manual for use in diagnosis. For further
information on using the scan tool to diagnose the
PCM and related sensors, refer to the applicable
reference section listed below. If all values are within
the typical range described below, refer to Symptoms
section for diagnosis. The Typical Scan Data
Values table contains all the parameters included in
the following data lists arranged in alphabetical order:

Specific Engine Data

CATALYST - Contains information specific to the
TWC diagnostics and parameters required to
verify proper TWC system operation.
EGR - Contains information specific to the
Exhaust Gas Recirculation system flow diagnostics
and the EGR valve pintle position sensor
diagnostics. Also displays parameters required to
verify proper EGR system operation.
EVAP - Contains information specific to the EVAP
system diagnostics. Also displays parameters
required to verify proper EVAP system operation.
H02S - Contains information specific to the
Heated Oxygen Sensor diagnostics and
parameters required to verify proper H02S
operation.
MISFIRE - Contains information specific to the
misfire diagnostics and parameters required
to verify proper operation with regard to misfire.

Engine Data

ENG 1- Contains general information regarding

fuel delivery and basic engine operating
conditions.
ENG 2 - Contains general information regarding
IC, KS, A/C, and basic engine operating
conditions.

Engine

Engine Controls - 3.SL

6-727

Typical Scan Tool Data Values

Engine Scan Tool Data List
\

Data List

Units
Displayed

Typical Data
Value

Reference

3X Crank Sensor

Misfire

RPM

Varies

OTC P1374 3X Reference Circuit

18X Crank Sensor

Misfire

RPM

Varies

Cranks But Does Not Run Diagnostic

A/C High Side Pressure

Engine 2

Volts

Varies with
refrigerant
temperature

PCM Controlled Air Conditioning

PCM Controlled Air Conditioning

Scan Tool Parameter

A/C Pressure Out Of Range

Engine 2

Yes I No

No (Yes with
low or high A/C
refrigerant
pressure)

A/C Request

Catalyst
Engine 2
Misfire

Yes I No

No (Yes with
A/CON)

PCM Controlled Air Conditioning

Actual EGR Position

Engine 1
Engine 2
EGR
Misfire

Percent

0%

OTC P1406 EGR Valve Pintle Position

Circuit

Air/Fuel Ratio

Engine 1
H02S
Catalyst

Ratio

14.2:1 - 14.7:1

Fuel Metering Modes of Operation

Information Sensors

BARO

Engine 2
EGR

kPa I Volts

65 - 110 kPa
(Depends on
altitude and
barometric
pressure).

Cam Signal Present

Misfire

Yes I No

Yes

OTC P0341 CMP Sensor Circuit

Performance

Clutch Pedal Switch

Engine 2

Applied I
Released

Released

OTC P0704 Clutch Switch Circuit

Commanded A/C

Catalyst
Engine 2
Misfire

On I Off

Off (On with

A/C compressor
engaged)

PCM Controlled Air Conditioning

Commanded
Fan 1/Commanded Fan 2

Catalyst
Engine 2

On I Off

Off (On with

fans running)

Electric Cooling Fan

Commanded Gen

Engine 1

On I Off

On

OTC P0560 System Voltage

Cruise Engaged

Engine 1

Engaged/
Disengaged

No

OTC P1554 Cruise Control Status Circuit

Cruise Inhibited

Engine 1

Yes I No

Yes

OTC P1554 Cruise Control Status Circuit

1/2/3/4

Automatic Transmission Diagnosis

Decel Fuel Mode

Engine 1
EGR
H02S
Catalyst
Misfire

Active I Inactive

Inactive

Fuel Metering Modes of Operation

Desired EGR Position

Engine 1
Engine 2
EGR
Misfire

Percent

0%

OTC P1406 EGR Valve Pintle Position

Circuit

Engine 1

Current Gear

\
)

Engine 1
EGR

6-728

Engine Controls - 3.8L

Engine

Engine Scan Tool Data List (cont'd)

Scan Tool Parameter

Data List

Units
Displayed

Typical Data
Value

RPM

PCM
commanded
idle speed
(varies with
temperature).

Idle Air Control System Check

85C - 105C I
185F - 220F
(varies with
temperature).

Information Sensors

Engine 1
Desired Idle Speed

Engine 2
EGR
EVAP

Reference

ECT

Engine 1,
Engine 2
EGR
Catalyst
H02S
Misfire

EGR Closed Valve Pintle

Position

EGR

Volts

0.14-1.0 volt

OTC P1406 EGR Valve Pintle Position

Circuit

EGR Duty Cycle

EGR

Percent

0%

OTC P1406 EGR Valve Pintle Position

Circuit

EGR Feedback

EGR

Volts

0.14-1.0volt

OTC P1406 EGR Valve Pintle Position

Circuit

EGR Position Error

EGR

Percent

0% - 100%

DTCP1406 EGR Valve Pintle Position

Circuit

EGR Flow Test Count

EGR

Counts

0-10

OTC P1406 EGR Valve Pintle Position

Circuit

Engine Load

Engine 2
Catalyst
Misfire

Percent

2% - 5% at idle
7% - 10% at
2500 RPM

Engine Run Time

Engine 1
Engine 2
EVAP
Catalyst

Hr: Min: Sec

Depends on
time since
startup.

Engine Speed

Engine 1
Engine 2
EGR
EVAP
Catalyst
H02S
Misfire

RPM

100 RPM
from Desired
Idle Speed

EVAP Canister Purge

EVAP
H02S

Percent

0% - 25%
(varies)

EVAP Control System

EVAP Fault History

EVAP

Fault I No Fault

No Fault

EVAP Control System

EVAP Vent Solenoid

EVAP

Open I Closed

Varies

EVAP Control System

Fuel Pump

Engine 2

On I Oft

On

Fuel Supply Components

oc,

OF

Fuel Tank Level

EVAP

Percent

Varies

OTC P1653 Fuel Level Output Control

Circuit

Fuel Tank Pressure

EVAP

Volts

Varies

OTC P0452 Fuel Tank Pressure

Sensor Low
OTC P0453 Fuel Tank Pressure High

Fuel Tank Pressure

EVAP

In H20

Varies

Fuel Trim Cell

Engine 1
Misfire

Cell#

Fuel Trim Learn

Engine
Catalyst

Enabled I
Disabled

Enabled

OTC P0171, P0172, P0174 and P0175

Generator Lamp

Engine 2

On I Oft

Off

PCM Controlled Warning Lamps

OTC P0452 Fuel Tank Pressure

Sensor Low
OTC P0453 Fuel Tank Pressure High

OTC P0172 Fuel Trim System

Rich Bank1

Engine

Engine Controls - 3.8L

6-729

Engine Scan Tool Data List (cont'd)

Data List

Units
Displayed

Typical Data
Value

Reference

H02S Bank 1 Sensor 1 I

H02S Bank 2 Sensor 1

Engine 1
Catalyst
H02S

Not Ready
I Ready

Ready

Information Sensors

H02S Bank 1 St:lnsor 1 I

H02S Bank 2 Sensor 1

Engine 1
Catalyst
H02S

millivolts

0-1000,
constantly
varying

Information Sensors

H02S Bank 1 Sensor 3

Engine 1
Catalyst
H02S

millivolts

0 - 1000,varies

Information Sensors

Information Sensors

Scan Tool Parameter

H02S Warm-Up Bank 1

Sensor 1 I Bank 2 Sensor 1 I
Bank 1 Sensor 3

H02S

Min: Sec

Depends dn
startup intake
air temperature,
startup engine
coolant
temperature,
and time to
H02S activity.

H02S XCounts Bank 1 I

H02S XCounts Bank 2

H02S

Counts

Varies

IAC Position

Engine 1
Engine 2
EGR
Catalyst
Misfire

Counts

10 - 40

Idle Air Control System Check

IAT

Engine 1
Engine 2
EVAP
Catalyst
H02S

oc, Of

Varies with
ambient air
temperature.

Information Sensors

Ignition 1

Engine 1
Engine 2
EGR
H02S

Volts

13 (Varies)

DTC P0560 System Voltage

Ignition Mode

Engine 2

IC I Bypass

IC

Electronic Ignition System

Injector Pulse Width

Engine 1

milliseconds

1.5 - 3.5
(Varies with
engine load)

Knock Retard

Engine 2

Degrees

oo

Knock Sensor System

Long Term Fuel Trim BN1

Engine 1
Misfire

Percent

-10% - 10%

DTC P0171 Fuel Trim System

Lean Bank1

Long Term Fuel Trim BN2

Engine 1
Misfire

Percent

-10% - 10%

DTC P0174 Fuel Trim System

Lean Bank2

Open I Closed

Closed

Fuel Metering Modes of Operation

gm/s

3 - 6 gm/s
at idle
13 - 16 gm/sat
2500 RPM
(Depends on
engine load and
barometric
pressure)

Information Sensors

Engine 1
Loop Status

MAF

Catalyst
H02S
Misfire
Engine 1
Engine 2
EVAP
Catalyst
H02S

6-730

Engine

Engine Controls - 3.8L

Engine Scan Tool Data List (cont'd)

Scan Tool Parameter

Data List

Units
Displayed

Typical Data
Value

Hz

1200 - 3000
(Depends on
engine load and
barometric
pressure)

DTC P0102 MAF Sensor Circuit Low

Frequency

29 - 48 kPa I
1 - 2 Volts
(Depends on
engine load and
barometric
pressure).

Information Sensors

MAF Frequency

Engine 1

MAP

Engine 1
Engine 2
EGR
EVAP

kPa I Volts

Reference

MIL

Engine 2

On I Off

Off

No Malfunction Indicator Lamp

Misfire Current Cylinder #

Misfire

Counts

0-4

DTC P0300 Engine Misfire Detected

Misfire History Cylinder #

Misfire

Counts

0-6

DTC P0300 Engine Misfire Detected

Misfire

Cylinder# IO

DTC P0300 Engine Misfire Detected

Active I Inactive

Inactive

Fuel Metering Modes of Operation

Misfiring Cylinder

Engine 1
Power Enrichment

Engine 2
Catalyst
H02S
Misfire

Rich/Lean

Engine 1

Rich I Lean

Constantly
changing

Fuel Metering Modes of Operation

Short Term Fuel Trim BN1

Engine 1
Catalyst
Misfire

Percent

-10% - 10%

DTC P0171 Fuel Trim System

Lean Bank1

Engine 1
Short Term Fuel Trim BN2

Catalyst
Misfire

Percent

-10% - 10%

DTC P0174 Fuel Trim System

Lean Bank2

Spark

Engine 2

Degrees

-20 (varies)

Electronic Ignition System

Start Up ECT

EVAP
H02S

oc, OF

Depends on
engine coolant
temperature at
time of startup

DTC P0125 ECT Excessive Time to

Closed Loop

Start Up IAT

EVAP
H02S

oc,

Depends on
intake air
temperature at
time of startup

DTC P0125 ECT Excessive Time to

Closed Loop

Throttle at Idle

Engine 1

Yes I No

Yes

DTC P0123 TP Sensor Circuit High

Voltage

Total Misfire Current Count

Misfire

Counts

0- 255

DTC P0300 Engine Misfire Detected

Total Misfire Failures Since

First Fail

Misfire

Counts

DTC P0300 Engine Misfire Detected

Total Misfire Passes Since

First Fail

Misfire

Counts

DTC P0300 Engine Misfire Detected

TP Angle

Engine 1
Engine 2
EGR
Catalyst
H02S
Misfire

Percent

0%

DTC P0123 TP Sensor Circuit High

Voltage

TP Sensor

Engine 1

Volts

0.20 - 0.74

Information Sensors

TR Switch A I B I C

Engine 2

Low/High

Varies
depending on
gear selected

Automatic Transmission Diagnosis

OF

Engine Controls - 3.SL

Engine

6-731

Engine Scan Tool Data List (cont'd)

Data List

Units
Displayed

Typical Data
Value

Reference

Trans Range

Engine 2

Park I Reverse
I Neutral I Drive
4 I Drive 3 I
Drive 2 I Low

Park

Automatic Transmission Diagnosis

TWC Diagnostic

Catalyst

Enabled I
Disabled

Enabled

OTC P0420 TWC System Low Efficiency

TWC Monitor Test Counter

Catalyst

Counts

OTC P0420 TWC System Low Efficiency

TWC Protection

Engine 1
Engine 2
Catalyst
H02S
Misfire

Active I Inactive

Inactive

Fuel Metering Modes of Operation

Vehicle Speed

Engine 1
Engine 2
EGR
Catalyst
Misfire

MPH, Km/h

Automatic Transmission Diagnosis

VTD Fuel Disable

Engine 2

Active I Inactive

Inactive

OTC P1629 Theft Deterrent Crank Signal

Malfunction

Scan Tool Parameter

Engine Scan Tool Data Definitions

A/C High Side Pressure: Scan Tool Displays
0.00 to 5.00 Volts.
Represents the A/C refrigerant pressure sensor signal.
The amount of pressure indicates the amount of
load that the A/C compressor is placing on the engine.
The PCM uses this information to adjust idle and to
control the cooling fans.
A/C Pressure Out Of Range: Scan Tool Displays
YES or NO.
YES displayed indicated that the PCM is monitoring
an A/C Refrigerant Pressure signal voltage which
is too high or too low to allow the A/C compressor
clutch to engage.
A/C Request: Scan Tool Displays YES or NO.
Indicates the state of the A/C request input circuit from
the HVAC controls. The PCM uses the A/C request
signal to determine whether A/C compressor operation
is being requested.
Actual EGR Position: Scan Tool Range 0% to 100%.
Represents the actual position of the EGR pintle in
percent. 0% displayed indicates a fully extended pintle
(EGR valve closed).
Air Fuel Ratio: Scan Tool Range 0.0 to 25.5.

Air Fuel Ratio indicates the PCM commanded value.

In closed loop, Air Fuel Ratio should normally be
around 14.2 - 14.7. A lower Air Fuel Ratio indicates a
richer commanded mixture, which may be seen
during Power Enrichment or TWC Protection modes.
A higher Air Fuel Ratio indicates a leaner commanded
mixture. This can be seen during Decel Fuel Mode.

BARO: Scan Tool Range 10 to 105 kPa I

o.oo to 5.00 Volts.

The barometric pressure reading is determined from

the MAP sensor signal monitored during key up
and Wide-Open Throttle (WOT} conditions. Barometric
pressure is used to adjust fuel delivery and spark
advance to compensate for altitude changes.
Commanded A/C: Scan Tool Displays ON or OFF.
Represents the PCM commanded state of the
A/C compressor clutch relay driver circuit. The A/C
compressor clutch should be engaged when
Commanded A/C displays ON.
Commanded Fan 1 I Commanded Fan 2: Scan Tool
Displays ON or OFF.
Represents the PCM commanded state of the fan 1
(low speed) and fan 2 (high speed) control circuits.
Clutch Pedal Switch: Scan Tool Displays Applied or
Released
The Clutch Anticipate Switch input allows the PCM to
adjust the IAC when the manual transmission
clutch is being disengaged. The PCM monitors the
Clutch Anticipate Switch input; if a low voltage
is monitored, the PCM considers the Clutch Anticipate
Switch closed to ground (clutch pedal released).
When the ground at the Clutch Anticipate Switch input
is interrupted (clutch pedal applied), the PCM will
immediately decrease lAC counts. This is done
to avoid a possible RPM flare caused by the sudden
change in engine load.
Commanded Gen: Scan Tool Displays ON or OFF.
OFF displayed indicates that the PCM has
commanded the generator control circuit OFF.
Cruise Engaged: Scan Tool Displays YES or NO.
Represents the state of the Cruise Status Input from
the SMCC module. CRUISE ENGAGED should
not display YES unless the vehicle is operating in a
cruise control mode.

6-732

Engine Controls - 3.SL

Cruise Inhibited: Scan Tool Displays YES or NO.

YES displayed indicates that the PCM is commanding
the SMCC module to inhibit cruise control operation.
Should display YES with park, neutral, reverse or
low gear selected.
Current Gear: Scan Tool Displays
numbers 1, 2, 3, or 4.
The PCM looks at Trans Range position and the gear
commanded by the PCM. The actual forward gear
that the Transaxle is in will be the lower of the
two because the manual valve can override the PCM
commanded gear.
Decel Fuel Mode: Scan Tool Displays ACTIVE or
INACTIVE.
ACTIVE displayed indicates that the PCM has
detected conditions appropriate to operate in
Deceleration Fuel Mode. The PCM will command
deceleration fuel mode when a sudden decrease in
throttle position has been detected while the vehicle is
traveling over 25 mph. While in Deceleration Fuel
mode, the PCM will decrease the amount of fuel
delivered by entering Open Loop and decreasing the
injector pulse width.
Desired EGR Position: Scan Tool Range 0%
to 100%.
Represents the EGR pintle position that the PCM is
commanding. Desired EGR Position should stay close
to Actual EGR Position.
Desired Idle Speed: Scan Tool Range
Oto 3187 RPM.
The idle speed that is commanded by the PCM. The
PCM will compensate for various engine loads
based on engine coolant temperature to keep the
engine at the desired idle speed.
ECT: Scan Tool Range -40C to 151C,
-40F to 304F.
The Engine Coolant Temperature (ECT) sensor is
mounted in the coolant stream. The PCM applies
5 volts to the ECT sensor circuit. The sensor is
a thermistor which changes internal resistance as
temperature changes. When the sensor is cold
(internal resistance high), the PCM monitors a high
signal voltage and interprets it as a cold engine. As the
sensor warms (internal resistance decreases), the
voltage signal decreases and the PCM interprets the
lower voltage as a warm engine.
EGR Closed Valve Pintle Position: Scan Tool
Range 0.0 to 5.0 Volts.
Represents the learned voltage that the PCM uses to
determine whether or not the EGR valve is fully
closed (0 percent pintle position). If the Desired EGR
Position is 0% and a difference of more than 0.4 volt
between EGR Feedback and EGR Closed Valve Pintle
Position is detected, DTC P1406 will set.
EGR Duty Cycle: Scan Tool Range 0% to 100%.
Represents the EGR valve driver PWM signal from the
PCM. A duty cycle of O percent indicates that no
EGR flow is being commanded; a 100 percent duty
cycle indicates maximum EGR flow commanded.

Engine
EGR Feedback: Scan Tool Range 0.00 to 5.00 Volts.
Indicates the EGR pintle position sensor signal
voltage being monitored by the PCM. A low voltage
indicates a fully extended pintle (closed valve); a
voltage near 5 volts indicates a fully retracted pintle
(open valve).
EGR Position Error: Scan Tool Range 0% to 100%.
Indicates the difference between Desired EGR
Position and Actual EGR Position currently being
monitored by the PCM. If the EGR Position Error
reaches an unacceptable level, DTC P1406 will set.
EGR Flow Test Count: Scan Tool Range O to 255.
Indicates the number of EGR flow test samples
collected during the current ignition cycle. The
maximum number of samples allowed is 1 during
normal operation. If the PCM battery teed has been
disconnected or a DTC P0401 has been cleared,
several EGA flow test samples will be allowed during
the next ignition cycle. This is to allow repair
verification during a single ignition cycle.
Engine Load: Scan Tool Range 0% to 100%.
Engine load is calculated by the PCM from engine
speed and MAF sensor readings. Engine Load should
increase with an increase in RPM or air flow.
Engine Run Time: Scan Tool Range
00:00:00 to 99:99:99 Hrs:Min:Sec.
Indicates the time elapsed since the engine was
started. If the engine is stopped, ENGINE RUN TIME
will be reset to 00:00:00,
Engine Speed: Scan Tool Range Oto 9999 RPM.
Engine speed is computed by the PCM from
the 3X reference input. It should remain close to
desired idle under various engine loads with engine
idling.
EVAP Canister Purge: Scan Tool Range 0%
to 100%.
Represents the PCM commanded PWM duty cycle of
the EVAP Purge valve. 0% displayed indicates no
purge; 100% displayed indicates full purge.
EVAP Vacuum Switch: Scan Tool Displays PURGE
or NO PURGE.
The EVAP vacuum switch is a normally closed switch
positioned in the purge line between the canister
and the EVAP purge valve. The EVAP purge vacuum
switch will open when vacuum increases to greater
than 5 inches of water in the purge line. The
EVAP purge vacuum switch input is used by the PCM
to monitor EVAP purge va:lve operation and to
ensure purge system integrity. The EVAP purge
vacuum switch should be closed with no vacuum
present (0% EVAP Canister Purge PWM). With EVAP
canister purge PWM at 25% or greater, the EVAP
purge vacuum switch should open and purge should
be indicated.
Fuel Pump: Scan Tool Displays ON or OFF.
Indicates the PCM commanded state of the fuel pump
relay control circuit.

Engine

Fuel Trim Cell: Scan Tool Range Oto 9.

Fuel trim cell is dependent upon engine speed and
MAF sensor readings. A plot of RPM vs. MAF is
divided into 10 cells. Fuel trim cell indicates which cell
is currently active.
Fuel Trim Learn: Scan Tool Displays NO or YES.
When conditions are appropriate tor enabling long term
fuel trim corrections, FUEL TRIM LEARN will display
yes. This indicates that the long term fuel trim is
responding to short term fuel trim. If the Fuel Trim
Learn displays NO, long term fuel trim will not respond
to changes in short term fuel trim.
Generator PWM: Scan Tool Range 0% to 100%.
Represents the field terminal input from the generator.
The field PWM duty cycle indicates generator output
level; a higher duty cycle indicates a higher generator
output. The PCM uses the generator F terminal
signal to adjust spark and IAC to compensate tor
variances in engine load caused by the generator.
Generator Lamp: Scan Tool Displays ON or OFF.
ON displayed indicates the PCM commanded state of
the generator lamp/check gauges lamp due to low
system voltage or a generator fault detected.
Heated Oxygen Sensors (H02S Bank 1 Sensor 1
AND H02S Bank 2Sensor 1): Scan Tool
Range 0-1132 mV
Represents the fuel control exhaust oxygen sensor
output voltage. Should fluctuate constantly within
a range between 10 mV (lean exhaust) and 1000 mV
(rich exhaust) while operating in Closed Loop.
Heated Oxygen Sensor (H02S Bank 1 Sensor 3):
Scan Tool Range 0-1132 mV
Represents the catalyst monitor exhaust oxygen
sensor output voltage. If the PCM detects a level of
Bank 1 H02S 3 activity that indicates the catalyst is no
longer operating efficiently, DTC P0420 will be set.
Heated Oxygen Sensors (H02S Bank 1 Sensor 1 and
H02S Bank 2 Sensor 1): Scan Tool Displays NOT
READY or READY
Indicates the status of the exhaust oxygen sensors.
The scan tool will indicate that the exhaust oxygen
sensors are ready when the PCM detects a fluctuating
H02S voltage sufficient to allow closed loop
operation. This will not occur unless the exhaust
oxygen sensors are warmed up.
H02S Warm-Up Time Bank 1 Sensor 1 I H02S
Warm-Up Time Bank 2 Sensor 1 I H02S Warm Up
Time Bank 1 Sensor 3: Scan Tool Range
00:00:00-99:99:99 HRS:MIN:SEC
Indicates time to warm-up tor each H02S. The H02S
warm up time is used tor the H02S heater test.
The PCM will run the heater test only after a cold start
(determined by engine coolant and intake air
temperature at the time of startup) and only once
during an ignition cycle. When the engine is started
the PCM will monitor the H02S voltage. When
the H02S voltage indicates a sufficiently active sensor,
the PCM looks at how much time has elapsed since
startup. If the PCM determines that too much time was
required tor the H02S to become active, a DTC will

Engine Controls - 3.SL

6-733

set. If the engine was warm when started, H02S

Warm-Up Time will display the value that was stored
last time the test ran. If info has been cleared,
H02S Warm-Up Time will display 00:00:00.
H02S Xcounts Bank 1 I H02S Xcounts Bank 2: Scan
Tool Range 0-255
Indicates the number of times each H02S signal has
crossed the 450 mV bias voltage during a 1 second
interval. A H02S signal that almost never crosses the
bias voltage could indicate a fuel trim problem, a
malfunctioning H02S circuit, or a
malfunctioning H02S.
IAC Position: Range O to 255.
Displays the commanded position of the idle air
control pintle in counts. A larger number of counts
means that more air is being commanded through the
idle air passage. IAC Position should respond fairly
quickly to changes in engine load to maintain desired
idle RPM.
IAT: Scan Tool Range -40C to 151C,
-40F to 304F.
The PCM converts the resistance of the intake air
temperature sensor to degrees. The PCM uses Intake
Air Temperature (IAT) to adjust fuel delivery and
spark timing according to incoming air density. IAT is
also compared to ECT at startup to identify cold
starts for the H02S heater and the EVAP diagnostics.
Ignition 1: Scan Tool Range O to 25.5 Volts.
Represents the system voltage measured by the PCM
at its ignition teed.
Ignition Mode: Scan Tool Displays BYPASS or IC.
Indicates the commanded state of the Bypass
signal output from the PCM. When BYPASS is
displayed, the ignition control module is controlling the
spark advance at a fixed 10 BTDC (Bypass mode).
IC displayed indicates that the PCM has requested
control of the spark advance (IC mode). The ignition
control module determines the correct operating
mode based on the level of voltage that the PCM
applies to the ignition control module bypass circuit.
The PCM provides 5 volts to the ignition control
module bypass circuit when conditions are appropriate
tor PCM control of spark timing (IC mode). If the
PCM does not apply 5 volts to the bypass circuit, or if
the ignition control module does not receive it, the
module will control spark timing.
Injector Pulse Width: Scan Tool Range
O to 1000 msec.
Indicates the amount of time the PCM is commanding
each injector ON during each engine cycle. A
longer injector pulse width will cause more fuel to be
delivered. Injector Pulse Width should increase
with increased engine load.
Knock Retard: Scan Tool Range 0.0 degress to
25.5 degrees.
Indicates the amount of spark the PCM is removing
from IC spark advance in response to the signal from
the knock sensors. The Traction Control system
Desired Torque signal from the EBTCM may cause
Knock Retard to display a value greater
than 0.0 degrees if Traction Control is active.

6-734

Engine Controls - 3.8L

KS Active Counter: Scan Tool Range 0-255.

An incrementing counter indicates that detonation is
currently being detected.
KS Minimum Learned Noise: Scan Tool Range
0.0 to 5.0 Volts.
Indicates the minimum level that the PCM has
detected on the noise channel while the noise level
was being learned. If a noise channel voltage is
detected below the minimum acceptable learned noise,
a problem is indicated.
KS Noise Channel: Scan Tool Range 0.0 to 5.0 Volts.
Indicates the current voltage level being monitored
on the KS noise channel. The PCM determines
whether knock is occurring by monitoring the signal
level on the KS circuit. The noise channel allows
the PCM to diagnose the KS module and the knock
sensor(s) by indicating the amount of normal
engine mechanical noise present. Normal engine
noise varies depending on engine speed and load.
Long Term Fuel Trim Bank 1: Scan Tool Range
-23% to 16%
Long Term Fuel Trim Bank 1 is derived from the Short
Term Fuel Trim Bank 1 value and represents a
long-term correction of bank 1 fuel delivery. A value of
0% indicates that fuel delivery requires no
compensation to maintain the PCM commanded
air/fuel ratio. A negative value significantly below 0%
indicates that the fuel system is rich and fuel
delivery is being reduced (decreased injector pulse
width). A positive value significantly greater than 0%
indicates that a lean condition exists and the PCM
is compensating by adding fuel (increased injector
pulse width). Because Long Term Fuel Trim tends to
follow Short Term Fuel Trim; a value in the negative
range due to canister purge at idle should not be
considered unusual. The PCM's maximum authority to
control fuel trim allows a range between -23% and
+ 16%. Fuel trim values at maximum authority
may indicate an excessively rich or lean system.
Long Term Fuel Trim Bank 2: Scan Tool Range
-23% to 16%
Long Term Fuel Trim Bank 2 is derived from the Short
Term Fuel Trim Bank 2 value and represents a
long-term correction of bank 2 fuel delivery. A value of
0% indicates that fuel delivery requires no
compensation to maintain the PCM commanded
air/fuel ratio. A negative value significantly below 0%
indicates that the fuel system is rich and fuel
delivery is being reduced (decreased injector pulse
width). A positive value significantly greater than 0%
indicates that a lean condition exists and the PCM
is compensating by adding fuel (increased injector
pulse width). Because Long Term Fuel Trim tends to
follow Short Term Fuel Trim; a value in the negative
range due to canister purge at idle should not be
considered unusual. The PCM's maximum authority to
control fuel trim allows a range between -23% and
+16%. Fuel trim values at maximum authority
may indicate an excessively rich or lean system.

Engine
Loop Status: Scan Tool Displays OPEN or CLOSED.
Closed Loop indicates that the PCM is controlling
fuel delivery according to oxygen sensor voltage. In
Open Loop, the PCM ignores the oxygen sensor
voltage and bases the amount of fuel to be delivered
on TP sensor, engine coolant, and MAF sensor
inputs only.
MAF: Scan Tool Range 0.0-512 gm/s.
MAF (Mass Air Flow) is the MAF Input Frequency
converted to grams of air per second. This indicates
the amount of air entering the engine.
MAF Input Frequency: Scan Tool Range
O to 32000 Hz.
The Mass Air Flow sensor input signal to the PCM is
a frequency which varies from around 3000 Hz at
idle to above 7000 Hz at wide-open throttle. The PCM
converts this frequency signal to grams per second
to be displayed on the scan tool as MAF.
MAP: Scan Tool Range 10-105 kPa/0.00 to 4.97 Volts.
The Manifold Absolute Pressure (MAP) sensor
measures the change in the intake manifold pressure
from engine load, EGR flow, and speed changes.
As intake manifold pressure increases, intake vacuum
decreases resulting in a higher MAP sensor voltage
and kPa reading. The MAP sensor signal is used
to monitor intake manifold pressure changes during
the EGR flow test, to update the BARO reading,
and as an enabling factor for many of the diagnostics.
MIL: Scan Tool Displays ON or OFF.
Indicates the PCM commanded state of the
Malfunction Indicator Lamp.
Misfire Current Cyl #1- Misfire Current Cyt #6:
Scan Tool Range Oto 198 Counts.
The Misfire Current counters indicate the number of
cylinder firing events detected as possible misfires on
each cylinder during the last 200 crankshaft
revolutions. The number that the counters display are
twice the actual number of misfire events detected.
The counters may normally display some activity, but
the activity should be very low and nearly equal for
all the cylinders.
Misfire History Cyl #1- Cyl #6: Scan Tool Range
O to 65535 Counts.
The Misfire History counters indicate the total level of
misfire that has been detected on each cylinder.
The number that the counters display are twice the
actual number of misfire events detected. The Misfire
History counters will not update or show any activity
until a misfire OTC (P0300) has become active.
The Misfire History counters will be updated every
time a 200 crankshaft revolution misfire test failure is
detected.

Engine
Power Enrichment: Scan Tool Displays ACTIVE or
INACTIVE.
ACTIVE displayed indicates that the PCM has
detected conditions appropriate to operate in Power
Enrichment mode. The PCM will command Power
Enrichment mode when a large increase in throttle
position and load is detected. While in Power
Enrichment, the PCM will increase the amount of fuel
delivered by entering Open Loop and increasing
the injector pulse width. This is done to prevent a
possible sag or hesitation from occurring during
acceleration.
Rich/Lean: Scan Tool Displays RICH or LEAN.
Indicates whether oxygen sensor voltage is greater
than a 600 mV threshold voltage (rich) or less than a
300 mV threshold voltage (lean). Should change
constantly while in closed loop, indicating that the PCM
is controlling the air/fuel mixture properly.
Short Term Fuel Trim Bank 1: Scan Tool Range
-11% to 20%
Short Term Fuel Trim Bank 1 represents a short-term
correction to bank 1 fuel delivery by the PCM in
response to the amount of time the bank 1 fuel control
oxygen sensor voltage spends above or below the
450 mV threshold. If the oxygen sensor voltage
has mainly remained less than 450 mV, indicating a
lean air/fuel mixture, short term fuel trim will increase
into the positive range above 0% and the PCM will
add fuel. If the oxygen sensor voltage stays mainly
above the threshold, short term fuel trim will decrease
below 0% into the negative range while the PCM
reduces fuel delivery to compensate for the indicated
rich condition. Under certain conditions such as
extended idle and high ambient temperatures, canister
purge may cause Short Term Fuel Trim to read in
the negative range during normal operation. The
PCM's maximum authority to control fuel trim allows a
range between -11 % and +20%. Fuel trim values at
maximum authority may indicate an excessively rich or
lean system.

Short Term Fuel Trim Bank 2: Scan Tool Range

-11% to 20%
Short Term Fuel Trim Bank 2 represents a short-term
correction to bank 2 fuel delivery by the PCM in
response to the amount of time the bank 2 fuel control
oxygen sensor voltage spends above or below the
450 mV threshold. If the oxygen sensor voltage
has mainly remained less than 450 mV, indicating a
lean air/fuel mixture, short term fuel trim will increase
into the positive range above 0% and the PCM will
add fuel. If the oxygen sensor voltage stays mainly
above the threshold, short term fuel trim will decrease
below 0% into the negative range while the PCM
reduces fuel delivery to compensate for the indicated
rich condition. Under certain conditions such as
extended idle and high ambient temperatures, canister
purge may cause Short Term Fuel Trim to read in
the negative range during normal operation. The
PCM's maximum authority to control fuel trim allows a
range between -11 % and +20%. Fuel trim values at
maximum authority may indicate an excessively rich or
lean system.

Engine Controls - 3.8L

6-735

Spark: Scan Tool Range -64 degrees to 64 degrees.

Displays the spark timing being commanded by
the PCM on the IC circuit. A negative (-) value
indicates degrees Before Top Dead Center (BTDC) or
spark advance; a positive value indicates degrees
After Top Dead Center (ATDC) or spark retard.
Because the ignition control module sets spark
advance at a fixed value of 10 BTDC while operating
in Bypass mode, the displayed Spark advance only
reflects true spark timing when the PCM has
commanded IC mode.
Start-Up Ect:. Scan Tool Range -40C to 151 C,
-40F to 304F.
Indicates the Engine Coolant Temperature at the time
that the vehicle was started. Used by the H02S
diagnostic to determine if the last startup was a
cold start.
Start-Up IAT: Scan Tool Range -40C to 151C,
-40F to 304F.
Indicates the Intake Air Temperature at the time that
the vehicle was started. Used by the H02S diagnostic
to determine if the last startup was a cold start.
Throttle At Idle: Scan Tool Displays YES or NO.
Indicates whether the TP Angle being monitored by the
PCM is at 0%.
Total Misfire Current Count: Scan Tool Range
Oto 99.
Indicates the total number of cylinder firing events that
were detected as being misfires during the last
200 crankshaft revolution sample period.
Total Misfire Failures Since First Fail: Scan Tool
Range O to 65535 Counts.
Indicates the number of 200 crankshaft revolution
sample periods during which the level of misfire was
sufficiently high to report a failure.
Total Misfire Passes Since First Fail: Scan Tool
Range O to 65535 Counts.
Indicates the number of 200 crankshaft revolution
sample periods during which the level of misfire was
sufficiently low to report a pass.
TP Angle: Scan Tool Range 0% to 100%.
TP Angle is computed by the PCM from the TP
Sensor voltage. TP Angle should display 0% at idle
and 100% at wide open throttle.
TP Sensor: Scan Tool Range 0.00 to 5.00 Volts.
The voltage being monitored by the PCM on the TP
sensor signal circuit.
Trans Range: Scan Tool Displays INVALID,
PARK/NEUTRAL, REVERSE, DRIVE 4, DRIVE 3,
DRIVE 2, or LOW
Trans Range represents the decoded status of the
three transmission range pressure switch inputs from
the Transmission Range Pressure Switch Assembly.
The combination of transmission range inputs indicates
the position of the transmission manual valve.

6-736

Engine Controls - 3.8L

Engine

TR Switch ABC: Scan Tool Displays High or Low

The TR A B C display represents the states of
the three inputs from the Transmission Range
Pressure Switch Assembly. High indicates a B+
voltage input signal being monitored at the PCM, Low
indicates a grounded input signal. The combination
of transmission range inputs indicates the position of
the transmission manual valve.
TWC Diagnostic: Scan Tool Displays ENABLED or
.
DISABLED.
ENABLED displayed indicates that MAF, H02S, ECT,
or VSS DTCs that would disable the TWC diagnostic
are not present.
TWC Monitor Test Counter: Scan Tool Range 0-49.
The TWC monitor test counter increments while
the TWC system diagnostic test is running and taking
samples. When the TWC Monitor Test Counter
reaches 49, the PCM will update the TWC diagnostic
statistical filter. At this point, the TWC Monitor Test
Counter will reset to O and begin incrementing again.
The TWC Monitor Test Counter is most useful
when verifying a Three-way catalytic converter
replacement or any repair associated with the
DTC P0420 diagnostic tab.le.
TWC Protection: Scan Tool Displays ACTIVE or
INACTIVE.
ACTIVE displayed indicates that the PCM has
detected conditions appropriate to operate in TWC
Protection mode. This is determined based on Engine
Load and Engine Coolant Temperature. While in
TWC Protection, the PCM will decrease Air/Fuel Ratio
to a value that depends on Mass Air Flow (higher
Mass Airflow = lower Air/Fuel Ratio).
VTD Fuel Disable: Scan Tool Displays ACTIVE or
INACTIVE.
The Theft Deterrent Fuel Enable circuit is an input
from the Vehicle Theft Deterrent Control Module tha:t
signals the PCM to enable the injectors if the
proper signal is received. The scan tool will normally
display INACTIVE. If the Vehicle Theft Deterrent
Control Module does not sent the correct Theft
Deterrent Fuel Enable signal to the PCM, the display

will switch to ACTIVE and the fuel system may be

disabled. Refer to DTCs P1626, P1629, or Vehicle
Theft Deterrent diagnosis for further information.
Vehicle Speed Scan Tool Range 0-255 km/h,
0-155 mph.
The vehicle speed sensor signal is converted into mph
and km/h for display.

DTC List
The service information contained in this manual
refers to the Federal calibration package - the United
States, Canada and Japan. For Unleaded Export
calibration vehicles some DTCs have been changed
from type B to type D or, in some cases, turned off (the
diagnostic does not run, no codes are stored, and
the Malfunction Indicator Lamp (MIL) will not illuminate.
This change is NOT reflected in the s.ervice
information on the DTCs diagnostic support information
page or in the Repair Instructions. When a type A
diagnostic fails, a DTC is set immediately and
the Malfunction Indicator Lamp (MIL) is illuminated.
When a type B DTC diagnostic fails, the Malfunction
Indicator Lamp (MIL) will illuminate if the fault is
present after two consecutive drive trips. A type D
DTC will set after one failure and be stored in history
but will not illuminate the Malfunction Indicator
Lamp (MIL). Unleaded Export calibration vehicles are
referenced only in the OTC Type table.
If a system is malfunctioning and the associated OTC
has been disabled, it may be beneficial to use the
diagnostic table as a guide to aid in diagnosis. Many
of the DTC tables include a functional check of
the system that may pinpoint a problem. However, it is
important to remember that the DTG tables are
specifically designed for use only when a DTC is set.
Therefore, a thorough understanding of the normal
operation of the system being diagnosed is necessary
and use of the tables for this purpose is at the
discretion of the technician.
Important: An export vehicle may have unrequired
emissions components removed.
Important: For Automatic Transmission DTC types,
refer to Transmission.

Diagnostic Trouble Code (DTC) Type Table

DTC
P0101

Description
Mass Air Flow System Performance

Domestic
RPO L36

Illuminate MIL

Yes

P0102

MAF Sensor Circuit Low Frequency

Yes

P0103

MAF Sensor Circuit High Frequency

Yes

P0107

MAP Sensor Circuit Low Voltage

Yes

P0108

MAP Sensor Circuit High Voltage

Yes

P0112

IAT Sensor Circuit Low Voltage

Yes

P0113

IAT Sensor Circuit High Voltage

Yes

P0117

ECT Sensor Circuit Low Voltage

Yes

P0118

ECT Sensor Circuit High Voltage

Yes

P0121

TP Sensor Performance

Yes

P0122

TP Sensor Circuit Low Voltage

Yes

Engine

Engine Controls - 3.8L

6-737

Diagnostic Trouble Code (DTC) Type Table (cont'd)

Domestic

OTC

Description

RPO L36

Illuminate MIL

P0123

TP Sensor Circuit High Voltage

Yes

P0125

ECT Excessive Time to Closed Loop

Yes

P0131

H02S Circuit Low Voltage Bank 1 Sensor 1

Yes

P0132

H02S Circuit High Voltage Bank 1 Sensor 1

Yes

P0133

H02S Circuit Slow Response Bank 1 Sensor 1

Yes

P0134

H02S CKT Insufficient Activity Bank 1 Sensor 1

Yes

P0135

H02S Heater Circuit Bank 1 Sensor 1

Yes

P0143

H02S Circuit Low Voltage Bank 1 Sensor 3 (Post-Converter)

Yes

P0144

H02S Circuit High Voltage Bank 1 Sensor 3 (Post-Converter)

Yes

P0146

H02S Circuit Insufficient Activity Bank 1 Sensor 3 (Post-Converter)

Yes

P0147

H02S Heater Circuit Bank 1 Sensor 3 (Post-Converter)

Yes

P0151

H02S Circuit Low Voltage Bank 2 Sensor 1

Yes

P0152

H02S Circuit High Voltage Bank 2 Sensor 1

Yes

P0153

H02S Circuit Slow Response Bank 2 Sensor 1

Yes

P0154

H02S Circuit Insufficient Activity Bank 2 Sensor 1

Yes

P0155

H02S Heater Circuit Bank 2 Sensor .1

Yes

P0171

Fuel Trim System Lean Bank 1

Yes

P0172

Fuel Trim System Rich Bank 1

Yes

P0174

Fuel Trim System Lean Bank 2

Yes

P0175

Fuel Trim System Rich Bank 2

Yes

P0201

Injector 1 Control Circuit

Yes

P0202

Injector 2 Control Circuit

Yes

P0203

Injector 3 Control Circuit

Yes

P0204

Injector 4 Control Circuit

Yes

P0205

Injector 5 Control Circuit

Yes

P0206

Injector 6 Control Circuit

Yes

P0300

Engine Misfire Detected

Yes

P0325

Knock Sensor System

Yes

P0327

Knock Sensor Circuit Bank 1

No

P0332

Knock Sensor Circuit Bank 2

No

P0336

18X Reference Signal Circuit

Yes

P0341

CMP Sensor Circuit Performance

Yes

P0401

EGR System Flow Insufficient

Yes

P0403

EGR Solenoid Control Circuit

Yes

P0404

EGR System Performance

Yes

P0405

EGR Pintle Position Circuit Low Voltage

Yes

P0420

TWC System Low Efficiency

Yes

P0440

EVAP System

Yes

P0442

EVAP Control System Small Leak Detected

Yes

P0446

EVAP Canister Vent Blocked

Yes

P0452

Fuel Tank Pressure Sensor Circuit Low Voltage

Yes

P0453

Fuel Tank Pressure Sensor Circuit High Voltage

Yes

P0500

Vehicle Speed Sensor Circuit

Yes

P0506

Idle Control System Low RPM

Yes

P0507

Idle Control System High RPM

Yes

P0530

A/C Refrigerant Pressure Sensor Circuit

No

P0560

System Voltage

No

6-738

Engine Controls - 3.SL

Engine

Diagnostic Trouble Code (OTC) Type Table (cont'd)

DTC
P0601

Description
PCM Memory

Domestic
RPO L36

Illuminate MIL

Yes

P0602

PCM Not Programmed

Yes

P0704

Clutch Anticipate Switch Circuit

No

P0705

Trans Range Switch Circuit

No

P0706

Trans Range Switch Performance

No

P0711

Transaxle Fluid Temperature (TFT) Sensor Circuit Performance.

Refer to 4L60-E Automatic Transmission Diagnosis

P0712

Transaxle Fluid Temperature (TFT) Sensor Circuit - Low Signal.

Refer to 4L60-E Automatic Transmission Diagnosis

P0713

Transaxle Fluid Temperature (TFT) Sensor Circuit - High Signal

Voltage. Refer to 4L60-E Automatic Transmission Diagnosis

P0716

Automatic Transmission Input (Shaft) Speed Sensor Circuit

Performance. Refer to 4L60-E Automatic Transmission Diagnosis

P0717

Automatic Transmission Input (Shaft) Speed Sensor No Input. Refer

to 4L60-E Automatic Transmission

P0719

Brake Switch Circuit Low. Refer to 4L60-E Automatic Transmission

Diagnosis

P0724

Brake Switch Circuit High. Refer to 4L60-E Automatic Transmission

Diagnosis

P0730

Incorrect Gear Ratio. Refer to 4L60-E Automatic Transmission

P0741

Torque Converter Clutch System Stuck Off. Refer to 4L60-E

Automatic Transmission Diagnosis

P0742

Torque Converter Clutch System Stuck On. Refer to 4L60-E

Automatic Transmission Diagnosis

P0748

Pressure Control Solenoid Valve Circuit Malfunction. Refer to

4L60-E Automatic Transmission Diagnosis

P0751

Shift Solenoid 1 - Performance/Stuck Off. Refer to 4L60-E

Automatic Transmission Diagnosis

P0753

Shift Solenoid 1 - Electrical. Refer to 4L60-E Automatic

Transmission Diagnosis

P0756

Shift Solenoid 2 - Performance/Stuck Off. Refer to 4L60-E

Automatic Transmission Diagnosis

P0758

Shift Solenoid 2 - Electrical. Refer to 4L60-E Automatic

Transmission Diagnosis

P1106

MAP Sensor CKT Intermittent High Voltage

No
No
No
Yes
Yes
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No

P1107

MAP Sensor CKT Intermittent Low Voltage

No

P1111

IAT Sensor CKT Intermittent High Voltage

No

P1112

IAT Sensor CKT Intermittent Low Voltage

No

P1114

ECT Sensor CKT Intermittent Low Voltage

No

P1115

ECT Sensor CKT Intermittent High Voltage

No

P1121

TP Sensor CKT Intermittent High Voltage

No

No

P1122

TP Sensor CKT Intermittent Low Voltage

P1133

H02S Insufficient Switching Bank 1 Sensor 1

Yes

P1134

H02S Transition Time Ratio Bank 1 Sensor 1

Yes

P1153

H02S Insufficient Switching Bank 2 Sensor 1

Yes

P1154

H02S Transition Time Ratio Bank 2 Sensor 1

Yes

P1336

CKP System Variation Not Learned

Yes

P1351

IC Circuit Open

Yes

P1352

Bypass Circuit Open

Yes

P1361

IC Circuit Not Toggling

Yes

P1362

Bypass Circuit Shorted

Yes

Engine

Engine Controls - 3.8L 6-739

Diagnostic Trouble Code (OTC) Type Table (cont'd)
Domestic

DTC

Description

Illuminate MIL

P1374

3X Reference Circuit

Yes

P1380

EBCM OTC Rough Data Unstable

No

P1381

Misfire Detected No EBCM/PCM Serial Data

No

P1404

EGR Valve Closed Pintle Position

Yes

P1441

EVAP System Flow During Non-Purge

Yes

P1554

Cruise Control Status Circuit

No

P1626

Theft Deterrent System Fuel Enable CKT

No

P1629

Theft Deterrent Crank Signal Malfunction

No

P1635

5 Volt Reference (A) Circuit

Yes

P1639

5 Volt Reference (B) Circuit

Yes

P1641

A/C Relay Control Circuit

No

P1651

Fan 1 Relay Control Circuit

Yes

P1652

Fan 2 and 3 Relay Control Circuit

Yes

P1653

Fuel Level Output Control Circuit

No

P1662

Cruise Control Inhibit Control Circuit

No

P1663

Generator Lamp Control Circuit

No

P1665

EVAP Vent Solenoid Control Circuit

Yes

P1671

MIL Control Circuit

No

P1672

Low Engine Oil Level Lamp Control Circuit

No

P1676

EVAP Canister Purge Solenoid Control CKT

Yes

Automatic Transmission Fluid Pressure Manual Valve Position

Switch Malfunction. Refer to 4L60-E Automatic Transmission
Diagnosis

Yes

P1810
P1811

Maximum Adapt and Long Shift. Refer to4L60-E Automatic

Transmission Diagnosis

.D

No

P1860

Torque Converter Clutch PWM Solenoid Circuit. Refer to 4L60-E

Automatic Transmission Diagnosis

Yes

P1887

TCC Release Switch Malfunction. Refer to4L60-E Automatic

Transmission Diagnosis

Fuel System Specifications (VIN K)

Fuel (Regular)

RPO L36

Notice: Your vehicle was not designed for fuel that

contains methanol. Don't use it. It can corrode
metal parts in your fuel system and also damage
plastic and rubber parts. That damage wouldn't
be cover~d under your warranty.
The following information appears in the General
Motors owner's manual for this vehicle.
Use regular unleaded gasoline rated at 87 octane or
higher. At a minimum, it should meet specifications
ASTM 04814 in the United States and CGSB
3.5-M93 in Canada. Improved gasoline specifications
have been developed by the American Automobile
Manufacturers Association (AAMA) for better vehicle
performance and engine protection. Gasolines
meeting the AAMA specification could provide
improved driveability and emission control system
protection compared to other gasolines.
Be sure the posted octane is at least 87. If the octane
is less than 87, you may get a heavy knocking
noise when you drive. If it's bad enough, it can
damage your engine.

Yes

If you're using fuel rated at 87 octane or higher and

you still hea.r heavy knocking, your engine needs
service. But don't worry if you hear a little pinging
noise when you're accelerating or driving up a
hill. That's normal, and you don't have to buy a higher
octane fuel to get rid of pinging. It's the heavy,
constant knock that means you have a problem.
If your vehicle is certified to meet California Emission
Standards (indicated on the underhood tune-up
label), it is designed to operate on fuels that meet
California specifications. If such fuels are not available
in states adopting California emissions standards,
your vehicle will operate satisfactorily on fuels meeting
federal specifications, but emission control system
performance may be affected.
The malfunction indicator lamp on your instrument
panel may turn on and/or your vehicle may fail
a smog-check test. If this occurs, return to a qualified
service outlet for diagnosis to determine the cause
of failure. In the event it is determined t.hat the cause
of the condition is the type of fuels used, repairs
may not be covered by your warranty.

6-740

Engine

Engine Controls - 3.8L

Some gasolines that are not reformulated for low

emissions contain an octane-enhancing additive called
methylcyclopentadienyl manganese tricarbonyl
(MMT); ask your service station operator whether or
not his fuel contains MMT. General Motors does
not recommend the use of such gasolines. If fuels
containing MMT are used, spark plug life may
be reduced and your emission control system
performance may be affected. The malfunction
indicator lamp on your instrument panel may turn on.
If this occurs, return to a qualified service outlet
for service.

To provide cleaner air, all gasolines in the United

States are now required to contain additives that will
help prevent deposits from forming in your engine and
fuel system, allowing your emission control system
to function properly. Therefore, you should not have to
add anything .to the fuel. In addition, gasolines
containing oxygenates, such as ethers and ethanol,
and reformulated gasolines may be available in
your area to help clean the air. General Motors
recommends that you use these gasolines if they
comply with the specifications described earlier.

GM SPO Group Numbers

Application

GM SPO Group Number

3.430

Accelerator Control Cable

Accelerator Pedal

3.451

Air Cleaner Assembly

3.402

Air Cleaner Duct Assembly

3.417

Air Filter

3.410

Body Control Module

2.560

Camshaft Position (CMP) Sensor

2.383

Clutch Anticipate Switch

4.054

Cooling Fans

1.050

Crankshaft Position (CKP) Sensor

2.383

Cruise Contol Module

3.887

Engine Coolant Temperature (ECT) Sensor

3.682

EV AP Canister

3.130

EVAP Fuel Tank Pressure Sensor

3.140

EVAP Hoses and Pipes

3.145

EVAP Purge Solenoid

3.140

EVAP Vacuum Switch

3.140

Fuel Hoses and Pipes

3.163

Fuel Injectors

3.300

Fuel Pressure Regulator Assembly

Fuel Pump

3.330
3.900

Fuel Pump Relay

3.900

Fuel Rail Assembly

3.330

Fuel Sender

3.107

Fuel Tank

3.001

Fuel Tank Straps

3.022

Heated Oxygen Sensor

3.682

Idle Air Control (IAC) Valve

3.338

lnline Fuel Filter

3.890

Ignition Coil

2.170

Ignition Control Module

2.j?O

Intake Air Temperature (IAT) Sensor

3.682

Intake Manifold Plenum

3.265

Knock Sensors

2.38;3

KS Module

3.670

Linear Exhaust Gas Recirculation (EGR) Valve

3.670

Manifold Absolute Pressure (MAP) Sensor

3.682

Mass Air Flow (MAF) Sensor

3.682

Engine

Engine Controls 3.SL

6741

GM SPO Group Numbers (cont'd)

Application

GM SPO Group Number

1.745
3.670
4.115
3.335
3.339
3.682

Positve Crankcase Vent Valve

Powertrain Control Module (PCM)
TCC Brake Switch
Throttle Body Assembly
Throttle Position (TP) Sensor
Vehicle Speed (VSS) Sensor

Schematic and Routing Diagrams

Emission Hose Routing Diagram
Emission Hose Routing Diagram

226742

Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)

Fuel Pressure Regulator

To Vacuum Brake Booster
EV AP Service Port
Intake Manifold
To EVAP Canister (Behind the Lett
Rear Tire)
Throttle Body
PCV Valve
EVAP Canister Purge Solenoid Valve
To Accessory
Manifold Vacuum Source

6-742

Engine

Engine Controls - 3.SL

Engine Controls Schematic References

Section Number - Subsection

Name

Reference on Schematic

Antilock Brakes!Traction Control - Cell 44

5 - Antilock Braking System

Antilock Brake System I Traction Control System - Cell 44

5 - Antilock Braking System

Automatic Transmission Controls - Cell 39

7 - Automatic Transmission

6 - Engine Cooling

Cooling Fans - Cell 31

Cruise Control - Cell 34

8 - Cruise Control

Data Link Connector (DLC) - Cell 50

8 - Wiring Systems

Fuse Block Details - Cell 11

8 - Wiring Systems

Ground Distribution - Cell 14

8 - Wiring Systems
8 - Instrument Panel, Gauges,
and Console

Instrument Panel - Cell 81

Power Distribution - Cell 10

8 - Wiring Systems

Sensors - Cell 20

6 - Engine Controls
5 - Antilock Braking System

Theft Deterrent System - Cell 133

Engine Controls Schematic Icons

Icon Definition

Icon

Refer to ESD Notice in Cautions and Notices.

19384

Refer to 080 If Symbol Description Notice in Cautions and Notices.

19385

'~/

Engine Controls Schematics (Power, Ground and MIL)

::::,

IL 0 c

___ ...

L-----0.8 PNK 39

0.8 PNK 439

a.SORN 340

L--- ----r-

(SERVICE

0.8
PPUWHT
5161-----
1035

Automatic

Transmission
Controls
Cell39

0.8 PPL/WHT 1035

1
P1 0

C101

0.8 PPL/WHT 1035

"!::fa - - - - - - - - - - - );~: - - - - - - - - - - - ~~:~:l. -:r- - - - - - - - - - - - - - -~~~ - - -;c;; - ~ 6~~:~rain

20
I
:

I ~

ENGINE SOON~

0.35 BRN/W~~r419
B C230

M~~

::::,
CD

!0Esc!

...

0.8 PPUWHT 1035

AS
'" - - - - - - - - - - - - - -, Instrument
I lnstrument----1'
Maffunction
~
J.. Indicator
I Cluster
I Cluster
I Cell 81
@ Lamp (MIL) I ~

0.5 PNK 439

________

5206 - - - - - - +
0.35 PNK 39

E C101

...

cc

i. _

19

Voltage (B+)

C1

0.35 BRN!WHJ 419_- - - - - - - - - - - - - - - - - - - - - 23

Voltage

C2

Voltage

g:~~ :Module

PCM
PCM
PCM
PCM
-=I
~o!;!!ld_ _ _ _ _G~u'!!:! _ _ _ _ ~o~nd_ _ _ _ _G~u~ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ...

16

--------60 --------56 --------57

0.8 BLK/WHT 451

0.8 BLK/WHT 451

(PCM)
~

C1

::::,

0.8 BLK/WHT 451

cc

0.8 BLK/WHT 451

L--------------------41~------~0~.8~B~L~K/W~-H-T________________--tA
451
5110

::::,
CD

~~~

Connector

::::,

.....
0

;;

3 BLK 451

co

.....
0)

.,,. G110

........

.1:1,,

192064

a,

Engine Control.s Schematics (Power, Ground and MIL)

IHot At AH Times I

r---------- ----,~

!Loe

ICell 10

jesc!

I Power
Distribution
I

Fuse Block
Details
Cell11

CIGAR/ACCY Fuse
Fuse 11
I Block
C425 A
I

C3

L---------- ----~
0.80RN 540

~
~

1~
Cell 11

......

,S:ii

.i:i.

m
:s
'9.
:::,
CD

n
0

:s

i'

w
or,
r

..,. _ _ _ _ . ._s_24_0'----------.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - rv - - - - - sv - ,PDwertrain

I
I
I

Serial
i>CM
C1 = BLU
C2=CLEAR

Data
(Class II)

~-T
-=-

Serial

n ..T

Data
~
(UART) -

:Module
Control
I
I

~---------------------------- ------------1
------ --~
Ground
Distribution
Cell 14

59
0.35 PPL 1807

.,._ -

15 C1
0.35 TAN 800
E C105

{PCM)

~~
~

0.35TAN 800
5 184 0.35 TAN ~
~~~-------1@1-----<<+-_;:~~~~B~LKIW=..:...:...:..:.H~T~.... s215
P110
800
~
P100
(PCM)
s21%
0.8 BLKIWHT 451
0.80RN 540
K c 23o 0.35 TAN 800
A12 C200A
1
0.8BLK 650
0.35 PPL 1807
C200D
0.35 TAN 800
Data Link
3 BU< 650
S225
- -. Connector (DLC)
0.35 TAN 800
._c;.;.e_11so..;...._ __,
\
2
9
16
5
4
\
Data Link
.... G200
Connector (DLC)
P110

Powertraln

C21 0

r-----------

.,._ -

m
::,

----------- ------------ ---------------

cc

::,
192070

(I)

Engine Controls Schematics (Ignition Control, Knock Sensors)

Instrument>
Cluster ~

r-----,
...

I
I

_____ ...
Tachometer
Input

813

Camshaft
Position (CMP)
Sensor

Crankshaft
Position (CKP)
Sensor

C
D
C
B
0.8
WHT/ 644 0.8
WHT/ 644
BLK
$144 BLK
0.8
RED/ 645

0.8
RED/ 645
BLK

BLK

S145e-~~--'-~if'--~~~~~~~

0.35WHT 121

0.8
RED/ 645
BLK

0.5 PNK 239

0.8
LTBLU/ 1800
WHT

S182

- - - - -

0.5 PNK 239

G C1 00

Power
Distribution
Cell10

0.5 PNKf.39
$107
- - - - -

BLK

M
CMP/CKP
Sensor
Ground

CMP
Sensor
Signal

CKP18x
Signal

CMP/CKP
Sensor Ignition
Positive Voltage

0.8PNK 239
p

5V

---

I
I

.J

WHT/ 644

0.8 BRN/WHT 633

0.8 YEL 573

0.8

(D

- - - - ,Und
I
e~hood
ENG CTRL I Electrical
MiniFuse I Center 2

_________ ...

L....--Z....

::::,

IHot In Run, Bulb Test And Start!

'" - - - - -

I Power
I Distribution
I Cell 10
I
I...

r~-...zd:~_____,:,t~-\---...J!\I

.____I)~4_Lli........__:~sor-Effect--:L-J1I I

m
::::,
cc

CKP
Sync
Signal

Ignition
Control (IC)
Module

Ignition
Positive
Voltage

5V

12V
Camshaft
,____ Position Sensor
Signal

Tachometer
Output

Reference
Signal

3x

18x
Reference
Signal

Bypass
Control

Ignition
Control (IC)

Ref Low

Ground

::::,

0.35 WHT 121

0.8
PPL/WHT 430

0.8 BLK 630

0.35

0.35

fl]

-r

331 _-~~ ---?. -------------~

LT BLU 1876
DK BLU 496
1
1
rBank1 Bank 2
Bank 1 I KS Signal
Knock
_
Knock I
Sensor
Sensor I
(KS)
(KS)

Bank2KS Signal

Camshaft Position
Sensor
Signal

0.8

-- - -- - !3 -------

18x - - Reference
Signal

-3x - - Reference
Signal

BLK

0.8WHT 423
0.8
TAN/BLK 424

0.8 LT
BLU/BLK 647

cc

Control

(D

0
::::,

0.8
RED/BLK 453

-- ----- ---

. -Bypass -

::::,

450

---------

- - - -Ignition - PCM .
Control (IC)
C1=BLU
C2=CLEAR

~~

" "I

C1

- Ref Low

G112
, Powertram
I Control
I Module
1(PCM).~

>

~-------~-------------------------------------J

192078

a,

Engine Controls Schematics (Fuel Pump Controls)

!Loe I

!Hot At All Times!

... - - - - -

- - - - ., Underhood
FUEL PUMP I Electrical
MiniFuse I Center 1

I Power
I ~~~~ution

I
I

HS

20A

1 ORN

'" - -

1 GRY
120

B3
B

1-

-~:~:;r~

G3

C405B

___

B8

0.35GRY 720

0.5 BLK/WHT

- -

- -

- -

Fuel

Fuel

Pump

Level

Motor

Sensor

Ii{

C3

- -

- - ., Fuel

- -

/\ :Unit
l Ii::e
F I

Ground
Distribution

ITan k

r~~/;L~f1~
1 PPL 30
A
D

.----.,Body
I Theft

r----liV
I
I

69

DK GRN 890

(TP) Sensor

55

~vet
Signal

~:~

r -

cor-

8110

.,_ -

., Instrument

Module I Gauge1

~ (BCM)

DSC3>

~n~ _.

A2

,!t

MA

$121
- """'. een 22
0.35 GRY 720
35

0.35 DK BLU 2290.35 DK BLU 1936

D

C230

3 BLK 451

C210

- ~.;~~-~~~U 1:;~o

~~~Tl465

1------ ------=~~

C101

-;- G110

0.35 DK BLU 229

3

C2

j_1~~:p - - - -

Pressure
sign al .,,.

Control

_____________________________________ -

-1~~~e----f:!~,~ ----~b~~~~ra1n

70

Control

12V

HC405A

Fuel -

Fuel Enable

~ s~n~

~:r_:305 Hf--~-~-~;sii~~:~---~r---_-_-_-_-_-_-_-_-_-_~tc:11_,
.

en

I Control I Fuel I Cluster

I Deterrent

0.35 GRY 598 DK GRN 890

30

.,

Cell14

C405B

o35 PPL

0
::::s

0.35 BLK/WHT 451

- - -;;~

0.35 DK GAN/WHT 465

~ Er~-~-~-~-~
~-;~R~r8;o- - ~
1 031---~~;; H31
. . .f-i--~--o-n_,
.
~~lr;O--1 BLK 150
C

~
451 ~

::::s

C101

--------

r -

::::s

(D

I
I
I
...I

a,

cc

Relay I

.. _--

5~ - - - G C405A
0.5
D ORN/BLK 469

1
1 GAY 120
C

C200D
C200A

1 GRY 120

$244

F3

AS

- - - , Underhood
10
_A_~---.......;.,;........ F I I Electrical
86 Pump
ue
ent er 2

!oEsc!

L.----- ____ . .

......

__ -

Signal

_
-

5V
-

C1

PCM
C1 =BLU

_ _ _ _ _ _ C2=CLEAR

I
I

Module
(PCM)

j.

~~

::::s

('2

::::s

192086

CD

___

Engine Controls Schematics (Fuel Injectors)

!Hot In Run, Bulb Test And

rPower
----I

I
I
I

Distribution
CeH 10

JB

L.-----

:::s

I
jEsc I

Start!

- - - - . , Underhood

!Loe

INJ 1
I Electrical
MiniFuse Center 2
15A
I

____ ..

c.c

:::s

(D

~
~

0.8 PNK/WHT 639

A C100

0.8 PNK 639

8102

r1nl
l1J

~njector

Fuel
~jector

l1J

0.5 PNK 639

0.5PNK 639

~jector

f1n] Fuel
~jector

l1J

f1nl
l1J

0.5 PNK 639

A
f1n]Fuel

A
f1n]Fuel

l1J

0.5 PNK 639

0.5PNK 639

0.5 PNK 639

f1n] Fuel
~jector.

LlJ

Fuel
~jector

m
:::s
c.c
:::s
(D

0.5 BLK 1744

79

0.5 LT GRN/BLK 1745

~ -;,~;,-1-,- - - - I
I

I
I

n1ec or
Driver

1=

----

0.5 PNK/BLK 1746

73 C1

0.5 BLK/WHT 845

0.5 LT BLU/BLK 844

42 C2

_______________ 1?

46

0.5 YEL/BLK 846

---------------~~

C1

-r~i ;-,----"rnj;:3-7----~:~r~ ~ ,------rnj:~:r:-,- ----~1!0~6-7- -: 6~~:~rain

1
DnJ. or
river

Drer

----

----T

....

----T

Driver

----T
_..
=

DriVer

....

PCM
C1=BLU
C2=CLEAR

L. - - - - - - - - - - - - - - - - - -

_,< ___ , -

--- -

_, __ -

_,._,_ - - - - - -

----T
_..
=

Driver

I Module
I (PCM)
I
jJ.
I

0
:::s

192091

- ,i

ti

Engine Controls Schematics (TP, MAP, ECT, IAT Sensors)

0,

Powertramr - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,
Module~~~~;:
~

J5V
5 Volt

33
35
o. GAY 598
Fuel Tank

Pressure
Sensor

j..:.

MAP

ECT

JSV

Sensor
Sensor
__Ground _ _ _ Signal _

25

C2 13

C1

C1~

ECT

C2

12

I___________
l~-,__-~~...I

C1

50

~
~

C2

0.35TAN 472

~I

rt-, c

B
Engine
Coolant I
Temperature I
(ECT) Sensor

Manifold!
Absolute
Pressure
(MAP) Sensor A - - - - - -

jesc!

_ _.,I

0.35GAY 598

JSV

Sensor
Signal_

0.35 YEL 410

0.35 GAY
8117
c:~-----___;~c..a-----598
0.35GAY 598

Posit~~~)
Sensor

IAT

C2=CLEAR
Sensor
_ _ _ _ _ _ _ _ Ground

26

0.35 LT GAN 432

.a:=.

Q)

:,

Sensor
_ _ _ _ _ _ _ _ _ _ Signal_

1._ _ _ _ _ _ _ _ ReferenceA _

!Loe I

I
......

CD

:,
" "I

in
(,.)

a,
r

rn

I
I

A- ., DK
0.35

0.35 OAN/BLK 469

ce.:,

Intake Air
Temperature
(IAT) Sensor

GAN 135
A17
r -

....

., Instrument

_... Cluster
1

0.35 BAN 718

0.35 BLK 452
0.35 PPL 719

0.35 DK BLU 417

66

~
:
L

C2

fensor1
Signal

61
-

C1

:nsor Ground

17
-

C1 =~~

C2=CLEAR

C1

~:nsor Ground

:~~~:~rain
I Module (PCM)
I ~

-----------------------------------------------------------~~

:,

ca
192097

:,
CD

,_/

Engine Controls Schematics (H02S Sensors)

!Hot In Run, Bulb Test And Start

Fuse Block
Details
Cell11

Distribution
Cell 10

ENG SEN
MiniFuse
20A

__________
JS

r -

...- - -

......

0.8 PNK 539

[B

......

H0251
Signal

......

H0251

H02S1
Low

Low

- - - - - - -

0.8

0.8

TAN/WHT 1653
B

H0251
Signal

0.8
PPL 1666

TAN 1667
A

PCM

29 -C1- - -10 - C2 -

0.8
PPLIWHT 1665

:::,
(I)

S104

Bank 2

. . - - 12 C2 - -27 -C1 -

0.8
PNK 539

I Electrical
I Center 2
..I

Bank 1

I
I

l
!Esc I
!Loe

0.8PNK 539
B C105

',

P-;;w; - - - - - - - ., Underhood

r -

...

:::,

ca

01 = BLU
C2=CLEAR
.

- - - - - - - - - - - -

0.8
PNK 539

Bank 1

H02S3

Low

Powertram
I Control
I Module
H~2S31 (PCM)
-

.,

Signal .

28- Cl- - -11 -C2 ,:,.

0.8
GRY 1981

0.8

0.8
DKBLU 1980

PNK 539

D
Heated Oxygen
Sensor Bank 1
Sensor3

Heated Oxygen
Sensor Bank 2
Sensor1

Heated Oxygen
Sensor Bank 1
Sensor1

::,

cc

(I)

c
0.8

0
:::,

O.SBLK 450

U)

0.8 BLK 450

BU< 450

'

1 BLK 450 ' - - - - - - - -1111 Ground

Distribution
G112 .,,. - - - - - - - - - -4 ,.,_.;""-ee1114
_.
192099

a,

Engine Controls Schematics (MAF Sensor, EVAP System, EGA Valve)

..:..

UI
!Hot In Run, Bulb Test And Starti
... -

Power

!Hot In Run, Bulb Test And Start!

-

Distribution
Cell 10

-P-;;we-; -

ENG SEN
MiniFuse

Distribution
Cell 10

~A

~----------------------------0.8 PNK 539

B C105

....----- 8104

cc

(I)

____ .,
WA

Positive
Voltage

Sensor
Signal

TPandMAP

Sensors

C200B
C200D
0.5 PNK 239
A2 C405B

PN:

-----,

I
I
I
I
I

AIC405D
0.5

-;;;

..-------------8117

0.35
GAY 598

239

[1]

Ground

:::,

02

Mass Airflow
(MAF) Sensor

0.5 PNK 239

MAF

P100

0.35YEL 492

Ignition

:::,

0.5 PNK 239

0.5 PNK 239

'------ 8107

:::,

8182

0.8 PNK 539

Underhood

- - - - -..
.-----:e-----11111-,

0.5 PNK 239

G C100

Fuses
Details
Cell11

ENG CTRL : Electrical

MiniFuse Center 2
1

0.5 PNK 239

Power

Distribution
Cell 10

0.8 PNK 539

Evaporative
[ ] ] Evaporative
Emission (EVAP)
Emission
Canister
(EVAP)

EE:

~:00

Vafve

0.35 WHT 1310

0.35 BL.K/WHT 451

B2IC405B

0.35 DK
GRN/WHT 428 0.35 WHT 1310
B

Ground

Distribution i,.- Cell ....

14_ _.

--0

3 BLK 451

Po~:~:~:
Module (PCM)
~
~

I
I
I

.l).G110

C210

_____

?~

C1

o.s '":

0.35 GRY 435

C2

~~;

Signal

-.. T Driver
..

-=-

-.. -T Driver
..

-:-

0.35GRY 598
0.35
BLK 552

0.35
LT BLU 697

l
'
~
~
_______
~
-~;so~ ---} -~:~::: -, -::i2s1: -r--

69

8110

0.35 BRN 1456

C4050

V
12

32

C1

28

C2

31

c,

-;-~:e-~~~-1----i~~:n~ -

lgrn!ion
Positive
Voltage

....f Control
..

-=-

Position
Signal

.....

PCM

-r
33

C2

SV

~fen~e~ :
I
I

C1=BLU

C2=CLEAR

~------------------------------------------------~
192107

:::,
<C

:::,
(I)

''----

__,.,,.

Engine Controls Schematics (Gen Control, IAC, Check Gauges Lamp)

:::,

!Loe I

IHot In Run Or Start I

... - - - - - - - - - - - - - - - - , IP

I Power
I Distribution
Cell 10

I Fuse

G3

GAGES
Fuse 9
H3 10 A
H4

Fuse Block
DetaHs
Cell11

I
I

~
~

0.8PNK 39
8206
0.35PNK 39

+--------

A5
~ ,:t;m:t- -

Cluster
Cell 81

I
I

ffi CHECK GAUGES

\V Indicator

Ignition
Positive
Voltage

~:~i:~fr 4700

II

Cluster
.&.
,-

I ~

(l) Level

I~ndicator :

Status

I
I

L----------------- ------ ---..1

A14

Stepper
Motor

'!

Coil

Coil
B

'

C220

0.35
BRN/WHT 1173

cc

49

~I A
Low

61

______ 38, C1
-

~I B
Low

~I B
High

C2

---1

Generator
Terminal L

.,,. Output

L------------------------- -

36

C1

s:~~ator
PCM
C1 = BLU

- - - _____c~~~R-

-r

58

! - - - - - - - G - - - - - - -t- - -

0.35
BAN 1174

0.35 RED 225

0.35 BAN 25

:::,
CD

3 BLK/WHT 451

P100

0.35 LT
GRN/WHT 1749

'~--------4~--------J

~I A
High

I 8110

A C220

0.35LT
GRN/BLK 444

44

..... -

.I

Cell14

:::,

0.35 LT
BLU/BLK 1748

Ground
Distribution

0.35RED 225

A"

0.35 LT
BLU /WHT 1747

I"' -

I
I
I Turn on I
L -

.....

0.35
BLKIWHT 451

D '

A15
0.35
BRN/WHT 1173

... - - , Generator
Input

~ Instrument

LOW OIL

Generator

Idle Air
Control
(IAC)
Valve

:::,
CD

loEsc!

Block
I
I

L----------------..1

Fuse Block
Details
Cell11

cc

---1
/

.,,.

L~w
Oil
Control

C2

sv

0
:::,

in

G110

(YI - , Powertrain
Control
Module
I
I (PCM) ~

co

~vel :
Signal

______________ ..,

a,

......
......

CJ1
192111

O>
I

Engine Controls Schematics (Cruise Control, VSS)

r----------------------------------1cru~e
1
1 Control
Cruise
Cruise
M d I
I
I

Disable
Input

Engaged
Output

VSS
Input

I
I

O U

r -

I
I

J ,.

0.35 WHT 85

KtP100

I 1nput I

812-;.,

,:~

_,

16 C3

.,

0.35 DK GRN/WHT 817

'"'Radio
I
I

!Loe I
0
! Esc!

r - "' Instrument
I vss I Cluster

iChevroleti

~
~

0.35 DK GRN/WHT 817

C200A
1
A 'C200D

0.35 DK GRN/WHT 817

0.35 DK GRN/WHT 817

0.35 DK GRN 83

8242

.....

(11

:::,

ca

:::,
C1)

0
:::,
" 'I

'ii
w

cor

0.35 DK GRN/WHT 817

D

,---------~

C105
G C220

~~P110

0.35 DK GRN/WHT 817

0.35 PPL 401

0.35WHT 85

C1

-C;is-;1- ----~-sv--------vssi-VSS1- ..:1--T

59

C2

,. -cr:s;-J_
-~f- Engaged

I Disable
I Output
I

55

64
65
-----------------------~--------

-=-

Input

sv

A.

0.35YEL 400

0.35 DK GRN 83

72

Vehicle Speed
Sensor (VSS)

-=-

VSS
Output

High

PCM

1C1=BLU

C2=CLEARI

Low

sv

-=-

C1

,Powertrain
I Control
I Module
I
I (PCM)

L---------------------------------------"

m
:::,

.1~.&.
~

(D

:::,
192113

C1)

~..___./

Engine Controls Schematics (2nd Gear, Clutch Anticipated Switch)

!Hot In Run!

r-------I

=l~ock
I Cell 11
I

!Loe I

, "-j

---,1/P

TURN B/U I Fuse

1 Block
Fuse 2
20A
I

F1

0.8 BRN 141

0.35GRY 48

Fuse Block
Details
Cell11

Cruise Control/
Clutch Anticipate
Switch

0.8 BRN 141

0.35 BLK/WHT 451

- - - - - -1;:m:a;on- - - - - -

II

n~-~7

C270

r------I
I
I
I

l..
Ground
Distribution
Cell14

O.SBLK/WHT 451
$110

3 BLK/WHT 451

0.35
PPL/WHT 1572

C4
-----------------

C200D
C200B

---------------

P100

0,35
PPL/WHT 1572

::,

cc

C105

::,
CD

0.35 BRN/WHTr1:----~-~ ::~r1572

0.35 GRY 48
18

21

C2

c,

0
::,

C1

t/1

~:~,- - - - - - - ~~ch_1_ - - - - - - - - -, ~n~C:ar- - - ~;- ~6~~:~~ain

Switch
---T
=
IM d I
e ~.....

I
I Signal

.,,.G110

I Start
1s
'th
WI c

451

0
C~- -------------Ate:

~----

Indicator

C200A

0.35
BRN/ 1571
WHT

0.35 BLK/WHT

0.8 BLK/WHT 451

B

ffi
\VGear

A13

0.35GRY 48

8215

~ ~~~r

0.35
BRN/ 1571

WHT
0.35 BLK/WHT 451

-1----

2
n
d
1
:[------~-- ----~
. Switch)

~-F

(Momentary

[B

$207

+- - - -

Signal

.,,.

::,
CD

!0Esc!

L.-------- ___ .
E1

::,
cc

.,,.

.,,.

Indicator
Control

C1 BLU
C2=CLEAR I

O U

1(PCM) ~

L.-----------~----------- ---------------'

192116

enI

Engine Controls Schematics (Brake Switch, TCC Solenoid)

r -

lHot In Run, Bulb Test And

Starti

I Pow~
I

Distribution
Cell 10

I1,....;....;

lHotln Run, Bulb Test And

"Underhood
I
Electrical
1 Center 2

ENG SEN

MlnlFuse

~A

I
I

J
I1,

Switch.

0.5 RED 839

0.5 RED 839

II

0.5 RED 839

~~C:rter.
Clutch
Solenoid
[]
(TCC SOL)

0.5 RED 839

. Clutch
Pulse Width
Modulation

P110

'iii'
(,.)

cor

0.5 RED 839

(3- 2 SS)
Valve
Assembly

(2-3 SS)
Valve

(1- 2 SS)
Valve

0.5 TAN/BLK 422

0.5 YELJBLK 1223

0.5 BAN 418

0.8
PPL 420

0.5 LT GAN 1222

0.5WHT 687

!~ ----------~!3
!
J
~
---T
----T
---T
---T
---T
!
!
!
!
!
1.-------------------------------------------------------------~
30 C1

-=-

......

-OOB:1= ~~ - 05T:r~ ~:~1---- OO~lm --05LTG+~----

H C230

Module I
~ (PCM) I

[]1 b:~~~er []11 ~!,!~: []1 ~;!n!~: []1 ~!n~~:

_ _ _ _ _ _ ...

::~:h,- .
Signal

CD

switch

I (Open with
TCC/Shifl I brake pedal
Interrupt I depressed)

0.8
PPL 420

Po"b~~:~~

m
j
ca

0.5RED 839

D C2

_J

......

(n
~

r------------------ --------------------,

r - - - - - - - , Stop Lamp

$107 - - - - - - - - - 0.5PNK 239

Automatic
Transmission

0.5 PNK 239

GIC230
0.8 PNK 539
C C2

[B

Fuse Block
Details
Cell 11

G C100

0.8PNK 539

II

0.5PNK 239

Fuse Block
Details
Cell11

P110

-----------,

- - - - - - - - --,.

0.5PNK 239
$182

0.8 PNK 539

B C105
0.8PNK 539

15A

~----- ____ ...

_ _ _ _ _ _ _ _ _ ...

8104

- - - - " Underhood
ENG CTRL I Electrical
Mlnlfuse 1 Center 2

I Power
Distribution
I Cell10

!Loe I
loEsc!

Starti

79

C2

_________
TCCSOL
Valve
Control

,-TCCPWMSOL - ,
Valve
Control

3V-12SS- ave
Assembly
Control

44

----------~
2V-13SS ave
Assembly
Control

-;

C1

1-2SS Valve
Control

- PCM
c1 = BLU
c 2 =CLEAR

I
I

m
j

cg
j

193106

CD

-~ /

m
::::,

Engine Controls Schematics (Trans Range)

r -

1
I
I
I

Transmission
Range A

Transmission
Range B

Transmission
Range C

TFT
Sensor
Input
Input
Signal
57 ----------17 ------------68 C2

!Loe

Powertra1n
1Control
I
I Module (PCM)

.,

22

0.5 DK BLU 1225

0.5 PNK 1224

0.5 RED 1226

jesc

Hatch

.&

Release
Cell134

L--------------------------------J~.._.
C1
Input

38

N
r -

0.5PNi1224

- - -

0.5DKB~uf'225 - -

0.35 ORN/BLK

REV

Switch

LO
Switch

03

04

Switch

Switch

0.5BR:f227 - - - - - -

Automatic
Transmission
Fluid Pressure
(TFP) Manual
~=:osltlon
Transmission
Fluid
Temperature
(TFT)

02
. Switch

r -

- - - - - - - - ,

- - __ -

- _ - -

_____ -

________

Bf

F C220
0.35
ORN/BLK 434

0.5 LT BLU/WHT 1229

Sensor

. ___________________________________ -1----1

I
I

______ ~.?

4--

PC SOL

Valve Low

cc

::::,

- - - -

(I)

-...
0
::::,

....J,

-r-PNP - - - - - - - - ,

________1~
-1'- - - - -

___________4~

::::,

Distribution

Cell14

0.8 BLK/WHT 451

0.5
RED/BLK 1228

0.35GRY 720

Sensor
Ground

..1.
Ground

P110

0.5 GRY 720

_ _ _ _
5121

35

- - - - -,

J C230 0.8 BLK/WHT 451

II Switch

A
0.35 BLK/WHT 451

0.5GRY 720 _ _ _ _ _ _

'Neutral
1Position

~--------1

0.5 PPL 1228

$215

A/C Pressure

II ~
A.. - ..2/'
I
N @-o

Ir::::::::::::iI

sensor

__ -

7- - - - - - ., Park

I P

Pressure
Control Solenoid
(PC SOL) Valve

0.5 LT BLU 1229

434

0.35
ORN/BLK 434
Automatic
Transmission

0.50~1226 - - - -

C2

.,,.

PC SOL
Valve High

Switch

iii'

G110

PCM
C1 = BLU

C2=CLEAR

Powertrain
I Control
I Module (PCM)
I .&.
~

~------------------------------------------------------------J~

12V

(I)

[B

$234

::::,

0.5 YEL/BLK 1227

I
I

cc

12V

192118

CJ)

Engine Controls Schematics (A/C HVAC Control)

!Hot In Run, Bulb Test And

'" - - - - - Power
Distribution
G7
I c H10
I
e
GG
._

Start!

!Hot In Runj

.------Power

- - - - - , Underhood
1

A/C-CRUISE I Electncal
MlnlFuse
C
2
15A
I enter

___________

I
I
I
I._

...

Distribution
Cell10

- - - - - , IP
HVAC
: Fuse
Fuse6
Block
20A
I

______ _____
E2

!Loe

[SJ

...

CJ)

:l

ca

:l
(D

-a

0.5 PNK 139

~-----------~
Fuse Block

0.5 PNK 139

0.5 PNK 139
'" - - - - - 010
os

0
:l

1 BRN 241

8165

Fuse Block
Details
Cell11

.:..
CII

1 BRN
241

Details
Cell11

S248

- - - - - , Underhood
NC
: Elect.rical
Compressor I Center 2

1 BRN 241

en
w

cor-

Clutch

Relay

C C2

...

_____________
~o
C8

I>
I

...

CL-,Jl:;..;...______B....:i;.__A-=..... Sensor

WHT

0.5 DKGRN 59

_____ ~ C100

0.35
RED/BlK 380 .

0.5 DKGRN 59

LT BLU/ 1688
BLK

0.5 DKGRN 59

0.35 DK GRN/WHT 459

FTP

NC
1Amp

899

DEF

_.. -HTR

BIL

.,,.-~

0.35DK

GRN/WHT 762

8111

F C230

~~~~~~~---~~o=.5~B=L~K=--~--' 8108 :
450

,,
/
/
/

= G112

P110
0.35 DK
GRN/WHT 762

0.35
GRY 720

T T

0.5 BLK 450

~
1

-~~- -:---1- -NC -1-39

I c:,~iol
I

~~-1-

1_-----,

------~? ______ .9.1 -~? ------------------~?

Sensor
Signal

Reference

I
I
...I

AIC

LT BLU/ 1688
BLK

Ground
Distribution
Cell14

I
I
I

\
~
'- - .....
Sensor

~~pressor
~Clutch

VENT

__________

0.35

f1iil

S115

I
I
I..

$121

Sensor

Compressor
Clutch Diode

0.35
GRY 720

I OFF
I

0.35

S114

899

11::-

Ic9--i

0.35,
DKGRN/ 459

'" - - - - - - - - - - , HVAC
1
/
control
1
1 Assembly

Sensor- Ground

"'"NC_

Request

Signal

C2

PCM
~ = BLU

Powertrain
Control
I Module
I (PCM)
:

=
=
sv
=
._ ____________________________________
. >
C2=CLEAR

::s

ca
:l

192127

(D

-___/

Engine Controls Schematics (Cooling Fans)

!Hot At All Times!
r -

I
I

L1

K1

! Hot At AIITmes
-

Power . .
Distribution
Cell to

COOL FAN
MaxiFuse
40A

COOLING
FAN
M' F

ini use
10A

J7

J6

:I

!Loe I
loEsc!

Underhood
I

I Electrical
Center 1
I

cc

:I
(I)

~----------------------------~
3 RED 402

Power
Distribution
Cell10

0.35 ORN 1640

$169

,-------

Fuse lock
Details

3 RED 402

Cell11

S179
0.35 ORN 1640 3 RED 402
3 WHT 504
Underhood r 83
Electrical : C 3 . . - - - - - -;..,,.Center 1
1

-- - --- -

.......

I
I

Engine
Cooling
Fan
Relay #1

Engine
Cooling

C4

Engine

~ :~;~e
Cooling

0.35
DK BLU 473

Cooling

r _

~ng- -

:I
(I)

H C100

A
3 BLK 150
1..---Ji'---------"""""'=3~B=LK:...:.-_ _ _ _ _ _ _ _ _ _ _S113
150
0.35 DK BLU 473
/ /
Ground

-J-c~;;;

------------------------------------ 5

I
Fan Relay 1
I --T Control
I

:I

cc

Fan

0.35 DK GRN 335

_

0.35 DK BLU 473 3 WHT 504

S166-------------------....
B

J C100
A
3 GRY 532

I7_

------~- ~"":

Fan

Engine
Cooling

g~: :~---------- -------------3~T i--_)

mo

~ B Left

C6

I
I ):J---=-....

~TB:1~

0.35 DK GRN 335

- - - -,

----------,B8

89

101"""""""-----L-

0.35 ORN 1640

0.35 ORN 1640

C1

PCM
C1=BLU
C2=CLEAR

...y

- 9
Fan Relay
2 ands
Control

~ Powertrain
Control
I Module (PCM)
I ~

L-~------------------------------J~

Distribution
1114

ee

..,_ -

:I
" ',i

'ii
w
CD

.J

3 BLK 150

rO')

=G106

......

192128

c.n
......

6-758

Engine

Engine Controls - 3.8L

Component Locator
Engine Controls Components
Location

Name

Locator View

Connector End View

1st - 2nd Shift

Solenoid Valve

Inside the automatic transmission

Automatic Transmission
Electronic Component
Views (Internal) in
Automatic Transmission

AT Internal Connector
End Views in Automatic
Transmission

2nd - 3rd Shift

Solenoid Valve

Inside the automatic transmission

Automatic Transmission
Electronic Component
Views (Internal) in
Automatic Transmission

AT Internal Connector
End Views in Automatic
Transmission

Inside the automatic transmission

Automatic Transmission
Electronic Component
Views (Internal) in
Automatic Transmission

AT Internal Connector
End Views in Automatic
Transmission

Front of engine, lower right side

HVAC Component Views

in HVAC Systems with
A/C- Manual

Engine Controls
Connector End Views

3rd - 2nd Shift

Solenoid Valve

A/C Compressor Clutch

A/C Clutch Diode
(V6 VINK)

Sealed in harness, approximately 3 cm

from injector 2 breakout

A/C Refrigerant
Pressure Sensor

Above the right front wheelhouse, attached

to refrigerant line

Automatic Transmission Behind engine

Body Control
Module (BCM)

Under the right side of 1/P, near the

blower motor

HVAC Component Views

in HVAC Systems with
A/C- Manual

Engine Controls
Connector End Views
AT lnline Harness
Connector End View in
Automatic Transmission

Body Control Module

Component Views in
Body Control Module

Body Control Module

Connector End Views in
Body Control Module

Camshaft Position
(CMP) Sensor

Mounted in engine front cover

Engine Controls
Component Views

Engine Controls
Connector End Views

Crankshaft Position
(CKP) Sensor

Lower front of engine

Engine Controls
Component Views

Engine Controls
Connector End Views

Cruise Control
Components in Cruise
Control

Cruise Control Connector

End Views in Cruise
Control

Cruise Control Module

Mounted to the left front frame rail, forward

of wheelhouse

Data Link
Connector {DLC}

Under the 1/P, right of the steering column

Mounted with brake pressure modulator

Electronic Brake Control valve on top of left front frame rail top front
Module (EBCM)
left side of engine
Electronic Ignition
Control Module (ICM)
(V6 VINK)

Engine Controls
Connector End Views

Antifock Brakes System

Connector End Views in
Antilock Brake System

Top front left side of engine

Engine Controls
Component Views

Engine Controls
Connector End Views

Engine Coolant
Temperature (ECT)
Sensor

Under throttle body, front side of engine

Engine Controls
Component Views

Engine Controls
Connector End Views

Engine Cooling Fan

Behind radiator

Evaporative Emission
(EVAP) Canister Purge
Solenoid Valve
(V6 VINK)

Cooling System
Connector End Views in
Engine Cooling

Engine Controls
Component Views

Engine Controls
Connector End Views

Front left side of engine, in front of ignition

control module

Engine Controls
Component Views

Engine Controls
Connector End Views

Front of engine, RH side next to

injector #2

Engine Controls
Component Views

Engine Controls
Connector End Views

Engine Oil Level Switch Lower left side of engine, in oil pan
(V6 VINK)
Exhaust Gas
Recirculation (EGR)
Valve (V6 VIN K)

Engine

Engine Controls - 3.8L

6-759

Engine Controls Components (cont'd)

Name

Location

Locator View

Connector End View

Evaporative Emission
(EVAP) Canister Vent
Solenoid Valve
(V6 VINK)

Top, right side engine, part of EVAP

canister

Engine Controls
Component Views

Engine Controls
Connector End Views

Fuel Injectors
(V6 VINK)

Mounted on intake manifold, part of

fuel rail

Engine Controls
Component Views

Engine Controls
Connector End Views

Fuel Tank Unit

Under rear of vehicle

Heated Oxygen Sensor

Bank 1 , Sensor 1
Mounted in left exhaust manifold
(V6 VINK)

Engine Controls
Component Views

Engine Controls
Connector End Views

Heated Oxygen Sensor

Bank 2, Sensor 1
Mounted in right exhaust manifold
(V6 VINK)

Engine Controls
Component Views

Engine Controls
Connector End Views

Heated Oxygen Sensor

Bank 1, Sensor 3
At rear of catalytic converter
(V6 VINK)

Engine Controls
Component Views

Engine Controls
Connector End Views

HVAC Component Views

in HVAC Systems with
A/C- Manual

HVAC Connector End

Views in HVAC Systems
with A/C - Manual

Engine Controls
Component Views

Engine Controls
Connector End Views

Left side of 1/P

Instrument Cluster
Component Views in
Instrument Panel,
Gauges, and Console

Instrument Cluster
Connector End Views in
Instrument Panel,
Gauges, and Console

Left end of the 1/P carrier

Power and Grounding

Component Views in
Wiring Systems

Power and Grounding

Connector End Views in
Wiring Systems

Mounted on air duct, in front of intake

manifold

Engine Controls
Component Views

Engine Controls
Connector End Views

Knock Sensor, LH
(V6 VINK)

In bottom left side of engine block

Engine Controls
Component Views

Engine Controls
Connector End Views

Knock Sensor, RH
(V6 VINK)

In bottom right side of engine block

Engine Controls
Component Views

Engine Controls
Connector End Views

Engine Controls
Component Views

Engine Controls
Connector End Views

Engine Controls
Component Views

Engine Controls
Connector End Views

HVAC Control
Idle Air Control (IAC)
Valve (V6 VINK)
Instrument Cluster

1/P Fuse Block

Intake Air Temperature
(IAT) Sensor

Center of 1/P, above radio

Right front of intake manifold

Manifold Absolute
Pressure (MAP) Sensor Mounted to right side of intake manifold
(V6 VINK)
Mass Air Flow (MAF)
Sensor (V6 VIN K)

Mounted on air duct, in front of intake

manifold

Park Neutral Position

Switch

Under console, on base of the shift

control lever

Powertrain Control
Module (PCM)
(V6 VINK)
Radio

Stoplamp Switch

Right side of engine compartment, rear of

wheelhouse

Undercoat Electrical
Center 1

Engine Controls
Connector End Views in
Engine Controls 5.7L

Powertrain Control
Module (PCM)

PCM Connector
End Views

Center of 1/P, below HVAC control

Entertainment
Component Views in
Entertainment

Entertainment Connector
End Views in
Entertainment

Mounted on the brake pedal bracket

Hydraulic Brakes
Component Views in
Hydraulic Brakes

Antilock Brakes System

Connector End Views in
Antilock Brake Systems

Throttle Actuator Control

Mounted on the Accelerato~ pedal
(TAC) Module
Throttle Position (TP)
Sensor

Mounted to front of throttle body

Left front corner of the engine
compartment

Engine Controls
Component Views

Engine Controls
Connector End Views

Power and Grounding

Component Views in
Wiring Systems

Electrical Center
Identification in Wiring
Systems

6-760

Engine

Engine Controls - 3.SL

Engine Controls Components (cont'd)
Name

Location

Undercoat Electrical
Center 2

Left front corner of the engine

compartment

Vehicle Speed Sensor

(Manual)

Rear left side of transmission

Locator View

Connector End View

Power and Grounding

Component Views in
Wiring Systems

Electrical Center
Identification in Wiring
Systems
Engine Controls
Connector End Views

C100 (10 cavities)

Eng_ine 'to forward lamp harness, in the

engine compartment, above right
wheelhouse

Harness Routing Views in

Wiring Systems

lnline Harness Connector

End Views in Wiring
Systems

C101 (10 cavities)

Eng_ine to forward lamp harness, in the

engine compartment, above right
wheelhouse

Harness Routing Views in

Wiring Systems ..

lnline Harness Connector

End Views in Wiring
Systems

C102 (1 cavities)

Eng_ine to forward lamp harness, in the

engme compartment, above right
wheelhouse

Harness Routing Views in

Wiring Systems

lnline Harness Connector

End Views in Wiring
Systems

C105 (8 cavities)

Engine to forward .lamp harness, in engine

compartment, above right wheelhouse

Harness Routing Views in

Wiring Systems

lnline Harness Connector

End Views in Wiring
Systems

C106 (7 cavities)

Engine to engine jumper harness

Harness Routing Views in

Wiring Systems

lnline Harness Connector

End Views in Wiring
Systems

Ct07 (7 cavities)

, Engine to engine jumper harness

Harness Routing Views in

Wiring Systems

lnline Harness Connector

End Views in Wiring
Systems

C108 (3 cavities)

Engine to camshaft position sensor jumper

harness

Harness Routing Views in

Wiring Systems

lnline Harness Connector

End Views in Wiring
Systems

C200A (17cavities)

F_orward lamp to 1/P harness, between left

kick panel ;3.nd steering column

Harness Routing Views in

Wiring Systems

lnline Harness Connector

End Views in Wiring
Systems

Forward lamp to 1/P harness between left

kick panel and steering colu~n

lnline Harness Connector

Harness RoutingYiews in
End Views in Wiring
Wiring Systems
Systems

C200D (48 cavities)

Part of the 1/P harness, between the left

kick panel and the steering column

Harness Routing Views in

Wiring Systems

lnline Harness Connector

End Views in Wiring
Systems

C210 (8 cavities)

1/P to engine harness, under right side of

1/P, behind knee bolster

Harness Routing Views in

Wiring Systems

lnline Harness Connector

End l(iews in Wiring
Systems

C220 ( 1O cavities)

1/P to engine harness; under right side of

1/P, behind knee bolster

Harness Routing Views in

Wiring Systems

. lnline Harness Connector

End Views in Wiring
Systems

C230 ( 1O cavities)

1/P to engine harness, under right side of

1/P, behind knee bolster

Harness Routing Views in

Wiring Systems

lnline Harness Connector

End Views in Wiring
Systems

C405A (7 cavities)

Fuel tank harness to 1/P harness pass

through connector, forward of rear axle

Harness Routing Views in

Wiring Systems

lnline Harness Connector

End Views in Wiring
Systems

1/P harness pass through connector,

forward of rear axle

Harness Routing Views in

Wiring Systems

lnline Harness Connector

End Views in Wiring
Systems

Fuel tank harness to 1/P harness pass

through connector, forward of rear axle

Harness Routing Views in

Wiring Systems

lnline Harness Connector

End Views in Wiring
Systems

C200B (18 cavities)

C405B (16 cavities)

C405D (4 cavities)

'

Gt06

Attached to top left side of radiator support

Power and Grounding

Components in Wiring
Systems

G110 (V6 VIN K)

Front of engine, bolted to pulley above A/C

clutch connector

Power and Grounding

Components in Wiring
Systems

Engine Controls - ~.SL

Engine

6-761

Engine Controls Components (cont'd)

Name

Locator View

Connector End View

G112

Attached to rear of left cylinder head

Power and Grounding

Components in .Wiring
Systems

G200

Near left "A" pillar, bolted to 1/P mounting

stud behind kick panel

Power and Grounding

Components in Wiring
Systems

G305

Bolted to left rocker panel at floor pan

bar 3

Power and Grounding

Components in Wiring
Systems

P100

Left side in dash panel, engine to

passenger compartment

Harness Routing Views in

Wiring Systems

.-

P110

Right side in dash panel, engine to

passenger compartment

Harness Routing Views in

Wiring Systems

8104 (V6 VINK)

Engine harness, main branch

approximately 15 cm from vehicle speed
sensor breakout

8107 (V6 VIN K)

Engine harness, main branch,

approximately 21 cm from powertrain
control module (PCM) breakout

8108 (V6 VINK)

Engine harness, main branch,

approximately 7 cm from vehicle speed
sensor breakout

8110 (V6 VIN K)

Engine harness, approximately 4 cm from

powertrain control module (PCM) breakout

Forward lamp harness, approximately

7 cm from engine coolant fans/cruise
control module breakout

8114 (V6 VINK)

Engine harness, approximately 3 cm from

generator breakout

8115 (V6 VINK)

Engine harness at generator breakout

8117(V6VINK)

Engine harness, approximately 2.5 cm

from engine fuel injector 5 breakout

8121 (V6 VINK)

Engine harness, main branch,

approximately 8 cm from powertrain
control module (PCM) breakout

8144 (V6 VINK)

Engine harness, approximately 2 cm from

engine fuel injector 3 breakout

8145 (V6 VINK)

Engine harness, approximately 3.5 cm

from engine fuel injector 3 breakout

8148 (V6 VINK)

1/P harness, approximately 2 cm from radio

connectors breakout

8159

Forward lamp harness, approximately

8 cm into secondary air injection bleed
valve solenoid breakout (CKT 429)

8165

Forward lamp harness, approximately

7 cm from main branch into underhood
electrical center 2 breakout (CKT 139)

8166

Forward lamp harness, approximately

14 cm from G105 breakout

8167

Forward lamp harness, approximately

7 cm from underhood electrical center 1
breakout

8169

Forward lamp harness, approximately

6 cm from main branch into underhood
electrical center 1 breakout

8177

Forward lamp harness, approximately

4 cm from main branch into underhood
electrical center 1 breakout

8113

Location

6-762

Engine

Engine Controls - 3.SL

Engine Controls Components (cont'd)
Name

"

Location

Locator View

Connector End View

S179

Forward lamp harness, approximately

25 cm from underhood electrical center 1
breakout

S182

Forward lamp harness, approximately

15 cm from underhood electrical center 1
breakout

S184

Forward lamp harness, approximately

5 cm from underhood electrical center 1
breakout

S206

1/P harness, at rear compartment lid

release relay breakout

S215

1/P harness, approximately 11 cm from

antenna cable breakout

S217

1/P harness, approximately 18 cm from

body control module (BCM) breakout

S225

1/P harness, approximately 6 cm from the

blower motor breakout

S234 (Automatic)

1/P harness, approximately 5 cm from the

body control module (BCM) breakout

S240

1/P harness, approximately 17 cm from the

antenna cable breakout

S242

1/P harness, approximately 4 cm from the

data link connector (DLC) breakout

S244 (Coupe)

1/P harness, approximately 40 cm back

from C405

S244 (Convertible)

1/P harness, approximately 46 cm back

from C405

Engine Controls - 3.8L

Engine

6-763

Engine Controls Component Views

Engine Component Locator View (Left Side)

203062

Legend
(1) Manifold Vacuum Source
(2) Ignition Control Module (ICM) and Coils
Assembly
(3) H02S Bank .1 Sensor 1 (Behind Exhaust
Downtube)

(4)
(5)
(6)
(7)

Engine Oil Level Switch

Crankshaft Position Sensor
Exhaust Gas Recirculation (EGR) Valve
Mass Air Flow (MAF) Sensor

6-764

Engine Controls .. 3.SL

Engine

Engine Component Locator View (Right Side)

203065

Legend

(1)
(2)
(3)
(4)
(5)
(6)

Fuel Pressure Regulator

Idle Air Control (IAC) Valve
Throttle Position (TP) Sensor
Engine Coolant Temperature (ECT) Sensor
Camshaft Position (CMP) Sensor
EVAP Canister Purge Solenoid Valve

(7) Heated Oxygen Sensor (H02S) Bank2

Sensor1
(8) Fuel Injectors
(9) Manifold Absolute Pressure (MAP) Sensor
(10) Positive Crankcase Ventilation (PCV) Valve

Engine Controls - 3.. 8L

Engine

6-765

Lower Left Side of Engine (V6 VIN K)

1
6

497429

Legend
(1) Starter solenoid
(2) Starter motor
(3) Oil level switch

(4) Lower control arm

(5) Steering gear
(6) Left engine mount

6-766

Engine Controls - 3.SL

Engine

Front Left Side of Engine (V6 VIN K)

497430

Legend
(1) Generator

Engine

Engine Controls 3.SL

6-767

PCM Connector End Views

Powertrain Control Module Connector C1 (Blue) End View
\
.1

..

41

~, 1

60

@@@@@@@@@@@@@@@@@@@@
:::i[~@@@@@@@@@@@@@@@@@@J] c
20

[[g]"
0
..

61

80

@@@@@@@@@@@@@@@@@@@@

of~@@@@@@@@@@@@@@@@@@~

,21

40

15026

Connector Part
Information
Pin
1

Circuit No.

Function
Not Used

PPUWHT

1572

2nd Gear Start Indicator

DKBLU

1936

Fuel Level Indicator

LTGRN

1222

Shift Solenoid A Control

DKBLU

473

Fan 2 Control (High Speed)

DKGRN

335

Fan 1 Control {Low Speed)

BLK

630

Camshaft Position PCM Input

PPUWHT

430

3X Reference

LT BLU/BLK

647

18X Reference

. 10-11

Not Used

12

BRN

718

ECT Sensor Ground

13

ORN/BLK

469

14

15

TAN

800

Serial Data

16

BLK/WHT

451

PCM Ground

17

PPL

719

IAT Sensor Ground

18

MAP Sensor Ground

Not Used

Not Used

19

PNK

439

Ignition Feed

20

ORN

340

Battery Feed

21
22
23-26

Wire Color

Blue PCM Connector C1

PNK

27

TAN/WHT

1224

1653

Not Used
Transmission Range A
Not Used
Bank

1 H02S 1 Low

28

GRA

1981

Bank 1 H02S 3 Low

29

TAN

1667

Bank 2 H02S 1 Low

30

PPL

420

31

BLK

552

Sensor Ground

32

GRA

435

EGR Valve Control

33

DK/BLU

496

Bank 1 Knock Sensor Signal

34

LT/BLU

1876

Bank 2 Knock Sensor Signal

35
36
37

RED

TCC Brake Switch

Not Used

225

Generator Control

Not Used

6-768

Engine

Eng.ine Controls 3.SL

Powertrain Control Module Connector C1 (Blue) End View (cont'd)

J 41
~,

60:@61

@@@@@@@@@@@@@@@@@@@@
~r~@@@@@@@@@@@@@@@@@@~) D

20

-,

80

@@@@@@@@@@@@@@@@@@@@
O[@@@@@@@@@@@@@@@@@@@~)c:]E

21

40

15026

Connector Part
Information
Pin

Wire Color

Circuit No.

38

LT GRN/WHT

1749

39-42

Function
IAC B High
Not Used

43

YEUBLK

846

Injector Control Cylinder #6

44

YEUBLK

1223

Shift Solenoid B Control

45

Not Used

46

LT BLU/Bl.K

844

Injector Control Cylinder #4

47

BLK/WHT

845

Injector Control Cylinder #5

48

RED/BLK

453

Reference Low

49-52

Not Used

53

TAN/BLK

424

Bypass

54

WHT

423

Ignition Control (IC)

55

DKGRN/WHT

817

VSS Output

56

BLK/WHT

451

PCM Ground

57

BLK/WHT

451

PCM Ground

Not Used

58

59

PPL

1807

Class 2 Data

60

BLK/WHT

451

PCM Ground

61

BLK

452

62-63

Sensor Ground

YEL

400

VSS High

65

PPL

401

VSS Low

Not Used

69

YEL

492

Mass Air Flow Signal

70

DKBLU

229

Theft Deterrent Fuel Enable

71

Not Used
Cruise Control Inhibit

72

DKGRN

83

73

LT GRN/BLK

1745

74-75
76
77-78
79
80

DKGRN/WHT

BLK

Not Used

64
66-68

'

Blue PCM Connector C1

Injector Control Cylinder #2

Not Used

428

EVAP Canister Purge Control

1744

Not Used
Injector Control Cylinder #1
Not Used

Engine

Engine Controls - 3.8L

6-769

Powertrain Control Module Connector C2 (Clear) End View

~
J 41

60
@@@@@@@@@@@@@@@@@@@@
~(Oo@@@@@@@@@@@@@@@@~)
1
~

u
'JJ

61@@@@@@@@@@@@@@@@@@@@.
80
p(@ooo@@@@@@@@@@@@@@o~l
~

15026

Connector Part
Information
Pin
1

Function

Circuit No.
-

Not Used

WHT

1310

EVAP Canister Vent Valve Control

DK GRN/WHT

465

Fuel Pump Relay Control

LT BLU

697

EGA Valve Power Feed

BRN/WHT

419

MIL Control

BRN/WHT

1173

Low Engine Oil Level Indicator Control

LT BLU/WHT

1747

IAC A High

8-9
10

Wire Color

Clear PCM Connector C2

PPL

1.666

Not Used
Bank 2 H02S 1 Signal

11

DKBLU

1980

Bank 1 H02S 3 Signal

12

PPL/WHT

1665

Bank 1 H02S 1 Signal

13-15

16

ORN/BLK

434

PNP Switch Signal

17

RED

1226

Transmission Range C (4L60E only)

18

GRA

48

19-20

Not Used

Cruise Control/Clutch Antidpate Switch

Not Used

21

BRN/WHT

1571

2nd Gear Start Signal

22

DK GRN/WHT

762

A/C Request

Not Used

23-24

25

LT GRN

432

MAP Sensor Signal

26

YEL

4109

ECT Sensor Signal

27

RED/BLK

380

A/C Refrigerant Pressure Sensor Signal

28

BRN

1456

EGR Pintle Position Signal

29-32

Not Used

33

GRA

598

5 Volt Reference A

34

LT BLU/BLK

1688

5 Volt Reference B

35

GRA

720

Sensor Ground

36-38
39
40-41
42
43

DKGRN/WHT
-

PNK/BLK

Not Used

459

A/C Compressor Clutch Relay Control

1746
-

Not Used
Injector Control Cylinder #3
Not Used

44

LT BLU/BLK

1748

IAC Valve A Low

45

RED/BLK

1228

Pressure Control Solenoid High

6-770

Engine

Engine Controls.- 3.8L

Powertrain Control Module Connector C2 (Clear) End View (cont'd)

J 41@@@@@@@@@@@@@@@@@@@@

60

r1

:i(~@@@@@@@@@@@@@@@JJ i::

'- 1

20

[g}
0

61

80

@@@@@@@@@@@@@@@@@@@@
p(~oo@@@@@@@@@@@@@@@@JJ i::

'"21

40 ,.,...

15026

Connector Part
Information

Clear PCM Connector C2

Pin

Wire Color

Circuit No.

46

LT BLU/WHT

1229

47

Function
Pressure Control Solenoid Low
Not Used

48

WHT

687

3-2 Control Solenoid Control

49

LT GRN/BLK

444

IAC Valve B Low

50

TAN

472

Intake Air Temperature Sensor

51-54

55
56

DKGRN

890

Not Used
Fuel Tank Pressure Sensor Signal
Not Used

57

DKBLU

1225

Transmission Range B (4L60E only

58

BRN

1174

Engine Oil Level Sensor Signal

59

WHT

85

Cruise Status

Not Used

25

Generator Control

Not Used

60
61
62-65
66
67

BRN

DKBLU

417

Throttle Position Sensor Signal

Not Used

68

YEUBLK

1227

69

PPL

30

Fuel Level Input

Not Used

70-75
76

77

YEUBLK

625
-

Transaxle Fluid Temperature Sensor

Starter Enable (If Equipped)

Not Used

78

BRN

418

TCC PWM Solenoid Control 4L60E Only

79

TAN/BLK

422

TCC Enable Solenoid Control 4L60E Only

Not Used

80

Engine

Engine Controls - 3.8L 6-771

Engine Controls Connector End Views

\

Camshaft Position (CMP) Sensor

A/C Compressor Clutch

)

~ c::::J

~~
73223
62440

1216-2017
2 Way F Metri-Pack
150 Series (GRV)

Connector Part
Information

Pin

A
B

Wire Color

Circuit
No.

DKGRN

59

Circuit
No.

BRN/WHT

633

Camshaft Position (CMP)

Sensor Signal - Input

RED/BLK

645

Reference Low

WHT/BLK

644

Ignition Feed

A/C Compressor Clutch

Control

450

BLK

Wire Color

Pin
Function

A/C Compressor Clutch

Ground

1216-2279
3 Way F Metri-Pack
150 Series (GRV)

Connector Part
Information

Function

Crankshaft Position (CKP) Sensor

A/C Refrigerant Pressure Sensor

C:J

-. . . ; :

~I Ic I I 1)
D

(~)
~

.h'
38608
219804

Connector Part
Information

Wire Color

Circuit
No.

GRY

720

A/C Refrigerant Pressure

Sensor Ground

LT BLU/
BLK

1688

A/C Refrigerant Pressure

Sensor 5.0V Reference

BLK

380

A/C Refrigerant Pressure

Sensor Signal

Pin

1211-0192
3 Way M Metri-Pack
150 Series Pull To Seat (BLK)

Connector Part
Information

12162834
4 Way Metri-Pack
150 Series (GRV)
Circuit
No.

Pin

Wire Color

LT BLU/
WHT

1800

Crankshaft Position (CKP)

Sensor Signal - Input

YEL

573

Reference Low

RED/BLK

645

Ignition Feed

WHT/BLK

644

Ignition Feed

Function

Function

6-772

Engine Controls - 3.8L

Engine

Data Link Connector (DLC)

Engine Coolant Temperature Sensor

68793

Connector Part
Information

Pin

Wire Color

1211-0250
16 Way F Metri-Pack
150 Series Sealed (BLK)
Circuit
No.

Function

62485

Connector Part
Information

Pin

Not Used

PPL

1807

Serial Data Line-Class 2

BLK

350

Grounp

BLK/WHT

351

Ground

Not Used

Not Used

BLK/WHT

1455

Not Used

10

Not Used

11

Not Used

12

Not Used

13

Not Used
DKGRN

835

14

Serial Data Line Entertainment and

Comfort (EC)

15

Not Used

16

ORN

1140

Circuit
No.

BRN

718

Engine Coolant
Temperature (ECT)
Sensor Ground

YEL

410

Engine Coolant
Temperature (ECT)
Sensor Signal

DKBLU

135

Engine Coolant
Temperature (ECT)
Sensor Output

Keyless Entry Program

Enable Signal

Wire Color

Not Used

1211-0192
3 Way F Metri-Pack
150 Series Pull to Seat (BLK)
Function

Engine Oil Level Switch

(.._

_.)

Fuse Output Battery

35437

Connector Part
Information

1205-2641
2 Way F MetriPack
150 Series Sealed

Pin

Wire Color

Circuit
No.

BLK/WHT

451

Ground

BRN

1174

Oil Level Switch Signal

Function

Engine

Engine Controls - 3.8L

Evaporative Emission {EVAP) Canister

Purge Valve

6-773

Exhaust Gas Recirculation {EGR) Valve

1/
(

.I c:::::::J

~-~
68773
35437

Connector Part
Information

1205-2643
2 Way Metri-Pack 150 Series
Sealed (RED)

Connector Part
Information

Seat (BLK)

Pin

Wire Color

Circuit
No.

PNK

239

Ignition Feed

WHT

1310

EVAP Canister Purge

Valve Control

Pin

Function

Evaporative Emission.{EVAP) Canister Vent

Valve

c
D

1218-6056
5 Way F Metri-Pack
150.2 Series Pull to

Wire Color

Circuit
No.

GRY

435

Exhaust Gas Recirculation

(EGR) Valve Control

BLK

552

Exhaust Gas Recirculation

(EGR) Sensor Ground

BRN

1456

Exhaust Gas Recirculation

(EGR) Pintle Position

GRY

598

Exhaust Gas Recirculation

(EGR) 5V Reference

LT BLU

697

Exhaust Gas Recirculation

(EGR) Valve Ignition Feed

Function

Fuel Injector #1

35437

Connector Part
Information

1205-2643
2 Way F Metri-Pack
150 Series Sealed (RED)

Pin

Wire Color

Circuit
No.

PNK

239

Ignition Feed

WHT

1310

EVAP Canister Vent

Valve Control

Function
154327

1212-9140
Connector Part
Information

2 Way F Metri-Pack
280.1 Series Pull To
Seat (BLK)
Circuit
No.

Pin

Wire Color

Function

PNK

639

Ignition Feed

BLK

1744

Fuel Injector #1 Control

6-774

Engine

Engine Controls - 3.SL

Fuel Injector #3

Fuel Injector #2

154327

Connector Part
Information

Pin

Wire Color

1212-9140
2 Way F Metri-Pack
280.1 Series Pull To
Seat (BLK)
Circuit
No.

154327

Connector Part
Information

Pin

Function

PNK

639

Ignition Feed

PNK/BLK

1746

Fuel Injector #3 Control

Wire Color

1212-9140
2 Way F Metri-Pack
280.1 Series Pull To
Seat (BLK)
Circuit
No.

Function

PNK

639

Ignition Feed

LT GAN/
BLK

1745

Fuel Injector #2 Control

Fuel Injector #5

Fuel Injector #4

154327
154327

Connector Part
Information

Pin

Wire Color

1212-9140
2 Way F Metri-Pack
280.1 Series Pull To
Seat (BLK)
Circuit
No.

Connector Part
Information

Function

PNK

639

Ignition Feed

BLK/WHT

845

Fuel Injector #5 Control

1212-9140
2 Way F Metri-Pack
280.1 Series Pull To
Seat (BLK)

Pin

Wire Color

Circuit
No.

PNK

639

Ignition Feed

LT BLU/
BLK

844

Fuel Injector #4 Control

Function

Engine Controls - 3.8L

Engine
Fuel Injector #6

6-775

Heated Oxygen Sensor (H02S), Bank 1,

Sensor1

@][I]
[] [!]

154327

68760

1212-9140
Connector Part
Information

Pin
A
B

2 Way F Metri-Pack
280.1 Series Pull To
Seat (BLK)

1216-0482
4 Way F Metri-Pack
150 Series Sealed (BLK)

Connector Part
Information

Wire Color

Circuit
No.

PNK

639

Ignition (RUN and

START)

YEUBLK

846

Fuel Injector #6 Control

Function

Function

Wire Color

TAN
/WHT

1653

LF Heated Oxygen
Sensor (H02S) - Low

PPUWHT

1665

LF Heated Oxygen
Sensor (H02S) - High

BLK

Ground

PNK

450
539

Fuel Tank Pressure Sensor

Circuit
No.

Pin

Ignition Feed

Heated Oxygen Sensor (H02S), Bank 2,

Sensor1

I
62453

Connector Part
Information

Pin

Wire Color

ORN/BLK

1205-9595
3 Way F Metri-Pack
150 Series (BLK)
Circuit
No.

DKGRN

469
890

GRY

416

68760

Function
Fuel Sensor Ground
Fuel Tank Pressure
Signal

5V Se(lsor Feed

Connector Part
Information

1216-0482
4 Way Metri-Pack
150 Series (BLK)

Wire Color

Circuit
No.

TAN

1667

RF Heated Oxygen
Sensor (H02S) - Low

PPL

1666

RF Heated Oxygen
Sensor (H02S) - High

BLK

Ground

PNK

450
539

Pin
A

@][I]
[] [!]

Function

Ignition Feed

6-776

Engine Controls - 3;8L

Engine

Heated Oxygen Sensor {H02S), Bank 1,

Sensor 3

Intake Air Temperature (IAT) Sensor

,....

f Fl

00
00

c==

68719
40407

121-60825
4 Way M Metri-Pack
150 Series Sealed (BLK)

Connector Part
Information ,

Pin

Connector Part
Information

Wire Color

Circuit
No,

GRY

1981

Heated Oxygen Sensor

(H02S) - Low

DKBLU

1980

Heated Oxygen Sensor

(H02$) - High

A
B

Function

BLK

450

Ground

PNK

539

Ignition Feed

Pin

1216-2199
2 Way F Metri-Pack
150.2 Series Pull to
Seat (GRV)

Wire Color

Circuit
No.

PPL

719

Intake Air Temperature

(IAT) Sensor Ground

TAN

472

Intake Air Temperature

(IAT) Sensor Signal

Function

Manifold Absolute Pressure (MAP) Sensor

Idle Air Control {IAC) Valve

I
I

~I Ic Isl
D

1)
68740

38608

Connector Part
Information

1216-2190
4 Way F Metri-Pack
150.2 Series Pull to
Seat (BLK)
Circuit
No.

Pin

Wire Color

LT GRN/
BLK

444

LTGRN
WHT

1749

LT BLU/
BLK

LT BLU/
WHT

1748
1747

Function
Idle Air Control (l:AC)
Valve Coil B Signal - Low

Connector Part
Information

Pin

Idle Air Control (IAC)

Valve Coil A Signal - High

Wire Color

Circuit
No.

ORN/BLK

469

Manifold Absolute
Pressure (MAP) Sensor
Ground

LTGRN

432

Manifold Absolute
Pressure (MAP) Sensor
Signal

GRY

598

Manifold Absolute
Pressure (MAP)
Sensor 5,0V Reference

Idle Air Control (IAC)

Valve Coil B Signal - High
Idle Air Control (IAC)
Valve Coil A Signal - Low

1212-9946
3 Way F Metri-Pack
150 Series (GRV)

Function

Engine

Engine Controls - 3.8L

Mass Air Flow (MAF) Sensor

6-n7

Vehicle Speed Sensor (VSS)

)
'

~
62471

62453

1205-9595
3 Way F Metri-Pack
150 Series (BLK)

Connector Part
Information

Pin

Wire Color

Circuit
No.

YEL

492

Connector Part
Information

Function

Pin

Mass Air Flow (MAF)

Sensor Signal

BLK/WHT

451

Ground

PNK

539

Ignition Feed

A
B

Throttle Position (TP) Sensor

c:::J

(i)
62485

Connector Part
Information

Pin

1211-0293
3 Way F Metri-Pack
150 Series Pull To Seat {BLK)

Wire Color

Circuit
No.

Function

BLK

452

Sensor Ground

DKBLU

417

Throttle Position Sensor

Signal

GRY

598

Throttle Position (TP)

Sensor 5V Reference

1216-2195
2 Way F Metri-Pack
150.2 Series Pull to
Seat {BLK)

Wire Color

Circuit
No.

PPL

401

Vehicle Speed Sensor

(VSS) Signal - Low

YEL

400

Vehicle Speed Sensor

(VSS) Signal - High

Function

6-778

Engine Controls - 3.SL

Engine

Diagnostic Information and Procedures

A Powertrain On Board Diagnostic (OBD) System Check
Refer to Power, Ground and MIL and Power, Ground,
and MIL.

Circuit Description
The Powertrain On-Board Diagnostic System Check
must be the starting point for any driveability complaint
diagnosis. Before using this procedure, you should
perform a careful visual/physical check of the PCM and
engine grounds for being clean and tight. The
Powertrain On-Board Diagnostic System Check is an
~rganized approach to identifying a problem created
by an electronic engine control system malfunction.

MIL Operation
The Malfunction Indicator Lamp (MIL) is located on
the instrument panel (CHECK ENGINE) or (SERVICE
ENGINE SOON). The MIL performs the following
functions:
It informs the driver that a problem has occurred
and. that the vehicle should be taken for service
as soon as possible.
As a bulb check and system check, the MIL will
illuminate with the ignition switch ON and the
engine not running. when the engine is started, the
MIL will turn OFF. If the MIL remains ON, the
self-diagnostic system has detected a problem. If
the problem goes away, the MIL will turn OFF
in most cases, but a diagnostic trouble code will
remain stored.
If the MIL is illuminated, then the engine stalls, the
MIL will remain Illuminated so long as the ignition
switch is ON.
Now, if the MIL is not illuminated and the engine
stalls, the MIL will not illuminate until the ignition
switch is cycled OFF, then ON.
Perform the Powertrain On-Board Diagnostic System
Check first, when the following conditions are
present:
When the MIL does not turn ON when the the
ignition switch is turned to the RUN position
When the MIL remains ON while the engine is
running
When you suspect a driveability problem

Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbed through wire insulation or a wire broken
inside the insulation. Check for poor connections or a
damaged harness. Inspect the PCM harness and
connectors for improper mating, broken locks,
improperly formed or damaged terminals, poor terminal
to wire connection, and damaged harness.

Test Description
The number(s) below refer to the Step number(s) on
the Diagnostic Table:
1. The MIL should be ON steady with the key ON I
engine OFF. If not, the No Malfunction Indicator
Lamp table should be used to isolate the
malfunction.
2. This test ensures that the PCM is capable
transmitting Class 2 serial data to the DLC and
that the Class 2 data circuit is not open or shorted.
If a problem is encountered and a malfunctioning
scan tool is suspected, try the scan tool on
another vehicle to verify operation. If a DLC
problem exists, the DLC Diagnosis table should
be used to diagnose the condition.
3. If the engine will not start, the Engine Cranks But
Will Not Run table should be used to diagnose
the condition.
4. The scan tool may display DTCs which are
diagnosed in 4L60-E Automatic Transmission
Diagnosis. Go to OTC List for a complete list of
DTCs supported by this vehicl.e application.
If multiple DTCs are stored, diagnose each DTC
according the the following priority:
PCM malfunction DTCs (P0601, P0602).
System voltage DTCs (P0560, P1635, P1639).
Component level DTCs (switches, sensor
range/performance, sensor high voltage,
sensor low voltage, ODMs, etc .... ).
System level DTCs (fuel trim, misfire, EGR
flow, TWC system, EVAP system, idle
control system, H02S response or HQ2S
transition time ratio).

5. A scan tool parameter which is not within the

typical range may help to isolate the area which is
causing the problem.

Engine

Engine Controls - 3.8L

6-779

A Powertrain On Board Diagnostic (OBD) System Check

Step

\
1

Action

1. Turn ON the ignition switch.

2. Observe the Malfunction Indicator Lamp (MIL).

Value(s)

No

Go to Step 2

Go to No
Malfunction
Indicator Lamp

Is the MIL ON?

1.
2.
3.
4.

Yes

Turn OFF the ignition switch.

Install a scan tool.
Turn ON the ignition switch.

Go to Data Link

Attempt to display PCM data with the scan tool.

Does the scan tool display PCM data?

Go to Step 3

Connector
Diagnosis

Go to Step 4

Go to Engine
Cranks but Does
Not Run

Go to the
applicable
OTC table

Go to Step 5

System OK

Go to
Component
System Checks

Attempt to start the engine.

Did the engine start and continue to run?

Display the following OTC Statuses using the scan tool

OTC Info feature. If any DTCs are stored, save the freeze
frame and fail record information using the scan tool:
Last Test Fail.

Fail This lgn.

MIL Request.
History.
Are any DTCs stored?

Compare PCM data values displayed on the scan tool to

the Engine Scan Tool Data List.
Are the displayed values normal or close to the typical
values?

6-780

Engine

Engine Controls - 3.SL

No Malfunction Indicator Lamp

Refer to Power, Ground and MIL.

Circuit Description
There should be a steady MIL with the ignition ON
and the engine not running. Ignition feed voltage
is supplied directly to the MIL bulb. The Powertrain
Control Module (PCM) turns the MIL ON by grounding
the MIL control circuit. No MIL with the key ON,
engine not running and DTC P1641 set suggests an
open in the MIL control circuit.

MIL Operation
The Malfunction Indicator Lamp (MIL) is located on
the instrument panel (CHECK ENGINE) or (SERVICE
ENGINE SOON). The MIL performs the following
functions:
It informs the driver that a problem has occurred
and that the vehicle should be taken for service
as soon as possible.
As a bulb check and system check, the MIL will
illuminate with the ignition switch ON and the
engine not running. when the engine is started, the
MIL will turn OFF. If the MIL remains ON, the
self-diagnostic system has detected a problem. If
the problem goes away, the MIL will turn OFF
in most cases, but a diagnostic trouble code will
remain stored.
If the MIL is illuminated, then the engine stalls, the
MIL will remain Illuminated so long as the ignition
switch is ON.
Now, if the MIL is not illuminated and the engine
stalls, the MIL will not illuminate until the ignition
switch is cycled OFF, then ON.

Perform the Powertrain On-Board Diagnostic System

Check first, when the following conditions are
present:
When the MIL does not turn ON when the the
ignition switch is turned to the RUN position
When the MIL remains ON while the engine is
running
When you suspect a driveability problem

Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbed through wire insulation or a wire broken
inside the insulation. Check the following items:
Inspect the PCM harness and connectors
for improper mating, broken locks, improperly
formed or damaged terminals, poor terminal
to wire connection, and damaged harness.
If the engine runs OK, check for a malfunctioning
light bulb, an open in the MIL control circuit, or
an open in the instrument cluster ignition feed.
If the engine cranks but will not run, check for an
open PCM ignition or battery feed or a poor
PCM to engine ground.

Test Description
Number(s) below refer to the Step number(s) on the
Diagnostic Table:
2. A no MIL condition accompanied by a no start
condition suggests a malfunctioning PCM
ignition feed or battery feed circuit.
9. Using a test light connected to B+, probe each of
the PCM ground terminals to ensure that a good
ground is present.
16. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

No Malfunction Indicator Lamp

Step

Action
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?

Value(s)

Check the fuse for the instrument cluster ignition feed

circuit.
Is the fuse OK?

1. Turn ON the ignition switch.

2. Probe the ignition feed circuit at the cluster connector
with a test light to ground.
Is the test light ON?

Go to Step 2

No
Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Step6

Go to Step 4

Go to Step 15

Go to Step 5

Go to Step 12

Go to Step 10

Go to Step 11

Yes

Attempt to start the engine.

Does the engine start?

1.
2.
3.
4.

Turn OFF the ignition switch.

Disconnect the PCM.
Turn ON the ignition switch.
Jumper the MIL control circuit at the PCM connector
to ground and observe the MIL.
Is the MIL ON?

Engine

Engine Controls - 3.SL 6-781

No Malfunction Indicator Lamp (cont'd)
Action

_Step

Value(s)

Check the PCM ignition feed and battery feed fuses.

Are both of the fuses OK?

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Turn ON the ignition switch.
4. Probe the ignition feed ci.rcuit at the PCM harness
connector with a test light to ground:
Is the test light ON?

Probe. the battery feed circuit ?t the PCM harness

connector with a test light to ground.
Is the test light ON?

1. Check for a malfunctioning PCM ground or a poor

9

10

11

PCM ground connection.

2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Check for a poor connection at the PCM.

2. If a poor connection is found, repair it as necessary.
Refer to Wiring Repairs.
Was a problem found?

1. Check the MIL control circuit for an open.

2. If the MIL control circuit is open, repair as necessary.
Refer to Wiring Repairs.
Was a problem found?

12

Repair open in the ignition feed circuit to the instrument

panel indicators. Refer to Wiring Repairs.
Is action complete?

13

Locate and repair open in PCM battery feed circuit or PCM

ignition feed circuit as necessary. Refer to Wiring Repairs.
Is action complete?

14

Locate and repair short to ground in PCM ignition feed

circuit or PCM battery feed circuit as necessary. Refer to
Wiring Repairs.
Is action complete?

15

Locate and repair short to ground in the instrument panel

indicators ignition feed circuit. Refer to Wiring Repairs.
Is action complete?

16

Replace the PCM.

Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.

Is action complete?

1. Check the MIL control circuit for a poor connection at

17

the instrument panel connector.

2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Yes

No

Go to Step 7

Go to Step 14

Go to Step 8

Go to Step 13

Go to Step 9

Go to Step 13

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check
Go to th.e A
Powertrain On
Board Diagnostic
(OBD) System
Check
Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check
Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check
Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check
Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check
Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check
Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 10

Go to Step 16

Go to Step 17

Go to the A
Powertrain On
Board Diagnostic
Go to
(OBD) System
Instrument Panel.
Check

6-782

Engine

Engine Controls - 3.8L

Data Link Connector Diagnosis

Refer to Power, Ground, and MIL.

Circuit Description
The Class 2 serial data circuit to the DLC allows
bi-directional communication between the PCM and
the scan tool. If communication between the scan tool
and the PCM cannot be established, the procedure
in the DLC Diagnosis table should be used to diagnose
the condition.

Diagnostic Aids
Check the following items:
For the PCM to establish communication with the
scan tool, system voltage must be between 9.0
and 16.0 volts. If system voltage is not within this
range, refer to Charging System for diagnosis.
Ensure that the correct application (model year,
carline, VIN code) has been selected on the
scan tool; if communication still cannot be
established try the scan tool on another vehicle to
ensure that the scan tool, Vehicle Interface
Module, or cables are not the cause of the
condition.

An intermittent may be caused by a poor

connection, rubbed through wire insulation or a
wire broken inside the insulation. Check for
poor connections or a damaged harness. Inspect
the PCM harness and connectors for improper
mating, broken locks, improperly formed or
damaged terminals, poor terminal to wire
connection, and damaged harness.

Test Description
Number(s) below refer to the Step number(s) on the
Diagnostic Table:
11. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

Engine Controls - 3.8L

Engine

6-783

Data Link Connector Diagnosis

Action

Step

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to $tep 10

Go to Step 4

Go to Step.9

Go to Step 5

Go to Step 7

Go to Step 8

Go to Step 6

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step11

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step11

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1. Disconnect the scan tool.

2. Turn ON the ignition switch.
3. Probe the DLC battery positive voltage circuit
(cavity 16) with a test light to chassis ground.

Is the test light ON?

Probe both of the DLC ground circuits (cavities 4 and 5)

with a test light to B+.
Is the test light ON at both ground circuits?

Probe the Class 2 serial data circuit at the DLC with a

J 39200 Digital Multimeter to ground.
Is the voltage near the specified value?

ov

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Turn ON the ignition switch.
4. Probe the Class 2 serial data circuit at the DLC with
a test light to B+.
Is the test light ON?

1. Check the Class 2 serial data circuit for an open

between the DLC and the PCM.
2. If a problem is found, repair as necessary. Refer to
Data Link Connector Diagnosis.
Was a problem found?

1. Check the Class 2 serial data circuit for a short to

voltage.
2. If a problem is found, repair as necessary. Refer to
Data Link Connector Diagnosis.

Was a problem found?

Locate and repair the short to ground in the Class 2 serial

data circuit. Refer to Data Link Connector Diagnosis.
Is action complete?

Locate and repair the open in the affected DLC ground

circuit. Refer to Wiring Repairs.
Is action complete?

10

Locate and repair the open or short to ground in the DLC

battery positive voltage circuit. Refer to Wiring Repairs.
Is action complete?

Go to the A
Powertrain On
Board Diagnostic
(080)
System Check

Go to the A
Powertrain On
Board Diagnostic
(080)
System Check

Go to the A
Powertrain On
Board Diagnostic
(080)
System Check

Go to the A
Powertrain On
Board Diagnostic
. (080)
System Check

Replace the PCM.

11

Important: Replacement PCM must be programmed.

Refer to PCM Replacement/Programming.
Is action complete'?

'

a:.;ts4

Engine Controls - 3.SL

Engine

Ertgine Cranks but Does Not Run

----,
ENG CTRL
MiniFuse
15A

BRN/WHT 633
WHT/ 644
BLK
WHT/ 644

Instrument .....
Cluster ~

r--'--,

I
I

Tachometer
Input

RED/ 645 BLK - - - - '

I
I

1
J

CMP
Sensor
Signal

CMP/CKP
Sensor
Ground

l
.___

CMP/CKP
Sensor Ignition
Positive Voltage

5V

LTBLU/ 1800
WHTH

CKP18x
Signal

-,

Power
Distribution
Cell10

PNKr39

i'

PNK 239

YEL 573

RED/ 645
BLK
WHT/ 644
BLK

Electrical
Center 2

L----.J

8131
WHT 121

L---------.J
Underhood PNK 239

RED/ 645
BLK

BLK

+ Ignition

.J

PNK 239 Control (IC)

CKP
Sync
Signal

Module

Ignition
Positive
Voltage

5V

sv
Tachometer
Output

Crankshaft
Position Sensor
---- Signal

18x
3x
Reference Reference
Signal
Signal

Bypass
Control

Ignition
Control (IC)

Ref Low Ground

WHT 121
BLK 630

Powertrain I"
Control I
... Module I

~ (PCM) I

Bl.l~

LT
PPL/
WHT 430
WHT 423
BLU/
RED/
BLK 647
TAN/
BLK 424
BLK 453
53
54
48 C1
9
8

18x- - - & - - - Bypa; lg;:;;li.;;; - - Rella,; - ,

Cra;s~f\62;7
Position
Reference
Ssenso r
Signal
igna1

Reference
Signal

Control

Control (IC)

PCM

Cl = BLU
C2 = CLEAR

I
I
I

L---------------------------.J

244305

Circuit Description
Th~ Electronic Ignition system uses a waste spark
method of spark distribution. In this type of ignition
system, the ignition control module triggers the correct
coil based on the sync signal received from the
crankshaft position sensor, resulting in both spark
plugs connected to the coil firing at the same time. The
spark plug for the cylinder on the exhaust stroke
requires a lower energy requirement to fire, leaving
the remaining high voltage to fire the spark plug for the
cylinder on the compression stroke.
During crank, the ignition control module monitors the
CKP sync signal. The CKP sync signal is used to
determine the correct cylinder pair to fire first. The CKP
sync signal is used only by the ignition control
module to initiate ignition coil firing sequence. It is not
passed to the PCM. After the ignition control module

processes the CKP sync signal, the ignition control

module monitors the 18X CKP signal and sends 18X
and 3X reference pulses to the PCM. When the
PCM receives these pulses, the PCM will command
all six injectors to allow a priming shot of fuel for all the
cylinders. After the priming, the injectors are left
OFF during the next six 3X reference pulses from the
ignition control module. This allows each cylinder a
chance to i..tse the fuel from the priming shot. During
_this waiting period, the PCM receives a camshaft
position signal pulse. The camshaft position signal
allows the PCM to operate the injectors sequentially
based on camshaft position. If the camshaft position
signal is not present at start-up, the PCM will
begin sequential fuel delivery with a 1 in 6 chance that
fuel delivery is correct.

Engine Controls - 3.8L

Engine

6-785

Diagnostic Aids

Test Description

An intermittent may be caused by a poor connection,

rubbed through wire insulation or a wire broken
inside the insulation. Check for the following items:

Number(s) below refer to the step number(s) on the

Diagnostic Table:
5. Determines if the ignition control module (ICM) is
receiving the 18X CKP Reference signal. If the
18X CKP signal to the ICM is not present,
there will be no RPM, spark, or fuel injector
pulses.
6. Ensures that the ICM has the proper voltage
supply and ground.
8. Verifies that the ICM is supplying the proper
sensor feed voltage.
24. Check for the proper operation of the CKP Sync
signal, ICM and related spark system components.
Without the CKP Sync signal the ICM is unable
to properly sequence the ignition coils.
35. If the 18X and CKP Sync signals to the ICM or
the 18X and 3X reference signals to the ICM
short together the vehicle will not start and run.
However, there will be spark and fuel injector
pulses.
46. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM .is being
replaced, the new PCM must be programmed.

Poor connection or damaged harness.

Inspect the PCM harness and connectors for
improper mating, broken locks, improperly formed
or damaged terminals, poor terminal to wire
connection, and damaged harness.
Malfunctioning Engine Coolant Temperature
Sensor.
Using a scan tool, compare Engine Coolant
Temperature with Intake Air Temperature on a
completely cool engine. Engine Coolant
Temperature should be within 10c of Intake Air
Temperature: If not, replace the ECT sensor.
Throttle Position Sensor.
If the TP angle is over 80%, the PCM may
operate in clear flood mode. The PCM will not
allow fuel delivery while operating in
clear flood mode.

Engine Cranks but Does Not Run

Step

Action
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?

Important: Before ~roceeding with this diagnostic Table,

ensure that the vehicle battery is fully charged.
Important: If any DTCs are stored as failed since code
clear, diagnose the DTCs before continuing with this table.
1. Check the.fuses which supply ignition positive voltage
to the foUowing components:
Electronic ignition control module.
Fuel injectors.
2. If either fuse is blown, locate and repair the short to
ground in the affected ignition positive voltage circuit.
Was a problem found?
1. Turn the ignition switch to the OFF position.
2. Install a fuel pressure gauge at the fitting on the
fuel rail.
3. Turn the ignition switch to the ON position.
4. Observe the fuel pressure gauge.
Is the fuel pressure within the specified values and
holding?

Value(s)

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to the. A
Powertrain On
Board Diagnostic
(080) System
Check

'
Go to Step 3

333-376 kPa
(48-55 psi)

Is any fuel pressure indicated?

Yes

Go to Step 5

Go to Step 4

Go to the Fuel
System
Pressure Test

Go to the Fuel
Pump Relay
Circuit Diagnosis

6-786

Engine Contro1s - 3.SL

Engine

Engine Cranks but Does Not Run (cont'd)

Action

Step

Value(s)

Yes

No

Go to Step 17

Go to Step 6

Go to Step B

Go to Step 7

Go to Step 39

Go to Step40

Go to Step 9

Go to Step 11

Go to Step 10

Go to Step 14

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 41

Go to Step 12

Go to Step 13

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step38

1. Turn the ignition switch to the OFF position.

2. Remove the fuel pressure gauge from the fuel rail.
3. Install the scan tool.

4. Turn the ignition switch to the ON position.

5. Select the Engine Data 1 display on the scan tool.
6. Observe the engine RPM while cranking the engine.
Does the scan tool indicate an engine RPM?
1. Turn the ignition switch to the OFF position.
2. disconnect the ignition control module (ICM)
connector.
3. Turn the ignition switch to the ON position.
4. Connect J 34132-8 test light between the ignition
positive feed and ground terminals in the ICM
connector.

Is the test light ON?

1. Leave the ICM connector disconnected.

2. Connect the test light between the ignition positive
feed and engine ground.

Is the test light ON?

1. Turn the ignition switch to the OFF position.
2. Reconnect the ICM connector.
3. Disconnect the 18X crankshaft position (CKP) sensor
connector.
8

4. Turn the ignition switch to the ON position.

5. Connect J 39200 Digital Multimeter (DMM) between
the 18X CKP sensor feed and sensor ground
terminals in the connector.

B+

Does the DMM display a voltage near the specified value?

10

11

Connect the DMM between the 18X CKP sensor signal

and sensor ground terminals in the connector.
Does the DMM display a voltage near the specified
values?
Check for poor terminal connections at the 18X CKP
sensor.
If a problem is found, repair as necessary. Refer to Wiring
Repairs
Was a problem found?
Connect the DMM between the 18X CKP sensor feed and
engine ground.

10V

B+

Does the DMM display a voltage near the specified value?

12

Turn the ignition switch to the OFF position.

Leave the 18X CKP sensor connector disconnected.
Disconnect the ICM connector.
Check the 18X CKP sensor ground for an open.
If a problem is found, repair as necessary. Refer to Wiring
Repairs.
Was a problem found?

Engine

Engine Controls - 3.8L

6-787

Engine Cranks but Does Not Run (cont'd)

Step

Action

Value(s)

Yes

No

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 41

Go to Step 15

Go to Step 16

Turn the ignition switch to the OFF position.

13

Leave the 18X CKP sensor connector disconnected.

Disconnect the ignition ICM connector.
Check the 18X CKP sensor feed for an open or short to
ground.
If a problem is found, repair as necessary. Refer to Wiring
Repairs.
Was a problem found?
Leave the DMM connected.

14

Turn the ignition switch to the OFF position.

Disconnect the ICM connector.
Turn the ignition switch to the ON position.
Dies the DMM display a voltage near than the
specified value?

10V

Locate and repair the short between the 18X CKP sensor
signal circuit and the following circuit(s):
15

18X CKP sensor feed circuit.

Battery positive voltage.
Refer to Wiring Repairs.
Is action complete?

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Turn the ignition switch to the OFF position.

16

Disconnect the ICM connector.

Turn the ignition switch to the ON position.
Check the 18X CKP signal circuit for the following
condition(s):
An open.
Short to ground or sensor ground.
If a problem is found, repair as necessary. Refer to Wiring
Repairs.
Was a problem found?

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 38

Go to Step 18

Go to Step 19

Go to Step 43

Go to Step 46

Go to Step 24

Go to Step 20

Go to Step 21

Go to Step 22

Turn the ignition switch to the OFF position.

17

Disconnect all of the fuel injector connectors.

Turn the ignition switch to the ON position.
Observe the fuel injector test light when installed in each
injector connector.
Was the injector test light ON for any of the injectors?

Leave the fuel injector connectors disconnected.

18

Turn the ignition switch to the OFF position.

Disconnect the PCM connector.
Turn the ignition switch to the ON position.
Observe the injector test light in the injector connectors.
Was the test light ON for any of the injectors?

Leave the fuel injector connectors disconnected.

19

20

Leave the injector test light installed in the injector

connector.
Observe the injector test light while cranking the engine
(repeat for each injector).
Did the injector test light blink for each injector?
Did the injector test light blink for any of the injectors?

6-788

Engine Controls - 3.8L

Engine

Engine Cranks but Does Not Run (cont'd)

Step

Action

21

Turn the ignition switch to the OFF position.

Leave the injector connectors disconnected.
Disconnect the PCM connector.
Check for an open in the fuel injector control circuit(s)
associated with the injector test light that did not blink.
If a problem is found, repair as necessary. Refer to Wiring
Repairs.
Was a problem found?

Leave the fuel injector connectors disconnected.

Turn the ignition switch to the ON position.
Connect a test light to ground.
Probe the ignition positive voltage feed circuit to each
injector connector.
Is the test light ON?

22

23

Locate and repair the open ignition positive feed circuit to

the fuel injectors. Refer to Wiring Repairs.
Is action complete?

Value(s)

Turn the ignition switch to the OFF position.

Disconnect a spark plug wire from the spark plug.
Install J 2676 Spark Tester in the end of the spark
plug wire.
Jumper the companion cylinder ignition wire to engine
ground. The companion cylinder is the cylinder that shares
the same ignition coil (i.e. 1/4, 2/5, 3/6).
Crank the engine while observing the spark tester. Spark
should be observed.
Repeat the above test for each ignition wire, noting any
cylinders that do not have spark.
Is spark available at all cylinders?

25

Is spark available at any cylinder?

26

Turn the ignition switch to the OFF position.

Disconnect the 18X CKP sensor connector.
Turn the ignition switch to the ON position.
Connect the DMM between the CKP Sync signal circuit
and ground.
Does the DMM display a voltage near the specified value?

10V

24

27

28

Check for poor terminal connections at the 18X CKP

sensor.
If a problem is found, repair as necessary. Refer to Wiring
Repairs.
Was a problem found?

Turn the ignition switch to the OFF position.

Disconnect the ICM connector.
turn the ignition switch to the ON position.
Check the CKP Sync signal circuit for a short to voltage or
the 18X CKP sensor feed circuit.
If a problem is found, repair as necessary. Refer to Wiring
Repairs.
Was a problem found?

Yes

No

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 44

Go to Step 44

Go to Step23

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 34

Go to Step25

Go to Step 30

Go to Step26

Go to Step 27

Go to Step28

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 41

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step29

Engine Controls - 3.8L

Engine

6-789

Engine Cranks but Does Not Run (cont'd)

Step

Action

Value(s)

29

Turn the ignition switch to the OFF position.

Disconnect the ICM connector.
turn the ignition switch to the ON position.
Check for the following circuit condition(s):
The CKP Sync signal circuit for a short to ground or
sensor ground.
An open CKP Sync signal circuit.
If a problem is found, repair as necessary. Refer to Wiring
Repairs.
Was a problem found?

30

Remove and visually/physically inspect the ignition coil(s)

and the ignition wires associated with the cylinders that did
not have spark. Ensure that the ignition wires, boots,
coil(s), and coil towers are free of cracks and carbon
tracking.
If a problem is found, replace the damaged ignition
component(s). Refer to Ignition coil Replacement.
Refer to the Secondary Wiring in Ignition System.
Was a problem found?

31

Measure the ignition coil secondary resistance.

If any resistance..is outside the specified values, replace
the malfunctioning ignition coil(s) as necessary. Refer to
Ignition Coil(s) Replacement.
Was a problem found?

32

33

Measure the resistance of the ignition wires associated

with the cylinders that did not have spark.
Replace the ignition w.ire(s) that measure greater than the
specified value. Refer to Secondary Wiring in Ignition
System.
Was a problem found? .
Connect a test light across the, ignition module primary
circuit (between the electronic ignition control module
terminals) for the coil(s) associated with the cylinders
which did not have spark.

5K-8K ohms
(5000 8000 ohms)

"

600 ohms/ft

34

35

)
36

Refer to Diagnostic Aids to check for the following

condition(s):
A short between the 18X CKP and CKP Sync signal inputs
to the ICM.
A short between the 18X and 3X reference signal inputs to
the PCM.
Stuck TP sensor.
Skewed ECT sensor.
Skewed or unresponsive MAP sensor.
If a problem is found, repair as necessary. Refer to Wiring.
Repairs.
Was a problem found?
Test the fuel for contamination. Refer to Alcohol-in-Fuel
Diagnosis.
If a problem is found, clean the fuel system and correct
the contaminated fuel conditions as necessary.
Was a problem found?

No

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 38

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 31

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 32

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 33

Go to Step 45

Go to Step 42

Go to Engine
Mechanical
Diagnosis in
Engine General
Information

Go to Step 35

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 36

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 37

Observe the test light while cranking the engine.

does the test light blink continuously while the engine is
being cranked?
Remove the spark plugs from all of the cylinders.
Visually/physically inspect the spark plug electrodes.
did the spark plug inspection reveal excessive fouling?

Yes

6-790

Engine Controls - 3.SL

Engine

Engine Cranks but Does Not Run (cont'd)

.. Step

Action

Value(s)

Yes

No

Repair the engine mechanical problem. Refer to Engine

Mechanical Diagnosis in Engine General Information to
diagnose the following condition(s):

37

38

39

Bent push rods.

Malfunctioning or incorrect camshaft
Leaking or sticky valves or rings.
Excessive valve deposits.
Loose or worn rocker arms.
weak valve springs.
Incorrect valve timing.
Leaking head gasket.
Is action complete?
Check for poor terminal connections at the ICM.
If a problem is found, repair as necessary. Refer to Wiring
Repairs.
Was a problem found?
Locate and repair the open in the ICM ground circuit.
Refer to Wiring Repairs.
Is action complete?
Locate and repair the open in the ignition positive feed
circuit to the ICM. Refer to Wiring Repairs.

40

Is action complete?

41

Replace the 18X CKP sensor. Refer to Crankshaft Position

Sensor Replacement.
Is action complete?

42

Replace the ICM.

Refer to Ignition Control Module Replacement.
Is action complete?

43

Locate and repair the short to ground in the fuel injector

control circuit(s) associated with the injector test light(s)
that stayed ON. Refer to Wiring Repairs.
Is action complete?

44

Check for poor terminal connections at the PCM.

If a problem is found, repair as necessary. Refer to Wiring
Repairs.
Was a problem found?

45

48

Replace the ignition coil{s) associated with the cylinder(s)

that did not have spark. Refer to Ignition Coil{s)
Replacement.
Is action complete?
Replace the PCM.
Important: Replacement PCM must be reprogrammed.
Refer to PCM Replacement/Programming.
Is action complete?

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 42

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
heck

Go to Step 46

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Engine

Engine Controls .. 3.SL

6-791

Fuel Pump Relay Circuit Diagnosis

r -

.-:"' -

!Hot At All Times!

- - - - -

Underhood
I El t .. I
FUEL PUMP
9C rtCa
Mini Fuse I Center 1

I Power

Distribution H9
I ee1110

HB

20A

GRY

L. -

.I

L0

IN

I
-

. -

. . -

L---

...

---

...
BLK/
WHT 451
Ground
Distribution
Cell14

DK.
GRN/WHT 465

BLK 451

1450

244306

Circuit Description
When the ignition switch is first turned ON, the PCM
energizes the fuel pump relay. The fuel pump relaytwill
remain ON as long as the engine is running or
cranking and the PCM is receiving reference pulses. If
no reference pulses are present, the PCM
de-energizes the fuel pump relay within 2 seconds
after the ignition is turned ON or the engine is stopped.
The fuel pump delivers fuel to the fuel rail and
injectors, then to the fuel pressure regulator. The fuel
pressure regulator controls fuel pressure by allowing
excess fuel to be returned to the fuel tank. With
the engine stopped, the fuel pump can be turned ON
by using the scan tool output controls function.

Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbed through the wire insulation or a wire broken
insideof the insulation.

Check for a poor connection or a damaged harness.

Inspect the PCM harness and connectors for
the following items:
Improper mating
Broken locks
Improperly formed or damaged terminals
Poor terminal to.wire connections
Damaged harnesses

Test De!5qription
Number(s) below refer to th1;1 Step number(s) on the
Diagnostic Table:
2. Verifiesthat the foel pump feed circuit is OK
between 'the fuel pump relay and the fuel pump,
and that the fuel pump can deliver adequate .
pressure to the fuel rail.
3. Checks the battery f~ed circuit to the fuel

pump relay. .

6-792

Engine Controls - 3.8L

Engine

4. Ensures that the fuel pump relay control circuit

and the PCM are capable of controlling the
fuel pump relay.

11 . Checks the fuel. pump feed circuit between the

fuel pump relay and the fuel pump. Also checks
the fuel pump ground circuit.

5. Checks the fuel pump control circuit for a short to

ground.

12. Determines whether the problem is being caused

by an open in the fuel pump feed circuit or the
fuel pump ground circuit.

6> Checks the fuel pump control circuit for an open.

1O. If the fuel pump is operating but incorrect pressure
is noted, the fuel pump wiring is OKanc;IJhe Fuel
System Pressure Test should be used for
diagnosis.

20. This vehicle is equipped with a PCM which utilizes

an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

Fuel Pump Relay Circuit Diagnosis

Action

Step

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Goto Step 10

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

1.
2.
3.
4.

Turn OFF the ignition switch.

Connect a fuel pressure gauge.
Disconnect the fuel pump relay.
Connect a fused jumper between the fuel pump feed
circuit at the fuel pump relay connector and B+.
5. Note the fuel pressure.
Is fuel pressure indicated at the specified value?

333-376 kPa
(48-55 psi)

1. Disconnect the jumper from the fuel' pump relay

connector.
2. Connect a J 34142-B Unpowered Test Light between
fuel pump relay connector cavities for the battery feed
circuit and the ground circuit.
3. Turn ON the ignition switch.
;
4. Observe the test light.
Is the test light ON?
.

;;--

1. Turn OFF the ignition switch.

2. Connect a J 34142-B Unpowered Test Light between
fuel purnp relay connector cavities for the fuel pump
relay control circuit and the ground circuit.
3. Observe the test light while turning ON the ignition
switch.
Did the test light turn ON for approximately 2 seconds?

1. Disconnect the test light from the fuel pump relay

connector.
2. Turn OFF the ignition switch.
3. Disconnect the PCM.
4. Probe the fuel pump relay control circuit at the PCM
cpnnector with the test light to B+.
Is the test lightON?

1. Check for continuity in. the fuel pump relay control

circuit between the PCM and the fuel pump relay.
2. If a problerTJ is found, repair as necessary.
Refer to
,.,,
Wiring Repairs.
'
Was a problem found?

1. Check the fuel pump relay control circyit for a poor

terminal connection at the PCM..
2. If a problem is found, rep.air as necessary. Refer to
Wiring Repairs.
Was a problem found?

(
Go to Step 4

Go. to Step 9

Go to Step B

Go to Step 5
"'

Go to Step 15

Go to Step 6

Go to Step 21

Go to Step 7

Go to Step 21

Go to Step 20

;,

Engine Controls - 3.8L

Engine

6-793

Fuel Pump Relay Circuit Diagnosis (cont'd)

Step

'

Value(s)

Action

Yes

No

Go to Step 21

G.o to Step 18

Go to Step 17

Go to Step 16

Go to the Fuel
System
Pressure Test

Go to Step 11

Go to Step 19

Go to Step 12

Go to Step 14

Go to Step 13

ttw

1. Check for a poor terminal conne.ction at

fuel
pump relay
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.

Was a problem found?

9.

.
Probe the battery feed circuit at the fuel pump relay
connector with the test ligh,t, to ground.

Is the test light ON?

10

Remove the fuel filler cap andJisten for the fuel pump
running.

Is the fuel pump running?

,1. Raise the vehicle (leave the fuel pump feed circuit
jumped to B+).

11

2. Disconnect the modular fuel sender electrical

c;onnector at the fuel ta.nk.
3. Connect the test light between the fuel pump feed
circuit and the fuel pump ground circuit at the
modular fuel sender harness connector:

Is the test light ON?

" Probe the fuel pump feed circuit af the modular fuel
12

sender harness connector with the test light to chassis

ground.

Is the test light ON?

13

Locate and repair open in the fuel pump feed circuit. Refer
to Wiring Repairs.
Locate and repair open in the fuel pump ground circuit.
Refer to Wiring Repairs.

Go to Step 21

Locate and repair short to ground in the fuel pump relay

control circuit. Refer to Wiring Repairs.
Locate and repair open in battery feed to the fuel pump
relay. Refer to Wiring Repairs.

Go to Step 21

Locate and repair open in ground circuit to the fuel pump

relay. Refer to Wiring Repairs.

19

Replace the fuel pump relay.

Is the action complete?
Replace the fuel pump. Refer to Fuel Sender Assembly
Replacement

20

Go to Step 21

Go to Step 21

Is the action complete?

Replace the PCM
Important: Replacement PCM must be programmed.
Refer to PCM Replacement/Programming

Go to Step 21

Is the action complete?

18

Go to Step 21

Is the action complete?

17

Is the action complete?

16

Go to Step 21

Is the action complete?

15

Is the action complete?

14

Go to Step 21

Is the action complete?

1. Turn ON the ignition switch.
2. Select FP Relay output control with the scan tool.
21

3. Observe the fuel pressure gauge while turning the

fuel pump ON with the scan tool.
Is fuel pressure indicated at the specified value?

333-376 kPa
(48-55 psi)
System OK

Go to Step 2

6794

Engine Controls - 3.SL

Fuel Syste~ Diagnosis

Fuel Metering System
Some failures of this system will result in an Engine
Cranks But Will Not Run symptom. If this condition
exists, Refer to Engine Cranks but Does Not Run. This
will determine if the problem is caused by the ignition
system, the PCM, or the fuel pump electrical circuit.
Refer to Fuel Pump Relay Circuit Diagnosis for the fuel
system wiring schematic.
If there is a fuel delivery problem, Refer to Fuel
System Pressure Test. This diagnoses the fuel
injectors, the. fuel pressure regulator, and the fuel
pump. If a malfunction occurs in the fuel metering
system, it usually results in either a rich H02S signal
or lean H02S signal. This condition is indicated by
the H02S voltage, causing the PCM to change the fuel
calculation (fuel injector pulse width) based on the
.H02S reading. Changes made to the fuel calculation
will be indicated by a change in the long term fuel
trim values which can be monitored with a scan tool.
Ideal long term fuel trim values are around 0%;
for a lean H02S signal, the PCM will add fuel, resulting
in a fuel trim value above 0% and for a rich H02S
signal the PCM will take away fuel, resulting in a fuel
trim value below 0%. Some variations in fuel trim
values are normal due to powertrain design. If the fuel
trim values are excessively greater or lower then 0%
Refer to OTC P0171 Fuel Trim System Lean Bank .1 or
OTC P0172 Fuel Trim System Rich Bank 1.

Engine
ldleAir Control.Valve
The scan tool displays IAC pintle position in counts.
"O" counts indicates the PCM is commanding the IAC
pintfe to be driven a.II the Way into a. f4lly seated
position. This is usually caused by a vacuum leak.
The higher the '~umber of count~. th~ more. air is being
commanded to bypass the IAQ pintle. Refer to Idle
Air Control System Diagnosis in order to diagnose the
IAC system, Re(ertb Rough, Unstable, or'lncorrect
Idle, Stalling in Symptoms for other possible causes of

idle problems.

Throttle Position (TP)Sensor

The TP sensor is mounted on the side of the thro1tle
body opposite the throttle lever. It senses the .
throttle valve angle, and relays that information to the
PCM. Knowledge of the throttle angle is needed by
the PCM to generate the required injector control
signals (pulse). For further information, refer to
Information. Sensors/Switches Description .

Mass Ajr Flow (MAF)Sensor

The MAF sensor is mounted to the, front of the. throttle
body, arid is usec;:l, to measure the amount of air
ent.ering the engine. Th.~ PCM u~es this information to
determine the operating condition of the engine and
to control fuel delivery. For further inf9rmation, refer to
lnformationSensors/Switches Description.

Fuel System Pressure Test

A fuel system pressure test is part of several of the
diagnostic cha.rts and symptom checks. To perform this
test, refer to Fuel System Pressure Test.

(
\

Engine Controls - 3.8L

Engine

6-795

DTC P0101 Mass Air Flow (MAF} Sensor Performance

uu
I

L-------------J
PNK 539

PNK 539

Fuse Block

Details
Cell 11

PNK 539

c,,,.

Ignition
Positive
Voltage

I\IIAF
Sensor
Signal

Mass Airflow
(MAF) Sensor

Ground

B
BLK/WHT 451
Ground
Distribution
Cell14

BLK 451

69 C1

,-------------,
.
MAF
Powertra1n

I Control
I Module
I
C2=CLEAR 1 (PCM)~
I
I
, ..~
L------------..1
~
I

Sensor

Signal

PCM

C1 = BLU

221655

Circuit Description
The Mass Air Flow (MAF) sensor measures the
amount of air which passes through it into the engine
during a given time. The PCM uses the mass air
flow information to monitor engine operating conditions
for fu~I delivery calculations. A large quantity of air
enten~g t~e engi~e indicates an acceleration or high
load s1tuat1on, while a small quantity of air indicates
deceleration or idle. The MAF sensor produces
a frequency signal which can be monitored using a
scan tool. The frequency will vary within a range
of around 2000 Hertz at idle to about 10 000 Hertz at
maximum engine load. OTC P0101 will be set if
the signal from the MAF sensor does not match a
predicted value based on barometric pressure
(calculated from MAP at key ON), throttle position,
and engine RPM.

Conditions for Setting the DTC

No TP sensor, MAP sensor, EVAP system, or
EGR system OTCs are set.
The engine is running.
System voltage is between 9V and 16V.

The throttle is steady and TP angle is less

than 50%.
EGR duty cycle is less than 50%.
EGR pintle position is less than 50%.

MAF signal,frequency indicates an airflow

significantly higher or lower than a predicted value.
The value is based on barometric pressure,
throttle position, intake air temperature, engine
coolant, and engine RPM.
The conditions are present for 2 seconds + 400
. 3X reference periods ( 133 crankshaft revolutions).

Action Taken When the DTC Sets

The PCM will illuminate the Malfunction Indicator
Lamp (MIL) the first time the malfunction is
detected.
The PCM calculates an airflow value based on
idle air control valve position, throttle position,
RPM and barometric pressure.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and the Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

6-796

Engine

Engine Controls - 3.8L

Diagnostic Aids
Check for the following conditions:
Skewed or stuck TP sensor - A faulty TP sensor
or TP sensor circuit can cause the PCM to
incorrectly calculate the predicted mass air flow
value. Observe the Throttle Angle displayed on the
scan tool with the throttle closed. If the Throttle
Angle reading is not 0%, check for the following
conditions and repair as necessary:
- Throttle plate sticking or excessive deposits
on the throttle plate or in the throttle bore
- TP sensor signal circuit shorted to voltage
- Poor connection or high resistance in the TP
sensor ground circuit
- If none of the above conditions are noted
and the Throttle Angle reading at closed
throttle is not 0%, replace the TP sensor.
Refer to TP Sensor Replacement
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.
Misrouted harness - Inspect the MAF sensor
harness to ensure that it is not routed too close to
high voltage wires such as spark plug leads.
Damaged harness - Inspect the wiring harness for
damage. If the harness appears to be OK,
observe the scan tool while moving connectors
and wiring harnesses related to the MAF sensor. A
change in the display will indicate the location
of the fault.
Plugged intake air duct or dirty air filter element A wide-open throttle acceleration from a stop
should cause the Mass Air Flow displayed on a
scan tool to increase from about 4-7 gm/sat idle to
100 gm/s or greater at the time of the 1-2 shift.
If not, check for a restriction.

Skewed or unresponsive MAP sensor - The

barometric pressure used to calculate the default
Mass Air Flow value is based on the MAP
sensor reading. A skewed MAP sensor at key ON
will cause the BARO reading to be incorrectly
calculated. Also, with the engine running,
an unresponsive MAP sensor (due to poor vacuum
connections, damaged vacuum source, or
defective vacuum hose(s), unmetered air into the
manifold) will cause inaccurate BARO reading
updates during wide-open throttle conditions. Both
of these conditions result in a difference between
the actual MAF sensor signal and the predicted
MAF value (PCM calculated). If a large difference
between these two values occurs DTC P0101
will set. This condition may also cause abnormal
IAC counts. With the IAC at an incorrect count
value, a hard start I no start condition may occur.
If DTC P0101 cannot be duplicated, the information
included in the Fail Records data can be useful
in determining vehicle mileage since the DTC was last
set. This may assist in determining how often the
DTC sets.

(
\

Test Description
Number(s) below refer to the Step number(s) on the
Diagnostic Chart:
3. This step verifies that the problem is present.
4. This step verifies a proper MAP/BARO value at
initial key ON. If the MAP sensor is stuck the
barometric pressure value will be incorrectly
calculated. This will cause the predicted Mass Air
Flow calculations to be inaccurate. DTC P0101
will set if the MAF sensor signal does not
match the predicted MAF value.
5. This step verifies a proper MAP sensor signal with
engine running. With a closed throttle and proper
engine vacuum, the MAP sensor signal should
be between 29 kPa and 48 kPa.
6. This step verifies a proper MAP sensor response
as the throttle is opened. As the throttle is
steadily opened, pressure in the intake manifold
increases. The MAP sensor signal should increase
steady as the pressure increases.
7. Checks for conditions which can cause a good
MAF sensor to appear faulty.
1O. A voltage reading of less than 4 or greater than
6 volts at the MAF sensor signal circuit indicates
a fault in the wiring or a poor connection.
11. Verifies that ignition feed voltage and a good
ground are available at the MAF sensor.
21. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

(
,

Engine Controls - 3.8L

Engine

6-797

DTC P0101 Mass Air Flow (MAF) Sensor Performance

Action

Step
\

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to
OTC P1635 5
Volt Reference
Circuit

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 8

Go to Step 6

Go to Step 7

Go to Step 9

Go to Step 8

Go to Step 22

Go to Step 9

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Is DTC P1635 also set?

1. Review and record scan tool Fail Records data.

2. Operate vehicle within Fail Records conditions
as noted.
3. Using a scan tool, monitor Specific OTC info for
OTC P0101.
Does the scan tool indicate OTC P0101 failed :this
ignittion?

1. Turn ON the ignition switch.

4

2. Observe MAP and BARO values displayed on the

scan tool.
Does the scan tool indicate a value within the
specified range?
1. Start the engine.
2. Observe the MAP sensor display on the scan tool
with the engine idling.
Does the scan tool display a value within the within the
specified range?
Monitor the MAP sensor display on the scan tool while
slowly increasing engine speed to 3000 RPM.
Does the MAP sensor value increase as engine speed
increases?

65-105 kPa

29-48 kPa

1. Check for the following conditions:

Objects blocking the throttle body inlet screen.
Intake manifold vacuum leaks.
Vacuum leaks at throttle body.

Vacuum leaks at EGR valve

PCV valve faulty, missing, or incorrectly installed.
Skewed or unresponsive MAP Sensor. Refer to
OTC P0101 Diagnostic Aids.
2. If a problem is found, repair as necessary.
Was a problem found?
Replace the MAP sensor. Refer to MAP Sensor
Replacement.
Is action complete?

Go to Step 22

Go to Step 10

Go to
OTC P0121
Throttle Position
(TP) Sensor
Performance

Go to Step 11

Go to Step 12

1. Turn ON the ignition switch.

10

2. With the throttle closed, observe the Throttle at Idle

display on the scan tool.
Does the scan tool display Yes?
1.
2.
3.
4.

Turn OFF the ignition switch.

Disconnect the MAF sensor connector.
Turn ON the ignition switch.
Using a DMM, measure voltage between the MAF
signal circuit and chassis ground.
Is the voltage near the specified value?

5V

6-798

Engine Controls - 3.8L

Engine

OTC P0101 Mass Air Flow (MAF) Sensor Performance (cont'd)

Action

Step

11

Connect a J 34142-8 Unpowered Test Light between the

MAF sensor ignition feed and ground circuits at the MAF
sensor harness connector.
Is the test light ON?

12

Is the voltage less than the specified value?

4.5V

13

av

14

Connect the test light between the MAF sensor ignition

feed circuit and chassis ground.
Is the test light ON?

1. Check for a poor connection at the MAF sensor.

2. If a poor connection is found, replace faulty
terminal(s). Refer to Wiring Repairs.
Was a problem found?

1. Check the MAF signal circuit for the following

conditions:
Open between the PCM and the MAF sensor.
Shorted to ground.
Poor connection at the PCM.
Shorted to the MAF sensor ground circuit.
If
a problem is found, repair as necessary. Refer to
2.
Wiring Repairs.
Was a problem found?

Locate and repair the open in the ground circuit to the

MAF sensor. Refer to Wiring Repairs
Is action complete?

Locate and repair the open in the ignition feed circuit to

the MAF sensor. Refer to Wiring Repairs.
Is action complete?

Locate and repair the short to voltage in the MAF signal

circuit. Refer to Wiring Repairs.
Is action complete?

Replace the MAF sensor. Go to MAF Sensor

Replacement.
Is action complete?

Replace the PCM.

Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Is action complete?

1. Turn ON the ignition switch.

2. Review and record scan tool Fail Records data.
3. Clear DTCs.
4. Operate vehicle within Fail Records conditions
as noted.
5. Using a scan tool, monitor Specific DTC info for
DTC P0101.
Does the scan tool indicate DTC P0101 failed this ignition?

16

17

18

19

20

21

22

Yes

No

Turn OFF the ignition switch.

Disconnect the PCM.
Turn ON the ignition switch.
Measure voltage between the MAF signal circuit and
ground.
Does the voltage measure near the specified value?

15

1.
2.
3.
4.

Value(s)

Go to Step 15

Go to Step 14

Go to Step 16

Go to Step 13

Go to Step 21

Go to Step 19

Go to Step 17

Go to Step 18

Go to Step 22

Go to Step20

Go to Step 22

Go to Step21

(
Go to Step 22
-

Go to Step 22
-

Go to Step 22
-

Go to Step22

Go to Step22

Go to Step 2

System OK

Engine

Engine Controls.- 3.8L 6-799

OTC P0102 Mass Air Flow (MAF) Ser1sor Circuit Low Frequency

!Hot
'" ,... ;

Bulb Test And Start

II) Run,

;;, -

.,.. -

.Distrib~tion
Cell 10

.J7

-.

l
-

ENG SEN
MiniFuse
20A

J6
L

..

- -

.,

Underhood
Electrical

1
-

Center 2

PNK 539

~NK 539

Fuse Block
Details
Cell11

PNK 539

Ignition

MAF
Sensor
Signal

Positive

Voltage,

Mass Airflow .
(MAF) Sensor

Ground

BLK/wHT 451
Ground
Distribution
Cell14

...- -

.,... .,... .,;...

BLK 451

',1,'

6t) C1

'" - - - -;,,,; .- ,- - - - - - ., Powertrain

I
I

Sensor
Signal

PCM
I
C1 = BLU
I
c2 = CLEAR I

Coritrol
Module

(PCM) ,A

~-----------.:..~

221655

Circuit Description
The Mass Air Flow (MAF) sensor measures the
amount of air which passes through it into the engiqe
during a given time. The PCM uses the mass air
flow information to monitor engine operating conditions
for fuel delivery calculations. A large quantity of air
entering the engine indicates an acceleration or high
load situation, while a small quantity of air indicates
deceleration or idle. The MAF sensor produces
a frequency signal which can be monitored using a
scan tool. The frequency will vary Within a range
of around 2000 Hertz at idle to about 10,000 Hertz at
maximum engine load. DTC P0102 will be set if
the signal frequency from the MAF .sensor is lower
than the possible range of a normally operating MAF
sensor.

,Conditions for Setting the DTC

No TP sensor, MAP sensor, EVAP system, or
EGR system DTCs are set.
The engine is running.
TP angle is less than 50%.

i
I

System voltage is greater than 8 volts.

MAF signal frequency is less than 1200 Hertz.
The above conditions present for longer
than 0.5 Seconds+ 400 3X reference periods (133
crankshaft revolutions).

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the first
trip in wbich the diagnostic test has been run
and failed.
The PCM will store condjtions which were present
when the DTC set as Freeze Frame and Fail
R_ecords data.

Conditions for Clearing the MIUDTC

The PCM wiliturn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear lnfofunction or by disconnecting the
PCM battery feed..

DiagnQstic Aids
A low minimum air rate,can. caus~ DTC P0102 to be
set during d.ecel.eration. Check the minimum air rate as
follows:
'
.
t. Run the engine until fully warm
(above 85C I 185F).
2. Disconnect the IAC.
3. Install a J 37027-A IAC System Monitor.
4. With the engine idling, command the LAC. valve .to.
the fully extended position (0 counts).

6800

Engine

Engine Controls- 3.BL

5. With the IAC fully extended, observe the Mass A:ir:

Flow reading on the scan tool.
6. Check for conditions that can cause a low
minimum air rate, including throttle bore and
throttle plate coking if the Mass Air Flow reading
is less than 2.27 g/sec.
7. If the minimum air rate is less than specification,
clean or replace the throttle body as necessary.
Go to Throttle Body Assembly Replacement.
Check for the following conditions:
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.
Misrouted harness - Inspect the MAF sensor
harness to ensure that it is not routed too close to
high voltage wires such as spark plug leads.
Damaged harness - Inspect the wiring harness for
damage.
If the harness appears to be OK, observe the
scan tool. while moving connectors and wiring'
harnesses related to the MAF sensor. A change in
the display will indicate the location of the fault.

Plugged intake air<luct or filter eJement -A

wide-open throttle acceleration from a stop should
cause the Mass Air Flow displayed on a scan
tool to increase from about 4-7 gm/sat idle to
ioo grn/s or greater at the time of the 1-2 shift. If
not, check for a restriction.
1.f .DTC P0102 cannot be duplicated, the information
included in the Fail Records data can be useful
in determining vehicle mileage since the DTC was last
set. This may assist in diagnosing the condition.

Test D~scription
Number(s) below refer to the Step number(s) on the
Diagnostic Table:
2. This step verifies that the problem is present
at idle.
5. A voltage reading of less than 4 or over 6 volts at
the MAF sensor signal circuit indicates a fault in
the wiring or a poor connection.
6. Verifies that ignition feed voltage and a good
ground'are available at the MAF sensor.
13. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

OTC P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency
Action

Step

Value(s)

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
-

1
''
.

;.,

Yes

1. Start the engine.

2. With the engine idling, monitor M:4.F Fr~quency

display on the scan tool.

1.2 kHz
(1200 Hz)

Is MAF Frequency less than the specified value?

,'

1. Turn ON the ignition switch.

2. Review and record scan tool Fail Records data.
3

3. Operate the vehicle within Fail Records conditions

as noted.

4. Using a scan tool, monitor Specific DTC info for

DTC P0102.

Go to Step 4

Does the .scan tool indicate DTC P0102 fail13d this ignition?

Go to.
Diagnostic Ai.ds

1. Check for the following conditions:

Objects blocking the MAF sensor inlet sc.reen
Vacuum leaks around the intake manifold
Vacuum leaks at throttle body
4

Vacuum leaks at the EGR valve flange ~nd pipes

Crankcase ventila\ion valve faulty, .missing, or

incorrectly installed

Low minimum air rate. Refer to Diagnostic Aids.

2. If a problem is found, repair as necessary.
Was a problem found?

Go to Step 14

Go to Step 5

Engine

Engine Controls - 3.SL 6-801

DTC P0102 Mass . Air Flow (MAF) Senso.r Circuit Low Frequency (cont'd)

Step

Action

1. Turn OFF the ignition switch.

2. Disconnect the MAF sensor connector.
3. Turn ON the ignition switch.

Value(s)

Go to Step 6

Go to Step 9

Go to Step B

Go to Step 7

Go to Step 10

Go to Step 11

Go to Step 14

Go to Step 12

Go to Step 14

Go to Step 13

Is the test light ON?

No

5V

4. Using a J 39200 DMM, measure voltage between the

MAF signal circuit and chassis ground.
Is the voltage near the specified value?
Connect a J 34142-8 Unpowered Test Light between the
MAF sensor ignition feed and ground circuits at the MAF
sensor harness connector.

Yes

Connect the test light between MAF sensor ignition feed

circuit and chassis ground.
Is the test light ON?

1. Check for a poor connection atthe MAF sensor.

2. If a poor connection is found, replace faulty
terminal(s). Refer to Wiring Repairs.
Was a problem found?

1. Check the MAF signal circuit between the PCM and

the MAF sensor for an open, short to ground, short to
the MAF ground circuit, or short to voltage.

2 .. If the MAF stgnal circuit is open or shorted, repair it

a,s necessary. Refer to Wiring Repairs.
Was a problem found?
Locate and repair the open in the ground circuit to the
MAF sensor. Refer to Wiring Repairs.
Is the action complete?

10

Locate and repair an open ignition feed fuse or an open in

the ignition feed circuit to the MAF sensor. Refer to Wiring
Repairs.

11

Is the action complete?

13

Is the action complete?

..

Go to Step 14

. Replace .the MAF sensor .. Refer to MAF Sensor

Replacement.

12

Go to Step 14

Go to Step 14

Replace the PCM .

Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.

Is the action complete?

Go to Step 14

.,

., 1. Turn ON the ignition switch

14

2. Review and record scan tool Fail Records data.

3. Cl.ear DTCs.
\
,,.
4 . .Operate the vehicle within. Fail Records conditions
as noted.

5. Using a scan tool, monitor Specific OTC info for

OTC P0102.
Does the scan tool indicate OTC P010,2 f.ailed this ignition?

Go to Step 2

System OK

6.:802

Engine.Controts. - 3.8L

Engine

DTC P0103 Mass Air F1ow (MAF) Sensor O.ircuit High Frequency
J L0 c

rsJ
A
N

L -

,- -

~ -

~ J

.-. -

PNK 539
PNK 539

Fuse Block

Details
Oell 11

PNK 539

MAF
Sensor

Ignition
Positive
Voltage

Signal

Mass Airflow
(MAF) Sensor

Ground

B
BLK!WHT 451
Ground

Distribution

.,._ -

69 Ct

,. .. - - iAF ""'7 .. -

Powertrain
Control
Module

- - .. - ,
I
PCM
C1 = BLU
I
C2=CLEAR I

1.

I.

Cell14

451

sensor .
Signal

(PCM)~

L------------.1

221655

Circuit Description

Action Taken When the

OTC Sets
.'
'

The Mass Air Flow (MAF) sensor measures the

amount of air which passes through it into the engine
during a given time. The PCM uses the mass air
flow information to monitor engine operating conditions
for fuel delivery calculations. A large quantity of air
entering the engine indicates an acceleration or high
load situation, while a small quantity of air indicates
deceleration or idle. The MAF sensor produces
a frequency signal which can be monitored using a
scan tool. The frequency will vary within a range
of around 2000 Hertz at idle to about 10,000 Hertz at
maximum engine load. DTC P0103 will be set if
the signal frequency from the MAF sensor is higher
than the possible :range of a normally operating
MAF sensor.

Conditions for Setting the OTC

.. No TP sensor, MAP. serisor, EVAP system, or
EGR system DTCs are set.
The engine is running.
TP angle is less than 50%.
System voltage is greater than 8 volts.
MAF signal frequency is greater
than 11,500 Hertz.
Above conditions present for longer
than 0.5 seconds+ 400 3X reference periods
(133 crankshaft revolutions).

The PCM will illuminate the M.IL during the first

trip in which the diagnostic test has been run
and failed.
The PCM -will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data ..

Conditions for Clearing the MILiDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTO can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed .

Engine

Engine Controls - 3.8L

6-803

Diagnostic Aids

Test Description

Check for the following conditions:

Poor connection at the PCM - Inspect harness
connectors for backed out terminals, improper
mating, broken locks, improperly formed or
damaged terminals, and poor terminal to wire
connection.
Misrouted harness - Inspect the MAF sensor
harness to ensure that it is not routed too close to
high voltage wires such as spark plug leads.
Damaged harness - Inspect the wiring harness for
damage.
If the harness appears to be OK, observe the
scan tool while moving connectors and wiring
harnesses related to the MAF sensor. A change in
the display will indicate the location of the fault.
If OTC P0103 cannot be duplicated, the information
included in the Fail Records data can be useful
in determining vehicle mileage since the OTC was
last set.

Number(s) below refer to the Step number(s) on the

Diagnostic Table:
2. This step verifies if the problem is present at idle.
4. A frequency reading with the MAF sensor
connector disconnected indicates an
Electromagnetic Interference (EMI) related fault or
a poor connection.
9. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

6-804

Engine Controls - 3.8L

Engine

DTC P0103 Mass Air Flow (MAF) Sensor Circuit High Frequency
Action

Step

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

1. Start engine.
2. With the engine idling, monitor MAF Frequency
display on the scan tool.
Is MAF Frequency greater than the specified value?

1. Review and record scan tool Fail Records data.

2. Operate the vehicle within Fail Records conditions
as noted.
3. Using a scan tool, monitor Specific DTC info for
DTC P0103.
Does the scan tool indicate DTC P0103 failed this ignition?

Value(s)

Yes

No

Go to Step 2

Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 7

Go to Step 10

Go to Step 6

Go to the A

11,500 Hz
(11.5kHz)

1. Turn OFF the ignition switch.

2. Disconnect the MAF sensor connector.
4

3. Start the engine.

4. Using a scan tool, monitor MAF Frequency.
Does scan tool indicate a MAF Frequency at the
specified value?
1. Check for a poor connection at the MAF sensor
harness terminals.
2. If a poor connection is found, replace faulty
terminal(s). Refer to Wiring Repairs.
Was a poor connection found?

O Hz

Replace the MAF sensor. Refer to MAF Sensor

Replacement.

Is the action complete?

10

Go to Step 10

1. Check MAF harness for incorrect routing.

Near secondary ignition wires or coils.
Near other high voltage components (solenoids,
relays, motors).
2. If incorrect routing is found, correct harness routing.
Was a problem found?

1. Check the MAF signal circuit terminal connections at

the PCM.
2. If a poor connection is found, replace faulty
terminal(s). Refer to Wiring Repairs.
Was a poor connection found?

Replace the PCM.

Important: Replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Is the action complete?

1. Turn ON the ignition switch, review and record scan

tool Fail Records data.
2. Clear DTCs.
3. Operate the vehicle within Fail Records conditions
as noted.
4. Using a scan tool, monitor Specific DTC info for
DTC P0103.
Does the scan tool indicate DTC P0103 failed this ignition?

Go to Step 10

Go to Step 8

Go to Step 10

Go to Step 9

Go to Step 10

Go to Step 2

System OK

Engine

Engine Controls - 3.SL 6-805

DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage

j~

Powertra1n r - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,

Jsv

Control :
Module (PCM)

,!, ~ _______
1

5 Volt
~ef:'..e':.:e

~_

PCM
MAP
C1 = BLU
Sensor
_ __ ~2 =~E~R _ _ _ ~g~I _

33 ' - - - - - - - - - - - - - - - - - - - - -

25 '

MAP
Sensor
_ _ ~o~nd_ _ _

L..2il

C2 13 ' C1

GRY 598
Fuel Tank
Pressure
Sensor

GRY

LT GRN 432

598
GRY 598
,,

GRY 598

I}==t>---11

8,-_

Manifold
Absolute
Pressure
(MAP) Sensor A
....,_______.....

TP sensor

I' - - - - - - - - ~

ORN/BLK 469

221661

Circuit Description
The Manifold Absolute Pressure (MAP) sensor
responds to changes in intake manifold pressure
(vacuum). The MAP sensor signal voltage to the PCM
varies from below 2 volts at idle (high vacuum) to
above 4 volts with the key ON, engine not running or
at wide-open throttle (low vacuum). The MAP
sensor is used to determine manifold pressure
changes while the EGR flow test diagnostic is being
run (refer to DTC P0401), to determine engine vacuum
level for some other diagnostics and to determine
barometric pressure (BARO). The PCM monitors the
MAP signals for voltages outside the normal range
of the MAP sensor. If the PCM detects a MAP signal
voltage that is excessively low, DTC P0107 will
be set.

Conditions for Setting the DTC

No TP sensor or ECT sensor DTCs present.

The engine is running.
System voltage is greater than 9 volts.
Throttle angle is greater than 0%, when engine
speed is less than 1000 RPM.
Throttle angle is greater than 10%, when engine
speed is greater than 1000 RPM.
The MAP sensor signal voltage is less
than 0.1 volt.
Above conditions present for longer than
200 3X reference periods (67 crankshaft
revolutions).

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM. Inspect harness
connectors for backed out terminals, improper
mating, broken locks, improperly formed or
damaged terminals, and poor terminal to wire
connection.
Damaged harness. Inspect the wiring harness for
damage. If the harness appears to be OK,
observe the MAP display on the scan tool while
moving connectors and wiring harnesses related to
the sensor. A change in the display will indicate
the location of the fault.
If DTC P0107 cannot be duplicated, the information
included in the Fail Records data can be useful
in determining since the DTC was last set. If it is
determined that the DTC occurs intermittently,
performing the DTC P1107 Diagnostic Chart may
isolate the cause of the fault.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
11. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

6-806

Engine Controls - 3.SL

Engine

DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage
Action

Step

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 10

Go to Step5

Go to Step 6

Go to StepB

Go to Step 12

Go to Step 7

Go to Step 12

Go to Step 11

Go to Step 12

Go to Step 9

Go to Step 12

Go to Step 11

1. Turn ON the ignition switch.

2

2. Observe the MAP value displayed on the scan tool.

av

Is MAP value near the specified value?

1. Turn ON the ignition switch.

2. Review and record scan tool Fail Records data.

3. Operate vehicle within Fail Records conditions
as noted.
4. Using a scan tool, monitor Specific OTC info for
OTC P0107.

Does scan tool indicate OTC P0107 failed?

1. Disconnect the MAP sensor electrical connector.
4

2. Jumper the 5 volt reference A circuit and the MAP

signal together at the MAP sensor harness connector.

4.6V

3. Observe the MAP value displayed on the scan tool.

Is MAP value greater than the specified value?

1. Connect a J 34142-8 Unpowered Test Light between

B+ and the MAP sensor signal circuit at the MAP
sensor harness connector.

4.6V

2. Observe the MAP value displayed on the scan tool.

Is MAP value greater than the specified value?
1. Turn OFF the ignition switch.
2. Disconnect the PCM and check the 5 volt reference A
circuit for an open or short to ground.
6

3. If the 5 volt reference A circuit is open or shorted to

ground, repair it as necessary. Refer to Wiring
Repairs.

Was a problem found?

Check the 5 volt reference A circuit for a poor connection

at the PCM and replace terminal if necessary. Refer to
Wiring Repairs.

Was a problem found?

1. Turn OFF the ignition switch.
2. Disconnect the PCM.

3. Check the MAP signal circuit tor an open, short to

ground, or short to the sensor ground circuit.
4. If the MAP sensor signal circuit is open or shorted to
ground, repair it as necessary. Refer to Wiring
Repairs.

Was a problem found?

Check the MAP sensor signal circuit for a poor connection

at the PCM and replace terminal if necessary. Refer to
Wiring Repairs.

Was a problem found

10

Replace the MAP sensor. Refer to MAP Sensor

Replacement
Is action complete?

Go to Step 12

Engine

Engine Controls - 3.8L

6-807

DTC P0107 .Manifold Absolute Pressl1re (MAP) Sensor Circuit Low Voltage (cont'd)
Action

Step

11

Replace the PCM.

Important: The replacementPCM must be programmed.
Refer to PCM Replacement/Programming.

Value(s)

Yes

Is action complete?

No

Go to Step 12

1. Turn ON the ignition switch.

12

2. Review and record scan tool Fail Records data.

3. Clear DTCs.
4. Operate vehicle within Fail Records conditions
as noted.
5. Using a scan tool, monitor Specific DTC info for
OTC P0107.
Does the scan tool indicate OTC P0107 failed?

Go to Step 4

System OK

6-808

Engine Controls - 3.8L

Engine

DTC P0108 Manifold Absolute Pressure (MAP) Sensor Circuit High Voltage
Powertrain

r -

Control :
Module (PCM)

~~ ~

Jsv
5 Volt
-

~ef~e~e~ -

PCM
C1 = BLU

MAP
Sensor

lc2=CLEAR

j~

.
I

- ~g~I-

33 ' - - - - - - - - - - - - - - - - - - - - -

25 "

MAP
Sensor
-

~0.'.:_nd_ .- -

C2 13

C1

L'..tiJ

GRY 598
Fuel Tank
Pressure
Sensor

GRY

LT GRN 432

598
GRY 598

'

GAY 598

I}=t>---11

C,

B,...

Manifold
Absolute

Pressure
(MAP) Sensor A'-...___ _ _ __.
11
ORN/BLK ...__
469

TP Sensor

I ________.
221661

Circuit Description
The Manifold Absolute Pressure (MAP) sensor
responds to changes in intake manifold pressure
(vacuum). The MAP sensor signal voltage to the PCM
varies from below 2 volts at idle (high vacuum) to
above 4 volts with the key ON, engine not running or
at wide-open throttle (low vacuum). The MAP
sensor is used to determine manifold pressure
changes while the linear EGR flow test diagnostic is
being run (refer to OTC P0401), to determine
engine vacuum level for some other diagnostics and
to determine barometric pressure (BARO). The
PCM monitors the MAP signals for voltages outside
the normal range of the MAP sensor. If the PCM
detects a MAP signal voltage that is excessively high,
OTC P0108 will be set.

Conditions for Setting the DTC

No TP sensor, or ECT sensor DTCs present.
Engine has been running for a length of time that
is determined by startup coolant temperature.
The length of time ranges from 2 minutes at less
than -30C (-22F) to 0.5 second at more
than 30C (86F).
Throttle position is less than 2% when engine
speed is less than 900 RPM.
The MAP sensor signal voltage is greater
than 4.2 volts.
The above conditions are present for longer
than 200 3X reference periods (67 crankshaft
revolutions).

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIL/DTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM - Inspect harness
connectors for backed out terminals, improper
mating, broken locks, improperly formed or
damaged terminals, and poor terminal to wire
connection.
Damaged harness - Inspect the wiring harness for
damage. If the harness appears to be OK,
observe the MAP display on the scan tool while
moving connectors and wiring harnesses related to
the sensor. A change in the display will indicate
the location of the fault.
If OTC P0108 cannot be duplicated, the information
included in the Fail Records data can be useful
in determining vehicle mileage since the OTC was last
set. If it is determined that the OTC occurs
intermittently, performing the OTC P1108 Diagnostic
Chart may isolate the cause of the fault.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
11 . This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

Engine

6-809

Engine Controls - 3.8L

DTC P0108 M~nifold Absolute Pressure:{J\IIAP) Sensor Cir.cuit High Voltage,

Step

Value(s) .

Action\

No ~
... . ,...

Yes

Goto the A
Powertiain On
Board Diagnostic
(080) System
Cher:;k,.

Was the Powertrain On-Boan:l Diagnostic (OBD) System

Check performed?

Go to Step2

'

1. If th(;) engine idle is rough, unstable or incorrec;t,.

repair the idle problem before continuing with this
table. Refer to Ro.ugh, Unstable, or Incorrect Idle and
Stalling:
2. With the engine idling, note the MAP value on the .
scari tool.
Is the MAP voltage greater than the specified value?

,.

. 3.5V
'

Go to Step 4

Go fo Step 3
.. ,

i.

Turn ON the ignition switch.

2. Review and record scan tool Fail Records data.
3. Operate the vehicle within Fail Records conditions
as noted.
.'
.
..

'

..

4. Using a scan tool, monitor Specific DTC irifo for

OTO P0108 . .

'

,..

<, '"

Gb to Step 4

Does sea\, tool indicate OTC P0108 failed?

10

)
11

1. Disconnect the MAP sensor electrical connector.

2. Note the MAP sensor voltage displayed on the
scan tool.
Is the MAP sensor voltage at the specified valu~?

ov

Probe the sensor ground circuit with a J 34142-8

Unpowered Test Light to B+.
Is the test light ON?

1. Check for poor sensor ground terminal connection at

the MAP sensor electrical connector.
2. If a problem is found, replace faulty terminal.
Was a problem found?

Check for a plugged or leaking vacuum supply to the MAP

sensor.
Is the vacuum supply OK?
Was a problem found?

1. Check continuity of the MAP sensor ground circuit.

2. If the MAP sensor ground circuit measures over
5 ohms, repair open or poor connection. Refer to
Wiring Repairs.
Was a problem found?

Is action complete?

. Go to Step 6

'
,'

Go to step 7

...Go to Step 9

Go to Step 16

Go to Step 11

Go to Step 16

Go to Step 8

Go to Step 15

Go to Step 12

Go to Step 16

Go to Step 10

Go to Step 16

Go to Step 11

1. Check for a poor sensor ground terminal connection

at the PCM.
2. If a problem is found, replace the faulty terminal.
Was a problem found?

Replace the PCM.

Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.

.
Go to Step 5 . .,

1. Check the MAP signal circuit for a short to voltage or

a short to the 5 volt reference A circuit.
2. If the MAP sensor signal circuit is shorted, repair
circuit as necessary. Refer to Wiring Repairs.
Was the MAP sensor signal circuit shorted?

Gb to
Diagnostic Aids

Go to Step 16

..

6-81 o Engine Controls - 3.8L

Engine

OTC P0108 Manifold Absolute Pressure (MAP) Sensor Circuit High Voltage (cont'd)
Step

Action
1.
2.
3.
4.

Turn OFF the ignition switch.

Disconnect the PCM.
Turn. ON the ignition switch.
Check for a short to voltage on the 5 volt reference A
circuit.
5. If the 5 volt reference A circuit is shorted, repair it as
necessary. Refer to Wiring Repairs.

12

Value(s)

14

Check for poor electrical connections at the MAP sensor

and replace terminals if necessary. Refer to Wiring
Repairs.
Was a problem found?

Replace the MAP sensor. Refer to MAP Sensor

Replacement.
Is action complete?

Repair the faulty vacuum source.

15

Is action complete?
1.
2.
3.
4.

16
.

Turn ON the ignition switch.

Review and record scan tool Fail Records data.
Clear DTCs
Operate vehicle within Fail Records conditions
as noted.

No

Was a problem found?

13

Yes

. ..

Go to Step 16

Go to Step 13

Go to Step 16

Go to Step 14

Go to Step 16

Go to Step 16

5.. Using a scan tool, monitor Specific OTC info for

OTC P0108.
Does scan tool indicate OTC P0108 failed?

Go to Step 4

System OK

Engine

Engine Controls - 3.8L

6-811

DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage

: J :

'" - - - - ~v- - - ., Powertrain

I
I

Control
I Module (PCM)

.IAT
Sensor

s,~a~ ____

__

.1

Ji

LJiJ

50IC2

TA~ 472

rn

Intake Air
Temperature
(IAT) Sensor

pptl 719
11

l C1

'" - - - - - iAT- - - - - - - - ., Powertrain

I

Sensor

Gmund

1c1C2=CLEARI
= BLU I I Module (PCM)
I

PCM

I I

Control

L---------------J

"'

221729

Circuit Description
The Intake Air Temperature (IAT) sensor is a
thermistor which measures the temperature of the air
entering the engine. The PCM applies 5 volts
through a pull-up resistor to the IAT sensor. When the
intake air is cold, the sensor resistance is high and
the PCM will monitor a high signal voltage on the IAT
signal circuit. If the intake air is warm, the sensor
resistance is lower causing the PCM to monitor a lower
voltage. DTC P0112 will set when the PCM detects
an excessively low signal voltage on the intake
air temperature sensor signal circuit.

Conditions for Setting the DTC

No ECT sensor, MAF sensor, or VSS DTCs
present
The engine has been running for over 1O seconds.
Vehicle speed is greater than 40 km/h (25 mph).
IAT signal voltage indicates an intake air
temperature greater than 135C (275F).
The above conditions are present for at least
20 seconds.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIL/DTC

The PCM will turn the Mll OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.
Damaged harness.
Inspect the wiring harness for damage. If the
harness appears to be OK, observe the IAT
display on the scan tool while moving connectors
and wiring harnesses related to the IAT sensor.
A change in the IAT display will indicate the
location of the malfunction.
Skewed or mis-scaled IAT Sensor.
Refer to Temperature vs Resistance table.
If DTC P0112 cannot be duplicated, the information
included in the Fail Records data can be useful
in determining vehicle mileage since the DTC was
last set.

6-812

Engine

Engine Controls - 3.SL

a shifted sensor that may be shorted above or

below a certain temperature. If this is the
case, replace the IAT sensor.

Test Description
Number(s) below refer to the Step number(s) on the
Diagnostic Table:

If the IAT sensor appears to be OK, the fault is

intermittent; refer to Diagnostic Aids.

2. Verifies that the fault is present

3. If DTC P0112 can be repeated only by duplicating
the Fail Records conditions, refer to the
Temperature Vs. Resistance Values Table. The
table may be used to test the IAT sensor at
various temperatures to evaluate the possibility of

(
'

8. This vehicle is equipped with a PCM which utilizes

an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage
Action

Step

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

1. Turn ON the ignition switch.

2. Observe the Intake Air Temp display on the scan tool.
Is Intake Air Temp. greater than specified value?

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

130C (266F)

1. Turn ON the ignition switch.

2. Review and record scan tool Fail Records data.
3

3. Operate the vehicle within Fail Records conditions

as noted.

4. Using a scan tool, monitor Specific DTC info for

OTC P0112.
Does the scan tool indicate DTC P0112 failed this ign?
4

1. Disconnect the IAT Sensor electrical connector.

2. Observe Intake Air Temperature on scan tool.
Is Intake Air Temperature less than the specified value?
1. Turn OFF the ignition switch
2. Disconnect the PCM electrical connectors.

3. Check the IAT sensor signal circuit for a short to

ground.

Go to Step 6

Go to Step 5

Go to Step 7

Go to Step B

Is the IAT sensor signal circuit shorted to ground?

6

-38C (-36F)

Replace the IAT Sensor. Refer to /AT Sensor

Replacement.
Is action complete?

Repair the IAT sensor signal circuit. Refer to Wiring

Repairs.
Is action complete?

Go to Step 9

Go to Step 9

Replace the PCM.

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.

Go to Step 9

Is action complete?
1. Turn ON the ignition switch.

2. Review and record scan tool Fail Records data.

3. Clear DTCs.
4. Operate the vehicle within Fail Records conditions
as noted.

5. Using a scan tool, monitor Specific DTC info for

OTC P0112.
Does the scan tool indicate OTC P0112 failed this ign?

Go to Step 2

System OK

Engine

Engine Controls - 3.SL

6-813

DTC P0113 Intake Air Temperature (IAT) Sensor Circuit High Voltage

: J :>

'" - - - - ~v- - - ., Powertrain

Control

I Module (PCM)

IAT

s,!a~ ____

S~nsor

L __

..1

50IC2

TA~ 472

rn

Intake Air
Temperature
(IAT) Sensor

pptl 719

171 C1

'" - - - - - iAT- - - - - - - - ., Powertrain

I

Sensor
Ground

PCM

IC1=BLU

I I Control

I I Module (PCM)

C2=CLEARI

>

L---------------J
221729

Circuit Description
The Intake Air Temperature (IAT) sensor is a
thermistor which measures the temperature of the air
entering the engine. The PCM applies 5 volts
through a pull-up resistor to the IAT sensor. When the
intake air is cold, the sensor resistance is high and
the PCM will monitor a high signal voltage on the IAT
signal circuit. If the intake air is warm, the sensor
resistance is lower causing the PCM to monitor a lower
voltage. OTC P0113 will set when the PCM detects
an excessively high signal voltage on the intake
air temperature sensor signal circuit.

Conditions for Setting the DTC

No ECT sensor, MAF sensor, or VSS OTC
present.
The engine has been running for over 3 minutes.
Vehicle speed is less than 56 km/h (35 mph).
Mass Air Flow is less than 12 gm/s.
Engine Coolant Temperature is greater than
60C (140F).
IAT signal voltage indicates an intake air
temperature less than -34C (-29F).
The above conditions are present for at least
20 seconds.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.
Damaged harness.
Inspect the wiring harness for damage. If the
harness appears to be OK, observe the IAT
display on the scan tool while moving connectors
and wiring harnesses related to the IAT sensor.
A change in the IAT display will indicate the
location of the malfunction.
Skewed or mis-scaled IAT Sensor.
Refer to Temperature vs Resistance table.
If OTC P0113 cannot be duplicated, the information
included in the Fail Records data can be useful
in determining vehicle mileage since the OTC was
last set.

6-814

Engine Controls - 3.SL

Engine

Test Description

a shifted s~nsor that may be open above or below

a certain temperature. If this is the case, replace
the IAT sensor. If the IAT sensor appears to
be OK, the fault is intermittent; refer to
Diagnostic Aids.

Number(s) below refer to the Step number(s) on the

Diagnostic Chart:
2. Verifies that the fault is present
3. If OTC P0113 can be repeated only by duplicating
the Fail Records conditions, refer to the
Temperature Vs. Resistance Values Table. The
table may be used to test the IAT sensor at
various temperatures to evaluate the possibility of

11. This vehicle is equipped with a PCM which utilizes

an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

DTC P0113 Intake Air Temperature (IAT) Sensor Circuit High Voltage
Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 6

Go to Steps

Go to Step 7

Go to Step 8

Go to Step 12

Go to Step 10

Go to Step 12

Go to Step 9

Go to Step 12

Go to Step 9

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1. Turn ON the ignition switch.

2. Observe the Intake Air Temp display on the
scan tool.
Is Intake Air Temp less than the specified value?
1. Turn ON the ignition switch.
2. Review and record scan tool Fail Records data
parameters.
3. Operate the vehicle.within Fail Records conditions
as noted.
4. Usjng a scan tool, monitor Specific DTC info for
DTC P0113.
.

-31 C (-24 F)

Does the scan tool indicate DTC P0113 failed?

1. Disconnect the IAT sensor electrical connector.

2. Jumper the IAT signal circuit and the sensor ground
circuit together at the IAT sensor harness connector.
3. Observe the Intake Air Temp display on the
scan tool.
Is Intake Air Temp near the specified value?

138C (280F)

1. Jumper the IAT signal circuit at the IAT sensor

harness connector to chassis ground.
2. Observe the Intake Air Temp display on the
scan tool.
Is Intake Air Temp near or above the specified value?

140C (284F)

1. Check for a short to voltage or poor connections at

the IAT sensor.
2. If a problem is found, repair as necessary.
Was a problem found?

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Check the IAT sensor ground circuit for an open.
4. If the IAT sensor ground circuit is open, repair as
necessary. Refer to Wiring Repairs.
Was the IAT sensor ground circuit open?

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Check the IAT signal circuit for an open.
4. If the IAT sensor signal circuit is open, repair it as
necessary. Refer to Wiring Repairs.
Was the IAT signal circuit open?

Engine Controls. - 3.BL

Engine

6-i&15

DTC P0113 Intake Air Temperature (IAT) Sensor Circuit High Voltage (cont'd)
Step

Action

Value(s)

Check for a poor sensor ground or IAT signal circuit

terminal connection at the PCM and replace terminal(s) if
necessary. Refer to Wiring Repairs.
Did any of the terminals need to be replaced?

10
.,:

Replace the IAT sensor. Refer to /AT Sensor Replacement

Is action complete?

11

Replace the PCM.

Important: Replacement PCM must be programmed. PCM
Replacement/Programming
Is action complete?

Yes

No

Go to Step 12

Go to Step 11

Go to Step 12

Go to Step 12

1. Turn ON the ignition switch.

2. Review and record scan tool Fail Records data.

12

3. Clear DTCs.
4. Operate the vehicle within Fail Records' conditions
as noted.
5. Using a scan tool, monitor Specific OTC info for
OTC P0113.
Does the scan tool indicate OTC P0113 failed?

Go to Step 2

System OK

f>.:81'6

Engine'Controls.; 3.SL

Engine

DTC f0111 Engine COE>lant Temperature {ECTf Sensor Cit;:Llit Low Voltage

: J

'" - - - - ~v- - - - - - - - - - - - ' , - - -.- - - , Pb\lllartrain

I
..
I

ECT
' S~nscir
S,gnat

L -

PCM
BLU
C2 = CLEAR

c1

ECT
Sensdl'

?BIC2
-

Giouna "

I
I

co.ntrol
Module (PCM)

>,

b.'-

LJ!1

-------~-~----~-~~--~~

12

YEL 410

C1

f-,

B
Engine'"
Coolant 1

. Temperatur~ ~.
(ECT) Sensor A-::;

1 C

~~K
GRN 135

A17
.- -

BAN 718

1
L

'"! Instrument ,A
1Cluster
~
.J

221815

Circuit Description
The Engine Coolant Temperature (ECT) sensor is a
thermistor mounted in the engine coolant stream. The
PCM applies a voltage (about 5.0 volts) through a
pull up resistor to the ECT signal circuit. When
the engine coolant is cold, the sensor (thermistor)
resistance is high, therefore the PCM will measure a
high signal voltage. As the engine coolant warms,
the sensor resistance becomes less, and the
ECT signal voltage measured at the PCM drops. With
a fully warmed up engine, the ECT signal voltage
should measure about 1.5 to 2.0 volts. OTC P0117 will
set when the PCM detects an excessively low signal
voltage on the engine coolant temperature sensor
signal circuit.

Conditions for Setting the DTC

Engine run time longer than 15 seconds
The ECT sensor signal indicates an engine
coolant temperature greater than 114C (237F).
The above conditions are present for up to
25 seconds

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.
Damaged harness.
Inspect the wiring harness for damage. If the
harness appears to be OK, observe the
ECT display on the scan tool while moving
connectors and wiring harnesses related to the
ECT sensor. A change in the ECT display
will indicate the location of the malfunction.
Skewed or mis-scaled ECT Sensor.
Refer to Temperature vs Resistance table.
If OTC P0117 cannot be duplicated, the information
included in the Fail Records data can be useful
in determining vehicle mileage since the OTC was last
set. If it is determined that the OTC occurs
intermittently, performing the DTC P1114 Diagnostic
Chart may isolate the cause of the malfunction.

Engine

Engine Controls - 3.8L

Test Description

may be shorted above or below a certain

temperature. If this is the case, replace the ECT
sensor. If the ECT sensor appears to be OK,
the fault is intermittent; refer to Diagnostic Aids.

Number(s) below refer to the Step number(s) on the

Diagnostic Chart.
2. Verifies that the fault is present
3. If DTC P0117 can be repeated only by duplicating
the Fail Records conditions, refer to Temperature
vs Resistance. The table may be used to test
the ECT sensor at various temperatures to
evaluate the possibility of a shifted sensor that

6-817

7. This vehicle is equipped with a PCM which utilizes

an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage
Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic .Aids

Go to Step 6

Go to Step 5

Go to Step B

Go to Step 7

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

1. Turn ON the ignition switch.

2. Observe the Eng. Cool. Temp. display on the
scan tool.
Is Eng. Cool. Temp. display near or greater than the
specified value?

139C (282F)

1. Turn ON the ignition switch.

2. Review and record scan tool Fail Records data.

3. Operate vehicle within Fail Records conditions

as noted.
4. Using a scan tool, monitor Specific DTC info for
DTC P0117.
Does scan tool indicate DTC P0117 failed this ignition?

1. Disconnect the ECT sensor e)ectric.al connector.

2. Observe the Eng. Cool. Temp.display on the
scan tool.
Is Eng. Cool. Temp. near or less than lhe specified value?

-39C (-38F)

1. Turn OFF the ignition switch.

.B
\
.I

2. Disconnect the PCM.

3. Check the ECT signal circuit for a short to ground or
a short to the sensor ground circuit.
4. If the ECT signal circuit is shorted, repair it as
necessary. Refer to Wiring Repairs.
Was the ECT signal circuitshorted to ground?

Replace the ECT sensor.Refer to ECT Sensor

Replacement
Is the action complete?

Replace the PCM.

Important: .The replacement PCM m.ust be programmed.
Refer to PCM Replacement/Programming.
Is the action complete?

1. Review and record scan tool Fail Records data.

2. Clear DTCs
3. Operate vehicle within Fail Records conditions
as noted ..
4. Using a scan tool,. monitor Specific OTC info for
DTC P0117.
Does the scan tool indicate OTC P0117 failed this ignition?

Go to Step B

Go to Step B

Go to Step 2

System OK

6-818

Engine Controls - 3.8L

Engine

DTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit High Voltage
r -

I
I

ECT

Sensor
_

J
-

- -

- - - -

sv

~g~I -

lc

- - - -

26IC2

1=BLU

_ .... -

- - - - -

__ -

- -

- , Powertrain

I Control

PCM

C2 =CLEAR

_ -

ECT
Sensor
-

_ -

- ~o~d- ..,.,

12 'C1

Mod,ule (PCM)

JI;,

U:tl

YEL 410

t-,

B
Engine,.
Coolant 1

1 C

Temperature I
I~DK
(ECT) Sensor LA-::; J
GAN 135
A17
,. -

BRN 718

1
L

, Instrument J;,
1Cluster
~
.J

221815

Circuit Description
The Engine Coolant Temperature (ECT) sensor is a
thermistor mounted in the engine coolant stream. The
PCM applies a voltage (about 5.0 volts) through a
pull up resistor to the ECT signal circuit. When
the engine coolant is cold, the sensor (thermistor)
resistance is high, therefore the PCM will measure a
high signal voltage. As the engine coolant warms,
the sensor resistance becomes less, and the
ECT signal voltage measured at the PCM drops. With
a fully warmed up engine, the ECT signal voltage
should measure about 1.5 to 2.0 volts. DTC P0118 will
set when the PCM detects an excessively high
signal voltage on. the engine coolant temperature
sensor signal circuit.

Conditions for Setting the DTC

Engine run time longer than 15 seconds
The ECT sensor signal indicates an engine
coolant temperature less than -34C (-29F).
The above condition is present for up to
25 seconds.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

. The PCM will .turn the MIL OFF during the third
consecutive trip in .which the diagnostic has

been run and passed.

The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
111alfunction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.
Damaged harness.
Inspect the wiring harness for damage. If the
harness appears to be OK, observe the
ECT display on the scan too.I .while moving
connectors and wiring harnesses related to the
ECT sensor. A change in the ECT display
will indicate .the location of the malfunction.
Skewed or mis-scaled ECT Sensor.
Refer to Temperature vs Resistance table.
If DTC P0118 cannot be duplicated, the information
included in the Fail Records data can be useful
in determining vehicle mileage since the DTC was last.
set. If it is determined that the DTC occurs
intermittently, performing the DTC P1115 Diagnostic
Chart may isolate the cause of the malfunction.

Engine Controls - 3.8L

Engine

may be shorted above or below a certain

temperature. If this is the case, replace the ECT
sensor. If the ECT sensor appears to be OK,
the fault is intermittent; refer to Diagnostic Aids.

Test Description
The number(s) below refer to the Step number(s) on
the Diagnostic Chart:
2. Verifies that the fault is present.
3. If DTC P0118 can be repeated only by duplicating
the Fail Records conditions, refer to Temperature
vs Resistance. The table may be used to test
the ECT sensor at various temperatures to
evaluate the possibility of a shifted sensor that

6-819

12. This vehicle is equipped with a PCM which utilizes

an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

DTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit High Voltage
Action

Step

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 13

Go to Step 5

Go to Step 7

Go to Step 6

Go to Step 8

Go to Step 9

Go to Step 13

Go to Step 11

Go to Step 13

Go to Step 10

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Turn ON the ignition switch, observe the Eng. Cool. Temp.

display on the scan tool Eng 1 data list.
Is Eng. Cool. Temp. display less than the specified value?

-38C (-36F)

1. Turn ON the ignition switch.

2. Review and record scan tool Fail Records data.
3. Operate the vehicle within Fail Records conditions
as noted.
4. Using a scan tool, monitor Specific OTC info for
OTC P0118.
Does the scan tool indicate OTC P0118 failed?

1. Turn OFF the ignition switch.

2. Disconnect the PCM and the ECT harness
connectors
3. Turn ON the ignition switch.
4. Check the ECT sensor signal circuit for a short to
voltage. If a problem is found, repair as necessary.
Refer to Wiring Repairs.
Was a problem found?

1. Turn OFF the ignition switch.

2. Reconnect the PCM.

3. Jumper the ECT signal circuit and the sensor ground
circuit together at the ECT sensor harness connector
4. Observe ECT displayed on the scan tool.
Is ECT at the specified value?
1. Jumper the ECT signal circuit at the ECT sensor
harness connector to chassis ground.
2. Observe the Eng. Cool. Temp. display on the
scan tool.
Is Eng. Cool. Temp. at the specified value?
Check for poor connections at the ECT sensor and replace
terminals if necessary. Refer to Wiring Repairs.
Did any terminals require replacement?
1.
2.
3.
4.

Turn OFF the ignition switch.

Disconnect the PCM.
Check the ECT sensor ground circuit for an open.
If the ECT sensor ground circuit is open, repair it as
necessary. Refer to Wiring Repairs.
Was the ECT sensor ground circuit open?

140C (284F)

140C (284F)

6-820

Engine Controls - 3.SL

Engine

DTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit High Voltage (cont'd)
Step

Action

Value(s)

Yes

No

Go to Step 13

.Go to Step 1O

Go to Step 13

Go to Step 12

1. Turn OFF the ignition switch.

2. Disconnect the PCM.

9

3. Check the ECT signal circuit for an open.

4. If the ECT sensor signal circuit is open, repair it as

necessary. Refer to Wiring Repairs.
Was the ECT signal circuit open?

10

Check for a poor sensor ground or ECT signal circuit

terminal connection at the PCM and replace terminal(s) if
necessary. Refer to Wiring Repairs.

Did any of the terminals need to be replaced?

11

Replace the ECT sensor. Refer to ECT Sensor

Replacement

12

Replace the PCM.

Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming
Is the action complete?

Go to Step 13

Is the action complete?

Go to Step 13

1. Review and record scan tool Fail Records data.

2. Clear DTCs
13

3. Operate the vehicle within Fail Records conditions

as noted.

4. Using a scan tool, monitor Specific OTC info for

OTC P0118.
Does the scan tool indicate OTC P0118 failed?

Go to Step 2

System OK

Engine

Engine Controls - 3.SL

6-821

DTC P0121 Throttle Position (TP) Sensor Performance

~ -

1
I

1
-

v- - - - -

1 Control

I Module

SVolt
Reference A

Powertrain

>

. - - - - - - 33' -C2 - - - - ..

Fuel Tank
PressureSensor

GAY

GAY 598

r :

MAP Sensor

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I

LJiJ

GAY

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598
GAY 598
598

DK BL'rJI 417
661 C2

(PCM)

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BL~r452
61 C1

w- , - - - - TI' -

- - - - - - - ., Powertrain

Sensor

Sensor

Signal

Ground

PCM

I Control

1g~:,~i~ARI :Module (PCM)>

L-------:-------------J

~
221819

Circuit Description
The Throttle Position (TP) sensor circuit provides a
voltage signal that changes relative to throttle
blade angle. The signal voltage will vary from less
than 1 volt at closed throttle to about 4 volts at Wide
Open Throttle (WOT). The TP signal is one of the most
important inputs used by the PCM for fuel control
and most of the PCM-controlled outputs. The PCM
monitors throttle position and compares actual throttle
position from the TP sensor to a predicted TP value
calculated from engine speed, If the PCM detects
an out of range condition, DTC P0121 will be set.

Conditions for Setting the OTC

No TP sensor, or MAP sensor DTCs set.

Idle air control is between O and 130 counts.
The engine is running.
MAP is less than 50 kPa to check tor a fixed high
TP sensor.
MAP is greater than 70 kPa to check for a fixed
low TP sensor.
Throttle angle is steady.
Predicted throttle angle is not close to actual
throttle angle.
The above conditions are present tor at least
10 seconds.

Action Taken When the OTC Sets

The PCM will illuminate the MIL during the first

trip in which the diagnostic test has been run
and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIL/OTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery teed.

Diagnostic Aids
The PCM will not complete the DTC P0121 diagnostic
test until both the stuck high and the stuck low
portions of the diagnostic have been completed . .When
verifying a repair or otherwise attempting to monitor
the DTC P0121 diagnostic, refer to Conditions for
Setting the DTC tor the MAP signal levels required to
complete both parts of the. diagnostic.
Check tor the following conditions:
Vacuum hoses disconnected or vacuum leaks.
Visually and physically check the tor the
following conditions:
- Disconnected vacuum hoses.
- Damaged vacuum hoses.
- Incorrect vacuum hoses routing.
- Damaged MAP sensor seal.
- Damaged fuel injector a-rings.
- Damaged gasket at the throttle body, intake
manifold, PCV valve cover, EGR pipes, or
EGR valve mounting surface.

6-822

Engine Controls - 3.SL

Incorrectly installed or malfunctioning PCV valve;

Damaged or sticking throttle plate or IAC valve
A throttle plate or IAC valve that allows too
much airflow while the throttle should be closed
may cause a high idle and DTC P0121 to be
set. Refer to Idle Air Control System Check for
diagnosis.
Incorrect 3X reference signal.
An incorrect 3X reference signal can cause the
MAP signal to stop updating. This condition
can cause the predicted TP sensor value to be
calculated incorrectly and DTC P0121 to be set. A
problem with the 3X reference signal should
cause DTC P1374 to be set. If DTC P1374 is set
with DTC P0121, diagnose DTC P1374 first.
Skewed MAP signal or malfunctioning MAP
sensor.
An incorrect MAP signal may cause the PCM to
incorrectly calculate the predicted TP sensor
value. Check for an unusually low MAP reading
during high engine load situations or a high
MAP reading at idle. Either condition can cause
DTC P0121 to be set.
Stuck open EGR valve.
An EGR valve that is stuck partially open may
cause the TP sensor low test to fail and
DTC P0121 to be set. A sticking EGR valve
should cause DTC P1406 to be set. If DTC P1406
is set with DTC P0121, diagnose DTC P1406 first.

Engine
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.
Damaged harness. Inspect the wiring harness for
damage. If the harness appears to be OK,
observe the TP sensor display on the scan tool
while moving connectors and wiring harnesses
related to the sensor. A change in the display will
indicate the location of the malfunction.
If DTC P0121 cannot be duplicated, the information
included in the Fail Records data can be useful
in determining vehicle mileage since the DTC was last
set. If it is determined that the DTC occurs
intermittently, performing the DTC P1122 and
DTC P1121 Diagnostic Charts may isolate the cause
of the malfunction.

Test Description
Number(s) below refer to the Step number(s) on the
Diagnostic Table:
2. An incorrect MAP signal may cause the PCM to
incorrectly calculate the predicted TP sensor
value during high engine load situations. Check
for an unusually low MAP reading. This condition
can cause DTC P0121 to be set.
12. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

DTC P0121 Throttle Position (TP) Sensor Performance

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Step 6

Go to Step 5

Go to Step4

Go to Step 13

Go to Step 12

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Important: If DTC P1635 is set, diagnose the other DTC

first. Refer to OTC P1635 5 Volt Reference Circuit.
1. Turn ON the ignition switch.
2. Observe the MAP reading on scan tool Eng. 1
data list.
Is the MAP reading less than the specified value?

65 kPa

1. Disconnect the MAP sensor.

2. Connect a J 34142-B Unpowered Test Light between
the 5 volt reference A circuit and the MAP signal
circuit at the MAP sensor harness connector.
3. Observe MAP reading on the scan tool.
Is MAPreading less than the specified value?

65 kPa

1. Check the MAP signal circuit between the PCM and

the MAP sensor for an open, short to ground, or short
to the MAP ground circuit.
2. If the MAP signal circuit is open or shorted, repair it
as necessary. Refer to Wiring Repairs.
Was the MAP signal circuit open or shorted?

Engine

Engine Controls - 3.8L

6-823

OTC P0121 Throttle Position (TP) Sensor Performance (cont'd)

Step

Action

Value(s)

Yes

No

Replace the MAP sensor. Refer to MAP Sensor

5

Replacement.

Go to Step 13

Is action complete?
Observe the TP Angle reading on the scan tool while
slowly opening the throttle.

Does TP Angle increase steadily and evenly from the.

closed throttle value to the wide open throttle value?
Closed throttle value is the first specified value.
Wide open throttle value is the second specified value.

0%
100%
Go to
Diagnostic Aids

Go to Step 7

Go to Step B

Go to Step 9

Go to Step 11

Go to Step 10

Go to Step 13

Go to Step 12

Go to Step 13

Go to Step 12

1. Disconnect the TP sensor.

2. Observe the TP sensor reading on the scan tool.

ov

Is the TP sensor reading near the specified value?

1. Connect a test light between the 5 volt reference A

circuit and the TP sensor signal circuit at the TP
sensor harness connector.
2. Observe the

fp

5V

sensor reading on the scan tool.

Is the TP sensor reading at the specified value?

Check the following items:
TP signal circuit for a short to voltage

TP sensor ground circuit for high resistance between

the PCM and the TP sensor
TP sensor ground circuit for a poor connection

If a problem is found, repair wiring harness as necessary.

Refer to Wiring Repairs.
Was a problem found?
Check the following items:

TP signal circuit or 5 volt reference A circuit for a poor

connection.
10

TP signal circuit or 5 volt reference A circuit for high

resistance between the PCM and the TP sensor.

If a problem is found, repair wiring harness as necessary.

Refer to Wiring Repairs.
Was a problem found?
11

Replace the TP sensor. Refer to TP Sensor Replacement.

Is action complete?

Go to Step 13

Replace the PCM.

12

Important: Replacement PCM must be programmed.

Refer to PCM Replacement/Programming

Go to Step 13

1. Review and record scan tool Fail Records data.

2. Clear DTCs
13

3. Operate the vehicle within Fail Records conditions

as noted.

4. Using a scan tool, monitor Specific OTC info for

OTC P0121.
Does the scan tool indicate OTC P0121 failed this ign?

Go to Step 2

System OK

6-824

Engine Controls - 3.8L

Engine

OTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage

'" -

I
I

SVolt
Reference A

- ;
5

Powertrain

GRY
598

GRY 598
GRY 598

l,--

GAY
598

.....

DK BL~Ji 417
661 C2
-

U!I

; ; . - - - - - - - - - - - - - - ~ MAPSensor

I ---f I~en;
r -

J.

.. - - - - - - 33 -C2 - - - - ..

Fuel Tank
Pressure
Sensor

1Control
I Module (PCM)

TP -

(TP)

BL~r452
61 C1

;...1 _-- - TI' - - - - ..... - - - .,

Sensor

Sensor

Signal

Ground

PCM

Powertrain

I I Control
Module (PCM) j.

lg~:~t~AR, :

L-------~-------------J

~
221819.

Circuit Description

Diagnostic Aids

The Throttle Position (TP) sensor circuit provides a

voltage signal that changes relative to throttle
blade angle. The signal voltage will vary from below
1 volt at closed throttle to about 4 volts at Wide
Open Throttle (WOT}. The TP signal is one of the
most important inputs used by the PCM for fuel control
and most of the PCM-controlled outputs. OTC P0122
will set when the PCM detects an excessively low
signal voltage on the throttle position sensor signal
circuit.

Check for the following conditions:

Conditions for Setting the DTC

No TP sensor, or MAP sensor DTCs are set.

The ignition is ON.
TP sensor signal voltage is less than 0.1 volt.
The above conditions are present for at least
1 second.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the first
trip in which the diagnostic test has been run
and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing .the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Poor connection at the PCM - Inspect harness

connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.
Damaged harness - Inspect the wiring harness for
damage. If the harness appears to be OK,
observe the throttle position display on the scan
tool while moving connectors and wiring harnesses
related to the TP sensor. A change in the
display will indicate the location of the fault.
If DTC P0122 cannot be duplicated, the information
included in the Fail Records data can be useful
in determining vehicle mileage since the DTC was last
set. If it is determined that the DTC occurs
intermittently, performing the DTC P1122 Diagnostic
Chart may isolate the cause of the fault.

Test Description
Number(s) below refer to the Step number(s) on the
Diagnostic Table:
13. This vehicle is equipped with a PCM which utilizes
an Electric3ally Erasable Programmable Read
Only Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

Engine

Engine Controls - 3.8L

6-825

DTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage

Step

Action
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?

)
1

Value(s)

Yes

No
Go to the A

Go to Step 2

Powertrain On
Board Diagnostic
(OBD) System
Check

Go to B,tep 4

Go to Step 3

Go to Step 4

Goto
Diagnostic Aids

Go to Step 10

Go to Step 5

Go to Step 6

Go to Step 8

Go to Step 14

Go to Step 7

Go to Step 14

Go to Step 13

Go to Step 14

Go to Step 9

Go to Step 14

Go to Step 10

1. Turn ON the ignition switch, engine not running.

2

2. With the throttle closed, observe the TP Sensor

display on the scan tool.

0.16V

Is TP Sensor display less than the specified value?

1. Turn ON the ignition switch.
2. Review and record scan tool Fail Records data.

3. Operate the vehicle within Fail Records conditions

as noted.

4. Using a scan tool, monitor Specific OTC info for

OTC P0122.
Does the scan tool indicate OTC P0122 failed?
1. Disconnect the TP sensor electrical connector.

2. Jumper the 5 volt reference A circuit and the TP

signal together at the TP sensor harness connector.

5V

3. Observe the TP Sensor display on the scan tool.

Is TP Sensor at the specified value?

1. Connect a J 34142-B Unpowered Test Light between

B+ and the TP sensor signal circuit at the TP sensor
harness connector

5V

2. Observe the TP Sensor display on the scan tool.

Is TP Sensor at the specified value?
1. Turn OFF the ignition switch.
2. Disconnect the PCM.

3. Check the 5 volt reference A circuit for an open or

6

short to ground.

4. If the 5 volt reference A circuit is open or shorted to

ground, repair it as necessary. Refer to Wiring
Repairs.
Is the 5 volt reference A circuit open or shorted to ground?

Check the 5 volt reference A circuit for a poor connection

at the PCM and replace terminal if necessary. Refer to

Wiring Repairs.

Did the terminal require replacement?

1. Turn OFF the ignition switch.
2. Disconnect the PCM.

3. Check the 5 volt reference A circuit for a short to

8

ground or for a short to the sensor ground circuit.

4. If a problem is found, repair as necessary, repair it as

necessary. Refer to Wiring Repairs.
Was a problem found?
1. Turn OFF the ignition switch.
2. Disconnect the PCM.

3. Check the TP signal circuit for an open, short to

ground, or short to the sensor ground circuit.

4. If the TP sensor signal circuit is open or shorted to

ground, repair it as necessary. Refer to Wiring
Repairs.
Was the TP signal circuit open or shorted to ground?

6-826

Engine

Engine Controls - 3.8L

OTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage. (cont'd)

Step

Action

Value(s)

Yes

No

..

10

11

1. Check the TP sensor signal circuit for a poor

connection at the PCM.
2. Replace terminal(s) if necessary. Refer to Wiring
Repairs.
Did the terminal require replacement?
Check the TP sensor signal and 5 volt reference circuits
for a poor connection at the TP sensor and replace
terminal(s) if necessary. Refer to Wiring Repairs.

(
-

12

Replace the TP sensor. Refer to TP Sensor Replacement

Is the action complete?

13

Replace the PCM.

Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming
Is the action complete?

14

Go to Step 13

Go to Step 14

Go to Step 12

Did either terminal require replacement?

1. Review and record scan tool Fail Records data.

2. Clear DTCs
3. Operate the vehicle within Fail Records conditions
as noted.

Go to Step 14

Go to Step 14

Go to Step 14

4. Using a scan tool, monitor Specific OTC info for

OTC P0122.
Does the scan tool indicate OTC P0122 failed?

Go to Step 4

System OK

(
\

Engine

Engine Controls - 3.8L 6-827

OTC P0123 Throttle Position (TP) Sensor Circuit High Voltage

I

- - - - - - - -sv - - - - -

~
\

SVolt
Reference A

Powertrain

1Control

I Module

. - - - - - - 33- -C2 - - - - ..

Fuel Tank
Pressure
Sensor

GAY
598

GRY 598
GAY 598

(PCM)

JM;'"l

J.

L2lli

GRY
598

- - - - - - - - - - - - - - - ~ MAP Sensor

I1.---....--......fI~:~;

-1----

DK Bli, 417
r - - - -

661 C2

[fPJ

BL~r452
61 Ci

TI' - - - - - - - - ., Powertrain

Sensor

Sensor

Signal

Ground

PCM

I Control

lg~:~i~ARI :Module (PCM) J.

L-------~-------------~

~
221819

Circuit Description

Diagnostic Aids

The Throttle Position (TP) sensor circuit provides a

voltage signal that changes relative to throttle
blade angle. The signal voltage will vary from below
1 volt at closed throttle to about 4 volts at Wide
Open Throttle (WOT). The TP signal is one of the
most important inputs used by the PCM for fuel control
and most of the PCM-controlled outputs. DTC3 P0123
will set when the PCM detects an excessively high
signal voltage on the throttle position sensor
signal circuit.

Check for the following conditions:

Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.
Damaged harness - Inspect the wiring harness for
damage. If the harness appears to be OK,
observe the TP sensor display on the scan tool
while moving connectors and wiring harnesses
related to the TP sensor. A change in the display
will indicate the location of the fault.
Faulty TP sensor - With the key ON, engine not
running, observe the TP sensor display on the
scan tool while slowly depressing the accelerator
to wide open throttle. If a voltage greater
than 4.71 volts is seen at any point in normal
accelerator travel, replace the TP sensor.
If DTC P0123 cannot be duplicated, the information
included in the Fail Records data can be useful
in determining vehicle mileage since the DTC was last
set. If it is determined that the DTC occurs
intermittently, performing the DTC P1121 Diagnostic
Chart may isolate the cause of the fault.

Conditions for Setting the DTC

No TP sensor, or MAP sensor DTCs are set.

The ignition is ON.
TP sensor signal voltage is greater than 4.8 volts.
The above conditions are present for at least
1 second.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the first
trip in which the diagnostic test has been run
and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

6-828

Engine Controls - 3.8L

Test Description
Number(s) below refer to the Step number(s) on the
Diagnostic Table:
8. Components that share the TP sensor 5 volt
reference A circuit include the following devices:
EGR valve
MAP sensor
Disconnect these components one at a time
while observing the TP sensor display on
the scan tool. If the reading changes drastically
when one of these components is
disconnected, replace the component that
affected the reading.

Engine
12. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 4

Go to Step 3

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

1. Turn ON the ignition switch, engine not running.

2

2. With the throttle closed, observe the TP Sensor

display on the scan tool Eng 1 data list.

4.7V

Is TP Sensor greater than the specified value?

1. Turn ON the ignition switch, engine not running.

2. Review and record scan tool Fail Records data.
3. Operate vehicle within Fail Records conditions
as noted.
4. Using a scan tool, monitor Specific OTC info for
OTC P0123.

Does scan tool indicate OTC P0123 failed?

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 6

1. Disconnect the TP sensor electrical connector.

4

2. Observe the TP Sensor display on the scan tool.

ov

Is TP Sensor near the specified value?

Probe the sensor ground circuit at the TP sensor harness

connector with a J 34142-8 Unpowered Test Light
connected to B+.

Is the test light ON?

Go to Step 7

Go to Step 10

1. Turn OFF the ignition switch.

2. Disconnect the PCM.

3. Turn ON the ignition switch and check for a short to

voltage on the TP sensor signal circuit.

4. If the TP sensor signal circuit is shorted, repair it as

necessary. Refer to Wiring Repairs.
Was the TP sensor signal circuit shorted?

Go to Step 13

Go to Step 12

Go to Step 13

Go to Step 8

1. Turn ON the ignition switch.

2. Monitor the TP Sensor scan tool display while
disconnecting each of the components that share the
5 volt reference A circuit (one at a time).
7

3. If the TP Sensor scan tool display changes, replace

the component that caused the display to change
when disconnected.
Does disconnecting any of these components cause the
TP Sensor display to change?

Engine Controls - 3.8L

Engine

6-829

DTC P0123 Throttle Position {TP) Sensor Circuit High Voltage {cont'd)
Action

Step

Value(s)

Yes

No

Go to Step 13

Go to Step 9

Go to Step 13

Go to Step 11

Go to Step 13

Go to Step 12

1. Turn OFF the ignition switch.

2. Disconnect the PCM.

3. Turn ON the ignition switch, engine not running.

4. Check for a short to voltage on the 5 volt reference A
circuit.

5. If the 5 volt reference A circuit is shorted, repair it as

necessary. Refer to Wiring Repairs.
Was the 5 volt reference A circuit shorted?
9

Check for poor electrical connections at the TP sensor and

replace terminals if necessary. Refer to Wiring Repairs.

Did any terminals require replacement?

1. Turn OFF the ignition switch.

10

2. Disconnect the PCM, and check the sensor ground

circuit for a poor connection at the PCM or for an
open sensor ground circuit to the TP sensor.

3. If a problem is found, repair it as necessary. Refer to

Wiring Repairs.
Was a problem found?
11

Replace the TP sensor. Refer to TP Sensor Replacement

Is the action complete?

Go to Step 13

Replace the PCM.

12

Important: Replacement PCM must be programmed.

Refer to PCM Replacement/Programming
Is the action complete?

Goto Step 13

1. Review and record scan tool Fail Records data.

2. Clear DTCs

)
13

3. Operate vehicle within Fail Records conditions

as noted.

4. Using a scan tool, monitor Specific OTC info for

OTC P0123.
Does scan tool indicate OTC P0123 failed?

Go to Step 4

System OK

6-830

Engine Controls - 3.8L

Engine

OTC P0125 Engine Coolant Temperature (ECT) Excessive Time to Closed

Loop Fuel Control
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ECT

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Sensor

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PCM
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Powertrain

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12 'C1

YEL 410

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1 C
Coolant 1
Temperature I
I~K
(ECT) Sensor LA-;:; .J
GAN 135
A17
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BRN 718

Instrument ,6
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221815

Circuit Description
To provide the best possible combination of
driveability, fuel economy, and emission control, a
closed loop air/fuel metering system is used. When the
vehicle is first started, the PCM controls fuel delivery
in open loop, ignoring the fuel control heated
oxygen sensors (Bank 1 H02S1 and Bank 2 H02S 1)
signals and calculating air/fuel ratio based on inputs
from the engine coolant temperature, throttle position,
and mass air flow sensors. The PCM will begin
using the fuel control heated oxygen sensor signals
for controlling fuel delivery (Closed Loop) when
the following conditions have been met:
The fuel control H02S output signals are varying,
indicating that the sensors are hot enough to
operate properly.
The Engine Coolant Temperature sensor indicates
coolant temperature above 21 C (70F).
Engine speed has been greater than 1200 RPM
for at least 8 seconds.
Time since startup is at least 16 seconds for a
warm engine or 50 seconds for a cold engine.

Conditions for Setting the OTC

Manual Transaxle
No IAT or ECT sensor DTCs present
Intake air temperature is greater
than -?C (-22F).
Engine coolant temperature is greater
than -39C (-39F).
Startup engine coolant temperature is less
than 40C (86F).
The length of time for the engine coolant to reach
a stabilized temperature of 40C (104F) takes
longer than it should. The amount of time ranges
between 5 and 8 minutes depending on engine
coolant temperature at startup and the amount of
air cycled by the engine since startup

Automatic Transaxle
No IAT or ECT sensor DTCs present
Intake air temperature is greater
than -7C (-22F).
Engine coolanJ temperature is greater
than -40C (-40F).
Startup engine coolant temperature is less
than 40C (86F).
The length of time for the engine coolant to reach
a stabilized temperature of 20c (68F) takes
longer than it should. The amount of time ranges
between 2 and 5 minutes depending on engine
coolant temperature at startup and the amount of
air cycled by the engine since startup

Action Taken When the OTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Engine
Diagnostic Aids

The DTC P0125 diagnostic test will not run if the

engine is started while the coolant temperature is less
than 0c (32F} or greater than 21 C (70F}. If it is
not possible to operate the vehicle under the
apprpriate conditions, check the following items:
Cooling system coolant level - Refer to Cooling
and Radiator.
Thermostat operation - Refer to Cooling and
Radiator.
Cooling fans operation - Refer to Electric Cooling
Fan Diagnosis.
Check for high resistance in wiring related to the
ECT sensor. Also, check for poor connections
at ECT sensor and PCM (refer to Troubleshooting
Procedures in Electrical Diagnosis).
DTC P0125 set indicates a skewed ECT sensor.
Comparing the engine coolant temperature
displayed on a scan tool with actual coolant
temperature measured with a thermometer may
isolate this condition. If the displayed engine
coolant temperature is not close to the actual
coolant temperature, replace the ECT sensor.
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.

Engine Controls - 3.8L

6-831

Damaged harness - Inspect the wiring harness for

damage. If the harness appears to be OK,
observe the display on the scan tool while moving
connectors and wiring harnesses related to the
sensor. A change in the display will indicate
the location of the fault.
If DTC P0125 cannot be duplicated, the information
included in the Fail Records data can be useful
in determining vehicle mileage since the DTC was
last set.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
2. Comparing the engine coolant temperature
displayed on a scan tool with actual coolant
temperature measured with a thermometer may
isolate this condition
If the displayed engine coolant temperature is not
close to the actual coolant temperature, replace
the ECT sensor.
If the temperatures are close, the fault is
intermittent. Refer to Diagnostic Aids.

6-832

Engine

Engine Controls - 3.SL

DTC P0125 Engine Coolant Temperature (ECT) Excessive Time to Closed Loop Fuel Control
Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to
Diagnostic Aids

Go to Step 3

Go to the
applicable ECT
sensor DTC chart

Go to Step 4

Go to Step 5

Go to Electric
Cooling Fan
Diagnosis

Go to Step 6

Go to Step 9

Go to Step 7

Go to Step 9

Go to Step 9

Go to Step 8

Go to Step 10

Go to Step 11

Was the Po~ertrain On-Board Diagnostic (OBD) System

Check performed?

1. Allow the engine to cool completely.

2. Start engine.

3. With the engine idling, monitor Eng. Cool. Temp.

display on the scan tool.

21C (70F)

Does Eng. Cool. Temp. increase to greater than the

specified value within 2 minutes?
Are any ECT sensor DTCs set?
3

--

1. Allow the engine to cool.

2. Turn. ON the ignition switch and observe cooling fans

operation.

Are the cooling fans off?

5

Check .the cooling system coolant level. Refer to Cooling

and Radiator.

Is the coolant level OK?

Check for proper operation of the thermostat. Refer to

Cooling and Radiator.

Is the thermostat operating correctly?

Compare Eng. Cool. Temp. displayed on the scan tool to

the actual coolant temperature measured with a
thermometer.

3C ( 5F)

Is the scan tool Eng. Cool. Temp. indication within the

specified value of the measured temperature?

Check for high resistance in wiring related to the ECT

sensor.

Also, check for poor connections at the ECT sensor and at

the PCM.
Was a problem found?
Refer to Cooling and Radiator for cooling system diagnosis
and repair condition as necessary.

10

11

Replace the faulty terminal(s) or repair faulty wiring as

necessary.
Refer to Wiring Repairs.
Is the action complete?
Replace the ECT sensor. Refer to ECT Sensor
Replacement

Go to Step 12

Is the action complete?

Go to Step 12

Go to Step 12

Is action complete?
1. Allow the engine to cool completely.
2. Clear DTCs.
12

3. Start engine.

4. With the engine idling, monitor Eng. Cool. Temp.

21C (70F)

display on the scan tool.

Does Eng. Cool. Temp. increase to above the specified
value within 2 minutes?

System OK

Go to Step2

Engine

Engine Controls - 3.SL

6-833

OTC P0131 H02S Circuit Low Voltage Bank 1 Sensor 1

!Hot In Run, Bulb Test A.nd Start!

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Bank 1
H02S 1
Signal

PNK 5~9- -

H02S 1
Low

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PCM
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C2 = CL.EAR

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PPL/WHT 1665

TAN/WHT 1653

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HeatedOxygen
Sensor (H02S)
Bank 2 Sensor 1
Heated Oxygen

Heated Oxygen
Sensor Bank 1
Sensor1

Sensor (H02S)
Bank 1 Sensor 3

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221847

Circuit Description
The PCM supplies a bias voltage of about 450 mV
between the H02S signal and low circuits. When
measured with a 1O megohm digital voltmeter, this may
display as low as 350 mV. The oxygen sensor
varies the voltage within a range of about 1000 mV
when the exhaust is rich, down through about 100 mV
when exhaust is lean. The PCM constantly monitors
the H02S signal during closed loop operation and
compensates for a rich or lean condition by decreasing
or increasing injector pulse width as necessary. If
the Bank 1 H02S 1 voltage remains excessively low
for an extended period of time, DTC P0131 will be set.

Conditions for Setting the DTC

No TP sensor, EVAP system, misfire, EGR Pintle,
IAT sensor, MAP sensor, fuel trim, fuel injector
circuit, ECT sensor, CKP sensor, or MAF sensor
DTCs are present.
Closed loop commanded air/fuel ratio is
between 14.5 and 14.8

System voltage is greater than 9 volts.

Throttle angle is between 3% and 40%
Bank 1 H02S 1 signal voltage remains below
175 mV for longer than 45 seconds during normal
closed loop operation
OR
Bank 1 H02S 1 signal voltage remains below
600 mV for longer than 55 seconds during
power enrichment mode fuel control operation.

6-834

Engine Controls - 3.SL

Action Taken When the OTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIL/OTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Heated oxygen sensor wiring damaged - The
sensor pigtail may be routed incorrectly and
contacting the exhaust system.
Poor PCM to engine block grounds
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.
Throttle body inlet screen blockage
Low fuel presspre - The system will go lean if
pressure is too low. The. PCM can compensate
for some decrease. However, if fuel pressure
is too low, a OTC P0131 may be set. Refer to Fuel
System Pressure Test.

Engine
Fuel injector(s),contaminated or faulty - Refer to
Fuel Injector Balance Test
Exhaust leaks - An exhaust leak may cause
outside air to be pulled into the exhaust gas
stream past the H02S, causing the system to
appear lean. Check for exhaust leaks that
may cause a false lean condition to be indicated.
Faulty MAF sensor - Disconnect the MAF sensor
and see if the lean condition is corrected. If so,
replace the MAF sensor.
Fuel contamination - Water, even in small
amounts, can be delivered to the fuel injectors.
The water can cause a lean exhaust to be
indicated. Excessive alcohol in the fuel can also
cause this condition. Refer to
Alcohol/Contaminants-in-Fuel Diagnosis for
procedure to check for fuel contamination.
If. none of the above conditions are present, replace
the affected H02S.

Test Description
Number(s) below refer to step number(s) on the
Diagnostic Table:
3. OTC P0131 failing during power enrichment
operation (TP angle above 60%) may indicate a
condition described in Diagnostic Aids. If the
OTC P0131 test passes while the Fail Records
conditions are being duplicated, an intermittent
condition is indicated. Review the Fail Records
vehicle mileage since the diagnostic test last
failed. This may help determine how often
the condition that caused the OTC to be set
occurs.

7. This vehicle is equipped with a PCM which utilizes

an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

Engine Controls - 3.Sl

Engine

6-835

DTC P0131 H02S Circuit Low Voltage Bank t Sensor 1

Action

Step

Value(s)

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to
Diagnostic Aids

Go to Step 5

Go to Step 6

Go to Step 7

1. Install a scan tool.

2. Engine at operating temperature
2

3. Operate vehicle within parameters specified under

OTC Will Set When criteria included in Diagnostic
Support.

300mV

4. Using a scan tool, monitor Bank 1 H02S 1 voltage.

Does the Bank 1 H02S 1 voltage remain below the
specified value?
1. Turn ON the ignition switch
2. Review and record scan tool Fail Records data and
note parameters.

3. Operate vehicle within Fail Records conditions

as noted.

4. Using a scan tool, monitor Specific OTC info for

OTC P0131 until the OTC P0131 test runs.
Note test result; does scan tool indicate OTC P0131 failed
this ign?

Disconnect Bank 1 H02S 1 and jumper the Bank 1 H02S

1 low circuit (PCM side) to ground.
Does scan tool indicate Bank 1 H02S 1 voltage near the
specified value?
Turn off the ignition, disconnect the PCM, and check the
Bank 1 H02S 1 signal c.ircuit for a short to ground or a
short to the sensor ground circuit. Is the Bank 1 H02S 1
signal circuit shorted?
Repair the Bank 1 H02S 1 signal circuit. Refer tp H02S
Replacement.

450mV

Go to Step B

Is action complete?
Replace the PCM.

Important: Replacement PCM must be programmed.

Refer to PCM Replacement/Programming
Is the action complete?

,.

Go to Step B

1. Turn ON the ignition switch

2. Review and record scan tool Fail Records data.
3. Clear DTCs

4. Operate vehicle within Fail Records conditions

as noted.

5. Using a scan tool, monitor Specific OTC info tor

OTC P0131 until the OTC P0131 test runs.
Note test result; does scan tool indicate OTC P0131 tailed
.
this ignition?

Go to Step 2

System OK

6-836

Engine Controls - 3.8L

Engine

DTC P0132 H02S Circuit High Voltage Bank 1 Sensor 1

!Hot In Run, Bulb Test And Start!

r - Power

]
Distribution
Cell 10

Fuse Block
Details
Cell11

- ENG SEN
MiniFuse
20 A

J7
J6

Underhood
I Electrical
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PNK 539

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Bank 1
H02S 1
Signal

Powertrain
I Control
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Cl=BLU
I Module
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C2 = CLEAR 1(PCM)
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PCM

H02S 1
Low

12-IC2 - -271-C1 - -- - - ~
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PNK 5;9- PPL/WHT 1665

TAN/WHT 1653

BA

...--+----+-----;--, Heated Oxygen

Sensor Bank 1
Sensor 1

Heated Oxygen
Sensor (H02S)
Bank2Sensor1
Heated Oxygen
Sensor (H02S)
Bank 1 Sensor 3

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221847

Circuit Description
The PCM supplies a bias voltage of about 450 mV
between the H02S signal and low circuits. When
measured with a 10 megohm digital voltmeter, this may
display as low as 320 mV. The oxygen sensor
varies the voltage within a range of about 1000 mV
when the exhaust is rich, down through about 1O mV
when exhaust is lean. The PCM constantly monitors
the H02S signal during closed loop operation
and compensates for a rich or lean condition by
decreasing or increasing injector pulse width as
necessary. If the Bank 1 H02S 1 voltage remains
excessively high for an extended period of time,
DTC P0132 will be set.

Conditions for Setting the DTC

No TP sensor, EVAP system, misfire, EGR Pintle,
IAT sensor, MAP sensor, fuel trim, fuel injector
circuit, ECT sensor, CKP sensor, or MAF sensor
DTCs are set.
Closed loop commanded air/fuel ratio is
between 14.5 and 14.8
System voltage is greater than 9 volts.
Throttle angle is between 3% and 40%
Bank 1 H02S 1 signal voltage remains above
975 mV for longer than 45 seconds during
normal closed loop operation.
OR
Bank 1 H02S 1 signal voltage remains above 11 O mV
for longer than 29 seconds during deceleration fuel
mode operation.

Engine
Action Taken When the OTC Sets
The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Diagnostic Aids
Check the following items:
High fuel pressure - The system will go rich if
pressure is too high. The PCM can compensate
for some increase. However, if fuel pressure is too
high, a OTC P0132 may be set. Refer to Fuel
System Pressure Test.
Fuel injector(s) contaminated or faulty - Refer to
Fuel Injector Balance Test.
Check the EVAP Canister for Fuel Saturation. If
the EVAP Canister is full of fuel, check canister
control and hoses. Refer to EVAP Control System
Diagnosis.
Disconnect the MAF sensor and see if the rich
condition is corrected. If so, replace the MAF
sensor.
Check for a leaking fuel pressure regulator
diaphragm by checking the vacuum line to the fuel
pressure regulator for the presence of fuel.
An intermittent TP sensor output will cause the
system to go rich due to a false indication of
the engine accelerating.

Engine Controls - 3.8L

6-837

Shorted H02S - If the H02S is internally shorted

the H02S voltage displayed on the scan tool will
be over 1 volt. Disconnect the affected H02S
and jumper the H02S low circuit to ground with
the key ON. If the displayed H02S voltage
changes from over 1000 mV to around 450 mV,
replace the H02S. Silicon contamination of
the H02S can also cause a high H02S voltage to
be indicated. This condition is indicated by a
powdery white deposit on the portion of the H02S
exposed to the exhaust stream. If contamination
is noticed, replace the affected H02S.
Open H02S Signal or Low Circuit or Faulty H02S
- A poor connection or open in the H02S signal
or low circuit can cause the OTC to set during
deceleration fuel mode. An H02S which is faulty
and not allowing a full voltage swing between
the rich and lean thresholds can also cause this
condition. Operate the vehicle while monitoring the
H02S voltage with a scan tool. If the H02S
voltage is limited within a range between 300mV
to 600mV, check the H02S signal and low
circuit wiring and associated terminal connections.
If the wiring and connections are OK, replace
the H02S.
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.

Test Description
Number(s) below refer to step numbers on the
Diagnostic Table:
3. OTC P0132 failing during deceleration fuel mode
operation (vehicle speed above 25 mph, TP
angle below 3%) may indicate a condition
described in Diagnostic Aids. If the OTC P0132
test passes while the Fail Records conditions are
being duplicated, an intermittent condition is
indicated. Review the Fail Records vehicle
mileage since the diagnostic test last failed. This
may help determine how often the condition
that caused the OTC to be set occurs.
8. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

6-838

Engine Controls - 3.8L

Engine

DTC P0132 H02S Circuit High Voltage Bank 1 Sensor 1

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 5

Go to Step 3

Go to Step 5

Go to Step 4

Go to Step 5

Go to
Diagnostic Aids

Go to
Diagnostic Aids

Go to Step 6

Go to Step 7

Go to Step 8

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1. Engine at operating temperature

2. Operate vehicle within parameters specified under
Conditions for Setting the DTC criteria included in
Diagnostic Support.
3. Monitor Bank 1 H02S 1 voltage display on the scan
tool H02S data list.
Does the H02S voltage remain above the specified value?

800 mV

Operate vehicle in Decel fuel mode (vehicle speed above

25 mph, TP angle below 3%) while monitoring H02S
1 voltage display on the scan tool H02S data list.
Does the H02S 1 voltage remain above the specified
value while in Decel fuel mode?

110 mV

1. Turn ON the ignition switch.

2. Review and record scan tool Fail Records data.
3. Operate vehicle within Fail Records conditions
as noted.
4. Using a scan tool, monitor Specific DTC info for
DTC P0132 until the OTC P0132 test runs.
Note test result; does scan tool indicate OTC P0132 failed
this ign?
Disconnect H02S 1 and jumper H02S low circuit to
ground.
Does scan tool indicate H02S 1 voltage near the
specified value?
1. Turn OFF the ignition switch
2. Disconnect PCM connector.
3. Turn ON the ignition switch.
4. Using a J 39200 DMM, measure voltage between the
H02S 1 sensor signal at PCM harness connector and
ground.
Does the DMM indicate a voltage greater than
specified value?
Repair short to voltage in the H02S 1 signal circuit. Refer
to H02S Replacement.

450 mV

600mV

Is action complete?

Go to Step 9

Replace the PCM.

Important: Replacement PCM must be programmed.

Refer to PCM Replacement/Programming.
Is action complete?
1. Turn ON the ignition switch.
2. Review and record scan tool Fail Records data.
3. Clear DTCs
4. Operate vehicle within Fail Records conditions
as noted.
5. Using a scan tool, monitor Specific OTC info for
OTC P0132 until the OTC P0132 test runs:
Note test result; does scan tool indicate OTC P0132 failed
this ign?

Go to Step 9

Go to Step 2

System OK

Engine Controls - 3.SL

Engine

6-839

DTC P0133 H02S Slow Response Bank 1 Sensor 1

-1--.., --,

!Hot In Run, Bulb Test A.nd Start!

Pow;
Ir - Distribution
I

J7

Underhood
I Electrical
1 Center 2

ENG SEN
MiniFuse
20 A

Cell 10

LJLl

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J6
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Fuse Block
Details
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PNK 539
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Bank 1

H02S 1
Signal

PCM
c1=BLU
C2 = CLEAR

H02S 1
Low

121C2 - -271-C1 - - - - -

PNK 5~9- PPL/WHT 1665

Powertrain
I Control
I
I Module
I
I (PCM)
I

.1

TAN/WHT 1653

DA

B...._

A
Heated Oxygen
Sensor Bank 1
Sensor1

>

Heated Oxygen
Sensor (H02S)
Bank 2 Sensor 1
Heated Oxygen
Sensor (H02S)
Bank 1 Sensor 3

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221847

Circuit Description
The PCM continuously monitors the Heated Oxygen
Sensor (H02S) activity. The PCM counts the
number of times that a rich to lean and a lean to rich
response is indicated. Then, the PCM adds the
amount of time it took to complete all transitions for a
100 second test period. With this information, an
average time for each transition can be determined. If
the average response time is too slow, a DTC P0133
will be set. A lean to rich transition is indicated
when the H02S voltage changes from less
than 300 mV to greater than 600 mV. A rich to lean
transition is indicated when the H02S voltage changes
from greater than 600 mV to less than 300 mV. An
H02S that responds too slowly is likely to be faulty and
should be replaced.

Conditions for Setting the DTC

No TP sensor, EVAP system, EGA, misfire, IAT

sensor, MAP sensor, fuel trim, H02S 1 Heater,
fuel injector circuit, EGA Pintle, ECT sensor, CKP
sensor, or MAF sensor DTCs are set.
The engine has been running in closed loop for at
least 1 minute.
Engine speed is between 1000 RPM
and 3000 RPM.

Engine Coolant Temperature greater

than 50C (122F).
Mass Air Flow is between the following limits:
Automatic Transaxle - Between 15 g/s
and 29 g/s.
Manual Transaxle - Between 10 g/s
and 30 g/s.
Automatic Transaxle - Bank 1 H02S 1 lean to rich
and rich to lean average transition response time
was longer than 90 milliseconds.
Manual Transaxle - Bank 1 H02S 1 lean to rich
average transition response time was longer
than 150 milliseconds. The rich to lean average
transition response time was longer
than 130 milliseconds.
The conditions are present during the 100 second
response test period.

Action Taken When the OTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

6-840

Engine Controls - 3.SL

Conditions for Clearing the MIL/DTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.

Engine
Damaged harness - Inspect the wiring harness
for damage. If the harness appears to be OK,
observe the Bank 1 H02S 1 display on the scan
tool while moving connectors and wiring harnesses
related to the sensor. A change in the display
will indicate the location of the fault.
If OTC P0133 cannot be duplicated, Review the Fail
Records vehicle mileage since the diagnostic test
last failed. This may help determine how often
the condition that caused the OTC to be set occurs.

Test Description
Number(s) below refer to the Step number(s) on the
Diagnostic Table:
2. This step verifies that the fault is currently
present.
3. H02S transition time, ratio mean volts and
switching DTCs set for multiple sensors indicate
probable contamination. Before replacing the
sensors, isolate and correct the source of
the contamination to avoid damaging the
replacement sensors.

DTC P0133 H02S Slow Response Bank 1 Sensor 1

Step

Action
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?

4
.

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Important: If any DTCs are set,(Except P0153, P1133,

P1134, P1135, P1136, P1153, P1154, P1155, and/or
P1156), refer to those DTCs before proceeding with this
diagnostic table.
1. Install scan tool
2. Engine idling at operating temperature
3. Operate vehicle within parameters specified under
DTC Will Set When criteria included in Diagnostic
Support.
4. Using a scan tool, monitor Specific DTC info for
DTC P0133.
Does scan tool indicate DTC P0133 failed this ignition?

Did the scan tool also indicate DTC P0153, P1133, P1134,
P1135, P1136, P1153, P1154, P1155, and/or P1156 failed
this ignition?

1. Perform Exhaust System Leak Test. Refer to Exhaust

System. After Exhaust System Leak Test has been
performed, return to .this diagnostic.
2. If an exhaust leak is found, repair as necessary .
Was an exhaust leak isolated?

Visually/physically inspect the following items:

Ensure that the Bank 1 H02S 1 is securely installed.
Check for corrosion on terminals.
Check terminal tension (at Bank 1 H02S 1 and at
the PCM).
Check for damaged wiring.
Was a problem found in any of the above areas?

Go to Step 3

Go to
Diagnostic Aids

Go to Step 8

Go to Step 4

Go to Step 2

Go to Step 5

Go to Step 9

Go to Step 6

Engine

Engine Controls - 3.8L

6-841

OTC P0133 H02S Slow Response Bank 1 Sensor 1 (cont'd)

Step

Action

Value(s)

Yes

No

Go to Step 7

Go to Step 10

Go to Step 12

Go to Step 11

1. Disconnect Bank 1 H02S 1 and jumper H02S low

(PCM side) signal circuit to ground.

2. Using a scan tool, monitor Bank 1 H02S 1 voltage.

450mV

Does the scan tool indicate voltage near the

specified value?

1. Jumper Bank 1 H02S 1 high and low (PCM side)

signal circuits to ground.
2. Using a scan tool, monitor Bank 1 H02S 1 voltage.

300mV

Does scan tool indicate voltage below specified value?

Replace affected Heated Oxygen Sensors. Refer to H02S
Replacement.

Important: Determine and correct the cause of the

contamination before replacing sensors. Check for the
following conditions:
Fuel contamination.
Engine oil/coolant consumption.

Use of improper RTV sealant.

Go to Step 13

Is the action complete?

9

10

Repair condition as necessary.

Is the action complete?
Repair an open Bank 1 H02S 1 low signal circuit or a
grounded Bank 1 H02S 1 high signal circuit. Refer to
H02S Replacement.

11

12

Replace Bank 1 H02S 1. H02S Replacement.

Is the action complete?

Go to Step 13

Is the action complete?

Repair open Bank 1 H02S 1 high signal circuit or faulty
PCM connections. Refer to H02S Replacement.
Is the action complete?

Go to Step 13

Go to Step 13

Go to Step 13

1. Review and record scan tool Fail Records data. Note

test result; does scan tool indicate OTC P0133 failed
this ign?
13

2. Clear DTCs.

3. Operate vehicle within Fail Records conditions

as noted.
Does the scan tool indicate OTC P0133 failed this ignition?

Go to Step 2

System OK

6-842

Engine Controls - 3.8L

Engine

DTC P0134 H02S Circuit Insufficient Activity Bank 1 Sensor

!Hot In Run, Bulb Test And Start!

- Power
]
Distribution
Cell 10

J7

I
Fuse Block
Details
Cell11

- ENG SEN
MiniFuse
20 A

J6

Underhood
I Electrical
I Center 2
I

L---------..1
PNK 539

._ -

-,

.....

' , PNK 539

.....

.....

-----------------------,
'"
I

I
I

L ___

PNK 539

- - - - - - - - - , Powertrain
PCM
I Control

Bank 1

121 C2

27

PPL/WHT 1665
T AN/WHT

DA

C1=BLU

H02S 1
H02S 1
C2 = CLEAR
~n~ _ _ _ L~N _ _ _ _ _ _ _

B.,..

IM d I
O Ue
~ (PCM)

>

C1

Heated Oxygen
Sensor (H02S)
Bank 2 Sensor 1

1653

A
Heated Oxygen
Sensor Bank 1
Sensor1

Heated Oxygen
Sensor (H02S)
Bank 1 Sensor 3

cy

L---------------

-------J
221847

Circuit Description

The following engine run time requirements

are met:
- Manual Transaxle - 4 minutes.
- Automatic Transaxle - 3 minutes.
Bank 1 H02S 1 signal voltage remains
between 400 mV and 500 mV for up to
30 seconds.

The PCM supplies a bias voltage of about 450 mV

between the H02S signal and low circuits. When
measured with a 10 megohm digital voltmeter, this
may display as low as 320 mV. The oxygen sensor
varies the voltage within a range of about
1000 mV when the exhaust is rich, down through
about 10 mV when exhaust is lean. The PCM
constantly monitors the H02S signal during closed
loop operation and compensates for a rich or
lean condition by decreasing or increasing injector
pulse width as necessary. If the Bank 1
H02S 1 voltage remains at or near the 450 mV bias
for an extended period of time, DTC P0134 will be set
indicating an open sensor signal or sensor low
'
circuit.

Action Taken When the DTC Sets

Conditions for Setting the DTC

Conditions for Clearing the MIL/DTC

No TP sensor, EVAP system, EGR Pintle, misfire,

IAT sensor, MAP sensor, fuel trim, fuel injector
circuit, ECT sensor, CKP Sensor, or MAF sensor
DTCs are set.
System voltage is greater than 9 volts
Commanded air fuel ratio is between
14.5 and 14.8

The PCM will illuminate the MIL during the second

consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.
The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Engine

Engine Controls - 3.SL

Diagnostic Aids

Check tor the following conditions:

Poor connection at the PCM - Inspect harness
connectors tor the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.
Damaged harness - Inspect the wiring harness
tor damage. It the harness appears to be OK,
observe the display on the scan tool while moving
connectors and wiring harnesses related to the
sensor. A change in the display will indicate
the location of the fault.
Damaged harness - Inspect the wiring harness
tor damage. It the harness appears to be OK,
observe the display on the scan tool while moving
connectors and wiring harnesses related to the
sensor. A change in the display will indicate
the location of the fault.
Faulty H02S heater or heater circuit - With the
ignition ON the H02S voltage displayed on a
scan tool should gradually drop to less
than 250 mV or rise to greater than 600 mV. It not,

6-843

disconnect the H02S and connect a J 34142-8

Unpowered test lamp between the H02S ignition
teed and heater ground circuits. It the J 34142-8
test lamp does not light, repair the open
ignition teed or sensor ground circuit as
necessary. Refer to Wiring Repairs. It the
J 34142~8 test lamp illuminates and the H02S
signal and low circuits are OK, replace the H02S.
Intermittent test - With the ignition ON,
monitor the H02S signal voltage while moving the
wiring harness and related connectors. It the
fault is induced, the H02S signal voltage
will change. This may help isolate the location of
the malfunction.
Review the Fail Records vehicle mileage since the
diagnostic test last tailed. This may help determine
how often the condition that caused the OTC to be set
occurs.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
12. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

OTC P0134 H02S Circuit Insufficient Activity Bank 1 Sensor

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to Step 4

Go to Step 4

Go to
Diagnostic Aids

Go to Step B

Go to Step 5

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1. Install scan tool

2. Engine at operating temperature
3. Operate engine above 1200 RPM for two minutes.
Does scan tool indicate Bank 1 H02S 1 voltage varying
outside the specified values?

400-500 mV

1. Turn ON the ignition switch.

2. Review and record scan tool Fail Records data and

note parameters.
3. Operate vehicle within Fail Records conditions
as noted.
4. Using a scan tool, monitor Specific DTC info for
OTC P0134 until the DTC P0134 test runs
Does scan tool indicate DTC failed this ignition?
1. Turn ON the ignition switch.
2. Disconnect H02S signal and jumper the H02S signal
and low circuits (PCM side) to ground.
3. Using a scan tool, monitor Bank 1 H02S 1 voltage.
Is Bank 1 H02S 1 voltage below the specified value?

150 mV

6-844

Engine

Engine Controls - 3.SL

OTC P0134 H02S Circuit Insufficient Activity Bank 1 Sensor (cont'd)

Step

Action

1. Remove the jumper wire from the Bank 1 H02S 1

(leave the bank 1 H02S 1 low circuit connected to
ground).
2. Using a J 39200 DMM, measure voltage between the
Bank 1 H02S 1 signal circuit (PCM side) and the
Bank 1 H02S 1 heater ground circuit.
Does Bank 1 H02S 1 signal voltage measure near the
specified value?

10

Value(s)

400 mV

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Check continuity of the Bank 1 H02S 1 signal circuit
and the Bank 1 H02S 1 low circuit.
4. If the Bank 1 H02S 1 signal or low circuit measures
over 5 ohms, repair open or poor connection as
necessary. Refer to H02S Replacement.
Was a Bank 1 H02S 1 signal circuit problem found and
corrected?

Check for a poor Bank 1 H02S 1 signal or low circuit

terminal connection at the Bank 1 H02S 1 harness
connector and replace terminal(s) if necessary. Refer to
H02S Replacement.
Was a problem found?

Check for poor Bank 1 H02S 1 signal or low circuit

terminal connection at the PCM.
If a problem is found, replace terminal(s) as necessary.
Refer to Wiring Repairs.
Was a problem found?

2. If a problem is found, replace terminal(s) as

necessary. Refer to Wiring Repairs.
Was a problem found?

No

\.

1. Turn OFF the ignition switch

2. Disconnect the PCM.
3. Check continuity of the Bank 1 H02S 1 low circuit.
4. If the Bank 1 H02S 1 low circuit measures over
5 ohms, repair open or poor connection as
necessary. Refer to H02S Replacement.
Was a Bank 1 H02S 1 low circuit problem found and
corrected?

1. Check for poor Bank 1 H02S 1 signal and the

Bank 1 H02S 1 low circuit for a poor terminal
connection at the PCM.

Yes

Go to Step 6

Go to Step 7

Go to Step 13

Go to Step 9

Go to Step 13

Go to Step 11

(
Go to Step 13

Go to Step 11

Go to Step 13

Go to Step 12

Go to Step 13

Go to Step 12

11

Replace Bank 1 H02S 1. Refer to H02S Replacement.

Is the action complete?

12

Replace the PCM.

Important: Replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Is the action complete?

Go to Step 13

Go to Step 13

1. Turn ON the ignition switch.

2. Review and record scan tool Fail Records data.
3. Clear DTCs
13

4. Operate vehicle within Fail Records conditions

as noted.
5. Using a scan tool, monitor Specific OTC info for
OTC P0134 until the OTC P0134 test runs.
Does scan tool indicate OTC failed this ignition?

Go to Step 2

System OK

Engine

Engine Controls - 3.SL

6-845

DTC P0135 H02S Heater Performance Bank 1 Sensor 1

!Hot In Run, Bulb Test And Start!

. . - P;w; - ] - - - - - , Underhood

I
I

Fuse Block
Details
Cell11

Distribution
cen 10

J7

I Electrical
1Center 2
I

ENG SEN
MiniFuse
20 A

J6

L---------.I
PNK 539

...- -

-~ .....

' , PNK 539

.....

-----------------------,
... - - - - - - - - - - - - - - - I
Bank 1
PCM
I
c1=BLU
I
H02S 1
H02S 1
C2 = CLEAR
Signal

Low

, Powertrain
I Control
I Module
I (PCM)

12-1C2 - -27I-C1 - - - - - ~
>

PNK 5~9- PPL/WHT 1665

.J

TAN/WHT 1653

DA

Heated Oxygen
Sensor (H02S)
Bank 2 Sensor 1

Heated Oxygen

Heated Oxygen
Sensor Bank 1
Sensor1

Sensor (H02S)
Bank 1 Sensor 3

cy
I

L-----------------------~
221847

Circuit Description

Heated oxygen sensors are used to minimize the

amount of time required for closed loop fuel control
operation and to allow accurate catalyst monitoring.
The oxygen sensor heater greatly decreases the
amount of time required for fuel control sensors Bank 1
H02S 1 and Bank 2 H02S 1 to become active. An
Oxygen sensor heater is also required by catalyst
monitor sensor Bank 1 H02S 3 to maintain a
sufficiently high temperature which allows accurate
exhaust oxygen content readings further from
the engine. The PCM will run the heater test only after
a cold start (determined by engine coolant and
intake air temperature at the time of startup) and only
once during an ignition cycle. When the engine is
started the PCM will monitor the H02S voltage. When
the H02S voltage indicates a sufficiently active
sensor, the PCM looks at how much time has elapsed
since startup. If the PCM determines that too much
time was required for the Bank 1 H02S 1 to become
active, a DTC P0135 will set. The time it should
take the H02S to reach operating temperature is
based on the engine coolant temperature at start-up
and the average Mass Air Flow since startup
(higher average airflow or higher startup engine
coolant temperature = shorter time to H02S activity).

Conditions for Setting the DTC

No TP sensor, EVAP system, EGR Pintle, misfire,
IAT sensor, MAP sensor, fuel trim, fuel injector,
ECT sensor, CKP Sensor, or MAF sensor DTCs
are set.
Intake Air Temperature (IAT) is less
than 35C (95F) at startup
Engine Coolant Temperature (ECT) is less
than 35C (95F) at startup.
IAT and ECT are within 6C (11F) of each other
at start-up.
Average mass air flow for the sample period is
less than 20 g/s.
Bank 1 H02S 1 voltage remains within 150 mV of
the bias voltage (about 450 mV) for a longer
amount of time than it should. The amount of time
ranges between 42 seconds and 2 minutes.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

6-846

Engine Controls - 3.BL

Engine

Conditions for Clearing the MIL/DTC

Test Description

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
tnalfu nction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Number(s) below refer to the step number(s) on the

Diagnostic Table:

2. The H02S should be allowed to cool before

performing this test. If the H02S heater is
functioning, the signal voltage will gradually
increase or decrease as the sensor element
warms. If the heater is not functioning, the H02S
signal will remain near the 450mv bias voltage.
4. This step ensures that the ignition feed circuit to
the H02S is not open or shorted. The test light
should be connected to a good chassis ground, in
case the H02S low or H02S heater ground
circuit is faulty

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.
Damaged harness - Inspect the wiring harness
for damage. If the harness appears to be OK,
observe the display on the scan tool while moving
connectors and wiring harnesses related to the
sensor. A change in the display will indicate
the location of the fault.
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help determine
how often the condition that caused the OTC to be set
occurs.

5. This step checks the H02S heater ground circuit.

6. This step checks for an open or shorted H02S
heater element. The heater element resistance
will vary according to H02S temperature (a
hot H02S heater element will measure a much
higher resistance than a H02S heater element at
room temperature). It is important to allow the
H02S to cool before measuring H02S heater
element resistance.
11. An open H02S signal or low circuit can cause the
H02S heater to appear faulty. Check these
circuits before replacing the sensor.

DTC P0135 H02S Heater Performance Bank 1 Sensor 1

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to
Diagnostic Aids

Go to Step 3

Go to Step 15

Go to Step 4

Go to Step 5

Go to Step 7

Go to Step 6

Go to Step 8

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Important: If engine has just been operating, allow engine

to cool for about one half hour before proceeding.
1. Turn ON the ignition switch
2. Monitor Bank 1 H02S 1 voltage on the scan tool
H02S data list.
Does H02S voltage go from bias voltage to greater than
the first specified value or less than the second
specified value?

600mV
300mV

Inspect fuse for Bank 1 H02S 1 ignition feed.

Is the fuse open?

1. Raise the vehicle.

2. Disconnect the H02S 1 electrical connector.
3. Probe the ignition feed circuit at Bank 1 H02S 1
electrical connector (PCM harness side) using a test
light connected to ground
Important: Use a k_nown good ground. Do not use
Bank 1H02S 1 heater ground or Bank 1 H02S 1 low.
Does the test light illuminate?

Connect the test light between the Bank 1 H02S 1 ignition

feed circuit and the Bank 1 H02S 1 heater ground.
Does test light illuminate?

Engine

Engine Controls - 3.SL

6-847

DTC P0135 H02S Heater Performance Bank 1 Sensor 1 (cont'd)

Step

Action

Value(s)

1. Allow the H02S to cool for at least 10 minutes.

2. Using a J 39200 Digital Multimeter, measure
resistance between the brown wires (Bank 1 H02S 1
ignition feed and Bank 1 H02S 1 heater ground) at
the Bank 1 H02S 1 pigtail.
Is H02S heater resistance within the specified values?

5 -10 ohms

Repair open Bank 1 H02S 1 ignition feed circuit to Bank 1

H02S 1. Refer to Wiring Repairs.

Repair open Bank 1 H02S 1 heater ground circuit. Refer

to Wiring Repairs.
Is action complete?
1. Check for a poor connection at the Bank 1 H02S 1
harness terminals
2. If a problem is found, repair as necessary. Refer to

No

Go to Step 9

Go to Step 14

Go to Step 16

Is action complete?

Yes

Go to Step 16

H02S Replacement.
Was a problem found?

10

1. Turn OFF the ignition switch.

2. Disconnect the PCM and check continuity of the
Bank 1 H02S 1 signal circuit and the Bank 1 H02S 1
low circuit.
3. If the Bank 1 H02S 1 signal circuit or H02S low
circuit measures over 5 ohms, repair open or poor
connection as necessary. Refer to H02S

Go to Step 16

Go to Step 10

Go to Step 16

Go to Step 11

Go to Step 16

Go to Step 12

Go to Step 16

Go to Step 13

Go to Step 16

Go to Step 14

Replacement.
Was a problem found?

11

1. Check for a poor Bank 1 H02S 1 signal or low circuit

terminal connection at the Bank 1 H02S 1 harness
connector.
2. If a problem is found, repair as necessary. Refer to

H02S Replacement.
Was a problem found?

12

1. Check for poor Bank 1 H02S 1 low circuit terminal

connection at the PCM.
2. If a problem is found, repair as necessary. Refer to

H02S Replacement.
Was a problem found?

13

1. Check for poor Bank 1 H02S 1 signal circuit terminal

connection at the. PCM
2. If a problem is found, repair as necessary. Refer to

H02S Replacement.
Was a problem found?
14

15

Replace Bank 1 H02S 1. Refer to H02S Replacement.

Is action complete?
Locate and repair short to ground in Bank 1 H02S 1
ignition feed circuit and replace faulty fuse. Refer to H02S

Replacement.

16

Go to Step 16

Is action complete?

Important: If engine has just been operating, allow engine

to cool for about one half hour before proceeding.
1. Clear DTCs.
2. Turn ON the ignition switch.
3. Monitor Bank 1 H02S 1 voltage for at least 2 minutes
on the scan tool.
Does H02S voltage go from bias voltage to greater than
the first specified value or less than the second
specified value?

Go to Step 16

600mV
300mV

System OK

Go to Step 2

6-848

Engine Controls - 3.8L

Engine

OTC P0143 H02S Circuit Low Voltage Bank 1 Sensor 3

-i- ,

!Hot In Run, Bulb Test And Start!

- Ir - Power
Distribution

J7

I
I

J6

Cen 10

Underhood
.
Electrical
I Center 2
I
I

ENG SEN
MiniFuse
20 A

L------ ----J

Fuse Block
Details

......- -

PNK 539

-,

Cell11

r-------------,I

Powertrain
Control
I
~ Module
I
~(PCM)

PCM
C1=BLU
C2=CLEAR

-.... -....

.....

PNK 539

--------------,

Bank1

---~-~I
H02S 3
Low

H02S 31
Signal

1.-------------"

G:I'~6K B~;1,:0

..
I

PNK 539

Heated Oxygen

Sensor (H02S)
Bank 1 Sensor 1

Heated Oxygen
Sensor (H02S)
Bank 2 Sensor 1

Heated Oxygen
Sensor Bank 1
Sensor3

l'
I
I
I

1~ __ .:. _______

: : ~ : , ~ __ - - _ --<
=

ro~d;

~C
Dist ribution
e1114

(
222057

Circuit Description
To control emissions of Hydrocarbons (HC), Carbon
Monoxide (CO), and Oxides of Nitrogen (NOx), a
three-way catalytic converter is used. The catalyst
within the converter promotes a chemical reaction
which oxidizes the HC and CO present in the exhaust
gas, converting them into harmless water vapor
and carbon dioxide. The catalyst also reduces NOx,
converting it to nitrogen. The PCM has the ability
to monitor this process using the Bank 1 H02S
3 heated oxygen sensor. The Bank 1 H02S 3 sensor
produces an output signal which indicates the
oxygen storage capacity of the catalyst; this in turn
indicates the catalyst's ability to convert exhaust gases
efficiently. If the Bank 1 H02S 3 signal voltage
remains excessively low for an extended period of
time, DTC P0143 will be set.

Conditions for Setting the DTC

No TP sensor, EVAP system, EGR Pintle, misfire,
IAT sensor, MAP sensor, fuel trim, fuel injector
circuit, ECT sensor, CKP Sensor, or MAF sensor
DTCs are present.
System voltage is greater than 9 volts.

Closed loop commanded air/fuel ratio is

between 14.5 - 14.8.
Throttle angle is between 3% and 40%.
Bank 1 H02S signal voltage remains below
10 mV during normal closed loop operation
for longer than the specified time:
- Manual Transaxle - 3 minutes.
- Automatic Transaxle - 5 minutes.
OR
Bank 1 H02S 3 signal voltage remains below
600 mV during power enrichment mode fuel
control for longer than the specified time:
- Manual Transaxle - 90 seconds.
- Automatic Transaxle - 60 seconds.

Action Taken When the OTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Engine
Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Damaged H02S wiring - The sensor pigtail may
be mispositioned and contacting the exhaust
system.
Poor PCM to engine grounds
Fuel pressure low - A condition which causes a
lean exhaust can cause DTC P0143 to set. The
system will go lean if pressure is too low. The
PCM can compensate for some decrease.
However, if fuel pressure is too low, a OTC P0143
may be set. Refer to Fuel System Diagnosis.
Fuel injector(s) faulty - Refer to Fuel Injector
Balance Test.
Vacuum leaks - Check for disconnected or
damaged vacuum hoses and for vacuum leaks at
the intake manifold, throttle body, EGA system,
and crankcase ventilation system.
Exhaust leaks - An exhaust leak may cause
outside air to be pulled into the exhaust gas
stream past the H02S, causing the OTC P0143 to
set. Check for exhaust leaks near the H02S
Bank 1 Sensor 1 and H02S Bank 2 Sensor 1.

Engine Controls - 3.8L

6-849

MAF sensor faulty - Disconnect the MAF sensor

and see if the condition is corrected. If so,
replace MAF sensor.
Fuel contamination - Water, even in small
amounts, can be delivered to the fuel injectors.
The water can cause a lean exhaust to be
indicated. Excessive alcohol in the fuel can also
cause this condition. Refer to Fuel System
Diagnosis for procedure to check for fuel
contamination.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
3. DTC P0143 being set during power enrichment
mode conditions may indicate a condition
described in the Diagnostic Aids above. If the
OTC P0143 test passes while the Fail Records
conditions are being duplicated, an intermittent
condition is indicated. Review the Fail Records
vehicle mileage since the diagnostic test last
failed. This may help determine how often
the condition. that caused the OTC to be set
occurs.
7. This. vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

6-850

Engine

Engine Controls - 3.8L

OTC P0143 H02S Circuit Low Voltage Bank 1 Sensor 3

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to
Diagnostic Aids

Go to Step 5

Go to Step 6

Go to Step 7

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1. Install scan tool

2. Engine at operating temperature
3. Operate vehicle within parameters specified under
OTC Will Set When criteria included in Diagnostic
Support.
4. Using a scan tool, monitor Bank 1 H02S 3 voltage.
Does the Bank 1 H02S 3 voltage remain below the
specified value?
1. Turn ON the ignition switch.
2. Review and record scan tool Fail Records data and
note parameters.
3. Operate vehicle within Fail. Records conditions
as noted.
4. Using a scan tool, monitor Specific OTC info for
OTC P0143 until the OTC P0143 test runs.
Does the scan tool indicate OTC P0143 failed this ignition?
Disconnect Bank 1 H02S 3 and jumper the Bank 1
H02S 3 low circuit (PCM side) to ground.
Does scan tool indicate Bank 1 H02S 3 voltage near the
specified value?

75mV

450mV

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Check the Bank 1 H02S 3 signal circuit for a short to
ground or a short to the sensor ground circuit.
Is the Bank 1 H02S 3 signal circuit shorted?

Repair the Bank 1 H02S 3 signal circuit. Refer to Wiring

Repairs.
Is the action complete?

Replace the PCM.

Important: Replacement PCM must be programmed.
Refer to PCM Replacement/Programming.

Turn ON the ignition switch.

Review and record scan tool Fail Records data.
Clear DTCs
Operate vehicle within Fail Records conditions
as noted.
5. Using a scan tool, monitor Specific OTC info for
OTC P0143 until the OTC P0143 test runs.
Does the scan tool indicate OTC P0143 failed this ignition?

Go to Step B

Is the action complete?

1.
2.
3.
4.

Go to Step B

Go to Step 2

System OK

Engine

Engine Controls - 3.8L

6-851

1- ,

DTC P0144 H02S Circuit High Voltage Bank 1 Sensor 3

!Hot In Run, Bulb Test And Start!

r - Power

Distribution
Cell 10

J7

ENG SEN
MiniFuse
20 A

J6

L------

Fuse Block
Details
Cell 11

Powertrain
Control

.....- -

PCM
C1=BLU
C2 = CLEAR

Bank1
H02S 3

______

-,

',

I
I
H02S 3 I

L~w ____ 8!Jn_!!

----.I

PNK 539

r-------------,

~ Module
I
~ (PCM) L

Underhood
I Electrical
I Center 2
I

'

PNK 539

'

--------------,
I
I
I

.1

G:r,~6K a~;r,:O

PNK 539

D
Heated Oxygen
Sensor Bank 1
Sensor3

Heated Oxygen
Sensor (H02S)
Bank 1 Sensor 1
Heated Oxygen
Sensor (H02S)
Bank 2 Sensor 1

l'
I

I
I

_ _ _ _ _ _ _ _ _ _ _ _ _ _ .JI
BLKt50

BLK 4~'
'-- - - - - - - __.,.
_ _ _ _ _ _ _ _ _ _ -'4
~

round
Distribution
Cell14

222057

Circuit Description
To control emissions of Hydrocarbons (HC), Carbon
Monoxide (CO), and Oxides of Nitrogen (NOx), a
three-way catalytic converter is used. The catalyst
within the converter promotes a chemical reaction
which oxidizes the HC and CO present in the exhaust
gas, converting them into harmless water vapor
and carbon dioxide. The catalyst also reduces NOx,
converting it to nitrogen. The PCM has the ability
to monitor this process using the Bank 1 H02S
3 heated oxygen sensor. The Bank 1 H02S 3 sensor
produces an output signal which indicates the
oxygen storage capacity of the catalyst; this in turn
indicates the catalyst's ability to convert exhaust gases
efficiently. If the Bank 1 H02S 3 signal voltage
remains excessively high for an extended period of
time, OTC P0144 will be set.

Conditions for Setting the DTC

No TP sensor, EVAP system, EGR Pintle, misfire,
IAT sensor, MAP sensor, fuel trim, fuel injector
circuit, ECT sensor, or MAF sensor DTCs are set.
Air/Fuel ratio is between 14.5 and 14.8.
Bank 1 H02S 3 signal voltage remains above
999 mV during normal closed loop operation
for longer than the specified time:
- Manual Transaxle - 7.5 minutes.
- Automatic Transaxle - 5 minutes.
OR
Bank 1 H02S 3 signal voltage remains above
200 mV for longer than 90 seconds during
deceleration fuel mode operation.

6-852

Engine Controls - 3.8L

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIL/DTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Fuel pressure high - An excessively rich fuel
mixture can cause a DTC P0144 to be set. Refer
to Fuel System Pressure Test
Fuel injector(s) faulty - Refer to Fuel Injector
Balance Test
Check the EVAP Canister for Fuel Saturation. If
the EVAP Canister is full of fuel, check canister
control and hoses. Refer to EVAP Control System
Diagnosis
Disconnect the MAF sensor and see if the rich
condition is corrected. If so, replace the MAF
sensor. Refer to MAF Sensor Replacement
Check for a leaking fuel pressure regulator
diaphragm by checking the vacuum line to the fuel
pressure regulator for the presence of fuel.
An intermittent TP sensor output will cause the
system to go rich, due to a false indication of
the engine accelerating.

Engine
Shorted H02S - If the H02S is internally shorted
the H02S voltage displayed on the scan tool will
be over 1 volt. Try disconnecting the affected
H02S and jumper the H02S low circuit to ground
with the key ON. If the displayed H02S voltage
changes from over 1000mV to around 450mV,
replace the H02S. Silicon contamination of
the H02S can also cause a high H02S voltage to
be indicated. This condition is indicated by a
powdery white deposit on the portion of the H02S
exposed to the exhaust stream. If contamination
is evident, replace the affected H02S. Refer
to H02S Replacement
Open H02S Signal or Low Circuit or Faulty H02S
- A poor connection or open in the H02S signal
or low circuit can cause the DTC to set during
deceleration fuel mode. An H02S which is faulty
and not allowing a full voltage swing between
the rich and lean thresholds can also cause this
condition. Operate the vehicle while monitoring the
H02S voltage with a scan tool. If the H02S
voltage is limited within a range between 300mV
to 600mV, check the H02S signal and low
circuit wiring and associated terminal connections.
If the wiring and connections are OK, replace
the H02S. Refer to H02S Replacement

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
3. DTC P0144 being set during deceleration fuel
mode operation may indicate a condition
described in the Diagnostic Aids above. If the
DTC P0144 test passes while the Fail Records
conditions are being duplicated, an intermittent
condition is indicated. Review the Fail Records
vehicle mileage since the diagnostic test last
failed. This may help determine how often
the condition that caused the DTC to be set
occurs.
7. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

Engine

Engine Controls - 3.8L

6-853

DTC P0144 H02S Circuit High Voltage Bank 1 Sensor 3

Action

Step

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Install scan tool

Engine at operating temperature
Operate vehicle within parameters specified under
OTC Will Set When criteria included in Diagnostic
Support.
Using a scan tool, monitor Bank 1 H02S 3 voltage.
Does the Bank 1 H02S 3 voltage remain above the
specified value?
1. Turn ON the ignition switch.
2. Review and record scan tool Fail Records data.
3. Operate vehicle within Fail Records conditions
as noted.
4. Using a scan tool, monitor Specific DTC info for
OTC P0144 until the OTC P0144 test runs.
Does scan tool indicate OTC P0144 failed?
1. Disconnect Bank 1 H02S 3
2. Jumper H02S low circuit to ground.
Does scan tool indicate Bank 1 H02S 3 voltage near the
specified value?

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to
Diagnostic Aids

Go to Step 5

Go to Step 6

Go to Step 7

999mV

450mV

1. Turn OFF the ignition switch.

)
5

2. Disconnect PCM connector

3. Turn ON the ignition switch.
4. Using a J 39200 DMM, measure voltage between the
Bank 1 H02S 3 sensor signal at th.e PCM harness
connector and ground.

999mV

Does the DMM indicate a voltage above specified value?

)
I

Repair short to voltage in the Bank 1 H02S 3 signal

circuit. Refer to Wiring Repairs.
Is the action complete?

Replace the PCM.

Important: Replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Is the action complete?

Turn ON the ignition switch.

Review and record scan tool Fail Records data.
Clear DTCs
Operate vehicle within Fail Records conditions
as noted.
5. Using a scan tool, monitor Specific DTC info for
OTC P0144 until the OTC P0144 test runs.
Does scan tool indicate OTC P0144 failed this ignition?

1.
2.
3.
4.

Go to Step 8

Go to Step 8

Go to Step 2

System OK

6-854

Engine Controls - 3.8L

Engine

OTC P0146 H02S Circuit Insufficient Activity Bank 1 Sensor 3

fHot In Run, Bulb Test And Start!

r -

Fuse Block
Details
Cell 11

Powertrain
Control
~ Module
~ (PCM)

- - - Power
Distribution
Cen 10

.,

Underhood

I Electrical

J7

ENG SEN
MinlFuse

I Center 2

J6

20 A

L"'"---,-----.1
PNK 539
~ - -,
-.... ,
PNK 539

r-------------,
PCM

......

......

......

'

Bank1

--------------,
I

PNK 539

Heated Oxygen
Sensor (H02S)
Bank 1 Sensor 1

D
Heated Oxygen
Sensor Bank 1
Sensor3

Heated Oxygen

Seneor (H02S)
Bank 2 Sensor 1

I.

I
I

BLKt50

-----

BLK 4~' ......__ - - - ...,. .- - _,,.

_ _ _ _ _ _ _ _ _ _ _,.

_ _ _ _ _ _ _ _ _ .J

Ground

Distribution.
Cell14

222057

:circuit Description
To control emissions of Hydrocarbons (HC), Carbon
Monoxide (CO), and Oxides of Nitrogen (NOx), a
three-way catalytic converter is used. The catalyst
within the converter promotes a chemical reaction
which oxidizes the HC and CO present in the exhaust
gas, converting them into harmless water vapor
and carbon dioxide. The catalyst also reduces NOx,
converting it to nitrogen. The PCM has the ability
to monitor this process using the Bank 1 H02S
3 heated oxygen sensor: The Bank 1 H02S 3 sensor
produces an output signal which indicates the
oxygen storage capacity of the catalyst; this in turn
indicates the catalyst's ability to convert exhaust gases
efficiently. If the Bank 1 H02S 3 signal voltage
remains at or near the 450mV bias for an extended
period of time, DTC P0146 will be set.

Conditions for Setting the OTC

No TP sensor, EVAP system, EGR Pintle, misfire,
IAT sensor, MAP sensor, fuel trim, fuel injector
circuit, ECT sensor, CKP Sensor, or MAF sensor
DTCs are set.
System voltage is greater than 9 volts.

The following' engine run time requirements

are met:
- Manual Transaxle - 4 minutes.
- Automatic Transaxle - 3 minutes.
Bank 1 H02S 3 signal voltage remains
between 425 mV and 475 mV for longer
than 7.5 minutes.

Action Taken When the OTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clear,ing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Engine Controls - 3.8L

Engine
Diagnostic Aids
Check for the following conditions:
Corroded exhaust flange bolts - Using a J 39200
DMM, ensure that continuity exists between the
engine block and the heated oxygen sensor shell.
If resistance is excessively high, replace
corroded exhaust flange attaching hardware as
necessary.
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.
Faulty H02S heater or heater circuit - With the
ignition ON the H02S voltage displayed on a
scan tool should gradually drop to below 300mV
or rise to above 600mV. If not, disconnect the
H02S and connect a test light between the H02S
ignition feed and heater ground circuits. If the
test light does not light, repair the open ignition
feed or sensor ground circuit as necessary. Refer

6-855

to Wiring Repairs. If the J34142-B test lamp lights

and the H02S signal and low circuits are OK,
replace the H02S. Refer to H02S Replacement
Intermittent test - With the ignition ON, monitor the
H02S signal voltage while moving the wiring
harness and related connectors. If the fault
is induced, the H02S signal voltage will change.
This may help isolate the location of the
malfunction.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
3. If the DTC P0146 test passes while the Fail
Records conditions are being duplicated, an
intermittent condition is indicated. Review the Fail
Records vehicle mileage since the diagnostic
test last failed. This may help determine how often
the condition that caused the OTC to be set
occurs.
13. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

DTC P0146 H02S Circuit Insufficient Activity Bank 1 Sensor 3

Step

Action

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

1. Engine at operating temperature

2. Operate engine above 1200 RPM for at least two
minutes
Does scan tool indicate Bank 1 H02S 3 voltage varying
outside the specified values?
1. Turn ON the ignition switch.
2. Review and record scan tool Fail Records data and
note parameters.
3. Operate vehicle within Fail Records conditions
as noted.
4. Using a scan tool, monitor Specific OTC info for
OTC P0146 until the OTC P0146 test runs.
Does the scan tool indicate OTC P0146 failed this ignition?

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Step 4

Go to Step 4

Go to
Diagnostic Aids

Go to Step B

Go to Step 5

Go to Step 6

Go to Step 7

424-475 mV

1. Turn ON the ignition switch.

2. Disconnect Bank 1 H02S 3.
3. Jumper the H02S signal and low circuits (PCM side)
to ground.
4. Using a scan tool, monitor Bank 1 H02S 3 voltage.
Is Bank 1 H02S 3 voltage below the specified value?

150 mV

1. Remove the jumper wire from the Bank 1 H02S 3

Signal Circuit {leave the Bank 1 H02S 3 low circuit
connected to ground).
2. Using a J 39200 DMM, measure voltage between the
Bank 1 H02S 3 signal circuit (PCM side) and the
Bank 1 H02S 3 heater ground circuit.
Does Bank 1 H02S 3 signal circuit voltage measure near
the specified value?

450mV

6-856

Engine Controls - 3.8L

Engine

DTC P0146 H02S Circuit Insufficient Activity Bank 1 Sensor 3 (cont'd)

Action

Step

10

11

12

13

14

15

1.
2.
3.
4.

Value(s)

Turn OFF the ignition switch.

Disconnect the PCM.
Check continuity of the Bank 1 H02S 3 low circuit.
If the Bank 1 H02S 3 low circuit measures over
5 ohms, repair open or poor connection as
necessary. Refer to Wiring Repairs.
Was Bank 1 H02S 3 low circuit probiem found and
corrected?

1. Turn OFF the ignition switch.

2. Disconnect the PCM and ch.eek continuity of the
Bank 1 H02S 3 signal circuit and the Bank 1 H02S 3
low circuit.
3. If the Bank 1 H02S 3 signal or low circuit measures
over 5 ohms, repair open or poor connection as
necessary. Refer to Wiring Repairs.
Was a problem found?

1. Check for a poor Bank 1 H02S 3 signal or low circuit

terminal connection at the Bank 1 H02S 3 harness
connector.
2. If a problem is found, replace terminal(s) as
necessary. Refer to Wiring Repairs.
Was a problem found?

1. Check for poor Bank 1 H02S 3 low circuit terminal

connection at the PCM.
2. If a problem is found, replace terminal(s) as
necessary. Refer to Wiring Repairs.
Was a problem found?

1. Check for poor Bank 1 H02S 3 signal and low circuit

and the Bank 1 H02S 3 low circuit for a poor terminal
connection at the PCM.
2. If a problem is found, replace terminal(s) as
necessary. Refer to Wiring Repairs.
Was a problem found?
Replace Bank 1 H02S 3. Refer to H02S Replacement.
Is the action completed?
Replace the PCM.
Important: Replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Is the action complete?
Check for poor Bank 1 H02S 3 signal circuit terminal
connection at the PCM and replace terminal if necessary.
Refer to Wiring Repairs.
Did the terminal require replacement?
Locate and repair cause of high resistance (corroded
exhaust flange bolts, separated exhaust flange).
Is the action complete?
1. Turn ON the ignition switch.
2. Review and record scan tool Fail Records data and
note parameters.
3. Clear DTCs
4. Operate vehicle within Fail Records conditions
as noted.
5. Using a scan tool, monitor Specific OTC info for
OTC P0146 until the OTC P0146 test runs.
Does the scan tool indicate OTC P0146 failed this ignition?

Yes

No
I

\.

Go to Step 15

Go to Step9

Go to Step 15

Go to Step 10

Go to Step 15

Go to.Step 11

Go to Step 15

Go to. Step 11

Go to Step 15

Go to Step 12

Go to Step 15

Go to Step 15

Go to Step 13

Go to Step 15

Go to Step 15

Go to Step 2

System OK

Engine Controls - 3.8L

Engine

6-857

i---.,

DTC P0147 H02S Heater Performance Bank 1 Sensor 3

!Hot In Run, Bulb Test And Start!

... - Powe-;
Distribution
I cen 10

...I
Fuse Block
Details
Cell 11

PCM
Cl=BLU
C2 = CLEAR

Bankl
H02S 3

_ _ _ _ _ _ L~w _ _ _ _

ENG SEN
MlnlFuse
20 A

__________

.-- -

J6

Underhood
I Electrical
.
I Center 2
_.I

PNK 539

-,

r-------------.,

Powertrain
Control
~ Module I
I
~(PCM) 1.

J7

',

I
I
H02S 3 I

PNK 539

....

'

--------------,

~n! _.

G:I'~DK~;r,:O

PNK 539

Heated Oxygen
Sensor (H02S)
Bank 1 Sensor 1

Heated Oxygen
Sensor (H02S)
Bank 2 Sensor 1

Heated Oxygen
Sensor Bank 1
Sensor 3

I
I

BLKt50______________ I
_.

BLK 4~' ' - - - - - - _____ .

____

-<11
~

round
Distribution
Cell14

222057

Circuit Description

Heated oxygen sensors are used to minimize the

amount of time required for closed loop fuel control
operation and to allow accurate catalyst monitoring.
The oxygen sensor heater greatly decreases the
amount of time required for fuel control sensors Bank 1
H02S 1 and Bank 2 H02S 1 to become active. An
oxygen sensor heater is required by catalyst monitor
sensor Bank 1 H02S 3 to maintain a sufficiently
high temperature which allows accurate exhaust
oxygen content readings further from the engine. The
PCM will run the heater test only after a cold start
(determined by engine coolant and intake air
temperature at the time of startup) and only once
during an ignition cycle. When the engine is started
the PCM will monitor the H02S voltage. When the
Bank 1 H02S 3 voltage indicates a sufficiently active
sensor, the PCM looks at how much time bas
elapsed since startup. If the PCM determines that too
much time was required for the Bank 1 H02S 3 to
become active, a DTC P0147 will set. The time
it should take the H02S to reach operating
temperature is based on the engine coolant
temperature at start-up and the average Mass Air
Flow since startup (higher average airflow or higher
startup engine coolant temperature = shorter time
to H02S activity).

Conditions for Setting the DTC

No TP sensor, EVAP system, EGR Pintle, misfire,
IAT sensor, MAP sensor, fuel trim, fuel injector
circuit, ECT sensor, CKP Sensor, or MAF sensor
DTCs are set.
Intake Air Temperature (IAT) is less
than 35C (95F) at startup
Engine Coolant Temperature (ECT) is less
than 35C (95F) at startup.
IAT and ECT are within 6C (11 F) of each other
at start-up.
The average mass air flow for the sample period
is less than the following grams/second (g/s):
- Manual Transaxle - 23 g/s.
- Automatic Transaxle - 20 g/s.
Bank 1 H02S 3 voltage remains within 150 mV of
the bias voltage (about 450 mV) for a longer than
the following amount of time:
- Manual Transaxle - The amount of time
ranges between 2 and 6 minutes.
- Automatic Transaxle - The amount of time
ranges between 2 and 4 minutes.
The amount of time depends on engine coolant
temperature at startup and the average air flow
since startup.

6-858

Engine Controls - 3.8L

Action Taken When the OTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.
Damaged harness - Inspect the wiring harness
for damage. If the harness appears to be OK,
observe the display on the scan tool while moving
connectors and wiring harnesses related to the
sensor. A change in the display will indicate
the location of the fault.

Engine
Review .the Fail Records vehicle mileage since the
diagnostic .test last failed. This may help determine
how often the condition that caused the DTC to be set
occurs.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:

2. The H02S should be allowed to cool before

performing this test. If the H02S heater is
functioning, the signal voltage will gradually
increase or decrease as the sensor element
warms. If the heater is not functioning, the H02S
signal will remain near the 450mV bias voltage.
4. This step ensures that the ignition feed circuit to
the H02S is not open or shorted. The J 34142-8
test lamp should be connected to a good
chassis ground, in case the H02S low or H02S
heater ground circuit is faulty.
5. This step checks the H02S heater ground circuit.
6. This step checks for an open or shorted H02S
heater element. The heater element resistance
will vary according to H02S temperature (a
hot H02S heater element will measure a much
higher resistance than a H02S heater element at
room temperature). It is important to allow the
H02S to cool before measuring H02S heater
element resistance.
11. An open H02S signal or low circuit can cause the
H02S heater to appear faulty. Check these
circuits before replacing the sensor.

DTC P0147 H02S Heater Performance Bank 1 Sensor 3

Step

Action

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Important: If engine has just been operating, allow engine

to cool for about one half hour before proceeding.
1. Turn ON the ignition switch.
2. monitor Bank 1 H02S 3 voltage on the scan tool
H02S data list.
Does H02S voltage go from bias voltage to greater than
the first specified value or less than the second
specified value?

Inspect fuse for Bank 1 H02S 3 ignition feed.

Is the fuse open?

1. Raise the vehicle.

2. Disconnect the Bank 1 H02S 3 electrical connector.
3. Probe the ignition feed circuit at .the Bank 1 H02S 3
electrical connector (PCM harness side) using a
J 34142-8 Unpowered test lamp connected to
ground.
Important: Use a known good ground. Do not use the
Bank 1 H02S 3 heater ground or Bank 1 H02S 3 low.
Does test lamp illuminate?

Value(s)

Yes

No

Go to the A

Go to Step 2

Powertrain On
Board Diagnostic
(OBD) System
Check

Go to
Diagnostic Aids

Go to Step 3

Go to Step 15

Go to Step 4

Go to Step 5

Go to Step 7

600mV
300 rt1V

Engine Controls - 3.SL 6-859

Engine

OTC P0147 H02S Heater Performance Bank .1 Sensor 3 (cont'd)

Step

Value(s)

Repair open Bank 1 H02S 3 ignition feed circuit to Bank 1

H02S 3. Refer to Wiring Repairs.
Is the action complete?

Repair open Bank 1 H02S 3 heater ground circuit. Refer

to Wiring Repairs.
Is the action complete?

1. Check for a poor connection at the Bank 1 H02S 3

harness terminals
2. If a poor connection is found, replace terminals. Refer
to Wiring Repairs.
Was a poor connection found?

10

11

12

13

14

15

16

1. Turn OFF the ignition switch.

2. Disconnect the PCM and check continuity of the
Bank 1 H02S 3 signal circuit and the Bank 1 H02S 3
low circuit.
3. If the Bank 1 H02S 3 signal circuit or H02S low
circuit measures over 5 ohms, repair open or poor
connection as necessary. Refer to Wiring Repairs.
Was a problem found?
Check for a poor Bank 1 H02S 3 signal or low circuit
terminal connection at the Bank 1 H02S 3 harness
connector and replace terminal(s) if necessary. Refer to
Wiring Repairs.
Did any terminals require replacement?
Check for poor Bank 1 H02S 3. low circuit terminal
connection at the PCM and replace terminal if necessary.
Refer to Wiring Repairs.
Did the terminal require replacement?
Check for poor Bank 1 H02S 3 signal circuit terminal
connection at the PCM and replace terminal if necessary.
Refer to Wiring Repairs.
Did the terminal require replacement?
Replace Bank 1 H02S 3. Refer to H02S Replacement
Is the action complete?
Locate and repair short to ground in Bank 1 H02S 3
ignition feed circuit and replace faulty fuse. Refer to Wiring
Repairs.
Is the action complete?
Important: If engine has justbeen operating, allow engine
to cool for about one half hour before proceeding.
1. Clear DTCs
2. Turn ON the ignition switch monitor Bank 1
H02S 3 voltage on the scan tool H02S data list.
Does H02S voltage go from bias voltage to greater than
the first specified value or less than the second
specified value?

Yes

No

Go to Step 6

Go to Step 8

Go to Step 9

Go to Step 14

1. Allow the H02S to cool for at least 10 minutes.

2. Using a J 39200 DMM, measure resistance between
(Bank 1 H02S 3 ignition feed and Bank 1 H02S 3
heater ground) at the Bank 1 H02S 3 pigtail.
Is H02S resistance within the specified values?

Action
Connect the test lamp between Bank 1 H02S 3 ignition
feed and Bank 1 H02S 3 heater ground.
Does test lamp illuminate?

5-10 ohms

Go to Step 16

Go to Step 16

Go to Step 16

Go to Step 10

Go to Step 16

Go to Step 11

Go to Step 16

Go td Step 12

Go to Step 16

Go to Step 13

Go to Step 16

Go to Step 14

Go to Step 16

Go to Step 16

600mV
300mV

System OK

Go to Step 2

6-860

Engine Controls - 3.8L

Engine

OTC P0151 H02S Circuit Low Voltage Bank 2 Sensor 1

!Hot In Run, Bulb Test And StartI

'" -P;ie-; - ] -- - - - ,I Underhood

I
J7.

Distribution

I
I

Cell 10

J6

L.-----Fuse Block
Details

Cell11

ENG SEN
MiniFuse

2DA

I
I

Electrical
Center 2

____ ...

PNK 539

+--- .....

' , PNK 539

.....

r--------------------------

Heated Oxygen
Sensor (H02SO
Bank 1 Sensor 1

Powertrain
Control
MO d U Ie
(PCM}

'" - - - - I
PCM
C1=BLU
I
I

C2 = CLEAR

Bank 2
H02S 1
Low

H02S 1.
Signal

,
1
I
I

L-----------------~
>
291 C1 101 C2
~
TA: 1667 P~L 1666 PN; 539

Heated Oxygen
Sensor (H02SO
Bank 1 Sensor 3

Heated Oxygen
Sensor Bank 2
Sensor 1

T
I

I
I

'. ------------------------::1~-~'_ "- _- - - - - - -~

~

.....,.Gr-ou-nd-,---.
Distribution
Cell14

226749

Circuit Description
The PCM supplies a bias voltage of about 450mV
between the H02S signal and low circuits. When
measured with a 1O megohm digital voltmete;, this
may display as low as 320mV. The oxygen sensor
varies the voltage within a range of about 1OOOmV
when the exhaust is rich, down through about 1OmV
when exhaust is lean. The PCM constantly monitors
the H02S signal during closed loop operation
and compensates for a rich or lean condition by
decreasing or increasing injector pulse width as
necessary. If the Bank 2 H02S 1 voltage remains
excessively low for an extended period of time,
OTC P0151 will be set.

Conditions for Setting the OTC

No TP sensor, EVAP system, EGR Pintle, misfire,
IAT sensor, MAP sensor, fuel trim, fuel injector
circuit, ECT sensor, CKP Sensor, or MAF sensor
OTCs are set.
System voltage is greater than 9 volts.
The commanded air/fuel ratio is between
14.5 and 14.8.
Throttle angle is between 3% and 40%.

Bank 2 H02S 1 signal voltage remains below

175 mV for longer than 45 seconds during normal
closed loop operation.
OR
Bank 2 H02S 1 signal voltage remains below
600 mV for longer than 60 seconds during
power enrichment mode fuel control operation.

Action Taken When the OTC Sets

Th.e PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
b~en run and passed.
The history OTC will clear after 40 consecutive
Wi:l,rm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Engine

Engine Controls - 3.8L

6-861

Diagnostic Aids

Test Description'

Check for the following conditions:

Heated oxygen sensor wiring damaged - The
sensor pigtail may be mispositioned and
contacting the exhaust system.
Poor PCM to engine grounds
Fuel pressure low - A condition which causes a
lean exhaust can cause DTC P0151 to set. The
system will go lean if pressure is too low. The
PCM can compensate for some decrease.
However, if fuel pressure is too low, a DTC P0151
may be set. Refer to Fuel System Pressure Test
Fuel injector(s) faulty - Refer to Fuel Injector
Balance Test.
Vacuum leaks - Check for disconnected or
damaged vacuum hoses and for vacuum leaks at
the intake manifold, throttle body, EGA system,
and crankcase ventilation system.
Exhaust leaks - An exhaust leak may cause
outside air to be pulled into the exhaust gas
stream past the H02S, causing the DTC P0151 to
set. Check for exhaust leaks near the H02S 2
sensor.
Disconnect the MAF sensor and see if the
condition is corrected. If so, replace MAF sensor.
Refer to MAF Sensor Replacement.
Fuel contamination - Water, even in small
amounts, can be deliveredto the fuel injectors.
The water can cause a lean exhaust to be
indicated. Excessive alcohol in the fuel can also
cause this condition. Refer to
Alcohol/Contaminants-in-Fuel Diagnosis

Number(s) below refer to the step number(s) on the

Diagnostic Table:
3. DTC P0151 failing during power enrichment fuel
mode may indicate a condition described in the
Diagnostic Aids above. If the DTC P0151 test
passes while the Fail Records conditions are being
duplicated, an intermittent condition is indicated.
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help
determine how often the condition that caused the
DTC to be set occurs.
7. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

s..862

Engine

Engine Controls - 3.SL

DTC P0151 H02S Circuit Low Voltage Bank 2 Sensor 1

Step.

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to
Diagnostic Aids

Go to Step 5

Go to Step 6

Go to Step 7

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1. Install scan tool

2. Engine at operating temperature
3. Operate vehicle within parameters specified under
DTC Will Set When criteria included in Diagnostic
Support.
4. Using a scan tool, monitor Bank 2 H02S 1 voltage.
Does the Bank 2 H02S 1 voltage remain below the
specified value?

300mV

1. Turn ON the ignition switch.

2. Review and record scan tool Fail Records data and
note parameters.
3. Operate vehicle within Fail Records conditions
as noted.
4. Using a scan tool, monitor Specific DTC info for
DTC P0151 until the DTC P0151 test runs.
Does scan tool indicate DTC P0151 failed this ignition?

1. Disconnect Bank 2 H02S 1.

2. Jumper the Bank 2 H02S 1 low circuit (PCM side) to
ground.
Does scan tool indicate Bank 2 H02S 1 voltage near the
specified value?

450mV

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Check the Bank 2 H02S 1 signal circuit for a short to
ground or a short to the sensor ground circuit.
Is the Bank 2 H02S 1 signal circuit shorted?

Repair the Bank 2 H02S 1 signal circuit. Refer to Wiring

Repairs.
Is the action complete?

Replace the PCM.

Important: Replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Is the action complete?

1.
2.
3.
4.

Turn ON the ignition switch.

Review and record scan tool Fail Records data.
Clear DTCs
Operate vehicle within Fail Records conditions
as noted.
5. Using a scan tool, monitor Specific DTC info for
DTC P0151 until the DTC P0151 test runs.
Does the scan tool indicate DTC P0151 failed this ignition?

Go to Step 8

Go to Step 8

Go to Step 2

System OK

Engine Controls - 3.8L

Engine

6-863

DTC P0152 H02S Circuit High Voltage Bank 2 Sensor 1

!Hot In Run, Bulb Test And Start!

P;,;

--

, Underhood

Cell 10

MlniFuse
20 A

r ~
I
Distribution
J7
EN.G SEN

I
I

J6

L-----..,._ - ..... PNK

Fuse Block
Details
Cell11

I Electrical
I Center 2

DJ

I
----..1

539

' , PNK 539

r------. ------------------I
I

Heated Oxygen
Sensor (H02SO
Bank 1 Sensor 1

Powertrain
Control
MOd UIe
(PCM)
~

r -

I
I
I

- -

PCM
C1=BLU
C2=CLEAR

- -

- ,

1
I
I

Bank2

H02S1
.Low

H02S 1
Signal

~-----------------J

r!~11~!7 P~OL11~!6
A

PNK 539
D

Heated Oxygen
Sensor (H02SO
Bank 1 Sensor 3

Heated Oxygen
Sensor Bank 2
Sensor 1

I
I
I
I

BLKt SO
L-------------------------',

BLK 450 "- - - - - - - _..,.

-

Ground
Distribution
__..,. '--=Ce"'-111.;..;.4_
_.

226749

Circuit Description
The PCM supplies a bias voltage of about 450mV
between the H02S signal and low circuits. When
measured with a 1O megohm digital voltmeter, this
may display as low as 320mV. The oxygen sensor
varies the voltage within a range of about 1OOOmV
when the exhaust is rich, down through about 10mV
when exhaust is lean.The PCM constantly monitors
the H02S signal during closed loop operation
and compensates for a rich or lean condition by
decreasing or increasing injector pulse width as
necessary. If the Bank 2 H02S 1 voltage remains
excessively high for an extended period of time,
OTC P0152 will be set.

Conditions for Setting the DTC

No TP sensor, EVAP system, misfire, EGR Pintle,
IAT sensor, MAP sensor, fuel trim, fuel injector
circuit, ECT sensor, CKP Sensor, or MAF sensor
DTCs are set.
Bank 2 H02S 1 signal voltage remains above
975 mV for longer than 45 seconds during normal
closed loop operation.
OR
Bank 2 H02S 1 signal voltage remains above
110 mV for longer than 30 seconds during
deceleration fuel mode operation.

6-864

Engine

Engine Controls - 3.8L

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
. been run and failed.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Fuel pressure high - An excessively rich fuel
mixture can cause a OTC P0152 to be set. Refer
to Refer to Fuel System Pressure Test.
Fuel injector(s) faulty - Refer to Fuel Injector
Balance Test
Check the EVAP Canister for Fuel Saturation. If
the EVAP Canister is full of fuel, check canister
control and hoses. Refer to EVAP Control System
Diagnosis
Disconnect the MAF sensor and see if rich
condition is corrected. If so, replace MAF sensor.
Refer to MAF Sensor Replacement
Check for a leaking fuel pressure regulator
diaphragm by checking the vacuum line to the fuel
pressure regulator for the presence of fuel.
An intermittent TP sensor output will cause the
system to go rich, due to a false indication of
the engine accelerating.

Shorted H02S - If the H02S is internally shorted

the H02S voltage displayed on the scan tool will
be over 1 volt. Try disconnecting the affected
H02S and jumper the H02S low circuit to ground
with the key ON. If the displayed H02S voltage
changes from over 1OOOmV to around 450mV,
replace the H02S. Silicon contamination of
the H02S can also cause a high H02S voltage to
be indicated. This condition is indicated by a
powdery white deposit on the portion of the H02S
exposed to the exhaust stream. If contamination
is evident, replace the affected H02S.
Open H02S Signal or Low Circuit or Faulty H02S
- A poor connection or open in the H02S signal
or low circuit can cause the OTC to set during
deceleration fuel mode. An H02S which is faulty
and 'not allowing a full voltage swing between
the rich and lean thresholds can also cause this
condition. Operate the vehicle while monitoring the
H02S voltage with a scan tool. If the H02S
voltage is limited within a range between 300nW
to 600mV, check the H02S signal and low
circuit wiring and associated terminal connections.
If the wiring and connections are OK, replace
the H02S.

\.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
3. OTC P0152 failing during deceleration fuel mode
operation may indicate a condition described in
the Diagnostic Aids above. If the DTC P0152 test
passes while the Fail Records conditions are
being duplicated, an intermittent condition
is indicated. Review the Fail Records vehicle
mileage si.nce the diagnostic test last failed. This
may help determine how often the condition
that caused the OTC to be set occurs.
7. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

Engine

Engine Controls - 3.BL

6-865

DTC P0152 H02S Circuit High Voltage Bank 2 Sensor 1

Action

Step

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 5

Go to Step 3

Go to Step 5

Go to Step 4

Go to Step 5

Go to
Diagnostic Aids

Go to
Diagnostic Aids

Go to Step 6

Go to Step 7

Go to Step 8

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

1. Engine at operating temperature.

2. Operate vehicle within parameters specified under

Conditions for Setting the DTC criteria included in
Diagnostic Support.

800mV

3. Monitor Bank 2 H02S 1 voltage display on the scan

tool H02S data list
Does the H02S voltage remain above the specified value?

Operate vehicle in Decel fuel mode (vehicle speed above

25 mph, TP angle below 3%) while monitoring Bank 2
H02S 1 voltage display on the scan tool H02S data list.

110 mV

Does the Bank 2 H02S 1 voltage remain above the

specified value while in Decel fuel mode?
1. Turn ON the ignition switch.
2. Review and record scan tool Fail Records data.
4

3. Operate vehicle within Fail Records conditions

as noted
4. Using a scan tool, monitor Specific OTC info for
DTC P0132 until the DTC P0132 test runs

Does the scan tool indicate DTC P0132 failed this ignition?

Disconnect Bank 2 H02S 1. and jumper Bank 2 H02S 1

low circuit to ground.
Does scan tool indicate Bank 2 H02S 1 voltage near the
specified value?

450mV

1. Turn OFF the ignition switch.

2. Disconnect PCM connector
3. Turn ON the ignition switch.
6

4. Using a J 39200 DMM, measure voltage between the

Bank 2 H02S 1 sensor signal at PCM harness
connector and ground.

600mV

Does the DMM indicate a voltage greater than

specified value?

Repair short to voltage in the Bank 2 H02S 1 signal

circuit. Refer to Wiring Repairs.

Is the action complete?

Go to Step 9

Replace the . PCM.

8

Important: Replacement PCM must be programmed.

Refer to PCM Replacement/Programming.

Is the action complete?

Go toStep 9

1. Turn ON the ignition switch.

2. Review and record scan tool Fail Records data.
3. Clear DTCs
9

4. Operate vehicle within Fail Records conditions

as noted.

5. Using a scan tool, monitor Specific DTC info for

DTC P0152 until the DTC P0152 test runs
Does the scan tool indicate DTC P0152 failed this ignition?

Go to Step 2

System OK

6-866

Engine Controls - 3.8L

Engine

1 ,

DTC P0153 H02S Slow Response Bank 2 Sensor 1

!Hot In Run, Bulb Test And Start!

Underhood

r - Power
I
Distribution

ce1110

J7

ENG SEN
rvliniFuse
20A

...----

I Center 2

I
----.J

J6

L------

Fuse Block
Details
Cell11

I Electrical

PNK 539

'

' , PNK 539

r-------------------------Powertrain r
Control I
MOd LI Ie II
(PCM)

PCM
C1=BLU
C2 = CLEAR

H02S 1
Low

H02S 1
Signal

I
TA:I
29

C1
1667

I
I
I

Bank 2

L----------------.

~
~

Heated Oxygen
Sensor (H02SO
Bank 1 Sensor 1

10 C2
P~L 1666

Heated Oxygen

PN K 539
0

Sensor (H02SO

Heated. Oxygen
Sensor Bank 2

Bank 1 Sensor 3

Sensor 1

I
I

I
I

'. -

l~

-.

: : . _ : _ , "-_- - - - - - - - - - - - - ~ l"""O!'Gr--ou--nd-.---,

Distribution
Cell14

(
226749

Circuit Description
The PCM continuously monitors the Heated Oxygen
Sensor (H02S) activity. The PCM counts the
number of times that the a rich to lean and lean to rich
response is indicated and adds the amount of time
it took to complete all transitions for a 100 second test
period. With this information, an average time for
each transition can be determined. If the average
response time is too slow, a OTC P0153 will be set., A
lean to rich transition is indicated when the H02S
voltage changes from less than 300 mV to greater
than 600 mV. A rich to lean transition is indicated when
the H02S voltage changes from more than 600 mV
to less than 300 mV. An H02S that responds too
slowly is likely to be faulty and should be replaced.

Conditions for Setting the OTC

No TP sensor, Bank 2 H02S 1 Heater, EVAP
system, EGR Pintle, misfire, IAT sensor, MAP
sensor, fuel trim, fuel injector circuit, ECT sensor,
or MAF sensor DTCs are set.
Engine has been running in closed loop for at
least 1 minute.
Engine speed is between 1000 RPM
and 3000 RPM.
Engine Coolant Temperature is greater than
50C (122F).

Mass Air Flow values are as follows:

- Manual T.ransaxle - Between 10 g/s
and 30 g/s.
- Automatic Transaxle - Between 15 g/s
and 29 g/s.
Automatic Transaxle - Bank 2 H02S 1 lean to rich
and rich to lean average transition response time
was longer than 90 milliseconds.
Manual Transaxle - Bank 2 H02S 1 lean to rich
average transition response time was longer
than 135 milliseconds. The rich to lean average
transition response time was longer
than 120 millisecondsec
The conditions are present during the 100 second
response test period.
Automatic Transaxle - Bank 1 H02S 1 lean to rich
and rich to lean average transition response time
was longer than 90 milliseconds.
Manual Transaxle - Bank 1 H02S 1 lean to rich
average transition response time was longer
than 150 milliseconds. The rich to lean average
transition response time was longer
than 130 milliseconds.
The conditions are present during the 100 second
response test period.

Engine Controls - 3.8L

Engine
Action Taken When the OTC Sets
The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIL/OTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.

6-867

Damaged harness - Inspect the wiring harness

for damage. If the harness appears to be OK,
observe the Bank 2 H02S 1 display on the scan
tool while moving connectors and wiring
ha.messes related to the sensor. A change in the
display will indicate the location of the fault.
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help determine
how often the condition that caused the OTC to be set
occurs.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
2. This step verifies that the fault is currently
present.
3. H02S transition time, ratio mean volts and
switching DTCs set for multiple sensors indicate
probable contamination. Before replacing the
sensors, isolate and correct the source of
the contamination to avoid damaging the
replacement sensors.

OTC P0153 H02S Slow Response Bank 2 Sensor 1

Step

Action
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?

Value(s)

Did the scan tool also indicate DTC P0153, P1133, P1134,
P1135, P1136, P1153, P1154, P1155, and/or P1156 test
failed this ignition?

Was an exhaust leak isolated?

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to
Diagnostic Aids

Go to Step 8

Go to Step 4

Go to Step 2

Go to Step 5

Important: If any DTCs are set, (except P0133, P1133,

P1134, P1135, P1136, P1153, P1154, P1155, and/or
P1156), refer to those DTCs before proceeding with this
diagnostic chart.
1. Install scan tool
2. Engine idling at operating temperature
3. Operate vehicle within parameters specified under
DTC Will Set When criteria included in Diagnostic
Support.
4. Using a scan tool, monitor Specific DTC info for
DTC P0153 until the DTC P0153 test runs.
5. Note the test result.
Does scan tool indicate DTC P0153 failed this ignition?

1. Perform Exhaust System Leak Test. Refer to Exhaust

Leakage. After Exhaust System Leak Test has been
performed, return to this diagnostic.
2. If an exhaust leak is found, repair as necessary.

Yes

6-868

Engine

Engine Controls - 3.8L

DTC P0153 H02S Slow Response Bank 2 Sensor 1 (cont'd)

Step

Action

Value(s)

Yes

No

Go to Step 9

Go to Step 6

Go to Step 7

Go to Step 10

Go to Step 12

Go to Step 11

Visually/physically inspect the following items:

Ensure that the Bank 2 H02S 1 is securely installed.
Check for corrosion on terminals.
5

Check terminal tension (at Bank 2 H02S 1 and at

the PCM).

Check for damaged wiring

Was a problem found in any of the above areas?
1. Disconnect Bank 2 H02S 1.
2. Jumper H02S low (PCM side) circuit to ground.

3. Using a scan tool, monitor Bank 2 H02S 1 voltage

450mV

Does the scan tool indicate voltage near the

specified value?

1. Jumper Bank 2 H02S 1 signal and low (PCM side)

circuits to ground.
2. Using a scan tool, monitor Bank 2 H02S 1 voltage

300mV

Does scan tool indicate voltage below specified value?

Replace affected Heated Oxygen Sensors. Refer to H02S
Replacement.
Important: Before replacing sensors, the cause of the
contamination must be determined and corrected.

Fuel contamination.

Use of improper RTV sealant

Engine oil/coolant consumption.

Go to Step 13

Is the action complete?

9

Repair condition as necessary.

Is the action complete?

10

Repair an open Bank 2 H02S 1 low circuit or a grounded

Bank 2 H02S 1 high signal circuit. Refer to Wiring
Repairs.

11

Repair an open Bank 2 H02S 1 signal circuit or faulty

PCM connections. Refer to Wiring Repairs.

Replace Bank 2 H02S 1. Refer to H02S Replacement.

Go to Step 13

Is the action complete?

Is the action complete?

Go to Step 13

Is the action complete?

12

Go to Step 13

Go to Step 13

1. Review and record scan tool Fail Records data.

2. Clear DTCs
13

3. Operate vehicle within Fail Records conditions

as noted.

4. Using a scan tool, monitor Specific OTC info for

OTC P0153 until the OTC P0153 test runs
Does the scan tool indicate OTC P0153 failed this ignition?

Go to Step 2

System OK

Engine

Engine Controls - 3.8L

-1- -,

6-869

DTC P0154 H02S Circuit Insufficient Activity Bank 2 Sensor 1

!Hot In Run, Bulb Test And Start!

Ir - Pow;

Distribution
Ce1110

J?

ENG SEN

J6

rvliniFuse
20A

L.-----Fuse Block
Details
Cell 11

r -

Heated Oxygen
Sensor (H02SO
Bank 1 Sensor 1

...----

'

'

H02S 1
Signal

I I

'

I
I
I

Bank 2

H02S 1

____ ...

' , PNK 539

-- -- - - - - - - - - - -- -- - - - Powertrain r - - - - - - - - - - - - - - - - - ,
PCM
C1=BLU
C2=CLEAR

LILI

PNK 539

Control I
MOd UIe II
(PCM)

Underhood
I Electrical
I Center 2

> L-----------------~
29 C1
10 C2
~
Low

TAN 1667

PPL 1666

PNK 539

Heated Oxygen
Sensor (H02SO
Bank 1 Sensor 3

Heated Oxygen
Sensor Bank 2
Sensor 1

I
I
I
I

'. ------------------------::1

-~-' '---_-------------~ ....,,.Gr--ou--nd~-,

4
-.. Distribution
Cell14

,I

226749

Circuit Description
The PCM supplies a bias voltage of about 450 mV
between the H02S signal and low circuits. When
measured with a 10 megohm digital voltmeter, this may
display as low as 320 mV. The oxygen sensor
varies the voltage within a range of about 1000 mV
when the exhaust is rich, down through about 10 mV
when exhaust is lean. The PCM constantly monitors
the H02S signal during closed loop operation
and compensates for a rich or lean condition by
decreasing or increasing injector pulse width as
necessary. If the Bank 2 H02S 1 voltage remains at
or near the 450 mV bias for an extended period
of time, OTC P0154 will be set, indicating an open
sensor signal or sensor low circuit.

Conditions for Setting the DTC

No TP sensor, EVAP system, EGR Pintle, misfire,

IAT sensor, MAP sensor, fuel trim, fuel injector
circuit, ECT sensor, or MAF sensor OTCs are set.
System voltage is greater than 9 volts.
The following engine run time requirements
are met:
- Manual Transaxle - 4 minutes.
- Automatic Transaxle - 3 minutes,
- Bank 2 H02S 1 signal voltage remains
between 400 mV and 500 mV for longer
than 2.5 minutes.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip iri which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

6-870

Engine Controls - 3.SL

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.
Damaged harness - Inspect the wiring harness
for damage.
Faulty H02S heater or heater circuit - With the
ignition ON the H02S voltage displayed on a
scan tool should gradually drop to below 300 mV
or rise to above 600 mV. If not, disconnect the
H02S and connect a J 34142-8 test lamp between
the H02S ignition feed and heater ground
circuits. If the J 34142-8 test lamp does not light,
repair the open ignition feed or sensor ground
circuit as necessary. Refer to H02S Replacement.
If the J 34142-8 test lamp lights and the H02S
signal and low circuits are OK, replace the H02S.
Refer to H02S Replacement

Engine
Intermittent test - With the ignition ON, monitor
the H02S signal voltage while moving the
wiring harness and related connectors. If the fault
is induced, the H02S signal voltage will change.
This may help isolate the location of the
malfunction.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
3. If the OTC P0154 test passes while the Fail
Records conditions are being duplicated, an
intermittent condition is indicated. Reviewing the
Fail Records vehicle mileage since the diagnostic
test last failed. This may help determine how
often the condition that caused the OTC to be set
occurs.
12. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

DTC P0154 H025 Circuit Insufficient Activity Bank 2 Sensor 1

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to Step 4

Go to Step 4

Go to
Diagnostic Aids

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

1. Install scan tool

2. Engine at operating temperature
3. Operate engine above 1200 RPM for two minutes.
Does the scan tool indicate H02S Bank 2
Sensor 1 voltage varying outside the specified values?
1. Turn ON the ignition switch.
2. Review and record scan tool Fail Records data and
note parameters.
3. Operate vehicle within Fail Records conditions
as noted.
4. Using a scan tool, monitor Specific OTC info for
OTC P0154 until the OTC P0154 test runs.
5. Note test result.
Does the scan tool indicate OTC P0154 failed this ignition?
1. Turn ON the ignition switch.
2. Disconnect H02S Bank 2 Sensor 1.
3. Jumper the H02S Bank 2 Sensor 1 low and signal
circuits (PCM side) to ground.
4. Using a scan tool, monitor H02S Bank 2
Sensor 1 voltage.
Is H02S Bank 2 Sensor 1 voltage below the
specified value?

400-500 mV

,;

150 mV

Go to Step B

Go to Step 5

Engine

Engine Controls - 3.8L

6-871

OTC P0154 H025 Circuit Insufficient Activity Bank 2 Sensor 1 (cont'd)

Step

Action

Value(s)

1. Remove the jumper wire from the H02S Bank 2

Sensor 1 (leave the H02S Bank 2 Sensor 1 low
circuit connected to ground).
2. Using a J 39200 DMM, measure voltage between the
H02S Bank 2 Sensor 1 signal circuit (PCM side) and
the heater ground circuit
Does H02S Bank 2 Sensor 1 voltage measure near the
specified value?

450mV

10

11

12

13

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Check continuity of the H02S Bank 2 Sensor 1 low
circuit.
4. If the H02S Bank 2 Sensor 1 low circuit measures
over 5 ohms, repair open or poor connection as
necessary. Refer to Wiring Repairs.
Was a H02S Bank 2 Sensor 1 low circuit problem found
and corrected?

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Check continuity of the H02S Bank 2 Sensor 1 signal
circuit and the H02S Bank 2 Sensor 1 low circuit.
4. If the H02S Bank 2 Sensor 1 signal or low circuit
measures over 5 ohms, repair open or poor
connection as necessary. Refer to Wiring Repairs.
Was a problem found?

1. Check for a poor H02S Bank 2 Sensor 1 signal or

low circuit terminal connection at the H02S Bank 2
Sensor 1 harness connector.
2. If a problem is found, replace terminal(s) as
necessary. Refer to Wiring Repairs.
Was a problem found?

1. Check for poor H02S Bank 2 Sensor 1 low circuit

terminal connection at the PCM.
2. and ,replace terminal if necessary. Refer to H02S
Replacement.
Was a problem found?

1. Check for poor H02S Bank 2 Sensor 1 signal circuit

terminal connection at the PCM.
2. If a problem is found, replace terminal(s) as
necessary. Refer to Wiring Repairs.
Was a problem found?
Replace H02S Bank 2 Sensor 1. Refer to H02S
Replacement.
Is the action complete?
Replace the PCM.
Important: Replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Is the action complete?
1. Turn ON the ignition switch.
2. Review and record scan tool Fail Records data.
3. Clear DTCs
4. Operate vehicle within Fail Records conditions
as noted.
5. Using a scan tool, monitor Specific DTC info for
DTC P0154 until the DTC P0154 test runs.
Does scan tool indicate DTC failed this ignition?

Yes

No

Go to Step 6

Go to Step 7

Go to Step 13

Go to Step 9

Go to Step 13

Go to Step 10

Go to Step 13

Go to Step 11

Go to Step 13

Go to Step 12

Go to Step 13

Go to Step 12

Go to Step 13

Go to Step 13

Go to Step 2

System OK

6-872

Engine Controls - 3.8L

Engine

OTC P0155 H02S Heater Performance Bank 2 Sensor 1

!Hot In Run, Bulb Test And Start!

'" -P-;,; - ] - - - - - ,,I Underhood

Distribution
Cell 10

Fuse Block
Details
Cell 11

J7

ENG SEN
MinlFuse

J6

20A

L------

..---- '

Electrical
I Center 2
I

----..1

Uil

PNK 539

' , PNK 539

'

-..,

r--------------------------

Heated Oxygen
Sensor (H02SO
Bank 1 Sensor 1

Powertrain
Control
MOd U Ie
(PCM)
~

'" - - - - - - - - - - - - - - - - - ,,
I
PCM
Bank 2
I
C1=BLU
I
I
I
C2=CLEAR
H02S 1
H02S 1
I

~-----------------J
Low

Signal

r!~r1~!7 P~~r1~!6 PNK

A

539

Heated Oxygen

Sensor (H02SO
Bank 1 Sensor 3

Heated Oxygen
Sensor Bank 2
Sensor 1

T
I
I
I
I

'. _----------------------- ~~t:~~------------_~ . . .--..

226749

Circuit Description
Heated oxygen sensors are used to minimize the
amount of time required for closed loop fuel control
operation and to allow accurate catalyst monitoring.
The oxygen sensor heater greatly decreases the
amount of time required for fuel control sensors Bank 1
H02S 1 and Bank 2 H02S 1 to become active. An
oxygen sensor heater ais required by catalyst monitor
sensor Bank 1 H02S 3 to maintain a sufficiently
high temperature which allows accurate exhaust
oxygen content readings further from the engine. The
PCM will run the heater test only after a cold start
(determined by engine coolant and intake air
temperature at the time of startup) and only once
during an ignition cycle. When the engine is started
the PCM will monitor the H02S voltage. When the
Bank 2 H02S 1 voltage indicates a sufficiently active
sensor, the PCM looks at how much time has
elapsed since startup. If the PCM determines that too
much time was required for the Bank 2 H02S 1 to
become active, a DTC P0155 will set. The time
it should take the H02S to reach operating
temperature is based on the engine coolant
temperature at start-up and the average Mass Air
Flow, since startup (higher average airflow or higher
startup engine coolant temperature = shorter time
to H02S activity).

Conditions for Setting the DTC

No TP sensor, EVAP system, EGR Pintle, misfire,
IAT sensor, MAP sensor, fuel trim, fuel injector
circuit, ECT sensor, CKP Sensor, or MAF sensor
DTCs are set.
Intake Air Temperature (IAT) is less
than 35C (95F) at startup
Engine Coolant Temperature (ECT) is less
than 35C (95F) at startup.
IAT and ECT are within 6C (11 F) of each other
at start-up.
The average mass air flow tor the sample period
is less than 20 g/s.
Bank. 2 H02S 1 voltage remains within 150 mV of
the bias voltage (about 450 mV) for a longer than .
the following amount of time:
- Manual Transaxle - The amount of time
ranges between 40 seconds and 2 minutes.
- Automatic Transaxle - The amount of
time ranges between 31 seconds and
2 minutes.
The amount of time depends on engine
coolant temperature at startup and the average
air flow since startup.

Engine
Action Taken When the OTC Sets
The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.
Damaged harness - Inspect the wiring harness
for damage. If the harness appears to be OK,
observe the display on the scan tool while moving
connectors and wiring harnesses related to the
sensor. A change in the display will indicate
the location of the fault. Review the Fail Records
vehicle mileage since the diagnostic test last
failed. This may help determine how often
the condition that caused the OTC to be set
occurs.

Engine Controls - 3.SL

6-873

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:

2. The H02S should be allowed to cool before

performing this test. If the H02S heater is
functioning, the signal voltage will gradually
increase or decrease as the sensor element
warms. If the heater is not functioning, the H02S
signal will remain near the 450mV bias voltage.
4. This step ensures that th.e ignition feed circuit to
the H02S is not open or shorted. The J 34142-8
test lamp should be connected to a good
chassis ground, in case the H02S low or H02S
heater ground circuit is faulty.
5. This step checks the H02S heater ground circuit.
6. This step checks for an open or shorted H02S
heater element. The heater element resistance
will vary according to H02S temperature (a
hot H02S heater element will measure a much
higher resistance than a H02S heater element at
room temperature). It is important to allow the
H02S to cool before measuring H02S heater
element resistance.
11. An open H02S signal or low circuit can cause the
H02S heater .to appear faulty. Check these
circuits before replacing the sensor.

6-874

Engine

Engine Controls - 3.SL

OTC P0155 H025 Heater Performance Bank 2 Sensor 1

Step

Action
Was the Powertrain On-Board Diagnostic (080) System
Check performed?

Important: If engine has just been operating, allow engine

to cool for about one half hour before proceeding.
Turn ON the ignition switch monitor H02S Bank 2
Sensor 1 voltage on the scan tool H02S data list.
Does H02S voltage go from bias voltage to greater than
the first specified value or less than the second
specified value?
Inspect fuse for H02S Bank 2 Sensor 1 ignition feed.
Is the fuse open?

Value(sJ--

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to
Diagnostic Aids

GiJ to Step 3

Go to Step 15

Go .to Step 4

Go to Step 5

Go to Step 7

Go to Step 6

Go to Step 8

Go to Step 9

Go to Step 14

600 mV
300 mV

1. Raise the vehicle.

2. Disconnect the H02S Bank 2 Sensor 1 electrical
connector.

Important: Use a known good ground. Do not use the

H02S Bank 2 Sensor 1 heater ground or Bank 2
H02S 1 low.
3. Probe the ignition feed circuit at the Bank 2 H02S 1
electrical connector (PCM harness side) using a
J 34142-B Unpowered test lamp connected to
ground.
Does the test lamp illuminate?
Connect J 34142-8 test lamp between H02S Bank 2
Sensor 1 ignition feed and H02S Bank 2 Sensor 1 heater
ground.

Does test lamp illuminate?

1. Allow the H02S to cool for at least 1O minutes.

2. Using a J 39200 DMM, measure resistance between
the H02S Bank 2 Sensor 1 ignition feed and H02S
Bank 2 Sensor 1 heater ground} at H02S Bank 2
Sensor 1 pigtail

5-10 ohms

Is H02S resistance within the specified values?

Repair an open H02S Bank 2 Sensor 1 ignition feed circuit

to H02S Bank 2 Sensor 1. Refer to Wiring Repairs.
Is the action complete?

Repair open H02S Bank 2 Sensor 1 heater ground circuit.

Refer to Wiring Repairs.
Is the action complete?

1. Check for a poor connection at the Bank 2 H02S 1

harness terminals.
2. If a poor connection is found, replace terminals. Refer
to Wiring Repairs.
Was a poor connection found?

Go to Step 16
-

Go to Step 16

Go to Step 16

Go to Step 10

Go to Step 16

Go to Step 11

1. Turn OFF the ignition switch.

2. Disconnect the PCM and check continuity of the
H02S Bank 2 Sensor 1 signal circuit and the H02S
Bank 2 Sensor 1 low circuit.
10

3. If the H02S Bank 2 Sensor 1 signal circuit or H02S

Bank 2 Sensor 1 low circuit measures over 5 ohms,
repair open or poor connection as necessary. Refer
to Wiring Repairs.
Was a problem found?

Engine

Engine Controls - 3.8L

6-875

DTC P0155 H02S Heater Performance Bank 2 Sensor 1 (cont'd)

Step

Action

Value{s)

11

Check for a poor signal or low circuit terminal connection

at the H02S Bank 2 Sensor 1 harness connector and
replace terminal(s) if necessary. Refer to Wiring Repairs.
Did any terminals require replacement?

12

Check for poor H02S Bank 2 Sensor 1 low circuit terminal

connection at the PCM and replace terminal if necessary.
Refer to Wiring Repairs.
Did the terminal require replacement?

13

Check for poor H02S Bank 2 Sensor 1 signal circuit

terminal connection at the PCM and replace terminal if
necessary. Refer to Wiring Repairs.
Did the terminal require replacement?

Replace H02S Bank 2 Sensor 1. Refer to H02S

Replacement.
Is the action complete?

Locate and repair short to ground in H02S Bank 2

Sensor 1 ignition feed circuit and replace faulty fuse. Refer
to Wiring Repairs.
Is the action complete?

14

15

16

Important: If engine has just been operating,. allow engine

to cool for about thirty minutes before proceeding.
1. Clear DTCs
2. Turn ON the ignition switch.
3. Monitor H02S Bank 2 Sensor 1 voltage on the scan
tool H02S data list.
Does H02S voltage go from bias voltage to greater than
the first specified value or less than the second
specified value?

Yes

No

Go to Step 16

Go to Step 12

Go to Step .16

Go to Step 13

Go to Step 16

Go to Step 14

Go to Step 16

Go to Step 16

600mV
300mV

System OK

Go to Step 2

6-876

Engine Controls - 3.8L

Engine

OTC P0171 Fuel Trim System Lean Bank 1

Circuit Description
To provide the best possible combination of
driveability, fuel economy, and emission control, a
closed loop air/fuel metering system is used. While in
closed loop, the PCM monitors the bank 1 H02S 1
and bank 2 H02S 1 signals and adjusts fuel delivery
based upon the H02S signal voltages. A change
made to fuel delivery will be indicated by the long and
short term fuel trim values which can be monitored
with a scan tool. Ideal fuel trim values are around 0%;
if the H02S signals are indicating a lean condition
the PCM will add fuel, resulting in fuel trim values
above 0%. If a rich condition is detected, the fuel trim
values will be below 0%, indicating that the PCM is
reducing the amount of fuel delivered. If an excessively
lean condition is detected on bank 1, the PCM will
set DTC P0171. The PCM s maximum authority
to control long term fuel trim allows a range between
-23% and + 16%. The PCM s maximum authority
to control short term fuel trim allows a range between
-11 % and +20%. The PCM monitors fuel trim
under various operating conditions (fuel trim cells)
before determining the status of the fuel trim
diagnostic. The fuel trim cells are weighted (assigned
a percentage of importance in determining the
total fuel trim status for the diagnostic) as follows:
Manaul Transaxle
Idle, purge commanded (Cell 10 approximately 27%)
Normal driving, purge commanded (Cell 2 approxmately 18%)
Acceleration, purge commanded (Cell 3 approximately 9%)
High Flow, purge commanded (Cell 4 approximately 9%)
Normal driving, no purge commanded (Cell 6 approximately 27%)
Acceleration, no purge commanded (Cell 7 approximately 9%)
Automatic Transaxle
Idle, purge commanded (Cell 1O approximately 15%)
Normal driving, purge commanded (Cell 2 approxmately 25%)
Deceleration, no purge commanded (Cell 5 approximately 5%)
Normal driving, no purge commanded (Cell 6 approximately 40%)
Idle, no purge commanded (Cell 9 approximately 5%)

Conditions for Setting the OTC

No TP sensor, EVAP system, H02S, misfire, IAT
sensor, MAP sensor, Idle speed, fuel injector(s),
IC/Bypass, EGR Pintle, EGR Flow, ECT
sensor, CKP sensor, CMP sensor, or MAF sensor
DTCs are set.
Engine coolant temperature between 20C (68F)
and 110C {230F).
Intake air temperature is between -18C {0F) and
70C (158F).
Manifold absolute pressure is between
15 kPa and .85 kPa.
Throttle angle is steady and less than 90%.
Vehicle speed is less than 132 km/h (82 mph).
Engine speed is between 600 and 4000 RPM.
Baro is greater than 70 kPa.
Air flow is between 3 gm/s and 150 gm/s.
Bank 1 long term fuel trim is at or near maximum
authority of + 16%.
Bank 1 short term fuel trim is at or near maximum
authority of +20%.
All of the conditions described above have been
met in the Fuel Trim Cells.

Action Taken When the OTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Engine
Diagnostic Aids
Check for the following conditions:
Heated oxygen sensor wiring - The sensor pigtail
may be routed incorrectly and contacting the
exhaust system.
Poor PCM to engine block grounds
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.
Fuel pressure low - The system will go lean if
pressure is too low. The PCM can compensate for
some decrease. However, if fuel pressure is too
low, a DTC P0171 may be set. Refer to Fuel
System Pressure Test.
Fuel injector(s) faulty - Refer to Fuel Injector
Balance Test.
Vacuum leaks - Check for disconnected or
damaged vacuum hoses and for vacuum leaks at
the intake manifold, throttle body, EGA system,
and crankcase ventilation system.
Exhaust leaks - An exhaust leak may cause
outside air to be pulled into the exhaust gas
stream past the H02S, causfng the system to
appear lean. Check for exhaust leaks that
may cause a false lean condition to be indicated.
Disconnect the MAF sensor and see if the
lean condition is corrected. If so, replace MAF
sensor. Refer to MAF Sensor Replacement

Engine Controls -

a~sL

6-877

Fuel contamination - Water, even in small

amounts, can be delivered to the fuel injectors.
The water can cause a lean exhaust to be
indicated. Excessive alcohol in the fuel can also
cause this condition. Refer to
Alcohol/Contaminants-in-Fuel Diagnosis.
Poor connection at PCM - Inspect harness
connectors for backed out terminals, improper
mating, broken locks, improperly formed or
damaged terminals, and poor terminal to wire
connection(s).
Damaged harness - Inspect the wiring harness
for damage. If the harness appears to be OK,
observe the affected H02S display on the
scan tool while moving connectors and wiring
harnesses related to the engine harness. A
change in the display will indicate the location of
the fault.
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help determine
how often the condition that caused the DTC to be set
occurs.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
2. DTCs other than P0171 and P0174 may indicate
a condition present which may cause a lean
condition. If this is the case, repairing the condition
which caused the other DTC will most likely
correct the DTC P0171/P0174.
4. If the DTC P0171 test passes while the Fail
Records conditions are being duplicated, the lean
condition ,s intermittent. Refer to Diagnostic Aids.

6-878

Engine Controls - 3.8L

Engine

OTC P0171 Fuel Trim System Lean Bank 1

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Repair the other

DTCs first

Go to Step 3

Go to Step 5

Go to Step 4

Go to Step 5

Go to
Diagnostic Aids

Go to Step 6

Go to Step 17

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Are any DTCs,set other than P0171.and P0174?

1. Start and run vehicle in closed loop.

2. Observe BANK 1 L.T. FUEL TRIM and BANK 1 S.T.
FUEL TRIM display on the scan tool.

Are the displayed values near or above the specified

values?
LT. FUEL TRIM is the first specified value.
S.T. FUEL TRIM is the second specified value.

+16%
+20%

1. Review and record the scan tool Fail Records data.

2. Clear the DTC P0171/P0174 and operate the vehicle
to duplicate the Fail Records conditions.

3. Monitor the scan tool Specific DTC info for

4

DTC P0171 while operating the vehicle to duplicate

the Fail Records conditions.

4. Continue operating the vehicle until the DTC P0171

test runs and note test result.
Does the scan tool indicate OTC P0171 failed this ign?

Was OTC P0174 also set?

Visually and physically inspect the vacuum hoses for

splits, kinks, and improper connections and repair any
problem found.

Did your inspection reveal a problem requiring repair?

Visually and physically inspect the PCV Valve for proper

installation and repair any problem found. Refer to
Crankcase Ventilation System Inspection. Did your
inspection reveal a problem requiring repair?
1. Inspect the throttle body inlet screen for damage or
for the presence of foreign objects which may
partially block the airflow sample through the MAF
sensor.

(
Go to Step 23

Go to Step 7

Go to Step 23

Go to Step 8

Go to Step 23

Go to Step 9

Go to Step 10

Go to Step 13

Go to Step 12

Go to Step 11

Go to Step 23

Go to Step 12

Go to Step 23

Go to Step 13

2. Correct any problem that is found as necessary.

Did your inspection of the throttle body reveal a condition
requiring repair?
9

10

11

Start the engine and note the idle quality.

Is a high or unsteady idle being experienced?

With the engine idling, observe the Idle Air Control display
on the scan tool.

Is the displayed value above the specified value?

Value displayed is in Counts.
1. Visually and physically inspect the throttle body,
intake manifold, EGR valve and the EGR feed pipes
for vacuum leaks.

2. Repair any vacuum leaks as necessary.

Did your inspection reveal a vacuum leak?

12

Perform the Idle Air Control (IAC) Valve Check. Refer to

Idle Air Control System Diagnosis
Did the Idle Air Control (IAC) Valve Check isolate a
problem requiring repair?

Engine

Engine Controls - 3.8L

6-879

OTC P0171 Fuel Trim System Lean Bank 1 (cont'd)

Step

Value(s)

Check the fuel for excessive water, alcohol, or other

contaminants. Refer to Alcohol/Contaminants-in-Fuel
Diagnosis. Refer to Engine Fuel.
Was the fuel contaminated?

1. Visually and physically inspect the PCM injector

grounds, power grounds and sensor grounds to
ensure that they are clean, tight, and in their proper
locations.
2. If a faulty ground condition is present, correct it as
necessary. Refer to Wiring Repairs.
Did your inspection reveal a condition requiring repair?

1. Disconnect the MAF sensor electrical connector.

2. Operate the vehicle in Closed Loop while monitoring
the Bank 1 S.T. Fuel Trim display on the scan tool
Does Bank 1 S.T. Fuel Trim value decrease to near the
specified value?

0%

16

Perform the Fuel System Pressure Test. Refer to Fuel

System Pressure Test.
Did the Fuel System Pressure Test isolate a condition
requiring repair?

17

Perform the Evaporative Emission System Check. Refer to

EVAP Control System Diagnosis
Did the Evaporative Emission System Check isolate a
problem requiring repair?

1. Visually and physically inspect the intake manifold,

injector 0-rings, EGR adapter, EGR valve and the
EGR feed pipes for vacuum leaks.
2. Repair any problem that is found
Did your inspection reveal a problem requiring repair?

13

14

15

Action

18

19

Visually and physically inspect the Bank1 exhaust manifold

for leaks and loose or missing hardware and correct any
problem found.

20

21

1. Visually and physically inspect the Bank 1 H02S to

ensure that it is installed securely and that the Bank 1
H02S pigtail and wiring harness are not contacting
the exhaust or otherwise damaged.
2. If a problem is found, correct it as necessary.
Replace the MAF sensor. Refer to MAF Sensor
Replacement.

Go to Step 23

Go to Step 14

Go to Step 23

Go to Step 15

Go to Step 22

Go to Step 16

Go to Step 23

Go to Step 17

Go to Step 23

Go to Step 18

Go to Step 23

Go to Step 19

Go to Step 23

Go to Step 20

Go to Step 23

Go to Step 21

Go to Step 23

Go to
Diagnostic Aids

Did your inspection reveal a problem requiring repair?

22

No

Did your inspection reveal a problem requiring repair?

Perform the Injector Balance Test. Refer to Fuel Injector
Balance Test.
Did the Injector Balance Test isolate a problem requiring
repair?

Yes

Is the action complete?

Go to Step 23

1. Review and record the scan tool Fail Records data.

2. Clear the DTC P0171 and operate the vehicle to
duplicate the Fail Records conditions.
23

3. Monitor the scan tool Specific DTC info for

DTC P0171 while operating the vehicle to duplicate
the Fail Records conditions.
4. Continue operating the vehicle until the DTC P0171
test runs and note test result.
Does the scan tool indicate DTC P0171 failed this ignition?

Go to Step 2

System OK

6-880

Engine Controls - 3.8L

Engine

OTC P0172 Fuel Trim System Rich Bank 1

Circuit Description
In order to provide the best possible combination of
driveability, fuel economy, and emission control,
a closed loop air/fuel metering system is used. While
in closed loop, the PCM monitors the bank 1 H02S
1 and bank 2 H02S 1 signals and adjusts fuel delivery
based upon the H02S signal voltages. A change
made to fuel delivery will be indicated by the long and
short term fuel trim values which can be monitored
with a scan tool. Ideal fuel trim values are around 0%;
if the H02S signals are indicating a lean condition
the PCM will add fuel, resulting in fuel trim values
above 0%. If a rich condition is detected, the fuel trim
values will be below 0%, indicating that the PCM is
reducing the amount of fuel delivered. If an excessively
rich condition is detected on bank 1 , the PCM will
set OTC P0172. The PCM s maximum authority
to control long term fuel trim allows a range between
-23% and + 16%. The PCM s maximum authority
to control short term fuel trim allows a range between
-11 % and +20%. The PCM monitors fuel trim
under various operating conditions (fuel trim cells)
before determining the status of the fuel trim
diagnostic. The fuel trim cells are weighted (assigned
a percentage of importance in determining the
total fuel trim status for the diagnostic) as follows:
Manaul Transaxle
Idle, purge commanded (Cell 1O approximately 27%)
Normal driving, purge commanded (Cell 2 approxmately 18%)
Acceleration, purge commanded (Cell 3 approximately 9%)
High Flow, purge commanded (Cell 4 approximately 9%)
Normal driving, no purge commanded (Cell 6 approximately 27%)
Acceleration, no purge commanded (Cell 7 approximately 9%)
Automatic Transaxle
Idle, purge commanded (Cell 10 approximately 15%)
Normal driving, purge commanded (Cell 2 approxmately 25%)
Deceleration, no purge commanded (Cell 5 approximately 5%)
Normal driving, no purge commanded (Cell 6 approximately 40%)
Idle, no purge commanded (Cell 9 approximately 5%)

Conditions for Setting the DTC

No TP sensor, EVAP system, H02S, misfire, IAT
sensor, MAP sensor, Idle speed, fuel injector(s),
IC/Bypass, EGR Pintle, EGR Flow, ECT
sensor, CKP sensor, CMP sensor, or MAF sensor
DTCs are set.
Engine coolant temperature between 20C (68F)
and 110C (230F).
Intake air temperature is between -18C (0F) and
70C (158F).
Manifold absolute pressure is between
15 kPa and 85 kPa.
Throttle angle is steady and less than 90%.
Vehicle speed is less than 132 km/h (82 mph).
Engine speed is between 600 and 4000 RPM.
Baro is greater than 70 kPa.
Air flow is between 3 gm/s and 150 gm/s.
Bank 1 Long term fuel trim is at or near maximum
authority of -23%
Bank 1 Short term fuel trim is at or near maximum
authority of -11 %.
All conditions have been met in the Fuel
Trim Cells.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Engine
Diagnostic Aids
Check the following items:
Fuel pressure high - The system will go rich if
pressure is too high. The PCM can compensate
for some increase. However, if fuel pressure is too
high, a DTC P0172 may be set. Refer to Fuel
System Pressure Test.
Fuel injector(s) faulty - Refer to Fuel Injector
Balance Test.
Check the EV AP Canister for Fuel Saturation. If
the EV AP Canister is full of fuel, check canister
control and hoses. Refer to EVAP Control System
Diagnosis.
Disconnect the MAF sensor and see if rich
condition is corrected. If so, replace the MAF
sensor. Refer to MAF Sensor Replacement.
Check for a leaking fuel pressure regulator
diaphragm by checking the vacuum line to the fuel
pressure regulator for the presence of fuel. If
there is fuel in the vacuum line, refer to Fuel
Pressure Regulator Replacement.
An intermittent TP sensor output will cause the
system to go rich due to a false indication of
the engine accelerating.
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.

\.

Engine Controls - 3.8L

6-881

Damaged harness - Inspect the wiring harness

for damage. If the harness appears to be OK,
observe the affected H02S display on the
scan tool while moving connectors and wiring
harnesses related to the engine harness. A
change in the display will indicate the location of
the fault.
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help determine
how often the condition that caused the OTC to be set
occurs.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
2. DTCs other than P0172 and P0175 may indicate
a condition present which may cause a lean
condition. If this is the case, repairing the condition
which caused the other DTC will most likely
correct the DTC P0172/P0175.
4. If the DTC P0172 test passes while the Fail
Records conditions are being duplicated, the rich
condition is intermittent. Refer to Diagnostic
Aids or Symptoms for additional information on
diagnosing intermittent problems.

6-882

Engine Controls - 3.8L

Engine

DTC P0172 Fuel Trim System Rich Bank 1

Step

Acti.on

Value(s)

Yes

No

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Are any DTCs set other than P0172 and P0175?

1. Start and run vehicle in closed loop.
2. Observe Bank 1 L.T. Fuel Trim and Bank 1 S.T. Fuel
Trim display on the scan tool Eng 1 data list
Are the displayed values at or near the specified values?
LT. FUEL TRIM is the first specified value.
S.T. FUEL TRIM is the second specified val.ue.

Is DTC P0175 also set?

Visually and physically inspect the air filter element and

replace it if necessary.
Did the air filter require replacement?

Visually and physically inspect the air intake duct for being
collapsed or restricted and repair if necessary.
Did your inspection reveal a condition requiring repair?

Inspect the throttle body inlet screen for damage or for the
presence of foreign objects which may partially block
airflow through the screen and correct any problem found.
Did your inspection of the throttle body reveal a condition
requiring repair or replacement?

Start the engine and note the idle quality.

Is a low or unsteady idle being experienced?

10

With the engine idling, observe the Idle Air Control display
on the scan tool.
Is Idle Air Control value less than the specified value?
Value is specified in Counts.

100

1. Turn the ignition off and physically inspect the throttle

body bore, throttle plate, and IAC passages for
coking and foreign objects.
2. If a problem was found, repair as necessary.
Did your inspection reveal a condition requiring repair?

1. Perform the Idle Air Control (IAC) Valve Check. Refer

to Idle Air Control System Diagnosis.
2. If a problem is found, repair as necessary.
Did the Idle Air Control (IAC) Valve Check isolate a
problem requiring repair?

1. Disconnect the vacuum hose from the fuel pressure

regulator and inspect the hose for the presence
of fuel.
2. If fuel is present in the vacuum hose, replace the fuel
pressure regulator. Refer to Fuel Pressure Regulator
Replacement.
Was the problem found?

11

12

13

Go to Step 5

Go to Step 4

Go to Step 5

Go to
Diagnostic Aids

Go to Step 6

Go to Step 18

Go to Step 22

Go to Step 7

Go to Step 22

Go to Step 8

Go to Step 22

Go to Step 9

Go to Step 10

Go to Step 12

Go to Step 12

Go to Step 11

Go to Step 22

Go to Step 12

Go to Step 22

Go to Step 13

Go to Step 22

Go to Step 14

_:23%

Go to Step 3

-11%

Go to the other
DTCs first.

1. Review and record the scan tool Fail Records data.

2. Clear the DTC P0172/P0175 and operate the vehicle
to duplicate the Fail Records conditions.
3. Monitor the scan tool Specific DTC info for
DTC P0172 while operating the vehicle to duplicate
the Fail Records conditions.
4. Continue operating the vehicle until the DTC P0172
test runs and note test result
Does the scan tool indicate DTC P0172 failed this ignition?

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Engine Controls - 3.8L

Engine

6-883

DTC P0172 Fuel Trim System Rich Bank 1 (cont'd)

Step

14

15

16

17

18

19

20

21

22

Action

1. Turn ON the ignition switch.

2. Monitor the TP Angle display on the scan tool while
slowly depressing the accelerator pedal.
Does the TP Angle display increase steadily and evenly
from minimum value at closed throttle to maximum value
at wide-open throttle?
1. Disconnect the MAF sensor electrical connector.
2. Operate the vehicle in Closed Loop while monitoring
the Bank 1 LT. Fuel Trim and Bank 1 S.T. Fuel Trim
display on the scan tool.
Did both values change to near the specified value?
1. Perform the Fuel System Pressure Test. Refer to
Fuel System Pressure Test.
2. If the Fuel System Pressure Test isolates a problem,
repair as necessary.
Did the Fuel System Pressure Test isolate a problem
requiring repair?
Perform the EV AP Control System Diagnosis. Refer to
EVAP Control System Diagnosis. If this isolates a problem,
repair as necessary.
Was a problem found?

Value(s)

,',

Go to Step 15

Go to Step 20

Go to Step 21

Go to Step 16

Go to Step 22

Go to Step 17

Go to Step 22

Go to Step 18

Go to Step 22

Go to Step 19

Go to Step 22

Go to
Diagnostic Aids

0%

1. Remove and visually/physically inspect the Bank 1

H02S 1 and the Bank 2 H02S 1 for silicon
contamination. This wiU be indicated by a powdery
white deposit on the portion of the H02S that is
exposed to the exhaust stream.
2. If contamination is evident on the Bank 1 or Bank 2
H02S, replace the contaminated sensor(s).
Did sensors require replac;ement?

1. Review and record the scan tool Fail Records data.

2. Clear the DTC P0172 and operate the vehicle to
duplicate the Fail Records conditions.
3. Monitor the scan tool Specific OTC info for
OTC P0172 while operating the vehicle to duplicate
the Fail Records conditions.
4. Continue operating the vehicle until the OTC P0172
test runs and note test result.
Does the scan tool indicate OTC P0172 failed this ignition?

No

0% to 100%

1. Perform the Fuel Injector Balance Test.

2. If this isolates a problem, repair as necessary. Refer
to Fuel Injector Balance Test.
Did the Fuel Injector Balance Test isolate a problem
requiring repair?

1. Check the TP sensor mounting screws and tighten or

replace, them as necessary if they are loose or
missing.
2. If the screws are OK, replace the TP sensor. Refer to
TP Sensor Replacement.
Is the action complete?
Replace the MAF sensor. Refer to MAF Sensor
Replacement.
Is the action complete?

Yes

Go to Step 22

Go to Step 22

Go to Step 2

System OK

6884

Engine Controls 3.8L

Engine

DTC P0174 Fuel Trim System Lean Bank 2

Circuit Description
To provide the best possible combination of
driveability, fuel economy, and emission control, a
closed loop air/fuel metering system is used. While in
closed loop, the PCM monitors the bank 1 H02S 1
and bank 2 H02S 1 signals and adjusts fuel delivery
based upon the H02S signal voltages. A change
made to fuel delivery will be indicated by the long and
short term fuel trim values which can be monitored
with a scan tool. Ideal fuel trim values are around 0%;
if the H02S signals are indicating a lean condition
the PCM will add fuel, resulting in fuel trim values
above 0%. If a rich condition is detected, the fuel trim
values will be below 0%, indicating that the PCM is
reducing the amount of fuel delivered. If an excessively
lean condition is detected on Bank 2, the PCM will
set OTC P017 4. The PCM s maximum authority
to control long term fuel trim allows a range between
-23%+and + 16%. The PCM s maximum authority
to control short term fuel trim allows a range between
-11 % and +20%. The PCM monitors fuel trim
under various operating conditions (fuel trim cells)
before determining the status of the fuel trim
diagnostic. The fuel trim cells are weighted (assigned
a percentage of importance in determining the
total fuel trim status for the diagnostic) as follows:
Manaul Transaxle
Idle, purge commanded (Cell 1O approximately 27%)
Normal driving, purge commanded (Cell 2 approxmately 18%)
Acceleration, purge commanded (Cell 3 approximately 9%)
High Flow, purge commanded (Cell 4 approximately 9%)
Normal driving, no purge commanded (Cell 6 approximately 27%)
Acceleration, no purge commanded (Cell 7 approximately 9%)
Automatic Transaxle
Idle, purge commanded (Cell 1O approximately 15%)
Normal driving, purge commanded (Cell 2 approxmately 25%)
Deceleration, no purge commanded (Cell 5 approximately 5%)
Normal driving, no purge commanded (Cell 6 approximately 40%)
Idle, no purge commanded (Cell 9 approximately 5%)

Conditions for Setting the OTC

No TP sensor, EVAP system, H02S, misfire, IAT
sensor, MAP sensor, Idle speed, fuel injector(s),
IC/Bypass, EGA Pintle, EGA Flow, ECT
sensor, CKP sensor, CMP sensor, or MAF sensor
DTCs are set.
Engine coolant temperature between 20C (68F)
and 110C (230F).
Intake air temperature is between -18C (0F) and
70C (158F).
Manifold absolute pressure is between
15 kPa and 85 kPa.
Throttle angle is steady and less than 90%.
Vehicle speed is less than 132 km/h (82 mph).
Engine speed is between 600 and 4000 RPM.
Baro is greater than 70 kPa.
Air flow is between 3 gm/s and 150 gm/s.
Bank 2 long term fuel trim is at or near maximum
authority of + 16%.
Bank 2 short term fuel trim is at or near maximum
authority of +20%.
All of the conditions described above have been
met in the Fuel Trim Cells.

Action Taken When the OTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Engine
Diagnostic Aids
Check for the following conditions:
Heated oxygen sensor wiring - The sensor pigtail
may be routed incorrectly and contacting the
exhaust system.
Poor PCM to engine block grounds.
Fuel pressure low - The system will go lean if
pressure is too low. The PCM can compensate for
some decrease. However, if fuel pressure is too
low, a OTC P0174 may be set. Refer to Fuel
System Pressure Test.
Fuel injector(s) faulty - Refer to Fuel Injector
Balance Test.
Vacuum leaks - This step checks for disconnected
or damaged vacuum hoses and for vacuum leaks
at the intake manifold, throttle body, EGR
system, and crankcase ventilation system.
Exhaust leaks - An exhaust leak may cause
outside air to be pulled into the exhaust gas
stream past the H02S, causing the system to
appear lean. Check for exhaust leaks that
may cause a false lean condition to be indicated.
Disconnect the MAF .sensor and see if the
lean condition is corrected. If so, replace MAF
sensor. Refer to MAF Sensor Replacement.
Fuel contamination - Water, even in small
amounts, can be delivered to the fuel injectors.
The water can cause a lean exhaust to be
indicated. Excessive alcohol in the fuel can also
cause this condition. Refer to
Alcohol/Contaminants-in-Fuel Diagnosis

Engine Controls - 3.8L

5;.995

Poor connection at the PCM - Inspect harness

connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.
Damaged harness - Inspect the wiring harness
for damage. If the harness appears to be OK,
observe the affected H02S display on the
scan tool while moving connectors and wiring
harnesses related to the engine harness. A
change in the display will indicate the location of
the fault.
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help determine
how often the condition that caused the OTC to be set
occurs.

Test Description
Number(s} below refer to the step number(s) on the
Diagnostic Table:
2. DTCs other than P0174 and P0174 may indicate
a condition present which may cause a lean
condition. If this is the case, repairing the condition
which caused the other OTC will most likely
correct the OTC P0174/P0174.
4. If the OTC P0174 test passes while the Fail
Records conditions are being duplicated, the lean
condition is intermittent. Refer to Diagnostic Aids.

6.;.886

Engine Controls - 3.8L

Step

Action

Engine

DTC P0174 Fuel Trim System Lean Bank 2

Value(s)

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Are any OTCs set other than P017 4 and P0171?

1. Start and run vehicle in closed loop.
2. Observe the Bank 2 LT. Fuel.Trim. and Bank 2 S.T.
Fuel Trim displays on the scan .tool.
Are the displayed. values at or near the specified values?
LT. FUEL TRIM is the first specified value.
S.T. FUEL TRIM is the second specified value.
1. Review and record the scan tool Fail Records data.
2. Clear the OTC P0171 I P0174 and operate the
vehicle to duplicate the Fail Records conditions.
3. Monitor the scan tool Specific OTC info for
OTC P0174 while operating the.vehicle to duplicate
the Fail Records conditions.
4. Continue operating the vehicle until the OTC P0174
test runs and note test result.
Does the scan tool indicate OTC P0174 failed this ignition?

'.

Go to Steps

'

Go to Step 5
Go to
DTCPQ171 Fuel
Trim System
Lean Bank 1

Go to
Diagnostic Aids

Go to Step 6

'

1. Visually and physically inspect the Bank 2 exhaust

manifold for leaks and loose or missing hardware.
2. Correct any problem found.
Did your inspection reveal a problem?

Perform the Fuel Injector Balance Test. Refer to Fuel

Injector Balance Test.
Did the Fuel Injector Balance Test isolate a problem?

10

1. Visually and physically inspect the Bank 2 H02S 1 to

ensure that it is installed securely and that the Bank 2
H02S 1 pigtail and wiring harness are not contacting
the exhaust or otherwise damaged.
2. If a problem is found, correct it as necessary.
Did your inspection reveal a problem?

1. Review and record the scan tool Fail Records data.

2. Clear the OTC P0174 and operate the vehicle to
duplicate the Fail Records conditions.
3. Monitor the scan tool Specific OTC info for
OTC P0174 while operating the vehicle to duplicate
the Fail Records conditions
4. Continue operating the vehicle until the OTC P0174
test runs and note test result
Does the scan tool indicate OTC P0174 failed this ignition?

11

Go to Step 4

1. Visually and physically inspect the intake manifold,

injector 0-rings, EGR adapter, EGR valve and the
EGR feed pipes for vacuum leaks.
2. Repair any problem that is found.
Did your inspection reveal a problem?

Go to Step 3

+16%
+20%

,'

Go to Step 2
Repair other
DTCs first.

No
Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Was OTC P0171 also set?

Perform the EV AP Co.ntrol System Diagnm~is

Refer to EVAP Control System Diagnosis.
Did the EV AP Control System Diagnosis isolate a
problem?

Yes

Go to Step 11

Go to Step 7

Go to Step 11

Go to Step B

Go to Step 11

Go to Step 9

Go to Step 11

Go to Step 10

Go to Step 11

Go to
Diagnostic Aids

(
Go to Step 2

System OK

Engine

Engine Contrbls - 3.8L

6,-887

Fuel Trim System. Rich Bank 2

DTCP0175
.
Circuit Description
To provide the best possiblecombination of
driveability, fuel economy, and emission control, a
closed loop air/fuel metering system is used. While in
closed loop, the PCM monitors the bank 1 H02S 1
and bank2 H02S 1 signalsand adjusts fuel delivery
based upon the H02S signal voltages: A change
made to fuel delivery Will be indicated bythe long and
short term fuel trim values which can be monitored
with a scan tool. Ideal fuel trim values are around 0%;
if ttie H02S signals are indicating a lean condition
the PCM will add fuel, resulting in fuel trim values
above:0%.. lf a rich condition is detected, the fuel trim
values will be below 0%, indicating that the PCM is
.reducing the amount of fuel deliverec.il,. rt an excessively
rich condition is detected on Bank,2, the PCM will
set DTC P0175. The PCM s maximum authority
to control long term fuel. trim allows a ranQe .between
-?3% and + 16%. The PCM s maximum. authority .
to control short term fuel trim.allows.'a r.c:1nQe.,between
-11 % and +20%. The PCM monitors fuel trim
under various operating conditions (fuel trim cells)
before determining the status of the fuel trim
diagnostic. The fuel trim cells are weighted (assigned
a percentage of importance in determining the
total fuel trim status for the diagnostic) as follows:
Manaul Transaxle
Idle, purge commanded (Cell 10 approximately 27%)
Normal driving, purge commanded (Cell 2 approxmately 18%)
Acceleration, purge commanded (Cell 3 approximately 9%)
High Flow, purge commanded (Cell 4 approximately 9%)
Normal driving, no purge commanded (Cell 6 approximately 27%)
Acceleration, no purge commanded (Cell 7 approximately 9%)
Automatic Transaxle
Idle, purge commanded (Cell 10 approximately 15%)
Normal driving, purge commanded (Cell 2 approxmately 25%)
Deceleration, no purge commanded (Cell 5 approximately 5%)
Normal driving, no purge commanded (Cell 6 approximately 40%)
Idle, no purge commanded (Cell 9 approximately 5%)

Conditions for Setting the OTC

No TP sensor, EVAP system, H02S, misfire, IAT
sensor, MAP sensor, Idle speed, fuel irijector(s),
IC/Bypass, EGR Piritle, EGA' Flow, ECT
sensor, CKP sensor, CMP sensor, or MAF sensor
DTCs are set.
'
Engine coolant temperature between 20C (68F)
and 110C (230F).
Intake air temperature is between - ta~C (0F) and
7:0~C (158F).
Manifold absolute pressure is between
15 kPa and 85 kPa.
Throttle angle is steady. and less than 90% .
Vehicle speed is less than 132 km/h (82 mph).
Engine speed is between 600 and 4000 RPM.
Baro is greater than 70 kPa.
Air, H<>w is between 3 gm/s and 150 gm/s.
Bank 2'Long term fuel trim is at or riear maximum
authority of -:-23% .

Bank 2 Short term fuel trim is at or near maximum

authority of -11 %.
All conditions have been met in the Fuel
Trim Cells.

Action Taken When the OTC Sets

The PCM will illuminate th.e .MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

6-888

Engine Controls - 3.8L

Diagnostic Aids
Check the following items:
Fuel pressure high - The system will go rich if
pressure is too high. The PCM can compensate
for some increase. However, if fuel pressure is too
high, a OTC P0175 may be set. Refer to Fuel
System Pressure Test.
Fuel injector(s) faulty - Refer to Fuel Injector
Balance Test.
Check the EVAP Canister for Fuel Saturation. If
the EVAP Canister is full of fuel, check canister
control and hoses. Refer to EVAP Control System
Diagnosis.
Disconnect the MAF sensor and see if the rich
condition is corrected. If so, replace the MAF
sensor. Refer to MAF Sensor Replacement.
Check for a leaking fuel pressure regulator
diaphragm by checking vacuum line to regulator
for the presence of fuel. If fuel is found in the
vacuum line to the fuel pressure regulator, refer to
Fuel Pressure Regulator Replacement.
An intermittent TP sensor output will cause the
system to go rich due to a false indication of
the engine accelerating.
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.

Engine
Damaged harness - Inspect the wiring harness
for damage. If the harness appears to be OK,
observe the affected H02S display on the
scan tool while moving connectors and wiring
harne.sses related to the engine harness. A
change in the display will indicate the location of
the fault. Review the Fail Records vehicle
mileage since the diagnostic test last failed. This
may help determine how often the condition
that caused the OTC to be set occurs.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
2. DTCs other than P0175 and P0175 may indicate
a condition present which may cause a lean
condition. If this is the- case, repairing the condition
which caused the other OTC will most likely
correct the OTC P0175/P0175.
4. If the OTC P0175 test passes while the Fail
Records conditions are being duplicated, the rich
condition is intermittent. Refer to Diagnostic Aids.

Engine Controls - 3.. 8L

Engine

6-889

DTC P0175 Fuel Trim System Rich .Bank 2

Action

Step

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Are any DTCs set other than P0172 and P0175?

1. Start and run vehicle in closed loop.
2. Observe the Bank 2 L.T. Fuel Trim and Bank 2 S.T.
Fuel Trim display on the scan tool Eng 1 data list.
Are the displayed values at or near the specified values?
LT. FUEL TRIM is the first specified value.
S.T. FUEL TRIM is the second specified value.
1. Review and record the scan tool Fail Records data.
2. Clear the DTC P0172 I P0175 and operate the
vehicle to duplicate the Fail Records conditions.
3. Monitor the scan tool Specific OTC info for
OTC P0175 while operating the vehicle to duplicate
the Fail Records conditions.
4. Continue operating the vehicle until the DTC P0175
test runs and note test result
Does the scan tool indicate DTC P0175 failed this ign?

Value(s)

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to other
DTCs first.

Go to Step 3

Goto Step 5

Go to Step 4

Go to Step 5

Go to
Diagnostic Aids

Go to
OTC P0172 Fuel
Trim System Rich
Bank 1

Go to Step 6

Go to Step B

Go to Step 7

Go to Step B

Go to
Diagnostic Aids

Go to Step 2

System OK

-23%
-11 %

Is OTC P0172 also set?

Yes

Perform the Injector Balance Test. Refer to Fuel Injector

Balance Test
Did the Injector Balance Test isolate a problem requiring
repair?

1. Remove and visually/physically inspect the Bank 2

H02S 1 and the Bank 1 H02S 1 for silicon
contamination. This will be indicated by a powdery
white deposit on the portion of the H02S that is
exposed to the exhaust stream.
2. If contamination is evident on the Bank 1 or Bank 2
H02S 1, replace contaminated sensors
Did sensors require replacement?

1. Review and record the scan tool Fail Records data.

2. Clear the OTC P0175 and operate the vehicle to
duplicate the Fail Records conditions.
3. Monitor the scan tool Specific OTC info for
OTC P0175 while operating the vehicle to duplicate
the Fail Records conditions.
4. Continue operating the vehicle until the OTC P0175
test runs and note test result
Does the scan tool indicate DTC P0175 failed this ignition?

6.-890

Engine

Engine Controls .. 3.8L

DTC P0201 Injector 1 Control Circuit

Refer to Fuel Injectors

Diagnostic Aids

Circuit Description

The misfire history counter may be useful in

determining which injector circuit is malfunctioning. If
DTC P0300 was set, look at the Misfire Hist#
display for each cylinder. The largest value stored in
the misfire history .counters will indicate the location bf
the malfunctioning injector circuit or injector.
Check fo(the following conditions:
Poor connection at the PCM or fuel injector.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wore connection.
Damag~d harness.
Inspect the. wiring t:iamess for damage.
Reviewing.the Fail Records vehicle mileage since the
diagnostic test la.st faile,d may help determine how
often the condition that caused the DTC to be
set occ'urs. This may qSsist in diagnosing the condition.

The PCM controls the fuel injectors by using an

ignition feed driver and ground circuit within the PCM.
The driver has the ability to detect an electrical
.
malfunction in the ignition feed or ground circuit. If an
electrical malfunction occurs in th.e ,fuel injector
circuit for engine cylinder #1, the ignition feed driver
signals the PCM to set DTC P0201.

Conditions for Running the DTC

The engine is running.

Conditions for Setting .the DTC

the PCM detects an electrical malfunction on the
injector circuit for engine cylinder #1 for longer
than 30 seconds.
The condition is present for at least 30 seconds.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
If the electrical malfunction could lead to possiqle
catalyst damage, the PCM will .immediately flash
the MIL while the fault remains at catalyst
damage levels.
The PCM will disable TCC operation.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery .feed.

Test Description

Number(s) below refer to the step number(s) on the

Diagnostic Table.
4. Checks for malfunctioning fuel injector control
circuit or ignition feed wiring.
9. Checks for a malfunction in the fuel injector
ignition feed circuit.
10. Checks for a short to ground in the injector control
circuit.
11. Checks for an open in the fuel injector control
circuit.
18. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

Engine Controls - 3.SL

Engine

6-891

OTC P0201 Injector 1 Control Circuit

Action

Step

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Value(s)

1. Turn ON the ignition switch.

2. Review and record scan tool Fail Records data.
3. Operate the vehicle within Fail Records conditions.
4. Monitor Specific OTC info for OTC P0201 on the
scan tool.
Does the scan tool indicate OTC P0201 failed this ign?

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Turn ON the ignition switch.
4. Using a J 39200 DMM, measure the voltage between
the cylinder #1 fuel injector control circuit at the PCM
connector and ground.
Does the cylinder #1 fuel injector control circuit measure
near the specified value?

B+

Check the fuel injectors. Refer to Fuel lnj Coil Test - ECT
Between 10-35 Degrees C or Fuel lnj Coil Test - ECT
Outside 10-35 Degrees C.
Are the fuel injectors OK?

1. Turn OFF the ignition switch.

2. Disconnect the cylinder #1 fuel injector.
3. Turn ON the ignition switch.
4. Measure the voltage between the cylinder #1 fuel
injector control circuit at the PCM connector and
ground.
Does the cylinder #1. fuel injector control circuit measure
near the specified value?

OV

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 17

Go to Step 7

Go to Step 16

Go to Step 19

Go to Step 8

Go to Step 19

Go to Step 18

With the engine idling, monitor Specific OTC info for

OTC P0201 on the scan tool.
Does the scan tool indicate OTC P0201 failed this ign?

Yes

1. Check for the following conditions:

The ignition feed circuit in the wire harness
between the fuse and the cylinder #1 fuel injector
for an intermittent open.

The cylinder #1 fuel injector control circuit between

the PCM and the injector for an intermittent open
or short to ground.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?
1. Check for poor terminal connections at the
cylinder #1 fuel injector connector.
2. Check the cylinder #1 fuel injector control circuit for
poor terminal connections at the PCM connector.

3. If a problem is found, repair as necessary. Refer to

Wiring Repairs.
Was a problem found?
\

6~892

Engine Controls - 3.SL

Engine

OTC P0201 Injector 1 Co.ntrol Circuit (cont'd)

Step

Action

Value(s)

Yes

No

Go to Step 10

Go to Step 14

Go to Step 15

Go to Step 11

Go to Step 12

Go to Step 13

Go to Step 19

Go to Step 17

1. Turn OFF the ignition switch.

10

11

2. Disconnect the cylinder #1 fuel injector connector.

3. Turn ON the ignition switch.
4. Measure voltage between ignition feed circuit at the
cylinder #1 fuel injector connector and ground.
Does the ignition feed circuit measure near the
specified value?
Probe the cylinder #1 fuel injector control circuit at the
cylinder #1 fuel injector harness connector with a test light
to B+.
Is the test light ON?
1. Turn OFF the ignition switch.
2. Install a fused jumper between the cylinder #1 fuel
injector control circuit and the ignition feed circuit at
the cylinder #1 fuel injector harness connector.
3. Turn ON the ignition switch.
4. Probe the cylinder #1 fuel injector control circuit at
the PCM connector with a test light to ground.

B+

Is the test light ON?

12

13

1. Check for a poor terminal connections at the

cylinder #1 fuel injector connector.
2. If a problerriis found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?
Locate and repair open in the cylinder #1 fuel injector
control circuit. Refer to Wiring Repairs.

14

15

16

17

18

19

Go to Step 19

Locate and repair open in the cylinder #1 fuel injector

ignition feed circuit. Refer to Wiring Repairs.
Is action complete?

Locate and repair short to ground in the cylinder #1 fuel

injector control circuit. Refer to Wiring R9pairs.
Is action complete?

Locate and repair short to voltage in the cylinder #1 fuel

injector control circuit. Refer to Wiring Repairs.
Is action complete?

Ov

Replace malfunctioning fuel injector(s). Refer to Fuel

Injector Replacement.
Is action complete?

Replace the PCM.

Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Is action complete?

1.
2.
3.
4.

Review and record scan tool Fail Records data.

Clear DTCs.
Operate the vehicle within Fail Records conditions.
Monitor Specific OTC info for OTC P0201 on the
scan tool.
Does the scan tool indicate OTC P0201 failed this ign?

Is action complete?

Go to Step 19'

Go to Step 19

Go to Step 19

Go to Step 19

Go to Step 19

Go to Step 2

System OK

Engine

Engine Controls. - 3.8L

6-893

DTC P0202 Injector 2 Control Circuit

\

Refer to Fuel Injectors

Diagnostic Aids

Circuit Description

The misfire history counter may be useful in

determining which injector circuit is malfunctioning. If
OTC P0300 was set, look at the Misfire Hist #
display for each cylinder. The largest value stored in
the misfire history counters will indicate the location of
the malfunctioning injector circuit or injector.
Check for the following conditions:
Poor connection at the PCM or fuel injector.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wore connection.
Damaged harness.
Inspect the wiring harness for damage.
Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the OTC to be
set occurs. This may assist in diagnosing the condition.

The PCM .controls the fuel injectors by using an

ignition feed driver and ground circuit within the PCM.
The driver has the ability to detect an electrical
malfunction in the ignition feed or ground circuit. If an
electrical malfunction occurs in the fuel injector
circuit for engine cylinder #2, the ignition feed driver
signals the PCM to set OTC P0202.

Conditions for Running the DTC

The engine is running.

Conditions for Setting the DTC

The PCM detects an electrical malfunction on the
injector circuit for engine cylinder #2 for longer
than 30 seconds.
The condition is present for at least 30 seconds.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second

consecutive trip in which the diagnostic test has
been run and failed.
11 the electrical malfunction could lead to possible
catalyst damage, the PCM will immediately flash
the MIL while the fault remains at catalyst
damage levels.
The PCM will disable TCC operation.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
4. Checks for malfunctioning fuel injector control
circuit or ignition feed wiring.
9. Checks for a malfunction in the fuel injector
ignition feed circuit.
10. Checks for a short to ground in the injector control
circuit.
11 . Checks for an open in the fuel injector control
circuit.
18. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

6-894

Engine Controls - 3.SL

Engine

DTC P0202 Injector 2 Control Circuit

Step

Action

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

With the engine idling, monitor Specific OTC info for

OTC P0202 on the scan tool.
Does the scan tool indicate OTC P0202 failed this ign?

Value(s)

Yes

No

Go to Step 2

Go to the A
Powerlrain On
Board Diagnostic
(OBD) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 17

Go to Step 7

Go to Step 16

Go to Step 19

Go to Step B

Go to Step 19

Go to Step 18

1. Turn ON the ignition switch.

2. Review and record scan tool Fail Records data.
3

3. Operate the vehicle within Fail Records conditions.

4. Monitor Specific OTC info for OTC P0202 on the
scan tool.

Does the scan tool indicate OTC P0202 failed this ign?

1.
2.
3.
4.

Turn OFF the ignition switch.

Disconnect the PCM.
Turn ON the ignition switch.
Using a J 39200 DMM, measure the. voltage between
the cylinder #2 fuel injector control circuit at the PCM
connector and ground.
Does the cylinder #2 fuel injector control circuit measure
near the specified value?

B+

Check the fuel injectors. Refer to Fuel lnj Coil Test - ECT
Between 10-35 Degrees C or Fuel lnj Coil Test, ECT
Outside 10-35 Degrees C.
Are the fuel injectors OK?

1.
2.
3.
4.

Turn OFF the ignition switch.

Disconnect the cylinder #2 fuel injector.
Turn ON the ignition switch.
Measure the voltage between the cylinder #2 fuel
injector control circuit at the PCM connector and
ground.
Does the cylinder #2 fuel injector control circuit measure
near the specified value?

ov

1. Check for the following conditions:

The ignition feed circuit in the wire harness
between the fuse and the cylinder #2 fuel injector
for an intermittent open.

The cylinder #2 fuel injector control circuit between

the PCM and the injector for an intermittent open
or short to ground.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?
1. Check for poor terminal connections at the
cylinder #2 fuel injector connector.
2. Check the cylinder #2 fuel injector control circuit for
poor terminal connections at the PCM connector.
3. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Engine

Engine Controls - 3.SL

6-895

DTC P0202 Injector 2 Control Circuit (cont'd)

Step

)
9

10

11

Action

Value(s)

13

14

15

16

17

18

19

No

Go to Step 10

Go to Step 14

Go to Step 15

Go to Step 11

Go to Step 12

Go to Step 13

Go to Step 19

Go to Step 17

1. Turn OFF the ignition switch.

2. Disconnect the cylinder #2 fuel injector connector.
3. Turn ON the ignition switch.
4. Measure voltage between ignition feed circuit at the
cylinder #2 fuel injector connector and ground'.
Does the ignition feed circuit measure near the
specified value?
Probe the cylinder #2. fuel injector control circuit at the
cyHnder #2 fuel injector harness connector with a test light
to B+.
Is the test light ON?
1. Turn OFF the ignition switch.
2. Install a fused jumper between the cylinder #2 fuel
injector control circuit and the ignition feed circuit at
the cylinder #2 fuel injector harness connector.
3. Turn ON the ignition switch.
4. Probe the cylinder #2 fuel injector control circuit at
the PCM connector with.a test light to ground,

B+

Is the test light ON?

12

Yes

'
1. Check for. a poor terminal connections at the
cylinder #2 fuel injector connectot.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Locate and repair open in the cylinder #2 fuel injector

control circuit. Refer to Wiring Repairs.
Is action complete?

Locate and repair open in the cylinder #2 fuel injector

ignition feed circuit. Ref.er to Wiring Repairs.
Is action complete?

Locate and repair short to ground in the cylinder #2 fuel

injector control circuit. Refer to Wiring Repairs.
Is action complete?

Locate and repair short to voltage in the cylinder #2 fuel

injector control circuit. Refer to Wiring Repairs.
Is action complete?

Ov

Replace malfunctioning fuel injector(s).

Refer to Fuel Injector Replacement.
Is action complete?

Replace the PCM.

Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Is action complete?

1. Review and record scan tool Fail Records data.

2. Clear DTCs.
3. Operate the vehicle within Fail Records conditions.
4. Monitor Specific OTC info for OTC P0202 on the
scan tool.
Does the scan tool indicate OTC P0202 failed this ign?

Go to Step 19

Go to Step 19

Go to Step 19

Go to Step 19
-

Go to Step 19

Go to Step 19

Go to Step 2

System OK

6-896

Engine

Engine Controls - 3.8L

OTC P0203 Injector 3 Control Circuit

Refer to Fuel Injectors

Diagnostic Aids

Circuit Description

The misfire history counter may be useful in

determining which injector circuit is malfunctioning. If
OTC P0300 was set, look at the Misfire Hist #
display for each cylinder. The largest value stored in
the misfire history counters will indicate the location of
the malfunctioning injector circuit or injector.
Check for the following conditions:
Poor connection at the PCM or fuel injector.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wore connection.
Damaged harness.
Inspect the wiring harness for damage.
Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the OTC to be
set occurs. This may assist in diagnosing the condition.

The PCM controls the fuel injectors by using an

ignition feed driver and ground circuit within the PCM.
The driver has the ability to detect an electrical
malfunction in the ignition feed or ground circuit. If an
electrical malfunction occurs in the fuel injector
circuit for engine cylinder #3, the ignition feed driver
signals the PCM to set OTC P0203.

Conditions for Running the DTC

The engine is running.

Conditions for Setting the DTC

The PCM detects an electrical malfunction on the
injector circuit for engine cylinder #3 for longer
than 30 seconds.
The condition is present for at least 30 seconds.

Action Taken When the DTC Sets

The PCM will 'illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
If the electrical malfunction could lead to possible
catalyst damage, the PCM will immediately flash
the MIL while the fault remains at catalyst
damage levels.
The PCM will disable TCC operation.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
4. Checks for malfunctioning fuel injector control
circuit or ignition feed wiring.
9. Checks for a malfunction in the fuel injector
ignition feed circuit.
10. Checks for a short to ground in the injector control
circuit.
11. Checks for an open in the fuel injector control
circuit.
18. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

Engine Controls - 3.8L

Engine

6-897

OTC P0203 Injector 3 Control Circuit

Action

Step

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 17

Go to Step 7

Go to Step 16

Go to Step 19

Go to Step B

Go to Step 19

Go to Step 18

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

With the engine idling, monitor Specific DTC info for

DTC P0203 on the scan tool.

Does the scan tool indicate DTC P0203 failed this ign?
1. Turn ON the ignition switch.
2. Review and record scan tool Fail Records data.
3

3. Operate the vehicle within Fail Records conditions.

4. Monitor Specific DTC info for DTC P0203 on the

scan tool.
Does the scan tool indicate DTC P0203 failed this ign?
1. Turn OFF the ignition switch.
2. Disconnect the PCM.
3. Turn ON the ignition switch.

4. Using a J 39200 DMM, measure the voltage between

B+

the cylinder #3 fuel injector control circuit at the PCM

connector and ground.
Does the cylinder #3 fuel injector control circuit measure
near the specified value?

Check the fuel injectors. Refer to Fuel lnj Coil Test - ECT
Between 10-35 Degrees C or Fuel lnj Coil Test - ECT
Outside 10-35 Degrees C.
Are the fuel injectors OK?

1. Tum OFF the ignition switch.

2. Disconnect the cylinder #3 fuel injector.
3. Turn ON the ignition switch.

4. Measure the voltage between the cylinder #3 fuel

ov

injector control circuit at the PCM connector and

ground.
Does the cylinder #3 fuel injector control circuit measure
near the specified value?
1. Check for the following conditions:
The ignition feed circuit in the wire harness
between the fuse and the cylinder #3 fuel injector
for an intermittent open.

The cylinder #3 fuel injector control circuit between

the PCM and the injector for an intermittent open
or short to ground.

2. If a problem is found, repair as necessary. Refer to

Wiring Repairs.
Was a problem found?
1. Check for poor terminal connections at the
cylinder #3 fuel injector connector.

2. Check the cylinder #3 fuel injector control circuit for

poor terminal connections at the PCM connector.

3. If a problem is found, repair as necessary. Refer to

Wiring Repairs.

Was a problem found?

6-898

Engine Controls - 3.8L

Engine

DTC P0203 Injector 3 Control Circuit (cont'd)

Step

Action

Turn OFF the ignition switch.

Disconnect the cylinder #3 fuel injector connector.
Turn ON the ignition switch.
Measure voltage between ignition feed circuit at the
cylinder #3 fuel injector connector and ground.
Does the ignition feed circuit measure near the
specified value?
',

B+

Probe the cylinder #3 fuel injector control .circuit at the

cylinder #3 fuel injector harness connector with ,a
J 34142-8 test lamp to B+.
Is the test lamp ON?

1. Turn OFF the ignition switch.

2. Install a fused jumper between the cylinder #3 fuel
ir:,jector control circuit and the ignition feed circuit at
the cylinder #3 fuel injector harness connector,
3. Turn ON the ignition switch.
4. Probe the cylinder #3 fuel injector control circuit at
the PCM connector with a J 34142-8 test lamp to
ground.
Is the test lamp ON?

12

1. Check for a poor terminal connections at the

cylinder #3 fuel injector connector.
2. If. a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

13

Locate and repair open in the cylinder #3 fuel injector

control circuit. Refer to Wiring Repairs.
Is action complete?

Locate and repair open in the cylinder #3 fuel injector

ignition feed circuit. Refer to Wiring Repairs.
Is action complete?

Locate and repair short to ground in the cylinder #3 fuel

injector control circuit. Refer to Wiring Repairs.
Is action complete?

Locate and repair short .to voltage in the. cylinder #3 fuel

injector control circuit. Refer fo Wiring Repairs. ,
Is action complete?

Ov

Replace malfunctioning fuel injector(s).

Refer to Fuel Injector Replacement.
Is action complete?

10

11

14

15

16

17

18

1.
2.
3.
4.

Value(s)

Replace the PCM.

Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.

19

No

Go to Step 10

Go to Step 14

Go to Step 15

Go to Step 11

Go tq Step 12

Go to Step 13

Go to Step 19

Go to Step 17

. Go to Step 19

Go to Step 19

Go to Step 19

Go to Step 19

Go to Step 19

Is action complete?
1.
2.
3.
4.

Yes

Go to St~p 19

Review and record scan tool Fail Records data.

Clear DTCs.
Operate the vehicle within Fail Records conditions.
Monitor Specific OTC info for DTC P0203 on the
scan tool.
Does the scan tool indicate DTC P0203 failed this ign?

Go to Step 2

System OK

Engihe

Engine Controls - 3.8L

6-899

DTC P0204 Injector 4 Control Circuit

Refer to Fuel Injectors

Diagnostic Aids

Circuit Description

The misfire history counter may be useful in

determining which injector circuit is malfunctioning. If
OTC P0300 was set, look at the Misfire Hist#
display for each cylinder. The largest value stored in
the misfire history counters will indicate the location of
the malfunctioning injector circuit or injector.
Check for the. following conditions:
Poor connection at the PCM or fuel injector.
Inspect harness connectors for backed out
terminals, improper mating, broken 1ocks,
improperly formed or damaged terminals, and
poor terminal to wore connection.
Damaged harness.
Inspect the wiring harness for damage.
Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the OTC to be
set occurs~. This may assist in diagnosing the condition.

.The PCM controls the fuel injectors by using an

'ignition feed driver and ground circuit within the PCM.
The driver has the ability to detect an ele.ctrical
malfunction in the ignition feed or ground circuit. If an
electrical malfunction occurs in the fuel injector
circuit for engine cylinder #4, the ignition feed driver
signals the PCM to set OTC P0204.

Conditions for Running the OTC

The engine is running.

Conditions for Setting the OTC

The PCM detects an electrical malfunction on the
injector circuit for engine cylinder #4 for longer
than 30 seconds.
The condition is present for at least 30 seconds.

Action Taken When the OTC Sets

)
I

The PCM will illuminate the MIL during the second

consecutive trip in which the diagnostic test has
been run and failed.
If the electrical malfunction could lead to possible
catalyst damage, the PCM will immediately flash
the MIL while the fault remains at catalyst
damage levels.
The PCM will disable TCC operation.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

Test Description
Num~er(s) below refer to the step number(s) on the
Diagnostic Table.
4. Checks for malfunctioning fuel injector control
circuit or ignition feed wiring.
9. Checks for a malfunction in the fuel injector
ignition feed circuit.
10. Checks for a short to ground in the injector control
ci~~
.
11. Checks for an.open in the fuel injector control
circuit.
18. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

6-900

Engine Controls - 3.8L

Engine

OTC P0204 Injector 4 Control Circuit

Action

Step

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

v'fith the engine idling, monitor Specific OTC info for

OTC P0204 on the scan tool.

Value(s)

Turn ON the ignition switch.

Review and record scan tool Fail Records data.
Operate the vehicle within Fail Records conditions.
Monitor Specific OTC info for OTC P0204 on the
scan tool.
Does the scan tool indicate OTC P0204 failed this ign?

1.
2.
3.
4.

Check the fuel injectors. R.efer to Fuel lnj Coil Test - ECT
Between 10-35 Degrees C or Fuel lnj Coil Test - ECT
Outside 10-35 Degrees C.
Are the fuel injectors OK?

1. Turn OFF the ignition switch.

2. Disconnect the cylinder #4 fuel injector.
3. Turn ON the ignition switch.
4. Measure the voltage between the cylinder #4 fuel
injector control circuit at the PCM connector and
ground.
Does the cylinder #4 fuel injector control circuit measure
ne.ar the specified value?

ov

Go to Step 3

Go to St(;lp 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 17

Go to Step 7

Go to Step 16

Go to Step 19

Go to Step B

Go to Step 19

Go to Step 18

2. If a problem is found, repair as necessary. Refer to

Wiring Repairs.
Was a problem found?

Go to Step 4

B+

1. Check for poor terminal connections at the

cylinder #4 fuel injector connector.
2. Check the cylinder #4 fuel injector control circuit for
poor terminal connections at the PCM connector.
3. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Turn OFF the ignition switch.

Disconnect the PCM.
Turn ON the ignition switch.
Using a J 39200 DMM, measure the voltage between
the cylinder #4 fuel injector control circuit at the PCM
connector and ground.
Does the cylinder #4 fuel injector control circ1,1it measure
near the specified value?

1. Check for the following conditions:

The ignition feed circuit in the wire harness
between the fuse and the cylinder #4 fuel injector
for an intermittent open.
The cylinder #4 fuel injector control circuit between
the PCM and the injector for an intermittent open
or short to ground.

No

Does the scan tool indicate OTC P0204 failed this ign?
1.
2.
3.
4.

Yes

Engine

Engine Controls - 3.SL 6-901

DTC P0204 Injector 4 Control Circuit (cont'd)

Step

10

11

Action

Value(s)

1. Turn OFF the ignition switch.

2. Disconnect the cylinder #4 fuel injector connector.
3. Turn ON the ignition switch.
4. Measure voltage between ignition feed circuit at the
cylinder #4 fuel injector connector and ground.
Does the ignition feed circuit measure near the
specified value?

B+

Probe the cylinder #4 fuel injector control circuit at the

cylinder #4 fuel injector harness connector with a
J 34142-8 test lamp to B+.
Is the test lamp ON?

1. Turn OFF the ignition switch.

2. Install a fused jumper between the cylinder #4 fuel
injector control circuit and the ignition feed circuit at
the cylinder #4 fuel injector harness connector.
3. Turn ON the ignition switch.
4. Probe the cylinder #4 fuel injector control circuit at
the PCM connector with a J 34142-8 test lamp to
ground.
Is the test lamp ON?

Yes

No

Go to Step 10

Go to Step 14

Go to Step 15

Go to Step 11

Go to Step 12

Go to Step 13

Go to Step 19

Go to Step 17

1. Check for a poor terminal connections at the

12

13

14

15

16

cylinder #4 fuel injector connector.

2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Locate and repair open in .the cylinder #4 fuel injector

control circuit. Refer to Wiring Repairs.
Is action complete?

Locate and repair open in the cylinder #4 fuel injector

ignition feed circuit. Refer to Wiring Repairs.
Is action complete?

Locate and repair short to ground in the cylinder #4 fuel

injector control circuit. Refer to Wiring Repairs.
Is action complete?

Locate and repair short to voltage in the cylinder #4 fuel

injector control circuit. Refer to Wiring Repairs.

18

Replace malfunctioning fuel injectors.

Refer to Fuel Injector Replacement.
Is action complete?
Replace the PCM.
Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.

19

Go to Step 19

Ov

Go to Step 19

Go to Step 19

Go to Step 19

Is action complete?
1. Review and record scan tool Fail Records data.
2. Clear DTCs.
3. Operate the vehicle within Fail Records conditions.
4. Monitor Specific DTC info for OTC P0204 on the
scan tool.
Does the scan tool indicate DTC P0204 failed this ign?

Go to Step 19

Is action complete?

17

Go to Step 19

Go to Step 2

System OK

Engine

6~902 . f;ngine Controls .. 3.SL

DTC P0205 Injector 5 Control Circuit
Refer to Fuel Injectors

Diagnostic Aids

Circuit Description

The misfire history counter may be useful in .

determining which injector circuit is malfunctioning. If
OTC P0300 was set, took at the Misfire Hist #
display for each cylinder. The largest value stored in
the misfire history counters will indicate the location of
the malfunctioning injector circuit or injector.
Check for the following conditions:
Poor connection at the PCM or fuel injector.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wore connection.
Damaged harness.
Inspect the wiring harness.for damage.
Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the otC to be
set occurs. This may assist in diagnosin!J the condition.

The PCM controls the fuel injectors by using an

ignition feed driver and ground circuit within the PCM.
The drive~.Jlas the ability to detect an electrical
malfunctio'fi in the ignition feed or ground circuit. If an
electrical malfunction occurs in the fuel injector
circuit for engine cylinder #5, the ignition feed driver
signals the PCM to set OTC P0205.

Conditions for .Running the DTC

The engine is running.

Conditions for Setting the DTC

The PCM detects an electrical malfunction on the
injector circuit for engine cylinder #5 for longer
than 30 seconds.
The condition is present for at least 30 seconds.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive tripin which the diagnostic test has
been run and failed.
If the electrical malfunction could lead to possible
catalyst damage, the PCM will immediately flash
the MIL while the fault remains at catalyst
damage levels.
The PCM will disable TCC operation.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
4. Checks for malfunctioning fuel injector control
circuit or ignition feed wiring.
9. Checks for a malfunction in the fuelinjector
ignition feed circuit.
10. Checks for a short to ground in the injector control
circuit.
11. Checks for an open in the fuel injector control
circuit.
18. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). Wheri the PCM is being
replaced, the new PCM must be programmed.

Engine Controls - 3.8L

Engine

6-903

OTC P0205 Injector 5 Control Circuit

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Go to Step.4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 17

Go to Step 7

Go to Step 16

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

With the engine idling, monitor Specific OTC info for

OTC P0205 on the scan tool.

Does the scan tool indicate OTC P0205 failed this ign'.?
1. Turn ON the ignition switch.
3

2. Review and record scan tool Fail Records data.

3. Operate the vehicle' within Fail .Records conditions.
4. Monitor Specific OTC info for DTC P0205 on the
scan tool.

Does the scan tool indicate OTC P0205 failed this ign?

1.
2.
3.
4.

Turn OFF the ignition switch.

Disconnect the PCM.
Turn ON the ignition switch.
Using a J 39200 DMM, measure the voltage between
the cylinder #5 fuel injector control circuit at the PCM
connector and ground.

B+

Does the cylinder #5 fuel injector control circuit measure

near the specified value?

Check the fuel injectors. Refer to Fuel lnj Coil Test - ECT
Between 10-35 Degrees C or. Fuel lnj Coil Test - ECT
Outside 10-35 Degrees. C.
Are the fuel injectors OK?
1.
2.
3.
4.

Turn OFF the ignition switch.

Disconnect the cylinder #5 fuel injector.
Turn ON the ignition switch.
Measure the voltage between the cylinder #5 fuel
injector control circuit atthe PCM connector and
ground.

ov

Does the cylinder #5 fuel injector control circuit measure

near the specified valu~?
1. Check for the following conditions:
The ignition feed circuit in the wire harness
between the fuse and the cylinder #5 fuel injector
for an intermittent open.

The cylinder #5 fuel injector control circuit between

the PCM and the injector for an intermittent open
or short to ground.

..

2. If a problem is found, repair as necessary. Refer to

Wiring Repairs.
Was a problem found?

1. Check for poor terminal connections at the

cylinder #5 fuel injector connector.
2. Check the cylinder #5 fuel injector control circuit for
poor terminal connections at the PCM connector.
3. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Go to Step 19

Go to Step 8

Go to Step 19

Go.to Step 18

6-904

Engine Controls - 3.SL

Engine

DTC P0205 Injector 5 Control Circuit (cont'd)

Action

Step

Value(s)

Turn OFF the ignition switch.

Disconnect the cylinder #5 fuel injector connector.
Turn ON the ignition switch.
Measure voltage between ignition feed circuit at the
cylinder #5 fuel injector connector and ground.
Does the ignition feed circuit measure near the
specified value?

B+

10

Probe the cylinder #5 fuel injector control circuit at the

cylinder #5 fuel injector harness connector with a
J 34142-B test lamp to B+.
Is the test lamp ON?

1. Turn OFF the ignition switch.

2. Install a fused jumper between the cylinder #5 fuel
injector control circuit and the ignition feed circuit at
the cylinder #5 fuel injector harness connector.
3. Turn ON the ignition switch.
4. Probe the cylinder #5 fuel injector control circuit at
the PCM connector with a J 34142-8 test lamp to
ground.
Is the test lamp ON?

1. Check for a poor terminal connections at the

cylinder #5 fuel injector connector.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Locate and repair open in the cylinder #5 fuel injector

control circuit. Refer to Wiring Repairs.
Is action complete?

Locate and repair open in the cylinder #5 fuel injector

ignition feed circuit. Refer to Wiring Repairs.
Is action complete?

Locate and repair short to ground in the cylinder #5 fuel

injector control circuit. Refer to Wiring Repairs.
Is action complete?

Locate and repair short to voltage in the cylinder #5 fuel

injector control circuit. Refer to Wiring Repairs.
Is action complete?

Ov

Replace malfunctioning fuel injector(s).

Refer to Fuel Injector Replacement.
Is action complete?

Replace the PCM.

Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Is action complete?

Review and record scan tool Fail Records data.

Clear DTCs.
Operate the vehicle within Fail Records conditions.
Monitor Specific DTC info for DTC P0205 on the
scan tool.
Does the scan tool indicate DTC P0205 failed this ign?

1.
2.
3.
4.

11

12

13

14

15

16

17

18

19

1.
2.
3.
4.

Yes

No

Go to Step 10

Go to Step 14

Go to Step 15

Go to Step 11

Go to Step 12

Go to Step 13

Go to Step 19

Go to Step 17

Go to Step 19

Go to Step 19

Go to Step 19

Go to Step 19

Go to Step 19

Go to Step 19

Go to Step 2

System OK

Engine

Engine Controls - 3.SL

6-905

DTC P0206 Injector 6 Control Circuit

Refer to Fuel Injectors

Diagnostic Aids

Circuit Description

The misfire history counter may be useful in

determining which injector circuit is malfunctioning. If
OTC P0300 was set, look at the Misfire Hist #
display for each cylinder. The largest value stored in
the misfire history counters will indicate the location of
the malfunctioning injector circuit or injector.
Check for the following conditions:
Poor connection at the PCM or fuel injector.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wore connection.
Damaged harness.
Inspect the wiring harness for damage,
Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the OTC to be
set occurs. This may assist in diagnosing the condition.

The PCM controls the fuel injectors by using an

ignition feed driver and ground circuit within the PCM.
The driver has the ability to detect an electrical
malfunction in the ignition feed or ground circuit. If an
electrical malfunction occurs in the fuel injector
circuit for engine cylinder #6, the ignition feed driver
signals the PCM to set OTC P0206.

Conditions for Running the OTC

The engine is running.

Conditions for Setting the OTC

The PCM detects an electrical malfunction on the
injector circuit for engine cylinder #6 for longer
than 30 seconds.
The condition is present for at least 30 seconds.

Action Taken When the OTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
If the electrical malfunction could lead to possible
catalyst damage, the PCM will immediately flash
the MIL while the fault remains at catalyst
damage levels.
The PCM will disable TCC operation.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
4. Checks for malfunctioning fuel injector control
circuit or ignition feed wiring.
9. Checks for a malfunction in the fuel injector
ignition feed circuit.
10. Checks for a short to ground in the injector control
circuit.
11. Checks for an open in the fuel injector control
circuit.
18. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

6-906

Engine

Engine Controls - 3.8L

OTC P0206 Injector 6 Control Circuit

Step

Action

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Value(s)

No

Go to Step 2

Go to the A
Powertrain Oh
Board Diagnostic
(OBD) System
Check
'

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

With the engine idling, monitor Specific OTC info for

DTC P0206 on the scan tool.
Does the scan tool indicate DTC P0206 failed this ign?

1. Turn ON the ignition switch.

2. Review and record scan tool Fail Records data.
3. Operate the vehicle within Fail Records conditions.
4. Monitor Specific OTC info for OTC P0206 on the
scan tool.
Does the scan tool indicate OTC P0206 failed this ign?

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Turn ON the ignition switch.
4. Using a J 39200 DMM, measure the voltage between
the cylinder #6 fuel injector control circuit at the PCM
connector and ground.
Does the cylinder #6 fuel injector control circuit measure
near the specified value?

B+

Check the fuel injectors. Refer to Fuel lnj Coil Test - ECT
Between 10-35 Degrees C or Fuel lnj Coil Test - ECT
Outside 10-35 Degrees C.
Are the fuel injectors OK?

1. Turn OFF the ignition switch.

2. Disconnect the cylinder #6 fuel injector.
3. Turn ON the ignition switch.
4. Measure the voltage between the cylinder #6 fuel
injector control circuit at the PCM connector and
ground.
Does the cylinder #6 fuel injector control circuit measure
near the specified value?

OV

Yes

cc

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 17

Goto Step 7

Go to Step 16

Go to Step 19

Go to Step 8

Go to Step 19

Go to Step 18

1. Check for the following conditions:

The ignition feed circuit in the wire harness
between the fuse and the cylinder #6 fuel injector
for an intermittent open.

The cylinder #6 fuel injector control circuit between

the PCM and the injector for an intermittent open
or short to ground.

2. If a problem is found, repair as necessary. Refer to

Wiring Repairs.
Was a problem found?

1. Check for poor terminal connections at the

cylinder #6 fuel injector connector.
2. Check the cylinder #6 fuel injector control circuit for
poor terminal connections at the PCM connector.
3. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

II

Engine Controls - 3.SL

Engine

6-907

DTC P0206 Injector 6 Control Circuit (cont'd)

Action

Step

Value(s)

Yes

No

Go to Step 10

Go to Step 14

Go to Step 15

Go to Step 11

Go to Step 12

Go to Step 13

Go to Step 19

Go to Step 17

1. Turn OFF the ignition switch.

2. Disconnect the cylinder #6 fuel injector connector.
3. Turn ON the ignition switch.
9

10

11

8+

4. Measure voltage between ignition teed circuit at the

cylinder #6 fuel injector connector and ground.
Does the ignition teed circuit measure near the
specified value?
Probe the cylinder #6 fuel injector control circuit at the
cylinder #6 fuel injector harness connector with a
J 34142-8 test lamp to 8+.
Is the test lamp ON?

1. Turn OFF the ignition switch.

2. Install a fused jumper between the cylinder #6 fuel
injector control circuit and the ignition teed circuit at
the cylinder #6 fuel injector harness connector.
3. Turn ON the ignition switch.
4. Probe the cylinder #6 fuel injector control circuit at
the PCM connector with a J 34142-8 test lamp to
ground.
Is the test lamp ON?

1. Check tor a poor terminal connections at the

cylinder #6 fuel injector connector.

12

13

2. It a problem is found, repair as necessary. Refer to

Wiring Repairs.
Was a problem found?
Locate and repair open in the cylinder #6 fuel injector
control circuit. Refer to Wiring Repairs.

14

15

16

17

Go to Step 19

Is action complete?
Locate and repair open in the cylinder #6 fuel injector
ignition teed circuit. Refer to Wiring Repairs.
Is action complete?

Locate and repair short to ground in the cylinder #6 fuel

injector control circuit. Refer to Wiring Repairs.
Is action complete?

Locate and repair short to voltage in the cylinder #6 fuel

injector control circuit. Refer to Wiring Repairs.
Is action complete?

Ov

Replace malfunctioning fuel injector(s)

Refer to Fuel Injector Replacement.
Is action complete?

Go to Step 19
-

Go to Step 19

Go to Step 19

Go to Step 19

Replace the PCM.

18

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming:

Is action complete?

19

1. Review and record scan tool Fail Records data.

2. Clear DTCs.
3. Operate the vehicle within Fail Records conditions.
4. Monitor Specific OTC into tor OTC P0206 on the
scan tool.
Does the scan tool indicate OTC P0206 tailed this ign?

Go to Step 19

Go to Step 2

System OK

6-908

Engine

Engine Controls - 3.SL

OTC P0230 Fuel Pump Relay Control Circuit

PCM

C1=BLU
C2=CLEAR

- -- ..

ORN/BL:14~! ____ BLK/W!I4~;::

BLK 452

BLK

BLK 452

452

GAY 120

:~~Is~~

r -

BLK~52

DKGRN/WHT 465

BLK 650

BLKI452

Ground
Distribution
Cell 14

Engine Data
Sensors

BLK 452

BLK

35 C2
r- s;;'ns";;; ., Powertrain Control>
~ ~o~d ~ Module (PCM) ~

350

BLK 451

Ground
Distribution
Cell14

Powertrain r
Control I
,
Module (PCM)I
I

>

3,...c2
-

- Fuel

Pump
Relay
Control

I
I
I

L---..1

154433

Circuit Description
The PCM provides ignition positive voltage to control
the fuel pump relay. The PCM has the ability to
detect an electrical malfunction on the relay control
circuit. When the ignition switch is first turned ON, the
PCM energizes the fuel pump relay which applies
power to the fuel pump. The fuel pump relay will
remain ON as long as the engine is running or
cranking and the PCM is receiving reference pulses. If
no reference pulses are present, the PCM
de-energizes the fuel pump relay within 2 seconds
after the ignition is turned ON or the engine is stopped.
With the engine stopped, the fuel pump can be
turned ON by using the scan tool output controls
function. If an electrical malfunction is detected, the
PCM will set OTC P0230.

Conditions for Running the DTC

The ignition is ON.
System voltage is between 9 and 16 volts.

Conditions for Setting the OTC

The PCM detects an electrical malfunction on the
fuel pump relay control circuit.
The condition is present for less than 1 second.

Engine

\I

Engine Controls - 3.8L

6-909

Diagnostic Aids

Test Description

An intermittent may be caused by a poorconnection,

rubbed through the wire insulation or a wire broken
inside of the insulation.
Check for the following conditions:
Poor connections at the PCM or fuel pump relay.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wire connection.
Damaged harness
Inspect the wiring harness for damage.
Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the OTC to be
set occurs. This may assist in diagnosing the condition.

Number(s) below refer to the Step number(s) on the

Diagnostic Table:
2. Ensures that the fuel pump relay control circuit
and the PCM are capable of controlling the
fuel pump relay. Using the scan tool to command
tt:ie fuel pump allows only a 2 second time in
the commanded state.
3. Checks the fuel pump control circuit for a short to
ground.
5. Checks the fuel pump control circuit for an open.
12. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

OTC P0230 Fuel Pump Relay Control Circuit

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 7

Go to Step 3

Go to Step 9

Go to Step 4

Go to Step 5

Go to Step 10

Go to Step 14

Go to Step 6

Go to Step 14

Go to Step 12

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1. Disconnect the fuel pump relay.

2. Connect a J 34142-8 test lamp between fuel pump
relay connector cavities for the fuel pump relay
control. circuit and the fuel pump relay ground circuit.
3. Select Fuel Pump output control with the scan tool.
4. Observe the J 34142-Btest lamp while commanding
the fuel pump ON.
Does the test lamp turn ON when the fuel pump is
commanded ON?

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Probe the fuel pump relay control circuit at the PCM
connector with a J 34142-B test lamp to B+.
Is the test lamp ON?

Probe the fuel pump relay ground circuit with a J 34142-8

test lamp connected to B+.
Is the test lamp ON?

1. Check for an open in the fuel pump relay control

circuit between the PCM and the fuel pump relay.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Check the fuel pump relay control circuit for a poor

terminal connection at the PCM.

2. If a problem is found, repair as necessary. Refer to

Wiring Repairs.
Was a problem found?

Engine

6-91 O Engine Controls - 3.8L

DTC P0230 Fuel Pump Relay Control Circuit (cont'd)
Step

Action
1.
2.
3.
4.

Turn OFF the ignition switch.

Disconnect the PCM.
Turn ON the ignition switch.

Probe the fuel pump relay control circuit at the PCM

harness connector with a J 34142-8 test lamp
connected to ground.
Is the test lamp ON?

Value(s)

Locate and repair short to ground in the fuel pump relay

control circuit. Refer to Wiring Repairs.
Is action complete?

Locate and repair open in the fuel pump relay ground

circuit. Refer to Wiring Repairs.

Go to Step 8

Go to Step 14

Go to Step 11

Go to Step 14

Replace the fuel pump relay. Refer to Fuel Pump Relay

Replacement.
Is action complete?

12

Replace the PCM

Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Is action complete?

13

Locate and repair the short to voltage in the fuel pump

control circuit.
Is action complete?

1. Review and record scan tool Fail Records data.

2. Clear DTCs.
3. Operate the vehicle within Fail Records conditions.
4. Using a scan tool, monitor Specific OTC info for
OTC P0230.
Does the scan tool indicate DTC P0230 failed this ignition?

14

Go to Step 13

Go to Step 14

Is action complete?
11

No

1. Check for a poor terminal connection at the fuel

pump relay.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

10

Yes

Go to Step 14

Go to Step 14

Go to Step 14

System OK

Go to Step 2

Engine

Engine Controls - 3.8L

6-911

DTC P0300 Engine Misfire Detected

Circuit Description

Diagnostic Aids

The PCM has the ability to detect a misfire by

monitoring the 3X reference and camshaft position
input signals from the Ignition Control Module.
The PCM monitors crankshaft speed variations
(reference period. differences) to determine if a misfire
is occurring. If 2% or more of all cylinder firing
events are misfires, emission levels may exceed
mandated standards. The PCM determines misfire
level based on the number of misfire events monitored
during a 200 engine revolution test sample. The
PCM continuously tracks 16 consecutive 200
revolution test samples. If 11 or more misfires are
.detected during any 10 of the 16 samples, OTC Pb300
will set. If the misfire is large enough to cause
possible three-way catalytic converter damage,
OTC P0300 may set puring the first 200 revolution
sample in which the misfire was detected. In the case
of a catalyst damaging misfire 1 the MIL will flash to
alert the vehicle operator of the potential of catalyst
damage.

The scan tool provides information that can be useful

in identifying the misfiring cylinder. If the OTC P0300
is currently stored as OTC status Failed Since
Code Clear, the misfire history counters (Misfire
History Cyl #1 - #6) will still contain a value that
represents the level of misfire detected on each
cylinder. The scan tool displayed misfire counter
values (Misfire History Cyl. #1 through #6) can
be useful in determining whether the misfire affects a
single cylinder, a cylinder pair (cylinders that share
an ignition coil - 1/4, 2/5, 3/6), or is random. If
the largest amount of activity is isolated to a cylinder
pair, check for the following conditions:
Secondary Ignition Wires.
Check the secondary wires associated with the
affected cylinder pair for disconnected ignition
wires or for excessive resistance. The wires
should measure less than 30,000 ohms
(30K ohms).
Damaged Or Malfunctioning Ignition Coil.
Check for cracks, carbon tracking or other
damage. Also check coil secondary resistance.
Secondary resistance should be
between 5000 ohms and 8000 ohms (SK ohms
and 8K ohms).
Substitute a Known Good Coil.
Switch ignition coils and retest. If the misfire
follows the coil, replace the ignition coil.
If the misfire is random, check for the following
conditions:
Crankshaft Position System Variation.
Refer to CKP System Variation Learn Procedure.
The crankshaft position system variation
compensating values are stored in the PCM
non-volatile memory after a learn procedure has
been performed. If the actual crankshaft
position variation is not within the crankshaft
position system variation compensating values
stored in the PCM, OTC P0300 may set. The
crankshaft position system variation learn
procedure is required when any of the following
service procedures have been performed:
- PCM replacement or reprogramming.
- Engine replacement.
- Crankshaft replacement.
- Crankshaft balancer replacement.
- Crankshaft position sensor replacement.
- Any engine repair(s) which disturbs
crankshaft/harmonic balancer to crankshaft
position sensor relationship.
System Grounds.
Ensure all connections are clean and properly
tightened.

Conditions for Setting the DTC

No TP sensor, MAP sensor, ECT sensor, CKP
sensor, CMP sensor, VSS, or MAF sensor
DTCs are set.
Engine speed between 550 and 5800 RPM.
System voltage between 9 and 16 volts.
The ECT sensor indicates a temperature between
-6C (21 F) and t20C (248F).
Throttle angle is steady.
The PCM is detecting a crankshaft RPM variation
indicating a misfire sufficient to cause three-way
catalytic converter damage or emissions levels
that exceed the mandated standard.

Action Taken When the DTC Sets

If the misfire level is non-catalyst damaging, the
PCM will illuminate. the MIL during the second
key cycle in which the OTC sets.
.11 the misfire. is severe enough to cause possible
catalyst damage, the PCM will immediately
flash the MIL while the. misfire remains at catalyst
damaging levels.
The PCM will disable TCC operation.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF on the third

consecutive trip cycle during which the diagnostic
has been run and the fault condition is no
longer present.
A history OTC P0300 will clear after 40
consecutive warm-up cycles have occurred without
a fault.
DTC P0300 can be cleared by using the scan tool
Clear Information function or by disconnecting the
PCM battery feed.

6-912

Engine Controls - 3.8L

Mass Air Flow sensor.

A Mass Air Flow (MAF) sensor output that causes
the PCM to sense a lower than riormal air flow
will cause a lean condition. Try operating the
vehicle within the fail records conditions with the
MAF sensor disconnected. If the lean or
misfiring condition is not present with the MAF
sensor disconnected, replace the MAF sensor.
Loss of EBCM/EBTCM Serial Data.
If the PCM stops receiving data from the
EBCM/EBTCM, DTC P0300 can set due to a loss
of rough road data. Check for stored ABS/TCS
DTCs, especially DTCs related. to a serial
data malfunction. Refer to A Diagnostic
System Check.
Air Induction System.
Vacuum leaks that cause intake air to bypass the
MAF sensor will cause a lean condition. Check
for disconnected or damaged vacuum hoses,
incorrectly installed or malfunctioning crankcase
ventilation valve, or for vacuum leaks at the
throttle body, EGR valve, and intake manifold
mounting surfaces.
Fuel Pressure.
Perform a fuel system pressure test. A
malfunctioning fuel pump, plugged filter, or
malfunctioning fuel system pressure regulator will
contribute to a lean condition.
Refer to Fuel System Pressure Test.
Fuel injector(s)
Refer to Fuel lnj Coil Test - ECT
Between 10-35 Degrees C.
Refer to Fuel lnj Coil Test - ECT Outside
10-35 Degrees C.
Contaminated Fuel.
Refer to Alcohol/Contaminants-in-Fuel Diagnosis.
EGR System.
Check for leaking valve, adapter, or feed pipes
which will contribute to a lean condition or
excessive EGR flow.
Extended Idle.
Excessive open loop operation caused by
extended idling or short trip driving may leave
deposits on the heated oxygen sensors. The
deposits cause oxygen sensors to respond slowly
to exhaust oxygen content, affecting fuel control
and causing a misfire to be indicated at idle. This

Engine
condition is not permanent. To determine if this
condition is causing the DTC P0300 to be
set, review the freeze frame and fail records data
for DTC P0300. If the DTC P0300 occurs at
high engine speeds, the condition described
above did not cause the DTC P0300 to set. If the
DTC P0300 occurs at idle or very low engine
speeds and at engine coolant temperatures less
than 80C (176F), the condition described
above is very likely the cause of the DTC P0300
being set. The deposits on the heated oxygen
sensors can be eliminated by operating the vehicle
fully warm at mass air flows above 15 gm/s.
Important: If the level of misfire was sufficient to
cause possible catalyst damage (if the MIL was
flashing), ensure that the DTC P0420 test is completed
and passed after verifying the misfire repair.
Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the DTC to be
set occurs. This may assist in diagnosing the condition.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. A condition that sets a DTC other than P0300
may also cause a misfire. If any of the indicated
DTCs are set with DTC P0300, diagnose and
repair the other DTC before using the
DTC P0300 table.
3. The Misfire Current Cyl # display may
normally display a small amount of activity
(0 - 10 counts) but should not steadily increment
during .an entire 200 revolution test sample
period.
4. Depending on the cause of the misfire, the Misfire
History Cyl # counter will display a very large
number for the misfiring cylinder(s); values for the
non-misfiring cylinders wiU be less than 1/2 as
great as the misfiring cylinder(s). When
investigating a misfire, always start with the
components associated with the cylinder(s) that
has the largest number of counts stored in
the Misfire History Cyl # counter.
5. Steps 5 through 12 check for conditions that can
cause a random cylinder misfire.
13. Steps 13 through 22 check for conditions that can
cause a non-random or single cylinder misfire.

DTC P0300 Engine Misfire Detected

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to the other
DTC first

Go to Step 3

Was the Powertrain Qn-,-Board Diagnostic (OBD) System

Check performed?

Are any of the following DTCs also set?

OTC P1380 Misfire Detected - Rough Road Data Not
Available

Engine Controls - 3.BL

Engine

6-913

DTC P0300 Engine Misfire Detected (cont'd)

Step

Action

Value(s)

1. Start and idle the engine.

2. Review and record scan tool Freeze Frame data.
3. Operate the vehicle to duplicate the conditions
present when the OTC was set (as defined by the
Freeze Frame data).
4. Monitor the scan tool Misfire Current Cyl # display for
each cylinder.
Is Misfire Current Cyl # display incrementing for any
cylinder (indicating a misfire currently occurring)?

View Misfire History Cyl # on the scan tool.

Does Misfire History Cyl # display a very large value for
more than one cylinder?

Yes

No

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 13

Go to Step 25

Go to Step 6

Go to Step 25

Go to Step 7

Go to Step 25

Go to Step B

Go to Step 25

Go to Step 9

Go to Step25

Go to Step 10

Go to Step 25

Go to Step 11

Go to Step 25

Go to Step 12

1. Visually and physically inspect the vacuum hoses for

5

splits, kinks, and improper connections. Refer to

Emission Hose Routing Diagram.
2. If a problem is found, repair as necessary.
Was problem found?

1. Visually and physically inspect the PCV valve for

6

improper installation and for damaged 0-rings. Refer

to Crankcase Ventilation System Inspection.
2. If a problem is found, repair as necessary.
Was problem found?

1. Inspect the throttle body inlet screen for damage or

7

for the presence of foreign objects that may partially

block the air flow sample through the MAF sensor.
2. If a problem is found, repair as necessary. Refer to
Throttle Body Assembly Replacement.
Was problem found?

1. Check fuel pressure. Refer to Fuel System

Pressure Test.
2. If a problem is found, repair as necessary.
Was problem found?

1. Check the fuel for excessive water, alcohol, or other

contaminants. Refer to Alcohol/Contaminants-in-Fuel
Diagnosis.

2. If a problem is found, repair as necessary.

Was a problem found?

1. Visually and physically inspect the PCM injector

10

grounds, power grounds and sensor grounds to

ensure that they are clean, tight, and in their proper
locations. Refer to Wiring Repairs.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Visually and physically inspect the following areas for

11

vacuum leaks:
Intake manifold.
Injector 0-rings.
EGR adapter
EGR valve.
EGR feed pipes.
2. If a problem is found, repair as necessary.
Was a problem found?

6-914

Engine

Engine Controls - 4.SL

DTC P0300 Engine Misfire Detected (cont'd)

Step

12

13

14

15

16

17

18

Action

Value(s)

1. Remove the EGR valve and visually/physically

inspect the valve to ensure that the pintle is not
sticking partially open. Also, inspect the EGR valve
pintle and seat for carbon deposits or burrs that may
interfere with the pintle closing completely.
2. If a problem is found, repair as necessary. Refer to
EGR Valve Replacement.
Was a problem found?

1. Check for proper fuel injector operation. Refer to Fuel

lnj Coil Test - ECT Between 10-35 Degrees C or Fuel
lnj Coil Test - ECT Outside 10-35 Degrees C.
2. If a problem is found, replace faulty injector(s) as
necessary.
Was a problem found?

1. Visually and physically inspect the ignition wires

associated with the cylinder(s) which were misfiring to
ensure that they are not damaged and are connected
to the proper cylinders at the coils and at the
spark plugs.
2. If a problem is found, repair as necessary. Refer to
On-Vehicle Service in Ignition System.
Was a problem found?

1. Install a J 26792 spark tester at the spark plug end of

the ignition wire for the cylinder that is indicated by
the Misfire Current Cyl # counters or Misfire History
Cyl # counters as having the most severe misfire
(largest number of counts).
2. Jumper the spark plug end of the companion cylinder
ignition wire to engine ground. The companion
cylinder is the cylinder that shares the same ignition
coil (i.e., 1/4; 2/5; 3/6).
3. Crank the engine while observing the J 26792 spark
tester. A crisp, blue spark should be observed.
Is adequate spark present?

1. Remove and visually/physically inspect the ignition

wires associated with the cylinders that were
indicated as misfiring. Ensure that the wires and
boots are free of carbon tracking and the insulation is
not damaged.
2. If a problem is found, replace malfunctioning ignition
wire(s) as necessary. Refer to On-Vehicle Service in
Ignition System.
Important: If carbon tracking or terminal discoloration is
apparent at the ignition coil end of any of the ignition
wires, replace the affected ignition wire and the associated
ignition coil. Refer to Ignition Coil(s) Replacement.
Was a problem found?

1. Measure the resistance of the ignition wires

associated with the cylinders that were indicated as
misfiring.
2. Replace any ignition wire(s) that measure greater
than the specified value. Refer to On-Vehicle Service
in Ignition System.
Was a problem found?
1. Remove and visually/physically inspect the ignition
coil{s) associated with the cylinders that were
indicated as misfiring. Ensure that the coil(s) and coil
towers are free of cracks and carbon tracking.
2. If a problem is found, replace damaged ignition coil(s)
as necessary. Refer to Ignition Coil(s) Replacement.
Was a problem found?

Yes

No

(
'
Go to Step 25

Go to Step 13

Go to Step 25

Go to Step 14

Go to Step 25

Go to Step 15

(
Go to Step 20

Go to Step 16

Go to Step 25

Go to Step 17

Go to Step 25

Go to Step 18

Go to Step 25

Go to Step 19

30 K ohms
(30,000 ohms)

Engine

6'"915

Engine Controls - 3.SL

OTC P0300 Engine Misfire Detected (cont'd)
Action

Step

Value(s)

Yes

No

Go to Step 25
Go to Base
Engine Misfire
Diagnosis in
Engine General
Information and
Mechanical
Diagnosis.

Go to Step 24

Go to Step 25

Go to Step 22

Go to Step 25

Go to Step 23

Go to Step 25

Goto
Diagnostic Aids

1. Measure the ignition coil secondary resistance.

19

2. If resistance is not between the specified values,

replace the faulty ignition coil{s) as necessary. Refer
to Ignition Coil(s) Replacement.
Did any ignition coils require replacement?

5K-8K ohms
(50008000 ohms)

1. Remove the spark plugs from the cylinders that were

indicated as misfiring.
20

2. Visually inspect the spark plug electrodes for

excessive fouling. Refer to On-Vehicle Service in
Ignition System.
Was a problem found?

Go to Step 21

1. Visually insp13ct spark plug insulators for cracks,

21

carbon tracking, or other damage. Also, check

electrodes for incorrect gap. Refer to Spark Plug
Visual Diagnosis in Ignition System.
2. If a problem is found, replace affected spark plug(s)
as necessary.
Was problem found?

1. Check for an engine mechanical problem.

22

Base engine problem. Refer to Base Engine

Misfire Diagnosis in Engine General Information
and Mechanical Diagnosis.
Damaged accessory drive belt or pulley.
Damaged driven accessory (generator, water
pump, drive belt tensioner, etc).
Loose or broken motor mount.
2. If a problem is found, repair as necessary.
Was a problem found?

1. Check for a transmission TCC problem. Refer to

Torque Converter Clutch Diagnosis.

23

24

2. If a problem is found, repair the transmission .as

necessary. Refer to Torque Converter Clutch
Diagnosis.
Was a problem found?
Replace the ignition control module. Refer to Ignition
Control Module Replacement.
Is the action complete?

Go to Step 25

1. Review and record Freeze Frame data

2. Clear DTCs.
3. Operate the vehicle to duplicate the conditions
25

present when the DTC was set (as defined by the

Freeze Frame data).
4. Monitor the scan tool Misfire Current Cyl # display for
each cylinder.
.
Is Misfire Current Cyl # display incrementing for any
cylinder (indicating a misfire currently occurring)?

Go to Step 2

System OK

6-916

Engine Controls - 3.8L

Engine

DTC P0325 Knock Sensor System

l
LT BLUI1876

LT BLU 1876
1

Bank 2
Knock
Sensor

[fil

33~1 __ ?~

DK BLU1~4-96_ _ _ _ _ _ _

(~)

Bank 1

... I

C1

Ba~ 1- sa';;'k 2 - - I - - - - 1 ., Powertrain

KS Signal KS Signal
PCM
1Control

1c1 :cLEAR
-BLU
11 Module
1

Knock
Sensor

~~

~-------------~

C2

"'
,.
l(PCM)~

222073

Circuit Description
The PCM contains integrated Knock Sensor (KS)
diagnostic circuitry. The PCM uses the circuitry
to diagnose the KS sensors and related wiring. The
PCM calculates an average voltage of each knock
sensor's signals and takes instantaneous signal
voltage readings. The PCM uses the instantaneous
signal voltage readings to determine the state of
the knock sensor circuitry. If the knock sensor system
is operating normally, the PCM should monitor
instantaneous KS signal voltage readings varying
outside a voltage range above and below the
calculated average voltage. If the PCM malfunctions in
a manner which will not allow proper diagnosis of
the KS circuit DTC 325 will set.

Conditions for Running the DTC

1. No TP sensor, VSS, CKP sensor, CMP sensor,
MAF sensor, or ECT sensor DTCs are set.
2. Engine speed:
- Manual Transaxle - engine speed is
between 1000 and 3000 RPM.
- Automatic Transaxle - engine speed is
between 1000 and 4000 RPM.
3. Throttle angle:
- Manual Transaxle - Throttle angle is greater
than 15%.
- Automatic Transaxle - Throttle angle is
greater than 3%.

4. Engine load:
- Manual Transaxle - engine load is greater
than 45%.
- Automatic Transaxle - engine load is greater
than 20%.
5. Engine coolant temperature is greater
than 75C (167F).
6. Maximum spark retard is less than 15 degrees.
7. System voltage is greater than 9 volts.

Conditions for Setting the DTC

The PCM detects a malfunction in the integrated
knock sensor diagnostic circuitry which will not
allow proper diagnosis of the knock sensor
circuits.
The conditions are present for 300 3X reference
periods (100 crankshaft revolutions).

Action Taken When the DTC Sets

The PCM will not illuminate the ;vtalfunction
Indicator Lamp (MIL).
The PCM will store conditions which were present
when the DTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.
The PCM will use a calculated spark retard value
to minimize knock during conditions when knock
is likely to occur. The calculated value will
vary based on engine speed and load.

Engine Controls - 3.8L

Engine
Conditions for Clearing the MIUDTC
A history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
OTC can be cleared by using the scan tool Clear
Info function or by disconnecting the PCM
battery feed.

6-917

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Ensures that the malfunction is present.
4. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

OTC P0325 Knock Sensor System

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Important: If an engine knock can be heard repair the

engine mechanical problem before proceeding with this
diagnostic. Refer to Engine Noise Diagnosis in Engine
Mechanical.
1. Operate engine within conditions specified in
diagnostic support. Refer to Conditions for Setting
the DTC.
2. Using a scan tool, monitor Specific DTC info for
DTC P0325 until the OTC P0325 test runs.
Note test result; does scan tool indicate DTC P0325 failed
this ign?

1. Turn ON the ignition switch.

2. Review and record scan tool Fail Records.data for
DTC P0325.
3. Operate vehicle within Fail Records conditions.
4. Using a scan tool, monitor Specific DTC info for
DTC P0325 until the DTC P0325 test runs.
,'
Does scan tool indicate DTC P0325 test failed this ign?

Replace the PCM.

Important: The replacement PCM must be programmed.

Go to PCM Replacement/Programming.
Is action complete?

Go to Step 5

1. Review and record Fail Records data

2. Clear DTCs.
3. Operate the vehicle within Fail Records conditions.
4. Using a scan tool, monitor Specific DTC info for
DTC P0325 untH the DTC P0325 test runs.
Does the scan tool indicate DTC P0325 test failed
this ign?

Go to Step 2

System OK

6-918

Engine

Engine Controls - 3.BL

OTC P0327 Knock Sensor (KS) Circuit

ITT
L..2w
l
. - - - - - - - ~ ~ L T BLUI1876
LT

BLU 1876

DK

331 __ ?~

BLuliss

Bank 2
Knock
Sensor
(KS)

~ Bank 1
_

Knock
Sensor
(KS)

Cl
s~k2 - - - - - - ., Powertrain
I
I I Control
I
KS Signal KS Signal
PCM
1c1
BLU
:
i
1
Module ...
C2 :CLEAR
~
~ _____________ ~ {PCM)~
r -

eari' 1-

222073

Circuit Description
The PCM contains integrated Knock Sensor (KS)
diagnostic circuitry. The PCM uses the circuitry
to diagnose the KS sensors and related wiring. The
PCM calculates an average voltage of each knock
sensor's signals .and takes instantaneous signal
voltage readings. The PCM uses the instantaneous
signal voltage readings to determine the state of
the knock sensor circuitry. If the knock sensor system
is operating normally, the PCM should monitor
instantaneous KS signal voltage readings varying
outside a voltage range above and below the
calculated average voltage. If the PCM detects a
Knock Sensor 1 signal voltage within the calculated
average voltage range, OTC P0327 will set.

Conditions for Running the OTC

1. No TP sensor, VSS, CKP sensor, CMP sensor,
MAF sensor, or ECT sensor OTCs are set.
2. Engine speed:
- Manual Transaxle - engine speed is
between 1000 and 3000 RPM.
- Automatic Transaxle - engine speed is
between 1000 and 4000 RPM.
3. Throttle angle:
- Manual Transaxle - Throttle angle is greater
than 15%.
- Automatic Transaxle - Throttle angle is
greater than 3%.

4. Engine load:
- Manual Transaxle - engine load is greater
than 45%.
- Automatic Transaxle - engine load is greater
than 20%.
5. Engine coolant temperature is greater
than 75C (167F).
6. Maximum spark retard is less than 15 degrees.
7. System voltage is greater than 9 volts.

Conditions for Setting the DTC

The PCM detects a Knock Sensor 1 signal
voltage within the calculated average
voltage range.
The conditions are present for 300 3X reference
periods (100 crankshaft revolutions).

Action Taken When the OTC Sets

The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM will store conditions which were present
when the OTC set as Fail Records dat;:i. only.
This information will not be stored as
Freeze Frame data.
The PCM will use a calculated spark retard value
to minimize knock during conditions when knock
is likely to occur. The calculated value will
vary based on engine speed and load.

EngineControls .3.8L

Engine
Conditions for Clearing theMIUDTC
A history OTC P0327 will clear after
40 consecuti.ve warm-up cycles have occurred
without a fault.
OTC P0327 can be cleared by using the scan tool
Clear Info function or by disconnecting the PCM
battery feed.

.Reviewing the Fail Records vehicle mileage since the

diagnostic test 1.~st failed may help determine how
often the condition that caused the OTC to be
set occurs. This may assist in diagnosing the ~ondition.

Test Description
Number(s) below refer to the step number(s) on the
1
Diagnostic Table.

Diagnostic Aids

2 .. Ensu~es that the malfunction is present.

Check for the following conditions:

Poor connection at the PCM or Knock Sensor 1.

5. Checks for a false knock signal caused by a

malfunctioning knock sensor.

Inspect knock sensor 1 and PCM connectors

for backed out terminals, broken locks, and
improperly formed or damaged terminals.
Misrouted harness.
Inspect the knock sensor harness to ensure that ft
is not routed too close to high voltage wires
such as spark plug leads.

6-919

6. Ensures that the knock sensor is capable of

producing a correct AC sigri,al.

11. This vehicle is equipped with a PCM which utilizes

anE1ectrical1y Erasable Programmable Read Only
Memory (E:EPROM). When the PCM is being
replaced, the new PCM must be programmed.

OTC P0327 Knock Sensor (KS) Circuit

Step

Value(s)

Action

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Important: If an engine knock can be heard, repair the

engine mechanical probtem before proceeding with this
diagnostic. Refer to Engine Noise Diagnosis (Base Engine)
in Engine Mechanical.
1. Operate the engine within conditions specified in
Conditions for Setting the DTC.
2. Using a scan tool, monitor Specific DTC info for
DTC P0327 until the DTC P0327 test runs.

Go to Step 4
.

1. Turn ON the ignition switch, engine not running.

2. Review and rec:ord scan tool Fail Records data for
DTC P0327.
3. Operate vehicle within Fail Records conditions,
4. Using a scan tool, monitor Specific DTC info for
DTC P0327 until the DTC P0327 test runs.
Does the scan tool indicate DTC P0327 failed this ignition?
1. Turn ON the ignition switch, engine not running.
2. Dis.connect the bank 1 knock sensor eleclrical
connector.
3. Using a J 39200 DMM, measure voltage between the
KS signal circuit at the bank 1 knock sensor and
..
ground.
Does the J 39200 DMM indicate voltage at the
specified value?
1. Connect the J 39200 DMM to measure voltage
between the bank 1 knock sensor terminal and
engine ground.
2. Select 2 volts AC scale on the J 39200 DMM.
3. Engine idling, observe the J 39200 DMM.
Is any signal indicated on the J 39200 DMM for the bank 1
knock sensor?

.Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Does scan tool indicate DTC P0327 failed this ignition?

No

Yes

Go to Step 3

Go to Step 4.

Go to
Diagnostic Aids

Go to Step 5

Go to Step B

Go to Step 9

Go to Step 6

5V.

6-920

Engine Controls - 3;8L

Engine

DTC P0327 Knock Sensor (KS) Circuit (cont'd)

Step

Action

1. Turn OFF the ignition switch.

2. J 39200 DMM still connected to measure voltage
between the the bank 1 knock sensor terminal and
engine ground.
3. Tap on the engine lift bracket while. observing the
J39200 DMM.
Is any signal indicated on the J 39200 DMM while tapping
on the engine lift bracket?

Value(s)

1. Check the the bank 1 KS signal circuit tor incorrect

routing near secondary wires or tor a poor terminal
connection at the knock sensor.
2. If a problem is found, repair as necessary.
Was a problem found?

Yes

No

Go to Step 7

Go to Step 9

Go to Step 12

Go to Step 10

Go to Step 12

Go to Step 10

1.
2.
3.
4.

Turn OFF the ignition switch.

Disconnect the PCM.
Turn ON the ignition switch.
Check the bank 1 KS signal ci~cuit between the PCM
and the knock sensor connectors fQr the following
conditions:
An open.
A short to voltage.
A short to ground.
5, If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

._

10

11

12

Replace the bank 1 knock sensor. Refer to Knock Sensor

Replacement.
Is action complete?

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Check the Bank 1 KS signal circuit for a poor terminal
connection at the PCM.
4. If a problem is found, repair as necessary.
Was a problem found?

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.
Replace the PCM.
Is action complete?

1. Review and record Fail Records data

2. Clear DTCs.
3. Operate the vehicle within Fail Records conditions.
4. Using a scan tool, monitor Specific OTC into tor
OTC P0327 until the OTC P0327 test runs.
Does the scan tool indicate OTC P0327 failed this ign?

Go to Step 12

Go to Step 12

Goto Step 11

Go to Step 12

Go to Step 2

System OK

Engine

Engine. Controls - 3.8L

6-921

DTC P0332 Knock Sensor 2 Circuit

L1i1

l
LT BLU11876
LT BLU 1876
1

Bank 2

3_3~1 __ 3~

DK BLU1~49_6_ _ _ _ _ _ _

Knock
Sensor
(KS)

~ Bank 1

Knock
. Sensor
~ (KS)

,. I

C1

ii'a~1- sa";;k2 - - - - - -1 ,

Powertrain
1Control
I
Module ,.
....
_____________ ~ (PCM)~
KS Signal KS Signal

PCM
C1 - BLU
1C2 -=--CLEAR 1

222073

Circuit Description
The PCM contains integrated Knock Sensor (KS)
diagnostic circuitry. The PCM uses the circuitry
to diagnose the KS sensors and related wiring. The
PCM calculates an average voltage of each knock
sensor's signals and takes instantaneous signal
. voltage readings. The PCM uses the instantaneous
signal voltage readings to determine the state of
the knock sensor circuitry. If the knock sensor system
is operating normally, the PCM should monitor
instantaneous KS signal voltage readings varying
outside a voltage range above and below the
calculated average voltage. If the PCM detects a
Knock Sensor 2 signal voltage within the calculated
average voltage range, DTC P0332 will set.

Conditions for Running the DTC

No TP sensor, VSS, CKP sensor, CMP sensor,
MAF sensor, or ECT sensor DTCs are set.
Engine speed:
- Manual Transaxle - engine speed is
between 1000 and 3000 RPM.
- Automatic Transaxle - engine speed is
between 1000 and 4000 RPM.
Throttle angle:
- Manual Transaxle - Throttle angle is greater
than 15%.
- Automatic Transaxle - Throttle angle is
greater than 3%.

Engine load:
- Manual Transaxle - engine load is greater
than 45%.
- Automatic Transaxle - engine load is greater
than 20%.
Engine coolant temperature is greater
than 75C (167F}.
Maximum spark retard is less than 15 degrees.
System voltage is greater than 9 volts.

Conditions for Setting the DTC

The PCM detects a Knock Sensor 2 signal
voltage within the calculated average
voltage range.
The conditions are present for 300 3X reference
periods (100 crankshaft revolutions).

Action Taken When the DTC Sets

The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM will store conditions which were present
when the DTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.
The PCM will use a calculated spark retard value
to minimize knock during conditions when knock
is likely to occur. The calculated value will
vary based on engine speed and load.

6-922

Engine

Engine- Controls - 3.SL

Conditions for Clearing the MIUDTC

A history OTC P0332 will clear after
40 consecutive warm-up cycles have occurred
without a fault.
OTC P0332 can be cleared by using the scan tool
Clear Info function or by disconnecting the PCM
battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM or Knock Sensor 2.
Inspect knock sensor 2 and PCM connectors
for backed out terminals, broken locks, and
improperly formed or damaged terminals.
Misrouted harness.
Inspect the knock sensor harness to ensure that it
is not routed too close to high voltage wires
such as spark plug leads.

Reviewing the Fail Records vehicle mileage sirice the

diagnostic test last failed may help determine how
often the condition that caused the OTC to be
set occurs. This may assist in diagnosing the condition.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Ensures that the malfunction is present.
5. Checks for a false knock signal caused by a
malfunctioning knock sensor.
6 .. Ensures that the knock sensor is capable of
producing a correct AC signal.
11. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

OTC P0332 Knock Sensor 2 Circuit

Step

Action
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?

Value(s)

Yes

Go to Step 2

Important: If an engine knock can be heard, repair the

engine mechanical problem before proceeding with this
diagnostic. Refer to Engine Noise Diagnosis (Base Engine)
in Engine Mechanical.
1. Operate the engine within conditions specified in
Conditions for Setting the OTC.
2. Using a scan tool, monitor Specific o:rc info for
OTC P0332 until the OTC P0332 test runs.
Does. sc'an tool indicate OTC P0332 failed this ignition?
1. Turn ON the ignition switch, engine not running.
2. Review and record scan tool Fail Records data for
OTC P0332.
3. Oper~te vehicle within Fail Records conditions.

No
Go to the A
Powertrain Oh
Board Diagnostic
(OBD) System
Check

. Go to St9p 4

Go to Step 3

4. Using a scan tool, m9nitor Specific OTC info for

OTC P0332 until the OTC P0332 test runs.
Doesthe scan tool indicate OTC P0332 failed this ignition?

1. Turn ON the ignition switch, engine not running.

2. Disconnect the bank #2 knock sensor electrical
connector.
3. Using a J39200 DMM measure voltage between the
bank #2 KS signal circuit and ground.
Does the J 39200 DMM indicate voltage at the specified
value for the bank #2 knock sensor?

5V

1. Connect the J 39200 DMM to measure voltage

between the Bank 2 knock sensor terminal and
engine ground.
2. Select 2 volts AC scale on the J 39200 DMM.
3. Engine idling, observe the J 39200 DMM.
Is any signal indicated on the J 39200 DMM for the bank
#2 knock sensor?

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 8

Go to Step 9

Go to Step 6

Engine

Engine Controls - 3.SL

6-923

DTC P0332 Knock Sensor 2 Circuit (cont'd)

Step

Action

Value(s)

Yes

No

Go to Step 7

Go to Step 9

Go to Step 12

Go to Step 10

Go to Step 12

Go to Step 10

1. Turn OFF the ignition switch.

2. J 39200 DMM still connected to measure voltage

between the bank #2 knock sensor terminal and
engine ground.
3. Tap on the engine lift bracket while observing the
J39200DMM.

Is any signal indicated on the J 39200 DMM while tapping

on the engine lift bracket?

1. Check the bank #2 KS signal circuit for incorrect

7

routing near secondary wires or for a poor terminal

connection at the knock sensor.
2. If a problem is found, repair as necessary.

Was a problem found?

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Turn ON the ignition switch.

4. Check the bank #2 KS signal circuit between the

PCM and the knock sensor connector for the

following conditions:
An open.

A short to voltage.
A short to ground.

5. If a problem is found, repair as necessary. Aefer to

Wiring Repairs.
Was a problem found?
9

Replace the Bank #2 knock sensor. Refer to Knock

Sensor Replacement.

Is action complete?

Go to Step 12

1. Turn OFF the ignition switch.

2. Disconnect the PCM.

10

3. Check the Bank #2 KS signal circuit for a poor

terminal connection at the PCM.

4. If a problem is found, repair as necessary.

Was a problem found?

11

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.
Replace the PCM.

Go to Step 12

Is action complete?

Go to Step 11

Go to Step 12

1. Review and record Fail Records data

2. Clear DTCs.

12

3. Operate the vehicle within Fail Records conditions.

4. Using a scan tool, monitor Specific DTC info for

DTC P0332 until the DTC P0332 test runs.
Does the scan tool indicate DTC P0332 failed this ign?

Go to Step 2

System OK

5:.924

Engine Controls - 3.SL

Engine

DTC P0336 1SX Reference Signal Circuit

!Hot In Ruri, Bulb Test And Start(

'"

I Power
I Distribution
I Cell 10

ENG CTRL
Mini Fuse

15 A

., Underhood
I
I Electrical
I Center 2
I

. _________ ..I

PNK 239

-----,

PNK 239

Power
Distribution

PNK 2~ - - -

C~I;

PNK 239
p
Ignition
Control (IC)
Module

Ignition
Positive
Voltage
Camshaft
Position
Signal

8~1630

18x

3x

Reference
Signal

Reference
Signal

~~UIB;r,;PLN;:t

r - - CMP- - - - - - - isx - - - - - 3 -;

I
I

sensor
Signal

Ground

Reference
Signal

Reference
Signal

BL~l450
-

PCM
C1 = BLU
C2=CLEAR

Powertrai n
I Control
I Module _...

.,

l(PCM) ~

L--------------------------~

222078

Circuit Description
The 1BX reference signal is produced by the ignition
control module. The ICM calculates the 18X reference
signal by filtering the Crankshaft Position (CKP)
sensor 18X pulses when the engine is running and
CKP sync pulses are also being received. The
PCM uses the 1BX reference signal to calculate engine
RPM and crankshaft position at engine speeds
below 1200 RPM. The PCM constantly monitors the
: number of pulses on the 18X reference circuit
and compares the number of 18X reference pulses to
the number of 3 X reference pulses and CAM
signal pulses being received. If the PCM receives an
incorrect number of pulses on the 18X reference
circuit, DTC P0336 will set and the PCM will use the
3X reference signal circuit for fuel and ignition
control. The engine will continue to start and run using
the 3X reference and CAM signals only.

Conditions for Setting the OTC

The engine is running (3X reference pulses are
being received).
The ratio of 3X reference pulses to CAM signal
pulses received by the PCM equals 6 to 1.
The ratio of 18X reference pulses to 3X reference
pulses received by the PCM does not equal
6 to 1.
The conditions are present for 300 3X reference
periods (100 crankshaft revolutions).

Action Taken When the OTC Sets

The PCM will illuminate the MIL during the second
consecutive trip 'in which the diagnostic test has
been run and failed.
The PCM will use the 3X reference signal circuit
for fuel and ignition control.
If equipped w1th traction control, the PCM will
command the EBTCM via serial data (CKT 800) to
set an ABS/TCS DTC, the EBTCM will turn
OFF traction control, and the EBTCM will
illuminate the TRACTION OFF lamp.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIL/OTC

The PCM will .turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Engine Controls - 3,8L

Engine
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbed through wire insulation or a wire broken
inside the insulation. Check for the following
conditions:
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.
Damaged harness - Inspect the wiring harness for
damage. If the harness appears to be OK,
disconnect the PCM, turn the ignition on and
observe a voltmeter connected to the
18X reference circuit at the PCM harness
connector while moving connectors and wiring
harnesses related to the ICM. A change in voltage
will indicate the location of the fault.
Incorrect harness routing near secondary ignition
components

6~925

Faulty Ignition Coil - Remove the ignition coils and

inspect the ignition control module and coils for
cracks, carbon tracking, or ot.her signs that
indicate that the coil secondary circuit is arcing to
the ICM or ICM wiring harness. Refer to Ignition
Coil(s) Replacement
Secondary ignition wire(s) arcing to wiring harness
- Check secondary ignition wires for carbon
tracking or other signs of damage.
Review the Fail Records vehicle rnHeage since the
diagnostic test last failed. This may help determine
how often the condition that caused the DTC to be set
occurs.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
10. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

DTC P0336 18X Reference Signal Circuit

Action

Step

Was the Powertrain On-Board Diagnostic (OBD) System

Check per-formed?
1

Attempt to start the engine.

Does the engine start?
1.
2.
3.
4.

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to Engine
Cranks but Does
Not Run

Go to Step 4

Go to
Diagnostic Aids

Go to Step 11

Go to Step 5

Go to Step 8

Go to Step 6

Go to Step 11

Go to Step 7

Review and record scan tool Fail Records data.

Clear DTC P0336.
Start the engine and idle for 1 minute.

Observe DTC P0336 test failed since code clear.

Does scan tool indicate DTC P0336 failed this ignition?
1.
2.
3.
4.

Turn OFF the ignition switch.

Disconnect the ignition control module.
Disconnect the PCM.
Check for an open or a short to ground in the
18X reference circuit between the ignition control
module harness connector and the PCM harness
connector.
5. If a problem is found, repair as necessary. Refer to
Wiring Repairs.

Was a problem found?

1. Reconnect the ignition control module.

2. Connect a DVM to measure voltage on the
18X reference circuit at the PCM connector.
3. Observe the voltage while cranking the engine.

3V

Is voltage near the specified value?

)
6

Check for a short to voltage

Check connections at the ignition control module and
replace terminals if necessary. Refer to Wiring Repairs.
Was the problem found?

6-926

Engine Controls - 3.8L

Engine

OTC P0336 18X Reference Signal Circuit {cont'd)

Step

Action

Replace the ignition control module. Refer to Ignition

Control Module Replacement.
Is action complete?

Value(s)

Yes

No

Go to Step 11

1. Check for the following conditions:

Incorrect harness routing near secondary ignition

components.
Ignition coil arcing to the wiring harness or to the
ignition control module (check ignition coils for
cracks, carbon tracking, or other signs of
damage). Refer to Ignition Coil(s) Replacement.
Secondary ignition wire(s) arcing to the wiring
harness. Refer to Secondary Wiring in Ignition
System.
2. If a problem is found, repair as necessary.
Was a problem found?

Check connections at the PCM and replace terminals if

necessary. Refer to Wiring Repairs.
Did any terminals require replacement?

10

Replace the PCM.

Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Is action complete?

Go to Step 11

Go to Step 9

Go to Step 11

Go to Step 10

Go to Step 11

1. Review and record scan tool Fail Records data.

2. Clear DTCs.
11

3. Operate vehicle within Fail Records conditions

as noted.
4. Using a scan tool, monitor Specific DTC info for
DTC P0336 until the DTC P0336 test runs.
Does scan tool indicate DTC P0336 failed this ignition?

(
Go to Step 2

System OK

Engine

Engine Controls - 3.8L 5..;927

OTC P0341 Camshaft Position (CMP) Sensor Performance

!Hot In Run, Bulb Test And Start!

II

Hall E.ffect
sensor

I1,.....;..-') --"""-'--------"=:=:======r:. .
_

---!

A,.

cv

RED/ 645

~ ~~;
I

-1- - ----riiPICKP - - ~

Sensor
Ground

Sensor
Signal

I
I
, I ,

WHT/ 644
. BLK
N

BLK
M

Sensor

- - - - , Underhood
I Electrical
1Center 2
. MiniFuse
15 A
I
L----- - - - - . I
PNK 239
EVAP Canister
ENG CTRL

- - - - - +

WHT/ 644
BLK
WHT/BLK
644
RED/BLK

RED/ 645
BLK

BRN/WHT 633

Camshaft
Position (CMP)

-1
. -.

PNK 239

645

Valve

PNK 239
- - - - - .....
PNK 239
p

CMP/CKP- - - - - - "."' -

Sens_or Ignition
Pos1t1ve Voltage

5V .
.
Camshaft
Position
Signal

Ven,t Solenoid

CKP
sensor

-Jgnit;n- Positive
Voltage

.
~

U:iJ

EVAP Canister
Purge Solenoid
Val11eand
Automatic
Transmission

~ Ignition
. Control (IC)
I Module
I
I
I
I

Ground

L------------------------------------J

sfKI630
7

r- -

I
I
I

stK

C1

- ..:. - . CaJTishaft.
Position
Signal

450

Powertrain
,
I Control
I Module ;,A
l(PCM) ~

.,

L--------J

222553

Circuit Description
Th_e camshaft position PCM input is produced by the
ignition control module. The ICM produces the
camshaft position PCM input by filtering the Camshaft
Position (CMP) sensor pulses when the engine is .
running and CKP sync pulses are also being received.
The PCM uses the camshaft position PCM input
pulses to initiate sequential fuel injection and
to determine crankshaft position for the misfire
diagnostic. The PCM constantly monitors the number
of pulses on the camshaft position PCM input
circuit and compares the number of camshaft position
PCM input pulses to the number of, 18X reference
pulses and the number of 3X reference pulses being
received. 'If the PCM receives an incorrect number
of pulses on the Garnshaft position PCM input circuit,
OTC P0341 will set and the PCM will initiate injector
sequence without the camshaft position PCM
input with a one in six chance that injector sequence
is correct. The engine will continue to start and
run normally, although the misfire diagnostic will be
disabled.

Conditions for Setting the OTC

The engine is running (3X reference pulses are
being received).
The .ratio of 3X. reference pulses to t8X reference
pulses received by the PCM equals 6.
The ratio of 3X reference pulses to .Cam pulses
received by the PCM does notequal 6.
The conditions are present for 300 3X reference
periods (100 crankshaft revolutions).

Action Taken When the OTC Se~~

The PCM will illuminate the M1L during the second
consecuitive trip cycle in which the dia1;1nostic test

has been run and fai,led.

The PCM will initiate injectorsequence \ivithout the
camshaft position signal with a one in six chance
that injector sequence is correct.
If equipped with traction control, the PCM will
command the EBTCM via.serial data (CKT 800) to
set an ABS/TCS DTC, the EBTCM will turn
OFF traction control, and the EBTCM will
illuminate the TRACTION OFF lamp.
The PM will store conditions which were present
when the DTC. set as Freeze Frame and Fail
Records data..

6-928

Engine

Engine Controls - 3.8L

Damaged harness - Inspect the wiring harness for

damage.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and ,passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbed through wire insulation or a wire broken
inside the insulation. Check for the following
conditions:
Faulty Ignition Coil - Remove the ignition coils and
inspect the ignition control module and coils for
cracks, carbon tracking, or other signs that
indicate that the coil secondary circuit is arcing to
the ICM or ICM wiring harness. Refer to Ignition
Coil(s) Replacement.
Secondary ignition wire(s) arcing to wiring harness
- Check secondary ignition wires for carbon
tracking or other signs of damage.
Poor connection at the PCM - Inspect harness
connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.

If the harness appears to be OK, disconnect the

PCM, turn the ignition on and observe a
voltmeter connected to the CAM signal circuit at
the PCM harness connector while moving
connectors and wiring harnesses related to the
ICM and the CMP sensor. A change in voltage will
indicate the location of the fault.
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help determine
how often the condition that caused the OTC to be set
occurs.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Ensures that the fault is present.
21. Determines whether the fault is being caused by a
missing camshaft magnet or a faulty PCM. The
voltage measured in this step should read around
4 volts, toggling to near O volts when the CMP
sensor interfaces with the camshaft magnet.
22. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

OTC P0341 Camshaft Position (CMP) Sensor Performance

Step

Action

Value(s)

Important: If the engine cranks but. will not run, refer to

Engine Cranks but Does Not Run.
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?

1. Tum ON the ignition switch, review and record scan

tool Fail Records data.
2. Operate vehlcle within Fail Records conditions
as noted.
3. Using a scan tool, monitor Specific DTC info for
DTC P0341 until the DTC P0341 test runs
Does the scan tool indicate DTC P0341 failed this ignition?

1. Turn OFF'the ignition switch.

2. Disconnect the PCM.
3. Connect a J 39200 DMM to monitor voltage on the
camshaft position input signal circuit at the PCM
connector.
4. Turn ON the ignition switch.
5. Observe the voltage displayed on the J 39200 DMM.
Important: If J 39200 DMM indicates O volts, bump over
engine to insure cam sensor magnet is not located under
the cam sensor at the time of this test.
Does the J 39200 DMM display a voltage near the
specified value?

5V

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to
Diagnostic Aids

Go to Step 4

Go to Step 5

Engine Controls ,. 3.8L

Engine

6~929

DTC P0341 Camshaft Position (CMP) Sensor Performance (cont'd)

Value(s)

Action

Step

Yes

No

Go to Step 16

Go to Step 8

Go to Step 7

Go to Step 6

Go to Step 24

Go to Step 13

Go to Step 24

Go to Step 18

Gq to Step 9

Go to Step 12

Go to Step 10

Go to Step 11

Go to Step 15

Go to Step 14

1. Turn OFF the ignition switch.

2. Without disconnecting the CMP harness connector,
remove the CMP sensor from the engine front cover.

Important: The magnet used must have sufficiant power

and the correct polarity. If the voltage remains at 5 volts,
retest using the oposite end of the magnet.

ov

3. Turn ON the ignition switch.

4. Turn ON the ignition switch.
5. Place a magnet on the CMP sensor.
Does the J 39200 DMM display voltage near the
specified value?
5

Does the voltage on the camshaft position input signal

circuit measure greater than the specified value?

..
5V

1. Turn OFF the ignition switch.

2. Disconnect the ignition control module (leave the
PCM disconnected).

3. Turn ON the ignition switch.

4. Probe the camshaft position input signal circuit and
the CMP sensor signal circuit at the ignition control
module connector with a J 34142-8 Unpowered test
lamp connected to B+.
5. If the J 34142-8 test lamp is ON, locate and repair
short to ground in the camshaft position input signal
circuit or the CMP sensor signal circuit as necessary.
Refer to Wiring Repairs.

Was a problem found?

1. Turn OFF the ignition switch.

2. Disconnect the ignition control module (leave the
PCM disconnected).
3. Turn ON the ignition switch.
7

4. Probe the camshaft position input signal circuit with

the J 34142-8 test lamp to ground.

5. If the J 34142-8 test lamp is on, locate and repair

short to voltage in the camshaft position input signal
circuit. Ref.er to Wiring Repairs.
Was a problem found?

1. Disconnect the CMP sensor.

2. Measure voltage bet)llleen the sensor feed .circuit and

the sensor grounq circuit at the CMP sensor harne~s
connector.

B+

Does the voltage measure near the specified value?

Measure voltage between the CMP sensor signal circuit

and the sensor ground circuit at the camshaft position
sensor harness connector.

5-7V

Does the voltage measure between the specified values?

1. Reconnect the J 39200 DMM to monitor voltage on

the camshaft position input signal circuit at the PCM
harness connector.

10

2. Monitor the voltage display on the J 39200 DMM

while repeatedly touching the CMP sensor signal
circuit at the CMP sensor connector with a J 34142-8
test lamp to ground.
Does the J 39200 DMM voltage display switch between
O and 5 volts when the J 34142-8 test lamp is repeatedly
touched to the CMP sensor signal circuit?

6-930

Engine. Controls - 3.SL

Engine

OTC P0341 Camshaft Position (CMP) Sensor Performance (cont'd)

Step

Action

11

1. Turn OFF the ignition switch.

2. Disconnect the ignition control module (leave the
CMP sensor disconnected).
3. Turn ON the ignition switch
4. Check for the following conditions:
The CMP sensor signal circuit for an open, a short
to voltage or a short to ground.
The camshaft position input signal circuit for a
short to voltage.
5. If a problem is found, repair it as necessary. Refer to
Wiring Repairs.
Was a problem found?

Value{s)

Yes

No

Go to Step 24

Go to Step 14

Go to Step 24

Go to Step 14

1. Turn OFF the ignition switch.

2. Disconnect the ignition control module and the CMP
sensor.

12

13

14

15

16

3. Check the following circuits for an open between the

ignition control module and the CMP sensor:
The sensor feed circuit.
The sensor ground circuit.
4. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?
1. Check for an open in the camshaft position input
signal circuit between the PCM and the ignition
control module.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs
Was a problem found?

Go to Step 24

Go to Step 14

1. Check for poor connections at the ignition control

module.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Go to Step 24

Go to Step 17

1. Check for poor connections at the camshaft position

sensor.
2. If a problem is found, repair it as necessary. Refer to
Was a problem found?

Go to Step 24

Go to Step 19

1. Check for poor co.nnections at the PCM.

2. If a problem is found, repair it as necessary. Referto .
Wiring Repairs.
Was a problem found?

Go to Step 24

Go to Step 20

Go to Step 24

Go to Step 18

1. Check for the following conditions:

Incorrect harness routing near secondary ignition
components.

17

Ignition coil arcing to the wiring harness or to the

ignition control module. Check ignition coils for
cracks, carbon tracking, or other signs of damage.
Refer to Ignition Coil(s) Replacement.

Secondary ignition wire(s) arcing to the wiring

harness. Refer to Secondary Wiring in Ignition
System .
. 2. If a prC>blem is found, repair as necessary.
Was a problem found?

Engine Controls - 3.8L . 6-93:1

E11gine

DTC P0341 Camshaft Position (CMP)Sensor Performance (cont'd)

Action

Step

18

19

Value(s)

Replace the ignition control module. Refer to Ignition

Control Module Replacement.
Is the action complete?

Replace the camshaft position sensor. Refer to Camshaft

Position Sensor Replacement.
Is the action complete?

Yes

No

Go to Step 24

Go to Step 24

1. Check for the following conditions:

20

Incorrect harness routing near secondary ignition

components.
Ignition coil arcing to wiring harness or ignition
control module. Check ignition coils for cracks,
carbon tracking, or other signs of damage. Refer
to Ignition Coil(s) Replacement.
Secondary ignition wire(s) arcing to wiring
harness. Refer to Secondary Wiring in Ignition
System.

2. If a problem is found, repair as necessary.

Was a problem found?

21

22

23

1. Reinstall the CMP sensor to the engine front cover.

2. Observe the J 39200DMM connected to monitor
voltage on the camshaft position input.signal circuit
while repeatedly bumping the engine with the starter.
Does voltage toggle between the specified values?
Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.

Replace the PCM.

Is the action complete?
Replace faulty or missing camshaft position sensor
magnet. Refer to 3800 Engine Unit Repair.

Go to Step 24

Go to Step 21

Go to Step 22

Go to Step 23

4V I OV

Go to Step 24

Go to Step 24

Is the action complete?

1. Review and record scan tool Fail Records data.

24

2. Clear DTCs.
3. Operate the vehicle within Fail Records conditions
as noted.
4. Using a scan tool, monitor Specific OTC info for
OTC P0341 until the OTC P0341 test runs
Does the scan tool indicate OTC P0341 failed this ignition?

Go to Step 2

System OK

6-932

Engine

Engine Controls -: 3.8L

DTC P0401 Exhaust Gas Recirculation (EGR) Flow Insufficient

Circuit Description
The PCM tests the EGA system during deceleration
by momentarily commanding the EGA valve open
while monitoring the Manjfold Absolute Pressure
(MAP) sensor signal. When the EGA valve is opened,
the PCM should see a proportional increase in
MAP. If the expected increase in MAP is not seen, the
PCM notes the amount of error that was detected
and adjusts an internal fail counter towards a
fail threshold level. When the fail counter exceeds the
fail threshold level, the PCM will set DTC P0401.
The number of test samples required to accomplish
this may vary according to the amount of
detected flow error.
Normally, the PCM will only allow one EGA flow test
sample to be taken during an ignition cycle. To
aid in verifying a repair, the PCM allows a specified
number of test samples during the first ignition
cycle following a scan tool Clear Info or a battery
disconnect. Between nine and twelve samples should
be sufficient for the PCM to determine adequate
EGA flow and pass the EGA test if the system is
operating correctly.

Conditions for Setting the OTC

Manual Transaxle
No TP sensor, VSS, Misfire, IAT sensor, MAP
sensor, Idle speed, EGA Pintle, Fuel injector, CKP
sensor, ECT sensor, or MAF sensor DTCs set.
System voltage is between 1O and 16 volts.
BARO:
- Manual Transaxle - BARO is greater
than 70 kPa.
- Automatic Transaxle - BARO is greater
than 65 kPa.
Engine Speed:
- Manual Transaxle - Engine speed is
between 1000 RPM and 1400 RPM.
- Automatic Transaxle - Engine speed is
between 1050 RPM and 1400 RPM.
Intake air temperature is greater
than 80C (176F).
Engine coolant temperature is greater
than 75C (167F).
IAC position is steady.
Vehicle speed is greater than 40 km/h (25 MPH).
The throttle is closed.
MAP changes monitored during the EGA flow test
indicate insufficient EGA flow.

Action Taken When the OTC Sets

The PCM will illuminate the MIL during the first
trip in which the diagnostic test has been run
and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Diagnostic Aids
Important: If the EGA valve shows signs of excessive
heat, check the exhaust system for blockage
(possibly a plugged catalytic converter). Refer to
Re$tricted Exhaust System Check.
To verify a repair, clear the information with the scan
tool and run the EGA flow test keeping the following
items in mind:
The PCM will only run the EGA flow test during a
gradual deceleration.
The PCM will only run the EGA test during a
closed throttle condition.
The PCM will only run the EGA test at vehicle
speeds greater than 40 km/h (25 mph).
Several deceleration cycles will be necessary to
run a sufficient number of EGA flow test
samples (9-12).
If the engine- speed increases more than 100 RPM
from the enabling RP.M (refer to Conditions for
Running the DTC), the PCM will reset the test.
If the engine speed decreases more than 300
RPM from the enabling RPM (refer to Conditions
for Running the DTC), the PCM will reset
the test.
When the PCM commands the EGA valve open
engine speed will drop. If the engine speed
drops below the following RPM values, the test
will not run:
- Manual Transaxle - 800 RPM.
- Automatic Transaxle - 700.
The EGA Test Counter displayed on the scan tool
can be useful in determining that the EGA flow
test is running and to keep track of the number of
test samples taken. The counter will increment
each time a test sample is taken.
Check for the following conditions:
Vacuum restriction to the MAP sensor - A
restriction to the MAP sensor can cause the EGA
flow test to fail due to insufficient MAP changes
being monitored during the test. Check for objects
blocking the vacuum to the MAP sensor. Also
check for kinked or pinched MAP sensor vacuum
hoses (if equipped.)

Engine

Engine Controls - 3.SL

Poor connection at the PCM - Inspect harness

connectors for the following conditions:
- Backed out terminals.
- Improper mating.
- Broken locks.
- Improperly formed or damaged terminals.
- Poor terminal to wire connection.
Poor connection or damaged harness - Inspect
the wiring harness for damage.

6-933

If the harness appears to be OK, observe. the

Actual EGR Position display on the scan tool while
moving connectors and wiring harnesses related
to the EGR valve. A change in the display will
indicate the location of the fault.
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help determine
how often the condition that caused tie DTC to be set
occurs.

OTC P0401 Exhaust Gas Recirculation (EGR) Flow Insufficient

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 5

Go to Step 3

Go to Step 5

Go to Step 4

Go to Step 5

Go to
Diagnostic Aids

System OK

Go to Step 2

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1. Inspect the exhaust system for modification of original

installed parts or leaks.
2. If a problem was found, repair exhaust system as
necessary.
Was a problem found?

1. Remove the EGR valve. Refer to EGR Valve

Replacement.

2. Visually and physically inspect the following items:

The pintle, the valve passages and the adapter for
excessive deposits or any kind of a restriction.
the EGR valve gasket and pipes for leaks.
3. If a problem is found, clean or replace EGR system
components as necessary.
Was a problem found?
1. Remove the EGR inlet and outlet pipes from the
exhaust manifold and the intake manifold. Refer to
EGR Valve Replacement
2. Inspect the manifold EGR ports and the EGR inlet
and outlet pipes for a blockage caused by excessive
deposits or other damage.
3. If a problem is found, correct the condition as
necessary.
Was a problem found?

1. Review and record the scan tobl Fail Records data.

2. Clear OTC and monitor EGR Test Count display on
the scan tool while operating the vehicle as specified
in OTC P0401 Diagnostic Aids.

3. Continue operating the vehicle until 9 -12 EGR Test

Count test samples have been taken.
4. Select scan tool Specific OTC information for
OTC P0401.
Does scan tool indicate DTC P0401 Test Ran and
Passed?

6~934 _Engine Controls - 3.BL

Engine

DTC P0403 Exhaust Gas Recirculation (EGR) Solenoid Co'ntrol Circuit

TP and MAP
Sensors

... -

(
~

Uil
E

GRY 598

BLK 552
LT BLU 697

:--r
4

I
I

BAN 1456

GRY 435

C2

~~~e lgrnt,?n
Pos1t1ve
Voltage

32

~~l~e ~~~e

-,

----T Control
...
=

1--- ----f

28

C1

C2

31

C1

33

~~~~~~

Pos1t1on
Signal

-=-

I
I

PCM

C1=BLU.
C2=CLEAR

C2

~~~~nee

:
I
I

I
I

L---------------------------------~

Powertrain
Control
Module
(PCM)

~
~

222140

Circuit Description
The PCM monitors the EGR valve pintle position input
to ensure that the valve responds properly to
commands from the PCM. The Linear EGR valve is
controlled by using an ignition positive driver and
ground circuit within the PCM. The driver has
the ability to detect an electrical malfunction in the
ignition positive or ground circuit. If an electrical
mat.function occurs, the driver signals the PCM to set
OTC P0403.

Conditions for Running the DTC

No TP, VSS, Misfire, IAT, MAP, Idle Speed, Fuel
Injector, ECT, CKP, or MAF sensor OTCs
are set.
System voltage is between 9 volts and 16 volts.

Conditions for Setting the DTC

The PCM detects an electrical malfunction in the
control circuit for the EGR valve.
The above condition is present for longer than
20 seconds.

Action Taken, When the DT_C Sets

The PCM will illuminate the MIL during the second .
consecutive trip in which the diagnostic test has

been run and failed.

The PCM will disable EGR for the ignition cycle.
The _PCM will store conditions which .were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will tum the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

Engine
Diagnostic Aids
Poor connection at PCM or EGR Valve.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wore connection.
Damaged harness.
Inspect the wiring harness for damage. If the
harness appears to be OK, connect J 39200 DMM
and check circuit continuity while moving
connectors and wiring harnesses related to the
EGR valve. A change in the display will indicate
the location of the malfunction.

Engine Controls - 3.SL

6-935

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
2. Verifies that the malfunction is present.
4. If DTC P0403 will only set under certain
conditions, the malfunction may be intermittent;
refer to Diagnostic Aids. If an intermittent
wiring problem is not present, check for a poor
connection at the PCM or the EGR valve.
20. This vehicle is equipped wfth a PCM which utilizes
an Eleddcally Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

6-936

Engine

Engine Controls - 3.8L

OTC P0403 Exhaust Gas Recirculation (EGR) Solenoid Control Circuit
Action

Step

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Value(s)

0%

1. Turn ON the ignition switch, engine not running.

2. Select the scan tool EGR valve output control
function.
3. Increment the EGR valve through all positions while
comparing Desired EGR Position to Actual EGR
Position.
Does Desired EGR Position remain close to Actual EGR
Position at all commanded positions?

1. Disconnect the EGR valve electrical connector.

2. Connect a J 34142-B test lamp between the EGR
valve ground circuit and the EGR valve control circuit
at the EGR valve harness connector.
3. Command the EGR valve to the 100% position with
the scan tool while observing the J 34142-B
test lamp.
Is the J 34142-B test lamp ON with the commanded EGR
valve position at 100%?

Probe the EGR valve ground circuit at the EGR valve

harness connector with a J 34142-B test lamp to B+.
Is the test lamp ON?

Probe the EGR valve control circuit at the EGR valve

harness connector with a J 34142-B test lamp to B+.

Turn OFF the ignition switch.

Disconnect the PCM.
Check the EGR valve control circuit for an open.
If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?
1. Turn OFF the ignition switch.
2. Disconnect the PCM.
3. Turn ON the ignition switch.
4. Probe the EGR valve control circuit with a J 34142-B
test lamp to ground.

10

Was a problem found?

Go to Step 9

Go to Step 4

Go to Step 5

Go to Step 5

Go to
Diagnostic Aids

(
Go to Step 10

Go to Step 6

Go to Step 7

Go to Step 14

Go to Step 13

Go to Step 8

Go to Step 21

Go to Step 19

Go to Step 12

Go to Step 20

Go to Step 21

Go to Step 11

Is the test lamp ON?

1. Check for poor terminal connections at the
EGR valve.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.

Go to Step 3

Is the test lamp ON?

1.
2.
3.
4.

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Does the scan tool indicate OTC P0403 failed this ignition?

No

With the engine idling, observe Actual EGR Position on

the scan tool.
Is Actual EGR Position at the specified value?

1. Review and record scan tool Fail Records data.

2. Operate the vehicle within Fail Records conditions.
3. Using a scan tool, monitor Specific OTC info for
OTC P0403 until the OTC P0403 test runs.

Yes

Engine

Engine Cootro.ls - 3.SL

6-937

DTC P0403 Exhaust Gas Recirculation (EGR) Solenoid Control Circuit. (cont'd)
Action

Step

11

12

13

14

15

16

17

Locate and repair the short to voltage in the EGR valve

control circuit. Refer to Wiring Repairs.
Is action complete?

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Probe the EGR valve control circuit at the EGR valve
harness connector with a J 34142-8 test lamp to B+.
Is the test lamp ON?

1.
2.
3.
4.

19

1. Check the EGR valve ground circuit for an open.

2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

20

Go to Step 16

Go to Step 15

Go to Step 21

Go to Step 20

a. problem found?

Go to Step 21

Go to Step 20

'

1. Check the circuits related to the EGR valve for poor

terminal connections at the PCM.
2 .. If a problem is found, repair as nec;essary. _Refer to
Wiring Repairs.
'
Was a problem found?

1. Review and record scan tool Fa,il Records data.

2. Clear DTCs.
3. Operate the vehicle within Fail Records conditions.
4. Using a scan tool, monitor Specific DTC info for
DTC P0403 until the DTC P0403 test runs.
Does the scan tool indicate DTC P0403 failed this ignition?

Go to Step 17

Locate and repair the short to ground in the EGR valve

control circ.uit. Refer to Wiring Repairs . .
Is action complete?

Replace the PCM.

Go to Step 18

Go to Step 21

Go to Step 21

Go to Step 21

Go to Step 20

. '

Is action complete?

21

Locate and repair the short to voltage in the EGR valve

ground circuit. Refer to Wiring Repairs.
Is action complete?

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.

No

Go to Step 21

Check for .the following conditions:

1. The EGR valve control circuit shorted to the EGR
valve ground circuit.
2. The EGR valve control circuit shorted t6'the EGR
pintle position se.nsor ground circuit:,
3. If a problem is found, repair as necessary. Refer to
Wiring Repairs.

Yes

Go to Step 21

Turn OFF the ignition switch.

Disconnect the PCM.
Turn ON the ignition switch.
Probe the EGR valve ground circuit at the EGR valve
harness connector with a J 34142-8 test lamp to
ground.
Is the test lamp ON?

Was
18

Value(s)

Replace the EGR valve. Refer to EGR Valve

Replacement.
Is action complete?

Go to Step 21

Go to Step 2

System OK

6-938

Engine

Engine Cdntrols - 3.SL

DTC P0404 Exhaust Gas RecirculaUon (EGR) Open Position Performance

TPandMAP
Sensors

... -

[5Jc

-- '-,

IM\I
~

GRY 598
E

GRY 598

BLK 552
LT BLU 697

:--r
4

BAN 1456

GRY 435

C2

~~~e Ignition
Positive
Voltage

32

C1

J ~~~ - g~=e
"- _-T Control

.A

1--- ---.-

28

C2

31

C1

~~~~~~

Position
Signal

33

C2
7

~~~~nce A

..,

POA
C1=BLU
C2=CLEAR

Powertrain
Control
Module

(PCM)

#,

L------------------------~--------J 4'4
{
222140

Circuit Description
The PCM monitors the EGR valve pintle position input
to ensure that the valve responds properly to
commands from the PCM. The PCM compares Actual
EGR Position with Desired EGR Position when the
valve is commanded open. If Actual EGA Position is
15% less than Desired EGR position when the PCM is
commanding the EGR va.lve opened, OTC P404
will set.

Conditions for Running the DTC

No TP, VSS, Misfire, IAT, MAP, Idle Speed, Fuel
Injector, ECT, CKP, or MAF sensor DTCs
are set.
System Voltage is between 9 and 16 volts.

Conditions for Setting the DTC

Actual EGR position is 15% less than Desired
EGR Position.
The above conditions are present for longer
than 20 seconds.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will disable EGR for the. rest of the
ignition cycle.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIL/DTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

Engine

Engine Controls - 3.&l. 6-939

Diagnostic Aids

Test Description

Check for the following condition(s):

Excessive deposits on the EGR Pintle or seat.
Remove the EGR valve and check for deposits
that may interfere with the EGR valve pintle
extending completely or cause the pintle to stick.
Poor connection at PCM or EGR Valve.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wire connection.
Damaged harness.
Inspect the wiring harness for damage. If the
harness appears to be OK, connect J 39200 DMM
and check circuit continuity while moving
connectors and wiring harnesses related to the
EGR valve. A change in the display will indicate
the location of the malfunction.
Reviewing the Fail Records vehicle milage since the
diagnostic test last failed may help determine how
often the condition that caused'the DTC to be set.

Number(s) below refer to the step number(s) on the

Diagnostic Table:
2. Verifies that the malfunction is present.
3. If DTC P0404 will only set under certain
conditions, the malfunction may be intermittent;
refer to Diagnostic Aids. If an intermittent
wiring problem is not present, check for a poor
connection at the PCM or the EGR valve: If
the connections are OK and OTC P0404 continues
to set, replace the EGR valve.
17. This vehicle Is equipped with a PCM which utiljzes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

6-940

Engine.

Engine Controls - 3.8L

DTC P0404 Exhaust Gas Recirculation (EGR) Open Position Performance

Step

Action

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Important: If any of the following DTCs are set, diagnose

the other OTC first.
OTC P0403 Exhaust Gas Recirculation (EGR)
Solenoid Control Circuit
OTC P0404 Exhaust Gas Recirculation (EGR) Open
Position Performance
1. Turn ON the igrnition switch.

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

''

2. Select the scan tool EGR valve output control

function.
3. Increment the EGR valve through all positions while
comparing Desired EGR Position to Actual EGR
Position.
Does Desired EGR Position remain close to Actual EGR
Position at all commanded positions?

1. Review and record scan tool Fail Records data.

2. Operate the vehicle within Fail Records conditions.
3. Using a scan tool, monitor Specific OTC info for
OTC P0404.
Does the scan tool indicate DTC P0404 failed this ignition?
1. Disconnect the EGR valve.
2. Turn the ignition ON.
3. Connect a J 39200 DMM to measure voltage
between the EGR pintle position sensor ground circuit
and the 5 volt reference A circuit at the EGR valve
connector.
4. Is the voltage at the specified value?

Go to Step 3

Go to Step 4

'

Go to Step 4

Go to
Diagnostic Aids

5V

Connect a J 39200 DMM between the 5 volt reference

circuit and chasis ground.
Is the voltage at the specified value?

Probe the EGR pintle position signal circuit at the EGR

valve harness connector with a J 34142-8 test light
connected to B+.
Is the test lamp ON?

Go to Step 6

Go to Step 5

Go to Step 12

Go to Step 11

Go to Step 9

Go to Step 7

Go to Step 10

Go to Step B

Go to Step 18

Go to Step 16

Go to Step 14

Go to Step 15

1. Connect a jumper between the 5 volt reference A

7

circuit and the EGR pintle position signal circuit at the

EGR valve connector.
2. Observe Actual EGR Position on the scan tool.
Is Actual EGR Position at the specified value?
1. Turn OFF the ignition switch.
2. Disconnect the PCM.
3. Check the EGR pintle position signal circuit for
an open.

100%

4. If a problem is found, repair as necessary. Refer to

Wiring Repairs.
Was a problem found?

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Probe the EGR pintle position signal circuit with a
J 34142-8 test lamp to B+.
Is the test lamp ON?

Engine

Engine Controls - 3.8L

6-941

DTC P0404 Exhaust Gas Recirculation (EGR) Open Position Performance (cont'd)
Action

Step

10

1. Check for poor terminal connections at the

EGR valve.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.

Value(s)

11

12

Check for the following conditions:

1. EGR pintle position sensor ground circuit open.
2. EGR pintle position sensor ground circuit shorted to
voltage.
3. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Replace the EGR valve. Refer to EGR Valve
Replacement.

15

16

Go to Step 18

1, Check the EGR pintle position signal circuit for a

short to the EGR pintle position sensor ground circuit.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
'}
Was a problem found?

Replace the PCM.

18

Go to Step 18

Go to Step 17

Go to Step 18

Go to Step 17

Go to Step 18

Is action complete?
1. Review and record scan tool Fail .Records data.
2. Clear OTCs.
3. Operate the..vehicle within Fail Records conditions.
4. Using a scan tool, monitor Specific OTC info for
OTC P0404.
Ooes the scan tool indicate OTC P0404 fail~d this ignition?

Go to Step 18

Was a problem found?

17

Go to Step 16

Go to Step 18

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.

Locate and correct the short to ground in the EGR pintle

position signal circuit. Refer to Wiring Repairs.
Is action complete?

1. Check the circuits related to. the EGR valve for poor
terminal connections at the PCM.
2. If a problem is found, repair as necesi,ary. Refer to
Wiring Repairs.

Go to Step 13

Go to Step 18

Is action complete?
14

Go to Step 18

Was a problem found?

13

No

Was a problem found?

Check for the following conditions:
1. 5 volt reference A circuit 6p!;ln between the PCM and
the EGR valve.
2. 5 volt reference A circuit shorted to ground.
3. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Yes

Go to Step 2

System OK

6-942

Engine Controls - 3.SL

Engine

DTC P0405 Exhaust Gas Recirculation (EGR) Position Sensor- Circuit Low Voltage
TPandMAP
Sensors

. - - -

-,- ,

LJiJ
E

GRY 598
D

GRY 598

BLK 552
LT BLU 697

BRN 1456
GRY 435

:--r--~~~:- -, ~~~e-1~~e -1--- . ~~~~~. - .--1~~~;~c~A~:

4

I
I

C2

lgrnt,?n

. Pos1t1ve

32

C1

---1control

Voltage

-=-

28

C2

31

C1

Pos1t1on
Signal

-=-

PCM

33

C2

Powertrain
Control
. Module
I
I (PCM)
I

L---------------------------------J

J.

a6.
222140

Circuit Description
The PCM monitors the EGR valve pintle position input
to ensure that the valve responds properly to
commands from the PCM and to detect a fault if the
pintle position sensor circuit is open or shorted. If
the PCM detects an excessively low EGR Feedback
signal voltage, OTC P0405 will set.

Conditions for Running the OTC

No TP sensor, MAF sensor, H02S, IAT sensor, or
ECT sensor OTCs are set.
Engine run time requirements:
- Manual Transaxle - The time ranges from
20 seconds to 1O minutes depending
upon engine coolant temperature at startup.
- Automatic Transaxle - The time ranges from
34 seconds to 8.5 minutes depending upon
engine coolant temperature at startup.
TP angle is greater than 2%.
System voltage is greater than 9 volts.

Conditions for Setting the OTC

EGR Feedback is less than 0.14 volt at any time.
The condition is present tor longer
than 20 seconds.

Action Taken When the OTC Sets

The .PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will disable EGR tor the rest of the
ignition cycle.
The PCMwill sotre conditions which were presetn
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIL/OTC

The PCM will tum the MIL-OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear lnof function or by disconnecting the
PCM battery feed.

Engine
Diagnostic Aids
Poor connection at PCM or EGR Valve.
Inspect the harness connectors for backed out
terminals, improper mating, borken locks,
improperly formed or damaged terminals, and
poor terminal to wire connection.
Damaged harness.
lnspec the wiring harness for damage. If the
harness appears to be OK, connect J 39200 DMM
and check circuit continuity while moving
connectors and wiring harnesses related to the
EGR valve. A change in the J 39200 DMM display
will indicate the location of the malfunciton.

Engine Controls - 3.SL

6-943

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
2. Verifies that the malfunction is present.
3. If DTC P0405 will only set under certain
conditions, the malfunction may be intermittent;
refer to Diagnostic Aids. If an intermittent
wiring problem is not present, check for a poor
connection at the PCM or the EGR valve.
18. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

5..944

Engine Controls - ,3.8-L

Engine

OTC P0405 Exhaust Gas Recirculation {EGR) Position Sensor Circuit Low Voltage
.

Step

Action

Was the Powertrain O.n-Board Diagnostic (OBD) System

Check performed?
1

Value(s)
..

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check.

Go to Step 3

Go to Step 4

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 9

Go to Step 8

Go to Step 6

Go to Step 13

Go to Step 7

Go to Step 19

Go to Step 17

Go to Step 12

Go to Step 15

Go to Step 10

Go to Step 11

Go to Step 16

Go to Step 18

1. Turn ON the ignition switch.

2. Select the scan tool EGR valve output control

function:

3. lncrementthe.EGR valve through all positions while

comparing; Desired EGR Position to Actual EGR
,Position.

Does Desired EGR Position remain close to Actual EGR

Position at all commanded positions?
1. Review and record scan tool Fail Records data.
2. Operate the vehicle within Fail Records conditions.

3. Using a scan tool, monitor Specific OTC info for

OTC P0405.
Does the scan tool indicate OTC P0405 failed this ign?
1. Disconnect the EGR valve electrical connector.

2. Connect a J 39200 DMM to measure voltage

4

between the EGR pintle position sensor ground circuit

and the 5 volt reference A circuit at the EGR valve
connector.

5V

Is the voltage at the specified value?

Probe the EGR valve pintle position circuit at the EGR

valve harness connector with a J 34142-8 test lamp
connected to B+.
Is the test lamp ON?
1. Connect a jumper between the 5 volt reference A
circuit and the pintle position circuit at the EGR valve
connector.

100%

2. Observe Actual EGR Position on the scan tool.

Is Actual EGR Position at the specified value?
1. Turn OFF the ignition switch.

2. Disconnect the PCM.

3. Check for an open in the EGR valve pintle position
circuit.

4. If a problem is found, repair as necessary. Refer to

Wiring Repairs.
Was a problem found?
1. Turn OFF the ignition switch.

2. Disconnect the PCM.

3. Probe the EGR valve pintle position circuit with a
J 34142-8 test lamp to B+.

Is the test lamp ON?

Probe the 5 volt reference A circuit with a J 34142-8 test

lamp to B+.

Is the test lamp ON?

1. Turn OFF the ignition switch.
10

2. Disconnect the PCM.

3. Probe the 5 volt reference A circuit with a J 34142-8

test lamp to B+.

Is the test lamp ON?

Engine

6-945

Engine Controls - 3.8L

OTC P0405 Exhaust Gas Recirculation (EGR) Position Sensor Circuit Low Voltage (cont'd)
Action

Step

Value(s)

Yes

No

Go to Step 19

Go to Step 17

1. Check for an open in the 5 volt reference A circuit

\
J

between the PCM and the EGR valve.

11

2. If a problem is found, repair as necessary. Refer to

Wiring Repairs.

Was a problem found?

12

Locate and correct the short to ground in the EGR valve

pintle position circuit. Refer to Wiring Repairs.

Is action complete?

Go to Step 19

Check for the following conditions:

13

1. Poor terminal connections at the EGR valve.

2. The EGR pintle position signal circuit shorted to the
EGR valve control circuit.

If a problem is found, repair as necessary. Refer to

Wiring Repairs.
Was a problem found?

Go to Step 19

Go to Step 14

Replace the EGR valve. Refer to EGR Valve

Replacement.

14

Notice: If the EGR valve shows signs of excessive heat,

check the exhaust system for blockage (possibly a
plugged converter) using the procedure found on the
restricted exhaust system check. If the exhaust system is
restricted, repair the cause; one of which might be an
injector which is open due to one of the following reasons:

Stuck
Grounded driver circuit
Possible faulty Control Module.
If this condition is found, the oi.1 should be checked for
possible fuel contamination.
Is action complete?

Go to Step 19

1. Check the EGR valve pintle position circuit for a short

to the sensor ground circuit.

15

2. If a problem is found, repair as necessary. Refer to

Wiring Repairs.
Was

16

a problem found?

Locate and repair short to ground in the 5 volt reference A

circuit. Refer to Wiring Repairs.

Go to Step 19
-

Is action complete?

Go to Step 18
-

Go to Step 19

1. Check the circuits related to the EGR valve for a poor

'terminal connection at the PCM.

17

2. If a problem is found, repair as necessary. Refer to

Wiring Repairs.

Go to Step 19

Was a problem found?

18

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.
Replace the PCM.

Go to Step 18

Go to Step 19

Is action complete?

1. Review and record scan tool Fail Records data.

2. Clear DTCs.

19

3. Operate the vehicle within Fail Records conditions.

4. Using a scan tool, monitor Specific OTC info for

DTC P0405.
Does the scan tool indicate DTC P0405 failed this ignition?

Go to Step 2

System OK

6-946

Engine ,controls - 3.BL

Engine

OTC P0420 Catalyst System Low Efficiency

Circuit Description

Conditions for Setting the DTC

To control emissions of Hydrocarbons (HC), Carbon

Monoxide (CO), and Oxides of Nitrogen (NOx), a
three-way catalytic converter is used. The catalyst
within the converter promotes a chemical reaction
which oxidizes the HC and CO. present in the exhaust
gas, converting them into harmless water vapor
and carbon dioxide. The catalyst also reduces NOx,
converting it to nitrogen. The converter also has
the ability to store excess oxygen and release the
stored oxygen to promote these reactions. This oxygen
storage capacity (OSC) is a measurement of the
catalyst's ability to control emissions. The PCM
monitors this process using a heated oxygen sensor
(H02S) located in the exhaust stream past the
three-way converter. When the catalyst is functioning
properly, the H02S 2 is slow to respond to a large
change in the H02S1 signal. When the H02S 2
responds quickly to a large change in the H02S 1
signal, the OSC and efficiency of the catalyst is
considered to be bad and the MIL will be illuminated if
subsequent tests also indicate a failure.

The PCM determines that ttle catalyst's oxygen

storage capacity is below a threshold considered
acceptable.

Conditions for Running the DTC

1. Meet conditions for engine warm up. Use the
scan tool catalyst data list in order to verify the
following.
No VSS sensor, Tp sensor, EVAP, H02S
sensor, misfire, IAT sensor, MAP sensor, IAC
sensor, Fuel trim, EGR, ECT sensor, MAF
sensor, or CKP sensor OTC's set.
Engine has been running longer
than 1O minutes.
Engine coolant temperature (ECT) is above
76C (168F).
Baro is above 75 kPa.
Vehicle is in Closed Loop.
Intake air temperature (IAT) is above -29C
(-20 F) and less than 100C (212F).
2. Warm up the catalyst.
Fully open hood.
Transmission is in park (automatic) or neutral
(manual).
Set the parking brake.
Engine speed is greater than 1500 RPM for
1 minute.
Return to Idle.
3. Test the catalyst.
Transmission is in drive (automatic) or neutral
(manual).
With in 5-20 seconds the air fuel ratio will go
lean above 15.3 for up to 7 seconds, then it
may go rich below 14.1 for up to 7 seconds.
Using the scan tool check and see if
OTC P0420 has passed or failed this
ignition cycle
0

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the first
trip in which the diagnostic test has been run
and failed.
The PCM will stor~ conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

Diagnostic Aids
Check for the following conditions:
The PCM will not, enable the catalyst test until
following conditions are met:
- Engine speed is plus or minus 100 RPM
from desired idle.
- Throttle Position (TP) is 0%.
- Short term integrator is between -20%
and +20%.
The catalyst test will abort if the vehicle falls out
side the conditions listed below while the test is
running:
- Engine speed is plus or minus 125 RPM
from desired idle.
- Throttle Position (TP) is 0%.
- Short term integrator is between -20%
and +20%.
The catalyst test may abort due to a change in
engine load (i.e., A/C, coolant fan). If this
problem occurs use the scan tool to force the
cooling fans on then repeat the test.
Important: When using the sc.an tool to force the
cooling fans on use the next list and previous list soft
keys to enter the catalyst data list. If the catalyst
data list is not entered this way the cooling fan control
will be canceled.
More than 6 te.sts may have to be attempted to
get 6 completed tests. An aborted test counts
as an attempted test.
The number of attempt tests is limited to 18 per
ignition cycle.

Engine

Engine Controls - a.SL

After returning to an idle ,the H02S 1 signal may

stay rich or lean for several seconds causing
the test to- be delayed.
Poor connection at PCM. Inspect harness
connectors for backed out terminals, improper
mating, broken locks, improperly formed or
damaged terminals, and poor terminal to wire
connection.
Damaged harness. Inspect the wiring harness for
damage. If the harness appears to be OK,
observe the display on the scan tool while moving
connectors and wiring harnesses related to the
sensor. A change in the display will indicate
the location of the fault.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
1. The powertrain OBD system check prompts the
technician to complete some basic checks and
store the freeze frame and failure records data on
the scan tool if applicable.

6-:947

3. Clearing the DTC's aUows the catalyst test to be

completed up to 6 time this ignition cycle. If the
A/C is not turned off the diagnostic will not
run. The engine must be warmed-up. The
converter needs to be warmed-up by raising the
engine speed above idle for the specified time
prior to each attempted test. Check and see
if DTC passed or failed this. ignition cycle. If the
DTC does not pass or fail look for a possible
reason that would cause the test to abort.
4. This step includes checks for conditions that can '
cause the three-way converter to appear
degraded. Repair any problems found before
proceeding with this table.
9. If the three-way converter needs to be replaced,
make sure that another condition is not present
which could damage the converter. ThesE:3
conditions may include: misfire, high engine oil or
coolant consumption, retarded spark timing or
weak spark. Correct any possible causes of
converter damage before replacing the converter.

2. If any component DTC's are set, diagnose those

DTC's first. A fault in a component can cause
the converter to appear degraded or may
have caused its failure.

DTC P0420 Catalyst

System Low Efficiency
...
Step

Action
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?

Value(s)

1. Clear DTC's using the scan tool.

2. Turn the A/C OFF.
Important: If the A/C is left on the following diagnostic will
not run.
3. St~rt the engine and wait until the vehical is fully
warmed up.
4. Fully open hood.
5. Operate the vehical within the conditions for running
this OTC.
6. Test may need to be completed up to 6 time inorder
to pass or fail.
Important: If more than 6 tests have been attempted and
the OTC has not passed or failed this ignition cycle the
test may be aborting. Refer to diagnostic aids.
Does the scan tool indicate the OTC ran and passed this
ignition cycle?

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to the
applicable OTC
refer to DTC List

Go to Step 3

System Ok

Go to Step 4

Are any other DTC(s) set?

Yes

6-948

Engine

Engine Controls. - 3.8~

OTC P0420 Catalyst System Low Efficiency (cont'd)

Step

Action

Value(s)

Yes

No

1. Visually and physically inspect the three-way catalytic

converter for damage.

2. Check for the following:
Dents.
Severe discoloration caused by excessive
temperatures.
Holes.

Internal rattle caused by damaged catalyst

substrate.
3. Also, ensure that the three-way catalytic converter is
a proper original equipment manufacturer part.
Did your im~pection reveal a problem?

Go to step 9

Go to step 5

Go to Step 7

Go to Step 6

Go to Step 8

Go to Step 9

1. Visually and physically inspect the exhaust system

for leaks.
2. If a problem is found.repair as n :essary.
Did your inspection reveal a problem?
Visually check for the following:

Oxygen sensor(s) for damage.

Oxygen sensor(s) wiring harness for damage.
Was a problem found?

.
-

Repair the exhaust system as necessary. Refer to Exhaust

systems
Is action Complete?

Repair the H02S sensor and wiring as necessary.Refer to

H02S Repair.
Is action complete?

Replace,the three way catalytic converter. Refer to

Exhaust systems
Notice: A misfiring condition may damage the replacement
three-way catalytic converter. Check for a misfiring
condition. If a misfire is present, repair the misfiring
condition before replacing the three-way catalytic
converter.
Is action complete?

Go to Step 10

Go to Step 10

Go to Step 10

1. Clear DTC's using the scan tool.

2. Turn the A/C OFF.
Important: If the A/C is left on the following diagnostic will
not run.
3. Start the engine and wait until the vehical is fully
warmed up.
10

4. Fully open hood.

5. Operate the vehical within the conditions for running

this OTC.
6. Test may need to be completed up to 6 time inorder
to pass or fail.
Important: If more than 6 tests have been attempted and
the OTC has not passed or failed this ignition cycle the
test may be aborting. Refer to diagnostic aids,

Does the scan tool indicate the OTC ran and passed this
ignition cycle?

11

Are there any additional DTCs that have not been

diagnosed?

Go to Step 11

Go to Step 4

Go to Applicable
OTC Table

System Ok

Engine

Engine Controls - 3.8L

6-949

DTC P0440 Evaporative Emission (EVAP) System

!Hot In Run, Bulb Test And Start!
r -

-. Underhood

;ower
Distribution
Cell 10

ENG CTRL

MiniFuse
15A

.. ___________ ...

Electrical
Center 2

M
L2w

IC Module

and
Transmission

PNK 239
+--------.

PNK 239

PNK 239

PN1239

PNKI239

-PN:l239

PN:1239

L -

Evaporative
[ ] ] Evaporative
Emission (EVAP)
Emi~sion (EVAP) .
Carnste:r Vent
[ ] ] Canister Purge
Solenoid
Solenoid
A
Valve
Valve
DK
WHT 1310
GRN/WHT 428
WHT 1310

II

BI

c,
r------------------------,p
J
J
WHTI1310

76

----T

2 C2

EVAP Canister
Purge Valve
Driver

!
1.-------.
I

--T

EVAP Canister
v~nt Valve
Driver

!
-------.

PCM
C1 = BLU

C2=CLEAR

I Cowertrl am

ontro

I Module

>

I (PCM) ~

________ .

222965

Circuit Description
The evaporative system includes the following
components:
The fuel tank.
The EVAP canister vent valve.
The fuel tank pressure sensor.
The fuel pipes and hoses.
The fuel cap.
The EVAP vapor lines.
Ther EVAP purge lines.
The evaporative emission canister.
The EVAP purge valve.
The evaporative leak detection diagnostic strategy is
based on applying vacuum to the EVAP system
and monitoring vacuum decay. The PCM monitors
vacuum level via the Fuel Tank Pressure sensor input.
At an appropriate time, the EVAP purge valve and
the EVAP canister vent valve are turned ON, allowing
engine vacuum to draw a small vacuum on the
entire evaporative emission system. If a sufficient

vacuum level cannot be achieved, a large leak or a

malfunctioning EVAP purge valve is indicated. This can
be caused by the following conditions:
Disconnected or malfunctioning fuel tank pressure
sensor.
Missing or malfunctioning fuel cap.
Disconnected, damaged, pinched, or blocked
EVAP purge line.
Disconnected or damaged EVAP canister
vent hose.
Disconnected, damaged, pinched, or blocked fuel
tank vapor line.
Disconnected or malfunctioning EVAP
purge valve.
Disconnected or malfunctioning EVAP canister
vent valve.
Open ignition feed circuit to the EVAP canister
vent or purge valve.
Damaged evaporative emissions canister.
Leaking fuel sender assembly o-ring.
Leaking fuel tank or fuel filler neck
Any of the above conditions can set DTC P0440.

6-950

Engine Controls - 3.SL

Engine

Conditions for Running the DTC

Kinked, pinched or plugged vacuum source,

EV~P purge, or fuel tank vapor line. Verify that the
lines are not restricted.
Malfunctioning or damaged canister.
A malfunctioning canister may intermittenly allow
charcoal into the EVAP purge solenoid, vacuum
switch, and associated lines causing a OTC to be
set. Use the following procedure to check for a
carbon release condition:
1. Turn OFF the ignition switch.
2. Remove the EVAP purge valve. Refer to
EVAP Canist'1r Purge Solenoid Valve
Replacement EVAP Canister Purge Solenoid.
3. Lightly tap the. EVAP purge valve and (if
applicable) the vacuum switch on a clean work
area looking for carbon particles exiting
either of the vacuum ports.
4. If no carbon release is evident, reinstall the
components and continue with the OTC P0440
diagnostic table. If carbon is being released
from either component, continue with this
service procedure.
5. Remove the charcoal canister from the vehicle.
6. Ensure that the main cylinder valve is turned
off on the J 4.1413 J 41413 EVAP
purge/pressure diagnostic station.
7. Disconnect the black hose that connects the
nitrogen cylinder to the EVAP purge/pressure
diagnostic station at the pressure regulator
by unscrewing the knurled nut on the regulator.
No tools are required to remove the black
hose from the regulator.
8. Using a section of vacuum line, connect one
end over the open threaded fitting of the
EVAP purge/pressure diagnostic station
pressure regulator.
9. Connect the remaining end to the EVAP purge
valve end of the EVAP purge line. at the
vehicle and tum on the main nitrogen cylinder
valve. Continue to blow any debris from the
purge line for 15 seconds.
10. Return the EVAP Pressure/Purge Diagnostic
Station to its original condition by re-installing
the black hose that was disconnected in
step 7.
11. Replace the following components:
- The EVAP purge valve. Refer to EVAP
Canister Purge Solenoid Valve Replacement
EVAP Canister Purge Solenoid.
- The EVAP canister. Refer to EVAP Canister
Replacement EVAP Canister.
12, .Proceed with the OTC P0440 diagnostic table.
Reviewing the Fail Records. vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the DTC to be
set occurs. This may assist in diagnosing the condition.

1. No VSS, TP sensor, H02S, Misfire, IAT sensor,

MAP sensor, Fuel Trim, Fuel Injector circuit, EGR
Pintle, ECT sensor, or MAF sensor DTCs
are set.
2. System voltage is between 5 and 16 volts.
3. Start up engine coolant temperature is
between 4 C and 30 C (40 F and 86 F).
4. Start up intake air temperature is between 4 C
and 30 C (40 F and 86 F).
5. Fuel tank fuel level is between 15% and 85%.
6. BARO is greater than 75 kPa.

Conditions For Setting the DTC

The EVAP system is not able to achieve or maintain
vacuum during the diagnostic test.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the first
trip in which the diagnostic test has been run
and failed.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.
Important: Although these diagnostics are considered
type A, they act like type B diagnostics under
certain conditions. Whenever the EVAP diagnostics
report that the syste!TI has passed, or if the battery has
been disconnected, the diagnostic must fail during
two consecutive cold start trips before setting a OTC.
The initial failure is. not reported to the diagnostic
executive or displayed on a scan tool. A passing
system always reports to the diagnostic executive
immediately.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF when the
diagnostic has been run and the malfunction
condition is no longer present.
A history OTC P0440 will clear after 40
consecutive warm-up cycles have occurred without
a malfunction.
OTC P0440 can be cleared by using the scan tool
Clear Info function or by disconnecting the PCM
battery feed.

Diagnostic Aids
Check for the following conditions:
Cracked or punctured EVAP canister.
Damaged or disconnected source vacuum line,
EVAP purge line, vent hose or fuel tank
vapor line.
Poor connection at the PCM.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wire connection.
Damaged harness.
Inspect the wiring harness to the EVAP canister
vent valve, the EVAP purge valve, and the
fuel tank pressure sensor for an intermittent open
or short circuit.

(,

Engine Controls - 3.8L

Engine
Test Description
Number(s) below refer to the step number(s). on the

Diagnostic Table.
2. If a vent valve or EVAP purge valve electrical
malfunction is present, the purge system will
not operate correctly. Repairing the electrical
malfunction will very likely correct the condition
that set OTC P0440.
.' .
3. Checks the fuel tank pressure .sensor at ambient
pressure.
4. Determines whether or not the EVAP system can
be sealed suffkiently to be pressurized. If not,
the large leak must be located and corrected
before continuing with diagnosis.

6-951

5. Verifies that the fuel talik pressure sensor

accurately reactsto EVAP system pressure

changes,
8. Checks for a blocked EVAP purge valve. The
PCM commands the EVAP purge valve OFF
(open) and the vent valve ON (closed) with the
scan tool System Pert EVAP output control
function activated. Any pressure in the system
should be released through the EVAP purge valve
within a few seconds when System Pert. is
activated.
9. Ensures that sufficient source vacuum is present
:
at the EVAP purge valve.

OTC P0440 Evaporative Emission (EVAP) System

''

sep

. Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Was the Powertrain On~Board Diagnostic System Check

performed?
'

Important: Visually/physicaliy inspect for the following

conditions:
Vacuum or purge lines disconnected. Refer to
Emission Hose Routing.Diagram.
Loose or missing fuel cap.

Go to the. other
OTC first

Go to Step 3

''

1. Turn OFF the ignition switch.

2. Remove the fuel cap.
t

:3

Go to
OTC P0452 Fuel
Tank Pressure
Sensor Circuit
Low Voltage

Oin. H20

3. Turn ()N the igni~on switch.

4. Observe Fuel Tank Pressure on the scan tool.
Is Fuel Tank Pressure at thE) specified value?

'

Go to Step 4

Important: Before continuing with diagnosis, zero the

EVAP Pressure and Vacuum (inches of H20) gauges on
the J 41413 EVAP pressure/purge diagnostic station.

1. Replace the fuel cap.

.2. Captur,e .Fail Record data for OTC P0440 and
clear bTCs.
3. Using the scan tool, command the EVAP ,canister
vent valve ON (Closed).
4. Connect the J 41413 EVAP pressure/purge diagnostic
station to the EVAP service port.
5. Attempt to pre~sur~e the EVAP system using the
EVAP pressure/purge diagnostic station (monitor
pressure using the EVAP pressure gauge on the
EVAP pressure/purge diagnostic station).
Can specified value be achieved?
1. Maintain EVAP system pressure at 5 inches of H20.
2. Observe Fuel Tank Pressure on the scan tool.
Is Fuel Tank Pressure at the specified value?

"

5in. H20

Go to Step 5

Go toBtep 6

Go to Step 8

Go.toStep 7

5 in. H20

'
'

..

6-952

Engine

Engine Controls - 3.8L

OTC P0440 Evaporative Emission (EVAP) System (cont'd)

Step

10

11

Action

1. Disconnect the fuel tank vapor line and the EV AP

purge line from the EVAP canister.
2. Block the canister fitting for the fuel tank vapor line.
3. Connect a hand vacuum pump to the canister fitting
for the EVAP purge line.
4. Ensure that the EVAP canister vent valve is still
commanded ON (Closed).
5. Attempt to apply vacuum to the EVAP canister.
Can vacuum be maintained at the specified value?
Visually/physically check for the following conditions:
1. Restricted fuel tank vapor line.
2. Restricted EVAP purge line.
3. If a problem is found, repair as necessary.
Was a problem found?

Value(s)

Yes

No

Go to Step 11

Go to Step 10

Go to Step 1.6

Go to
OTC P0452 Fuel
Tank Pressure
Sensor Circuit
Low Voltage

Go to Step 9

Go to Step 13

Refer to
Diagnostic Aids

Go to Step 14

Go to Step 16

Go to Step 15

Go to Step 16

Go to Step 12

5 in. Hg

1. Disconnect the vacuum source line at the EVAP

purge valve and plug the vacuum source fitting on the
solenoid.
2. Using the scan tool output tests function, select
System Pert. and activate.
3. Pressurize the EVAP system to the first specified
value (monitor pressure using the EVAP pressure
gauge on EVAP pressure/purge diagnostic station).
. 4. Observe the EVAP pressure gauge on the EV AP
pressure/purge diagnostic station while removing the
plug from the EVAP purge valve vacuum source
fitting.
Does the EVAP pressure decrease to the second specified
value within 15 seconds while System Pert. is activated?

5 in. H20
O in. H20

1. Connect the in. Hg vacuum gauge on the EVAP

pressure/purge diagnostic station to the vacuum
source line.
2. Start the engine.
3. Run the engine above 2000 RPM and observe the
source vacuum level.
Is the source vacuum level greater than the
specified value?

-15in.Hg

Visually/physically check for the following conditions:

1. Vent hose disconnected or damaged.
2. EVAP canister damaged.
3. If a problem is found, repair as necessary.
Was a problem found?

Visually/physically check for the following conditions: .

1. Missing or malfunctioning fuel cap.
2. Disconnected or leaking fuel tank vapor line.
3. Disconnected or damaged EVAP purge line.
4. If a problem is found, repair as necessary.
Was a problem found?

Engine

Engine Controls - 3.8L

6-953

DTC P0440 Evaporative Emission (EVAP) System (cont'd)

Step

Action

Value(s)

12

1. Using the scan tool, command the EVAP canister

vent valve ON.
2. With the EVAP pressure/purge diagnostic station
connected to the EVAP service port, continuously
attempt to pressurize the EVAP system by leaving
the EVAP pressure/purge diagnostic station control
kn<'b in the pressurize position
3. Using the ultrasonic leak detector J 41416, locate and
repair leak in EVAP system. It may be necessary to
partially lower the fuel tank to examine the top tank
connections.
Is action complete?

\,
/

Yes

No

Go to Step 16

Replace the EVAP purge valve. Refer to EVAP Canister

Purge Solenoid Valve Replacement.
13

14

Important: Check for carbon release into the EVAP

system. Refer to Diagnostic Aids.
Is action complete?

Locate and repair cause of no source vacuum to the

EVAP purge valve.
Important: Check for carbon release into the EVAP
system. Refer to Diagnostic Aids.

Go to Step 16

Is action complete?
15

16

Replace the EVAP canister vent valve. Refer to EVAP

Vent Valve Replacement.
Is action complete?
1. Turn ON the ignition switch.
2. Using the scan tool, command the EVAP canister
vent valve ON (Closed).
3. Pressurize the EVAP system to the first specified
value using the EVAP pressure/purge diagnostic
station (monitor pressure using the gauge on the
EVAP pressure/purge diagnostic station).
4. Switch the rotary switch on the EVAP pressure/purge
diagnostic station to HOLD and observe the EVAP
pressure gauge.
Does the EVAP pressure decrease to iess than the
second specified value withi.n 2 minutes?.

Go to Step 16

Go to Step 16

15 in. H20
10 in. H20

Go to Step :3

System OK

Engine

~-~ngine Controls - 3.SL

DTC P0442/ Evaporative Emission (EVAP) Control System
Small Leak Detected
.
.

I I

!Hot In Run, Bulb Test And Start(

~

Distribution

G9

cen 10
I

.,Underhood
ENG CTRL : Electrical
rvliniFuse Center 2

15 A

I
IC Module

and
Transmission

+------,

,------'!.__--~

+-

PNK 239

PNK 239.

PNK1239

PNK1239

-PNK 239

PNKI239

L -

Loe

- ; 0111:;r- - - - - - - -

[!]II

[!]

Evaporative '
Evaporative
Emi~sion (EVAP)
E:mi~sion (EVAP)
Canister Purge
Canister Vent
Solenoid
Solenoid
.
A
Valve
Valve
DK
WHT 1310
GRN/WHT 428
WHT 1310

BI

1e

WHTI1310

C1

2 C2

r------------------------,
.
I
J
J
I Powertrain
EVAP Canister

1
I

-T

EVAP Canister
Vent Valve

Purge Valve

---...Driver

."., Driver

-!

PCM
C1 = BLU
C2=CLEAR

Control
I Module j.
I (PCM) ~

L------------------------~

(
222965

Circuit Description
The evaporative system includes the following
components:
The fuel tank.
The EVAP canister vent valve.
The fuel tank pressure sensor.
The fuel pipes and hoses.
The fuel cap.
The EVAP vapor lines.
Ther EV AP purge lines.
The evaporative emission canister.
The EVAP purge valve.
The evaporative leak detection diagnostic strategy is
based on applying vacuum to the EVAP system
and monitoring vacuum decay. The PCM monitors
vacuum level via the Fuel Tank Pressure sensor input.
At an appropriate time, the EV AP purge valve and
the EVAP canister vent valve are turned ON, allowing
engine vacuum to draw a small vacuum on the
entire evaporative emission system. After the desired
vacuum level has been achieved, the EVAP purge
valve is turned OFF, sealing the system. A leak
is detected by monitoring for a decrease in vacuum
level over a given time period, all other variables
remaining constant. A small leak in the system will
cause DTC P0442 to be set.

Conditions for Running the DTC

1. No VSS, TP sensor, H02S, Misfire, IAT sensor,
MAP sensor, Fuel Trim, Fuel Injector, EGR Pintle,
ECT sensor, or MAF sensorDTCs are set.
2. The _9Tc P0440, diagnostic test has passed.
1

Conditions for Setting the DTC

A vacuum decay condition indicating a small leak is
detected during the diagnostic test.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the first
trip in which the diagnostic test has been run
and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.
Important: Although these diagnostics are considered
type A, they act like type B diagnostics under
certain conditions. Whenever the EVAP diagnostics
report that the system has passed, or if the battery has
been disconnected, the diagnostic must fail during
two consecutive cold start trips before setting a DTC.
The initial failure is not reported to the diagnostic
executive or displayed on a scan tool. A passing
system always reports to the diagnostic executive
immediately.

Engine
Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.

The history DTC will clear after 40 consecutive

warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Cracked or punctured EVAP canister.
Damaged source vacuum line, EVAP purge line,
EVAP vent hose or fuel tank vapor line.
Poor connection at PCM.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wire connection.

Engine Controls - 3.SL

6-955

Damaged harness.
Inspect the wiring harness to the EVAP canister
vent valve EVAP purge valve and the fuel
tank pressure sensor for an intermittent open or
short circuit.

Reviewing the Fail Records vehicle mileage since the

diagnostic test last failed may help determine how
often the condition that caused the DTC to be
set occurs. This may assist in diagnosing the condition.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. If a EVAP canister vent valve or EVAP purge
valve electrical malfunction is present, the
purge system will not operate correctly. Repairing
the electrical malfunction will very likely correct
the condition that set DTC P0442.
3. Checks the fuel tank pressure sensor at ambient
pressure.
4. Verifies that the fuel tank pressure sensor
accurately reflects EVAP system pressure
changes.

6-956

Engine

Engine Controls - 3~8L

OTC P0442 Evaporative Emission (EVAP) Control System Small Leak Detected

Step

Action

Was the Powertrain On-Board Diagnostic System Check

performed?
1

Important: Visually/physically inspect for the following

conditions:
Vacuum or purge lines disconnected. Refer to
Emission Hose. Routing Diagram. G r 7 '-/ (
Loose or missing fuel cap.

1. Turn OFF the ignition switch.

2. Remove the fuel cap.
3. Turn ON the ignition switch.

Value(s)

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to the other
DTC first

Go to Step 3

Go to Step 4

Go to
OTC P0452 Fuel
Tank Pressure
Sensor Circuit
Low Voltage

Go to Step 5

Go to
OTC P0452 Fuel
Tank Pressure
Sensor Circuit
Low Voltage

Go to Step 6

Go to
Diagnostic Aids

Go to Step 9

Go to Step 7

O in. H20

5 in. H20

15 in. H20
10 in. H20

4. Switch the rotary switch on the J 41413 EVAP

pressure/purge diagnostic station to HOLD and
observe the EVAP pressure gauge.
Does the EVAP pressure decrease to less than the
second specified value within 2 minutes?
1. Disconnect the fuel tank vapor line and the EVAP
purge line from the EVAP canister.
2. Block the fuel tank vapor line fitting on the canister.

3. Connect a hand vacuum pump to the EVAP purge

6

line fitting on the canister.

4. Ensure that the EVAP canister vent valve is still
commanded ON (Closed).
5. Attempt to apply vacuum to the canister.
Can the specified vacuum be maintained?

6. Observe Fuel Tank Pressure on the scan tool.

Is Fuel Tank Pressure at the specified value?
1. Turn ON the ignition switch, engine not running.
2. Using the scan tool, command the EVAP canister
vent valve ON (Closed).
3. Pressurize the EVAP system to the first specified
value using the EVAP pressure/purge diagnostic
station (monitor pressure using the EVAP pressure
gauge on the EVAP pressure/purge diagnostic
station).

No

4. Observe Fuel Tank Pressure on the scan tool.

Is Fuel Tank Pressure at the specified value?
Important: Before continuing with diagnosis, zero the
EVAP Pressure and Vacuum (inches of H20) gauges on
the J 41413 EVAP pressure/purge diagnostic station.
1. Replace the fuel cap.
2. Capture Fail Record data for DTC P0442 and
clear DTCs.
3. Connect the J 41413 EVAP pressure/purge diagnostic
station to the EV AP service port.
4. Using the scan tool, command the EVAP canister
vent valve ON (Closed).
5. Pressurize the EVAP system to the specified value
using the EVAP pressure/purge diagnostic station
(monitor pressure using the EVAP pressure gauge on
the EVAP pressure/purge diagnostic station).

Yes

5 in. Hg

Engine

Engine Controls - 3.8L 6-957

DTC P0442 Evaporative Emission (EVAP) Control System Small Leak Detected (cont'd)
Action

Step

Value(s)

Yes

No

Go to Step 11

Go to Step B

Visually/physically check for the following conditions:

1. Vent hose disconnected or damaged.

7

2. EVAP canister damaged. Refer to EVAP Canister

Replacement.
3. If a problem is found, repair as necessary.

Was a problem found?

Replace the EVAP canister vent valve. Refer to EVAP

Vent Valve Replacement.
l'.9 -\ f'\ ~
Is action complete?

Go to Step 11

Visually/physically check for the following conditions:

1.
2.
3.
4.

Malfunctioning (leaking) fuel cap

Leaking fuel tank vapor line.
Damaged EVAP purge line.

If a problem is found, repair as necessary.

Go to Step 11

Was a problem found?

Go to Step 10

1. Using the scan tool, command the EVAP canister

vent valve ON (Closed).

10

2. With the EVAP pressure/purge diagnostic station

connected to the EVAP service port, attempt to
pressurize the EVAP system by leaving the EVAP
pressure/purge diagnostic station control knob in the
pressurize position.

3. Using the ultrasonic leak detector J 41416, locate and

repair leak in EVAP system (It may be necessary to
partially lower the fuel tank to examine the top tank
connections).
Go to Step 11

Is action complete?

1. Turn ON the ignition switch.

2. Using the scan tool, command the EVAP canister
vent valve ON (Closed).

3. Pressurize the EVAP systerri to the first specified

11

value usfng the EVAP pressure/purge diagnostic

station (monitor pressure using the EVAP pressure
gauge on the EVAP pressure/purge diagnostic
station).

15 in. H20
10 in. H20

4. Switch the rotary switch on the J41413 EVAP

pressure/purge diagnostic station to HOLD.

5. Observe the EVAP pressure gauge on the EVAP

pressure/purge diagnostic station.
Does the EVAP pressure decrease to less than the
second specified value within 2 minutes?

Go to Step 3

System OK

6-958

Engine Controls - 3.8L

Engine

DTC P0446 Evaporative Emission (EVAP) Vent System Performance

lHot In Run, Bulb Test And
r- -

Start!

- , Underhood

;ower
Distribution
cen 10

ENG CTRL : Electrical

MiniFuse Center 2
15 A
I

. ___________ ...

IC Module
and
Transmission

PNK 239
+------...._

PNK 239

PNK 239

PNK1239

PNKI239

-PN:1239

PN:1239

L -

Evaporative
[ ] Evaporative
Emi~sion (EVAP)
Emission (EVAP)
Caniste:r Vent
[ ] Canister Purge
Solenoid
Solenoid
Valve
Valve
A
DK
WHT 1310
GRN/WHT 428
WHT 1310

II

BI

76

~
1
I

C1

WHTI1310
2 C2

- -,-E~P-ca:is~r - - - -;--;;A;

;:ni;e; -

---T

Purge Valve
Driver

---T

V~nt Valve
Driver

P~M- - ~ 6ow;rt~ain

Cl = BLU
C2=CLEAR

on ro
I Module J.
I (PCM) ~

L------------------------~

\
222965

Circuit Description
The evaporative system includes the following
components:
The fuel tank.
The EVAP canister vent valve.
The fuel tank pressure sensor.
The fuel pipes and hoses.
The fuel cap.
The EVAP vapor lines.
Ther EVAP purge lines.
The evaporative emission canister.
The EV AP purge valve.
A restricted or blocked EVAP canister vent path is
detected by monitoring fuel tank pressure during
normal operation (EVAP canister vent valve open,

EVAP purge valve normal). With the EVAP canister

vent valve open, vacuum level in the system should be
very low unless the vent path is blocked. A blockage
can be caused by the following conditions:
Malfunctioning EVAP canister vent valve (stuck
closed).
Plugged kinked or pinched EVAP canister
vent hose.
Shorted EVAP canistervent valve control circuit.
Plugged evaporative canister.
An incorrect fuel tank. pressure sensor signal is
detected by monitoring fuel tank pressure when the
key is first turned ON during a cold start. If the
fuel tank pressure signal is out of range, the EVAP
diagnostic will not be able to detect leaks.
If any of the conditions described above are present,
DTC P0446 will set.

Engine
Conditions for Running the OTC
No VSS, TP sensor, H02S, Misfire,.JATsensor,
MAP sensor, Fuel Trim, Fuel Injector, EGR
Pintle, ECT sensor, IAT sensor, or MAF sensor
DTCs are set.
.Start up engine coolant temperature is
between 4C and 30C (40F and 86F).
Start up Intake air temperature is between 4C
and 30C (40F and 86F).
Fuel tank level is between 15% and 85%.
BARQ is greater than 75 kPa.
System voltage is between 5 and 16 volts.
or
No VSS, TP sensor, H02S, Misfire, IAT sensor,
MAP sensor, Fuel Trim, Fuel Injector, EGR
Pintle, ECT sensor, IAT sensor, or MAF sensor
DTCs are set
The DTC P0442 diagnostic test has passed.
Normal system operation is commanded (EVAP
canister vent valve open, .EVAP purge valve
normal).

Conditions for Setting the OTC

Fuel tank pressure is less than -10 in. H20.
The above conditions are present for up to
30 seconds.

Action Taken When the OTC Sets

Important: Although these diagnostics are considered
type A, they act like type B diagnostics under
certain conditions. Whenever the EVAP diagnostics
report that the system has passed, or if the battery has
been discpnnected, the diagnostic must fail during
two consecutive cold start trips before setting a DTC.
The initial failure is not reported to the diagnostic
execuUve or displayed pn.a scan tool. A passing
system always reports to tl'le diagnostic executive
immediately.
The PCM will illuminate the MIL during the first,
trip in which the diagnostic test has been run
and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Engine Controls ..,. 3.SL

6-959

Conditions for Clearing the MIL/OTC

The PCM will tum the MIL Oi=F during thethird
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

Diagnostic Aids
Check for the following. conditions:
Poor connection at PCM.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damagedterminals, and
poor terminal to wire connection.
Damaged harness.
Inspect the wiring harness to the EVAP canister
vent valve and the fuel tank pressure sensor
for an intermittent open or short circuit.
, Kinked, pinched or plugged vent hose.
Verify tha:t the vent hoseJ;ietween the canister
and the EVAP canister vent valve is not restricted.
Reviewing the Fail Records vehicle milea,ge since the
diagnostic test last failed may, help determine how
often the condition that caused the DTC to be
set occurs. This may assist in diagnosing the condition ..

. Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.

2. If a EVAP canister vent valve electrical malfunction

is present, .the purge system will not operate
correctly. Repairing the electrical malfunction will
very likely correct the condition that set
DTC P0446.
3. Checks 'the fuel tank pressure sensor at ambient
pressure.
4. Verifies that the fuel tank pressure sensor reacts
to E;:V AP system pressure changes.
6. Checks for' a blocked EVAP canister.

6-960

Engine Controls - 3.BL

Engine

OTC P0446 Evaporative Emission (EVAP) Vent System Performance

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to
DTCP1665
EVAP Vent
Solenoid Control
Circuit

Go to Step 3

Go to Step 4

Go to
OTC P0452 Fuel
Tank Pressure
Sensor Circuit
Low Voltage

Was the Powertrain On-Board Diagnostic System Check

performed?

Is OTC P1665 also set?

1. Turn ON the ignition switch.

2. Capture Fail Record data for DTC P0446 and
clear DTCs.
3

3. Turn OFF the ignition switch.

4. Remove the fuel cap.
5. Turn ON the ignition switch.

O in. H20

6. Observe Fuel Tank Pressure on the scan tool.

Is Fuel Tank Pressure at the specified value?
Important: Before continuing with diagnosis, zero the
EVAP Pressure and Vacuum (inches of H20) gauges on
the J 41413 EVAP pressure/purge diagnostic station (refer
to tool operating instructions).
1. Replace the fuel cap.
2. Using the scan tool, command the EVAP canister
vent valve ON (Closed).
4

3. Connect the J 41413 EVAP pressure/purge diagnostic

station to the EVAP service port.
4. Pressurize the EV AP system to the specified value
using the J 41413 EVAP pressure/purge diagnostic
station (monitor pressure using the EVAP pressure
gauge on the J 41413 EVAP pressure/purge
diagnostic station).
5. Observe Fuel TankPressure on the scan tool.
Is Fuel Tank Pressure at the specified value?

5 in. H20

1. Maintain EVAP pressure at the first specified value.

2. Using the scan tool, command the EVAP canister
vent valve OFF (Open) while observing the EVAP
pressure gauge on the EVAP pressure/purge
diagnostic station.
Does EVAP pressure return to the second specified value
within 5 seconds?

5 in. H20
O in. H20

1. Disconnect the large vent hose (marked AIR) from

the EVAP canister.
2. Switch the rotary switch on the EVAP pressure/purge
diagnostic station to PURGE.
3. Start the vehicle and allow to reach operating
temperature
4. Using the scan tool, command the EVAP purge valve
ON (open).
5. Monitor the Vacuum (inches H20) gauge on the
EVAP pressure/purge diagnostic station for
5 seconds while holding the engine speed at
2500 RPM.
Does the vacuum remain less than the specified value?

-45 in. H20

Go to Step 5

Go to
OTC P0452 Fuel
Tank Pressure
Sensor Circuit
Low Voltage

Go to
Diagnostic Aids

Go to Step 6

Go to Step 7

Go to Step 9

E.ngine Controls - 3~8L

Engine

6-961

OTC P0446 Evaporative Emi.ssion (EVAP) Vent System Performance (cont'd)

Step

Value(s)

1. Inspect the vent hose between the EVAP canister

and the EVAP vent solenoid for being kinked,
pinched,. or otherwise blocked.
2. If a problem is found, repair as necessary.
Was a problem found?

Replace the EVAP Canister Vent Valve. Refer to EVAP

Vent Valve Replacement Is action complete?

Replace the EVAP canister. Refer to EVAP Canister

Replacement.
Is action complete?

10

Action

1. Using the scan tool, command the EVAP canister

vent valve ON (Closed).
2. Pressurize the EVAP system to the first
specified value.
3. Switch the rotary switch on the EVAP pressure/purge
diagnostic station to HOLD.
4. Using the scan tool, command the EVAP canister
vent valve OFF (Open) while observing the EVAP
pressure gauge on the EVAP pressure/purge
diagnostic station.
Does EVAP pressure return to the second specified value
within 5 seconds?

Yes

No

Go to Step 10

Go to Step 8

Go to Step 10

Go to Step 10

5 in. H20

O in. H20

System OK

Go to Step 3

6-962

Engine Controls .. 3.SL

Engine

DTC ~0452 Fuel Tank Pressure Sensor Circuit Low VoJ~age

...

-----

,... , Underhood

I Power
Distribution
I Cell10
I

FUEL PUMP. 1 Electrical

MiniFuse I Cen.ter 1
20 A

'

ORN 1340

120

... -I

-----cl _______ 1

I
I

Fuel
Level
Sensor

_____ _

---------,

I~

l_

'I

Fuel
Tank
Pressure

s~~

69 A

I
I

~P- ~e:s:~ - - - - -

;u;
Tank

- - -

Distribution

Signal

.,__

Cell14

BLK 451
DK

GRN/WHT 465

GAY 720

~~N/WHT 465

-<II Sensors

- - - - - - - - - - - - - - - - ?_.. . C2
~n;,- - - - - - - - --1~e1 -

_3_5_

Ground

Pressure

BLK/WHT 451

-1----

_?~ ..A. -

Ground

- -

I
I
I

T GRYr598- -DK GANT890 -G-RY1720

PPL 30- -

~F~el-,- Level
I Signal

.I

BLK/WHT 451

sf_ --GR~r890- - ~

I150----PPL130- -ciRv1598 -DK G-R-N1890

Cell 14

Center 2

,I
I

85

-~

---------1GRY/BLK 416
PPL 30

.......
~1-~~-i~..,..~ti-on.....

Pump
Relay

GRY
120.

1 Electrical
,.
Fue-1 I

BB
L ~ -

BLK 150
BLK

86

87A--- 87

~E ----B - - -

~;

I.
I

- ----- ---;
I
Fuel
Pump
Motor

- - - , Underhood

A10

BLKJWHT 651
GRY 120
D_ ORN/BLK 469

Tank
Unit I

~---'-~ -~---~

GAY

~~ ...

PCM
C1 =BLU
C2=CLEAR

.- - Pump
\
Control

_j_
12V

~Powertrain
Control
I Module
I (PCM)
I

~---------------------------------J

>.

223019

Circuit Description
The PCM monitors the fuel tank pressure sensor
signal to detect vacuum decay and excess vacuum
during the enhanced EVAP diagnostic. The fuel
tank pressure sensor measures the difference between
the air pressure (or vacuum) in the tank and the
outside air pressure. The PCM applies a 5.0 volt
reference and ground to the sensor. The sensor will
return a signal voltage between 0.06 and 4.9 volts.
If the PCM detects a fuel tank pressure sensor signal
that is excessively low, DTC P0452 will set.

Conditions for Running the OTC

The ignition is ON.

Conditions for Setting the OTC

The fuel tank pressure sensor signal is less
than 0.06 volts.
The conditions is present for 5 seconds.

Action Taken When the OTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MILJDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

Engine Controls - 3.8L

Engine

6-963

Diagnostic Aids

Test Description

Check for the following condition(s):

Poor connection at the PCM or Fuel Tank
Pressure Sensor.
Inspect harness connectors for backed out
terminals, improper mating broken locks,
improperly formed or damaged terminals, and
poor terminal to wire conneciton.
Damaged harness.
Inspect the wiring harness for damage. If the
harness appears to be OK, observe the Fuel Tank
Pressure Sensor display on the scan tool while
moving connectors and wiring related to the
sensor. A change in the display will indicate the
location of the malfunction.

Nurnber(s) l;>elow refer to the step number(s) on the

Diagnostic Table.
12. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

OTC P0452 Fuel Tank Pressure Sensor Circuit Low Voltage

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 4

Go to Step 3

Go to StepA

Go to
Diagnostic Aids

Go to Step B

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 13

Go to Step 7

Was the Powertrain On-Board Diagnostic(OBD) System

Check performed?
1

1. Ignition ON, engine not running.

2

2. Observe fuel tank pressure sensor voltage displayed

on the scan tool.
Is fuel tank pressure sensor voltage less than the
specified value?

0.3V

1. Review and record scan tool Fail Records data.

3

2. Clear DTCs.
3. Operate the vehicle within fail records conditions.
4. Monitor specific DTC info for DTC P0452.
Does the scan tool indicate DTC P0452 failed this ign?

1. Disconnect the fuel tank pressure sensor electrical

connector.
2. Connect a jumper between the fuel tank pressure
signal circuit and the 5 volt reference A circuit at the
fuel tank pressure sensor harness connector.
3. Observe fuel tank pressure sensor voltage displayed
on the scan tool.
Is fuel tank pressure sensor voltage near the
specified value?

5V

Using a J 39200 DMM, measure voltage between the

5 volt reference A circuit and the sensor ground circuit at
the fuel tank pressure sensor harness connector.
Is voltage near the specified value?

5V

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Check the 5 volt reference A circuit for a poor
terminal connection at the PCM.
4. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

6-964

Engine

Engine Controls - 3.8L

DTC P0452 Fuel Tank Pressure Sensor Circuit Low Voltage (cont'd)
Value(s)

Step

Action

1. Check the 5 volt reference A circuit between the fuel

tank pressure sensor and the PCM for an open, short
to ground, or short to the sensor ground circuit.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Check for poor terminal connections at the fuel tank

pressure sensor connector.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Check the fuel tank pressure sensor signal circuit for
a poor terminal connection at the PCM.
4. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

10

1. Check the fuel tank pressure signal circuit between

the fuel tank pressure sensor connector and the PCM
for an open, short to ground, or short to the sensor
ground circuit.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.

12

13

Replace the fuel tank pressure sensor. Refer to Fuel Tank

Pressure Sensor Replacement.
Is action complete?
Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.

Replace the PCM.

Is action complete?
1. Review and record scan tool Fail Records data.
2. Clear DTCs.
3. Operate the vehicle within fail records conditions.
4. Monitor specific OTC info for OTC P0452.
Does the scan tool indicate OTC P0452 failed this ign?

No

Go to Step 13

Go to Step 12

Go to Step 13

Go to Step 11

Go to Step 13

Go to Step 10

Go to Step 13

Go to Step 12

Was a problem found?

11

Yes

Go to Step 13

Go to Step 13

Go to Step 2

System OK

Engine

Engine Controls - 3.8L

6-965

DTC P0453 Fuel Tank Pressure Sensor Circuit High Voltage

!Hot At All Times!

'" - - - - -

- - - - , Underhood
FUEL PUMP I Electrical
MiniFuse I Center 1

I Power
I g:1r;~ution

Uil

.. _________ ...

20 A

GRY
120

I
I

ORN

'" - -

- - - , Underhood

10
1Electrical
.--A-- , , . . - - - - , , . . . - - . F 1
as P~:P I Center 2
Relay I

I
I

BLK/WHT1~5~ - - - -

I
- -----

BB

GRY 120

..
I
Tank
Unit I
~~

I
I

_______ D_ ORN/BLK 469

---; ---------,

Fuel

Fuel

Pump
Motor

Level

Sensor

I~

P:

..I

BLK/WHT 451
BLK/WHT 451

I
Pressure I
_Sensor I

~r- -- 1

Tank

GR~ 890- -

I1so----PPL13o--G-RvT s0a -01< GRNI aeo

......,..g~-:~-i~~-lio_n...,

ABV

- - --

Fuel

Ground
Distribution
Cel114

DK
GRN/WHT 465

t.------G~! ~K G:I~ ~:t~~: g~N::'::

-1----- --~c:--GRY 720

:.-1~~~ _j_
~--: __________ : ______________ ~:_
___
~~:~~1-

~~~

I Signal

Pressure

Signal

~BLK 451

--------1GRY/BLK 416
BLK 150
PPL 30
BLK

GRY
120

lI

__

~E ----B ---

~~:~-

c1 ~ BLU

c2~CLEAR

Control

~6~~:~rain
I Module
1 (PCM) J.
~

223019

Circuit Description
The PCM monitors the fuel tank pressure sensor
signal to detect vacuum decay and excess vacuum
during the enhanced EVAP diagnostic. The fuel
tank pressure sensor measures the difference between
the air pressure (or vacuum) in the tank and the
outside air pressure. The PCM applies a 5.0 volt
reference and ground to the sensor. The sensor will
return a signal voltage between 0.1 and 4.9 volts. If the
PCM detects a fuel tank pressure sensor signal that
is excessively high, DTC P0453 will set.

Conditions for Running the OTC

The ignition is ON.

Conditions for Setting the OTC

The fuel tank pressure sensor signal is greater
than 4.9 volts.
The conditions is present for 5 seconds.

Action Taken When the OTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIL/OTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

6-966

Engine Controls

3.SL

. Engine

Diagnostic Aids

Test Description

Check for the following condition(s):

Poor connection at the PCM or Fuel Tank
Pressure Sensor.
Inspect harness connectors for backed out
terminals, improper mating broken locks,
improperly formed or damaged terminals, and
poor terminal to wire conneciton.
Damaged harness.
lnspec the wiring harness for damage. If the
harness appears to be OK, observe the Fuel Tank
Pressure Sensor display on the scan tool while
moving connectors and wiring related to the
sensor. A change in the display will indicate the
location of the malfunction.

Number(s) below referto the step number(s) on the

Diagnostic Table.
10. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

Engine Controls - ,3.8L 6~967

Engine

DTC P0453 Fuel Tank Press1,1re Sensor Circuit High Voltage,

Step

Value(s)

Action
Was the Powertrain On-Board Diagnostic(OBD) System
Check performed?

Go to Step 2

No
Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 6

Go to Step 5

Go to Step 11

Go to Step 10

Go to Step 11

Go to Step 7

Go to Step 11

Go to Step B

Go to Step 11

Go to Step 9

Yes

1. Turn ON the ignition switch, engine not running.

2. Observe fuel tank pressure sensor voltage on the
scan tool.
Is fuel tank pressure sensor voltage greater than the
specified value?

4.7V

'

'

1. Operate the vehicle within the conditions described in

Conditions for Setting the DTC.
2. Monitor specific DTC info fo~ DTC P0453.
Does the scan tool indicate DTC P0453 failed this ign?

1. Disconnect the fuel tank pr~ssure sensor.

2. Observe the fuel tank pressure sensor voltage
displayed on the scan tool.
Is fuel tank pressure sensor voltage near the
specified value?

OV

1.
2.
. 3.
4.

Turn OFF the ignition switch.

Disconnect the PCM .
Turn ON the ignition switch.
Check the fuel tank pressure signal ckcuit for a short
to voltage or a short to the 5, volt reference A. .circuit.
5. If a problem is found, repair as necessary, Refer to
Wiring Repairs.
:
Was a problem found?

\,,

10

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Check the fuel tank pressure sensor ground circuit for.
a poor terminal connection at the PCM.
4. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Check for an open in the fuel tank pressure sensor

ground circuit.
2. If a problem is found, repair as necessary. Refer to
Wirin9 Repairs.
Was a problem found?

1. Check for poor terminal connections at the fuel tank

pressure sensor connector.,
2. If a problem is found, repair as nece~sary. Refer to
Wiring Repairs.
Was a problem found?
Replace the fuel tank pressure sensor.
Is action complete?
..
Important: The replacement PCM 'must be programmed.
Refer to PCM Replacement/Programming.
Replace the PCM.
Is action complete?
"'

)
I

11

',

,,
'

Go to Step 11

,'

'

1. Review and record scan toof Fail Records data.

2. Clear DTCs.
3. Operate the vehicle within fail records conditions.
4. Monitor specific DTC info for DTC P0453.
Does the scan tool indicate DTC P0453 failed this ign?

Go to Step 11

'

'
Go to Step 2

System OK

6-968

Engine Controls - 3.8L

Engine

DTC P0500 Vehicle Speed Sensor (VSS) Circuit

I I
L~c

Vehicle Speed

~ Sensor (VSS)

Av

YEL 400

PPL 401

'" -----1----1-----,
64

I
I
I
I

65

vss

vss

High

Low

C1

PCM

_
5V

c1~BLU
C2-CLEAR

Powert. rain
I Control
I Module
I (PCM)
I
~

>

L------------------~
223029

Circuit Description

Diagnostic Aids

Vehicle speed information is provided to the PCM by

the Vehicle Speed Sensor (VSS). The VSS consists
of a magnetic pickup sensor mounted to the
transmission case which interfaces with a rotor
pressed onto to the transmission output shaft. The
VSS produces a frequency signal that is proportional
to vehicle speed. The PCM converts the VSS
signal to vehicle speed, displayed on the scan tool in
miles per hour and kilometers per hour. The PCM
also uses the VSS signal to generate the 4000 pulses
per mile vehicle speed signal used by the instrument
cluster and the stepper motor cruise control module.

The scan tool should display vehicle speed while the

drive wheels are turning.If you suspect that an
intermittent fault exists, check for the following
conditions:

Conditions for Setting the DTC

Engine speed is greater than 1000 RPM.
Engine load and engine speed acceleration
indicate that the vehicle is in gear.
Vehicle speed sensor indicates a speed of less
than 5 km/h (3 MPH) for greater than 20 seconds.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the first
trip in which the diagnostic test has been run
and failed.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Poor connection at the PCM or the VSS - Inspect

harness connectors for the following conditions:
Backed out terminals.

Improper mating.
Broken locks.
Improperly formed or damaged terminals.
Poor terminal to wire connection.
Damaged harness - Inspect the wiring harness
for damaged insulation. Check for bolts, brackets,
etc.interfering with the wiring harness and
rubbing through the wiring insulation. Damaged
insulation can cause an intermittent condition.
Loose or damaged VSS rotor ----' A damaged VSS
rotor may cause an erratic or incorrect vehicle
speed to be displayed.Refer to Manual
Transmission section for on-vehicle service.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
2. If the condition that caused the OTC to set cannot
be duplicated, checking the items referred to in
Diagnostic Aids may isolate the cause of
an intermittent fault.

Engine

Engine Controls - 3.SL

6-969

DTC P0500 Vehicle Speed Sensor (VSS) Circuit

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to
Diagnostic Aids

Go to Step 3

Go to Step 7

Go to Step 4

Go to Step 6

Go to Step 5

Go to Step B

Go to Step 7

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1.
2.
3.
4.

Turn OFF the ignition switch.

Raise drive wheels
Start the engine and idle in gear.

Observe the vehicle speed display on the scan tool.

Does the scan tool display vehicle speed greater than the
specified value?

Observe the cluster speedometer with the engine still

idling in gear.
Does the speedometer display vehicle speed greater than
the specified value?

1. Turn OFF the ignition switch.

2. Disconnect the VSS electrical connector.
3. Connect J 33431-8 Signal Generator and Instrument
Panel Tester to the VSS harness connector.

4. Turn ON the ignition switch.

5. Turn ON the Signal Generator, set signal generator to

generate a VSS signal.

6. Observe the vehicle speed display on the scan tool.

Does the scan tool display vehicle speed greater than the
specified value?

1.
2.
3.
4.

Turn OFF the ignition switch.

Disconnect the PCM.
Turn.ON the ignition switch.
Check for the following conditions:
VSS High circuit open, shorted to ground, or
shorted to voltage.

If a problem is found, repair as necessary. Refer

to Wiring Repairs.
5. VSS Low circuit open or shorted to voltage.
Was a problem found?

Replace the VSS. Refer to Automatic Transmission

On-Vehicle Service.
Is the action complete?
Important: Replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Replace the PCM.
Is the action complete?

1.
2.
3.
4.

Go to Step .B

Go to Step B

Turn OFF the ignition switch.

Raise drive wheels.

Start the engine and idle ingear.
Observe vehicle speed display on the scan tool.
Does the scan tool display vehicle speed greater than the
specified the specified value?

System OK

Go to Step 3

6-970

Engine Controls - 3.8L

Engine

OTC P0506 Idle Speed Low

Idle Air
Contr61
(IAC)

Stepper
Motor

LT
BLU/WHT 1747

DI

.. -

I
I .
I

Valve

Coil
B

cv

LT
GRN/BLK 444

Al
.

Bl

~~N/WHT 1749

38C1

49

IAC -....; ;;...- ,;;_-...;;; -IAC - ;;_-_;;;-....;;;_-!AC.:.-_;;;~ ;;;_-.:.,Ac Coil A

High

J,

~:U/BLK1748
44

Coil A
Low

Coil B
Low

Coil B
High

.,

Powertram

I Control
I
PCM . 1 I Module
C1=BLU
II
C2=CLEARI I (PCM) ..
.

L---------------------------~

4~
223033

Circuit Description
The PCM controls engine idle speed by adjusting the
position of the Idle Air Control (IAC) motor pintle.
The IAC is a bi-directional motor driven by two coils.
The PCM sends pulses (steps) to the IAC to extend or
retract the IAC pintle into a passage in the throttle
body to decrease or ir,crease air flow. The commanded
IAC position (displayed in counts) can be monitored
on the scan tool; a higher number of counts indicates
more commanded airflow (pintle retracted) This
method allows highly accurate control of idle speed
and quick response to changes in engine load. If
the PCM detects a condition where too low of an idle
speed is present and the PCM is unable to adjust
idle speed by increasing the IAC counts, DTC P0506
will set indicating a problem with the idle control
system.

Conditions for Setting the DTC

No TP sensor, EVAP system, misfire, IAT sensor,
MAP sensor, Fuel Trim, Fuel Injector, EGR
Pintle, ECT sensor, CKP sensor, VSS, or MAF
sensor DTCs are set.
System voltage is between 9 and 16 volts.
Baro is greater than 65 kPa.
Engine Coolant Temperature is greater
than 70C (158F).
The engine has been running for at least
2 minutes.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present .
when the DT<:; set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.

The DTC can be cleared by using the SCc}n tool

Clear Information function or by disconnecting

the PCM battery feed.

Diagnostic Aids
Check for the following conditions:
1. Poor connection at the PCM or IAC motor ~
Inspect harness connectors for the following
conditions:
2. Backed out terminals.
3. Improper mating.
4. Broken tocks.

Vehicle Speed is less than 5 km/h (3 mph).

5. Improperly formed or damaged terminals.

Intake Air Temperature is greater

than -18C (0F).

6. Poor terminal to wire connection.

The throttle is closed.

Engine Speed is more than 100 RPM lower than
Desired Idle.
The conditions are present for longer
than 15 seconds.

7. Damaged harness for damage.

Inspect the wiring harness

8. Restricted air intake system - Check for a

possible collapsed air intake duct, restricted
air filter element, or foreign objects blocking the
air intake system.

Engine

i
/

Engine Controls - 3.8L 6-971

9. Throttle body - Check for objects blocking the

IAC passage or throttle bore, excessive deposits
in the IAC passage and on the IAC pintle, and
excessive deposits in the throttle bore and on the
throttle plate.
10. Large vacuum leak - Check tor a condition that
causes a large vacuum leak, such as a incorrectly
installed or faulty PCV valve or brake booster
hose disconnected.
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help determine
how often the condition that caused the DTC to be set
occurs.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
.10. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

OTC P0506 Idle Speed Low

Action

Step

;l

Value{s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board. Diagnostic
(080) System
Check

Diagnose other
DTCs first.

Go to Step 3

Go to
Diagnostic Aids

Go to Step 4

Go to Step 6

Go to Step 5

Go to Step 11

Go to Step 9

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Are any other DTCs set?

1. Start the engine.
2. Turn OFF all accessories (A/C, Rear defroster etc.).
3. Using a scan tool, command RPM up to 1500, down
to 650, and then up to 1500 while monitoring Engine
Speed on the scan tool.
Does Engine Speed remain within the specified value of
Desired Idle for each RPM command?
1. Disconnect the IAC.
2. Install a J 37027-A IAC System Monitor.
3. With the engine running, command RPM up to 1500;
down to 650, and then up to 1500 while observing
the node light.

100 RPM

Does each node light cycle red and gre,en (never OFF)?

1. Check the following circuits for an open, short to

voltage, or short to ground:
IAC A Low
IAC A High
IAC B Low
IAC B High
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

6-972

Engine Controls - 3.8L

Engine

DTC P0506 Idle Speed Low (cont'd)

Step

Action

Value(s)

Yes

No

1. Visually/physically inspect for the following conditions:

Throttle body tampering. (Adjustment screw
turned).
Check for a possible collapsed air intake duct,
restricted air filter element, or foreign objects
.blocking the air intake system.
Remove the IAC valve. Refer to /AC Valve
Replacement.

Check for objects blocking the IAC passage or

throttle bore, excessive deposits in the IAC
passage and on the IAC pintle, and excessive
deposits in the throttle bore and on the
throttle plate.
Unusual engine loading caused by a, binding
generator or A/C compressor.
2. If a problem is found, repair as necessary.
Was a problem found?

Go to Step 11

Go to Step 7

Go to Step 11

Go to Step 8

for a poor connection at the IAC harness

. 1. Check
connector.

2. If a problem is found, replace faulty terminals as

necessary. Refer to Wiring Repairs.

Was a problem found?

Replace the IAC valve. Refer to /AC Valve Replacement.

Is action complete?

Go to Step 11

1. Check for a poor connection at the PCM harness

connector.

2. If a problem is found, replace faulty terminals as

necessary. Refer to Wiring Repairs.

Was a problem found?

10

Important: The replacement PCM must be program(Tled.

Refer to PCM Replacement/Programming.
Replace the PCM.
Is action complete?

Go to Step 11

Go to Step 10

..

Go to Step 11

1. Start the engine.

11

2. All accessories OFF (A/C, Rear defroster etc.).

3. Using a scan tool, command RPM up to 1500, down
to 650, and then up to 1500 while monitoring Engine
Speed on the scan tool.
Does Engine Speed remain within the specified value of
Desired Idle for each RPM command?

100 RPM

System OK

Go to Step 2

Engine

Engine Controls - 3.SL

6-973

DTC P0507 Idle Speed High

!Loe I

Idle Air
Stepper
Motor

Control

(IAC)
Valve

[SJ

~oil

~
~~U/W:Tlv1747
7

~TRN/B:K!444

~:U/BLK 1748
44
49
-------- --------

.. - - -1Ac - - - I
I
I
I

Cl

Coil A
High

Bl

~~N/WHT 1749
38C1
--------

1Ac - - - - 1Ac- - - - -IAC - - - - - - , Powertrain

Coil A
Low

Coil B
Low

Coil B
High

I Control
I Module
C1=BW
I
.._
C2=CLEAR I (PCM) ,i.
PCM

L---------------------------J

~
223033

Circuit Description

Vehicle Speed is less than 5 km/h (3 mph).

The PCM controls engine idle speed by adjusting the

position of the Idle Air Control (IAC) motor pintle.
The IAC is a bi-directional motor driven by two coils.
The PCM sends pulses (steps) to the IAC to extend or
retract the IAC pintle into a passage in the throttle
body to decrease or increase air flow. The commanded
IAC position (displayed in counts) can be monitored
on the scan tool; a higher number of counts indicates
more commanded airflow (pintle retracted) This
method allows highly accurate control of idle speed
and quick response to changes in engine load. If
the PCM detects a condition where too low of an idle
speed is present and the PCM is unable to adjust
idle speed by increasing the IAC counts, OTC P0507
will set indicating a problem with the idle control
system.

Intake Air Temperature is greater

than -18C (0F).

Conditions for Setting the DTC

No TP sensor, EVAP system, misfire, IAT sensor,
MAP sensor, Fuel Trim, Fuel Injector, EGR
Pintle, ECT sensor, CKP sensor, VSS, or MAF
sensor DTCs are set.
System voltage is between 9 and 16 volts.
Baro is greater than 65 kPa.
Engine Coolant Temperature is greater
than 70C (158F).
The engine has been running for at least
2 minutes.

The throttle is closed.

Engine Speed is more than 175 RPM higher than
Desired Idle.
The conditions are present for. longer
than 15 seconds.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery"feed.

6-974

Engine Controls - 3.8L

Engine

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM or IAC motor Inspect harness connectors for the following
conditions:
Backed out terminals.
Improper mating.
!3roken locks.
Improperly formed or damaged terminals.
Poor terminal to wire connection.
Damaged harness - Inspect the wiring harness
for damage.
Vacuum leak - Check for a condition .that causes
vacuum leak, such as disconnected or damaged
boses, leaks at EGR valve and EGR pipe to
!htake manifold, leaks at throttle body, faulty or
Incorrectly installed CRANKCASE VENTILATION
valve, leaks at intake manifold, etc.

Throttle body - CheckJor a sticking throttle plate:

Also. inspect the IAC passage for deposits or
objects Which will not allow the IAC pintle to fully
extend.
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help determine
how often the condition that caused the OTC to be set
occurs.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
10. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

DTC P0507 Idle Speed High

Step

Action
Was the Powertrain On-Board Diagnostic System Check
performed?
'

Are any other DTCs set?

Value(s)

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
heck

Diagnose the
other DTCs first.

Go to Step 3

1. Start the engine.

2. Turn OFF all accessories (A/C, Rear defroster etc.).
3. Using a scan tool, command RPM up to 1500, down
to 650, and then up to 1500 while monitoring Engine
Speed on the scan tool.
Does Engine Speed remain .within 100 rpm of the RPM
commanded?

1. Disconnect the IAC Valve.

2. Install a J 37027-A IAC System Monitor.
3. Wi.th the engine running, command RPM up to 1500,
down to 650, al'ld then up to 1500 while observing
the. node light.
Does each node light cycle red and green (never OFF)?

Go to
Diagnostic Aids

Go to Step 4

'

Go to Step 6

Go to Step 5

Go to Step 11

Go to Step 9

1.
2.
3.
4.

Turn the ignition OFF.

Disconnect the PCM.
Turn the ignition ON.
Check the following circuits for an open, short to
voltage; or short to ground:
IAC A Low
IAC A High
IAC B Low
IAC B High
5. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Yes

Engine. Controls - 3.SL

Engine

6-975

DTC P0507 Idle Speed High (cont'd)

Action

Step

Value(s)

Yes

No

Go to Step 11

Go to Step 7

Go to Step 11

Go to Step 8

1. Visually/physically inspect for the following conditions:

'

10

Vacuum leaks
Throttle body tampering (throttle lever stop screw
turned)
Throttle plate or throttle shaft binding
Accelerator and cruise control cables misadjusted
or binding
Faulty, missing, or incorrectly installed PCV valve
2. If a problem is found, repair as necessary.
Was a problem found?
1. Check for a poor connection at the IAC harness
connector.
2. If a problem is found, replace faulty terminals as
necessary. Refer to Wiring Repairs.
Was a problem found?
Replace the IAC valve. Refer to /AC Valve Replacement.
Is the action complete?
1. Check for a poor connection at the PCM harness
connector.
'"-,,
2. If a problem is found, replace faulty terminals as
necessary. Refer to Wiring Repairs.
Was a problem found?
Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.

Replace the PCM.

Is the action complete?

Go to Step 11

Go to Step 11

Go to Step 10

Go to Step 11

1. Start engine.
2. Turn OFF all accessories (A/C, Rear dafroster etc.).
11

3. Using a scan tool, command RPM up to 1500, down

to 650, and then up to 1500 while monitoring Engine
Speed on the scan tool.
Does Engine Speed remain within 100 rpm of the RPM
commanded?

System OK

Go to Step 2

6-976

Engine Controls - 3.8L

Engine

DTC P0530 Air Conditioning (A/C) Refrigerant Pressure Sensor Circuit

,------<1------ I;::,?,igerant
_~
l .
I. L
Pressure

C""":":~-------,,--A----'. Sensor
8
GRY 720
GRY 474

TFT,
,-. __ -<Ill Fuel Level and
1
Fuel Tank

RED/BLK 380

Pressure Sensors

GRY 720

27 '" ______

I
I

-AIC - - - - - 5~ 0 ;
Refrigerant
Pressure

sensor
Signal

_;3j_ _ _;39.,.. C2
-

Reference1

-s;;;s.; - - - - - - - Ground

V
5

1c1

PCM

BLU

C2=CLEARI

I
I
I

L-----------------------J

Powertrain
Control
Module

.&

(PCM) ~

~
223152

Circuit Description
The A/C system uses an A/C refrigerant pressure
sensor mounted in the high pressure side of the A/C
refrigerant system to monitor A/C refrigerant pressure.
The PCM uses this information to turn ON the
engine coolant fans when the A/C refrigerant pressure
is high and to keep the compressor disengaged
when A/C refrigerant pressure is excessively high or
low. The PCM applies a 5.0 volt reference and a
sensor ground to the sensor. Changes in the
A/C refrigerant pressure will cause the A/C refrigerant
pressure input to the PCM to vary. The PCM
monitors the A/C refrigerant pressure signal circuit and
can determine when the signal is outside of the
possible range of the sensor. When the signal is out
of range (high or low) for a prolonged period of
time, the PCM will set OTC P0530. When OTC P0530
is set, the PCM will not allow the A/C compressor
clutch to engage. This is done to protect the
compressor.

Conditions for Setting the DTC

The engine is running.
A/C is requested.
The A/C refrigerant pressure sensor signal voltage
is less than 0.1 volt.
OR
The A/C refrigerant pressure sensor signal voltage
is greater than 4.9 volts.
Either of the conditions are present for longer
than 20 seconds.

Action Taken When the OTC Sets

The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM will store conditions which were present
when the OTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.
A/C compressor operation will be disabled while
the high or low pressure indication exists.

Conditions for Clearing the MIUDTC

A history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
OTC can be cleared by using the scan tool Clear
Information function or by disconnecting the
PCM battery feed.

Engine Controls - 3.8L 6-977

Engine
Diagnostic Aids
Check for the following conditions:
Important: Be sure to inspect PCM engine grounds
for being secure and clean.
Poor connection at PCM - Inspect harness connectors
for the following items:
Backed out terminals
Improper mating
Broken locks
Improperly formed or damaged terminals
Poor terminal to wire connections
Damaged harness - Inspect the wiring harness for
damage.
If the harness appears to be OK, observe the A/C
pressure display on the scan tool while moving
connectors and wiring harnesses related to
the A/C refrigerant pressure sensor. A change in
the A/C pressure display will indicate the
location of the fault.

If DTC P0530 cannot be duplicated, review the Fail

Records vehicle mileage since the diagnostic test last
failed. This may help determine how often the
condition that caused the DTC to be set occurs.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Normal A/C pressure sensor signal voltage is
between 0.1 and 4.8 volts. If A/C voltage is within
range, review Fail Records data to determine
the conditions that were present when
DTC P0530 set.
4. If the A/C refrigerant pressure signal voltage stays
high after disconnecting the A/C refrigerant
pressure sensor electrical connector, the signal
circuit is shorted to voltage or the PCM is faulty.
20. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

DTC P0530 Air Conditioning (A/C) Refrigerant Pressure Sensor Circuit

Action

Step

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 5

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 12

Go to Step 11

Go to Step 16

Go to Step 6

Go to Step 9

Go to Step 7

Go to Step 17

Go to Step 8

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Observe the A/C refrigerant (high side) pressure sensor

voltage displayed on the scan tool.
Is the A/C refrigerant pressure sensor voltage less than
the specified value?
Is the A/C refrigerant (high side) pressure sensor voltage
greater than the specified value?
Disconnect the A/C refrigerant pressure sensor while
observing A/C refrigerant pressure sensor voltage on the
scan tool.

0.1V

4.BV

OV

Does the scan tool indicate voltage near the

specified value?
1. Disconnect the A/C refrigerant pressure sensor.

2. Connect a fused jumper between the terminals for the

A/C refrigerant pressure signal circuit and the 5 volt
reference B circuit at the A/C refrigerant pressure
sensor harness connector.

SV

3. Observe A/C refrigerant (high side) pressure sensor

voltage on the scan tool.
Does the scan tool indicate A/C refrigerant pressure
sensor voltage near the specified value?

Using a J 39200 DMM, measure voltage between the

5 volt reference B circuit and the ground circuit at the A/C
refrigerant pressure sensor harness connector.

SV

Is voltage near the specified value?

Check for a poor 5 volt reference B circuit terminal

connection at the PCM.
Was a problem found?

6978

Engine

Engine Controls - 3.8L

DTC P0530 Air Conditioning (A/C) Refrigerant Pressure Sensor Circuit (cont'd)

Step

Value(s)

Action

Yes

No

Check tor the following conditioris:

A short to ground in the 5 volt reference B circuit.

8

An open in the 5 volt reference B circuit.

'

Faulty splice in the 5 volt reference B circuit.

Was a problem found?
9

'

Chack the A/C refrigerant pressure signal circuit for a poor

terminal connection at the PCM.

10

11

12

13

Check for a poor sensor ground circuit terminal connection

at the A/C refrigerant pressure sensor connector.
Check for an open or a faulty splice in the sensor ground
circuit.

16

Replace the faulty harness connector terminal. Refer to

Wiring Repairs.
Locate and repair open/short circuit in wiring harness as
necessary. Refer to Wiring Repairs.

19

20

Go to Step 14

Go to Step 17

Go to Step 15

(
Go to Step 18

Go to Step 19

Go to Step 17

Go to Step 19

Go to Step 21

Go to Step 21

Is the action complete?

Important: The replacement PCM must be programmed.

Refer to PCM ReplacemenVProgramming.
Replace the PCM.

Go to Step 17

Go to Step 21

Is the action complete?

Replace the A/C refrigerant pressure sensor. Refer to
Heater, Ventilation and Air Conditioning On-Vehicle
Service.

Go to Step 13

Is the action complete?

18

Go to Step 18

Was a problem found?

17

Go to Step 20

Was a problem found?

Check for a poor 5 volt referenqe B .circuit or A/C
refrigerant pressure signal circuit terminal connection at
the A/C refrigerant pressure sensor.

Go to Step 18

Was a problem found?

15

Go to Step 20

Was a problem found?

14

Go to Step 18

Was a problem found?

Check for a poor sensor ground circuit terminal connection
at the PCM.

Go to Step 10

Was a problem found?

Check for a short to voltage on the 5 volt reference B

circuit.

Go to Step 17

Was a problem found?

Check the A/C refrigerant pressure signal circuit between
the A/C pressure sensor connector and the PCM for a
short to voltage.

Go to Step 13

Was a problem found?

Check the A/C refrigerant pressure signal circuit between
the A/C refrigerant pressure sensor connector and the
PCM for ari open or short to ground.

Go to Step 18

Go to Step 21

Is the action complete?

1. Clear DTCs.
21

2. Note the A/C refrigerant pressure sensor voltage.

Is the A/C refrigerant pressure sensor voltage between the
specified values?

0.1-4.8V
System OK

Go to Step 2

Engine

Engine Controls - 3.SL

6-979

DTC POSSO System Voltage

!Hot In Run Or Start l

'" - - - - - - - - - -

I
I

- - - - , IP
I Fuse

Power
Distribution
Cell 10

Fuse Block
Details
Cell11

...,....

L.JiJ

L---------Fuse Block
Details
Cell 11

Block

----J

__PNK_39
~ Instrument
Cluster

PNK 39
AS

r-----------------------------,
I Instrument --+------------------,

I Cluster
I
I

ts'\ CHECK GAUGES

\.V Indicator

Cell81

4700

_______...

Indicator

_ _ ...

Generator
Status

~ - - , . . . - - - - - ! Control

.--,
I
. I
Turn on I
I input

.._

I
I

/,,

Cell14

BLK/WHT 451

(f]f-owo1L I
Level
I
Indicator

Ground
Distribution

BLKJ 451
WHT
A

Generator

25
BRN
61 C2

Ignition
Positive
Voltage

,... ......

REDT 2~5

361 C1

-J-

G- - t - -

--1 r:r':'ia~~
1

_ Output

PCM
C1 = BLU
C2=CLEAR

~~7at; - - - - - }- ~wControl

-r

BRN/WHT 1173
BR~r1174
6 ________ 58 C2

---1011

~ Control

~~~ ~
Signal

I Module
I

5V

6~~:~~ain

L------------------------------------------..1

(PCM)

.&
~~

223198

Circuit Description
Th.e PCM monitors system voltp.ge on the PCM
ignition feed circuit. If the system voltage is out of
tolerance, DTC P0560 will be set. When the conditions
that set DTC P0560 are present, operation of some
vehicle systems and components may be affected.

Conditions for Setting the DTC

The engine is running.
System voltage monitored at the PCM ignition
feed circuit is less than 10 volts or
greater than 16 volts.
Above conditions must be present for longer
than 25 seconds.

Action Taken When the DTC Sets

The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM will store conditions which were present
when the DTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

Conditions for C.learing the MILJDTC

A history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
DTC can be cleared by using the scan tool Clear
Information function or by disconnecting the
PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Important: Be sure to inspect PCM engine grounds
for being secure and clean.
Poor connection at PCM - Inspect harness
connectors for the following items:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connections
Damaged harness - Inspect the wiring harness for
damage.
If the harness appears to be OK, observe the
Ignition 1 voltage display on the scan tool
while moving connectors and wiring related to the
PCM, dash harness, and engine harness. A
change in the display will indicate the location of
the fault.
Important: Charging with a battery charger while
starting the engine can cause DTC P0560 to be set.
If DTC P0560 cannot be duplicated, review the
Fail Records vehicle mileage since the diagnostic test
last failed. This may help determine how often the
condition that caused the DTC to be set occurs. For
complete information and additional diagnostics for the
vehicle charging system, refer to Charging System.

6-980

Engine Controls - 3.8L

Engine

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
13. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

DTC POSSO System Voltage

Step

Action

Was the Powertrain On-Board Diagnostic System Check

performed?
1

Value(s)

1. Start and run engine above 1000 RPM.

2. Observe Ignition 1 on the scan tool Eng. 2 data list.
Is Ignition 1 voltage between the specified values?

1. Review and record the scan tool Fail Records data.

2. Clear the DTC P0560 and operate the vehicle to
duplicate the Fail Records conditions.
3. Using a scan tool, monitor Specific DTC info for
DTC P0560 until the DTC P0560 test runs.
Note test result; Does the scan tool indicate DTC failed
this ignition?
1. Install a J 39200 DMM between the battery terminals.
2. Monitor the J 39200 DMM while running the engine
above 1000 RPM.

Go to Step 2
Go to
DTCP1635 5
Volt Reference
Circuit

Go to Step 3

Go to Step 4

Go to Step 5

Go to Step 5

Go to
Diagnostic Aids

10-16V

(
\

10-16V

Does DVM show battery voltage between the specified

values?

No

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Is DTC P1635 also set?

2

Yes

1. Load the electrical system by turning ON the

headlamps and the HVAC high blower.
2. Monitor the J 39200 DMM while running the engine
above 2000 RPM.
Does the J 39200 DMM show battery voltage between the
specified values?

10-16V

1. Turn OFF the ignition switch.

2. Disconnect the generator electrical connector.
3. Turn the Turn ON the ignition switch.
4. Connect a J 39200 DMM to measure voltage
between the generator control circuit at the generator
harness connector and ground.
5. Command the Gen. L Term. ON using the scan tool.
Does the J 39200 DMM display voltage near the specified
value with the Gen. L Term. commanded ON?

B+

Compare the Ignition 1 voltage displayed on the scan tool

with the actual battery voltage read with the J 39200 DMM.
Does the scan tool Ignition 1 value closely match the
actual value read with the J 39200 DMM?

1. Check the PCM ignition feed circuit for a poor

connection between the ignition switch and the PCM.
Refer to Wiring Repairs.
2. If a problem is found, replace faulty terminal(s).
Was a problem found?

Go to Step 6

Go to Step 7

Go to Step 8

Go to Step 7

Go to Step 12

Go to Step 10

Go to
Diagnostic Aids

Go to Step 9

Go to Step 14

Go to Step 13

6-981

Engine Controls - 3.SL

Engine

OTC POSSO System Voltage (cont'd)

Step

Action

Value(s)

10

1. Check the generator control circuit for an open or a

short to ground betwee.n the PCM and the generator.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Check the generator control circuit for a poor terminal

connection at the PCM.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

11

Yes

No

Go to Step 14

Go to Step 11

Go to Step 14

Go to Step 13

Go to Step 14

Go to Charging
Systems
Diagnosis.

1. Check the generator control circuit for a poor terminal

connection at the generator.
12

2. If a problem is found, repair as necessary. Refer to

Wiring Repairs.
Was a problem found?

Important: The replacement PCM must be programmed.

13

Refer to PCM Replacement/Programming.

Replace the PCM.

Go to Step 14

Is the action complete?

14

1. Start and run the engine above 1000 RPM.

2. Observe Ignition 1 011 the scan tool Eng. 2 data list.
Is Ignition 1 voltage between the specified values?

10-16V
System OK

Go to Step 5

6-982

Engine

Engine Controls - 3.8L

DTC P0601 Control Module Read Only Memory (ROM)

Conditions for Clearing the MIL/OTC

Circuit Description

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

The PCM used in this vehicle utilizes an Electrically

Erasable Programmable Read-Only Memory
(EEPROM). The EEPROM contains program
information and the calibrations required for powertrain
diagnostics operation.
Unlike the PROM used in past applications, the
EEPROM is not replaceable. When the PCM is
replaced or a calibration update is required, the PCM
must be programmed using approved Techline
equipment.

Conditions for Setting the OTC

The PCM does not contain the correct program
required to operate the vehicle.

Action Taken When the OTC Sets

The PCM will illuminate the MIL during the first
trip in which the diagnostic test has been run
and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Diagnostic Aids
DTC P0601 indicates that the contents of the
EEPROM have changed since the PCM was
programmed. The only possible repair is PCM
replacement. Remember to program the replacement
PCM with the correct software and calibration for
the vehicle.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

OTC P0601 Control Module Read Only Memory (ROM)

Step

Action
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.
Replace the PCM.
Is action complete?

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Engine

Engine .Controls - 3.SL

6-983

OTC P0602 Control Module Not Programmed

Circuit Description

Action Taken When the OTC Sets

The PCM 'will not illuminate the Malfunction
Indicator Lamp (MIL).
. The PCM will store conditions which were present
when the OTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

The PCM used in this vehicle utilizes an Electrica:lly

Erasable Programmable Read-Only Memory
(EEPROM). The EEPROM contains program
information and the calibrations required tor powertrain
'diagnortics operation.
Unlike the PROM used in past applications, the
EEPROM is not replaceable. When thePCM is
replaced or a calibration update is required, the PCM
must be programmed using approved Techline
equipment.

Conditions, for Clearing the MIUDTC

A history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
OTC can be cleared by using the scan tool Clear
Information function or by disconnecting the
PCM battery feed.

Conditions for Setting the OTC

The PCM does not contain the ,c~rrect program
required to operate the vehicle.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
3. Thi.s vehicle. i.l:> equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must qe progralT}rned.

DTC P0602 Control Modute Not Programmed

Step

'

':

Actior

'"

V,alue{s)

Was the Powertrain On-Board Diagnostic.. (OBD) System

Check performed?

'"

,,,'

Yes

No

Go to Step 2

Gp to A
Powertr{lin .on
'Board Diagnostic
(OBQ) $ystem
Cf1eck

Gq tp,Step $

Sy$temQ~

..

1. Program the PCM with borrect i,oftware, Refer to

2

PCM Replacement/Programming
2. Retest for DTC P0602.
Did DTC P0602 set?

Important: The teplacement PCM mustbe programmed.

Refer to PCM Replacement/Programming.
Replace the PCM.
Is action complete?

.. Go to A
Powertrain On .
Board Diagnostic
(OBD) System

Che,c;k

6-984

Engine Controls .. 3.8L

Engine

DTC P0704 Clutch Switch Circuit

GRY 48

[lJ

(
Cruise Control/
Clutch Anticipate
Switch

D
BLl<JWHT 451

BLK/WHT 451
GRY 48
BLK/WHT
- - a-----------,--'l'--.;....._-4~5::-:1-"--~--4

...
I Clutch
Anticipate
I Switch

G
d
roun
Distribution

........_Ce......
11_14_

_.

BLK/WHT 451

Signal

1
~

2nd Gear
Start Switch

PCM
C1 ~ BLU

II Control

C2=CLEAR

L-----------J

Module
(PCM)

>

~
223254

Circuit Description
The Clutch Anticipate Switch i11put allows the PCM to
adjust the IAC when the manual transmission
clutch is being disengaged. The PCM monitors the
Clutch Anticipate Switch input; if a low voltage
is monitored, the PCM considers the Clutch Anticipate
Switch closed to ground (clutch engaged). When
the ground at the Clutch Anticipate Switch input is
interrupted (clutch being disengaged), the PCM
will immediately decrease IAC counts. This is done to
avoid a possible RPM flare caused by the sudden
change in engine load.

Conditions for Setting .the DTC

Engine load and engine speed acceleration
indicate that the veh_icle is in gear and moving.
The Clutch Anticipate Switch PCM input indicates
that the clutch is engaged. (clutch switch closed
to ground).
Above conditions must be present for longer
than 3 minutes.
OR
Changes in the vehicle speed to engine speed
ratio indicate that more than 150 gear changes
have occurred.
The state of the Clutch Anticipate Switch did not
change.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
key cycle in which the OTC sets.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF on the third
consecutive trip cycle during which the diagnostic
has been run and the fault condition is no

lbnger present.
A history OTC P0704 will clear after
40 consecutive warm-up cycles have
occurred without a fault.
OTC P0704 can be cleared by using the scan tool
Clear Information function or by disconnecting the
PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at PCM - Inspect harness connectors
for the following items:
Backed out terminals
lmprop.er mating
Broken locks
Improperly formed or damaged terminals
Poor terminal to wire connections
Damaged harness - Inspect the wiring harness
tor damage. If the harness appears to be OK,
observe the Clutch Anticipate Switch display on
the scan tool while moving connectors and
wiring harnesses related to the switch. A change
in the display will indicate the location of the
fault. Review the Fail Records vehicle mileage
since the diagnostic test last failed. This may help
determine how often the condition that caused
the OTC to be set occurs.

Engine

Engine Controls - 3.8L

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:
2. This step checks the true state of the clutch pedal
switch.

6-985

15. This vehicle is equipped with a PCM which utilizes

an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

7. This step checks the integrity of the Clutch

Anticpate Switch input circuit.

OTC P0704 Clutch Switch Circuit

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Step 6

Go to.
Diagnostic Aids

Go to Step 4

Go to Step 13

Go to Step 5

Go to Step 9

Go to Step 15

Go to Step 7

Go to Step 10

Go to Step 11

Go to Step 8

Go to Step16

Go to Step 14

Was the Powertrain On-Board Diagnostic (080) System

Check performed?
1

1. Turn ON the ignition switch.

2. Observe the Clutch Pedal Switch display on the
scan tool.
Does the Clutch Pedal Switch display Released?

Depress the clutch pedal while observing the Clutch Pedal

Switch display on the scan tool.
Does the Clutch Pedal Switch display change to Applied?

1. Disconnect the Clutch Anticipate Switch electrical

connector.
2. Observe the Clutch Pedal Switch display on the
scan tool.
Does the Clutch Pedal Switch display change to Applied?

1. Turn OFF the ignition switch.

2. Disconnect the PCM
3. Probe the Clutch Anticipate Switch signal circuit at
the PCM harness connector with a J 34142-8 test
lamp to B+.
Is the test lamp ON?

1. Disconnect the clutch pedal switch electrical

connector.
2. Probe the Clutch Anticipate Switch ground circuit at
the Clutch Anticipate Switch harness connector with a
J 34142-8 test lamp to B+
Is the test lamp ON?

1. Connect a fused jumper between the Clutch

Anticipate Switch signal circuit and the Clutch
Anticipate Switch ground circuit.
2. Observe the Clutch Pedal Switch display on the
scan tool.
Does the Clutch Pedal Switch display Released?

1. Turn OFF the ignition switch.

2. Disconnect the PCM.

3. Turn ON the ignition switch.
4. Check the clutch input circuit for the following
conditions:
Open between the Clutch Anticipate Switch and
the PCM
Shorted to voltage
5. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

,6~986

Engine Controls 3.SL

Step

Action

Engine

DTC P0704 Clutch Switch Circuit (cont'd)

Value{s)

to

Locate and repair short. ground in Clutch Anticipate

Switch Signal circuit. Refer to Wiring Repairs.

'

Yes

Go to Step 16

Is action complete?
10

Locate and repair open in Clutch Anticipate Switch ground

circuit. Refer to Wiring Repairs.

No

Go to Step 16

Is action complete?

1. Check Gluten Ant1cipate Switch adjustment.

11

2. If a problem is found, adjust the Clutch Anticipate

Switch as necessary. Refer to Clutch Anticipate
Switch Replacement.

Go to Step 16

Was a problem found?

Go to Step 12
'

1. Check for poor terminal connections at the Clutch

Anticipate Switch.
12
'

2. If a problem is found, replace terminals as necessary.

Refer to Wiring Repairs.

Go to Step 16

Was a problem found?

13

Replace the Clutch Anticipate Switch. Refer to Clutch.

Anticipate Switch Replacement.
Is action complete?

Go to Step 13

Go to Step 16

1. Check for terminal poor connections at PCM.

14

2. If a problem is found, replace terminals as necessary.

Refer to Wiring Repairs.

Go to Step 16

Was a problem found?

15

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.
Replace the PCM.

Go to Step 15

"'.(

'Go to Step 16

Is action complete?
1. Turn ON the ignition switch.
16

2. Observe the Clutch Pedal Switch display on the

scan tool.

Does the Clutch Pedal Switch display Released?

17

Depress the clutch pedal while observing the Clutch Pedal

Switch display on the scan tool.
Does the Clutch Pedal Switch display change to Applied?

Go to Step 17

Go to Step 6

System OK

Go to Step 4

Engine

Engine Controls - 3.SL

6-987

OTC P0705 Trans Range Switch Circuit

LliJ

ORN/BLK
434
r -

1
I

ORN/BLK 434

B
-

Park

1Neutral

I Position

II ~
R--- .. -2l
I
N @-- D
I
I

II Switch
I
I
I

L--------J
BLK/WHT 451

At

ORN/BLK 434

BLK/WHT 4~ - - -

Ground

BLK/WHTt 51

Distribution
Cell14

T
_ _ _ _ _J

BLK 451

-1-PNP -----------

16 C2
r -

I
I
I1.

Powertrain
I Control
c1 = BLu
I Module (PCM)
C2=CLEAR
I
12V _ _ _ _ _ _ _ _ _ _ _ _ .I
Switch

PCM

254440

Circuit Description
The Transmission Range Switch is part of the
Transmission Park/Neutral Position (PNP) switch
mounted on the transmission manual shaft. The four
inputs from the transmission range switch indicate
to the PCM which position is selected by the
Transmission selector lever. This information is used
for ignition timing, EVAP canister purge, EGR and
IAC valve operation. The combination of the four
transmission range input states determine the PCM
commanded shift pattern. The input voltage level at the
PCM is high (B+) when the transmission range
switch is open and low when the switch is closed to
ground. The state of each input is represented on the
scan tool as High=high voltage level, Low=low
voltage level. The four parameters represent
transmission range switch Parity, A, B, and C inputs
respectively.

A problem which causes the PCM to detect an invalid

transmission range input combination will set
DTC P0705. Valid transmission range input
combinations are shown in the Transmission Range
Switch Valid Input Combinations table.

Transmission Range Switch Valid Input

Combinations
Scan Tool Trans Range
PABC Display
X=High
O=Low

Gear Selector Position

p

Park (P)

Low

Low

High

High

Reverse (R)

High

Low

Low

High

Neutral (N)

Low

High

Low

High

Drive4 (OD)

High

High

Low

Low

Drive3 (3)

Low

Low

Low

Low

Drive2 (2)

High

Low

High

Low

Drive 1 (1)

Low

High

High

Low

Conditions for Setting the OTC

The Transmission Range Switch inputs indicate
an invalid combination.
The condition is present:
- Manual Transaxle - the condition is present
for longer than 1O seconds.
- Automatic Transaxle - the condition is
present for longer than 5 seconds.

5..999

Engine Controls .. 3.8L

Action Taken When the OTC Sets

The PCM will default to a 04 transmission range
display.
The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM will store conditions which were present
when the OTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

Conditions for Clearing the MIUDTC

A history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
OTC can be cleared by using the scan tool Clear
Info function or by disconnecting the PCM
battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM.
Inspect hamess connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wire connection.

Engine
Damaged harness.
Inspect the wiring harness for damage.
If the harness appears to be OK, observe the TR
P A B C switch display on the scan tool while
moving connectors and wiring harnesses related
to the sensor. A change in the display will
indicate the location of the malfunction.
Important: Vehicle should not be driven with
transmission range switch disconnected, as idle
quality will be affected.
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help determine
how often the condition that caused the OTC to be set
occurs.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
1G. This vehicle i.s equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

Engine Controls - 3.8L

Engine
..

DTC P0705 Trans Range Switch Circuit

Action

Step

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 10

Go to Step 5

Go to Step 7

Go to Step 17

Go to Step 6

Go to Step 17

Go to Step 13

P=Low
A=LOW
B=Low
C=LOW

Go to Step 8

Go to Step 10

P=Low
A=Low
B=Low
C=LOW

Go to Step 9

Go to Step 14

Go to Step 17

Go to Step 16

Go to Step 17

Go to Step 11

Value(s)

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1. Turn ON the ignition switch.

2. Place the transmission in Park.
3. Observe the scan tool TR P A B C display.
Does the scan tool TR P A B C display the specified
values?
1. Observe the scan tool TR P A B C display while
selecting each gear position.
2. Record TR P A B C status in each gear position.
3. Compare the scan tool display with each gear
position selected to the Transmission Range Switch
Valid Combinations Table.
Does the scan tool display match the Transmission Range
Switch Valid Combinations table in each gear position?
Does the scan tool TR P A B C display the specified
values?

''

P=High
A=High
B=High
C=High

1. Check for an open in the ground circuit to the

Transmission Range switch 7 wire connector.
2. 1.f a problem is found, repair as necessary. Refer to
Repair Procedures in Electrical Diagnosis.
Was a problem found?

P=Low
A=LOW
B=High
C=High

1. Check the Transmission Range switch 4-way

connector for being disc<;mnected.
2. If a problem is found, repair as necessary.
Was a problem found?

Does scan tool TR P A B C display the specified values?

1. Disconnect the Transmission Range switch 4-wire

connector.
2. Observe the scan tool TR PA BC display.
Does scan tool TR P A B C display the specified values?
1. Turn OFF the ignition switch.
2. Disconnect the PCM.
3. Check the Transmission Range input wiring for being
pinched or otherwise shorted to ground.
4. lf. a problem is found,. repair as necessary. Refer to
Repair Procedures in Electrical Diagnosis.

Was a problem found?

10

5..999

1. Check for crossed wires to the Transmission Range

Switch 4 wire connector.
2. If a problem is found, repair as necessary. Refer to
Repair Procedures in Electrical Diagnosis.
Was a problem found?

6-990

Engine

Engine Controls 3.BL

DTC P0705 Trans Range Switch Circuit (cont'd)

Step

Action

Value(s)

1. Turn .OFF the ignition switch.

2. Disconnect the Transmission Range switch and
the PCM.
3. Turn ON the ignition switch.
4. Check for an open, short to ground, or short to
voltage in the circuit which caused the incorrect
transmission range switch input combination.
5. If a problem is found, repair as necessary. Refer to
Repair Procedures in Electrical Diagnosis.
Was a problem found?

1. Reconnect the Transmission Range switch.

2. At the PCM connector, connect a test light between
B+ and the trans range circuit which caused the
incorrect transmission range switch input
combination.
3. Observe and record the state of the test light while
selecting each gear position.
4. Compare the test light state in each gear position
with the Transmission Range Switch Valid
Combinations Table.
Is the test light ON when the input should equal Low and
OFF when the input should equal High?

1. Check for poor terminal connections at the

Transmission Range switch 4-way and 7-way
connectors.
2. If a problem is found, repair as necessary. Refer to
Repair Procedures in Electrical Diagnosis.
Was a problem found?

Replace the transmission range switch. Refer to 4L60-E

Transmission On-Vehicle Service.
Is action complete?

15

1. Check for poor terminal connections at the PCM.

2. If a problem is found, repair as necessary. Refer to.
Repair Procedures in Electrical Diagnosis.
Was a problem found?

16

Replace the PCM.

Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Is action complete?

1. Clear DTCs.
2. Observe the scan tool TR P A B C display while
selecting each gear position.
3. Compare the scan tool display with each gear
position selected to the Transmission Range Switch
Valid Combinations Table.
Does the scan tool display match the Transmission Range
Switch Valid Combinations table in each gear position?

11

12

13

14

17

Yes

No

Go to Step 17

Go to Step 12

'

Go to Step 15

Go to Step 13

Go to Step 17

Go to Step 14

Go to Step 17

Go to Step 17

Go to Step 16

Go to Step 17

System OK

Go to Step2

Engine

Engine Controls 3.SL

6-991

DTC P0706 Trans Range Switch Performance

ORN/BLK
434
B
r -

I Position

I'Switch

.-2
/

N @--o

, .

Park

I Neutral

I ~ R-.
.I
--...

ORN/BLK 434.

I .
I

I
I

L--------..1

At

BLK/WHT 451

r - -

I
I
I
L

Distr.ibution
Cell14

____

_]

BLK 451

-1-PNP-:- - - - - - - - - -: -, Powertrain
Control
Switch

Ground

BLK/WHT1451

. 16 C2

BLK/WHT 4~ - - -

OF{N/BLK 434

PCM

C1=BLU
C2=CLEAR

12V _ _ _ _ _ _ _ _ _ _ _ _

I
~
I Module (PCM) ~
I
J

)
254440

Circuit Description
lhe Transmission Range Switch. is part of the.
Transmission Park/Neutral Position,(PNP) switch
mounted on the transmission manual shaft. The four
inputs from the transmission range switch indicate
to the PCM which position is selecte.d by the
Transmission selector lever. This information is used
for ignition timing, EVAP canister purge, EGA and
IAC valve operation. The combination of the four
tran.smission range input states determine the PCM
commanded shift pattern. The input voltage level at the
PCM is high (B+) .when the transmission range
switch is open and low when the switch is clqsed to
ground. The state of each input is represented on the
scan tool as High=high voltage level, Low=low
voltage level. The four parameters represent
transmission range switch Parity, A, B, and C inputs
respectively.
A problem with the transmission range switch
adjustment which causes the PCM to detect vehicle
startup while a gear position other than Park or Neutral
is selected will set DTC P0706.

Transmission Range Switch Valid Input

; '.Combinations

Gear Sel~ctor,. Position

. Sc~n T.ool Trans Range

PABC Display
X=High
O=Low'
. p'
c
B
A

Park (P)

Low

Low

High

High

Reverse (R)

High

Low

Low

High

Neutral (N)

Low

High

Lbw

High
Low

Drive4 (OD)

High

High

Low

Drive3 (3)

Low

Low

Low

Low

Drive2 (2)

High

Low

High

Low

Drive 1 (1)

Low

High

High

Low

Conditions for Running the OTC .

The system voltage {Ignition 1) is greater than 9 volts.

Conditions for Setting the OTC

The Transmission Range Switch inputs indicate a
gear position other than Park or Neutral during
startup.

The above conditions are present for

2 consecutive startups.

6-992

Engine

Engine Controls - 3.SL

Action Taken When the OTC Sets

Diagnostic Aids

The PCM defaults to a 04 transaxle range

display.

DTC P0706 set indicates a misadjusted Park Neutral

Position I Transmission Range Switch.

The PCM will not illuminate the Malfunction

Indicator Lamp (MIL).

Important: Vehicle should not be driven with transaxle

range switch disconnected, as idle quality will be
affected.
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help determine
how often the condition that caused the DTC to be set
occurs.

The PCM will store conditions which were present

when the DTC set as Fail Records data only.
rhis information will not be stored as
Freeze Frame data.

Conditions for Clearing the MIUDTC

A history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
DTC can be cleared by using the scan tool Clear
Information function or by disconnecting the
PCM battery feed.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
11. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

OTC P0706 Trans Range Switch Performance

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to
DTCP0705
Trans Range
Switch Circuit

Go to Step 3

Go to Step 4

Go to Step 5

Go to
Diagnostic Aids

Go to Step 5

Go to Step 6

Go to Step B

Go to Step 7

Go to Step B

Go to Step 12

Go to Step 11

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Is OTC P0705 also set?

1. Turn ON the ignition switch.

2. Select park transmission position.
3. Observe the scan tobl Trans Range display.
Does Trans .Range display indicate P-N?

1. Select neutral transaxle position.

2. Observe scan tool Trans Range display.
Does Trans Range display indicate P-N?

Observe the sc;:an tool TR Switch P I A I B I C display.

Does scan tool TR Switch P I A I B I C display the
specified values?

1. Disconnect the Transmission Range switch 4-wire

connector.
2: Observe the scan tool TR Switch P I A I B I C
display.
Does scan toot TR Switch P I A I B I C display the
specified values?
1. Turn OFF the ignition switch.
2. Disconnectthe PCM.
3. Check the Transmission Range input wiring for being
pinched or otherwise shorted to ground.
4. If a problem is found, repair as necessary. Refer to
Repair Procedures in Electrical Diagnosis.
Was a problem found?

P=Low
A=Low
B=Low
C=Low
P=Low
A=LOW
B=Low
C=Low

Engine Controls - 3.BL

Engine

6-993

OTC P0706 Trans Range' Switch Performance (cont'd)

Action

Step

Value(s)

Yes

No

Go to Step 12

Go to Step 9

Go to Step 12

Go to Step 10

1. Attempt to adjust the PNP I Trans Range switch.

Refer to 4L60-E Transmission On-Vehicle Service.

2. Recheck the Trans Range scan tool display with Park

and Neutral selected.

Does the scan tool display P-N with Park and Neutral
selected?
1. Check for crossed wires to the Transmission Range
switch 4 wire connector.
9

2. If a problem is found, repair as necessary. Refer to

Repair Procedures in Electrical Diagnosis.

Was a problem found?

rn

Replace the Transmission Range switch. Refer to 4L60-E

Transmission On-Vehicle Service.

Go to Step 12

Is action complete?
Replace the PCM.

11

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.

Go to Step 12

Is action complete?
1. Cle~r DTCs.
2. Observe the scan tool TR Switch P I A I B I
while selecting each gear position.

Cdisplay

3. Record TR Switch P I A l B l C status ih each gear

12

position.

4. Compare the scan tool display with each gear

position selected to the Transmission Range Switch
Valid Combinations Table.

Does the scan tool display match the TransmiS&ion Range

Switch Valid Combinations table in .each gear position?

System OK

Go to Step2

5.;994

Engine Controls

'!'

3.8L

Engine

DTC P1106 Manifold: Absolute Pressure (MAP).., Sensor Circuit Intermittent High Voltage
"'

Powertrain r

Module~~~~; :

~~

jsv

5~
_ _ _ _ _ _ _ ~f:.'.:e'::e _:: _

_ __

. -

Pressure
Sensor

MAP .

~-~

~~

j~

_G:= ':-E~R~ __ ~g~I _

25

GRY

598

RCM

33
GAY 598
Fuel Tank

MAP

' :

~~
_ ... ~o!:;1d_ ,- _

C2 13

C1

~c
lS]
N

i1\.

LT GRN 432

GRY 598

GRY 598

221661

Circuit Description
'rhe Manifold Absolute Pressure (MAP) sensor
responds to changes in intake manifold pressure
(vacuum). The MAP sensor signal voltage to the PCM
varies from below 2 volts at idle (high vacuum) to
above 4 volts with the key ON, engine not running or
at wide-open throttle (low vacuum). The MAP
sensor is used to determine manifold pressure
changes while the linear EGR flow test diagnostic is
being run (refer to OTC P0401 ), to determine
engine vacuum level for some other diagnostics and
to determine barometric pressure (BARO). The
PCM monitors the MAP signal for voltages outside the
normal range of the MAP sensor. If the PCM detects
a MAP signal voltage that is intermittently high,
OTC P1106 will be set.

Conditions for Setting the OTC

No TP sensor DTCs present.
Engine has been running for a length of time that
is determined by startup coolant temperature.
The length of time ranges from 2 minutes at less
than -30C (-22F} to 0.5 second at more
than 30C (86F}.
Throttle position is less than 2% when engine
speed is less than 900 RPM.
OR
Throttle position is 0% when engine speed is
greater than 900 RPM.
The MAP sensor indicates a signal voltage
intermittently greater than 4.2 volts.
The above conditions are present for longer
than 5 seconds.

Action Taken When the DTC.Sefs

The PCM will not illuminate the Malfunction
lnd_icator Lamp (MIL),.
.,
The PCM will store conditions. which were present
. when.the OTC set as Fail Records data only.
This information wm not .be stored as
Freeze Frame data.

Conditions for Clearing the MIUDTC

. A hfstory :ore Will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
OTC can be cleared by using the scan tool Clear
Information function or by disconnecting the
PCM battery feed.

Diagnostic Aids
Check for the following conditions:
1. Poor connection at PCM - Inspect harness
connectors for the following items:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connections
2. Damaged harness. Inspect the wiring harness for
damage.
3. If the harness appears to be OK, observe the
MAP display on the scan tool while moving
connectors and wiring harnesses related to the
sensor. A change in the display will indicate
the location of the fault.
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help determine
how often the condition that caused the OTC to be set
occurs.

Engine

Engine Controls - 3.SL

6995

OTC P1106 Manifold Absolute Pressure (MAP)Sensor Circuit Intermittent High Voltage
Action

Step

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

)
1

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Select DTC info, Last Tst Fail and note any other
DTCs set.
2

Is DTC P0108 also set?

Go to
OTC P0108
Manifold Absolute
Pressure (MAP)
Sensor Circuit
High Voltage

Is DTC P1121 also set?

Go to Step 6

Go to Step 4

Check for a poor sensor ground circuit terminal connection

at the MAP sensor.

Go to Step 9

Go to Step 5

Go to Step 10

Go to Step 8

Go to Step 10

Go to Step 7

Go to Sfep 9

Go to Step 8

Go to Step 10

Go to
Diagnostic Aids

Was a problem found?

5

Check the MAP signal circuit between the MAP sensor

connector and the PCM for an intermittent short to voltage.

Go to Step 3

Was a problem found?

Check for an intermittent short to voltage on the 5 volt
reference A circuit between the PCM and the following
components:
The MAP sensor.

The Fuiel Tank Pressure Sensor.

The TP sensor
Refer to Wiring Repairs.
Was a problem found?

Check for a poor sensor ground circuit terminal connection

at the PCM.

Was a problem found?

8

Check for an intermittent open in the sensor ground circuit.

Refer to Wiring Repairs.

Was a problem found?

9

Replace the faulty harness connector terminal for sensor

ground circuit. Refer to Wiring Repairs.

10

Locate and repair intermittent open/short circuit in wiring

harness as necessary. Refer to Wiring Repairs.

Is action complete?

Go to Step 11

. Go to Step 11

Is action complete?
1. Review and record scan tool Fail Records data.
2. Clear DTCs.

3. Operate vehicle within Fail Records conditions

11

as noted.

4. Using a scan tool, monitor Specific DTC info for

DTC P1106.
Does scan tool indicate DTC P1106 failed?

Go to Step 2

System OK

6~996

Engine Controls - 3.SL.

Engine

DTC P1107Manifold Absolute Pressure (MAP) Senso~ Circuit Intermittent Low Voltage
Powertrain r
Control I
Module (PCM) II

J
-

":"' -

__________ ,

I
5 Volt
~ , . _ _ _ _ _ _ _ Reference A_

sv

_ _

PCM

C1 = BLU
Sensor
... lc2=CLEAR _ _ _ Signal_

------------------------,;

33
GAY 598
Fuel Tank
Pressure
Sensor

GAY

25

II

Sensor
__Ground

C2 13

__

Li

C1

LT GAN 432

598
GAY 598

GAY 598

I}==t>-11

BA

Man.ifold
Absolute
Pressure
(MAP) Sensor A
...,,.....-.- - - - - - - '

TP Sensor

, ORN/BLK I..__
469
_ _ _ _ _ ___J
221661

Circuit Description
The Manifold Absolute Pressure (MAP) sensor
responds to changes in intake manifold pressure
(vacuum). The MAP sensor signal voltage to the PCM
varies from below 2 volts at idle (high vacuum) to
above 4 volts with the key ON, engine not running or
at wide-open throttle (low vacuum). The MAP
sensor is used to determine manifold pressure
changes while the linear EGR flow test diagnostic is
being run (refer to DTC P0401 ), to determine
engine vacuum level for some other diagnostics and
to determine barometric pressure (BARO). The
PCM monitors the MAP signal for voltages outside the
normal range of the MAP sensor. If the PCM detects
a MAP signal voltage that is intermittently low,
DTC P1107 will be set.

Conditions for Setting the OTC

No TP sensor DTCs are present.
The ignition is ON.
Throttle angle is steady above 0% when engine
speed is below than 1000 rpm.
OR
Throttle angle is steady above 10% when engine
speed is greater than 1000 rpm.
The MAP sensor indicates a signal voltage
intermittently below 0.1 volt.
The condition is present for longer than 5 seconds.

Action Taken When the OTC Sets

The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM will store conditions which were present
when the DTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

Conditions for Clearing the MIUDTC

A. history DTC wiU clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
DTC can be cleared by using the scan tool Clear
Information function or by disconnecting the
PCM battery feed.
.

Diagnostic Aids
Check for the following conditions:
1. Poor connection at PCM - Inspect harness
connectors for the following items.:
- eacked out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connections
2. Damaged harness. Inspect the wiring harness for
damage.
3. If the harness appears to be OK, observe the
MAP display on the scan tool while moving
connectors and wiring harnesses related to the
sensor. A change in the display will indicate
the location of the fault.
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help determine
how often the condition that caused the DTC to be set
occurs.

Engine

Engine Controls - .3.SL 6-997

OTC PU07Manifold Absolute Pressure (MAP) Sensor Circuit .Intermittent Low Voltage
Action

Step

Value(s)

Yes

No

Go to Step 2

Goto A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to
DTCP0107
Manifold Absolute
Pressure (MAP)
Sensor Circuit
Low Voltage or
DTCP1635 5
Volt Reference
Circuit

Go to Step 3

Go to Step 6

Go to Step 4

Go to Step 9

Go to Step 5

Go to Step 10

Go to Step 8

Go to Step 10

Go to Step 7

Go to Step 9

Go to Step B

Go to Step 10

Go to
Diagnostic Aids

Was the Powertrain On-Board Diagnostic (080) System

Check performed?

Select OTC info, Last Tst Fail and note any other
DTCs set.
Is OTC P0107 or P1635 also set?

Is OTC P1122 also set?

Check for a poor 5 volt reference A circuit or MAP signal

circuit terminal connection at the MAP sensor. Refer to
Wiring Repairs.

Was a problem found?

Check the MAP signal circuit between the MAP sensor
connector and the PCM for an intermittent open or short to
ground. Refer to Wiring Repairs.
Was a problem found?

Check for an intermittent short to ground on the 5 volt

reference A circuit between the PCM and the following
components:
The MAP sensor.
The Fuel Tank Pressure Sensor..
The TP sensor.
Refer to Wiring Repairs
Was a problem found?

Check for a poor 5 volt reference A terminal connection at

.,
the PCM.
Was a problem found?

Check for an intermittent open or a faulty splice in the

5 volt reference A circuit.
Was a problem found?

Replace the faulty harness connector terminal(s) for the

5 volt reference A circuit and/or the MAP signal circuit as
necessary. Refer to Wiring Repairs.
Is action complete?

Repair intermittent open/short circuit in wiring.harness as

necessary. Refer to Wiring Repairs.
Is action complete?

10

11

1. Review and record scan tool Fail Records data.

2. Clear DTCs.
3. Operate vehicle within Fail Records conditions
as noted.
4. Using a scan tool, monitor Specific DTC info for
OTC P1107.
Does scan tool indicate OTC P1107 failed?

Go to Step 11

Go to Step 11

Go to Step 2

System OK

si:.ggs

OTC

Engine Controls .; 3.8L

PH 11

Engine

Intake Air Temperature (IAT) Sensor Circuit Intermittent High Voltage

.. - - - - -v- - - ., Powertrain
5
1 Control
:
IAT
Module (PCM)

r :

1
I
L

S~nsor4

s,~a.:_ ____

__

.J ~

50IC2

TA~ 472

rn
pptr
171

.- - - - - - iAT7

Intake Air
Temperature
(IAT) Sensor

719
C1
-

Sensor

Ground

.,

Powertrain

PCM : I I Control

1c1C2=CLE:AR
BLU .. 11 Module (PCM) ~
I
~
=

L---------------J
221729

Circuit Description
The Intake Air Temperature (IAT) sensor is a
thermistor which measures the temperature of the air
entering the engine. The PCM applies 5 volts
~hrough a pull-up resistor to the IAT sensor. When the
intake air is cold, the sensor resistance is high and
the PCM will monitor a high signal voltage on the IAT
signal circuit. If the intake air is warm, the sensor
resistance is lower causing the PCM to monitor a lower
voltage. OTC P1111 wiHset when the PCM detects
an intermittently high signal voltage on the intake
air temperature sensor signal circuit.

Conditions for Setting the DTC

No ECT sensor, MAF sensor, or VSS OTCs are
present
The engine has been running for over 3 minutes.
Engine coolant temperature is greater than
60C (140F).
Vehicle speed is less than 56 km/h (35 mph).
Mass air flow is less than 12 g/s.
IAT signal voltage intermittently indicates an
intake air temperature less than -34C (-29F).
The condition is present for longer than 5 seconds.

Action Taken When the DTC Sets

The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM will store conditions which were present
when the OTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

Conditions for Clearing the MIUDTC

A history OTC will clear after 40 consecutive
warm~up cycles have occurred without a
malfunction.
OTC can be cleared by using the scan tool Clear
Information function or by disconnecting the
PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at PCM - Inspect harness
connectors for the following items:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal tci wire connections
Damaged harness
Inspect the wiring harness for damage.
If the harness appears to be OK, observe the IAT
display on the scan tool while moving connectors
and wiring harnesses related to the IAT sensor.
A change in the IAT display will indicate the
location of the fault.

Skewed or mis-scaled IAT Sensor.

Refer to Temperature vs Resistance table.
Reviewing the,Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the OTC to be
set occurs. This rnay assist in diagnosing the condition.

Jingine Controls. - 3,.81- 6~999

Engine

OTC Pt111 Intake Air Temperature .(IAT) Sensor Circuit lnqtl'fllittent High V<:>ltage
.
Action

Step
"'
;

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Select OTC info, Last Tst Fail and note any other
DTCs set.

3
'

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to
OTC P0113
Intake Air
Temperature
(IA T) Sensor
Circuit High
Voltage

Go to Step 3

Go to Step 9

Go to Step 4

Yes

Value(s)

Is OTC P0113 also set?

1. Check for a poor sensor ground circuit terminal

connection at the IAT sensor. Refer to Wiring
Repairs.

2. If a problem is found, repair as necessary. Refer to

Wiring Repairs.

Was a problem found?

1. Check for a poor IAT signal circuit terminal
connection at the IAT sensor.

2. If a problem is found, repair as necessary. Heter to

Wiring Repairs.
'
'
Was a problem found?

1. Check the IAT signal circuit between the IAT sensor

connector and thePCM for an intermitt~nt open.

)
6

<

.,

Go to$tep 9

.Go to Step 6

Go to Step 9

Go,to Step 7

.
,'e

'

''

,,

1' Check for ar, intermittent open in the sensor ground

,.
circuit.
'.
2. If a probh~m is f91,.1nd, repair as necessary. Refer to
Wiring Repairs.

Go to Step B

Go, to Step 9

Was a problem found?

,,.:

'

1. Check the IAT signal circuit between the IAT sensor

connector.and the PCMfor an.intermittent short to
voltage.
.
.
'
Refer to
2. If a problem is found, repair as necessary.
..,
~
Wiring Repairs.

1. Check f<>r, a. pqo~ sensor grounq circuit terminal

connection afthe rcM. .,
2. If a problem' is found,, repair as necessary. Refer to
Wiring Repairs.

'

2. If a problem is found; 'repair as necessary. Refer to

Wiring Repairs.
Was a problem found?

Was a problem found and repaired?

Go to Step 5

Go to Step 9

Was a problem found?

-e's

'

Go to Step.9

Go t6
Diagnostic Aids

Go to Step2

System OK

1. ,Revi~w and record scan tool Fctil R.ecords data.

2. Clear DTCs.

3. Operate the vehicle within Fail Records conditions

as noted.
.
4. Using scan tool, rnonitor ~pecific DT'C info for
OTC P1111.
.
.

Does scan tool indicate OTC P11 f1. failed,? .

6-1000

Engine Controls - 3.Sl

Engine

DTC P1112 lntake Air Temperature (IAT) Sensor Circuit Intermittent Low Voltage

: J :

'" - - - - -;,v- - - , Powertrain

Control

I Module (PCM)

IAT

S~nsor

s,~a~ ____

__

..1 ~

50IC2

TA~ 472

rn

Intake Air
Temperature
(IAT) Sensor

pptl 719

171

C1

'" - - - - - iAT- - - - - - - - ., Powertrain

I
I

Sensor
Ground

PCM

I I Control

1c1C2=CLEARI
BLU I I Module {PCM) ~
I
~
=

L---------------J
221729

Circuit Description

Diagnostic Aids

The Intake Air Temperature (IAT) sensor is a

thermistor which measures the temperature of the air
entering the engine. The PCM applies 5 volts
through a pull-up resistor to the IAT sensor. When the
intake air is cold, the sensor resistance is high and
the PCM will monitor a high signal voltage on the IAT
signal circuit. If the intake air is warm, the sensor
resistance is lower causing the PCM to monitor a lower
voltage. OTC P1112 will set when the PCM detects
an intermittently low signal voltage on the intake
air temperature sensor signal circuit.

Check for the following conditions:

Poor connection at PCM - Inspect harness
connectors for the following items:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connections
Damaged harness.
Inspect the wiring harness for damage.
If the harness appears to be OK, observe the IAT
display on the scan tool while moving connectors
and wiring harnesses related to the IAT sensor.
A change in the IAT display will indicate the
location of the fault.
Skewed or mis-scaled IAT Sensor.
Refer to Temperature vs Resistance table.
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help determine
how often the condition that caused the OTC to be set
occurs.

Conditions for Setting the DTC

1. No ECT sensor, MAF sensor, or VSS DTCs are
present.
2. The engine has been running for over 1O seconds.
3. Vehicle speed is greater than 25 mph.
4. The IAT sensor intermittently indicates an intake
air temperature greater than 135C (275F).
5. The condition is present for longer than 5 seconds.

Action Taken When the DTC Sets

The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM will store conditions which were present
when the OTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

Conditions for Clearing the MIUDTC

A history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
OTC can be cleared by using the scan tool Clear
lnformationrmation function or by disconnecting
the PCM battery feed.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Verifies that the fault is present.
3. If OTC P1112 can be repeated only by duplicating
the Fail Records conditions, refer to the
Temperature Vs. Resistance Values Table. The
table may be used to test the IAT sensor at
various temperatures to evaluate the possibility of
a shifted sensor that may be shorted above or
below a certain temperature. If this is the
case, replace the IAT sensor.

Engine

Engine Controls - 3.8L

6-1001

DTC P1112 Intake Air Temperature (IAT) Sensor Circuit Intermittent Low Voltage
Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to
OTC P0112
Intake Air
Temperature
(IA T) Sensor
Circuit Low
Voltage

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 2

System OK

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Select OTC info, Last Tst Fail and note any other
DTCs set.
Is OTC P0112 also set?

1. Check the IAT signal circuit between the IAT sensor

connector and the PCM for an intermittent short to
ground.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Review and record scan tool Fail Records data.

2. Clear DTCs.
3. Operate vehicle within Fail Records conditions
as noted.
4. Using a scan tool, monitor Specfic OTC info for
OTC P1112.
Does the scan tool indicate OTC P1112 failed?

6-1002

Engine Controls - 3.BL

Engine

DTC P1114 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent Low Voltage
TPand MAP
Sensors

-4 ,_ -

GRY 598
E

yy,;
3
.__}_-_-_-_-_-_-_- _-_1________1. . ~Ee~~)~=:~~n
I Exhaust Gas

B
GAY 598

BLK 552
LT BLU 697

BAN 1456,
GAY 435

C2

32

C1

28

C2

31

C1

33

C2

(
222140

Circuit Description
The Engine Coolant Temperature (ECT) sensor is a
thermistor mounted in the engine coolant stream. The
PCM applies a voltage (about 5.0 volts) through a
pull up resistor to the ECT signal circuit. When
the engine coolant is cold, the sensor (thermistor)
resistance is high, therefore the PCM will measure a
high signal voltage. As the engine coolant warms,
the sensor resistance becomes less, and the
ECT signal voltage measured at the PCM drops. With
a fully warmed up engine, the ECT signal voltage
should measure about 1.5 to 2.0 volts. If the PCM
detects an ECT signal that is intermittently below the
range of the ECT sensor, DTC P1114 will set.

Conditions for Setting the DTC

The engine has been running longer
than 15 seconds.
The ECT sensor intermittently indicates an engine
coolant temperature greater than 114C (237F).
The condition is present for longer than 5 seconds.

Action Taken When the DTC Sets

The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM will store conditions which were present
when the DTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

Conditions for Clearing the MIUDTC

A history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
DTC can be cleared by using the scan tool Clear
Information function or by disconnecting the
PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at PCM - Inspect harness
connectors for the following items:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connections
Damaged harness
Inspect the wiring harness for damage.
If the harness appears to be OK, observe the
ECT display on the scan tool while moving
connectors and wiring harnesses related to the
ECT sensor. A change in the ECT display
will indicate the location of the fault.
Skewed or mis-scaled ECT Sensor.
Refer to Temperature vs Resistance table.

Engine

Engine Controls - 3.8L

6-1003

Reviewing the Fail Records vehicle mileage since the

diagnostic test last failed may help determine how
often the condition that caused the DTC to be
set occurs. This may assist in diagnosing the condition.

DTC P1114 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent Low Voltage
Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
heck

Go to
OTC P0117
Engine Coolant
Temperature
(ECT) Sensor
Circuit Low
Voltage

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 2

System OK

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Select OTC info, Last Tst Fail and note any other
DTCs set.
Is OTC P0117 also set?

1. Check the ECT signal circuit between the ECT

sensor connector and the PCM for an intermittent
short to ground.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Review and record scan tool Fail Records data.

2. Clear DTCs.
3. Operate vehicle within Fail Records conditions
4

as noted.
4. Using a scan tool, monitor Specific OTC info for
OTC P1114.
Does the scan tool indicate OTC P1114 failed?

6-1004

Engine Controls - 3.8L

Engine

DTC P1115 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent High Voltage
~

- - - -

I
I

ECT

S~nsor

L -

~(l~f -

~-

- - - - - - - - - - - - - - - - - - -

lcI =PCM

1 BLU .

_ _ ... _ _ _ ...;.. _

Powertrain

I Control

ECT.

C2 = CLEAR I

26IC2

Sensor
-

YEL 410

- ~O~d- -

1 Module (PCM}

J.

.I~

L1iJ

12 'C1 .

f-,

Engine r
1
1
Coolant
~c

Temperature I
I
DK
(ECT) ~ensor, LA-:::: .,
GAN 135

A17
BRN 718

r 1
L

J.

, Instrument
1Cluster
~

..I

221815

Circuit Description
The Engine Coolant Temperature (ECT) sensor is a ,
thermistor mounted in the engine coolant stream. The
PCM applies a voltage (about 5.0 volts) through a
pull up resistor to the ECT signal circuit. When
the engine coolant is cold, the sensor (thermistor)
resistance is high, therefore the PCM will measure a
high signal voltage. As the engine coolant warms,
the sensor resistance becomes less, and the
ECT signal voltage measured at the PCM drops. With
a fully warmed up engine, the ECT signal voltage
should measure about 1.5 to 2.0 volts. If the PCM
detects an ECT signal that is intermittently above the
range of the ECT sensor, OTC P1115 will set.

Conditions for Setting the DTC

The engine has been running longer
than 15 seconds.
The ECT sensor intermittently indicates an engine
coolant temperature less than -34C (-29F).
The condition is present for longer than 5 seconds.

Action Taken When the DTC Sets

The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM will store conditions which were present
when the OTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

Conditions for Clearing the MIUDTC

A history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
OTC can be cleared by using the scan tool Clear
Information function or by disconnecting the
PCM battery feed.

Diagnostic Aids
Check for. the following conditions:
Poor connection at PCM - Inspect harness
connectors for the following items:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connections
Damaged harness
Inspect the wiring harness for damage.
If the harness appears to be OK, observe the
ECT display on the scan tool while moving
connectors and wiring harnesses related to the
ECT sensor. A change in the ECT display
will indicate the location of the fault.
Skewed or mis-scaled ECT Sensor.
Refer to Temperature vs Resistance table.
Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the OTC to be
set occurs. This may assist in diagnosing the condition.

Engine

Engine Controls 3.SL 6-1005

OTC P1115 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent High Voltage
Step

Action

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Value{s)

'
2

1. Check for a poor sensor ground circuit terminal

connection at the ECT sensor.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to
DTCP0118
Engine Coolant
Temperature
(ECT) Sensor
Circuit High
Voltage

Go to Step 3

Go to Step 9

Go to Step 4

Go to Step 9

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 9

Go to Step 7

Go to Step 9

Go to Step 8

Go to Step 9

Goto
Diagnostic Aids

Go to Step 2

System OK

'
Select DTC info, Last Tst Fail and note any other
DTCs set.
Is DTC P0118 also set?

Yes

Was a problem found?

.

1. Check for a poor ECT signal circuit terminai

connection at the ECT sensor.
2. If a problem is found, repair as necessary. Refer to
Wiring f!eP.airs,
Was a problem found?

1. Check the ECT signal circuit between the ECT

sensor connector and the PCM for an
intermittent open.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Check the ECT signal circuit between the.ECT

sensor connector and .the PCM for an intermittent
short to volt~ge.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.

Was a problem found?

1. Check for a poor sensor ground circuit terminal

connection at the PCM.
2. If a problem is found, n~pair as necessary. Refer to
Wiring Repairs.

Was a problem found?

1. Check for an irttermittent open in the sensor ground

circciit.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
,,-,
Was a problem found?
..
:,
1. Review and record sear, tool.Fail Records data.
2. Clear DTCs.
3. Operate vehicle within Fail Records conditions
as noted.
4. Using a scan tool, monitor Specific DTC info for
DTC P1115.
Does scan tool indicate DTC P1115 failed?

6-1006

Engine Controls - 3.SL

Engine

OTC P1121 Throttle Position (TP) Sensor Circuit Intermittent High Voltage

sv -

I
1

- - -

~ Powertrain

1 Control

1Module

Volt
.
5
Reference A

>

L------3~C2----J
Fuel Tank
Pressure
Sensor

MAP Sensor

C,

81

DK BLU 417
66 C2
r

L'..t!J

GRY
GAY 598
GRY
~-5-9_8____G_R_Y___5_9_8_ ___::59:.:..8;..:..:...._ _.~

I1~---i I~; :~
I
I
I

(PCM)

TP
Sensor
Signal

[TP)

AI

BLK 452
61 C1
TP
Sensor
Ground

Powertrain
I Control
I I M d I (PCM)
lc2=CLEARI
o ue
I
-

- PCM
IC1 = BLU
I

.,

L-------~-------------J

>

~
221819

Circuit Description
The Throttle Position (TP) sensor circuit provides a
voltage signal that changes relative to throttle
blade angle. The signal voltage will vary from 1 volt at
closed throttle to 4 volts at Wide Open Throttle
(WOT). The TP signal is one of th~ most important
inputs used by the PCM for fuel control and most
of the PCM-controlled outputs. If the PCM detects a
TP signal voltage that is intermittently greater than the
range of the TP sensor, DTC P1121 will be set.

Conditions for Setting the DTC

The ignition is ON.
TP sensor intermittently indicates a throttle
position signal greater than 4.8 volts.
The condition is present for longer than 5 seconds.

Action Taken When the DTC Sets

The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM will store conditions which were present
when the DTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

Conditions for Clearing the MIUDTC

A history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
OTC can be cleared by using the scan tool Clear
Information function or by disconnecting the
PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at PCM - Inspect harness
connectors for the following items:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connections
Damaged harness. Inspect the wiring harness for
damage.
If the harness appears to be OK, observe the
throttle position display on the scan tool while
moving connectors and wiring harnesses related
to the TP sensor. A change in the display will
indicate the location of the fault.
If DTC P1121 cannot be duplicated, reviewing the Fail
Records vehicle mileage since the diagnostic test
last failed may help determine how often the condition
that caused the DTC to be set occurs. This may
assist in diagnosing the condition.

Engine

Engine Controls - 3J3L

6-1007

DTC P1121 Throttle Position (TP) Sensor .Circuit Intermittent High Voltage
Action

Step

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Select DTC info, Last Tst Fail and note any other
DTCs set.
Is DTC P0123 also set?

Is DTC P1106 also set?

Check for a poor sensor ground circuit terminal connection

at the TP sensor. Was a problem found?

Check the TP signal circuit between the TP sensor

connector and the PCM for an intermittent short to voltage.
Was a problem fond?

Go to
DTCP0123
Throttle Position
(TP) Sensor
Circuit High
Voltage

Go to Step 3

Go to Step 6

Go to Step 4

Go to Step 9

Go to Step 5

Go to Step 10

Go to Step 8

Go to Step 10

Go to Step 7

Go to Step 9

Go to Step 8

Go to $tep 10

Go to
Diagnostic Aids

Check for an intermittent short to voltage on the 5 volt

reference A circuit between the PCM and the following
components:
6

. MAP sensor
Fuel Tank Pressure Sensor
TP sensor

Was a problem found?

Check for a. poor sensor ground terminal connection at the
PCM. Refer to Troubleshooting Procedures.
Was a problem found?

Check for an intermittent open in the sensor ground circuit.

Was a problem found?

Replace the faulty harness connector terminal for sensor

ground circuit. Refer to Wiring Repairs.
Is action complete?

10

Repair intermittent open/short circuitin wiring harness as

necessary. Refer to Wiring Repairs.
Is action complete?

11

1. Review and record scan tool Fail Records data.

2. Clear DTCs.
3. Operate vehicle within Fail Re.cords conditions
as noted.
4. Using a scan tool, monitor Specific DTC info for
DTC P1121.
Does scan tool. indicate DTC P1121 failed?

Goto Step 11

Go to Step 11

Go to Step 2

System OK

6-1008

Engine, Controls - 3.SL

Engine

DTC P1122 Throttle Position (TP) Sensor Circuit Intermittent Low Voltage

~ Powertrain

.,..sv

I
1

1Control

Volt
5
Reference A .

.. - - - - - - 33 -C2 - - - -

Fuel Tank
Pressure
Sensor

Module (PCM)

.1

GRY
GRY 598
GRY
.,__5_9_8____G_R_Y__.5_9_8_--=5=-98.:....:...__ _
~

11~-..---rn;~:;
1

L}iJ

MAP Sensor

c'

8
DK BLU 417
661 C2

I
I
I

TP
Sensor
Signal

[IP)

BL~r452
61 C1
TP Sensor
Ground

- ., Powertrain
I
PCM
I I Control ,
IC1=BLU I IM d I (PCM)
lc2=CLEARI
o u e
~

L-------~-------------~

~
221819

Circuit Description
The Throttle Position (TP) sensor circuit provides a
voltage signal that changes relative to throttle
blade angle. The signal voltage will vary from 1 volt at
closed throttle to 4 volts at Wide Open Throttle
(WOT). The TP signal is one of the most important
inputs used by the PCM for fuel control and most
of the PCM-controlled outputs. If the PCM detects a
TP signal voltage that is intermittently less than
the range of the TP sensor, DTC P1122 will be set.

Conditions for Setting the DTC

The ignition is ON.
TP sensor intermittently indicates a throttle
position signal less than 0.1 volt.
The condition is present for longer than 5 seconds.

Action Taken When the DTC Sets

The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM will store conditions which were present
when the DTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

Conditions for Clearing the MIL/DTC

A history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
DTC can be cleared by using the scan tool Clear
Information function or by disconnecting the
PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at PCM - Inspect harness
connectors for the following items:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connections
Damaged harness. Inspect the wiring harness for
damage.
If the harness appears to be OK, observe the
throttle position display on the scan tool while
moving connectors and wiring harnesses related
to the TP sensor. A change in the display will
indicate the location of the fault.
If DTC P1122 cannot be duplicated, reviewing the Fail
Records vehicle mileage since the diagnostic test
last failed may help determine how often the condition
that caused the DTC to be set occurs. This may
assist in diagnosing the condition.

Engine

Engine Controls - 3.8L

6-1009

OTC P1122 Throttle Position {TP) Sensor Circuit Intermittent Low Voltage
Action

Step

Value{s}

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to
OTC P0122
Throttle Position
(TP) Sensor
Circuit Low
Voltage

Go to Step 3

Go to Step 6

Go to Step 4

Go to Step 9

Go to Step 5

Go to Step 10

Go to Step B

Go to Step 10

Go to Step 7

Go to Step 9

Go to Step B

Go to Step 10

Go to
Diagnostic Aids

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Important: If OTC P1635 is also set refer to that

code first.
Select OTC info, Last Tst Fail and note any other DTCs
set. Is OTC P0122 also set?

Is OTC P1107 also set?

Check for a poor 5 volt reference A circuit or TP signal

circuit terminal connection at the TP sensor.
Was a problem found?

Check the TP signal circuit between the TP sensor

connector and the PCM for an intermittent open or short to
ground.
Was a problem found?

Check for an intermittent short to ground on the 5 volt

reference A circuit between the PCM and the following
components:
6

The MAP sensor

The Fuel Tank Pressure Sensor
The TP sensor
Was a problem found?

Check for a poor 5 volt reference A circuit terminal

connection at the PCM.
Was a problem found?

Check for an intermittent open or a faulty splice in the

5 volt reference A circuit. Refer to Wiring Repairs.
Was a problem found?

Replace the faulty harness connector terminal(s) for the

5 volt reference A circuit and/or the TP signal circuit as
necessary. Refer to Wiring Repairs.
Is the action complete?

10

Repair intermittent open/short circuit in wiring harness as

necessary. Refer to Wiring Repairs.

Go to Step 11

11

Does the scan tool indicate OTC P1122 failed?

)
/

Go to Step 11

Is action complete?
1. Review and record scan tool Fail Records data.
2. Clear DTCs.
3. Operate the vehicle within Fail Records conditions
as noted.
4. Using a scan tool, monitor Specific OTC info for
OTC P1122.

Go to Step 2

System OK

6-1010

Engine

EhgineControls - a.al

DTC P1133 H02S tnsufficient:~witching Bank 1 Sensor 1

fQ

dJ

!Hot In Run, Bulb Test And Slart!

Underhood
I Electrical
ENG SEN
MiniFuse I Center 2
20 A
' . I. .

r - Power

]
Distribution
Cell 10

I
I
I ..

Fuse Block
Details

Cell11

J7
J6

L------ ----J
.----, ..... PNK 539
'

, ..... PNK 539

-----------------------,
r -

I
I

Bar,k 1 '.,

H02S 1
Signal

PNK 5~9- -

PCM. .

c1=BLU
H02S 1
Low

C2 = CLEAR

12[C2 --271-C1 - - - - -

PPL/WHT 1665

Powertrain

I Control
!Module
I (PCM)

'

...

t
Heated Oxygen
Sensor (H02S)
Bank 2 Sensor 1

TAN/WHT 1653

B,...

I
I
I

H~led 01<ygen

Sensor (H02S)

,.

Bank 1 Sens~r, 3

Heated Oxygen
Sensor Bank 1
Sensor1

cy
I

L---------~--~-~~-------J
I

221847

Circuit Description
The PCM monitors the Heated Oxygen Sensor
(H02S) activity. The PCM counts the number of times
that the H02S signal voltage crosses the rich to
lean and lean to rich thresholds during a 100 second
test period. If the PCM .determines that the H02S
did not switch enough times, DTC P1133 will be set: A
lean to rich switch is determined when the H02S
voltage changes from less than 300 mV to greater
than 600 mV. A rich to lean switch is determined when
the H02S voltage changes from more than 600 mV
to less than 300 mV.

Conditions for Setting the OTC

No TP sensor, EVAP system, misfire, IAT sensor,
MAP sensor, Fuel Trim, Fuel Injector, EGR
Pintle, ECT sensor, CKP sensor, or MAF sens6r
DTCs are sElt. .
The engine has been running at least 1 minute.
Engine speed is between 1000 RPM and
3000 RPM.
Mass Air Flow: is between 15 gm/s and 30 gm/s.
- Manual Transaxle - MAF is between
10 and 30 g/s.
- Automatic Transaxle - MAF is between
15 and 29 g/s.
Engine Temperature is greater than 50C (122F).
The conditions are present for a 100 second
test period.

Bank 1 H02S 1 Switches:

- Manual Transaxle - The PCM monitors fewer
. than 40 lean to rich and rich to lean switches
for Bank 1 H02S t.
- Automatic Transaxle - The PCM monitors
fewer than 45 lean to rich and 40 rich to
lean switches for Bank 1 Hd2S 1.

Action Taken When

the OTC Sets
'
,

The PCM will illuminate the MIL during the second

key cycle in which the DTC sets.
Open Loop fuel control will be in effect.
The PCM will store conditions Which were present
when the DTC set as Freeze Frame and Fail
Records data.
i

Conditions for Clearing the MIL/OTC

The PCM will turn the MIL OFF on the third
consecutive trip cycle during which the diagnostic
has been run and the fault condition is no
longer present.
A history DTC P1133 will clear after
40 consecutive warm-up cycles have occurred
without a fault.
DTC P1133 can be cleared by using the scan tool
Clear Information function or by disconnecting the
PCM battery feed.

Engine

Engin~ Controls - 3.8L 6-1Q11

Diagnostic Aids

Test Description

A malfunction in the H02S heater ignition feed or

ground circuit may cause a OTC P1133 to set. Check
H02S heater circuitry for intermittent faults or poor
connections. If connections and wiring are OK
and OTC P1133 continues to set, replace the Bank 1
H02S 1. Review the Fail Records vehicle mileage
since the diagnostic test last failed. This may
help determine how often the condition that caused
the OTC to be set occurs.

Number(s) below refer to the step number(s) on the

Diagnostic Table:
3. A condition that affects other heated oxygen
sensors indicates probable contamination.
To avoid damaging replacement sensors, correct
the condition which caused the contamination
'
before replacing the affected sensors.
5. This step checks for conditions which may cause
the heated oxygen sensor to appear faulty.
Correct any of the described conditions if present.
8. To avoid damaging replacement sensors, correct
the condition which caused the contamination
before replacing the affected .sensors.

OTC P1133 H02S Insufficient Switching Bank 1 Sensor 1

Step

Action

Value(s)

Yes

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Go to Step 2

No

Go to the A
Powertrain On
Board' Diagnostic
(080) System
,.
Check

Important: If any DTC.s are set (except P1153, P1154,

P1155, and/or P1156), refer to those DTCs before
proceeding with this diagnostic chart.

1. Engine idling at operating temperature.

2. Operate vehicle within parameters specified under
Conditions for Setting the DTC criteria included in
Diagnostic Support.
3. Using a scan tool, monitor Specific DTC info for
DTC P1133 until the DTC P1133 test runs.
Does scan tool in.dicate DTC failed this ignition?

Did scan tool also indicate P1153, P1154, P1155, and/or

P1156 test failed?

1. Perform the Exhaust System Leak Test. Refer to

Exhaust Leakage. After Exhaust System Leak Test
has been performed, return to this diagnostic.
2. If an exhaust leak is found, repair as necessary.
Was an exhaust leak isolated?

Visually/physically inspect the following items:

Ensure that the Bank 1 H02S 1 is securely installed.
Check for corrosion on terminals.
Check terminal tension (at Bank 1 H02S 1 and at
the PCM).
Check for damaged wiring.
Was a problem found in any of the above areas?

'

1. Disconnect Bank 1 H02S 1 and jumper H02S low

(PCM side) signal circuit to ground.
2. Using a scan tool, monitor Bank 1 H02S 1 voltage
Does the scan tool indicate voltage near the
specified value?

450mV

1. Jumper Bank 1 H02S 1 high and low (PCM side)

signal circuits to ground.
2. Using a scan tool, monitor Bank 1 H02S 1 voltage.
Does scan tool indicate voltage below specified value?

300mV

Go to Step 3

Go to
Diagnostic Aids

Go to Step 8

Go to Step 4

Go to Step 2

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 7

Go to Step 10

Go to Step 12

Go to Step 11

'

6-1012

Engine

Engine Controls - 3.SL

OTC P1133 H02S Insufficient Switching Bank 1 Sensor 1 (cont'd)

Step

Action

Replace affected Heated Oxygen Sensors. Refer to H02S

Replacement.
Important: Before you replace Heated Oxygen Sensors,
the cause of the contamination must be determined and
corrected.
Fuel contamination
Use of improper RTV sealant
Engine oil/coolant consumption
Is the action complete?

Value(s)

Repair condition as necessary.

Is the action complete?

10

Repair an open Bank 1 H02S 1 low signal circuit or.~

grounded Bank 1 H02S 1 high signal circuit. Refer to
H02S Replacement.
Is the action complete?

11

Repair an open Bank 1 H02S 1 high signal circuit or faulty

PCM connections. Refer to H02S Replacement.
Is the action complete?

12

Replace Bank 1 H02S 1. Refer to H02S Replacement.

Is the action complete?

13

1. Clear DTCs.
2. Engine idling at operating temperature
3. Operate vehicle within parameters specified under
Conditions for Setting the OTC criteria included in
Diagnostic Support.
4. Using a scan tool, monitor Specific OTC info for
OTC P1133 until the OTC P1133 test runs.
Does scan tool indicate OTC failed this ignition?

Yes

No

(
-

Go to Step 13
Go to Step 13

Go to Step 13

Go to Step 13

Go to Step 13

(
Go to Step2

System OK

Engine Controls - 3.8L

Engine

6-1013

DTC P1134 H02S Transition Time Ratio Sensor 1

\

-i:-:----,

!Hot In Run, Bulb Test And Start!

!

r -

P-;;we-;

Distribution
cen 10

J7.
.
J6

Underhood
Electrical
I Center 2

ENG SEN
MlniFuse
20 A

L.2w

I
1.-----____ ..I
Fuse Bock
Details
Ce1M1

PNK 539

+---,

' , .. PNK 539

....

'

'

-----------------------,
r -

Bank 1

H02S 1
Signal

PNK 5~9- -

PCM
c1=BLU
C2 = CLEAR

.1

H02S 1
Low

Powertrain

I Control

I Module
I (PCM)

PPL/WHT 1665

TAN/WHT 1653

DA

121C2 - -271-C1 - - - - - ., ~
Jt.

BA

A
Heated Oxygen
Sensor Bank 1
Sensor1

Heated Oxygen
Sensor (H02S)
Bank2Sensor1
Heated Oxygen
Sensor (H02S)
Bank 1 Sensor 3

cy
I

L-----------------------~
221847

, Circuit Description

Mass Air Flow: is between 15 gm/s and 30 gm/s.

- Manual Transaxle - MAF is between
1O and 30 g/s.
- Automatic Transaxle - MAF is between
15 and 29 g/s.
Engine Temperature is greater than 50C (122F).
The conditions are present for a 100 second
test period.
Bank 1 H02S 1 Transition Time:
- Manual. Transaxle - Bank 1 H02S 1 transition
time ratio is less and 0.5 and greater
than 3.25.
- Automatic Transaxle - Bank 1 H02S 1
transition time ratio is less than 0.4 and
greater than 4.

The PCM continuously monitors the Heated Oxygen

Sensor (H02S) activity. The PCM counts the
number of times that the H02S responds from rich to
lean and from lean to rich and adds the amount of
time it took to complete all transitions during
the 100 second test period. With this information, an
average time for all transitions can be determined. The
PCM then divides the rich to lean average by the
lean to rich average to obtain a ratio. If the H02S .
transition time ratio is not within range, DTC P1134 will
be set, indicating that the oxygen sensor is not
responding as expected to changes in exhaust oxygen
content.

Conditions for Setting the OTC

No TP sensor, EVAP system, misfire, IAT sensor,
MAP sensor, Fuel Trim, Fuel Injector, EGR
Pintle, ECT sensor, CKP sensor, or MAF sensor
DTCs are set.
The engine has been running at least 1 minute.
Engine speed is between 1000 RPM and
3000 RPM.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second

key cycle in which the OTC sets.
Open Loop fuel control will be in effect.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

6-1014

Engine

Engine Controls - 3.SL

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF on the third
consecutive trip cycle during which the diagnostic
has been run and the fault condition is no
longer present.
A history DTC P1134 will clear after
40 consecutive warm-up cycles have
occurred without a fault.
DTC P1134 can be cleared by using the scan tool
Clear Information function or by disconnecting the
PCM battery feed.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table:

Diagnostic Aids
A malfunction in the H02S heater ignition feed or
ground circuit may cause a DTC P1134 to set. Check
H02S heater circuitry for intermittent faults or poor
connections. If connections and wiring are OK
and DTC P1134 continues to set, replace the bank 1
H02S 1. Review the Fail Records vehicle mileage
since the diagnostic test last failed. This may
help determine how often the condition that caused
the DTC to be set occurs.

3. A condition that affects other heated oxygen

sensors indicates probable contamination.
To avoid damaging replacement sensors, correct
the condition which caused the contamination
before replacing the affected sensors.

5. This step checks for conditions which may cause

the heated oxygen sensor to appear faulty.
Correct any of the described conditions if present.
8. To avoid damaging replacement sensors, correct
the condition which caused the contamination
before replacing the affected sensors.

OTC P1134 H02S Transition Time Ratio Sensor 1

Step

Action
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?

Value(s)

Did scan tool also indicate P1153, P1154, P1155, and/or

P1156 test failed?

1. Perform Exhaust System Leak Test. Refer to Exhaust

Leakage. After you perforr:n the Exhaust System Leak
Test, return to this diagnostic.
2. If an exhaust leak is found, repair as necessary.
Was an exhaust leak isolated?

Visually/physically inspect the following items:

Ensure that the Bank 1 H02S 1 is securely installed.
Check for corrosion on terminals.
Check terminal tension (at Bank 1 H02S 1 and at
the PCM).
Check for damaged wiring.
Was a problem found in any of the above areas?

Does the scan tool indicate voltage near the

specified value?

Go to Step 2

1. Disconnect Bank 1 H02S 1 and jumper H02S low

(PCM side) signal circuit to ground.
2. Using a scan tool, monitor Bank 1 H02S 1 voltage.

No
Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Important: If any DTCs are set (except P1153, P1154,

P1155, and/or P1156), refer to those DTCs before
proceeding with this diagnostic chart.
1. Engine idling at operating temperature
2. Operate vehicle within parameters specified under
Conditions for Setting the OTC criteria included in
Diagnostic Support.
3. Using a scan tool, monitor Specific OTC info for
OTC P1134 until the OTC P1134 test runs.
Does scan tool indicate OTC failed this ignition?

Yes

Go to Step 3

Go to
Diagnostic Aids

Go to Step B

Go to Step 4

Go to Step2

Go to Step 5

Go to Step 9

Go to Step 6

(
450mV
Go to Step 7

Go to Step 10

Engine

Engine Controls - 3.8L

6-1015

DTC P1134 H02S Transition Time Ratio Sensor 1 (c(')nfd)

Step

Action

Value(s)

1. Jumper Bank 1 H02S 1 high and low (PCM side)

signal circuits to ground.
2. Using a scan tool, monitor Bank 1 H02S 1 voltage.
Does scan tool indicate voltage below specified value?

Replace affected Heated Oxygen Sensors. Refer to H02S

Replacement.
Important: Before replacing sensors, the cause of the
contamination must be determined and corrected.
Fuel contamination
Use of improper RTV sealant.
Engine oil/coolant consumption
Is the action complete?

Repair condition as necessary.

Is the action complete?

10

Repair an open Bank 1 H02S 1 low signal circuit or a

grounded Bank 1 H02S.,1 high signal circuit. Refer to
H02S Replacement
Is the action complete?

Repair open Bank 1 H02S 1 high signal circuit or faulty

PCM connections. Refer to H02S Replacement.
Is the action complete?

12

Replace Bank 1 H02S 1. Refer to HO~S Replacement.

Is the action complete?

13

1. Clear DTCs
2. Engine idling at operating temperature
3. Operate vehicle within parameters specified under
Conditions for Setting the OTC criteria included in
Diagnostic Support.
4. Using a scan tool, monitor Specific OTC info for
OTC P11.34 until the OTC P1134 test runs.
Does scan tool indicate OTC failed tt'lis ignition?

)
'

No-

Go to Step 12

Go to Step 11

300mV

Go to Step 13

'

11

Yes

><

Go to Step 13

Go to Step 13

Go to Step 13
Go to Step 13

'
,,,

Go to Step 2

System OK

6-1016

Engine

Engine Controls - ~.SL

OTC P1153 H02S Insufficient Switching Bank,2 Sensor 1

-i----,-,

!Hot In Run, Bulb Test And Start!

.-1 - P;,;

--

Distribution

Cell 10

J7-

JS

L. -

Fuse Block

'
...- -

Details

...... -

...,:_,

ENG. SEN

MiniFuse
20A
~ - .- -

Underhood
I
Electric_al
I Center 2
I

J.

PNK 539
-

1
Cell 1

'

'

'

PNK 539
.....

r-----------------------'-
Powertrain .- - - - - - - - - - - - - - - - - - ,
Control I
PCM
Bank 2
I
C1 = BLU
I
MO d UIe II
C2 = CLEAR
H02S 1
H02S 1
I
I
(PCM)
Low
Signal

...

...

L -

Heated Oxygen
Sensor (H02SO
Bank 1 Sensor 1

29- C1 - -10 -C2 -

TANI1667
A

PPLI1666
B _

.I

PNK 539
D

Heated Oxygen
Sensor (H02SO
Bank 1 Sensor 3

Heated Oxygen
Sensor Bank 2
Sensor 1

T
I
I

I
I

'. -

1~

- -.

~~~_:_, ~-_-_-_--------~ ---Gr-ou-nd-Distribution

'-=Ce"'-111.:.;:.4_ _.

(
226749

Circuit Description
The PCM monitors the Heated Oxygen Sensor
(H02S) activity. The PCM counts the number of times
that the H02S signal voltage crosses the rich to
lean and lean to rich thresholds for a 100 second test
period. If the PCM determines that the H02S did
not switch enough times, OTC P1153 will be set. A
lean to rich switch is determined when the H02S
voltage changes from less than 300 mV to greater
than 600 mV. A rich to lean switch is determined when
the H02S voltage changes from more than 600 mV
to less than 300mV.

Conditions for Setting the DTC

No TP sensor, EVAP system, misfire, IAT sensor,
MAP sensor, Fuel Trim, Fuel Injector, EGR
Pintle, ECT sensor, CKP sensor, or MAF sensor
OTCs are set.
The engine has been running at least 1 minute.
Engine speed is between 1000 RPM and
3000 RPM.
Mass Air Flow: is between 15 gm/s and 30 gm/s.
- Manual Transaxle - MAF is between
10 and 30 g/s.
- Automatic Transaxle - MAF is between
15 and 29 g/s.
Engine Temperature is greater than 50C (122F).
The conditions are present for a 100 second
test period.

Bank 2 H02S 1 Switches:

- Manual Transaxle - The PCM monitors fewer
than 40 lean to rich and_ rich to lean switches
for Bank 2 H02S 1.
- Automatic Transaxle - The PCM monitors
fewer than 45 lean to rich and 40 rich to
lean switches for Bank 2 H02S 1.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
key cycle in which the OTC sets.
Open Loop fuel control will be in effect.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF on the third
consecutive trip cycle during which the diagnostic
has been run and the fault condition is no
longer present.
A history OTC P1153 will clear after
40 consecutive warm-up cycles have
occurred without a fault
OTC P1153 can be cleared by using the scan tool
Clear Information function or by disconnecting the
PCM battery feed.

Engine

Engine Controls - 3.8L

6-1017

Diagnostic Aids

Test Description

A malfunction in the H02S heater ignition feed or

ground circuit may cause a DTC P1153 to set. Check
H02S heater circuitry for intermittent faults or poor
connections. If connections and wiring are OK
and OTC P1153 continues to set, replace the Bank 2
H02S 1. Review the Fail Records vehicle mileage
since the diagnostic test last failed. This may
help determine how often the condition that caused
the OTC to be set occurs.

Number(s) below refer to the step number(s) on the

Diagnostic Table:
3. A condition that affects other heated oxygen
sensors indicates probable contamination.
To avoid damaging replacement sensors, correct
the condition which caused the contamination
before replacing the affected sensors.
5. This step checks for conditions which may cause
the heated oxygen sensor to appear faulty.
Correct any of the described conditions if present.
8. To avoid damaging replacement sensors, correct
the condition which caused the contamination
before replacing the affected sensors.

6-1018

Engine

Engine Controls 3.8L

DTC P1153 H02S Insufficient Switching Bank 2 Sensor 1
Action

Step

Was the Powertrain On-Board Diagnostic (OBD) System

C.heck
performed?
'
; ' .
1

,.

lmp9i;-tant: If 1my other DTCs are set, refer to those DTCs

before proceeding with this diagnostic chart.
1. Install scan' tool.
2. Engine idling at operating temper~iture
3. Operate. vehicle within parameters specified under
Conditions for Setting the OTC criteria included in
Diagnostic- Support.
4. Using a scan tool, monit<i>r Specific OTC info for
OTC P1153 until the OTC P1153 test runs.
Does scan tool indicate OTC failed this ignition

1. Perform Exhaust System Leak Test. Refer to Exhaust

Leakage. After Exhaust System Leak Test has been
performed, return to this diagnostic.
2. If an exhaust leak is found, repair as necessary.
Was an exhaust leak isolated?
Visually/physically inspect the following items:
Ensure that the Bank 2 H02S 1 is securely installed.
Check for corrosion on terminals.
Check terminal tension (at Bank 2 H02S 1 and at
the PCM).
Check for damaged wiring.
Was a problem found in any of the above areas?

Go to Step 2

No
Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to
Diagnostic Aids

Go to Step 11

Go to Step 4

Go to Step 7

Go to Step 5

1. Disconnect Bank 2 H02S 1 and jumper H02S low

(PCM side) signal circuit to ground.
2. Using a scan tool, monitor Bank 2 H02S 1 voltage
Does the scan tool indicate voltage near the
specified value?

450mV

1. Jumper Bank 2 H02S 1 high and low (PCM side)

signal circuits to ground.
2. Using a scan tool, monitor Bank 2 H02S 1 voltage.
Does scan tool indicate voltage below specified value?

200mV

Repair condition as necessary.

Is the action complete?
Repair an open Bank 2 H02S 1 low signal circuit or a
grounded Bank 2 H02S 1 high signal circuit. Refer to
H02S Replacement.
Is the action complete?
Repair an open Bank 2 H02S 1 high signal circuit or faulty
PCM connections. Refer to H02S Replacement.
Is the action complete?

Ye$

Value(s)
,

Go to Step 6

Go to Step B

Go to Step 10

Go to Step 9

Go to Step 11

Go to Step 11

Go to Step 11

10

Replace Bank 2 H02S 1. Refer to H02S Replacement

Is the action complete?

11

1. Clear DTCs
2. Engine idling at operating temperature.
3. Operate vehicle within parameters specified under
Conditions for Setting the OTC criteria included in
Diagnostic Support.
4. Using a scan tool, monitor Specific OTC info for
OTC P1153 until the OTC P1153 te
Does scan tool indicate OTC failed this ignition?

Go to Step 11

Go to Step 2

System OK

Engine

Engine Controls - 3.SL

6-1019

OTC P1154 H02S Transition Time Ratio Bank 2 Sensor 1

!Hot In Run, Bulb Test And Start!
~I'"-P;,er
Distribution
J7
ENG SEN
I
ce1110
MinlFuse
I
J6
20 A

L------

Fuse Block
Details
Cell11

Underhood
I Electrical
I Center 2
I

----..1

PNK 539

...--- '

' , PNK 539

......

r-------------------------Powertrain
Control
MOd UIe
(PCM)

Low

101 C2

C1
TAN 1667
A

Sensor (H02SO
Bank 1 Sensor 1

Signal

L-----------------~

291

Heated Oxygen

'" - - - - - - - - - - - - - - - - - ,
I
PCM
Bank 2
I
C1=BLU
I
I
I
C2=CLEAR
H02S 1
H02S 1
I

PPL 1666

PNK 539

Heated Oxygen
Sensor (H02SO
Bank 1 Sensor 3

Heated Oxygen
Sensor Bank 2
Sensor 1

T
I

I
I

'. -

1~

_ _,

: ~ :~_:_, '-_- - - - - - - - - - - - - ~ _...Gr-ou-nd-Distribution

Cell14

226749

Circuit Description
The PCM continuously monitors the Heated Oxygen
Sensor (H02S) activity, The PCM counts the
number of times that the H02S responds from rich to
lean and from lean to rich and adds the amount of
time it took to complete all transitions for a 100 second
test period. With this information, an average time
for all transitions can be determined. The PCM then
divides the rich to lean average by the lean to rich
average to obtain a ratio. If the H02S transition time
ratio is not within range, DTC P1154 will be set
indicating that the oxygen sensor is not responding as
expected to changes in exhaust oxygen content

Conditions for Setting the DTC

No TP sensor, EVAP system, misfire, IAT sensor,
MAP sensor, Fuel Trim, Fuel Injector, EGR
Pintle, ECT sensor, CKP sensor, or MAF sensor
DTCs are set
The engine has been running at least 1 minute.
Engine speed is between 1000 RPM and
3000 RPM.
Mass Air Flow: is between 15 gm/s and 30 gm/s.
- Manual Transaxle - MAF is between
10 and 30 g/s.
- Automatic Transaxle - MAF is between
15 and 29 g/s.
Engine Temperature is greater than 50C (122F).

The conditions are present for a 100 second test

period.
Bank 2 H02S 1 Transition Time:
- Manual Transaxle - Bank 2 H02S 1 transition
time ratio is less and 0.5 and greater
than 3.25.
- Automatic Transaxle - Bank 2 H02S 1
transition time ratio is less than OA and
greater than 4.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
key cycle in which the DTC sets.
Open Loop fuel control will be in effect
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIL/DTC

The PCM will turn the MIL OFF on the third
consecutive trip cycle during which the diagnostic
has been run and the fault condition is no
longer present
A history DTC P1154 will clear after
40 consecutive warm-up cycles have
occurred without a fault
DTC P1154 can be cleared by using the scan tool
Clear Information function or by disconnecting the
PCM battery feed.

6-1020

Engine Controls - 3.SL

Engine

Diagnostic Aids

Test Description

A malfunction in the H02S heater ignition feed or

ground circuit may cause a DTC P1154 to set. Check
H02S heater circuitry for intermittent faults or poor
connections. If connections and wiring are OK
and DTC P1154 continues to set, replace the Bank 2
H02S 1. Review the Fail Records vehicle mileage
since the diagnostic test last failed. This may
help determine how often the condition that caused
the DTC to be set occurs.

Number(s) below refer to the step number(s) on the

Diagnostic Table:
3. A condition that affects other heated oxygen
sensors indicates probable contamination.
To avoid damaging replacement sensors, correct
the condition which caused the contamination
before replacing the affected sensors.
5. This step checks for conditions which may cause
the heated oxygen sensor to appear faulty.
Correct any of the described conditions if present.
8. In order to avoid damaging replacement sensors,
correct the condition which caused the
contamination before replacing the affected
sensors.

Engine

Engine Controls - 3~8L

6-1021

DTC P1154 H02S Transition Time Ratio Bank 2 Sensor 1

Step

Action

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

9
10

11

Important: If any other DTCs are set, refer to those DTCs

before proceeding with this diagnostic chart.
1. Install scan tool
2. Engine idling at operating temperature
3. Operate vehicle within parameters specified under
Conditions for Setting the DTC criteria included in
Diagnostic Support.
4. Using a scan tool, monitor Specific DTC info for
DTC P1154 until the DTC P1154 test runs
Does scan tool indicate DTC failed this ignition?

1. Perform Exhaust System Leak Test. Refer to Exhaust

Leakage. After Exhaust System Leak Test has been
performed, return to this diagnostic.
2. If an exhaust leak is found, repair as necessary
Was an exhaust leak isolated?
Visually/physically inspect the following items:
Ensure that the Bank 2 H02S 1 is securely installed.
Check for corrosion on terminals.
Check terminal tension (at Bank 2 H02S 1 and at
the PCM).
Check for damaged wiring.
Was a problem found, in any of the above areas?
1. Disconnect Bank 2 H02S 1 and jumper H02S low
(PCM side) signal circuit to ground.
2. Using a scantool, monitor Bank 2 H02S 1 voltage.
Does the scan tool indicate voltage near the
specified value?
1. Jumper Bank 2 H02S 1 high and low (PCM side)
signal circuits to ground.
2. Using a scan tool, monitor Bank 2 H02S 1 voltage
Does the scan tool indicate voltage below specified value?
Repair condition as necessary.
Is the action complete?
Repair an open Bank 2 H02S 1 low signal circuit or a
grounded Bank 2 H02S 1 high signal circuit. Refer to
H02S Replacement.
Is the action complete?
Repair open Bank 2 H02S 1 high signal circuit or faulty
PCM connections. Refer to H02S Replacement.
Is the action complete?
Replace Bank 2 H02S 1. Refer to H02S Replacement.
Is the action complete?
1. Clear DTCs
2. Engine idling at operating temperature.
3. Operate vehicle within parameters specified under
Conditions for Setting the DTC criteria included in
Diagnostic Support.
4. Using a scan tool, monitor Specific DTC info for
DTC P1154 until the DTC P1154 test runs
Does scan tool indicate DTC failed this ignition?

Value(s)

Yes

Go to Step 2

No
Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to
Diagnostic Aids

Go to Step 11

Go to Step 4

Go to Step 7

Go to Step 5

Go to Step 6

Go to Step 8

Go to Step 10

Go to Step 9

450mV

200mV

Go to Step 11

Go to Step 11

Go to Step 11

Go to Step 11

Go to Step 2

System OK

6-1022

Engine Controls - 3.8L

Engine

DTC P1336 Crankshaft Position (CKP) System Variation Not Learned

Circuit Description
The crankshaft position system variation learning
feature is used to calculate reference period errors
caused by slight tolerance variations in the crankshaft,
the crankshaft balancer interrupter rings, and the
crankshaft position sensor hall effect switches. The
calculated error allows the PCM to accurately
compensate for reference period varations. This
enhances the ability of the PCM to detect misfire
events over a wider range of engine speed and load.
The crankshaft position system variation values
are stored in the PCM non-volatile memory after a
learn procedure has been performed. OTC P1336 set
indicates that the crankshaft position system
variation values have not been stored in the PCM and
the crankshaft position system variation learn
procedure must be performed. The learn procedure is
required after the following service procedures
have been performed, regardless of whether or not
OTC P1336 is set:
PCM replacement.
Engine replacement.
Crankshaft replacement.
Crankshaft balancer replacement.
Crankshaft position sensor replacement.
Any engine repair(s) which disturbs
crankshaft/harmonic balancer to crankshaft
position sensor relationship.

Conditions for Running the DTC

No CMP or CKP sensor OTCs are set.
Engine Coolant Temperature is greater than
70C (158F).

Conditions for Setting the DTC

Crankshaft position system variation values are not
stored in the PCM memory.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the first
trip in which the diagnostic test has been run
and failed.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

Diagnostic Aids
The crankshaft position system variation compensating
values are stored in the PCM non-volatile memory
after a learn procedure has been performed. If
the actual crankshaft position variation is not within
the crankshaft position system variation compensating
values stored in the PCM, OTC P0300 may set
(refer to Diagnostic Aids for OTC P0300).
The crankshaft position system variation learn
procedure must be performed when replacing the
PCM to clear OTC P1336. The crankshaft position
system variation learn procedure is also required when
the following service procedures have been performed,
regardless of whether or not OTC P1336 is set:
Engine replacement.
Crankshaft replacement.
Crankshaft balancer replacement.
Crankshaft position sensor replacement.
Any engine repair(s) which disturbs
crankshaft/harmonic balancer to crankshaft
position sensor relationship.
If the crankshaft position system variation learn
procedure cannot be performed sucessfully, check for
the following conditions and correct as necessary:
Engine coolant temperature below 70 C (158 F).
Allow the engine to warm to above
70 C (158 F).
Powertrain OTCs set.
The scan tool crankshaft position system variation
learn function will be disabled if any powertrain
OTCs other than OTC P1336 are stored.
Camshaft position signal problem detected.
Refer to OTC P0341 Camshaft Position (CMP)
Sensor Performance.
3X reference signal problem detected.
Refer to OTC P1374 Crankshaft Position (CKP)
High to Low Resolution Frequency Correlation
18X reference signal problem detected.
Refer to OTC P0336 18X Reference Signal
Circuit.

Engine Controls - 3.SL

Engine

6-1023

OTC P1336 Crankshaft Position (CKP) System Variation Not Learned

Action

Step

Value(s)

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Perform the crankshaft position system variation learn

procedure. Refer to CKP System Variation Learn
Procedure.
Is action complete?

i
/

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Yes

System OK

5.,1024

Engine.

Engine Controls - 3.SL

OTC P1351 Ignition Coil Control Circuit High Voltage

!Hot In Run. Bulb Test And Start!

ILOC

- - - - , Underhood

I .

ENG CTRL

: Electrical

MlniFuse
15A

Center 2
1

PNK
PNK

EVAP Canister Purge

_ _ _ _ _ -~ Solenoid Valve and
EVAP ~anisterVent
239
Solenoid Valve

PNK 239
_ _ _P"'""N~K-..
239
PNK 239
p

----J
239

L-----

Transmission

'" -

I
I
I
I

-lgni~n- -

Positive

Voltage
Bypass
Control

Ignition
Control (IC)

Ignition
I Control (IC)
I Module
I
I

L------------------------~
TAN/BL~t24
WH~1423 RED/BL~1453 8~1'50
Ref Low

Ground

~
M
~
~
.. - - Bypa-;,------------ - - - - -lg-;;iti;n----------- - - - - ~f i:;w- , Powertrain

I
I

Control

PCM

Control (IC)

C1=BW
C2=CLEAR

I Control
IModule

>

I (PCM) ~

L--------------------~

226761

Circuit Description
The Ignition Control Module (ICM) sends signals that
the PCM requires for fuel control and spark advance
calculations. At the start of engine crank, the ICM
controls spark advance (Bypass mode.) When
the second 3X reference pulse is recognized by the
PCM, the PCM applies 5 volts to the Bypass
circuit, commanding the ICM to switch spark advance
to PCM control (IC mode). If the PCM detects an
open in the IC circuit, DTC P1351 will set. The engine
will start and may run in Bypass mode timing.

Conditions for Running the DTC

The engine is running.

Conditions for Setting the DTC

The PCM detects an open in the IC circuit.
The conditions is present for 300 3X reference
periods (100 crankshaft revolutions).

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

Engine

Engine Controls - 3.8L

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM or ICM.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wire connection.

6-1025

Damaged haroess.
Inspect the wiring harness for damage. l.f the
harness. appears to be OK, disconnect the ICM,
turn the ignition ON and observe a DMM
connected between the IC circuit and B+ while
moving connectors and wiring harnesses related
to the ICM. A change in voltage will indicate
the location of the malfunction.
. Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the OTC to be
set occurs. This may assist in diagnosing the condition.

DTC P1351 Ignition Coil Control Circuit High Voltage

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Go to Step 8

Go to Step 5

Go to Step 8

Go to Step 7

Go to Step 8

Go. to Step 6

Was the Powertrain On-Board Diagnostic (OBD) System.

Check performed?

1
..

1. Turn OFF the ignition swiich.

2. Disconnect the PCM:
3. Connect J39200 DMM between the IC and Reference
Low Circuits.
4. Turn ON the ignition switch.
5. Observe the resistance value on the DMM.

500 ohms

Does the DMM display. a resistanc~ below the

specified value?
,'

1.
2.
3.
4.
5.

Turn OFF the ignition switch.

Leave the PCM disconnected.
Disconnect the Ignition Control Module connector.
Check for an open in the IC circuit.
If a problem is found, repair as necessary.'Hefer to
Wiring Repairs.
Was.a problem found?

1. Check for poor terminal connections at the PCM.

2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Check for poor terminal.connections at the Ignition

Control Module.
2. If a: problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a pr.oblem found?

Replace the Ignition Control Module. Refer to Ignition

Control Module Replacement.

ts action complete?
7

Replace the PCM.

Important: Replacement PCM must be reprogrammed.
Refer to PCM Replacement/Programming.
Is action complete?
1.
2.
3.
4.

Review and record scan tool Fail Records data.

Clear DTCs.
Operate the vehicle within Fail Records conditions.
Using the scan tool, monitor Specific OTC Info for
OTC P1351.
Does the scan tool indicate OTC P1351 failed this ignition?

''

Go to Step 8

Go to Step 8

Go to Step 2

System OK

6-1026

Engine .Controls - 3.SL

Engine.

DT.C P1352 Ignition Bypass .Circuit High Voltage

'" - - - - -

- - - - , Underhood
I
I Electrical
I Center2

I Power
Distribution Ge
'I Cell1o
.

ENG CTRL
MinlFuse
15 A

GS

L-----

----.I

PNK 239
_ _
PNK 239

_ _

EVAP Canister Purge

_.,. Solenoid Valve and
EVAP ~anlsterVent
Solenoid Valve

PNK 239
----'-~--~..,.:--- ,;,ansmission

PNK 239
p
'" - - - - - - - - -1gn;ic;n- - - - - - - - - - - - - , Ignition
I
Positive
I Control (IC)
I
Voltage
I Module
I
I

Bypass
Control

I
I

Ignition
Control (IC)

L------------------------~
'KcT
TAN/BL~r24
w:TI423 ~ED/BL~1453 BLKf50
53 ------------
M
----------Ref Low

,. -

I
I

- Bypa7s Control

PCl\il

-1gn111;n - - - - Control (IC)

c1=BLU
C2=CLEAA

Ground

ief ~.; , P,owertrain

I Control
IModule
I (PCM) ~

>

L--------------------~

226761

Circuit Description
The Ignition Control Module (ICM) sends signals that
the PCM requires for fuel control and spark advance
calculations. At the start of engine crank, the ICM
controls spark advance (Bypass mode.) When
the second 3X reference pulse is recognized by the
PCM, the PCM applies 5 volts to the Bypass
circuit, commanding the ICM to switch spark advance
to PCM control (IC mode}. If the PCM detects an
open in the Bypass circuit, OTC P1352 will set. The .
engine will start arid may run in Bypass mode timing.

Conditions for Running the DTC

The engine is running.

Conditions for Setting the DTC

The PCM detects an open in the Bypass circuit.
The conditions is present for 300 3X reference
periods (100 crankshaft revolutions).

, Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and. failed.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles haye occurred without. a
malfunction.
The OTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

Engine

Engine Controls - 3.8L

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wire connection.

6-1027

Damaged harness.
Inspect the wiring harness for damage. If the
harness appears to be OK, disconnect the ICM,
turn the ignition ON and observe a DMM
connected between the IC circuit and B+ while
moving connectors and wiring harnesses related
to the ICM. A change in voltage will indicate
the location of the malfunction.
Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the DTC to be
set occurs. This may assist in diagnosing the condition.

TC P1352 Ignition Bypass Circuit High Voltage

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Go to Step B

Go to Step 5

Go to.Step B

Go to Step 7

Go to Step B

Go to Step 6

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Connect J 39200 DMM between the IC and
Reference Low Circuits.
4. Turn ON the ignition switch.
5. Probe the BYPASS circuit with a J 34142-8 test lamp
connected to B+.
Does the J 39200 DMM display a resistance above the
specified value?

5000 ohms

1. Turn OFF the ignition switch.

2. Leave the PCM disconnected.
3. Disconnect the Ignition Control Module connector.
4. Check for an open in the BYPASS circuit.
5. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Check for poor terminal connections at the PCM.

2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Check for poor terminal connections at the Ignition

Control Module.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?
Replace the Ignition Control Module. Refer to Ignition
Control Module Replacement.
Is action complete?

Go to Step B

Important: Replacement PCM must be reprogrammed.

Refer to PCM Replacement/Programming.
Replace the PCM.
Is action complete?

1. Review and record scan tool Fail Records data.

2. Clear DTCs.
3. Operate the vehicle within Fail Records conditions.
4. Using the scan tool, monitor Specific OTC Info for
OTC P1352.
Does the scan tool indicate OTC P1352 failed this ignition?

Go to Step 8

Go to Step 2

System OK

6-1028

Engine Controls - 3.8L

Engine

DTC P1361 Ignition Coil Control Circuit Low Voltage

!Hot In Run, Bulb Test And Startl

- - - - ., Underhood
ENG CTRL
MiniFuse
15 A
... _ _ _ _ _

Electrical,
Center 2
1
:

____ J

PNK 239
PNK

EVAP Canister Purge

_ _ _ _ _ -~ Solenoid Valve and
EVAP Canister Vent
239
Solenoid Valve

PNK 239

PNK
239

PNK 239
p
'" -

-lgniti;;n- -

I
I
I

Transmission

Ignition
I Control (IC)
I Module
I

.,

Posrtive
Voltage

Bypass
Control

Ignition
Control (IC)

L------------------------J
TAN/BL~l424
wH\1423 RED/BL~1453
I" -

I
I

~
Bypa;; :..-..:
Control

Ground

Ref Low

"~t5

--= :..-..:. -..:l~tl;;-n-..:. -...: --= :..- :..-~f Low- ,

PClvl

Control (IC)

C1=BLU
C2=CLEAR

Powertrain

I Control
I Module
I (PCM) ~

>

L--------------------J

226761

Circuit Description
The Ignition Control Module (ICM) sends signals that
the PCM requires for fuel control and spark advance
calculations. At the start of engine crank, the ICM
controls spark advance (Bypass mode). When
the second 3X reference pulse is recognized by the
PCM, the PCM applies 5 volts to the Bypass
circuit. The 5 volts on the Bypass circuit commands
the ICM to switch spark advance to PCM control
(IC mode). At this time, The ICM will remove
the ground it has applied to the IC circuit. When the
IC pulses are not grounded, the PCM can use
the IC pulses to control spark advance. A short in the
IC circuit or an open or short to ground in the
Bypass circuit will cause the PCM to monitor no IC
pulses after the PCM has switched the Bypass circuit
ON. The PCM will set OTC P1361 under either of
these conditions. The engine may be started but will
run on Bypass mode timing.

Action Taken When the OTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MILJDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Conditions for Setting the OTC

The PCM does not monitor IC pulses while IC
mode spark advance is commanded.
The conditions is present for 300 3X reference
periods (100 crankshaft revolutions).

Engine

Engine Controls - 3.8L

Diagnostic Aids
Check for the following conditions:
Poor connection at PCM - Inspect harness
connectors for the following items:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire. connections
Damaged harness
Inspect the wiring harness for damage. If the
harness appears to be OK, disconnect the ICM,
turn the ignition ON and observe a DMM
connected between the IC circuit and B+ while
moving connectors and wiring harnesses related
to the ICM. A change in voltage will indicate
the location of the fault.

6-1029

Review the Fail Records vehicle mileage since the

diagnostic test last failed. This may help determine
how often the condition that caused the OTC to be set
occurs.

Test Description
Number(s) below refer to the step number(s) on the
Qiagnostic Table.
13. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

DTC P1361 Ignition Coil Control Circuit Low Voltage

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to
Diagnostic Aids

Go to Step.B

Go to Step 4

Go to Step 9

Go to Step 5

Go to Step 10

Go to Step 6

Go to Step 15

Go to Step 7

Go to Step 15

Go to Step 14

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

1. Start engine and let idle for 2 minutes.

2. Observe DTCs.
Did DTC P1361 set this ignition?

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3

3. Install a J 34142-8 Unpowered test lamp between B+

and the bypass circuit at the PCM harness connector.
Is the test lamp ON?
1. Turn ON the ignition switch.
2. With the J 34142-8 test lamp installed between B+
and the bypass circuit, measure the resistance
between the IC circuit and the reference low circuit
using a J 39200 Digital Multimeter.
Is resistance greater than the specified value?
1. Turn OFF the ignition switch.
2. Disconnect the ignition control module 14-way
connector.
3. Probe the IC circuit with the J 34142-B test lamp
connected to B+.
Is the test lamp ON?
1. Check the bypass circuit for an open.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.

5K ohms
(5000 ohms)

Was a problem found?

1. Check the bypass circuit for a poor terminal

connection at the ignition control module.
2. If a problem is found, replace faulty terminal. Refer to
Wiring Repairs.
Was a problem found?

6-1030

Engine Controls - 3.SL

Engine

DTC P1361 Ignition Coil Control Circuit Low Voltage (cont'd)

Step

Action

1. Turn OFF the ignition switch.

2. Disconnect the ignition control module 14-way
connector.
3. Turn ON the ignition switch.
4. Observe the J 34142-8 test lamp connected between
the bypass circuit and B+.
ls the test lamp ON?

10

Locate and repair short to ground in the IC circuit. Refer to

Wiring Repairs.
ls action complete?

Locate and repair short to ground in the bypass circuit.

Refer to Wiring Repairs.
Is action complete?

1. Check the Bypass circuit for a poor terminal

connection at the PCM.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.
Replace the PCM.
Is action complete?

Replace the ignition control module. Refer to Ignition

Control Module Replacement.
Is action complete?

1. Review and record scan tool Fail Records data.

2. Clear DTCs.
3. Operate the vehicle within Fail Records conditions
as noted.
4. Using a scan tool, monitor Specific DTC info for
DTC P1361
Does the scan tool indicate DTC P1361 failed?

12

13

14

15

Yes

No

Go to Step 11

Go to Step 14

Go to Step 15

Go to Step 12

Turn OFF the ignition switch.

Disconnect the ignition control module.
Turn ON the ignition switch.
Check the IC circuit for a short to voltage.
If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

11

1.
2.
3.
4.
5.

Value(s)

Go to Step 15

Go to Step 15

Go to Step 15

Go to Step 13

Go to Step 15
-

Go to Step 15

Go to Step 2

System OK

Engine

Engine Controls - 3.SL

6-1031

OTC P1362 Ignition Bypass Circuit Low Voltage

!Hot In Run, Bulb Test And Start!

., Underhood
: Electrical
11/liniFuse
Center 2
1

ENG CTRL

15A

L-----

LliJ

----J

PNK 239
_

EVAP Canister Purge

_ _ -~ Solenoid Valve and
EVAP Canister Vent
Solenoid Valve

_ _

PNK 239
PNK 239

PNK

Transmission

239

PNK 239
p
A

'" -

- lgnit~n- -

I
I
I
L

53

I
I

.,

Ignition

I Control (IC)

I Module
I

Bypass
C_:;n~I -

Ignition
I
_ _ _ _ _ ~n~olJ!C2._ _ _ _ ~e!_:o~ _ _ _G~u~ _.

TAN/B!I424
.. -

Positive
Voltage

54
-------------

- Bypa-;;; Control

Bttso

w:Tl423 RED/BL~1453
-

- - PCM

C1=BLU
C2=CLEAR

48

-----------

-lg-;;iti;-n '."" Control (IC)

C1

Powertrain
I Control
I Module
I (PCM) ~ .

- ~1 ~w- .,

>

L--------------------..1

226761

Circuit Description
The Ignition Control Module (ICM) sends signals that
the PCM requires for fuel control and spark advance
calculations. At the start of engine crank, the ICM
controls spark advance (Bypass mode.) When
the second 3X reference pulse is recognized by the
PCM, the PCM applies 5 volts to the Bypass
circuit, commanding the ICM to switch spark advance
to PCM control (IC mode). If the PCM detects a
short to voltage in the Bypass circuit, DTC P1362 will
set. A short to ground in the IC circuit or Bypass
circuit will cause both DTC P1361 and DTC P1362 to
set. The engine will start and may run in Bypass
mode timing.

Conditions for Running the OTC

The engine is running.

Conditions for Setting the OTC

The PCM detects a short to voltage in the Bypass
circuit.
The conditions is present for 300 3X reference
periods (100 crankshaft revolutions).

Action Taken When the OTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIL/OTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will 9lear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

6-1032

Engine

Engine Controls - 3.SL

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wire connection.

Damaged harness.
Inspect the wiring harness for damage. If the
harness appears to be OK, disconnect the ICM,
turn the ignition ON and observe a DMM
connected between the IC circuit and B+ while
moving connectors and wiring harnesses related
to the ICM. A change in voltage will indicate
the location of the malfunction.
Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the DTC to be
set occurs. This may assist in diagnosing the condition.

DTC P1362 Ignition Bypass Circuit Low Voltage

Action

Step

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 6

Go to Step 3

Go to Step 4

Go to Step 13

Go to Step 5

Go to Step 12

Was the Powertrain On Board Diagnostic (OBD) System

Check performed?

Is DTC P1361 set also?

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3

3. Turn ON the ignition switch.

4. Probe the BYPASS circuit with a test light to ground.
Is the test light ON?
1. Turn OFF the ignition switch.
2. Leave the PCM disconnected.
3. Disconnect the Ignition Control Module connector.
4. Turn ON the ignition switch
5. Probe the BYPASS circuit with a test light to ground.
Is the test light ON?
Locate and repair the short to voltage in the BYPASS
circuit. Refer to Wiring Repairs.
Is action complete?
1.
2.
3.
4.

Turn OFF the ignition switch.

Disconnect the PCM.
Disconnect the Ignition Control Module.
Probe the IC circuit with a test light to B+.

Go to Step 14

Is the test light ON?

Locate and repair the short to ground in the IC circuit.

Refer to Wiring Repairs.

Go to Step 7

Locate and repair the short to ground in the BYPASS

circuit. Refer to Wiring Repairs.
Is action complete?

Go to Step 8

Go to Step 14

Is action complete?
1. Leave the ignition switch OFF.
2. Leave the PCM disconnected.
3. Leave the Ignition Control Module disconnected.
4. Probe the BYPASS circuit with a test light to B+.
Is the test light ON?

Go to Step 9

Go to Step 10

Go to Step 14

Engine .Conttols - 3.8L 5.. ~ 033

Engine

DTC P1362 Ignition Bypass Circuit Low. Voltage {cont'd)

Action

Step
\

10

11

12

13

14

1.
2.
3.
4.

Yes

No

Go to Step 14

Go to Step 11

Go to Step 13

Go to Step 12

Leave the ignition switch OFF.

Leave the PCM disconnected.

Leave the Ignition Control Module disconnected.

Check for a short between the IC and BYPASS
circuits.
5. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?
1.
2.
3.
4.
5.

Value{s)

Leave the ignition switch OFF.

Reconnect the Ignition Control Module.
Leave the PCM disconnected.
Turn ON the igntiion switch.

Using J39200 DMM, observe the resistance between

the IC and Reference Low circuits while probing the
BYPASS circuit With a test light to B+.
Does the resistance switch fron below the first value to
above the second value?
Replace the Ignition Control Module. Refer to Ignition
Coil(s) Replacement.
Is action complete?

500 ohms
5000 ohms

Go to Step 14
I

Replace the PCM.

Important: Replacement PCM must be reprogrammed.
Refer to PCM Replacement/Programming.
Is action complete?

1. Review and record scan tool Fail Records data.

2. Clear DTCs.
3. Operate the vehicle within Fail Records conditions.
4. Using the scan tool, monitor Specific OTC Info for
OTC P13e2.
Does the scan tool indicate DTC P1362 failed this ignition?

Go to Step 14

"'

Go to Step 2

System OK

6-1034

Engine Controls - 3.8L

Engine

DTC P1374 Crankshaft Position (CKP)' High to Low Resolution Frequency Correlation
!Hot In Run, Bulb Test And

'" - - - - I Power

I Distribution
eeu 10
I

I...

Start!

- - - - "' Underhood
I
ENG CTRL
I Electrical
Center .2
MlnlFuse
1
I

15A

_________ ...I
PNK 239

PNK 239

Power

Distribution

PNK 2~ - - -

f,

C~I;

PNK 239
p

Ignition
Control (IC)
Module

Ignition

Positive
Voltage
Camshaft

18x

3x

Position

Reference
Signal

Reference
Signal

Signal

Qround

_~:u~~+:P~:1: 8~1450

8~163~__ _
r - - CMPI
I

Sensor
Signal

- -

isx - - - - - 3'; - - - - -:-

Reference
Signal

Reference
Signal

- - - ., Powertrain

PCM
C1 = BLU
C2~CLEAR

I Control'
I Module

.&

l(PCM) ~

L--------------------------J

222078

Circuit Description
The 3X reference signal is produced by the ignition
control module. The ICM calculates the 3X reference
signal by dividing the Crankshaft Position (CKP)
sensor 18X pulses by 3 when the engine is running
and CKP sync pulses are also being received.
The PCM uses the 3X reference signal to calculate
engine rpm and crankshaft position at engine speeds
above 1200 rpm. The PCM also uses the pulses
on this circuit to initiate injector pulses. The PCM
constantly monitors the number of pulses on
the 3X reference circuit and compares the number of
3X reference pulses to the number of 18 X reference
pulses and CAM signal pulses being received. If
the PCM receives an incorrect number of pulses on
the 3X reference circuit, OTC P1374 will set and
the PCM will use the 18X reference signal circuit for
fuel and ignition control. The engine will continue
to start and run using the 18X reference and Camshaft
Position PCM input signals only.

Conditions for Setting the OTC

'fhe engine has been running. for longer than
3 seconds.
The ratio of 18X reference pulses to CAM signal
pulses received by the PCM equals 36:1.
The ratio of 18X reference pulses to 3X reference
pulses received by the PCM does not equal 6:1.
The condition is present for 300 3X reference
periods (100 crankshaft revolutions).

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the OTC test has run
and failed.
The PCM will use the 18X reference signal circuit
for fuel and ignition control.
If equipped with traction control, the PCM will
command the EBTCM via serial data (CKT 800) to
turn OFF traction control, and the EBTCM will
illuminate the TRACTION OFF lamp.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Engine Controls - 3.8L

Engine
Conditions for Clearing the MIUDTC

Malfunctioning Ignition Coil.

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

Diagnostic Aids
An intermittent may be caused by a ,Poor connection,
rubbed through wire insulation or a wire broken
inside the insulation. Check for the following
conditions:
Poor connection.
Inspect the PCM harness and connectors for
improper mating, broken locks, improperly formed
or damaged terminals, and poor terminal to
wire connection.
Damaged harness.
Inspect the wiring harness for damage. If the
harness appears to be OK, disconnect the PCM,
turn the ignition ON and observe a voltmeter
connected to the 3X reference circuit at the PCM
harness connector while moving connectors
and wiring harnesses related to the ICM.
A change in voltage will indicate the location of
the malfunction.

6-1035

Remove the ignition coils and inspect the ignition

control module and coils for cracks, carbon
tracking, or other signs that indicate that the coil
secondary circuit is arcing to the ICM or ICM
wiring harness. Refer to TBD.
Secondary ignition wire(s) arcing to wiring
harness.
Check secondary ignition wires for carbon
tracking or other signs of damage.
Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the DTC to be
set occurs. This may assist in diagnosing the condition.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
10. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

OTC P1374 Crankshaft Position (CKP) High to Low Resolution Frequency Correlation
Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Engine
Cranks but Does
Not Run

Go to Step 4

Go to
Diagnostic Aids

Go to Step B

Go to Step 5

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Attempt to start the engine.

Does the engine start and continue to run?

1. Review and record scan tool Fail Records data.

2. Operate the vehicle within Fail Records conditions.
3. Monitor Specific OTC info for OTC P1374 on the
scan,tool.
Does the scan tool indicate OTC P1374 failed this ign?

1. Turn OFF the ignition switch.

2. Disconnect the ignition control module 14-way
connector.

3. Install a J 34730-2A Injector test lamp at any injector

harness connector.
4. Turn ON the ignition switch.
5. Connect a J 34142-8 test lamp to B+.
6. Repeatedly touch the J 34142-8 test lamp to the
3X reference circuit at the ignition control module
harness connector while observing the injector
test lamp.
Does the injector test lamp blink?

6-1036

Engine Controls - 3.8L

Engine

DTC P1374 Crankshaft Position (CKP) High to Low Resolution Frequency Correlation (cont'd)
Step

. Value(s)

Action

Yes

No

1. Turn OFF the ignition switch.

2. Disconnect the PCM.

3. Turn ON the ignition switch.
4. Check for the following conditions:

3X reference circuit open.

3X reference circuit shorted to ground.

3X reference circuit shorted to voltage.

5. If a problem is found, repair as necessary. Refer to

Wiring Repairs.
Was a problem found?

1. Check the 3X reference circuit for a poor terminal

connection at the PCM.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?
1. Check for the following conditions:
Incorrect harness routing near secondary ignition
components.
Ignition coil arcing to the wiring harness or to the
ignition control module.
Ignition coils for cracks, carbon tracking, or other
signs of damage. Refer to Ignition Coil(s)
Replacement.
Secondary ignition wire(s) arcing to the wiring
harness. Refer to On-Vehicle Service in Ignition
System.

Go to Step 11

Go to Step 6

Go to Step 11

Go to Step 7

'

''

2. If a problem is found, repair as necessary.

Was a problem found?

1. Check for loose terminal connections at the Ignition

Control Module (ICM).
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Replace the ignition control module. Refer to Ignition

Coil(s) Replacement.
Is action complete?

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.
Replace the PCM.
Is action complete?

10

Go to Step 11

Go to Step 10

Go to Step 11

Go to Step 9

Go to Step 11

Go to Step 11

1. Review and record scan tool Fail Records data.

2. Clear DTCs.
11

3. Operate the vehicle within Fail Records conditions.

4. Using a scan tool, monitor Specific DTC info for
DTC P1374.
Does the scan tool indicate DTC P1374 failed?

Go to Step 2

System OK

Engine

Engine Controls - 3.8L 6-1037

OTC P1380 Misfire Detected - Rough Road Data Not Available

Action Taken When the DTC Sets

Refer to Antilock Brake System.

Circuit Description
The PCM receives rough road information from the
EBCM I EBTCM on the serial data circuit (CKT 800).
The PCM uses the rough road information to
enhance the misfire diagnostic by distinguishing
crankshaft speed variations caused by driving on rough
road surfaces from variations caused by true misfires.
The EBCM I EBTCM transmits rough road information
based on inputs from the wheel speed sensors. If
the EBCM I EBTCM detects a condition which will not
allow it to properly identify rough road situations
while a misfire condition is being detected by the PCM,
OTC P1380 will be set.

The PCM will not illuminate the Malfunction

Indicator Lamp (MIL}.
The PCM will store conditions which were present
when the OTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

Conditions for Clearing the MIUDTC

A history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
OTC can be cleared by using the scan tool Clear
Info function or by disconnecting the PCM
battery feed.

Conditions for Running the DTC

Engine load is less than 87%.

Engine speed is less than 5000 RPM ..
Vehicle speed is greater than 10 mph.
A misfire OTC is occurring and requesting the MIL
to be illuminated.

Conditions for Setting the DTC

The PCM has detected a EBCM I EBTCM rough road
sensing error..

Diagnostic Aids
OTC P1380 set indicates that the ABS I TCS system
has detected a malfunction which will not allow
the EBCM I EBTCM to transmit correct rough road
data to the PCM. The Diagnostic System Check
in ABS Brakes should be used to diagnose this
condition.

DTC P1380 Misfire Detected - Rough Road Data Not Available

Step

Action

Value(s)

Yes

No

Go to the

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

6-1038

Engine

Engine Controls - 3.8L

DTC P1381 Misfire Detected - No Communication with Brake Control Module

Refer to Antilock Brake System.

Diagnostic Aids

Circuit Description

Check for the following conditions:

Poor conneciton at the PCM or at the
EBCM I E.BTCM.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wire connection.
Damaged harness.
lnpsec the wiring harness for damage. If the
harness appears to be OK, observe ABS data on
the scan tool while moving connectors and
wiring harnesses related to the EBCM I EBTCM.
A loss of ABS data will indicate the location of
the malfunction.
Reviewing the Fail Records vehicle mileage since the
diagnostic test .last failed may help determine how
often the condition that caused the OTC to be
set occurs. This may assist in diagnosing the condition.

The PCM receives rough road information from the

EBCM I EBTCM on the Class 2 serial data circuit. The
PCM uses the rough road information to enhance
the misfire diagnostic by distinguishing crankshaft
speed variations caused by driving on rough
road surfaces from variations caused by true misfires.
The EBCM I EBTCM transmits rough road information
based on imputs from the wheel speed sensors. If
a loss of communication occurs which causes the PCM
not to receive rough road information while OTC P0300
is requesting the MIL, DTC P1381 will set.

Conditions for Running the DTC

1.
2.
3.
4.

Engine load is less than 87%.

Engine speed is less than 5000 RPM.
Vehicle speed is greater than 1O mph.
A misfire DTC is occurring and requesting the MIL
to be illuminated.

Conditions for Setting the DTC

The PCM is detecting a loss of communication with
the EBCM I EBTCM for at least 1O seconds.

Action Taken When the DTC Sets

The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM will store conditions which were present
when the DTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Ensures that the EBCM/EBTCM is capable of
transmitting serial data on the UART serial
data circuit.
4. Checks the UART serial data circuit at the
EBCM/EBTCM for correct voltage.

Conditions for Clearing the MIL/DTC

A history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
OTC can be cleared by using the scan tool Clear
Info function or by disconnecting the PCM
battery feed.

(
\

Engine

Engine Controls - 3.SL

6-1039

DTC P1381 Misfire Detected - No Communication with Brake Control Module

Action

Step

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

'
2

1.
2.
3.
Can

Value(s)

1. Check the serial data circuit for an open or a poor

connection between the PCM and the EBCM.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Turn OFF the ignition switch.

Disconnect the EBCM.
Turn ON the ignition switch.
Using a J 39200 Digital Multimeter, measure voltage
on the serial data circuit at the EBCM harness
connector.
Does vbltage vary within a range between the specified
values?
1. Check for a poor connection at the EBCM.
2. If ~ problem is found, replace terminal(s) as
necessary. Refer to Wiring Repairs.
Was a problem found?

Go to Step2

Go to Step 3

Go to Step 4

System OK

Go to
Diagnostic Aids

Go to Step 5

Go to Step 6

Go to Step 7

Go to Step 6

Go to Step 7

Go to the
Antilock Brake
System
Diagnostic
System Check in
ABS!TCS

System OK

Go to Step 4

1-5V

1. Check for an open in the serial data circuit to the

EBCM. Refer to UART Data Line in Electrical
Diagnosis for a complete mechanization.
2. If a problem is found, repair as n~cessary. Refer to
Wiring Repairs.
Was a problem found?

1.
2.
3.
Can

Turn ON the ignition switch.

Select chassis application on the scan tool.
Attempt to display ABS data on the scan tool.
ABS data be displayed?

No

Go to the A
Powertrain On
Board Diagnosti~
(OBD) System
Check

Turn ON the ignition switch.

Select chassis application on the scan tool.
Attempt to display ABS data on the scan tool.
ABS data be displayed?

1.
2.
3.
4.

Yes

'61040

Engine'Controls .. 3.Sl

Engine

OTC P1404 Exha'ust Gas RE!Circulation (EGR) Closed Position Performance

TPandMAP
Sensors

-..-----,

LJiJ
GRY 598
D

GRY 598

BLK 552
LT BLU 697

BRN 1456
GAY 435

:--r--:~: --, ~~~e ~~~e -1----~~.~~~- ---- f ~~~:~~A-:

4

C2

32

28

C1

C2

31

C1

33

C2

I
I

Ignition
Posilfve
Voltage

-- _-T Control
..
-=-

Pos1t1on
Signal

-=-

PCM
C1=BLU
C2=CLEAR

I
I
I
I

L---------------------------------J

Powertrain
Control
Module
(PCM)

>

222140

Circuit Description
The PCM monitors the EGA valve pintle position input
to ensure that the valve responds properly to
commands from the PCM. When the ignition switch is
turned ON, the PCM learns the EGR closed valve
pintle position. The PCM compares the learned EGA
closed valve pintle position to the Actual EGA
position when the EGR valve is commanded closed. If
the Actual EGR positron indicates that the EGR
valve is still open when the PCM is commanding the
EGR valve closed, DTC P1404 will set.

Conditions for Running the DTC

No TP, VSS, Misfire, IAT sensor, MAP sensor,
Idle Speed, Fuel Injector, ECT, CKP, or MAF
sensor DTCs are set.
System voltage is between 1O volts and 16 volts.

Conditions for Setting the DTC

EGA Feedback is 0.2 volt greater than the EGA
Closed Valve Pintle Position when the Desired
EGA Position is commanded to 0%
The above condition is present for longer
than 20 seconds.

Action taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will disable EGA for the ignition cycle
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MILJDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

Engine

Engine Controls - 3.8L

6-1041

Diagnostic Aids

Test Description

Check for the following condition(s):

Excessive deposits on the EGR valve pintle
or seat.
Remove the EGR valve and check for deposits
that may interfere with the EGR valve pintle
extendiFlg completely or cause the pintle to stick.
Poor connections at PCM or EGR valve.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor temrinal to wire connection.
Damaged harness.
Inspect the wiring harness for damage. If the
wiring appears to be OK, connect J 39200 DMM
and check circuit continuity while moving
connectors and wiring harnesses related to the
EGR valve. A change in the DMM display
will indicate the location of the malfunction.

Number(s) below refer to the step number(s) on the

Diagnostic Table:
2. Verifies that the malfunction is present.
4. If DTC P1404 will only set under certain
conditions, the malfunction may be intermittent;
refer to OTC P1404 Diagnostic Aids. If an
intermittent wiring problem is not present, check
for a poor connection at the PCM or the EGR
valve. If the connections are OK and DTC P1404
continues to set, replace the EGR valve. Refer
to EGR Valve Replacement.
14. his vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read
Only Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

OTC P1404 Exhaust Gas Recirculation (EGR) Closed Position Performance

Action

Step

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Step 5

Go to Step 4

Go to Step 6

Go to Step 5

Go to
Diagnostic Aids

Go to Step 6

Go to Step 7

Go to Step 9

Go to Step B

Go to Step 12

Go to Step 11

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Important: If OTC P0403 is set, diagnose the other

OTC first.
With the engine idling, observe Actual EGR Position
display on the scan tool.
Is Actual EGR Position at the specified value?

0%

1. Turn ON the ignition switch.

2. Select the scan tool EGR valve output control
function.
3. Increment the EGR valve through all positions while
comparing Desired EGR Position to Actual EGR
Position.
Does Desired EGR Position remain close to Actual EGR
Position at all commanded positions?

1. Review and record scan tool Fail Records data.

2. Operate the vehicle within Fail Records conditions.
3. Using a scan tool, monitor Specific OTC info for
OTC P1404 until the OTC P1404 test runs.
Does the scan tool indicate OTC P1404 failed this ign?

1. Disconnect the EGR valve electrical connector.

2. Observe Actual EGR Position on the scan tool.
Is Actual EGR Position at the specified value?

0%

Probe the EGR pintle position sensor ground circuit at the

EGR valve harness connector with a J 34142-8 test lamp
to B+.
Is the test lamp ON?

1.
2.
3.
4.

Turn OFF the ignition switch.

Disconnect the PCM.
Turn ON the ignition switch.
Measure voltage between the EGR valve pintle
position signal circuit and ground.
Is the measured voltage near the specified value?

ov

6-1042

Engine

Engine Controls - 3.8L

DTC P1404 Exhaust Gas Recirculation (EGR) Closed Position Performance (cont'd)
Step

10

11

12

13

14

15

Action
1. Check the EGR pintle position sensor ground circuit
for an open betwe~n the PCM and the EGR valve.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?
1. Check for p<1or terminal connections at the
EGR valve.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?
Replace the EGR valve. Refer to EGR Valve
Replacement.
Notice: If the EGR valve shows signs of excessive heat,
check the exhaust system for blockage (possibly a
plugged converter) using the procedure found on the
restricted exhaust system check. If the exhaust system is
restricted, repair the cause; one of which might be an
injector which is open due to one of the following reasons:
Stuck
Grounded driver circuit
Possible faulty Control Module.
If this condition is found, the oil should be checked tor
possible fuel contamination.
Is action complete?
Locate and repair short to voltage in the EGR pintle
position signal circuit. Refer to Wiring Repairs.
Is action complete?

(
Go to Step 15

Go to Step 13

Go to Step 15

Go to Step 10

Go to Step 15

Go

1. Check the circuits related to the EGR valve tor poor

terminal connections at the PCM.
2. It a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.
Replace the PCM.
Is action complete?

Review and record scan tool Fail Records data.

Clear DTCs.
Operate .the vehide within Fail Records conditions.
Using a scan tool, monitor Specific OTC info tor
OTC P1404.
Does the scan tool indicate OTC P1404 tailed this ignition?

No

1. Check tor the following conditions:

The EGR valve pintle position signal circuit for a
short to the 5 volt reference circuit.
The EGR valve pintle position signal circuit for a
short to the EGR valve control circuit.
2. It a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1.
2.
3.
4.

Yes

Value(s)

to Step 15

Go to Step 15

Go to Step 14

Go to Step 15

Go to Step 14

Go to Step 15

Go to Step 2

System OK

Engine

Engine Controls - 3.SL 6-1043

DTC P1441 Evaporative Emission (EVAP) System Flow During Non-Purge

!Hot In

Run, Bulb Test And Start!

~ -

Distribution
cen 10

:;, 0111

GS

- - - ., Underhood
ENG CTRL : Electrical
MiniFuse Center 2

15 A

I1,,,

PNK 239
IC Module
and
-+--------Transmission
+
PNK 239
:
L -

___________

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PNK 239

PNK1239

PNKI239

-PN:l239

PNtl23~

Evaporative
[ ] ] Evaporative
Emission (EVAP)
Emi~sion (EVAP)
Canister Purge
Canister Vent
Solenoid
Solenoid
Valve
Valve
A
DK
WHT 1310
GRN/WHT 428
WHT 1310

II

BI

WHTI1310
2 C2
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I
EVAP Canister
EVAP Canister
PCM
I C
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Purge
Valve

vent
Valve
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~
222965

Circuit Description
The evaporative system includes the following
components:
The fuel tank.
The EVAP canister vent valve.
The fuel tank pressure sensor.
The fuel pipes and hoses.
The fuel cap.
The EV AP vapor lines.
The EV AP purge lines.
The evaporative emission canister.
The EV AP purge valve.
The Powertrain Control Module (PCM) supplies a
ground to energize the valve valve (purge ON). The
EVAP purge valve control is Pulse Width Modulated
(PWM) or turned ON and OFF several times a second.
The duty cycle (pulse width) is determined by engine
operating conditions including load, throttle position,
coolant temperature and ambient temperature.
The duty cycle is calculated by the PCM and the
output is commanded when the appropriate conditions
have been met. The system checks for conditions

that cause the EVAP system to purge continuously by

commanding the EV AP canister vent valve ON and
the EVAP purge valve OFF (EVAP canister vent valve
CLOSED, EVAP purge PWM 0%). If vacuum level
in the fuel tank increases during the test, a continuous
purge flow condition is indicated. This can be
caused by any of the following conditions:
EVAP purge valve leaking.
EVAP purge and engine vacuum lines switched at
the EVAP purge valve.
EVAP purge valve control circuit grounded.
If any of these conditions are present, DTC P1441
will set.

Conditions for Running the OTC

No VSS, TP, H02S, Misfire, IAT, MAP, Fuel Trim,
Injector circuit, EGR Pintle Position, ECT, or MAF
sensor DTCs set.
The DTC P0442 diagnostic test has passed.

Conditions for Setting the OTC

A continuous open purge flow condition is detected
during the diagnostic test (fuel tank pressure
decreases to less than -11 in. H20).

6-1044

Enginecontrols - 3.SL

Engine

Action Taken When the OTC Sets

Malfunctioning or damaged canister.

A malfunctioning canister may intermittenly allow
charcoal into the EVAP purge solenoid, vacuum
switch, and associat.ed lines causing a OTC to be
set. Use the following procedure to check for a
carbon release condition:
1. Turn OFF the ignition switch.
2. Bemove the EVAP purge valve. Refer to
EVAP Canister Purge Solenoid Valve
Replacement.
3. Lightly tap the EVAP purge valve and (if
applicable) the vacuum switch on a clean work
area looking for carbon particles exiting
either of the vacuum ports.
4. If no carbon release is evident, reinstall the
components and continue with the OTC P1441
table. If carbon is being released from either
component, continue with this service
procedure.
5. Remove the charcoal canister from the vehicle .
6. Ensure that the main cylinder valve is turned
off on the J 41413 EVAP purge/pressure
diagnostic station.
7. Disconnect the black hose that connects the
nitrogen cylinder to the EVAP purge/pressure
diagnostic station at the pressure regulator
by unscrewing the knurled nut on the regulator.
No tools are required to remove the black
hose from the regulator .
.8. Using a section of vacuum line, connect one
end over the open threaded fitting of the
EVAP purge/pressure diagnostic station
pressure regulator.
9. Connect the remaining end to the EVAP purge
valve end of the EVAP purge line at the
vehicle and turn on the main nitrogen cylinder
valve. Continue to blow any debris from the
purge line for 15 seconds.
10. Return the EVAP Pressure/Purge Diagnostic
Station to its original condition by re-installing
the black hose that was disconnected in
step 7.
11. Replace the EVAP purge valve. Refer to
EVAP Canister Purge Solenoid Valve
Replacement.
12. Proceed with the the OTC P1441
diagnostic table.
Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the OTC to set occurs.
This may assist in diagnosing the condition.

The PCM will illuminate the MIL during the first

trip in which the diagnostic test has been run
and failed.
The PCM will store conditions which were prese'nt
when the OTC set as Freeze Frame and Fail
Records data.

Important: Although these diagnostics are considered

type A, they act like type B diagnostics under
certain conditions. Whenever the EV AP diagnostics
report that the system has passed, or if the battery has
been disconnected, the diagnostic must fail during
two consecutive cold start trips before setting a DTC.
The initial failure is not reported to the diagnostic
executive or displayed on a scan tool. A passing
system always reports to the diagnostic executive
immediately.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Info function or by disconhecting the
PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wire connection.
Damaged harness.
Inspect the wiring harness for damage.
If the harness appears to be OK, connect the
J 41413 EVAP pressure/purge diagnostic
station to the EVAP service port, pressurize the
EVAP system to 10 in. H20 and observe the Fuel
Tank Pressure display on the scan tool while, .
moving connectors and wiring harnesses related
to the EVAP purge valve. A sudden change in
the display will indicate the location of the
malfunction.
Incorrect vacuum line routing.
Verify that the source vacuum line routing to the
EVAP purge valve is correct and that the
EVAP purge and source vacuum lines to the
EVAP purge solenoid are not switched.

Engine

Engine Controls - 3.SL

5. Verifies that the fuel tank pressure sensor

accurately reacts to EVAP system pressure
changes.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. If an EV AP purge valve electrical malfunction is
present, the purge system will not operate
correctly. Repairing the electrical malfunction will
very likely correct the condition that set
DTC P1441.
3. Checks the Fuel Tank Pressure sensor at ambient
pressure
4. Checks for a stuck open EVAP purge valve.

6-1045

6. If the EVAP purge and engine vacuum lines are

switched at the EVAP purge solenoid, the
solenoid valve will leak vacuum.
10. The PCM will command the EVAP purge and
EVAP canister vent valves closed with the
scan tool Seal System EV AP output control
function activated. Fuel tank pressure should not
decrease under this condition.

DTC P1441 Evaporative Emission (EVAP) System Flow During Non-Purge

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to
DTCP1676
EVAP Canister
Purge Solenoid
Control CKT

Go to Step 3

Go to Step 4

Go to
DTC P0453 Fuel
Tank Pressure
Sensor Circuit
High Voltage

Go to Step 5

Go to Step 6

Go to Step 6

Go to
DTC P0452 Fuel
Tank Pressure
Sensor Circuit
Low Voltage

Go to Step 7

Go to Step 9

Was the Powertrain On-Board Diagnostic System Check

performed?

Was DTC P1676 also set?

1. Turn OFF the ignition switch.

2. Remove the fuel cap.
3. Turn ON the ignition switch.
4. Observe Fuel Tank Pressure on the scan tool.
Is Fuel Tank Pressure at the specified value?

O in. H20

Important: Before continuing with diagnosis, zero the

EVAP Pressure and Vacuum (inches of H20) gauges on
the J 41413 EVAP pressure/purge diagnostic station (refer
to tool operating instructions).
1. Replace the fuel cap.

2. Capture Fail Record data for DTC P1441 and

clear DTCs.
3. Connect the EVAP pressure/purge diagnostic station
to the EV AP service port.
4. Using the scan tool, command the EVAP canister
vent valve ON (Closed).
5. Attempt to pressurize the EVAP system to the
specified value using the J 41413 EVAP
pressure/purge diagnostic station (monitor pressure
using the EVAP pressure gauge on the J 41413
EVAP pressure/purge diagnostic station).
Can the specified value be achieved?
1. Maintain tank pressure at 5 inches of H20.
2. Observe Fuel Tank Pressure on the scan tool.
Is Fuel Tank Pressure at the specified value?
Check the EVAP purge and source vacuum line routing
and connections at the EVAP purge valve. Refer to
Emission Hose Routing Diagram.
Are the EVAP purge and source vacuum lines connected
correctly at the EVAP purge valve?

5 in. H20

5 in. H20

6-1046

Engine Controls". 3.SL

OTC P1441 Evaporative Emission (EVAP) System Flow During Non-Purge (cont'd)

Step

Action

1. Remove the engine vacuum source line from the

EVAP purge valve.
2. Connect a vacuum hand pump to the engine vacuum
side of the EVAP purge valve and apply specified
vacuum to the solenoid.

Value{$)

Yes

No

Go to
Diagnostic Aids

Go to Step B

15 in. Hg

Does the EVAP purge valve maintain vacuum at the

specified value?
Replace the EVAP purge valve. Go to EVAP Canister
Purge Solenoicf Valve Replacement.

Important: Check for carbon release into the EVAP

system. Refer to Diagnostic Aids.

Go to Step 10 ,

Is action .complete?
9

Correct the EV AP purge and source vacuum line routing

and connections.

Go to Step 10

Is action complete?
1. Start the engine.
2. Remove the fuel cap.

3. Using the scan tool output tests function, select Seal

10

System and activate.

4. Replace the fuel cap.
5. Switch the rotary switch on the EVAP pressure/purge
diagnostic station to PURGE.
6. Run the engine at idle while monitoring the Vacuum
(inches of H20) gauge .on the EVAP pressure/purge
diagnostic station for at least 10 seconds.
Does vacuum remain at the specified value while the scan
tool Seal System function is activated?

O in. H20

System OK

Go to Step 3

Engine

Engine Controls .. 3.8L

61047

DTC P1554 Cruise Control Feedback Circuit

r -

I
I

Cruise

- -

- , -

Cruise

- -

., Cruise

L-------~----------------J

DK GR~I83

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sv

Input

WHT

1c1 =BLU

Input
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817

WHT

:::::T:::

-D~: ~-1- ;n;:~: 1-- - - - - ~ - :_- ~ - - - - - Output \

- , Instrument
vss1c luster

R~dio

~~*RN/

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-1~~f-vs~ --- 6~:~~Wn

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Output

C2=CLEAR

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L------~-----------------------------J
226768

Circuit Description
The PCM has the ability to disable cruise control if
conditions are detected which would make cruise
control operation undesirable. The following conditions
may cause cruise control to be.inhibited by the PCM:
Engine not running long enough for cruise
control operation.
Transaxle range switch indicates park, neutral,
low, or reverse gear selected.
Engine speed is too high or too low.
Vehicle speed is too high or too low.
ABS system is active for longer than 2 seconds.
Vehicle acceleration or deceleration rate
is too high.
If any of these conditions are present, the PCM will
interrupt the ground on the cruise inhibit circuit
to request that cruise control be disengaged. If the
cruise status signal indicates that cruise control is still
engaged while the PCM is inhibiting cruise control
operation, DTC P1554 will be set. :

Conditions for Setting the DTC

The PCM is commanding the SMCC module to
inhibit cruise control operation (Cruise Inhibit
circuit not grounded).
The Cruise Status circuit signal indicates that
cruise control is engaged.
The above conditions are present for longer
than 1 second.

Action Taken When the DTC Sets

The PCM will not illuminate the Malfunction

Indicator Lamp (MIL).
The PCM will store conditions which were present
when the DTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

Conditions for Clearing the MIUDTC

A history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
DTC can be cleared by using the scan tool Clear
Information functionor by disconnecting the
PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at PCM - Inspect harness
connectors for the following items:
- Backed out terminals
- Improper mating
- . Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connections
Damaged harness - Inspect the wiring harness for
damage.
If the harness appears to be OK, observe the
Cruise Status display on the scan tool while
moving connectors and wiring harnesses related
to the Stepper Motor Cruise Control module.
A change in the display will indicate the location
of the malfunction.
If DTC P1554 cannot be duplicated, the information
included in the Failure records data can be useful
in determining how many ignition cycles have passed
since the DTC was last set.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
7. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

6-1048

Engine

Engine Controls - 3.BL

DTC P1554 Cruise Control Feedback Circuit

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to
DTCP1662
Cruise Control
Inhibit Control
Circuit

Go to Step 3

Go to Step 4

Go to Step 5

Go to Step 6

Go to Step 7

Go to Step 8

Go to Step 7

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Is OTC P1662 also set?

1. Turn OFF the ignition switch.

2. Disconnect the cruise control module.
3. Turn ON the ignition switch.
3

4. Using a J 39200 DMM, measure voltage between the

cruise engaged circuit at the cruise control module
harness connector and ground.

7V

Is voltage greater than the specified value?

1. Turn OFF the ignition switch.
2. Reconnect the cruise control module.
3. Disconnect the PCM.
4

4. Turn ON the ignition switch.

5. Probe the cruise engaged circuit at the PCM harness

connector with a J 34142-8 Unpowered test lamp
connected to B+.
Is the test lamp ON?
1. Turn OFF the ignition switch.
2. Disconnect the PCM.
5

3. Probe the cruise engaged circuit at the PCM harness

connector with a J 34142-8 Unpowered test lamp
connected to B+.

Is the test lamp ON?

6

Replace the cruise control module. Refer to Cruise Control

Module Replacement in Cruise Control.
Is action complete?

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.
Replace the PCM.

Go to Step 9

Is action complete?
Locate and repair short to ground in the cruise engaged
circuit. Refer to Wiring Repairs.

Go to Step 9

Go to Step 9

Is action complete?
1. Clear OTC P1554.

2. Start the engine and observe DTCs.

Did OTC P1554 set?

Go to Step 2

System OK

Engine Controls - 3.8L 6-1049

Engine
OTC P1626 Theft Deterrent Fuel Enable Signal Lost

~Theft- I

~ Body

Deterrent
Control
I
Fuel Enable Module

IMAl
L-1il

~s~n~ _ ~ (BCM)

08IC3 ~
>

DK BLU 229

DK BLUI229
70 C1

.. - - - - - - - - Fu; - - - - - - - - "'

I
I
I

I
I

lEnable

Control
I

sv

PCM

Powertrain

I
Control
I Module
l I (PCM)

1c1:asw I
C2=CLEAAI

1
I

_...

L---------------~--J~
226770

Circuit Description
The Body Control Module (BCM) produces the Theft
Deterrent Fuel Enable signal when ignition is ON
and the proper key resistor pellet is sensed. The PCM
monitors the Fuel Enable signal during crank. If the
proper signal is present on the Theft Deterrent
Fuel Enable circuit, the PCM enables fuel delivery to
allow the engine to start. If the PCM detects that
the fuel enable signal is not present or incorrect while
the engine is running, DTC P1626 will be set.
DTC P1626 can cause a no-start condition or normal
operation depending on when the loss of the fuel
enable signal was detected. The engine will continue
to start and run if the condition that set DTC P1626
occurred after the BCM sensed the proper key resistor
pellet and signaled the PCM to continue fuel delivery.
The engine will start and immediately stall if the
condition that set DTC P1626 occurred before the
BCM sensed the proper key resistor pellet. With this
condition present, the PCM will inhibit fuel delivery and
disable the starter. If the problem affects inputs to
the BCM, the starter motor may be disabled. If
this condition is present, refer to Vehicle Theft
Deterrent System for further diagnosis.

Conditions for Setting the DTC

The engine is running.
The PCM detects an incorrect signal on the Theft
Deterrent Fuel Enable Circuit.
The condition is present for longer than 2 seconds.

Action Taken When the DTC Sets

The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM will store conditions which were present
when the DTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

Conditions for Clearing the MIUDTC

A history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
DTC can be cleared by using the scan tool Clear
Information function or by disconnecting the
PCM battery feed.

6...1050

Engine:,Controls - 3.8L

Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbed through wire insulation or a wire broken
inside the insulation. Check for:
Poor connection at PCM - Inspect harness
connectors for the following items:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connections
Damaged harness - Inspect the wiring harness for
damage. If the harness appears to be OK,
disconnect the vehicle theft deterrent module, turn
the ignition ON and observe. a DMM connected
to the theft deterrent fuel enable circuit at the
vehicle theft deterrent module harness connector
while moving connectors and wiring harnesses
related to the vehicle theft deterrent system.
A change in voltage will indicate the location of
the malfunction.

.Engine
Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the DTC to be
set occurs. This may assist in diagnosing the condition.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
9. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

Engine

Engine Controls - 3.8L

5..1051

DTC P1626 Theft Deterrent Fuel Enable Signal Lost

Action

Step

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Vehicle
Theft Deterrant
System.

Go to Step 4

Go to Step 6

Go to Step 5

Go to Step 8

Go to
Diagnostic Aids

Go to Step 7

Go to Step 11

Go to Step 7

Go to Step 11

Go to Step 9

Go to Step 11

Go to Step 10

Was the Powertrain On-Board Diagnostic (080) System

Check performed?

)
1

Important: Before continuing diagnosis, ensure that the

vehicle battery is fully charged.
Attempt to start the engine.
Does the engine crank?

1. Turn OFF the ignition switch.

2. Disconnect the body control module.
3. Turn ON the ignition switch.
3

4. Using a J 39200 DMM, measure voltage between the

5V

vehicle theft deterrent fuel enable circuit at the body

control module harness connector and a known good
ground.
Does the voltage measure near the specified value?

1. Turn OFF the ignition switch.

2. Reconnect the body control module.
3. Turn ON the ignition switch.
4. Backprobe the body control module connector to
measure frequency between the vehicle theft
deterrent fuel enable circuit and ground.
Is the frequency between the specified values?
1. Turn OFF the ignition switch.
2. Clear OTC P1626.
3. Attempt to start the vehicle.
Does the vehicle start and continue running?

40-60 Hz

1. Check the vehicle theft deterrent fuel enable circuit

6

for an open, short to ground, or short to voltage.

2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Check the theft deterrent fuel enable circuit for a poor

7

connection at.the PCM.

2. If a problem is found, replace faulty terminal.

Was a problem found?

1. Check for poor connections at the Body Control

8

Module.
2. If a problem is found, replace faulty terminal(s). Refer
to Wiring Repairs.
Was a problem found?

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.
Replace the PCM.
Is action complete?

10

Service the body control module. Refer to BCM Service in

section 80.
Is action compl~te?

1. Clear DTCs.
2. Observe VTD Fuel Disable on the scan tool while
cranking the engine.
Does VTD Fuel Disable display Active?

)
11

Go to Step 11

Go to Step 11

Go to Step 2

System OK

6-1052

Engine Controls-- 3.8L

Engine

OTC P1629 Theft Deterrent Fuel Enable Signal Not Received

~Theft-

~ Body

Control
Module
~s~n~ _ ~ (BCM)

Deterrent
I
I
Fuel Enable

08IC3 ~
>

DK BLU 229
DK BLUI229

70 C1

'" - - - - - - - - Fu;i - - - - - - - - ., Powertrain

I
I

I
I
I

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Enable
Control

sv

PCM

1c1-BLU

I Control
I Module
I I (PCM)
I 1 .._

C2=CLEARI I

~------------------J~
226770

Circuit Description

Diagnostic Aids

The Body Control Module (BCM) produces the Theft

Deterrent Fuel Enable signal when ignition is ON
and the proper key resistor pellet is sensed. The PCM
monitors the Fuel Enable signal during crank. If the
proper signal is present on the Theft Deterrent
Fuel Enable circuit, the PCM enables fuel delivery and
starter operation to allow the engine to start. If the
PCM detects that the fuel enable signal is not present
or incorrect while an attempt is made to start the
engine, OTC P1629 will be set. The engine will not
start and the starter motor will be disabled. This
conditions will occur if the problem also affects inputs
to the BCM. Refer to Vehicle Theft Deterrent
System for further diagnosis.

An intermittent may be caused by a poor connection,

rubbed through wire insulation or a wire broken
inside the insulation. Check for:

Conditions for Setting the OTC

OTC P1626 is not present.
An attempt is made to start the engine.
The PCM detects an incorrect signal on the Theft
Deterrent Fuel Enable Circuit.

Action Taken When the OTC Sets

The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM will store conditions which were present
when the OTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

Conditions for Clearing the MIL/OTC

A history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
OTC can be cleared by using the scan tool Clear
Information function or by disconnecting the
PCM battery feed.

Poor connection at PCM - Inspect harness

connectors for the following items:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connections
Damaged harness - Inspect the wiring harness for
damage. If the harness appears to be OK,
disconnect the vehicle theft deterrent module, turn
the ignition ON and observe a DMM connected
to the theft deterrent fuel enable circuit at the
vehicle theft deterrent module harness connector
while moving connectors and wiring harnesses
related to the vehicle theft deterrent system.
A change in voltage will indicate the location of
the malfunction.
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help determine
how often the condition that caused the DTC to be set
occurs.

Test Description
Number(s) ..below refer to the step number(s) on the
Diagnostic Table.
9. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

Engine

Engine. Controls - 3.SL

6-1053

DTC P1629 Theft Deterrent Fuel Enable Signal Not Received

Action

Step

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to Vehicle
Theft Deterrent
(VTD) System
Check.

Go to Step 4

Go to Step 6

Go to Step 5

Go to Step 8

Go to
Diagnostic Aids

Go to Step 7

Go to Step 11

Go to Step 7

Go to Step 11

Go to Step 9

Go to Step 11

Go to Step 10

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Important: Before continuing diagnosis, ensure that the

vehicle battery is fully charged.
Attempt to start the engine,
Does the engine crank?

1. Turn OFF the ignition switch.

2. Disconnect the body control module.
3. Turn ON the ignition switch.
4. Using a J 39200 DMM, measure voltage between the
vehicle theft deterrent fuel enable circuit at the body
control module harness connector and a known good
ground.
Does voltage measure near the specified value?

5V

1. Turn OFF the ignition switch.

2. Reconnect the body control module.
3. Turn ON the ignition switch.
4. Backprobe the body control module connector to
measure frequency between the vehicle theft
deterrent fuel enable circuit and ground.
Is the frequency between the specified values?
1. Turn ON the ignition switch.
2. Clear OTC P1629.
3. Attempt to start the vehicle.
Does the vehicle start and continue running?
1. Check fhe vehicle theft'deterrent fuel enable circuit
for an open, short to ground, or short to voltage.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
';

40-60 Hz

Was a problem found?

1. Check the theft deterrent fuel enable circuit for a poor

connection at the PCM.
2. If a problem is found, replace faulty terminal. Refer to
Wiring Repairs.

Was a problem found?

1. Check for poor connections at the body control

module.
2. If a problem is found, replace faulty terminal(s). Refer
to Wiring Repairs.
Was a problem found?
Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.

Replace the PCM.

Is action complete?

Go to Step 11

10

Service the body control module.

Is action complete?

11

1. Clear DTCs.
2. Observe VTD Fuel Disable on the scan tool while
cranking the engine.
Does VTD Fuel Disable display Active?

Go to Step 11

Go to Step 2

System OK

6-1054

Engine Controls - 3.8L

Engine

DTC P1635 5 Volt Reference Circuit

r- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,, Powertrain
I
sv
-=I Control

Fuel Tank

Pressure
Sensor

5 Volt
__ !e.'.'.:re~c:_A_

MAP

Sensor
_ _ _ _ _ _ _ _ _ _ !ig:ai_

Pos~}.:11 !

ii
A

Module (PCM)

JI;

LTG:J: ~
13

~:y ::: :
....-~~~~C....,......,

PCM

C1 = BLU
_ :2.:_C~~ __

G~-~

~~~=1~1

(MAP) Sensor A

DK BLU 417
BLK 452

66

C2

61

ORN/BLK 469

C1

'" - - - TP - , - - - - rP - - - - - - - - - I

I
I

Sensor
Signal

Sensor
Ground

PCM
C1=BLU
C2=CLEAR

~
I
I

L-----------------------J

Powertrain
Control
Module (PCM)

j;
~

226855

Circuit Description
The PCM uses the 5 Volt Reference A circuit as a
sensor feed to the following sensors:
The TP sensor.
The MAP sensor.
The EGA Valve Pintle Position sensor.
The Fuel Tank Pressure sensor.
The PCM monitors the voltage on the 5 Volt Reference
A circuit. If the voltage is out of tolerance, the PCM
will set DTC P1635.

Conditions for Setting the OTC

The PCM detects a voltage out of tolerance
condition on the 5 Volt Reference A circuit.
The above condition is present for longer
than 10 seconds.

Action Taken When the OTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Engine Control.s - 3.8L

Engine
Diagnostic Aids

Important: Be sure to inspect PCM and engine

grounds for being secure and clean.
Check for the following conditions:
Poor connection at PCM - Inspect harness
connectors for the following items:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connections
Damaged harness - Inspect the wiring harness for
damage.
If the harness appears to be OK, observe the
MAP display on the scan tool with the ignition ON,
engine not running while moving connectors

and wiring harnesses related to the following

sensors. A change in the MAP display will indicate
the location of the fault.
- The TP sensor
- The MAP sensor
- The EGR valve

6.1055

Review the Fail Records vehicle mileage since the

diagnostic test last failed. This may help determine
how often the condition that caused the DTC to be set
occurs.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
5. A faulty EGR valve can leak a small amount of
current from the ignition feed circuitto the
5 volt reference A circuit. If the problem does not
exist with the EGR valve disconnected, replace
the EGR valve.
13. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is .being
replaced, the new PCM must be programmed.

DTC P1635 5 Volt Reference Circuit

Step

Action

..

Value(s)

Yes ..

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 14

Go to Step 3

Diagnose the
other OTC first

Go to Step 4

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1. Visually/physically check the PCM and engine

grounds. Ensure .that the grounds are clean and
secure.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Select OTC info, Last Tst Fail and note any other
DTCs set.
Are any of the following DTCs set?
OTC P0107 Manifold Absolute Pressure (MAP) Sensor
Circuit Low Voltage
OTC P0108 Manifold Absolute Pressure (MAP) Sensor
Circuit High Voltage
OTC P0122 Throttle Position (TP) Sensor Circuit Low
Voltage
OTC P0123 Throttle Position (TP) Sensor Circuit High
Voltage
DTC P1106 Manifold AP$Olute Pressure (MAP)Sens9r
Circuit Intermittent High Voltage
OTC P1107Manifold Absolute Pressure (MAP) Sensor
Circuit Intermittent Low Voltage
OTC Pt 121 Throttle Position (TP) Sensor Circuit
Intermittent High Voltage
OTC Pt 122 Throttle Position (TP) Sensor Circuit
Intermittent Low Voltage

6-1056

Engine Controls .. 3.8L

Engine

OTC P1635 5 Volt Reference Circuit (cont'd)

Step

Action

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Turn ON the ignition switch.
4. Using a J 39200 DMM, measure voltage between the

Value(s)

Yes

No

(
5.5V

5 volt reference A circuit and the PCM ground circuit

at the PCM harness connector.
Is voltage greater than the specified value indicated?

Monitor the J 39200 DMM connected between the 5 volt

reference A circuit and the PCM ground circuit while
disconnecting the EGR valve.
Is voltage ~reater than the specified value still indicated
with the E R valve disconnected?

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step B

Go to Step 14

Go to Step 7

Go to Step 14

Go to Step 13

5.5V

1. Monitor the J 39200 DMM connected between the

5 volt reference A circuit and the PCM ground circuit

while disconnecting the following sensors (one at
a time):
TP sensor
MAP sensor
2. If voltage changes when one of the above
components is disconnected, locate and repair short
to voltage in the affected sensor signal circuit. Refer
to Wiring Repairs.
Was a problem found?

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Turn ON the ignition switch.
7

4. Check the 5 volt reference A circuit for a short to

voltage.
5. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?
Replace the EGR valve. Refer to EGR Valve Replacement
Is action complete?

Go to Step 14

1. Turn OFF the ignition switch.

2. Reconnect the PCM.
3. Disconnect the following components:

The TP Sensor.
The EGR Valve.
The MAP Sensor.
The Fuel Tank Pressure Sensor.
4. Connect the J 39200 DMM to measure voltage
between the 5 volt reference A circuit and the sensor
ground circuit at the TP sensor connector.
Is voltage less than the specified value indicated?

4.5V

Go. to Step 12

Go to Step 10

Engihe Controls - 3.8L

Engine

6-1057

DTC P1635 5 Volt Reference Circuit (cont'd)

Step

Action

Value(s)

10

1. Monitor the DVM connected between the 5 volt

reference A circuit and the sensor ground circuit while
reconnecting the following components (one at
a time):
The EGR Valve.
The MAP Sensor.
The Fuel Tnk Pressure Sensor.
2. If the voltage changes when one of the following
components is reconnected, replace the affected
component.
Refer to EGR Valve Replacement.
Refer to Fuel Tank Pressure Sensor Replacement.
Refer to MAP Sensor Replacement.
Was a problem found?

1. Disconnect the EGR valve.

2. Connect the DVM to measure voltage between the
5 volt reference A circuit and the sensor ground
circuit at the EGR valve harness connector.
3. Monitor the voltage while reconnecting the TP sensor.
4. If the voltage changes when the TP sensor is
reconnected, replace the TP sensor. Refer to TP
Sensor Replacement.
Was a problem found?

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Check the 5 volt reference A circuit for a short to
ground.
4. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

11

12

13

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.

Replace PCM.
Is action complete?

Yes

No

Go to Step 14

Go to Step 11

Go to Step 14

Go to Step 13

Go to Step 14

Go to Step 13

Go to Step 14

1. Review and record scan tool Fail Records data.

14

2. Clear DTCs.
3. Operate vehicle within Fail Records conditions
as noted.
4. Using a scan tool, monitor Specific DTC info for
DTC P1635 until the DTC P1635 test runs.
Does scan tool indicate DTC P1635 failed this ign?

Go to Step 2

System OK

Engine Oontr.ol.s "': 3.8L

6-1058

Engine

(?TC P1_~39 5 Volt Reference (B) Circuit

l IRefrigerant
. Pressure
A/C

~
. L-...:........_

II

C - - - - -~-A
....._. Sensor'
8
GRY 720
GRY 474
TFT,

L0 c

[SJ

..

A\

__ __. Fuel Level and

Fuel Tank
Pressure Sensors

RED/BLK 380

GRY 720

r -

A/C

I.

Retriger.ant
Pressure
Sensor
Signal

I
I

1 1

27 - - - - - - - _;3~

- _;39.,.. C2 - . . . , - - . ,

5 Volt

Reference
8

Sensor
Ground

SV

I P9vvertra1 n

PCM
G1=BLU
C2=CLEAR

Control
1 Module
I
I

L-----------------------~

Jl.:

(PCM) ,._ .

223152

Diagnostic Aids .

Circuit Description
The PCM uses the 5 Volt Reference B circuit as a
sensor feed for the A/C Refrigerant Pressure Sensor.
"fhe PCM monitors the voltage on the 5 Volt
Reference B circuit. If the voltage is out of tolerance,
the PCM will set OTC P1639.

Conditions for Setting the DTC

The PCM detects a voltage out of tolerance
condition on the 5 Volt Reference B circuit.
' Above conditibn for longer than 1o seconds.

Action Taken When the DTC Sets

The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM will store conditions which were present
when the OTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

Conditions for Clearing the MIL/DTC

'

A history DTC will clear after 40 consecutive

warm-up cycles have occurred without a
malfunction.
OTC can be cleared by using the scan tool Clear
Information function or by disconnecting the
PCM battery feed.

Important: Inspect the PCM and engine grounds for

being secure and clean:
. Check for the following conditions:
Poor connection at PCM - Inspect harness
connectors for the following items:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connections
Oar,naged harness - ln~pe9t the wiring harness for
damage.
If the harness appears to be OK, observe the A/C
pressure display on the scan tool while moving
connectors and wiring harnesses related to
the A/C refrigerant pressure sensor. A change in
the A/C pressure display will indicate the
loc.ation of the fault.

Review the Fail Records vehicle mileage since the

diagnC>stic te.st last failed. This may help determine
how often the .condition that caused the OTC to be set
occurs ..

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
10. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

Engine Controls - 3.SL

Engine .

6-1059

OTC P1639 5 Volt Reference (B) Circuit

Action

Step

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 11

Go to Step 3

Go to
OTC P0530 Air
Conditioning
(A/C) Refrigerant
Pressure Sensor
Circuit

Go to Step 4

Go to Step 5

Go to Step 7

Go to Step 6

Go to Step 10

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

,, Visually/physically check the PCM and engine grounds.

2

Ensure that the grounds are clean and secure.

Was a problem found?

1. Ensure that the A/C is OFF.

2. Observe A/C High Side Pressure display on the
scan tool.
Does the scan tool display voltage greater than the first
specified value or less than the second specified value?

4.8
0.1 V

1. Disconnect the A/C refrigerant pressure sensor.

2. Using a J 39200 DMM, measure voltage between the
5 volt reterence B circuit and the sensor ground
circuit
Is voltage greater than the specified value?

5.5V

1.
2.
3.
4.

Turn OFF the ignition switch.

Disconnect the PCM.
Turn ON the ignition switch.
measure voltage between the 5 volt reference B
circuit and the PCM ground circuit at the PCM
harness connector.
Is voltage greater than the specified value indicated?
Locate and repair short to voltage on the 5 volt
reference B circuit. Refer to Wiring Repairs.

5.5V

Is voltage less than the specified value indicated?

Go to Step 11

Is action complete?
4.5V

Go to Step 9

Go to Step 8

Go to Step 11

Go to Step 10

Go to Step 11

Go to Step 10

1. Check for a short to voltage in the 5 volt reference B

circuit.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Turn OFF the ignition switch.

10

2. Disconnect the PCM.

3. Check the 5 volt reference B circuit for a short to
ground or a short to the sensor ground circuit.
4. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?
Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Replace PCM.

Go to Step 11

Is action complet~?

11

1. Review and record scan tool Fail Records data.

2. Clear DTCs.
.3. Operate vehicle within Fail R.ecords conditions
as note,d.

4. Using a scan tool, monitor Specific DTC info for

OTC P1639 until the OTC P1639 tes.t runs.
Note test result; does the scan tool indicate OTC P1639
failed this ign?

Go to Step 2

System OK

6-,1060

Engine Controls- 3.8L

Engine

OTC P1641 A/C Relay Control Circuit

.. I

Power
Distribution
Cell 10

A/C-CRUISE
Mini Fuse
15A

G7

GB

DJS

f.

I~~

'

- - .,
~ -

.,

~~pressor
Clutch
Relay

:,

Fuse Block
Details
Cell11

Underhood

~=~::~;I

BAN
241

BRN 241

C C2

I
I

---c~i~; ~R~l;9----~
86

I
I
20 A I
I

HVAC
Fuse 6

BRN 241

---

87

F2

ce1110

PNK 139

-----

Power
Distribution

I
L------

------,

PNK 139

r -

r------

IP I
Fuse I
Block I

PNK 139
- -

!Loe

IHot In Runl

-----J

L-----Fuse Block
Details
Cell11

., Underhood
: Electrical
Center 2
I

HVAC'"I
Control
Assembly 1

OFF

DEF

WHT
DKGRN 59

- -HTR
VENT

------

DKGRN 59
DKGRN 59

DK GRN/WHT 459

ill]

AIC
Compressor
Clutch Diode

sv

1 Amp

~~~presser
Clutch

Pressure
Sensor

B
r

Ground
Distribution
Cell14

GRY 47

39

BLK I
450

27

34

DK
GRN/WH'f 762
GRY 720
_ ~ __ __ _ __ _ ___ __ __ _ _ ___ . C2

--~-r ~t-=-1-.;_-=5~:t--1-- - ;;n;,-

A/C
I Relay
I Control
/ /

-<II Sensors

RED/BLK 380

BLK 450 ;

GRN1WHT 762

\NC
Rerr;gernnt

899

899

L - - - - - - .---..1
.
A C2
DK

~-

-~ -

Sensor
Signal

Reference
B

-~ -

-C~N:I; -

Ground

- 5~ -

NC -

-1- ~

Request
Signal

C1 = BLU
C2=CLEAR

I
I

~ -

- :.

6~~i~~ain
Module
(PCM)~

~
248315

Circuit Description
Output Driver Modules (ODMs) are used by the PCM
to turn on many of the cu.rrent-driven devices that
are needed to control various engine and Transaxle
functions. Each ODM is capable of controlling up to.
7 separate outputs by applying ground to the
device which the PCM is commanding ON. Unlike the
Quad Driver Modules (QDMs) used in prior model
years, ODMs have the capability of diagnosing each
output circuit individually. OTC P1641 set indicates an
improper voltage level has been detected on the
output circuit which controls the A/C
compressor control relay.

Conditions for Setting the DTC

The ignition is ON.
An improper voltage level has been detected on
the output circuit which controls the A/C
compressor control relay.
The above conditions are present for at least
30 seconds.

Action Taken When the DTC Sets

The PCM will not illuminate the Malfunction
Indicator Lamp {MIL).
The PCM will store conditions which were present
when the OTC set as Fail Records data only.
This information' will not be stor.ed as
Freeze Frame data.

Engine
Conditions for Clearing the MIUDTC
A history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
OTC can be cleared by using the scan tool Clear
Info function or by disconnecting the PCM
battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM. Inspect harness
connectors for backed out terminals, improper
mating, broken locks, improperly formed or
damaged terminals, and poor terminal to wire
connection.
Damaged harness. Inspect the wiring harness for
damage. If the harness appears to be OK,
disconnect the PCM, turn the ignition ON and
observe a DMM connected between the A/C
compressor control relay control circuit and ground
at the PCM harness connector while moving
connectors and wiring harnesses related to the
A/C compressor control relay. A change in voltage
will indicate the location of the malfunction.
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help determine
how often the condition that caused the OTC to be set
occurs.

Engine Controls - 3.8L

6-1061

Test Description
The number(s) below refer to Step number(s) on the
diagnostic table:
2. Stored diagnostic trouble codes may disable the
A/C compressor. This diagnostic table may
lead to improper diagnosis and replacement of
good parts if diagnostic trouble codes are present.
3. The A/C compressor clutch should engage if the
appropriate conditions have been met.
4. The A/C compressor clutch should not be engaged
with the engine running if an A/C mode is not
selected at the control head.
6. Checks for an A/C request signal from the control
head to the PCM.
12. Checks the ignition positive voltage circuit to the
AfC relay.
13. Determines whether the A/C relay or the circuitry
is at fault.
21. Determines if the PCM is turning the A/C relay
ON due to a false A/C request.
22. Isolates the problem to the A/C control head or
the PCM.
27. Determines if the A/C relay is malfunctioning or
the A/C relay control circuit is grounded all
the time.
36. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

.~lOf?~ Engi11f Controls.~ 3.SL

.,

$tep
;,

OTC P1641 A/C Relay Control Circuit

. Was the Powertrain On-Board Diagnostic (OBD) System

Che~k pertormed?

No

Go to Sfep 2

Gb to the A
Powertra;n On
Board o;agnosf;c
(080) System
Check

Diagnose other
DTCs first.

Go to Step 3

Yes

Value(s}

Ac:tion

!ere any other powertrain DTCs stored?

important: Before continuing with diagnosi's, the following

conditions must be met:
Intake air temperature greater than 9 C (48 F).
Engine coolant temperature less than 119 C (246 F).
1. With the A/C OFF, start and idle the engine.
2. Observe the A/C compressor.
Is the A/C compressor clutch engaged?

'
~,,

Go to Step 21

Go to Step 4

Go to
Dfagnostic Aids

Go to Step 5

._!

4,

1. Run ttie engine at 1000-1500 RPM.

2. Select an A/C mode on l;-IV AC control head.
3. Observe the A/C compressor.

_,

Is the A/C compressor clut~h engaged?

,..

With an A/C mode still selected, observe A/C Request on

the scan tool.
Does A/C Request display Yes?

_.{

1.
2.
3.
4.

Turn OFF the ignition switch.

"
Disconnect the PCM.
Turn ON the ignition $witch.
Wifh an A/C mode still selected, measure voltage on
the A/C request circuit at the PCM harness
connector.
Does the voltage measure near the specified value?

..
:

'.

Go to Step 9
..

Go to Step 6

Go to Step 8

Go to Step 7

Go to Step 38

Go to Diagnosis
in Manual
Control Air
Conditioning

Go to Step 38

Go to Step36

Go to Step 12

Go to Step 10

Go To Step 11

Go to Refrigerant
Recovery and
Recycling,
Adding Oil,
Evacuating and
Recharging
Procedures in
Heater,
Ventilation and
Air Conditioning

"'

B+

1. Check the A/C request circuit for the following

conditions:
Open.
Shorted to ground.

Poor connection at the A/C control head or A/C

programmer (as applicable).
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Check the A/C request circuit for a poor connection at

the PCM.

2. If a problem is found, repair as necessary. Refer to

Wiring Repairs.
Was a problem found?

Observe A/C Refrigerant Pressure on the scan tool.

Is indicated A/C pressure between the specified values?

0.35-4.27 V

1. Connect a J 39500 Refrigerant Recovery, Recycling,

10

and Recharging Station to monitor high side

refrigerant pressure. Refer to Heater, Ventilation and
Air Conditioning.
2. Observe high side refrigerant pressure on the gauge.
Is high side refrigerant pressure within the specified
values?

234-2854 kPa
(34-414 psi)

Engine Control.s - 3~8L 6-1063

Engine

OTC P1641 A/C Relay Control Circuit (cont'd)

Action

Step

11

1. Turn OFF the ignition switch.

2. Disconnect the PCM and the NC refrigerant pressure
sensor.
3. Measure the resistance of the following circuits
between the PCM and the NC refrigerant pressure
sensor:
The NC refrigerant pressure sensor signal circuit.

Value(s)

Yes

No

Go to Step 38

Go to Step 18

Go to Step 13

Go To Step 31

Go to Step 14

Go to Step 15

Go to Step 38. .

Go to Step 32

5 ohms

The 5 volt reference 13 circuit.

The sensor ground circuit.
4. If any resistance is higher than the specified value,
locate and repair cause of high resistance in circuit
as necessary. Refer to Wiring Repairs.
Was a problem found?

12

1. Disconnect the NC relay electrical connector.

2. Probe both ignition positive voltage circuits at the NC
relay harness connector with a test light to ground.

Is the test light ON?

13

14

Connect a fused jumper between the ignition positive

voltage circuit and NC compressor clutch control circuit
(CKT 59) at the NC relay connector.
Does the NC compressor clutch engage?
1. Check for poor connections at NC relay.
2. If a problem is found, replace faulty terminals as
necessary. Refer to Wiring Repairs.

Was a problem found?

15

16

1. Disconnect the NC compressor clutch electrical

connector (leave the ignition positive voltage circuit
and NC compressor clutch control circuit (CKT 59)
jumpered at the NC relay connector).
'
2. Connect a test light between NC compressor clutch
control circuif(CKT 59) and the compressor ground
circuit.
Is the test light ON?
1. Check for poor connections at the NC compressor
clutch.
2. If a problem is found, replace faulty terminals as
necessary. Refer to Wiring Repairs.

.,
-

18

'Go to Step 17

Go to Step 38

Go to Step 34

Go to Step 38

Go to Step 35

Go to Step 19

Go to Step 20

Was a problem found?

17

Go to Step 16

1. Check for an open or short to ground in the NC

compressor clutch control circuit (CKT 59).
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Leave the PCM and the NC refrigerant pressure

sensor disconnected.
2. Turn ON the ignition switch.
3. Using a J 39200 Digital Multimeter, measure voltage
between the NC refrigerant pressure signal circuit
and ground.
Does the voltage measure near the specified value?

OV

..

6-1064

Engine

Engine Controls - 3.8L

DTC P1641 A/C Relay Control Circuit (cont'd)
Action

Step

19

1. Check for the following conditions:

The 5 volt reference B circuit for a poor
connection at the PCM.
The 5 volt reference B circuit for a poor
connection at the A/C refrigerant pressure sensor.
The A/C refrigerant pressure signal circuit for a
poor connection at the PCM.
The A/C refrigerant pressure signal circuit for a
poor connection at the A/C refrigerant pressure
sensor.
The sensor ground circuit for a poor connection at
the A/C refrigerant pressure sensor.
2. If a problem is found, repair as necessary. Refer to

Value(s)

Yes

No

Wiring Repairs.

Was a problem found?

Go to Step 38

Locate and repair short to voltage in the A/C refrigerant

pressure signal circuit.
Is action complete?

1. Turn ON the ignition switch.

2. A/C OFF
3. Observe A/C Request on the scan tool.
Does A/C Request display Yes1

Turn OFF the ignition switch.

Disconnect the PCM.
Turn ON the ignition switch.
A/C OFF.
Using a J 39200 Digital Multimeter, measure voltage
between the A/C request circuit at the PCM harness
connector and ground.
Does the voltage measure near the specified value?

B+

Turn OFF the ignition switch.

Disconnect the HVAC control head.
Turn ON the ignition switch.
Check the A/C request circuit for a short to B+.
If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Disconnect the A/C relay.

2. Start the vehicle.
3. Observe the A/C compressor.
Is the A/C compressor clutch engaged?

Probe the A/C compressor clutch control circuit (CKT 59)

at the A/C relay harness connector with a test light to
ground.
Is the test light ON?

26

Replace the A/C relay.

Is action complete?

27

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Probe the A/C relay control circuit at the PCM
connector with a test light connected to B+.
Is the test light ON?

20

21

22

23

24

25

1.
2.
3.
4.
5.

1.
2.
3.
4.
5.

Go to Step37

Go to Step 38

Go To Step 22

Go To Step24

(
Go To Step 23

Go to Step36

Go to Step 38

Go to Diagnosis
in Manual
Control Air
Conditioning

Go to Step 29

Go to Step25

Go to Step 26

Go to Step27

Go to Step 38

Go to Step 28

Go to Step 36

Engine

Engine Controls - 3.8L

6-1065

DTC P1641 A/C Relay Control Circuit (cont'd)

Action

Step

28

29

Repair short to ground in the A/C compressor clutch relay

control circuit. Refer to Wiring Repairs.
Is action complete?
1. Turn OFF the ignition switch.
2. Disconnect the A/C compressor clutch electrical
connector.
3. Start the engine.
4. Observe the A/C compressor.

Value(s)

Go To Step 34

Locate and repair short to voltage in the A/C compressor

clutch control circuit (CKT 59). Refer to Wiring Repairs.
Is action complete?

31

Repair open or short to ground in the ignition positive

voltage circuit to the A/C compressor relay. Refer to Wiring
Repairs.
Is action complete?

32

Check the A/C relay control circuit for a open or short to

voltage.
Was problem found and repaired?

33

Replace the A/C compressor relay.

Is action complete?

34

Repair the A/C compressor clutch. Refer to V5 Air

Conditioning Compressor.
Is action complete?

Locate and repair open in the A/C compressor clutch

ground circuit (CKT 450).
Is action complete?

35

No

Go to Step 38

Is the A/C compressor clutch engaged?

30

Yes

Go to Step 30

Go to Step 38

Go to Step 38

Go to Step 38
Go to Step 38

Go to Step 33

Go to Step 38
-

Go to Step 38

Replace the PCM.

36

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.

Go to Step 38

Is action complete?

37

Replace the A/C refrigerant pressure sensor. Refer to

On-Vehicle Service in Heater, Ventilation and Air
Conditioning.

Go to Step 38

Is action complete?
Important: Before continuing with diagnosis, the following
conditions must be met:
Intake air temperature greater than 9 C (48 F).

38

39

Engine coolant temperature less .than 119 C (246 F).

1. With the A/C OFF, start and idle the engine.
2. Observe the A/C compressor.
Is the A/C compressor clutch engaged?
1. Run the engine at 1000-1500 rpm.
2. Select an A/C mode on the HVAC control head.
3. Observe A/C compressor.
Is the A/C compressor clutch engaged?

Go to Step 21

Go to Step 39

System OK

Go to Step 5

6-1066

Engine Controls - 3.8L

Engine

OTC P1651 Fan 1 Relay Control Circuit

fHot At All Times!
,. - L1
K1
L--

COOL FAN
MaxiFuse
40 A

6~s:~ution

J7

- - ., Underhood
~~~LING
: Electrical
MiniFuse
Center 1

J6

10 A

Cell 10

(M;1

L'.w

----J

-------------

RED 402

Power
Distribution
Cell10

fL::-1
LLl

!Hot At All Times!

- - - - - - - - - -

ORN 1640

r - - - - - -...

Fuse Block

Details
Cell.11

ORN 1640

RED 402

Underhood
RED 402 Electrical
Center 1

ORN 1640
ORN 1640

WHT 504

r-----

-----.,

(
GRY 532

BLK

DK GRNI335
6
r -

I
I

DK BLU 473
5 C1

150

- .;;..-..:.-...:-;.:-::..-..:.-..:.-..;;--::....-.:..-..:.-..: ..::::..-..:.-..:-:..:-::.. - - -_ - - , Powertrain

Cooling
Fan Relay 1

---1Control

CONN ID
C1=BLU
C2 = CLEAR

Cooling
Fan Relay

- . 12and3
Control

',
BLK 150 '.,_ ___ ,

I Control
I Module .._
I (PCM) ~
~

L--------------------------~

Ground
Distribution
Cell 14

254432

Circuit Description
Output Driver Modules (ODMs) are used by the PCM
to turn on many of the current-driven devices that
are needed to control various engine and Transaxle
functions. Each ODM is capable of controlling up to
7 separate outputs by applying ground to the
device which the PCM is commanding ON. Unlike the
Quad Driver Modules (QDMs) used in prior model
years, ODMs have the capability of diagnosing each
output circuit individually. DTC P1651 set indicates an
improper voltage level has been detected on the
output circuit which controls the Fan 1 Relay.

Conditions for Setting the DTC

The ignition is ON.
An improper voltage level has been detected on
the output circuit which controls the low
speed fans.
The above conditions present for at least
30 seconds.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Engine
Conditions for Clearing the MIUDTC
The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The OTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at PCM - Inspect harness
connectors for the following items:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connections
Damaged harness - Inspect the wiring harness for
damage.

If the harness appears to be OK, disconnect the

PCM, turn the ignition ON and observe a
voltmeter connected between the Fan 1 relay
driver circuit and ground at the PCM harness
connector while moving connectors and wiring
harnesses related to the Fan 1 relay. A change in
voltage will indicate the location of the fault.

Engine Controls - 3.8L

6-1067

Review the Fail Records vehicle mileage since the

diagnostic test last failed. This may help determine
how often the condition that caused the OTC to be set
occurs.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Normally, battery feed voltage should be present
on the control circuit with the PCM disconnected
and the ignition turned ON.
3. Checks for a shorted component or a short to B+
on the control circuit. Either condition would
result in a measured current of over 500 milliamps.
Also checks for a component that is going open
while being operated, resulting in a measured
current of O milliamps.
4. Checks for a short to B+ on the cooling fan relay
#1 control circuit.
15. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

6-1068

Engine

Engine Controls - 3.8L

DTC P1651 Fan 1 Relay Control Circuit
Action

Step

Was the Powertrain On-Board Diagnostic (080) System

Check performed?
1

1.
2.
3.
4.

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Step 6

Go to Step 11

Go to Step 4

Turn OFF the ignition switch.

Disconnect the PCM.
Turn ON the ignition switch.
Using a J 39200 DMM, measure voltage between the
cooling fan relay #1 control circuit at the PCM
harness connector and ground.
Is voltage near the specified value?

B+

1. Disconnect the cooling fans.

2. Connect the J 39200 DMM to measure current
between the cooling fan relay #1 control circuit at the
PCM harness connector and ground.
3. Monitor the current reading on the J 39200 DMM for
at least 2 minutes.
Does the current reading remain between the specified
values?

0.05-0.5 amps
(50-500 mA)

1. Turn OFF the ignition switch.

2. Reconnect the cooling fans.
3. Disconnect cooling fan relay #1 (leave the PCM
disconnected).
4. Turn ON the ignition Sl(Vitch.
5. Using the J 39200 DMM, measure voltage between
the cooling fan relay #1 control circuit and ground.
Is voltage at the specified value?

ov

Locate and repair short to voltage in the cooling fan

relay #1 control circuit. Refer to Wiring Repairs.
Is action complete?

1. Turn OFF the ignition switch.

2. Check the battery feed fuse for the low speed cooling
fan relay coil.
Is the fuse open?

1. Locate and repair short to ground in battery feed

circuit for the low speed cooling fan relay coil. Refer
to Wiring Repairs.
2. Replace the fuse.
Is action complete?

1. Disconnect cooling fan relay #1.

2. Turn ON the ignition switch.
3. Measure voltage between the battery feed circuit for
the low speed cooling fan relay coil and ground.
Is voltage near the specified value?

B+

1. Check the cooling fan relay #1 control circuit for an

open or a short to ground.
2. If a problem is found, repair the cooling fan relay #1
control circuit. Refer to Wiring Repairs.
Was a problem found?

(
\

Go to Step 10

Go to Step 5

Go to Step 16

Go to Step 7

Go to Step 8

Go to Step 16

Go to Step 9

Go to Step 13

Go to Step 16

Go to Step 10

Engine Controls - 3.SL

Engine

6-1069

OTC P1651 Fan 1 Relay Control Circuit (cont'd)

Action

Step

Value(s)

Yes

No

Go to Step 16

Go to Step 14

Go to
Diagnostic Aids

Go to Step 12

Go to Step 16

Go to Step 15

1. Check for the following conditions:

The cooling fan relay #1 control circuit for a poor
connection at the PCM.
10

11

The cooling fan relay #1 control circuit for a poor

connection at cooling fan relay #1.
The cooling fan relay #1 battery feed circuit for a
poor connection at cooJing fan relay #1.
2. If a problem is found, replace faulty terminal(s) as
necessary. Refer to Wiring Repairs.
Was a problem found?
1. Turn OFF the ignition switch.
2. Reconnect the cooling fans.
3. Reconnect the PCM.
4. Disconnect the low speed cooling fan relay.
5. Turn ON the ignition switch.
6. Connect a J 34142-B test lamp between the cooling
fan relay #1 control circuit and the battery feed circuit
at the low speed cooling fan relay harness connector.
7. Using the scan tool outputs test function, cycle the
fan 1 output ON and OFF.
Does the test lamp flash ON and OFF?

'

12

1. Check the cooling fan relay #1 control circuit for a

poor connection at the PCM.
2. If a problem is found, replace faulty terminal. Refer to
Wiring Repairs

Was a problem found?

13

14

15

Locate and repair open in the battery feed circuit to the

low speed cooling fan relay coil. Refer to Wiring Repairs.
Is action complete?

Replace cooling fan relay #1.

Is action complete?

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.

Replace the PCM.

Is action complete?

Go to Step 16
Go to Step16

Go to Step16

1. Turn OFF the ignition switch.

2. Reconnect any relay, cooling fan, and PCM
connectors that were disconnected in the
previous step.
3. Turn ON the ignition switch.

4. Review and record scan tool Fail Records data.

16

5. Clear DTCs.
6. Operate the vehicle within Fail Records conditions
as noted.
7. Using a scan tool, monitor Specific DTC info for
OTC P1651 until the OTC P1651 test runs.
Note test result; does the scan tool indicate DTC P1651
failed this ign?

Go to Step 2

System OK

6-1070

Engine Controls - 3.~L

Engine

DTC P1652 Fan 2 Relay Control Circuit

! Hot At All Times!
r - L1

L--

! Hot At All limes!

-

COOL FAN
MaxiFuse
40 A

:;~~f~utlon
Cell 10

J7

Underhood
Electri.cal
Center 1

~~NOLING
MiniFuse
10 A

1.
----J
ORN 1640
JS

-------------

RED 402

Power
Distribution
Cell10

Fuse Block

,------._

Details
Cell11

ORN 1640

RED 402

Underhood
RED 402 Electrical
Center 1

ORN 1640

""

83

0
-

~'

-----.,

89

1 1'}---

;:;., , 11

ORN 1640

WHT 504

- - - Engine

Cooling

LTB:B~r.09 - - - -

co

I Cooling
Engine

~"" .. ~""

QB8

C6

Engine
Cooling

~ --:.;-;,,;- - - -

DKB:~ 4~3- - -

am

C \

DK BU:J 473

WHT 504

~~~ine
Cooling
Fan

~ :~;~e
Cooling

DKBLU 473

Fan

DK GRN 335

BLK 150

GRY 532

BL.K

DK GRNI335

~
I

DK BLU 473

- - ) ~-f~~:~ ~- ~ -.: -~
----T
._

control

C~N:

~~ -~ -

5
-

C1=BLU
C2-CLEAR

150

""

C1

-,-j;f~niy- ~.
----T

2and3
._ Control

BLK 150 " .... ___ ,

6~~:~~ain

I Module "I (PCM) ~

~

~--------------------------~

Ground
Distribution
Cell 14

254432

Circuit Description
Output Driver Modules (ODMs) are used by the PCM to
turn on many of the current-driven devices that are
needed to control various engine and Transaxle
functions. Each ODM is capable of controlling up to
7 separate outputs by applying ground to the device
which the PCM is commanding ON. Unlike the Quad
Driver Modules (QDMs) used in prior model years,
ODMs have the capability of diagnosing each output
circuit individually. DTC P1652 set indicates an
improper voltage .level has been detected on ODM B
output 2, which controls the high speed and series/
parallel cooling fan relays.

Conditions for Setting the DTC

The ignition is ON.
An improper voltage level has been detected on
the output circuit which controls the high
speed fans.
The above conditions are present for at least
30 seconds.

Action Taken When the DTC Sets.

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Engine
Conditions for Clearing the MIUDTC
The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at PCM - Inspect harness
connectors for the following items:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connections
Damaged harness - Inspect the wiring harness for

damage.
If the harness appears to be OK, disconnect the
PCM, turn the ignition ON and observe a DMM
connected between the Fan 2 driver circuit
and ground at the PCM harness connector while
moving connectors and wiring harnesses
related to the series/parallel fan relay and the high
speed fan relay. A chartge in voltage will indicate
the location of the fault.

Engine Controls - 3.8L 6-1071

Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help determine
how often the condition that caused the OTC to be set
occurs.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Normally, battery feed voltage should be present
on the control circuit with the PCM disconnected
and the ignition turned ON.
3. Checks for a shorted component or a short to B+
on the control circuit. Either condition would
result in a measured current of over 500 milliamps.
Also checks for a component that is going open
while being operated, resulting in a measured
current of O milliamps.
4. Checks for a short to B+ on the cooling fan relay
#2 and #3 control circuit.
15. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

6-1072

Engine Controls - 3.8L

Engine

DTC P1652 Fan 2 Relay Control Circuit

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to Step 6

Go to Step 11

Go to Step 4

Go to Step 14

Go to Step 5

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Turn OFF the ignition switch.

Disconnect the PCM.
Turn ON the ignition switch.
Using a J 39200 DMM, measure voltage between the
cooling fan relay #2 and #3 control circuit at the PCM
harness connector and ground.
Is the voltage near th~ specified value?

B+

1. Disconnect the right engine cooling fan.

2. Connect the J 39200 DMM to measure current
between the cooling fan relay #2 and #3 control
circuit at the PCM harness connector and ground.
3. Monitor the current reading on the J 39200 DMM for
at least 2 minutes.
Does the current reading remain between the specified
values?

0.1 to 0.5 amps

(100 to 500 mA)

1. Disconnect engine cooling fan relays #2 and #3

(leave the PCM disconnected).
2. Reconnect the right engine cooling fan.
3. Using the J 39200 DMM, measure voltage between
the the cooling fan relay #2 and #3 control circuit and
ground.
Is voltage at the specified value?

ov

Locate and repair short to voltage in the fan 2 and 3 relay

control circuit. Refer to Wiring Repairs.
Is action complete?

1. Turn OFF the ignition switch.

2. Check the battery feed fuse for the engine cooling fan
relay #3 and engine cooling fan relay #2 coil.
Is the fuse open?

1. Locate and repair short to ground in the battery feed

circuit for engine cooling fan relays #3 and #2. Refer
to Wiring Repairs.
2. Replace the fuse.
Is action complete?

1. Disconnect engine cooling fan relay #2.

2. Turn ON the ignition switch.
3. Measure voltage between the relay coil battery feed
circuit at engine cooling fan relay #2 cavity F5 and
ground.
Is voltage near the specified value?

B+

1. Check the engine cooling fan relay #2 and #3 control

circuit for an open or a short to ground.
2. If a problem is found, repair the engine cooling fan
relay #2 and #3 control circuit. Refer to Wiring
Repairs.
Was a problem found?

1.
2.
3.
4.

Go to Step 18

Go to Step 7

Go to Step 8

Go to Step 18

Go to Step 9

Go to Step 13

Go to Step 18

Go to Step 10

Engine

Engine Controls - 3.8L

6-1073

DTC P1652 Fan 2 Relay Control Circuit (cont'd)

Step

10

11

12

13

14

15

16
17

18

\,,

Action
Check for the following conditions:
The engine cooling fan relay #2 and #3 control circuit
for poor connections at the cooling fan relays.
The battery feed circuit for poor connections at the
cooling fan relays.
The engine cooling fan relay #2 and #3 control circuit
for a poor connection at the PCM.
Was a problem found?

1. Turn OFF the ignition switch.

2. Reconnect the right cooling fan.
3. Reconnect the PCM.
4. Disconnect engine cooling fan relay #2.
5. Turn ON the ignition switch.
6. Connect a J 34142-B Unpowered test lamp between
the cooling fan relay #2 and #3 control circuit at the
right side cooling fan relay harness connector
and B+.
7. Using the scan tool outputs test function, cycle fan 2
ON and OFF.
Does the test lamp flash ON and OFF?
1. Check the cooling fan relay #2 and #3 control circuit
for a poor connection at the PCM.
2. If a problem is found, replace faulty terminal. Refer to
Wiring Repairs.
Was a problem found?
Locate and repair open in battery feed circuit to the
cooling fan relay(s) coil. Refer to Wiring Repairs.
Is action complete?

Value(s)

Go to Step 18

Go to
Diagnostic Aids

Go to
Diagnostic Aids

Go to Step 12

Go to Step 18

Go to Step 15

Go to Step 18

0.25 amp
(250 mA)

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.
Replace the PCM.
Is action complete?

1. Turn OFF the ignition switch.

2. Reconnect any relay, cooling fan, and PCM
connectors that were disconnected in the
previous step.
3. Turn ON the ignition switch.
4. Review and record scan tool Fail Records data.
5. Clear DTCs.
6. Operate the vehicle within Fail Records conditions
as noted.
7. Using a scan tool, monitor Specific OTC info for
OTC P1652 until the OTC P1652 test runs
Does the scan tool indicate OTC P1652 failed this ignition?

No

1. Reconnect engine cooling fan relay #3.

2. Install the J 39200 DMM to measure current between
the cooling fan relay #2 and #3 control circuit and
ground.
3. Monitor the current reading on the J 39200 DMM for
at least 2 minutes.
Does the current reading remain below the
specified value?

Replace engine cooling fan relay #2.

Is action complete?
Replace engine cooling fan relay #3.
Is action complete?

Yes

Go to Step 16

Go to Step 17

Go to Step 18

Go to Step 18
Go to Step 18

Go to Step 2

System OK

6-1074

Engine Controls

.;i

3.SL

Engine

DTC P1653 Fuel Le"'el Output Control Circuit

.- - ., Instrument
I Fuel I Cluster
I Gaugel

lnput ,

.I,

A2v- ~

DK BLU

11936

DK BLUI1936
3

~ - - F:;-01

C1

-1-------

Level

Signal

I
I

PCM

~ Powertra:in
Control
I
Module.
1 , I (PCM).

IC1=BLU
I
C2=CLEARI

L-----------...1

>

239633

Circuit Description
Output Driver Modules (ODMs) are used by the PCM
to turn on many of the current-driven devices that
are needed to control various ~ngine and Transaxle
functions. Each ODM is capable of controlling up to
7 separate outputs by applying ground to the
device which the PCM is commanding ON. Unlike the
Quad Driver Modules (QDMs) used in prior model
years, ODMs have the capability of diagnosing each
output circuit individually. OTC P1653 set indicates an
improper voltage level has been detected on output
circuit which controls the fuel level gage in the
instrument cluster.

Conditions for Setting the OTC

Th~ ignition is ON.
An improper voltage level has been detected on
output circuit which controls the fuel level gauge.
The above conditions present for at least
30 seconds.

Action Taken When the OTC Sets

The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM will .store conditions which were present
when the OTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

Conditions for Clearing the MIUDTC

A history OTC will clear after 40 consecutive
warm-up cycles have occurred without a

malfunction.
OTC can be cleared by using the scan tool Clear
Information function or by disconnecting the
PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at PCM - Inspect harness
connectors for the following items:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connections
Damaged harness - Inspect the wiring harness for
damage.
If the harness appears to be OK, disconnect the
PCM, turn the ignition ON and observe a DMM
connected between the cruise control inhibit driver
circuit and ground at the PCM harness connector
while moving connectors and wiring harnesses
related to the stepper motor cruise control module.
A change in voltage will indicate the location of
the fault.
Review the Fail Records vehicle mileage since the
diagnostic test last failed.. This may help determine
how often the condition that caused the OTC to be set
occurs.

EogJne

E;n,gine Conirols ."; ;3.8~ 6-.107S

'

Test Description

4. Checks .tor a ,shorted component or a short to B+

on the output control circuit. Either condition
., would result fr. measured current of over.
0.75 amps. Also Ghecks for a component that is
going open wh.ile beirig,op~rated, resulting in
a measurecj current of O amps. ..
5. Che.cks for'a malfunctioning instruR1ent cluster.
16. This vehicle is equipp~d with a PC~ which utilize~
an Electrically Erasable Programmable Head Only
Memory (EEPROM). When ttie PCM is being
replaced, the new PCM must be programt'11ed.
.

Number(s) below.refer to the step number(s),on the

. ..
. ..
.. ..... . .
Diagnostic Chart.

\~

....

.-

,,,,,,

3. Normally, ignition feed voltage should be present

on the output control circuit with the PCM
disconnected' and the ignition turned ON.

DTC P1653 Fuel Level Output Control Circuit

. Step

Adtioo

Yes

Value(s) .....

..

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Go to $tep.2
,..

_.

..Was_ the Jnstrum~Jit Cius.fer Syst~rn chec:_k .in .Electrical

Diagnosis performed?

;,!

,'

1. Turn OFF the ignition switch.

. 2. D.iscionnect the_J;>CM .
3. Turn ON the ignition switch:

4. Using a J 39200 Digital Multimeter connected to

G..o tc;, Sf~p 3.

,-,

,,.. ,

Go to .'the A
Powerttain On
Board Diagnostic
(080) $ystem
Check

' 'No..

'

8.5V

..

',!

Goto the
lnsfri:iment
Cluster $ystem
Check in
Electrical
Diagnosis

..

ground, probe the fuel level output circuit.

Is voltage near the specified Value?

Go to Step 4

Go to Step 7

1. Set the digital multimeter to the 1O amp scale and

install the digital multimeter to meas'ure current.

between the affected PCM output circuit and ground.
2. Monitor the current reading on the digital ~ultimeter
for at least 2 minutes.
Does the current reading rernaifl batween the spetjfiad.
values?

1:

>
i

'

Gerti> Step 5

..

OV

and ground.

Is voltage at the specified va}ue?

Go to Step 15

Locate and repair the short to voltage in the affected PCM

output circuit. Refer to Wiring Repairs.
Is action complete?
, .. ,,
,;
..

Check the ignition feed fuse for the instrument panel

cluster.
Is the the fuse blown?

GQ to Step 6

'

Go to Step 17

Go to Step 8

..

feed circuit for the instrument panel cluster. Refer to

Wiring Repairs.
2. Replace the fuse.
Is action complete?

Go to Step 17

,.. . ~.

Go to Step 9

1. Locate and repair the short to ground in the ignition

~'.

Go to Step 12

""

3. Measure voltage betwe~n the fuel level output circuit

.:

0:001 Amp0.75 Amps

1. Disconnect the instrument panel cluster.

2. Leave the PCM disconnected

<.

6-1076

Engine Controls - 3~8L

Engine

OTC P1653 Fuel LeveJ Output Control Circuit (cont'd)

Action

Step

10

11

Value(s)

1. Disconnect the instrument panel cluster.

2. Turn ON the ignition switch.
3. Measure voltage between the ignition feed circuit for
the instrument panel cluster and ground.
Is voltage near the specified value?

B+

1. Check the fuel level control circuit for an open or a

short to ground.
2. If a problem is found repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Check the fuel level control circuit and the ignition

feed circuit for a poor connection at the instrument
panel cluster.
2. If a problem is found, replace the terminal(s). Refer to
Wiring Repairs.
Was a problem found?

1. Check the fuel level output control circuit for a poor

connection at the PCM.
2. If a problem is found, replace the terminal. Refer to
Wiring Repairs.
Was a problem found?

14

Locate and repair open in the ignition feed circuit to the

instrument panel cluster indicator lamps. R.efer to Wiring
Repairs.
ls action complete?

15

Replace the instrument panel cluster. Refer to On-Vehicle

Service in Instrument Panel, Gages and Console.
Is action complete?

13

No

Turn OFF the ignition switch.

Leave the PCM disconnected
Turn the ignition switch ON.
Connect one end of a fused jumper to the fuel level .
output circuit and touch the other end to ground for at
least 30 seconds.
Does the fuel gauge indicate EMPTY?

12

1.
2.
3.
4.

Yes

Go to Step 10

Go to Step 14

Go to Step 17

Go to Step 11

Go to Step 17

Go to Step 15

Go io Step 13

Go to
Diagnostic Aids

Go to Step 17

Go to Step 16

Go to Step 17

Go to Step 17

Replace the PCM.

16

Important: Replacement PCM must be programmed.

Refer to PCM Replacement/Programming

17

Operate the fuel gage using the scan tool output tests
function.
Does the fuel gage operate properly?

Is action complete?

Go to Step 17

System OK

Go to Step 3

Engine

Engine Controls - 3.SL

6-1077

OTC P1662 Cruise Control Inhibit Control Circuit

,. - - - - - - - - - - - - - - - - - - - - - - - - ., Cruise
I
Cruise
Cruise
I Control
I
~;~~~le
I Module

6:r31ed
~!~1
L-------~----------------J

DK

GR~r83 WH~I85

~~*R~J
GRN/T

817

DK

DK GANIS~- - - 72

~
I
I
I

C1

~~185
59

WHT

C2

Input

j_

5V

1c1 =BLU

Instrument

L-J ~
>

812

~adio

~~~RN/

.,

L-1:!J

DKGRN/ 817
WHT

817

.:::
1
-------1~T~,;;;- --~6~:~~Wn
:;:::;

-D~: ~"-1- ~n~:~:1-- -----, -:"- ~

Output \

817

I vss I Cluster
I Input I

WHT 55 C1

Output

C2=CLEARI

I Module
I (PCM) /.
I
~

L------------------------------------J

226768

Circuit Description

Diagnostic Aids

Output Driver Modules (ODMs) are used by the PCM

to turn on many of the current-driven devices that
are needed to control various engine and Transaxle
functions. Each ODM is capable of controlling up to
7 separate outputs by applying ground to the
device which the PCM is commanding ON. Unlike the
Quad Driver Modules (QDMs) used in prior model
years, ODMs have the capability of diagnosing each
output circuit individually. DTC P1662 set indicates an
improper voltage level has been detected on the
output circuit which controls the stepper motor cruise
control inhibit circuit.

Check for the following conditions:

Poor connection at PCM - Inspect harness
connectors for the following items:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly formed or damaged terminals
- Poor terminal to wire connections
Damaged harness - Inspect the wiring harness for
damage.
If the harness appears to be OK, disconnect the
PCM, turn the ignition ON and observe a DMM
connected between the cruise control inhibit driver
circuit and ground at the PCM harness connector
while moving connectors and wiring harnesses
related to the stepper motor cruise control module.
A change in voltage will indicate the location of
the fault.
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help determine
how often the condition that caused the DTC to be set
occurs.

Conditions for Setting the DTC

The ignition is ON.
An improper voltage level has been detected on
the output circuit which controls the cruise
control inhibit.
The above conditions present for at least
30 seconds.

Action Taken When the DTC Sets

The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM will store conditions which were present
when the DTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

Conditions for Clearing the MIL/DTC

A history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
DTC can be cleared by using the scan tool Clear
Information function or by disconnecting the
PCM battery feed.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Normally, ignition feed voltage should be present
on the control circuit with the PCM disconnected
and the ignition turned ON.
3. Checks for a shorted component or a short to B+
on the control circuit. Either condition would
result in a measured current of over 500 milliamps.
Also checks for a component that is going open
while being operated, resulting in a measured
current of O milliamps.
4. Checks for a short to B+ on the cruise control
inhibit control circuit.

6~1078

Engine Controls -

a~sL

Engine

15. This vehicle is equipped with a PCM which utilizes

.an Electrically Erasable Programmable Read. Only
Memory (El=PROM). When the PCM is being
replaced, the new PCM must be programmed.

DTC P1662 Cruise Control Inhibit Control Circuit

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Step 6

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Turn ON the ignition switch.
4. Using a J 39200 DMM, measure voltage between the
cruise control inhibit circuit at the PCM harness
connector and ground.
Is voltage near the specified value?

10.5V
..

1. Connect the J 39200 DMM to measure current

3

between the cruise inhibit control circuit at the PCM

harness connector and ground.
2. Monitor the current reading on the J 39200 DMM for
at least 2 minutes.
Does the current reading remain between the specified
values?

0.001-0.75 amps
(1-750 mA)

1. Turn OFF the ignition switch.

2. Disconnect the stepper motor cruise control module
(leave the PCM disconnected).
3. Turn ON the ignition switch.
4. Using the J 39200 DMM, measure voltage between
the cruise inhibit control circuit and ground.
Is voltage at the specified value?

OV

Locate and repair short to voltage in the cruise inhibit

control circuit. Refer to Wiring Repairs.
Is action complete?

1. Turn OFF the ignition switch.

2. Check the ignition feed fuse for the stepper motor
cruise control module. Refer to Wiring Repairs.
Is the fuse open?

Go to Step 11

Go to Step 4

Go to Step 10

Go to Step 5

Go to Step 16

Go to Step 7

Go to Step 8

1. Locate and repair short to ground in ignition feed

7

circuit for the stepper motor cruise control module.

Refer to Wiring Repairs.
2. Replace the fuse.
Is action complete?
..

1. Disconnect the stepper motor cruise control module.

2. Turn ON the ignition switch.
3. Measure voltage between the ignition feed circuit for
the stepper motor cruise control module and ground.
Is voltage near the specified value?

Go to Step 16

B+
Go to Step 9

Go to Step 13

1. Check the cruise inhibit control circuit for an open or

9

a short to ground.
2. If a problem is found, repair the cruise inhibit control
circuit. Refer to Wiring Repairs.
Wa$ a problem found?

Go to Step 16

Go to Step 10

Engine ControJs -

Engine

a~aL

6.;1079

DTC P1662 Cruise Control Inhibit Control Circuit {cont'd)

Step

Action

Value(s)

.:fo

1. Check for the following conditions:

The cruise inhibit control circuit for a poor
connection at the PCM.
The cruise inhibit control circuit for a poor
connection at stepper motor cruise control module .
The stepper motor cruise control module ignition
feed circuit for a poor connection at the stepper
motor cruise control module.
2. it a problem is found, replace faulty terminal(s) as
necessary. Refer to Wiring Repairs.
Was a problem found?

'

11

1. .Turn OFF the ignition switch.

2. Reconnect the,, PCM.
3. Disconnect the stepper motor cruise control module.
4. Turn ON the ignition switch.
5. Connect a J 34142-8 UnpoV11ered test lamp bE1t\f\(eE1n
the cruise inhibit control circuit and the ignition feed
circuit at the stepper motor c;ruise control mod4le
harness connector.
6. Using the scan tool outputs test funcUon, cycle the
cruise inhibit output ON and OFF.

Yes

No

Go to Step .16

Go to Step 14

Go to
Diagnostic Aids

Go to Step 12

J}o to Step 16

Go to Step 15

,,

Does the test lamp flash ON and OFF?

1:'Check the cruise inhibit Control circuit for a poor
connection at the PCM.
'
1?

13

2. If a problem is found, replace faulty terminal. Refer to

Wiring Repairs.
Was a problem found?
Locate and repair open in the ignition feed circuit to the
stepper motor cruise control module. Refer to Wiring
Repairs.
Js.action compl.ete?

Go tq Step 16

,'

14

15

16

Replace the stepper.motor cruise control, module. Refer to

Cruise Control On-Vehicle Service.
, Is action complete?
Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Replace the PCM.
Is action complete?
1. Review and re.cord scan tool F~il Records data.
2. Clear DTCs.
3. Operate the vehicle within Fail Records conditions
as noted.
4. Using a scan tool, monitor 'Specific OTC info for
OTC P1662 until the OTC P1662test runs.
Does the scan tool indicate OTC P,1662 failed this ign?

l,

,._

',

-
Go to Step 16
,

Go to Step 16

Go to Step 2

System QK

''

6-1080

Engine Controls - 3.SL

Engine

OTC P1663 Generator Lamp Control Circuit

I I

! Hot In Run Or Start l

'" - - - - - - - - - I
I

Power
Distribution
Cell 10

L0 c

- - - - "'IP

I Fuse
I

Fuse Block
Details
Cell11

[5:J

Block

L---------- ----~

PNK 39

Fuse Block
Details
Cell11

+---

J.

PNK 39
AS

Instrument
Cluster

..I -----------------------------,

........

Instrument--+-----------+-----~

I Cluster

ffi CHECK GAUGES

\l.J Indicator

Cell81

I
I
I
r -

I
I
L

Turn on
input

I
I

I
I
I
I

---1~

Generator
Terminal L
Output

PCM
C1 = BLU
C2=CLEAR

Ground
Distribution
Ce1114

BLK/WHT 451

BLK/ 451
WHT

BI

-f

BRN/WHT 1173
BAN 1174
6 ________ 58 C2

-G;ne7at; Lamp
Control

Indicator I

Generator

RED 225
36 C1
-

_;:,

<ifi-owOIL I
Level
I

~-----1

BRN 25
61 C2
'" - , -

Ignition
Positive
Voltage
Indicator
Control
Generator
...__ _ _ _ _Status
_ __.

__ ~

----1
---1
~

Low
Oil
Control

SV

oii - , Powertrain
I Control
Module

Level
Signal I
II

(PCM)

L------------------------------------------~

.&

~
223198

Circuit Description
Output Driver Modules (ODMs) are used by the PCM
to turn on many of the current-driven devices that
are needed to control various engine and Transaxle
functions. Each ODM is capable of controlling up to
7 separate outputs by applying ground to the
device which the PCM is commanding ON. Unlike the
Quad Driver Modules (QDMs) used in prior model
years, ODMs have the capability of diagnosing each
output circuit individually. OTC P1663 set indicates an
improper voltage level on the output circuit which
controls the generator lamp.

Conditions for Setting the DTC

Conditions for Clearing the MIUDTC

A history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
OTC can be cleared by using the scan tool Clear
Information function or by disconnecting the
PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at PCM - Inspect harness
connectors for the following items:
- Backed out terminals

The ignition is ON.

- Improper mating

An improper voltage level has been detected on

the output circuit which controls the
generator lamp.

- Broken locks

The above conditions are present for at least

30 seconds.

Action Taken When the DTC Sets

The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM will store conditions which were present
when the OTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

- Improperly formed or damaged terminals

- Poor terminal to wire connections
Damaged harness - Inspect the wiring harness for
damage.
If the harness appears to be OK, disconnect the
PCM, turn the ignition ON and observe a DMM
connected between the generator lamp control
circuit and ground at the PCM harness connector
while moving connectors and wiring harnesses
related to the generator lamp. A change in voltage
will indicate the location of the fault.

Engine Controls - 3.8L

Engine
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help determine
how often the condition that caused the OTC to be set
occurs.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Normally, ignition feed voltage should be present
on the control circuit with the PCM disconnected
and the ignition turned ON.

6-1081

3. Checks for a shorted component or a short to B+

on the control circuit. Either condition would
result in a measured current of over 500 milliamps.
Also checks for a component that is causing an
open circuit while being operated, resulting in
a measured current of O milliamps.
4. Checks for a short to voltage on the control
circuit.
14. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

OTC P1663 Generator Lamp Control Circuit

Step

Action

Value(s)

Yes

No

Go to Step2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to Step 6

Go to Step

Go to Step 4

Go to Step10

Go to Step 5

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
-

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Turn ON the ignition switch.
4. Using a J 39200 DMM, measure voltage between the
generator lamp control circuit at the PCM harness
connector and ground.
Is voltage near the specified value?

B+

1. Connect the J 39200 DMM to measure current

between the generator lamp control circuit at the
PCM harness connector and ground.
2. Monitor the current reading on the J 39200 DMM tor
at least 2 minutes.
Does the current reading remain between the specified
values?

0.002-0.5 amps
(2-500 mA)

1. Turn OFF the ignition switch.

2. Disconnect the instrument cluster (leave the PCM

4

disconnected).
3. Turn ON the ignition switch.
4. Using the J 39200 DMM, measure voltage between
the generator lamp control circuit and ground.
Is voltage at the specified value?

ov

Locate and repair short to voltage in the generator lamp

control circuit. Refer to Wiring Repairs.
Is action complete?

Check the ignition teed fuse tor the instrument panel

indicators.
Is the fuse open?

1. Locate and repair short to ground in ignition teed

circuit tor the instrument cluster indicators. Refer to
Wiring Repairs.
2. Replace fuse.
Is action complete?

Go to Step 15

Go to Step 7

Go to Step 8

Go to Step 15

&;;.1082

En9ine,Contro1s,.,. 3.8L

Engine

, DTC P1663 Generator Lamp Control Circuit (cont'd)

Step

Value(s)

Action

Yes

No
,,

'

1. Disconnect the instrument cluster.

2. Turn ON the ignition switch.
3. Measure voltage between the ignition feed circuit for
the instrument cluster indicators and ground.
Is voltage near the specified value?
,,
1. Check the. generator lamp control circuit. for an open
or a short to ground.
2. If problem is :found,. repair the generator lamp
control circuit. Refer to Wiring Repairs.
Was a problem found?
,
::. ;'

(
B+

Go to step 9

,,

'

'(

,'

'

10

11

1. Check the generator lamp control circuit and the

instrument cluster indicators ignition feed circuit for a
poor connection at the instrument cluster and at
the PCM.
2 ..If a problem is found, replace faulty terminal(s). Refer
to Wiring Repairs.
Was a problem found?
1.
2.
3.
4.
5.

Go to Step 15

Go to Step 10

,,

Go to Step15
.,

Go to Instrument
Cluster
System Check.

Turn OFF the ignition switch.

Reconnect the PCM.
Disconnect the instrument cluster.
Turn ON the ignition switch.
Connect a J 34142-8 Unpowered test lamp between
the generator lamp control circuit and the ignition
feed circuit at the instrument cluster harness
connector.

"

Go to
Diagnostic Aids

Does the test lamp flash ON and OFF?..

12

1. Check the generator lamp control circuit for a poorconnection at the PCM.
2. If a problem is found, replace faulty terminal. Refer to
Wiring Repairs.
Was a problem found?

13

Locate and repair open in the ignition feed circuit to the

instrument cluster indicators. Refer to Wiring Repairs.
Is action complete?

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.
Replace the PCM.
Is action complete?

1. Review and record scan tool Fail Records data.

2. Clear DTCs.
3. Operate the vehicle within Fail Records conditions.
4. Using a scan tool, monitor Specific OTC info for
OTC P1663 until the OTC P1663 test runs.
Does the scan tool indicate OTC P1663 failed this ignition?

(
Go to Step 12

.......:....

Go to Step 15

',

15

',

..

6. Using the scan tool outputs test function, cycle the

generator lamp ON and OFF.

14

.Go to Step 13

Go to Step 14

Go' to Step 15

Go to Step 15

Go to Step 2

System OK

Engine

Engine Controls - 3.8L

6-1083

OTC P1665 EVAP Vent Solenoid Control Circuit

fHot In Run, Bulb Test And

r. -

;ower

Start!
- , Underhood

- - -

ENG CTRL I Electrical

MiniFuse : Center 2
15 A

Distribution
Gell 10

LliJ

IC Module
and
Transmission

L.-----------..1
PNK 239
+-------,.

PNK 239

PNK 239

PN1239

. PNKJ239

-PN:1239

PN:1239

L -

Evaporative
[ ] ] Evaporative
Emi~sion (EVAP)
Emi~sion (EVAP)
Canister Vent
[ ] ] Canister Purge
Solenoid
Solenoid
Valve
A
Valve
DK
WHT 1310
GRN/WHT 428
WHT 1310

II

BI

76

C1

'" J

. WHTr 1310
2 C2

EVAP Canister
Purge Valve

-.Driver

J
-1

.EVAP Canister

PCM

Vent Valve

c1 =

Driver

C2=CLEAR

BLU

I Powertrain
C
I
ontro
:

~~~~e ~"-.

L------------------------~
222965

Circuit Description
Output Driver Modules (ODMs) are used by the PCM
to turn on many of the current-driven devices that
are needed to control various engine and Transaxle
functions. Each ODM is capable of controlling up to
7 separate outputs by applying ground to the
device which the PCM is commanding ON. Unlike the
Quad Driver Modules (QDMs) used in prior model
years, ODMs have the capability of diagnosing each
output circuit individually. DTC P1665 set indicates an
improper voltage level has been detected on the
output circuit which controls the EVAP
canister vent valve.

Conditions for Setting the DTC

The ignition is ON.
An improper voltage level has been detected on
the output circuit which control the EVAP
canister vent valve.
The above conditions are present for at least
30 seconds.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second

consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the OTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIL/DTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Info function or by disconnecting the
PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at PCM or the EVAP canister
vent valve.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wire connection.
Damaged harness.
Inspect the wiring harness for damage.
If the harness appears to be OK, disconnect the
PCM, turn the ignition ON and observe a
voltmeter connected to the EVAP canister vent
valve control circuit at the PCM harness connector
while moving connectors and wiring harnesses
related to the EVAP canister vent yalve. A change
in voltage will indicate the location of the
malfunction.

6-1084

Engine Controls - 3.8L

Review the Fail Records vehicle mileage since the

diagnostic test last failed. This may help determine
how often the condition that caused the OTC to be set
occurs.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart.
2. Ignition feed voltage should be present on the
control circuit with the PCM disconnected and the
ignition turned ON.

Engine
3. Checks for a shorted component or a: short to B+
on the control circuit. Either condition would
result in a measured current of over 800 milliamps.
Also checks for a component that is going open
while being operated, resulting in a measured
current of O milliamps.
4. Checks for a short to voltage on the control
circuit.

OTC P1665 EVAP Vent Solenoid Control Circuit

Action

Step

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to Step 6

Go to Step 11

Go to Step 4

Go to Step 14

Go to Step 5

Was the Powertrain On-Board Diagnostic System Check

performed?
1

1.
2.
3.
4.

Turn OFF the ignition switch.

disconnect the PCM.

Turn ON the ignition switch.
Using a J 39200 DMM, measure voltage between the
EVAP canister vent valve control circuit at the PCM
harness connector and ground.
Is voltage near the specified value?
1. Connect the J 39200 DMM to measure current
between the EV AP canister vent valve control circuit
at the PCM harness connector and ground.
2. Monitor the current reading on the J 39200 DMM for
at least 2 minutes.
Does the current reading remain between the specified
values?
1. Disconnect the EVAP canister vent valve (leave the
PCM disconnected).
2. Using a J 39200 DMM, measure voltage between the
EVAP vent solenoid control circuit and ground.

B+

0.1-0.8 Amps
(100 - 800 mA)

OV

Is voltage at the specified value?

Locate and repair short to voltage in the EVAP canister

vent valve control circuit. Refer to Wiring Repairs.
Is action complete?

1. Turn OFF the ignition switch.

2. Check the ignition feed fuse for the EVAP canister
vent valve.
Is the fuse blown?

1. Locate and repair short to ground in ignition feed

circuit for the EVAP canister vent valve. Refer to
Wiring Repairs.
2. Replace fuse.
Is action complete?

Go to Step 16

Go to Step 7

Go to Step 8

Go to Step 16

1. Disconnect the EVAP canister vent valve.

8

2. Turn ON the ignition switch.

3. Measure voltage between the ignition feed circuit for
the EVAP EVAP canister vent valve and ground.
Is voltage near the specified value?

B+
Go to Step 9

Go to Step 13

Engine Controls - 3.8L

Engine

6-1085

DTC P1665 EVAP Vent Solenoid Control Circuit (cont'd)

Value(s)

Step

Action

1. Check the EVAP canister vent valve control circuit for

an open or a short to ground.
2. If a problem is found, repair the EVAP canister vent
valve control circuit. Refer to Wiring Repairs.
Was a problem found?

1. Check the EVAP canister vent valve control circuit

and the ignition feed circuit for a poor connection at
the EVAP ca.nister vent valve and at the PCM.
2. If a problem is found, replace loose terminal(s). Refer
to Wiring Repairs.
Was a problem found?

10

11

1. Turn OFF the ignition switch.

2. Reconnect the PCM.
3. Disconnect the EVAP canister vent valve.
4. Turn ON the ignition switch.
5. Connect a J 34142-8 test lamp between the EVAP
canister vent valve control circuit and the ignition feed
circuit at the EVAP canister vent valve harness
connector.
6. Using the scan tool outputs test function, cycle the
EVAP vent solenoid ON and OFF.

12

13

Locate and repair open in the ignition feed circuit to the

EVAP canister vent valve. Refer to Wiring Repairs.

15

Replace the EVAP canister vent valve. Refer to EVAP

Vent Valve Replacement.
Is action complete?
Important: Replacement PCM must be programmed.
Refer to PCM ReplacemenVProgramming.

Replace the PCM.

Is action complete?

Go to Step 16

Go to Step 10

Go to Step 16

Go to Step 14

Go to
Diagnostic Aids

Go to Step 12

Go to Step 16

Go to Step 15

Go to Step 16

Is action complete?
14

No

Does the test lamp flash ON and OFF?

1. Check the EVAP canister vent valve control circuit for
a poor connection at the PCM.
2. If a problem is found, replace loose terminal.
Was a problem found?

Yes

Go to Step 16

Go to Step 16

1. Review and record scan tool Fail Records data.

2. Clear DTCs.
3. Operate the vehicle within Fail Records conditions
16

as noted.

4. Using a scan tool, monitor Specific DTC info for

DTC P1675 until the DTC P1675 test runs.
Does the scan tool indicate DTC P1675 failed this ign?

Go to Step 2

System OK

6-1086

Engine

Engine Controls - 3.8L

DTC P1671 MIL Control Circuit

iHot In Run, Bulb Test And Start

.. - - - - - -

G3
GAUGES
H
FusAe 9
3
10
-4-----. H4

Fuse Block

I Details
I Cell 11

L------

- - - , IP

_____ __.

IFuse

Block
1

----J

PNK 39
AS

PNK 39

r - - - - - - - - - - - - I Instrument~
Mattunction
~
J... lnl!licato;
I Cluster

(!)

I Cell 81

y~
-.!,

Fuse Block
Details
Cell11

Ll!I

-1 Instrument
Cl
I

Lamp (MIL)
I
(SERVICE
I
ENGINE SOON) I

L----. -~------~

uster
~

~ ..~4

A4I

BRN/WHT 419
BRN/WHTI419

-.:r ----5

r -

I
I
I

MIL-

C2

control

1
~

-;:c~ - , Powertrain
I Control
C2=CLEAR I Module~
C1 =BLU

l(PCM)~

L----------.-------~

226858

Circuit Description

Diagnostic Aids

Output Driver Modules (ODMs) are used by the PCM

to turn on many of the current-driven devices that
are needed to control various engine and Transaxle
functions. Each ODM is capable of controlling up to
7 separate outputs by applying ground to the
device which the PCM is commanding ON. Unlike the
Quad Driver Modules (QDMs) used in prior model
years, ODMs have the capability of diagnosing each
output circuit individually. OTC P1671 set indicates an
improper voltage level on the output circuit that
controls the Malfunction Indicator Lamp (MIL).

Check for the following conditions:

Poor connection at the PCM.
Inspect harness. co.nnectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wire connection.
Damaged harness.
Inspect the wiring harness for damage. If the
harness appears to be OK, disconn.ect the PCM,
turn the ignition ON and observe a DMM
connected between the MIL control circuit and
ground at the PCM harness connector while
moving connectors and wiring harnesses related
to the MIL. A change in voltage will indicate
the location of the malfunction.
Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the OTC to be
set occurs. This may assist in diagnosing the condition.

Conditions for Setting the OTC

Ignition is ON.
An improper voltage level has been detected on
the output circuit which controls the Malfunction
Indicator Lamp (MIL).
Above conditions for at least 30 seconds.

Action Taken When the OTC Sets

The PCM will not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM will store conditions which were present
when the OTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

Conditions for Clearing the MIUDTC

A history OTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
OTC can be cleared by using the scan tool Clear
Info function or by disconnecting the PCM
battery feed.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Normally, ignition feed voltage should be present
on the control circuit with the PCM disconnected
and the ignition turned ON.
3. Checks for a shorted component or a short to B+
on the control circuit. Either condition would
result in a measured current of over 500 milliamps.
Also checks for a component that is causing an
open circuit while being operated, resulting in
a measured current of O milliamps.
4. Checks for a short to voltage on the control
circuit.
14. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

Engine Controls .;; 3.8L &-1.087,

Engine

OTC P1671 MIL Control Circuit

,,

Step

Acti<>.n
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?

No

Yes

Value(s)

'

Go to Step 2

Go to the A
Powettrain On
Board Diagnostic
(080)
System 1 Check
,,

1. Turn OFF the ignition switch.

2. Disconnect the PCM.

'

3. Turri ON the ignition switch.

4. Using a J 39200 DMM, rneasure voltage between the

B+
:

MIL .control circuit at the PCM harness connector and

ground.
'
'
.. '
;
Is voltage near the specified value?

Go to Step 3

Go to Step 6

Go to Step 11

Go to Step 4

1. Connect the J 39200 DMM to measure current

3

between the MIL control circuit at the PCM harness

connector and ground.
2. Monitor the current reading on the J 39200 DMM,for
at least 2 minutes.

0.0010.75 Arnps
(1-750 mA)

Does the current reading remain between the specified

values?

1. Turn OFF the ignition switch.

2. Disc_onnect the instrum~nt panel (leave the PCM

disconnecte_p).
,.~ ...
Turn
ON the ignition switch.
3.

ov

4. Using a J 39200 DMM, measure voltage between the

MIL control circuit and ground.

Go to Step 10

Is voltage at the specified value?

Locate and repair short to vo!tage in the MIL control

circuit. Refer to WJring Repairs.
Is action complete?
.
Check the ignition feed fuse for the instrument panel
indicators.

Go to $tep 5

:',

Go to Step 15

Go to Step 7

Is the fuse blown?

Go to Step 8

1. Locate and repair short to ground in ignition feed

7

circuit for the instrument panel indicators. Refer to

Wiring Repairs.

2. Replace fuse.

Go to Step 15

Is action complete?

1. Disconnect the instrument cluster.

2. Turn ON the ignition switch.

3. Measure voltage between the ignition feed circuit for

B+

the instrument cluster indicators and ground.

Is voltage near the specified value?

Go to Step 9

Go to Step 13

Go to Step 15

Go to Step 10

Go to Step 15

Go to Instrument
Cluster
System Check.

1. Check the MIL control circuit for an open or a short to

ground.

2. If a problem is found, repair the MIL control circuit.

Refer to Wiring Repairs.

Was a problem found?

1. Check the MIL control circuit and the instrument

10

panel indicators ignition feed circuit for a poor

connection at the instrument panel and at the PCM.
2. If a problem is found, replace loose terminal(s). Refer
to Wiring Repairs.
Was a problem found?

6-1088

Engine

Engine Controls - 3.8L

DTC P1671 MIL Control Circuit (cont'd)

Step

Action
1.
2.
3.
4.

11

Value(s)

5. Connect a J 34142-8 test lamp between the MIL

control circuit and the ignition feed circuit at the
instrument panel harness connector.
6. Using the scan tool outputs test function, cycle the
MIL ON and OFF.
Does the test lamp flash ON and OFF?

Go to
Diagnostic Aids

Go to Step 12

Go to Step 15

Go to Step 14

12

13

Locate and repair open in the ignition feed circuit to the 1/P
indicators. Refer to Wiring Repairs.
Is action complete?

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.
Replace the PCM.
Is action complete?

15

No

Turn OFF the ignition switch.

Reconnect the PCM.
Disconnect the instrument cluster.
Turn ON the ignition switch.

1. Check the MIL control circuit for a poor connection at

the PCM.
2. If a problem is found, replace loose terminal. Refer to
Wiring Repairs
Was a problem found?

14

Yes

1. Review and record scan tool Fail Records data.

2. Clear DTCs.
3. Operate the vehicle within Fail Records conditions.
4. Using a scan tool, monitor Specific OTC info for
OTC P1671 until the OTC P1671 test runs.
Does the scan tool indicate OTC P1671 failed this ignition?

Go to Step 15

Go to Step 15

(
Go to Step 2

System OK

Engine Controls - 3.SL

Engine

6-1089

DTC P1672 Low Engine Oil Level Lamp Control CKT

i Hot In Run Or Start i

'" - - - - - - - - - -

I Power
II

~~\~ution

Fuse Block
Details
Cell11

L----------

- - - - , IP
I
II

BFuloscek

LliJ

----J

Fuse Block

Details
Cell11

------------------------------,

.. Instrument

I
Cluster
I Cell 81

I
I

ffi CHECK GAUGES

I..V Indicator

I
I

470 n
Indicator
Control

lgnttion
Positive
Voltage
Generator
Status

Level
Indicator

~
I
I

PCM

~ _c::<:-E~R -

Ground

Dl.stribution

Cell 14

WHT 451

I\

BRN/WHT11173
6

~~,

11

BR~ 11174 BLK/WHT 451

sslc2

-------------A

- - [:ator - - - - - } c1= BLU

.......

BU{/

I
I

~ ----------------:~~r-:.~ -~A~~~r,~~ --~

REDI225
36 c1

I ,.
I ~

(i) LOWOIL
}

Instrument

I
Cl USter
I

L~ -

--- 0T Oil
Control

r-- ~~~ ~ 6~:~~ain

Signal I

Module

I (PCM)

- - - - - - - - - - - - _ :_V __ - ~

,I.

,4
226860

Circuit Description
Output Driver Modules (ODMs) are used by the PCM
to turn ON many of the current-driven devices that
are needed to control various engine and Transmission
functions. Each ODM is capable of controlling up to
7 separate outputs by applying ground to the
device which the PCM is commanding ON. Unlike the
Quad Driver Modules (QOMs) used in prior model
years, OOMs have the capability of diagnosing each
output circuit individually. OTC P1672 set indicates an
improper voltage level has been detected on the
output circuit which controls the low engine oil level.

Conditions for Setting the OTC

The ignition is ON.
An improper voltage level has been detected on
the output circuit which controls the low engine
oil level lamp.
Above conditions for at least 30 seconds.

Action Taken When the OTC Sets

The PCM will not illuminate the MIL.
The PCM will store conditions which were present
when the OTC set as Fail Records data only.
This information will not be stored as
Freeze Frame data.

Conditions for Clearing the MIUDTC

A history OTC P1672 will clear after 40
consecutive warm-up cycles have occurred
without a fault.
OTC P1672 can be cleared by using the scan tool
Clear Info function or by disconnecting the PCM
battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wire connection.
Damaged harness.
Inspect the wiring harness for damage.
If the harness appears to be OK, disconnect the
PCM, turn the ignition ON and observe a digital
multimeter connected between the low engine
oil level lamp control circuit and ground at
the PCM harness connector while moving
connectors and wiring harnesses related to the
instument panel. A change in voltage will indicate
the location of the malfunction.
Review the Fail Records vehicle mileage since the
diagnostic test last failed. This may help determine
how often the condition that caused the OTC to be set
occurs.

6-1090

Engine, Controls. - 3.SL

Engine

Test Description

4. Checks for a shortJo voltage on the control

circuit.

Number(s) below refer to the step number(s) on the

Diagnostic Table.

14. This vehicle is equipped with a PCM which utilizes

an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be pn;>grammed.

2. Normally, ignition feed voltage should be present

on the control circuit with the PCM disconnected
and the ignition turned ON.
3. Checks for a shorted component or a short to B+
on the control circuit. Either condition would
result in a measured current of over 750 milliamps.
Also checks for a component that is causing an
open circuit while being operated, resulting in
a measured current of O milliamps.

OTC P1672 Low Engin~ Oil Level Lamp ContrC)I CKT

Step

..' ' ' .

Action

,;,

,,

Was the Powertrain .on-Board Diagnostic (OBD) System

Check performed?

Value(s)

Yes

No
1
Go to the A
Powertrain On
Board Diagnostic

"

-'

(080)
Go to Step 2

System 11 Check,

Go to Step 3

Go to Step 6

1. Turn OFF the ignition switch.

2: Disconnect the PCM.

3. Turn ON the ignition switch.

2

4. Using a J 39200 Digital Multimeter, measure voltage.

between the engine low oil level lamp control circuit
at the PCM .harness connector and ground.
Is the voltage near the specified value?

B+

''

1. Connect the digital multimeter to measure current

3

between the engine low oil level lamp control circuit

at the PCM harness connector and ground.

2. Monitor the current reading on the digital multimeter
for at least 2. min,utes.
Does the current reading remain petween the specified
values?
.

0.0010.75 Amps
(1-750 mA)

'

'

Go to Step 11

Go td Step 4

',,

1. Turn OFF the ignition switch.

2. Dfsconnect the instrument panel (leave the PCM
disconnected).
'
3. Turn ON the ignition switch.
4. Using a digital multimeter; ni~asure voltage between
the engine low oil level lamp control circuit and
ground.

''

..av '

'

,,,,

Is voltage atJhe specified value?

Go to Step 10

Go to Step 5

,,,

Locate and repair short to voltage in the engine low oil

level lamp control circuit. Refer to Wiring Repairs.
Is action complete?

Check the. ignition feed fuse for the instrument panel

indicators.
Is the fuse blown?

Go to Step 15

...

'
Go to Step 7

Go t0:Step B

1. Locate and repair short to gro1;1nd in ignition feed

7

circuit for the instrument panel indicators. Refer to

Wiring Repairs.
2. Replace fuse.
Is actiori complete? -,

._

Go to Step 15

,,,,;

Engine

Engine Controls -3.SL

s. 1.091

DTC P1672 Low Engine Oil Level Lamp Control CKT (cont'd)
Action

Step

Value(s)

Yes

No

Go to Step 9

Go to Step 13

Go to Step 15

Go to Step 10

Go to Step 15

Go to Instrument
Cluster
System Check

Go to
Diagnostic Aids

Go to Step 12

Go to Step 15

Go to Step 14

1. Disconnect the instrument cluster.

2. Turn ON the ignition switch.

10

3. Measure voltage between the ignition feed circuit for

the instrument cluster indicators and ground.
Is voltage near the specified value?
1. Check the engine low oil level lamp control circuit for
an open or a short to ground.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Check the engine low oil level lamp control circuit and
the instrument panel indicators ignition feed circuit for
a poor connection at the instrument panel and at
the PCM.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1.
2.
3.
4.
11

B+

Turn OFF the ignition switch.

Reconnect the PCM.
Disconnect the instrument cluster.
Turn ON the ignition switch.

5. Connect a test light between the engine low oil level

lamp control circuit and the. ignition feed circuit at.the

instrument panel hamess connector.
6. Using the scan tool outputs test function, cycle the
engine low oil level lamp ON and OFF.
Does the test light flash ON and OFF?

12

13

1. Check the engine low oil level lamp control circuit for
a poor connection at the PCM.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?
Locate and repair open in the ignition feed circuit to the 1/P
indicators. Refer to Wiring Repairs.

Is action complete?

14

15

Replace the PCM.

Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Is action complete?
1. Review and record scan tool Fail Records data.
2. Clear DTCs.
3. Operate the vehicle within Fail Records conditions.

Go to Step 15

Go to Step 15

4. Using a scan tool, monitor Specific OTC info for

OTC P1672 until the OTC P1672 test runs.
Does the scan tool indicate OTC P1672 failed this ignition?

Go to Step 2

System OK

6-1092

Engine

Engine Controls .. 3.8L

OTC P1676 EVAP Canister Purge Solenoid Control CKT

!Hot In Run, Bulb Test And Start!
.. -

;,;,- -

1.,

ENG CTRL I
tliliniFuse
15 A
I

Distribution
Cell 10

___________

Unde~hood
Electrical
Center 2

...

PNK 239

IC Module

+ - - - - - - ,

and
Transmission

PNK 239

PNK 239

PN1239

PNKI239

-PN:l239

PN:1239

L -

Evaporative
Emission (EVAP)
Canister Purge
Solenoid
Valve

A
DK

GRN/WHT 428

rnII

Evaporative
.
Emi~sion (EVAP)
Carnst~r Vent
Solenoid
Valve
WHT 1310
1'
WHT 1310

BI
l

WHTI1310
76

C1

2 C2

222965

Circuit Description
Output Driver Modules (ODMs) are used by the PCM
to turn on many of the current-driven devices that
are needed to control various engine and Transmission
functions. Each ODM is capable of controlling up to
7 separate outputs by applying ground to the
device which the PCM is commanding ON. Unlike the
Quad Driver Modules (QDMs) used in prior model
years, ODMs have the capability of diagnosing each
output circuit individually. DTC P1676 set indicates an
improper voltage level has been detected on the
output circuit which controls the EVAP Canister Purge
Solenoid Valve.

Conditions for Setting the DTC

The ignition is ON.
An improper voltage level has been detected on
the output circuit which controls the EVAP
canister purge valve.
The above conditions are present for at least
30 seconds.

Action Taken When the DTC Sets

The PCM will illuminate the MIL during the second
consecutive trip in which the diagnostic test has
been run and failed.
The PCM will store conditions which were present
when the DTC set as Freeze Frame and Fail
Records data.

Conditions for Clearing the MIUDTC

The PCM will turn the MIL OFF during the third
consecutive trip in which the diagnostic has
been run and passed.
The history DTC will clear after 40 consecutive
warm-up cycles have occurred without a
malfunction.
The DTC can be cleared by using the scan tool
Clear Information function or by disconnecting
the PCM battery feed.

Diagnostic Aids
Check for the following conditions:
Poor connection at the PCM.
Inspect harness connectors for backed out
terminals, .improper mating, broken locks,
improperly form'ed or damaged terminals, and
poor terminal to wire connection.
Damaged harness.
Inspect the wiring harness for damage. If the
harness appears to be OK, disconnect the PCM,
turn the ignition ON and observe a voltmeter
connected between the EVAP purge solenoid
control circuit and ground at the PCM harness
connector while moving connectors and
wiring harnesses related to the EVAP purge
solenoid. A change in voltage will indicate the
location of the malfunction.

Engine

Engine Controls - 3.SL

Review the Fail Records vehicle mileage since the

diagnostic test last failed. This may help determine
how often the condition that caused the OTC to be set
occurs.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Normally, ignition feed voltage should be present
on the control circuit with the PCM disconnected
and the ignition turned ON.

6-1093

3. Checks fora.shorted.component or a short to B+

on the control circuit. Either condition would
result in a measured current of over 500 milliamps.
Also checks for a component that is going open
while being operated, resulting in a measured
current of O milliamps.
4. Checks for a short to voltage on the control
circuit.
15. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

DTC P1676 EVAP Canister Purge Solenoid Control CKT

Step

Action

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Step 6

Value(s)

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Turn ON the ignition switch.

4. Using a J 39200 Digital Multimeter, measure voltage

between the EVAP purge valve control circuit at the
PCM harness connector and ground.
Is voltage near the specified value?

B+

'

1. Connect the digital multimeter to measure current

between the EVAP purge valve control circuit at the
PCM harness connector and ground.
2. Monitor the current reading on the digital multimeter
for at least 2 minutes.
Does the current reading remain between the specified
values?

0.05-0.5 amps
(50-500 mA)

Go to Step 11

Go to Step 4

Go to Step 10

Go to Step 5

'

1. Turn OFF the ignition switch.

2. Disconnect the EVAP purge valve (leave the PCM
disconnected).
l
3. Turn ON the ignition switch.
4. Using the digital multimeter, measure voltage
between the EVAP purge valve control circuit and
ground.
Is voltage at the specified value?

ov

Locate and repair short to voltage in the EVAP purge

valve control circuit. Refer to Wiring Repairs.
Is action complete?

Check the ignition feed fuse for the EVAP purge valve.
Is the fuse blown?

1. Locate and repair short to ground in ignition feed

circuit for the EVAP purge valve. Refer to Wiring
Repairs.
2. Replace the fuse.
Is action complete?

1. Disconnect the EVAP purge valve.

2. Turn ON the ignition switch.
3. Measure voltage between the ignition feed circuit for
the EVAP purge valve and ground.
Is voltage near the specified value?

B+

Go to Step 16

,.

Go to Step 7

.Go to Step 8

Go to Step 16

Go to Step 9

Go to Step 13

~.;.1 <>9,~. , Engine 'Cor,ttrols - 3.8L

.Engine

OTC P1676 EVAP'Canister Purge Solenoid Control CKT (cont'd)

Step,

,'

Value(s)

Action

Yes

No

1:- ,t<::Check the EVAP purge valve control circuit for an

, , open or a short to ground.

2. If a problem is found, repair the EVAP purge valve

control circuit. Refer to Wiring Repairs.
Was a problem found?

'

',

!;..

,,

1,,

r.

Go to Step 10

Go to Step 16

Go to Step 14

Check for the following conditions:

The EVAP purge valve control circuit for a poor
connection at the PCM.

...
,,

Go to Step 16

The EVAP purge valve control circuit for a poor

connectioo. at EVAP purge valve.

10

-,.,

The EVAP purge valve ignition feed circuit for a

poor connection at the EVAP purge valve.

2. If a problem is found, replace loose terminal(s) as

necessary. Refer to Wiring Repairs.

Was a problem found?

1. Turn OFF the ignition switch.

2. Reconnect the PCM.

'.

3. Disconnect the EVAP purge valve.

4. Turn ON the ignition switch.
5. Connect a test light between the EVAP purge valve
control circuit and the ignition feed circuit at the
EVAP purge valve harness connector.

11

6. Using the scan.tool outputs test function, cycle the

EVAP purge solenoid O\:Jtput ON and OFF.

F,

Goto
Diagnostic Aids

Does the test light flash ON and OFF?

1. Check the EVAP purge valve control circuit for a poor
connection at the PCM.
2. If a problem is found, replace loose terminal. Refer to
Wiring Repairs.

12

(
Go to Step 16

Was a problem found?

Locate and repair open in ignition feed circuit to the EVAP
purge valve. Refer to Wiring Repairs.

13

Replace the EVAP purge valve.

.
15

Is action complete?
Replace the PCM .
Important: Replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Is action complete?

Go to Step 15

Go to Step . 16

Is action complete?
14

Go to Step 12

Go to Step 16

Gq to.Step 16

1. Review and record scan tool Fail Records data.

2.

16

.Clear OTCs.
3. Ope.rate the vehicle within Fail Records conditions.

4, Using a scan tool, monitor Specific OTC info for

OTC P1655 until the OTC P1655 test runs.
Does the scan tool indicate OTC P1655 failed this ign?

Go to Step 2

System OK

Engine

lfngine .controls. ,a.SL 6-1095

Intermittent Conditions

Important: Problem may or may not turn On the

Malfunction Indicator Lamp (MIL) or store a OTC. DO
NOT use the Diagnostic Trouble Code (OTC) charts
for intermittent problems. The fault must be present to
locate the problem.
Most intermittent problems are caused by faulty
electrical connections or wiring. Perform a' careful
visual/physical check for the .following conditions: .
Poor matin,g qf the connector halves or a term.irial
not fully seated in the connector (backed out).
Improperly formed or damaged terminal.
All connector terminals in the problem circuit
should be carefully checked for proper contact
tension.
Poor ie.rminal to wire connection.
This requires removing the terminal from the
connector body to check.
Road test the vehicle with a J 39200 Digitaf Multimeter
connected to a suspected cfrcuit. An abnormal
'
voltage when malfunction occurs is a good indication
that there is a fault in the circuit being mbnitdred.
Use a scan tool to help detect intermittent conditions.
The Tech 1 & Tech 2 ~ave Several feptures that
can be used to locate an intermittent condition. Use
the following features to find intermittent faults:
The Snapshot feature can be triggered to capture
and store engine parameters within the scan tool
when the malfunction occurs. This stored
information then can be reviewed by the service
technician to see what caused the malfunction.

Checks

Using a Scan Tool's Freeze Frame data or Failure

Records data can also aid in locating an
intermittent condition. Review and record the
information in the freeze frame or failure record
assocJated with the intermittent OTC being
diagnosed. The vehicle can be driven within the
conditipn~ .that were present when the
OTC originally set.
Loss of diagnostic code memory. To check, disconnect
MAP sensor and idle engine until the MIL (Service
'
Engine Soon) comes ON. OTC P0107 should be
stored and kept in memory when ignition is turned
OFF. If not thePOM is faulty: When this testis .
completed, make sure that you clear the DTC P0107
from memory.
An intermittent MIL (Service Engine Soon) with no
stored OTC may be caused by the following:
Ignition coil shorted to ground and arcing at
ignition wires or plugs.
MIL (Service Engine Soon) wire to PCM shorted
to ground.
Poor PCM grounds, refer to Engine Controls.
If the intermittent condition exists as a start and then
stall, check for DTCs relating to the vehicle theft
deterrent system.
Check for improper installation of electrical options
such as lights, cellular phones etc. Route Ignition
Control Module (ICM) wiring away from secondary
ignition wires and ignition coils. Check all wires from
the PCM to the ignition control module for poor
connections.
Check for open diode across A/C compressor clutch
apd check for other open diodes (refer to wiring
dip.grams in Electrical Diagnosis section BA).
If problem has not been found, refer to Engine Controls

Connector End Vi~ws.

Hard Start
',

Action

Definition: Engine cranks OK, but does not start for a long time, Does eventually run, .or may start but immediately dies.
Preliminary

Refer to the A Powertrilin On. Board Diagnostic (080) System Check.

Search for bulletins.

Sensor/System

Check Engine Coolant Temperature (ECT} sensor for being shifted in value.
Install a scan tool and compare the displayed Engine Coolant Temperature with
Intake Air Temperature ori a cold engine ..Check the resistance of the ECT
sensor lf engine coolant temperature is not within 3C (5F} of intake air
temperature. Refer to TemperaJure vs Resistance. If the ECT sensor resistance
is not within the specification, refer to OTC P0117 Engine Coolant Temperature
(ECT) Sensor Circuit Low Voltage or OTC P0118 Engine Coolant Temperature
(ECT) Sensoi Circuit High Voltage.
Check the throttle body inlet screen '.for foreign objects or damage that may
affect the MAF sensor airflow sample. Refer to Throttle Body Air Inlet Screen
Replacement.

'i

Using a scan tool, check IAGoperation. Refer to Idle Air Control System
Diagnosis.
i
EGR system. Check the for the following conditions:
- EGR pipes and adapter for vacuum leaks.
- Remove the EGRvalve and check for P. stuck open pintle. Refer to EGR
,,.,,.
Valve Replacement.

6-1096

Engine

Engine Controls - 3.8L

Hard Start (cont'd)
Action

Checks

Fuel System

Check the fuel pump relay circuit for proper operation.

Refer to Fuel Pump Relay Circuit Diagnosis.
Check for incorrect fuel pressure.
Refer to Fuel Pump Relay Circuit Diagnosis

Check the fuel injectors.

- Refer to Fuel lnj Coil Test - ECT Between 10-35 Degrees C.
- Refer to Fuel lnj Coil Test - ECT Outside 10-35 Degrees C.
Check for fuel contamination. Refer to AlcohoVContaminants-in-Fuel Diagnosis.
Ignition System

Check for proper ignition voltage output using the following steps:
- Clip the spark tester J 26792 to engine ground.
- Connect one end of a spark plug wire to the spark tester; leave the other end
of the spark plug wire to the coil being tested.
- Connect one end of another spark plug wire to the other coil tower; connect
the other end of the spark plug wire to ground.
- Crank the engine while observing the spark tester; a crisp blue spark should
be observed.
- Repeat the above steps for each coil.
If adequate spark is not present at the coil(s), check for the following conditions:
- Coil(s) - Cracks, carbon tracking/arcing, or a resistance value outside the
specified range.
Coil Secondary Resistance

5000 - 8000 ohms (5K - SK ohms)

- Spark Plug wires - Signs of arcing/cross firing, cracks, carbon tracking, plug
boot damage, pinched, incorrect routing, or a resistance value greater than
the specified value.
VIN 1 Spark Plug Wires Resistance
7000 ohms (7K ohms)
VIN K Spark Plug Wires Resistance
10000 ohms (10K ohms)
Important: Spraying the secondary ignition wires with a light mist of water may help
locate an intermittent problem. Ignition components will arc to ground when a
secondary component is malfunctioning.

- Malfunctioning ignition control module.

- Ignition System Wiring - Loose ignition module feed or ground connection, or
damaged system wiring.
Remove spark plugs and check for the following conditions:
- Fouled plugs
- Cracks
-Wear
- Incorrect gap
- Burned or damaged electrodes
- Incorrect heat range
If spark plugs are gas or oil fouled, the cause of the fouling must be determined
before replacing the spark plugs.
Engine Mechanical

Excessive oil in combustion chamber-Leaking valve seals. Refer to Engine

Mechanical.
Low cylinder compression. Refer to Engine Mechanical.
For incorrect basic engine parts. Inspect the following:
- Cylinder heads
- Camshaft and valve train components
- Pistons, etc.
Refer to Engine Mechanical.

I
\

Engine

Engine Controls - 3.SL

6-1097

Surges/Chuggles
Checks

Action

Definition: Engine power variation under steady throttle or cruise. Feels like the vehicle speeds up and slows down with no
change in the accelerator pedal.
Preliminary

Refer to the A Powertrain On Board Diagnostic (080) System Check.

Search for bulletins.
Be sure driver understands transmission torque converter clutch, and A/C
compressor operation as explained in the owners manual. Inform customer how
TCC and the A/C clutch operates.

Sensor/System

Check the Heated Oxygen Sensor(s). The Heated Oxygen Sensors should
respond quickly to different throttle positions. If not, check the H02S for silicon
or other contaminants from fuel or use of incorrect RTV sealant. The sensors
may have white powdery coating. Silicon contamination causes a high but
false H02S signal voltage (rich exhaust indication). The PCM will reduce the
amount of fuel delivered to the engine, causing a severe driveability problem.
Refer to Heated Oxygen Sensor(s) in Information Sensors/Switches Description.
Check MAF Sensor and related wiring.
Check the EGR valve for a stuck open pintle.

a:

Fuel System

Check the fuel pressure.

Refer to Fuel. Pump Relay Circuit Diagnosis.
Check for contaminated fuel. Refer to Alcohol/Contaminants-in-Fuel Diagnosis.
Ensure each injector harness is connected to the correct injector/cylinder. Refer
to Fuel Injectors.
Check items which can cause an engine to run rich (long term fuel trim is
significantly in the negative range). Refer to Diagnostic Aids for OTC P0172 Fuel
Trim System Rich Bank 1.
Check items that can cause an engine to run lean (long term fuel trim is
significantly in the positive range). Refer to Diagnostic Aids for OTC P0171 Fuel
Trim System Lean Bank 1.

6-1098

Engine

Engine Controls 3.8l

Surges/Chuggles (cont'd)
Checks

Ignition System

Action
Check for proper ignition voltage output using the following steps:
- Clip the spark tester J 26792 to engine ground.
- Connect.one end of a spafk plug wire to the spark tester; leave the other end
of the spark plug wire to the coil being tested.
- Connect one end of another spark plug wire to the other coil tower; connect
the other end ofthe spark plug wire to ground.
- Crank th~ engine while observing the spark tester; a crisp blue spark should
be observed.
- Repeat the above steps for E!ach coil.
11 adequate spatk .is not present at the coil(s), check for the following conditions:
- Coil(s) - Cracks, c;arbon tracking/arcing, or a resistance value outside the
specified rarige.

Coil Secondary Resistance

5000 - 8000 ohms (SK - 8K ohms)
- Spark Plug wires - Signs of arcing/cross firing, cracks, carbon tracking, plug
boot damage, pinched, incorrect routing, or a resistance value greater than
the specified value.

VIN K Spark Plug Wires 'Resistance

10000 ohms (10K ohtns)

Important: Spraying the secondary ignition wires with a light mist of water may help
locate an intermittent problem. Ignition components will arc to ground when a
secondary component is malfunctioning.
- Malfunctioning ignition control module.
- Ignition System Wiring ~ Loose ignition module feed or ground connection, or
damaged system wiring.
Remove spark plugs and check for the following conditions:
- Fouled plugs
- Cracks
-Wear
- Incorrect gap
- Burned or damaged electrodes
- Incorrect heat range
If spark plugs are gas or oil fouled, the cause of the fouling must be determined
before replacing the spark plugs.
Additional Checks

Check TCC operation. Refer to 4L60-E Automatic Transmission Diagnosis.

Check the exhaust system for a possiQle restriction:
- Inspect the exhaust system for damaged or collapsed pipes.
- Inspect the muffler for heat distress or possible internal failure.
- Check for possible plugged Three-Way catalytic converter. Refer to Restricted
Exhaust System Check and/or Exhaust System.

Engine

Engine Controls - 3.SL

6-1099

Lack of Power, Sluggishness, or Sponginess

Checks

Action

Definition: Engine delivers less than expected power. Little or no increase in speed when the accelerator pedal is pusheq
down part way.
Preliminary Checks

Refer to the APowertrain On Board Diagnostic (080) System Check.

Search for bulletins.

Fuel System

Check the follwing items

Check for incorrect 'fuel pressure.
- Refer to Fuel Pump Relay Circuit Diagnosis.
- Check the fuel injectors.
- Refer to Fuel lnj Coil Test - ECT Between 10-35 Degrees C.
- Refer to Fuel lnj Coil Test - ECT Outside 10-35 Degrees C.
- Check for contaminated fuel. Refer to Alcohol/Contaminants-in-Fuel

Diagnosis.
- Check items which can cause an engine to run rich (long term fuel trim is
significantly in the negative range). Refer to Diagnostic Aids for OTC P0172
Fuel Trim System Rich Bank 1.
- Check items that can cause an engine to run lean (long term fuel trim is
sign1ficantly in the positive range). Refer to Diagnostic Aids for OTC P0171
Fuel Trim System Lean Bank .1.

Sensor/System

Using a scan tool, monitor KS system for excessive spark retard activity.
Check the EGR valve for a stuck open pintle. Refer to EGR Valve
Replacement.
"

Check for a restricted intake duct or a dirty air cleaner element. Refer to Air
Cleaner Element Replacement:

s~1100

Engine Controls - 3.SL

Engine

Lack of Power, Sluggishness, or Sponginess (cont'd)

Checks
Ignition System

Action
Check for proper ignition voltage output using the following steps:
- Clip the spa!k tester J 26792 to engine ground.
- Connect one end of.a spark.plug wire to the spark tester; leave the other end
of the spark plug wire to the coil b~ing 'tested.
- Connect one .end of another spark plug wire to the other coil tower; connect
the other end of the spark plug wire to ground.
- Crank the engine while observing the s.park tester; a crisp blue spark should
be obse.rved.
- Repeat the above steps for each coil.
If adequate spark is not present at the coil(s), check for the following conditions:
Coil(s) - Cracks, carbon tracking/arcing, or a resistance value outside the
specified range.

Coil Secondary Resistance

5000 - 8000 ohms (5K - 8K ohms)
Spark Plug wires - Signs of arcing/cross firing, cracks, carbon tracking, plug boot
damage, pinched, inGorrect routing, or a resistance value greater than the
specified value.

VIN 1 Spark Plug Wires Resistance

7000 ohms (7K ohms)

VIN K Spark Plug Wires Resistance.

10000 ohms (1 OK ohms)
Important: Spraying the secondary ignition wires with a light mist of water may help
locate an intermittent problem. Ignition components will arc to ground when a
secondary corpponent.is malfunctioning.
Malfunctioning ignition control module.
Ignition System Wiring - Loose ignition module feed or ground connection, or
damaged system wiring.
Remove spark plugs and check for the following conditions:
- Fouled plugs
- Cracks
-Wear
- Incorrect gap
- Burned or damaged electrodes
- Incorrect heat range
If spark plugs are gas or oil fouled, the cause of the fouling must be determined
before replacing the spark plugs.
Engine Mechanical

Excessive oil in combustion chamber-Leaking valve seals. Refer to Engine

Mechanical.
Low cylinder compression. Refer to Engine Mechanical.
For incorrect basic engine parts. Inspect the following:
- Camshaft
- Cylinder heads
- Pistons, etc.
Refer to Engine Mechanical.

Additional Checks

Check the exhaust system for a possible restriction.

Inspect the exhaust system for damaged or collapsed pipes.
Inspect the muffler for heat distress or possible internal failure.
Check for a plugged three-way catalytic converter. Refer to Restricted Exhaust
System Check and/or Exhaust System.
Check for proper TCC operation. Refer to 4L60-E Automatic Transmission
Diagnosis.

Engine

Engine Controls - 3.8L

6-1101

Detonation/Spark Knock
Checks

Action

Definition: A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change
with throttle opening.

Preliminary Checks

Refer to the A Powertrain On Board Diagnostic (080) System Check

Search for bulletins.

Fuel System

Check for incorrectfuel pressure.

Refer to Fuel Pump Relay Circuit Diagnosis.
Check for contaminated fuel. Refer to Alcohol/Contaminants-in-Fuel Diagnosis.
Check items that ca.n cause an engine to run lean (long term fuel trim
significantly in the positive range). Refer to Diagnostic Aids for OTC P0171 Fuel
Trim System Lean Bank 1.

Ignition System

Engine Cooling System

Engine Mechanical

Check the spark plugs for proper heat range.

Refer to General Information.
Check for obvious overheating problems:
Low engine coolant.
Restricted air flow to radiator, or restricted water flow through radiator.
Electric cooling fan(s) operation. Refer to Electric Cooling Fan Diagnosis.
Correct cbolant solution should be a 50/50 mix of GM 1052753 or equivalent
antifreeze coolant and water. Refer to Engine Cooling.
Excessive oil in combustion chamber-Leaking valve seals. Refer to Engine
Mechanical.
Low cylinder compression. Refer to Engine Mechanical.
Combustion chambers for excessive carbon buildup. Clean using Top engine
cleaner. Follow instructions on can.
For incorrect basic engine parts. Inspect the following:
- Camshaft
- Cylinder heads
- Pistons, etc.
Refer to

Additional Checks

Check for proper EGR system operation. Refer to OTC P0401 Exhaust Gas
Recirculation (EGR) Flow Insufficient.
Check the Transaxle Range Switch input with the vehicle in drive and the gear
selector in drive or overdrive.
Check TCC operation. A malfunctioning TCC can cause the engine to spark
knock. Refer to 4T65-E Automatic Transaxle Diagnosis.
If scan tool readings are normal and there are no engine mechanical problems,
fill the fuel tank with a known quality gasoline that has a minimum octane
reading of 87 and re-evaluate vehicle performance.

6-1102

Engine

Engine Controls 3.8L

Hesitation, Sag, Stumble
Checks

Action

..

Definition: Momentary lack of response as the accelerator is pushed down. Can occur at any vehicle speed. Usually' more
pronounced when first trying.to make the vehicle move, as from a stop sign. May cause the engine to stall if severe enough.
Preliminary

Refer to the A Powertrain On f3oard Diagnostic (OBD) System Check.

Search for bulletins.

Sensor/System

.Check the HeatedOefegen Sensor(s). The Heated Oxygen Sensors should

respond quickly to di erent throttle positions. If not, check the H02S for silicon
or other contaminants from fuel or use of incorrect RTV sealant. The sensors
,may have a white powdery coating. Silicon contamination causes a high but
false H02S signal .voltage (rich,.exhaust indication). The PCM will reduce the
amount of fuel delivered to the engine, causing a severe driveability problem.
Refer to Heafed Oxygen Sensor(s) in Information Sensors/Switches Description.
Check the TP Sensor ~nd related wiring.
Check the MAF Sensor and related wiring.
Check the EGR valve for a sticking pintle. Refer to EGR Valve Replacement.

Fuel System

Check the. fuel pressure.

Refer to Fuel Pump Relay Circuit Diagnosis.
Check for contaminated fuel. Refer to Alcohol/Contaminants-in-Fuel Diagnosis.
Check the injectors.
.Refer to Fqe/ lnj Coil Test - ECT Between 10-35 Degrees C.

Refer to Fuel lnj Coil Test - ECT Outside 10-35 Degrees C.

Check items which can cause an engine to run rich (long term fuel trim is
significantly in the negative range). Refer to Diagnostic Aids for OTC P0172 Fuel
Trim System Rich Bank 1.
Check items that can .cause an engine to.run lean (long term fuel trim is
significantly in the positive range). Refer to Diagnostic Aids for OTC P0171 Fuel
Trim System Lean Bank 1.

Engine

Engine Controls - 3.BL

6/"1103

Hesitationic Sag, Stumble (cont'd)

Checks
Ignition 'System

Action
. Check for proper ignition voltage .output using the following steps:
- Clip the spark tester J 26792 to engine ground.
- Connect one end of a spark plug wire to the spark tester; leave the other end
of the sp~rk plugwire to the coil being tested.
- Connect one end of another spark plug wire to the other coil tower; connect
the other end of the. spark plug wire to ground .
..:. Crank the engine while observing the spark tester; a crisp blue spark should
be observed.

~ Repeat the above steps for each coil.

If adequate spark is not present at the coil(s), check for the following conditions:
- Coil(s) - Cracks, carbon tracking/arcing, or a resistance value outside the
specified ,range,

con Secondary .Resistance

5000 - 8000 ohms (5K - SK ohms)
,- Spark Plug wires - Sjgns of arcing/cross firing, cracks, carbon tracking, plug
boot damage, pinched, incorrect routing, or a resistance value greater than
the specifie~ value.
VIN 1 Spllrk. Plug Wires Resistance
7000 ohms (7K ohms)
VIN K Spai:k Plug Wires Resistance
10000 ohms (10K ohms)

Important: Spraying the secondary ignition wires with a light mist of water may help
locate an intermittent problem. Ignition components will arc to ground when a
secondary component is malfunctioning.
- Malfunctioning ignition control module.
~ lgnrtion System Wiring - Loose ignition module feed or ground connection, or
damaged system wiring.
Remove spark plugs and check for the following conditions:
- Fouled plugs
- Cracks
-Wear
- lncorrecfgap
damaged electrodes
- Burned
..:. lncorre~t heat range
If spark plugs are gas or oil fouled, the cause of the fouling must be determined
before replacing the spark plugs.

or

6-1104

Engine Controls - 3.SL

Engine
Cuts Out, Misses

Checks

Action

Definition: Steady pulsation or jerking that follows engine speed, usually more pronounced as engine load increases.
Preliminary

Refer to the A Powertrain On Board Diagnostic (OBD) System Check.

Search for bulletins.

Fuel System

Check system fuel pressure.

Refer to Fuel Pump Relay 'circuit Diagnosis.
Check the fuel injectors.

Refer to Fuel lnj Coil Test - ECT Between 10-35 Degrees C.

Refer to Fuel lnj Coil Test - ECT Outside 10-35 Degrees C.
Check for contaminated fuel. Refer to Alcohol/Contaminants-in-Fuel Diagnosis.
Check items which can cause an engine to run rich (long term fuel trim
significantly in the negative range). Refer to Diagnostic Aids for DTC P0172 Fuel
Trim System Rich Bank 1.

Check items that can cause an engine to run lean (long term fuel trim
significantly in the positive range). Refer to Diagnostic Aids for DTC P0171 Fuel
Trim System Lean Bank t.
Check for fuel in the Fuel Pressure Regulator vacuum hose. If fuel is present,
replace the fuel pressure regulator. Refer to Fuel Pressure Regulator
Replacement.
.

Sensor/System

1. Check for conditions which cause an incorrect idle speed.

- Throttle body tampering, excessivl3 desposits, or damage.
- Resfricte.d air intake duct or dirty air cleaner element. Refer to Air Cleaner
Element.
- Large vacuum leak.

2. Check the TP Sensor and related circuit wiring. Refer to DTC P0123 Throttle
Position (TP) Sensor Circuit High Voltage.

3. Check the EGR system:

- The EGR pipes and adapter for vacuum leaks.
- Remove the EGR valve and check for a sticking pintle. Refer to EGR Valve
Replacement.
4. Check the PCV valve for proper installation.
- Refer to Crankcase Ventilation System Inspection.
- Check the Transaxle Range Switch input with the vehicle in drive and the
gear selector in drive or overdrive. Refer to Transaxle Range Switch Valid
Combinations table in DTC P0705 Trans Range Switch Circuit.
- Check for the following conditions:
- Bent harmonic balancer interrupter rings.
- Damaged Crankshaft Position Sensor.

Engine Controls - 3.8L

Engine

6-1105

Cuts Out, Misses (cont'd)

Checks
Ignition System

Action
Check for proper ignition voltage output using the following steps:
- Clip the spark tester J 26792 to engine ground.
- Connect one end of a spark plug wire to the spark tester; leave the other end
of the spark plug wire to the coil being tested.
- Connect one end of another spark plug wire to the other coil tower; connect
the other end of the spark plug wire to ground.
- Crank the engine while observing the spark tester; a crisp blue spark should
be observed.
- Repeat the above steps for each coil.
If adequate spark is not present at the coil(s), check for the following conditions:
- Coil(s) - Cracks, carbon tracking/arcing, or a resistance value outside the
specified range.
Coil Secondary Resistance
5000 - 8000 ohms (5K - BK ohms)
- Spark Plug wires - Signs of arcing/cross firing, cracks, carbon tracking, plug
boot damage, pinched, incorrect routing, or a resistance value greater than
the specified value.
VIN 1 Spark Plug Wires Resistance
7000 ohms (7K ohms)
VIN K Spark Plug Wires Resistance
10000 ohms (10K ohms)
Important: Spraying the secondary ignition wires with a light mist of water may help
locate an intermittent problem. Ignition components will arc to ground when a
secondary component is malfunctioning.
- Malfunctioning ignition control module.
- Ignition System Wiring - Loose ignition module feed or ground connection, or
damaged system wiring.
Remove spark plugs and check for the following conditions:
- Fouled plugs
- Cracks
-Wear
- Incorrect gap
- Burned or damaged electrodes
- Incorrect heat range
If spark plugs are gas or oil fouled, the cause of the fouling must be determined
before replacing the spark plugs.
Check for the following intermittent ignition system conditions:
- Intermittent CKP Sync or CKP 18X Signal.
- Intermittent ignition feed circuit or sensor ground circuit to the crankshaft
position sensor or the camshaft position sensor.
- Intermittent 3X reference signal.
- Intermittent camshaft position signal

5.;1106 .. Engine Controls. ~ 3~8L.

Engine
'Cuts Out; Misses' (cont'd)

Checks

Engine Mechanical

Action

Check engine mechanical for the following:

- Check compression.
- Sticking or leaking. valves.
-Wori1 camshaft lobe(s).
--'Valve'timing.
- Bent push rods.
- Worn rocker arms.
- Broken valv,e springs .
..., .Excessive oil in yomb~stion chaqiber-Leaking valve seals.
. - Low cylinder compression.
For incorrect basic engine parts .. Inspect the following:
:,..- Camshaft ,
'-- Cylinder heads
- Pistons, etc.
Refer to Engine Mechanical for diagnosis procedures.

Additional Checks

,Qreck the ext)aui;;t system for a possible restriction.

- Inspect exhaust system for damaged or collapsed pipes.
:-- Inspect mufflersf?r heat distress or possible internal failure.
- For possiple plugged Three-Way catalytic converter. Refer to Restricted
Exhaust System Check and/or Exhaust System.
<

'

'

':1

'

An. engine rniss conditio.n can be caused by Electromagnetic Interference (EMI)

on the reference circuit E.MI can usually be detected by monitoring engine RPM
with a scan tooL A sudden increase or decrease in RPM with little change in
a6tual engine RPM change indicates that EMI is present. Check routing of
secondary ignition wires: Also, check ignition coils for cracks, carbon tracking, or
signs of arcing.
Check for intake and exhaust manifold passages for casting flash. Refer to
Engine Mechanical.
Check for loose, worn, or bfoken motor mounts. Refer to Engine Mechanical..

Poor Fuel E<:onomy

Checks

Action

Definition: Fuel economy, as measured by an actual road tei;"t is noticeably lower than expected. Also, economy is
noticeably lower than it was on this vehicle at one time, as previously shown: by an actual road test.
Preliminary

' Board Diafjnostic (080) System Check.

Refer to th13 A Powertrain On
Search for bulletins ..
Check owner.s driving habits.
- ts A/C ON full tim~ (Defroster mode ON)?
- A~e tires at correct pressure}
- Are exces~vely heavy loads being carried?
- Is acceleration too much, too often?

Fuel System

Check for incorrect fuel pressure.

Refer to Fuel System Pressure Test.
Check the fuel injectors.
- Refer to Fuel lnj Coil Test - ECT Between 10-35 Degrees C.
- Refer to Fuel lnj Coil Test - ECT Outside 10-35 Degrees C.
Check for contaminated fuel. Refer to Alcohol/Contaminants-in-Fuel Diagnosis.
Ensure each injector harness is connected to the correct injector/cylinder. Refer
to Engine Controls Schematics.
Check for fuel in the pressure regulator vacuum hose.

Engine Controls -,3.8L 61107

Engine
Poor Fuel Economy (cont'd)

Action

Checks
Sensor/System

Check the intake system and crankcase for air leaks.

Check for proper calibration.of speedometer. Connect J 33431-8 (Signal
Generator) to VSS.electrical connector. Ignition ON, tester ON and monitor the
speedometer.

Ignition System

Check for proper ignition voltage output using the following steps:
- Clip the spark tester .J 26792 .to engine ground.
- Connect one end of a spark plug wire to the spark tester; leave the other end
of the spark plug wire to the coil being .tested.
- Connect one end of another spark plug wire to the other coil tower; connect
the other en'd of the spark plug wire to ground.
- Crank the engine while observing the spark tester; a spark should be
observed.
- Repeat the above steps for each coil.
If adequate spark is not present at the coil(s), check for the following conditions:
.
- Coil(s) - Cracks, carbon tracking/arcing, or a resistance value outsideJh.e,
specified range:

Coil Secondary Resistance

5000 - 8000 ohms (5K - BK ohms)
- Spark Plug wires - Signs of arcing/cross firing, cracks, carbon tracking, plug
boot damage, pinched, incorrect routing, or a resistance greater than the
specified value.

Spark Plug Wires Resistance

10000 ohms (10K ohms)
lmp~>rtant: Spraying the secondary ignition wires with a light .mist of water may help'
locate an intermittent problem. Ignition components will arc to ground when a

secondary component is malfunctioning.

- Malfunctioning ignition control module.
...
(

- Ignition System Wiring - Loose ignition module feed or ground connectioh, o(

damaged system wiring.
Remove spark plugs and check for the following conditions:
- Fo.uled plugs
-Cracks
-Wear
-. Incorrect gap
- Burned or damaged electrodes
- ln~orrect heat range
If. spark plugsare gas or. oil fouled, the cause of the fouling must be determined
before replacing the spark plugs.

Engine Cooling System

Check engine .coolant level for being low.

Check for incorrect or malfunctioning engine thermostat.

\I

6-1108

Engine Controls .;. 3.SL

.

Engine
Poor Fuel Economy (cont'd)

Checks
Engine Mechanical

Action
Check engine mechanical for the following:
- Check compression.
.;.:

Sticking or leaking valves.

Worn camshaft lobe(s).
Valve timing.
Bent push rods .
Worn ~ocker arms ..

- Broken valve springs.

- Excessive oil in combustion chamber-Leaking valve seals.
For incorrect basic engine parts. Inspect for the following:
- Camshaft
- Cylinder heads
- Pistons, etc.
Additional Checks

Check TCC operation.

Check the exhaust system for a possible restriction.
- Inspect exhauJ?t system for damaged or collapsed pipes.
- Inspect mufflers for heat distress or possible internal failure.
- For possible plugged Three-Way catalytic converter. Refer to Restricted
Exhaust System Check and/or Exhaust System.

Rough, Unstable, or Incorrect Idle and Stalling

Checks

Action

Definition: Engine runs unevenly at idle. If severe, the engine or vehicle may shake. Engine idle speed may vary in RPM.
Either condition may be severe enough to stall the engine.

Prelimin~ry Checks

Refer to the.. A Powertrain On Board Diagnostic (OBD) System Check.

Search for bulletins.

Fuel System

Check the fuel pressure.

Refer to Fuel System Pressure Test.
Check the injectors.
- Refer to Fuel lnj Coil Test - ECT Between 10-35 Degrees C.
- Refer to Fuel lnj Coil Test - ECT Outside 10-35 Degrees C.
Check for contaminated fuel. Refer to Alcohol/Contaminants-in-Fuel Diagnosis.
Check for fuel in the pressure regulator vacuum hose.
Ensure each injector harness' is connected to the correct injector/cylinder. Refer
to Engine Controls Schematics.
Check items which can cause an engine to run rich (long term fuel trim is
significantly in the negative range)'. Refer to Diagnostic Aids for OTC P0172 Fuel
Trim System Rich Bank 1.
Check items that can cause an engine to run lean (long term fuel trim is
significantly in the positive range). Refer to Diagnostic Aids for OTC P0171 Fuel
Trim System Lean Bank 1.

Sensor/System

Check for conditions which cause an incorrect idle speed.

- Throttle body tampering, excessive desposits, or damage.
- Restricted air intake duct or dirty air cleaner element.
- Large vacuum leak.
Check the crankcase ventilation valve for proper installation.
Check the TP Sensor and related wiring.
Check the EGR system for proper operation. Refer to OTC P0401 Exhaust Gas
Recirculation (EGR) Flow Insufficient.
Check the Transaxle Range Switch input with the vehicle in drive and the gear
selector in drive or overdrive. Refer to the Transaxle Range Switch Valid
Combinations table in OTC P0705 Trans Range Switch Circuit.

Engine

Engine Controls - 3.SL

6-1109

Rough, Unstable, or Incorrect Idle and Stalling (cont'd)

Checks
Ignition System

Action
Check for proper ignition voltage output using the following steps:
- Clip the spark tester J 26792 to engine ground.
- Connect one end of a spark plug wire to the spark tester; leave the other end
of the spark plug wire to the coil being tested.
- Connect one end of another spark plug wire to the other coil tower; connect
the other end of the spark plug wire to ground.
- Crank the engine while observing the spark tester; a spark should be
observed.
- Repeat the above steps for each coil.
If adequate spark is not present at the coil(s), check for the following conditions:
- Coil(s) - Cracks, carbon tracking/arcing, or a resistance value outside the
specified range.
Coil Secondary Resistance
5000 - 8000 ohms (5K - BK ohms)
- Spark Plug wires - Signs of arcing/cross firing, cracks, carbon tracking, plug
boot damage, pinched, incorrect routing, or a resistance value greater than
the specified value.
VIN K Spark Plug Wires Resistance
10000 ohms (10K ohms)
Important: Spraying the secondary ignition wires with a light mist of water may help
locate an intermittent problem. Ignition components will arc to ground when a
secondary component is malfunctioning.
- Malfunctioning ignition control module.
- Ignition System Wiring - Loose ignition module feed or ground connection, or
damaged system wiring.
Remove spark plugs and check for the following conditions:
- Fouled plugs
- Cracks
-Wear
- Incorrect gap
- Burned or damaged electrodes
- Incorrect heat range
If spark plugs are gas or oil fouled, the cause of the fouling must be determined
before replacing the spark plugs.

Engine Mechanical

'

Check engine mechanical for the following:

- Check compression.
-

Sticking or leaking valves.

Worn camshaft lobe(s).
Valve timing.
Bent push rods.

- Worn rocker arms.

- Broken valve springs.
- Excessive oil in combustion chamber-Leaking valve seals.
For incorrect basic engine parts. Inspect the following:
- Camshaft
- Cylinder heads
- Pistons, etc.

6~1110

Engine

Engine Controls - 3.8L

Rough, Unstable, or Incorrect Idle and Stalling (cont'd)
Checks

Additional Checks

Action
Check the exhaust system for a possible restriction.
- Inspect exhaust system for damaged or collapsed pipes.
- Inspect mufflers for heat distress or possible internal failure.
- For possible plugged Three-Way catalytic converter. Refer to Restricted
Exhaust System Check and/or Exhaust System.
Check for loose, worn, or broken motor mounts.
An engine miss condition can be caused by Electromagnetic Interference (EMI)
on the reference circuit. EMI can usually be detected by monitoring engine RPM
with a scan tool. A sudden increase or decrease in RPM with little change in
actual engine RPM indicates that EMI is present. Check for incorrect routing of
secondary ignition wires. Also check the ignition coils for cracks, carbon
tracking, or signs of arcing.
Check for loose, worn or broken motor mounts. Refer to Engine Mechanical for
inspection of mounts.
Check for intake and exhaust manifold passages for casting flash.

Dieseling, Run-On
Checks

Action

Definition: Engine continues to run after key is turned OFF, but runs very rough. If engine runs smooth, check the ignition
switch and adjustment.
Preliminary Checks

Refer to the A Powertrain On Board Diagnostic (OBD) System Check.

Search for bulletins.

Fuel System

Check the fuel injectors. Refer to Fuel lnj Coil Test - ECT Between 10-35 Degrees C.
Refer to Fuel lnj Coil Test- ECT Outside 10-35 Degrees C.

Additional Check(s)

Check for short between B+ and any of the ignition feed circuits. Refer to Wiring
Repairs.

Backfire
Checks

Actions

Definition: Fuel ignites in the intake manifold, or in the exhaust system, making loud popping noise.
Preliminary Checks

Refer to the A Powertrain On Board Diagnostic (OBD) System Check.

Search for bulletins.

Sensor/System

Check for the following intermittent ignition system conditions:

- Intermittent CKP Sync or CKP 18X Signal.
- Intermittent ignition feed circuit or sensor ground circuit to the crankshaft
position sensor or the camshaft position sensor.
- Intermittent 3X reference signal.
- Intermittent camshaft position signal
Check the throttle body inlet screen for foreign objects or damage that can affect
the MAF sensor airflow sample.

Fuel System

Check for incorrect fuel pressure.

Refer to Fuel System Pressure Test.
Check for contaminated fuel. Refer to Alcohol/Contaminants-in-Fuel Diagnosis.
Ensure each injector harness connector is connected to the correct injector.
Refer to Engine Controls Schematics.

Engine

Engine Controls - 3.SL

6-1111

Backfire (cont'd)
Checks
Ignition System

Engine Mechanical

Additional Checks

Actions

Check for proper ignition voltage output using the following steps:
- Clip the spark tester J 26792 to engine ground.
- Connect one end of a spark plug wire to the spark tester; leave the other end
of the spark plug wire to the coil being tested.
- Connect one end of another spark plug wire to the other coil tower; connect
the other end of the spark plug wire to ground.
- Crank the engine while observing the spark tester; a spark should be
observed.
- Repeat the above steps for each coil.
If adequate spark is not present at the coil(s), check for the following conditions:
- Coil(s) - Cracks, carbon tracking/arcing, or a resistance value outside the
specified range.
Coil Secondary Resistance
5000 - 8000 ohms (5K - BK ohms)
- Spark Plug wires - Signs of arcing/cross firing, cracks, carbon tracking, plug
boot damage, pinched, incorrect routing, or a resistance value greater than
the specified value.
VIN K Spark Plug Wires Resistance
10000 ohms 10K ohms)
Important: Spraying the secondary ignition wires with a light mist of water may help
locate an intermittent problem. Ignition components will arc to ground when a
secondary component is malfunctioning.
- Malfunctioning ignition control module.
- Ignition System Wiring - Loose ignition module feed or ground connection, or
damaged system wiring.
Remove spark plugs and check for the following conditions:
- Fouled plugs
- Cracks
-Wear
- Incorrect gap
- Burned or damaged electrodes
- Incorrect heat range
If spark plugs are gas or oil fouled, the cause of the fouling must be determined
before replacing the spark plugs.
Check engine mechanical:
Check compression.
Sticking or leaking valves.
Worn camshaft lobe(s).
Valve timing.
Bent push rods.
Worn rocker arms.
Broken valve springs.
Excessive oil in combustion chamber-Leaking valve seals.
Low cylinder compression.
For incorrect basic engine parts. Inspect the following:
Camshaft
Cylinder heads
Pistons, etc.
Check Intake and exhaust manifold(s) for casting flash.
Check TCC operation.
Check the exhaust system for a possible restriction.
- Inspect exhaust system for damaged or collapsed pipes.
- Inspect mufflers for heat distress or possible internal failure.
- For possible plugged Three-Way catalytic converter. Refer to Restricted
Exhaust System Check.

5;.1112

Engine Controls - 3.8L

Engine

Restricted Exhaust System Check

Step

Action

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Value(s)

8:6 kPa
(1.25 psi)

1. Leave the transmission in Park or Neutral.

2. With the exhaust back pressure tester in place of
H02S Bank 1 Sensor 2, increase engine speed to
2000 rpm.
3. Observe the exhaust system back pressure reading
on the gage.
Does the reading exceed the specified value?

20. 7 kPa (3 psi)

1. Reinstall H02S Bank 1 Sensor 2.

2. Remove H02S Bank 1 Sensor 3.
3. In place of H02S Bank 1 Sensor 3, install
J 35314-A/BT-8515/BT-8515A Exhaust Back
Pressure Tester.
4. Engine at normal operating temperature.
5. Leave the transmission in Park or Neutral.
6. Increase engine speed to 2000 rpm.
7. Observe the exhaust system back pressure reading
on the gage.
Does the reading exceed the specified value?

20.7 kPa (3 psi)

Locate and repair the restriction in the exhaust system

past the three way catalytic converter. Possible faults
include the following:
Collapsed pipe.
Heat distress.
Internal muffler failure.
Is action complete?

Replace the three way catalytic Converter.

Is action complete?

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

System OK

1. Remove H02S Bank 1 Sensor 2. Refer to H02S

Replacement.
2. In place of H02S Bank 1 Sensor 2, install a
J 35314-A!BT-8515/BT-8515A Exhaust Back
Pressure Tester.
3. Start the engine.
4. With the transmission in Park or Neutral and the
engine idling at normal operating temperature,
observe the exhaust system back pressure reading
on the gage.
Does the reading exceed the specified value?

Yes

(
\

Go to Step 5

Go to Step 6

Go to Step 7
Go to Step 7

Engine Controls - 3.SL 6-1113

Engine

Restricted Exhaust System Check (cont'd)

Step

Action

Yes

No

Go to Step 4

Go to Step 8

Go to Step 5

System OK

1. Remove H02S Bank 1 Sensor 2.

2. In place of H02S Bank 1 Sensor 2, install
J 35314-A/BT-8515/BT-8515A Exhaust Back Pessure
Tester.

)
7

3. Leave the transmission in Park or Neutral.

4. Engine idling at normal operating temperature.
5. Observe the exhaust system back pressure reading
on the gage.
Does the reading exceed the specified value?
1. Leave the transmission in Park or Neutral.
2. With exhaust each pressure tester in place of H02S
Bank 1 Sensor 2, increase engine speed to
2000 rpm.
3. Observe the exhaust system back pressure reading
on the gage.
Does the reading exceed the specified value?

Powertrain Control Module Diagnosis

The approved procedure .tor diagnosing all powertrain
control system malfunctions is included in the
Strategy Based Diagnostic Flow. The preliminary
checks and the Powertrain On-Board Diagnostic
System Check must be performed to successfully
diagnose and repair the powertrain systems.

Value(s)

To read and clear diagnostic trouble codes, use a

scan tool.
Important: Use a scan tool to clear diagnostic trouble
codes from the PCM memory. Diagnostic trouble
codes can also be cleared by turning OFF the ignition
and disconnecting the battery power from the PCM
for 30 seconds, but this method will also ca1.1se
all diagnostic information in the PCM memory to be
cleared and all the diagnostic tests will have to
be re-run.
Since the PCM can have a failure which may affect
only one circuit, following the approved diagnostic
procedures will determine which circuit has a problem
and where it is. If a diagnostic table indicates that
the PCM connections or PCM is the cause of a
problem and the PCM is replaced, but does not correct
the problem, one of the following conditions may exist:
There is a problem with the PCM terminal
connections. The diagnostic table will indicate that
the PCM connections or PCM is the problem.
The terminals may have to be removed from the
PCM connector in order to check the.m properly.

8.6 kPa
(1.25 psi)

20. 7 kPa (3 psi)

The EEPROM program is not correct for the

application.
Incorrect components may cause a malfunction
and may or may not set a DTC.
The problem is intermittent. This means that the
problem is not present at the time the system is
being checked. In this case, refer to the Symptoms
portion of the manual and make a careful visual
and physical inspection of all suspected
components and wiring associated with the
affected system.
Shorted solenoid, relay coil, or harness. Solenoids
and relays are turned ON and OFF by the PCM
using intemal electronic switches called drivers.
Each driver is part of a group of seven called
output driver modules. A shorted solenoid, relay
coil, or harness will not damage the PCM but
will cause the solenoid or relay to be inoperative.
The J 34636 tester, or equivalent, provides a
fast, accurate means of checking for a shorted coil
or a short to battery voltage.

6-1114

Engine Controls - 3.8L

Engine

PCM Controlled Warning Lamps Diagnosis

I I

!Hot In Run Or Start !

~ ;o:e;- -

I Distribution
Cell 1o

G3

GAGES
Fuse 9
H3
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Fuse Block
Details
Cell11

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PNK 39
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~ Instrument
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Cluster

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G) CHECK GAUGES

Cell 81

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Indicator
4700
Indicator
Control

Turn on

61

Generator
Status

225

RED
36 C1

1~

Terminal L
Output

-~~~7at; -

PCM
C1 = BLU
C2=CLEAR

Control

BLK/ 451
WHT

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Indicator

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,__----+----.J

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Level
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Ignition
Positive
Voltage

B~~l~~~ Gene,;;;o~ - - - - - - - - - - - - - -:J61I2~5- I

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-

Signal
SV

I Module
I (PCM)

L------------------------------------------J

>

~
223198

Circuit Description
The PCM controlled lamps are powered through the
IGN 1 fuse. The PCM energizes the the bulb or
indicator by supplying a path to ground through
the PCM.
Conditions which will illuminate each lamp are as
follows:
.
Low Oil Level Lamp - When the ignition is first
turned ON, the PCM commands the Low Oil Level
Lamp ON for a brief period of time to test the
bulb. The PCM also checks the engine oil level
using the Engine Oil Level Switch input. The PCM
determines whether or not to test for low oil
level based on the difference between engine
coolant temperature at the last shutdown
and engine coolant temperature at startup. This is
to ensure that the oil has drained back into the
sump before testing. To test for low oil level
at startup, one of the following conditions must be
present:
- If the engine coolant temperature was
between 15C (59F) and 130C (266F) at
the last key OFF, the engine coolant
termperature at key ON must be at least
12C (22F) cooler than the engine coolant
temperature at the last key OFF.

- If the engine coolant termperature was

higher than 100C (212F) at the last
key OFF, the time between last key OFF and
the present key ON must be sufficient to
allow the oil to drain back to the sump. The
PCM will remian powered up for 1O seconds
to ensure that the oil has drained back to
the sump. If the key is turned back ON while
the PCM is still powered up, the oi.1 level
will not be tested.
Generator Lamp - The PCM supplies battery
voltage to the generator's internal regulator
(generator terminal L). When a fault in the
Charging System occurs, the internal regulator
grounds the L terminal voltage and the PCM
commands the generator lamp ON. The PCM will
command the generator lamp ON when the
following condition(s) are present:
- Engine speed is above 1200 RPM and
system voltage is below 10 volts for at least
10 seconds.
- The PCM detects a low voltage condition on
the generator's L terminal for at least
10 seconds.
If DTC P0560 is set, refer to OTC P0560
System Voltage.

Engine
Second Gear Lamp (4L60E Transaxle Only) - The
PCM supplies 12 volts to the second gear start
switch through a pull-up resistor. The second gear
start switch is a normally open switch. The PCM
senses a high input voltage, commands normal
transaxle shifting, and the second gear start lamp
is not illuminated. When the second gear start
switch is closed, the input voltage to the PCM is
pulled low. The PCM turns the second gear
lamp ON and commands the to vehicle begin in
second gear (the following gears shift in
normal sequence).

Diagnostic Aids
A PCM controlled lamp ON at all times most likely
indicates that a condition is present which requires the
attention of the vehicle operator.
Check for the following conditions:
Poor connection at PCM. Inspect harness
connectors for backed out terminals, improper
mating, broken locks, improperly formed or
damaged terminals, and poor terminal to wire
connection.
Damaged harness. Inspect the wiring harness for
damage. If the harness appears to be OK,
disconnect the PCM and turn the ignition ON.
Observe a voltmeter connected to the affected
PCM output circuit while moving connectors and
wiring harnesses related to the PCM output
circuit. A change in voltage will indicate the
location of the fault.
Engine Oil Level Switch circuit: Use the Engine
Oil Level Sensor/Switch Diagnosis.

Engine Controls - 3.SL

6-1115

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart.
3. Normally, ignition feed voltage should be present
on the output control circuit with the PCM
disconnected and the ignition turned ON.
4. Checks for a shorted component or a short to B+
on the output control circuit. Either condition
would result in a measured current of over
1.5 amps. Also checks for a component that is
going open while being operated, resulting
in a measured current of O amps.
5. Checks for a faulty instrument cluster.
16. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

6-1116

Engine

Engine Controls - 3.SL

PCM Controlled Warning Lamps Diagnosis
Action

Step

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to the
Instrument
Cluster System
Check in
Electrical
Diagnosis

Go to Step 4

Go to Step 7

Go to Step 12

Go to Step 5

Go to Step 15

Go to Step 6

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Was the Instrument Cluster System Check in Electrical

Diagnosis performed?

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Turn ON the ignition switch.
4. Using a J 39200 Digital Multimeter, measure voltage
between the affected lamp control circuit at the PCM
harness connector and ground.
Is voltage near the specified value?

B+

1. Connect the digital multimeter to measure current

between the affected lamp control circuit and ground.
4

2. Monitor the current reading on the digital multimeter

for at least 2 minutes.
Does the current reading remain between the
specified value?
1. Disconnect the instrument cluster (leave the PCM
disconnected).
2. Measure voltage between the affected lamp control
circuit and ground.
Is voltage at the specified value?
Locate and repair the short to voltage in the affected lamp
control circuit. Refer to Wiring Repairs.

0.002-0.5 amps
2-500 mA

OV

Check the ignition positive voltage feed fuse for the

instrument cluster indicator lamps.
Is the the fuse open?
1. Locate and repair the short to ground in the ignition
positive voltage circuit for the instrument cluster
indicator lamps. Refer to Wiring Repairs.

Go to Step B

2. Replace the fuse.

Is action complete?

10

Go to Step 17

Is action complete?

Go to Step 9

Go to Step 17

1. Disconnect the instrument cluster.

2. Ignition ON.
3. Measure voltage between the ignition positive voltage
circuit for the instrument cluster indicator lamps and
ground.
Is voltage near the specified value?

B+

1. Check the affected lamp control circuit for an open or

a short to ground.
2. If a problem is found repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Go to Step 10

Go to Step 14

Go to Step 17

Go to Step 11

Engine Controls - 3.SL

Engine

6-1117

PCM Controlled Warning Lamps Diagnosis (cont'd)

Action

Step

Value(s)

Yes

No

Go to Step 17

Go to Step 15

Go to
Diagnostic Aids

Go to Step 13

Go to Step 17

Go to Step 16

1. Check the affected PCM lamp control circuit and the

11

ignition positive voltage circuit for a poor connection

at the instrument cluster or at the PCM.
2. If a problem is found, replace the faulty terminal{s).
Refer to Wiring Repairs.
Was a problem found?

1. Turn OFF the ignition switch.

2. Reconnect the PCM and disconnect the instrument

12

cluster.
3. Turn ON the ignition switch.
4. Connect a J 34142-8 Unpowered Test Light between
the affected tamp control circuit and the ignition
positive voltage circuit at the instrument cluster
harness connector.
5. Using the scan tool outputs test function, cycle the
affected lamp ON and OFF.
Does the test light flash ON and OFF?

1. Check the affected PCM output circuit for a poor

13

14

connection at the PCM.

2. If a problem is found, replace the faulty terminal.
Refer to Wiring Repairs.
Was a problem found?
Locate and repair open in the ignition positive voltage
circuit to the instrument cluster indicator lamps. Refer to
Wiring Repairs.

Go to Step 17

Is action complete?

)
15

Replace the instrument cluster. Refer to On-Vehicle

Service in Instrument Panel, Gages, and Console.

Go to Step 17

Is action complete?
Replace the PCM.

16

Important: The replacement PCM must be programmed.

Refer to PCM Replacement/Programming.

Go to Step 17

Is action complete?

17

Operate the affected lamp control circuit using the scan

tool output tests function.
Does the affected lamp control circuit operate properly?

System OK

Go to Step 3

6-1118

Engine

Engine Controls - 3.8L

PCM Controlled A/C Circuit Diagnosis

I I

!Hot In Run, Bulb Test And Start!

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Power
Distribution
Ce1110

- - - - - ., Underhood
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VENT

..

DKGRN 59

DEF

I
I
I

__________ ..,
A C2

DKGRN 59
899

A/C

DK GRN/WHT 459

~~~pressor
Clutch

Pressure

Sensor

Compressor Bv
Clutch Diode

Ground
Distribution
Cell14

1 Amp

899

lr-<l=il 1~geranl

[ID

BLK
450

DK
GHN/WHT 762

GRY 47
GRY 720

____ _2}

_____3j

-i-

_ _?9

_______________ _____ C2
~n;,- -c~N~I; - - - AfC ~ Powertrain

- - ~-J A/C -1--5;;-o,;- -1--

A/C \
I Relay
I Control _
/ /

39

-<II Sensors

RED/BLK 380

BLK 450 ;

DK
GRN/WHT 762

_- -

Sensor
Signal

Reference
B

Ground

C1 = BLU
C2=CLEAR

_
-

-~ -

- 5~ -

Request
Signal

- :.

I
I

Control
Module
(PCM)~

-~

248315

Circuit Description

Ignition voltage is below 10.5 volts.

When an A/C mode is selected, the HVAC control

head supplies a battery positive voltage signal to the
PCM A/C request input. The A/C compressor
clutch relay is controlled by the PCM. The PCM
provides a ground path for the A/C relay coil. When
the A/C compressor relay is engaged battery positive
voltage is supplied to the compressor clutch coil.
The PCM will enable the A/C compressor clutch
whenever the engine is running and the A/C has been
requested unless one or more of the following
conditions are present:
Throttle angle is greater than 90%.
A/C head pressure is greater than 414 psi
(4.27 volts) or less than 34 psi (0.35 volt) (as
determined by the A/C refrigerant pressure
sensor).

Engine speed is greater than 5440 RPM.

ECT is greater than 125C (257F).
IAT is less than 5C (41F}.
Any of the conditions described above will inhibit A/C
compressor relay operation.

Engine

Engine Controls - 3.SL

6-1119

Diagnostic Aids

Test Description

Check for the following conditions:

Poor connection at the PCM or the HVAC control
head. Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wire connection.
Damaged harness. Inspect the wiring harness for
damage.
If the harness appears to be OK, disconnect the
PCM, turn the ignition ON and observe a
voltmeter connected between the A/C relay
control circuit at the PCM harness connector and
ground while moving connectors and wiring
harnesses related to the A/C relay. A change in
voltage will indicate the location of the malfunction.
Check for conditions that will disable A/C operation:
Throttle angle greater than 90%.
A/C head pressure greater than 414 psi
(4.27 volts) or less than 34 psi (0.35 volt) (as
determined by the A/C refrigerant pressure
sensor).
Ignition voltage below 10.5 volts.
Engine speed greater than 5440 RPM.
ECT greater than 125C (257F).
IAT less than 5C (41F).

The number(s) below refer to Step number(s) on the

diagnostic table:
2. Stored diagnostic trouble codes may disable the
A/C compressor. This diagnostic table may
lead to improper diagnosis and replacement of
good parts if diagnostic trouble codes are present.
3. The A/C compressor clutch should erigage if the
appropriate conditions have been met.
4. The A/C compressor clutch should not be engaged
with the engine running if an A/C mode is not
selected at the control head.
6. Checks for an A/C request signal from the control
head to the PCM.
12. Checks the ignition positive voltage circuit to the
A/C relay.
13. Determines whether the A/C relay or the circuitry
is at fault.
21. Determines if the PCM is turning the A/C relay
ON due to a false A/C request.
22. Isolates the problem to the A/C control head or
the PCM.
27. Determines if the A/C relay is malfunctioning or
the A/C relay control circuit is grounded all
the time.
35. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). W.hen the PCM is being
replaced, the new PCM must be programmed.

6-1120

Engine Controls - 3.8L

Engine

PCM Controlled A/C Circuit Diagnosis

Step

Action
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?

Are any powertrain DTCs stored?

Important: Before continuing with diagnosis, the following

conditions must be met:
Intake air temperature greater than 9 C (48 F).
Engine coolant temperature less than 119 C (246 F).
1. With the A/C OFF, start and idle the engine.
2. Observe the A/C compressor.

Value(s)

With an A/C mode still selected, observe A/C Request on

the scan tool.

Diagnose
DTCs first.

Go to Step3

Go to Step 21

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 9

Go to Step 6

Does A/C Request display Yes?

1.
2.
3.
4.

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(080) System
Check

Is the A/C compressor clutch engaged?

No

Is the A/C compressor clutch engaged?

1. Run the engine at 1000-1500 RPM.

2. Select an A/C mode on HVAC control head.
3. Observe the A/C compressor.

Yes

Turn OFF the ignition switch.

Disconnect the PCM.
Turn ON the ignition switch.
With an A/C mode still selected, measure voltage on
the A/C request circuit at the PCM harness
connector.

B+

Does the voltage measure near the specified value?

(
Go to Step 8

Go to Step 7

Go to Step 37

Go to Diagnosis
in Manual
Control Air
Conditioning

Go to Step 37

Go to Step 35

Go to Step 12

Go to Step 10

Go To Step 11

Go to Refrigerant
Recovery and
Recycling,
Adding Oil,
Evacuating and
Recharging
Procedures in
Heater,
Ventilation and
Air Conditioning

1. Check the A/C request circuit for the following

conditions:
Open.
Shorted to ground.

Poor connection at the A/C control head or A/C

programmer (as applicable).

2. If a problem is found, repair as necessary. Refer to

Wiring Repairs.
Was a problem found?

1. Check the A/C request circuit for a poor connection at

the PCM.

2. If a problem is found, repair as necessary. Refer to

Wiring Repairs.

Was a problem found?

Observe A/C Refrigerant Pressure on the scan tool.

Is indicated A/C pressure between the specified values?

0.35-4.27 V

1. Connect a J 39500 Refrigerant Recovery, Recycling,

and Recharging Station to monitor high side
refrigerant pressure. Refer to Heater, Ventilation and
Air Conditioning.

10

2. Observe high side refrigerant pressure on the gauge.

Is high side refrigerant pressure within the specified
values?

234-2854 kPa
(34-414 psi)

Engine Controls - 3.SL

Engine

6-1121

PCM Controlled A/C Circuit Diagnosis (cont'd)

Action

Step

Value(s)

Yes

No

Go to Step 37

Go to Step 18

Go to Step 13

Go To Step 31

Go to Step 14

Go to Step 15

Go to Step 37

Go to Step 32

Go to Step 16

Go to Step 17

Go to Step 37

Go to Step 33

Go to Step 37

Go to Step 34

Go to Step 19

Go to Step 20

1. Turn OFF the ignition switch.

2. Disconnect the PCM and the A/C refrigerant pressure

sensor.

3. Measure the resistance of the following circuits

between the PCM and the A/C refrigerant pressure
sensor:
11

The A/C refrigerant pressure sensor signal circuit.

5 ohms

The 5 volt reference B circuit.

The sensor ground circuit.
4. If any resistance is higher than the specified value,
locate and repair cause of high resistance in circuit
as necessary. Refer to Wiring Repairs.
Was a problem found?
1. Disconnect the A/C relay electrical connector.

12

2. Probe both ignition positive voltage circuits at the A/C

relay harness connector with a test light to ground.

Is the test light ON?

13

Connect a fused jumper between the ignition positive

voltage circuit and A/C compressor clutch control circuit
(CKT 59) at the A/C relay connector.

Does the A/C compressor clutch engage?

1. Check for poor connections at A/C relay.
14

2. If a problem is found, replace faulty terminals as

necessary. Refer to Wiring Repairs.

Was a problem found?

15

1. Disconnect the A/C compressor clutch electrical

connector (leave the ignition positive voltage circuit
and A/C compressor clutch control circuit (CKT 59)
jumpered at the A/C relay connector).

2. Connect a test light between A/C compres:,or clutch

control circuit (CKT 59) and the compressor ground

circuit.
Is the test light ON?

16

1. Check for poor connections at the A/C compressor

clutch.
2. If a problem is found, replace faulty terminals as
necessary. Refer to Wiring Repairs.

Was a problem found?

1. Check for an open or short to ground in the A/C
compressor clutch control circuit (CKT 59).
17

2. If a problem is found, repair as necessary. Refer to

Wiring Repairs.
Was a problem found?
1. Leave the PCM and the A/C refrigerant pressure
sensor disconnected.

2. Turn ON the ignition switch.

18

3. Using a J 39200 Digital Multimeter, measure voltage

OV

between the A/C refrigerant pressure signal circuit

and ground.
Does the voltage measure near the specified value?

6-1122

Engine Controls - 3.8L

Engine

PCM Controlled A/C Circuit Diagnosis (cont'd)

Step

Action

Value(s)

19

1 . Check for the following conditions:

The 5 volt reference B circuit for a poor
connection at the PCM.
The 5 volt reference B circuit for a poor
connection at the A/C refrigerant pressure sensor.
The A/C refrigerant pressure signal circuit for a
poor connection at the PCM.
The A/C refrigerant pressure signal circuit for a
poor connection at the A/C refrigerant pressure
sensor.
The sensor ground circuit for a poor connection at
the A/C refrigerant pressure sensor.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Locate and repair short to voltage in the A/C refrigerant

pressure signal circuit.
Is action complete?

1. Turn ON the ignition switch.

2. A/C OFF
3. Observe A/C Request on the scan tool.
Does A/C Request display Yes?

20

21

Turn OFF the ignition switch.

Disconnect the HVAC control head.
Turn ON the ignition switch.
Check the A/C request circuit for a short to B+.
If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

24

1. Disconnect the A/C relay.

2. Start the vehicle.
3. Observe the A/C compressor.
Is the A/C compressor clutch engaged?

25

Probe the A/C compressor clutch control circuit (CKT 59)

at the A/C relay harness connector with a test light to
ground.
Is the test light ON?

26

Replace the A/C relay.

Is action complete?

27

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Probe the A/C relay control circuit at the PCM
connector with a test light connected to B+.
Is the test light ON?

23

Go to Step 37

Go to Step 36

Go To Step 22

B+

1.
2.
3.
4.
5.

No

Go to Step 37

Turn OFF the ignition switch.

Disconnect the PCM.
Turn ON the ignition switch.
A/C OFF.
Using a J 39200 Digital Multimeter, measure voltage
between the A/C request circuit at the PCM harness
connector and ground.
Does the voltage measure near the specified value?

22

1.
2.
3.
4.
5.

Yes

Go To Step24

(
Go To Step 23

Go to Step35

Go to Step 37

Go to Diagnosis
in Manual
Control Air
Conditioning

Go to Step 29

Go to Step25

Go to Step 27

Go to Step26

Go to Step 37

Go to Step 28

Go to Step 35

Engine

Engine Controls - 3.8L

6-1123

PCM Controlled A/C Circuit Diagnosis (cont'd)

Action

Step

28

Repair short to ground in the A/C compressor clutch relay

control circuit. Refer to Wiring Repairs.

Value(s)

Is action complete?

29

30

1. Turn OFF the ignition switch.

2. Disconnect the A/C compressor clutch electrical
connector.
3. Start the engine.
4. Observe the A/C compressor.
Is the A/C compressor clutch engaged?
Locate and repair short to voltage in the A/C compressor
clutch control circuit (CKT 59). Refer to Wiring Repairs.

Go To Step 33

Go to Step 37

32

Replace the A/C compressor relay.

Is action complete?

33

Repair the A/C compressor clutch. Refer to V5 Air

Conditioning Compressor.
Is action complete?

Locate and repair open in the A/C compressor clutch

ground circuit (CKT 450).
Is action complete?

Replace the PCM.

Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Is action complete?

36

Replace the A/C refrigerant pressure sensor. Refer to

On-Vehicle Service in Heater, Ventilation and Air
Conditioning.

38

Go to Step 37
Go to Step 37

Go to Step 37

Go to Step 37

Go to Step 37

Is action complete?

37

Go to Step 30

35

Repair open or short to ground in the ignition positive

voltage circuit to the A/C compressor relay. Refer to Wiring
Repairs.
Is action complete?

34

No

Go to Step 37

Is action complete?

31

Yes

Go to Step 37

Important: Before continuing with diagnosis, the following

conditions must be met:
Intake air temperature greater than 9 C (48 F).
Engine coolant temperature less than 119 C (246 F).
1. With the A/C OFF, start and idle the engine.
2. Observe the A/C pompressor.
Is the A/C compressor clutch engaged?

1. Run the engine at 1000-1500 rpm.

2. Select an A/C mode on the HVAC control head.
3. Observe A/C compressor.
Is the A/C compressor clutch engaged?

Go to Step 21

Go to Step 38

System OK

Go to Step 5

6-1124

Engine Controls - 3.8L

Engine

Electric Cooling Fan Diagnosis

! Hot At All Times!
.. -

L1
K1

L--

! Hot At All Times!

-

-Po:e;- -

COOL FAN
MaxiFuse
A
40

J7

.,

Underhood

I Electrical
I
Center 1
I

COOLING
FAN
MiniFuse

J6

10 A

----J

-------------

RED 402

Power
Distribution
Cell10

Distribution
Cell 10

ORN 1640

-.-------------'I'-----------~

r - - - - - -~

ORN 1640.

RED 402

.---------'If'---~

ORN 1640

WHT 504

----------

~----

ORN 1640

------ ----

B3

B9

BB

C6

~~~1~:g

~~~il~ig

---~' L~ ::B~r.~ ----

_c~

-~~

Underhood
RED 402 Electrical
Center 1

-----.,

mu
11--.
n
I
l..1:::!._EJ ::;., " . l1- 4 : ;., "
C3

Fuse Block
Details
Cell11

C4 .,,.

~~~~:g

---\ ~:".,.,
4~3- -- " ---:;; ;o~ ----,

DK:~

DK BLU 473

WHT 504

~~ftgine
Cooling
Fan

DKGRN 335

Cooling
Fan

13~

DK GR6N

~ Right
Engine

DK BLU 473

GRY 532

" DK

BLi

~3

~~

r - - -,- Cooi:ng- - - - - - - - - - - - - - -,- co;;iin; - ,

I
I

Fan Relay 1

-..1Control

CONN ID
C1 = BLU
C2 = CLEAR

..
1

Fan Relay
2 and 3
Control

L _ _ _ :_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _:: _ _ _ _

BLK 150

BLK 1~''

Powertrain
I Control
I Module
~
~ (PCM)~

'- - - -

..l
Ground
Distribution
Cell 11!

254432

Circuit Description:
Power for the fan motors is supplied through a 40 amp
MaxiFuse located in the Underhood Fuse Block.
The cooling fan relays receive power from a 25 amp
fuse located in the Underhood Fuse Block.
During low speed fans operation the PCM supplies a
ground path for the engine cooling fan relay #1.
This closes the engine cooling fan relay #1 contacts,
allowing current to flow from the 40 amp Maxifuse,
through the relay contacts, and to the left engine
cooling fan. During low speed operation, the ground
path for the left cooling fan is through the engine
cooling fan relay #3 and the right engine cooling fan
motor. The result is a series circuit with both
cooling fans running at low speed.

During high speed cooling fan operation, the PCM

supplies a ground path for the engine cooling fan
relay #1. After a 6 second delay, the PCM supplies a
ground path for engine cooling fan relay #2 and
engine cooling fan relay #3. The 6 second delay
ensures that the cooling fan electrical load will
not exceed the capacity of the system. During high
speed fans operation, both the engine cooling fans are
supplied current from the 40 amp Maxifuse and
each cooling fan has its own ground path.

Engine Controls - 3.8L

Engine
Diagnostic Aids
The PCM will complete the ground path for cooling fan
relay #1 under any of the following conditions:
When engine coolant temperature exceeds
105C (221 F).
When A/C is requested and ambient temperature
is greater than 10C (50F).
When A/C refrigerant pressure is greater
than 190 psi (2 volts).
For high speed cooling fans operation, the PCM will
delay control of the cooling fan #2 and #3 relays for
6 seconds. The 6 second delay ensures that the
cooling fan electrical load will not exceed the capacity
of the system. The PCM will complete the ground
paths for cooling fan relays #1, #2, and #3 under any
of the following conditions:
When engine coolant temperature exceeds
113C (235F).
When A/C refrigerant pressure is greater
than 275 psi (2.9 volts).

6-1125

Check for the following conditions:

Poor connection at the PCM, cooling fan relays,
or cooling fan motors. Inspect harness connectors
for backed out terminals, improper mating,
broken locks, improperly formed or damaged
terminals, and poor terminal to wire connection.
Damaged harness. Inspect the wiring harness for
damage.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
2. Stored diagnostic troubl.e codes may affect engine
cooling fans operation. This diagnostic table may
lead to improper diagnosis and replacement of
good parts if diagnostic trouble codes are present. O
6. Ambient temperature must be greater than 9C
(48F) before the PCM will enable the cooling
a
fans due to A/C request. The PCM will enable the '
cooling fans if A/C refrigerant pressure increases
regardless of ambient temperature.
77. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.

Electric Cooling Fan Diagnosis

Step

Action
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?

.1

I
I

Are any powertrain DTCs stored?

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Diagnose the
DTCs first.

Go to Step 3

Go to Step 32

Go to Step 4

Go to Step 5

Go to Step 8

Go to Step 6

Go to Step 58

Go to
Diagnostic Aids

Go to Step 7

Go to Step 77

Go to PCM
Controlled A/C
Circuit Diagnosis

Go to Step 9

Go to Step 16

1. Ensure that the engine coolant temperature is below

100C (212F).
2. Turn the A/C OFF.
3. Engine running.
4. Observe the cooling fans.
Are the cooling fan(s) running?

1. Command Fan 1 ON using the scan tool output tests

function.
2. Observe the cooling fans.
Are both cooling fans running at low speed?

1. Command Fan 2 ON using the scan tool output tests

function.
2. Wait 6 seconds.
3. Observe the cooling fans
Are both fans running at high speed?

Important: Ambient temperature must be greater

than 9C (48F).
1. Exit scan tool output tests.
2. Engine running.
3. Turn the A/C ON.
Are the cooling fans running?

View A/C Request on the scan tool.

Does A/C Request on the scan tool display Yes?

Is either cooling fan running?

6-1126

Engine Controls - 3.SL

Engine

Electric Cooling Fan Diagnosis (cont'd)

Step

Action

Is th~ left cooling fan running?

10

11

12

13

1.
2.
3.
4.

Turn OFF the ignition switch.

Disconnect the right engine cooling fan.
Turn ON the ignition switch.
Command Fan 1 ON using the scan tool output tests
function.
5. Observe the cooling fans.
Is the left engine cooling fan running?

Value(s)

Go to Step 11

Locate and repair short to ground in CKT 532. Refer to

Wiring Repairs.
Is actipn complete?

1. Check CKT 504 for a short to ground.

2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Go to Step 12

....

Go to Step 13

Go to Step81

'

15

Replace the left engine cooling fan diode.

Is action complete?

16

1. Ignition ON, engine not running.

2. Remove the low speed engine cooling fan relay #1
from the Underhood Electrical Center.
3. Probe Underhood Electrical Center cavity 01 with a
test light connected to ground.
Is the test light ON?

1. Identify the cause of no battery positive voltage to

Underhood Electrical Center cavity 01:
Blown fuse link. If the fuse link is blown, locate
and correct short circuit.
- Stalled right engine or left engine cooling fan.
- Shorted right engine or left engine cooling fan
motor windings.
- Short to ground in CKT 402, CKT 532, or
CKT 504.
Open in CKT 402.
2. Repair the cause of no battery positive voltage to
Underhood Electrical Center cavity 01. Refer to
Wiring Repairs.
Is action complete?

Probe Underhood Electrical Center cavity 05 with a test

light connected to ground.
Is the test light ON?

18

Go' to Step 80
f,;

17

Go to Step 14

Turn OFF the ignition switch.

Disconnect the left engine cooling fan.
Turn ON the ignition switch.
Command Fan 1 ON using the scan tool output tests
function.
5. Observe the cooling fans.
Is the right engine cooling fan running?

14

Goto Step 10

No

'

. '

.Remove the series/parallel engine cooling fan relay #3

from the Underhood Electrical Center.
Is the left engine cooling fan running?

1.
2.
3.
4.

Yes

Gp to Step BJ

Go to Step 76

..,

Go to Step 15

Go to Step 79

Go to Step 81

Goto Step 18

Go to Step 17

"

Go to Step 81

Go to Step 20

Go to Step 19

Engine Controls - 3.SL

Engine

6-1127

Electric Cooling Fan Diagnosis {cont'd)

Step

19

20

21

22

23

24

Action

Value(s)

1. Identify the cause of no battery positive voltage to

Underhood Electrical Center cavity D5:
Blown fuse. If the fuse is blown, locate short
circuit.
- CKT 1440 shorted to ground.
- Shorted low speed engine cooling fan
relay #1 coil.
- Shorted series/parallel engine cooling fan
relay #3 coil.
- Shorted high speed engine cooling fan
relay #2 coil.
- Circuit unrelated to cooling fans.
CKT 1440 open.
2. Repair cause of no battery positive voltage to
Underhood Electrical Center cavity D5. Refer to
Wiring Repairs.
Is action complete?

1. Turn OFF the ignition switch.

2. Disconnect both cooling fans.
3. Connect terminals A and B together at both cooling
fan connectors using fused jumpers.
4. Turn ON the ignition switch.
5. Connect a test light between Underhood Electrical
Center cavities D1 and D4.
Is the test light ON?

1. Connect a test light between Underhood Electrical

Center cavities D2 and D5.
2. Turn ON the ignition switch.
3. Command Fan 1 ON using the scan tool output tests
function.
4. Observe the test light.
Is the test light ON?

1. Turn OFF the ignition switch

2. Remove the jumpers from the engine cooling fan
connectors and reconnect the cooling fans.
3. Install a fused jumper between Underhood Electrical
Center cavities D1 and D4.
4. Turn ON the ignition switch.
5. Observe the cooling fans.
Are both cooling fans running?

1. Check for poor low speed engine cooling fan relay #1

connections at the Underhood Electrical Center.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Check for poor connections at the cooling fan motors.

2. If a problem.is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Yes

No

Go to Step 81

Go to Step 21

Go to Step 27

Go to Step 22

Go to Step 25

Go to Step 23

Go to Step 24

Go to Step 81

Go to Step 37

Go to Step 81

Go to Step 63

6-1128

Engine

Engine Controls - 3.8L

Electric Cooling Fan Diagnosis (cont'd)

Step

Action

Value(s)

25

1. Turn OFF the ignition switch.

2. Disconnect the PCM blue connector C1.
3. Install a fused jumper between Underhood Electrical
Center cavities D1 and D2.
4. Turn ON the ignition switch.
5. Probe PCM harness connector cavity C1-32 with a
test light to ground.
Is the test light ON?

26

Locate and repair open in the cooling fan relay #1 control

circuit (CKT 335) between the PCM and Underhood
Electrical Center cavity D2.
Is action complete?

Yes

No

Go to Step 77

Go to Step26

Go to Step 81

1.
2.
3.
4.

Turn OFF the ignition switch.

Remove the jumpers from the cooling fan connectors.
Reconnect the cooling fans.
Install a fused jumper between Underhood Electrical
Center cavities D1 and 04.
5. Remove the series/parallel engine cooling fan relay
#3 from the Underhood Electrical Center.
6. Probe Underhood Electrical Center cavity J4 with a
test light connected to ground.
Is the test light ON?

Connect a test light between Underhood Electrical Center

cavities J3 and J4.
Is the test light ON?

1. Check for an open in CKT 504 between Underhood

Electrical Center cavity J3 and right engine cooling
fan terminal B.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Check for a poor connection at Underhood Relay

Center cavities J3 or J4.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Check for an open in CKT 409 between Underhood

Relay Center cavity D4 and left engine cooling fan
harness connector terminal B.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Using scan tool, view A/C Request.

Does the scan tool display Yes?

33

27

Go to Step 28

Go to Step 31

Go to Step 30

Go to Step29

Go to Step 81

Go to Step 57

Go to Step 81

Go to Step 76

Go to Step 81

Go to Step 56

Go to PCM
Controlled A/C
Circuit Diagnosis

Go to Step 33

Are both cooling fan(s) running at low speed?

Go to Step 34

Go to Step 40

34

Remove low speed engine cooling fan relay #1 from the

Underhood Relay Center.
Are the cooling fans running?

Go to Step 35

Go to Step 36

35

Locate and repair short to voltage in CKT 409. Refer to

Wiring Repairs.
Is action complete?

Using a test light connected to B+, probe Underhood

Relay Center cavity D2.
Is the test light ON?

Replace low speed engine cooling fan relay #1.

Is action complete?

28

29

30

31

32

36

37

Go to Step 81

Go to Step 38
Go to Step 81

Go to Step 37

Engine

Engine Controls - 3.8L 6-1129

Electric Cooling Fan Diagnosis (cont'd)

Step

Action

1. Turn OFF the ignition switch

2. Disconnect the blue PCM connector C1.
3. Probe Underhood Relay Center cavity D2 with a test
light connected to B+.
Is the test light ON?

Locate and repair short to ground in the cooling fan

relay #1 control circuit (CKT 335). Refer to Wiring Repairs.
Is action complete?

40

Are both cooling fans running at high speed?

41

View A/C Pressure on the scan tool.

Does the scan tool display voltage less than the
specified value?

38

39

42

43

44

Yes

No

Go to Step 39

Go to Step77

Value(s)

Go to Step 81
Go to Step 41

Go to Step 42

Go to Step 77

Go to Step 44

Go to Step 43

Go to Step 77

Go to Step 81

Go to Step

1.2V

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
3. Turn ON the ignition switch.
4. Observe the cooling fans.
Is the right engine cooling fan running at high speed?

1. Check for a short to ground in the cooling fan #2

and #3 qontml circuit (CKT 473).
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Turn OFF the ignition switch.

2. Disconnect the A/C refrigerant pressure sensor
electrical connector.
3. Turn ON the ignition switch.
4. View A/C Pressure on the scan tool.
Does the scan tool display voltage near the
specified value?

OV

q2

Go to Step 46

Go to Step 45

Go to Step 77

Go to Step 51

Go to Step 47

Go to Step 49

Go to Step 48

.Go .to Step 50

Probe the A/C refrigerant pressure signal circuit with a

J 39200 Digital Multimeter connected to the A/C refrigerant

45

pressure sensor ground.

Does the digital multimeter display voltage near the
specified value?

ov

46

Probe the A/C refrigerant pressure sensor ground with a

test light to B+.
Is the test light ON?

47

Probe the A/C refrigerant pressure sensor 5 volt reference

circuit B with a J 39200 Digital Multimeter connected to the
A/C refrigerant pressure sensor ground.
Does the digital multimeter display voltage near the
specified value?

5V

48

Replace the A/C refrigerant pressure sensor. Refer to

On-Vehicle Service in Heater, Ventilation, and Air
Conditioning.
Is action complete?

49

Locate arid repair open or short to voltage in the A/C

refrigerant pressure sensor ground circuit. Refer to Wiring
Repairs.
Is action complete?

50

Locate and repair open or short to ground in the A/C

refrigerant pressure sensor 5 volt reference B circuit. Refer
to Wiring Repairs.
Is action complete?

51

Locate and repair short to voltage in the A/C refrigerant

pressure signal circuit. Refer to Wiring Repairs.
Is action complete?

Go to Step 81

Go to Step.81

Go to Step 81

Go to Step 81

6-1130

Engine

Engine Controls - 3.SL

Electric Cooling Fan Diagnosis (cont'd)
Action

Step

52

53

54

55

56

57

58

59

60

Value(s)

1. Remove the high speed engine cooling fan relay #2

from the Underhood Electrical Center.
2. Observe the cooling fans.
Is the right engine cooling fan running at high speed?

Remove series/parallel engine cooling fan relay #3 from

the Underhood Electrical Center.
Is the right engine cooling fan running at high speed?

Locate and repair short to B+ in CKT 504. Refer to Wiring

Repairs.
Is action complete?

Locate and repair short to B+ in CKT 532. Refer to Wiring

Repairs.
Is action complete?

1. Check for an open in CKT 532 between Underhood

Electrical Center cavity J4 and left engine cooling fan
terminal A.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Check for an open in CKT 150 between right engine

cooling fan terminal A and ground.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Ignition ON, engine not running.

2. Remove the high speed engine cooling fan relay #2
from the Underhood Electrical Center.
3. Install a test light between Underhood Electrical
Center cavity F2 and B+.
4. Command Fan 2 ON using the scan tool output
controls function.
5. Wait 6 seconds.
6. Observe the test light.
Is the test light ON?

1. Remove the series/parallel engine cooling fan relay

#3 from the Underhood Electrical Center.
2. Install a test light between Underhood Electrical
Center cavity J2 and B+.
3. Command Fan 2 ON using the scan tool output
controls function.
4. Wait 6 seconds.
5. Observe the test light.
Is the test light ON?

1.
2.
3.
4.

Turn OFF the ignition switch.

Disconnect the PCM.
Turn ON the ignition switch.
Check the cooling fan relay #2 and #3 control circuit
(CKT 473) for an open or a short to voltage between
Underhood Electrical Center cavity J2 and the PCM.
5. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Yes

No
(

i.

Go to Step 53

Go to Step 70

Go to Step 54

Go to Step 55
-

Go to Step 81

Go to Step 81

Go to Step 81

Go to Step 79

Go to Step 81

Go to Step 80

Go to Step 61

Go to Step 59

Go to Step 78

Go to Step 60

Go to Step 81

Go to Step 77

Engine Controls .. 3.SL

Engine

6-1131

Electric Cooling Fan Diagnosis {cont'd)

Action

Step

61

62

63

64

65

66

67

68

69

70

Value(s)

Turn OFF the ignition switch

Reinstall high speed engine cooling fan relay #2.
Disconnect both cooling fan electrical connectors.
Turn ON the ignition switch.
Command Fan 2 ON using the scan tool output
controls function.
6. Wait 6 seconds.
7. Probe terminal B (CKT 504) at the right engine
cooling fan connector with a test light to ground.
Is the test light ON?

Probe terminal A (CKT 532) at the left engine cooling fan

connector with a test light to B+.
Is the test light ON?

1. Identify cause of inoperative cooling fan:

Open right engine cooling fan motor windings.
Open left engine cooling fan motor windings.
Stalled cooling fan(s).
2. Replace the affected cooling fan motor. Refer to
On-Vehicle Service in Cooling and Radiator.
Is action complete?

1. Remove the high speed engine cooling fan relay #2

from the Underhood Electrical Center.
2. Turn ON the ignition switch.
3. Probe Underhood Electrical Center cavity F5 with a
test light connected to ground.
Is the test light ON?

Locate and repair open in the ignition positive voltage

circuit to high speed engine cooling fan relay #2. Refer to
Wiring Rl;lpairs.
Is action complete?

Probe Underhood Electrical Center F4 with a test light

connected to ground.
Is the test light ON?

Locate and repair open in battery positive voltage circuit to

Underhood Electrical Center cavity F4. Refer to Wiring
Repairs.
Is action complete?

1. Check CKT 504 for an open between right engine

cooling fan terminal B and Underhood Electrical
Center cavity F1 .
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

1. Check for poor high speed engine cooling fan relay

#2 terminal connections at the Underhood Electrical
Center.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?

Replace high speed engine cooling fan relay #2.

Is action complete?

1.
2.
3.
4.
5.

Yes

No

Go to Step 62

Go to Step 64

Go to Step 63

Go to Step 71

Go to Step 81

Go to Step 66

Go to Step 65

Go to Step 81

Go to Step 68

Go to Step 67

Go to Step 81

Go to Step 81

Go to Step 69

Go to Step 81

Go to Step 70

Go to Step 81

6-1132

Engine Controls - 3.SL

Engine

Electric Cooling Fan Diagnosis (cont'd)

Step

71

72

73

74

75

76

77

78

79

80

81

82

83

Action

1. Remove the series/parallel cooling #3 fan relay from

the Underhood Electrical Center.
2. Turn ON the ignition switch.
3. Probe Underhood Electrical Center cavity JS with a
test light connected to ground.
Is the test light ON?
Locate and repair open in battery positive voltage circuit to
Underhood Electrical Center cavity JS. Refer to Wiring
Repairs.
Is action complete?
Probe Underhood Electrical Center cavity J 1 with a test
light to B+.
Is the test light ON?
Locate and repair open in CKT 150 between Underhood
Electrical Center cavity J1 and ground. Refer to Wiring
Repairs.
Is action complete?
1. Check for poor series/parallel engine cooling fan relay
#3 terminal connections at the Underhood Electrical
Center.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.
Was a problem found?
Replace the series/parallel engine cooling fan relay #3.
Is action complete?
Replace the PCM.
Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Is action complete?
Repair open in the cooling fan relay #2 and #3 control
circuit (CKT 473) to Underhood Electrical Center cavity F2.
Refer to Wiring Repairs.
Is action complete?
Replace the left engine cooling fan motor. Refer to
On-Vehicle Service in Cooling and Radiator.
Is action complete?
Replace the right engine cooling fan motor. Refer to
On-Vehicle Service in Cooling and Radiator.
Is action complete?

Value(s)

Yes

No

(
Go to Step 73

Go to Step 72

Go to Step 81

Go to Step 75

Go to Step 74
-

Go to Step 81

Go to Step 81

Go to Step 81

Go to Step 76

Go to Step 81

Go to Step 81

Go to Step 81

Go to Step 81

1. Engine coolant below 100C (212F).

2. Turn the A/C OFF.
3. Engine running.
Observe the cooling fans.
Are the cooling fan(s) running?

1. Command Fan 1 ON using the scan tool output tests

function.
2. Observe the cooling fans.
Are both cooling fans running at low speed?

1. Command Fan 2 ON using the scan tool output tests

function.
2. Wait 6 seconds.
3. Observe the cooling fans.
Are both cooling fans running at high speed?

Go to Step 32

Go to Step82

Go to Step 83

Go to Step 8

System OK

Go to Step58

Engine

Engine Controls - 3.8L

6-1133

Engine Oil Level Sensor/Switch Diagnosis

\I
I

Circuit Description

Diagnostic Aids

The Engine Oil Level Switch is a simple float switch

that is grounded when the engine oil level is OK. The
PCM checks the Engine Oil Level switch circuit at
startup. Before checking the state of the Engine
Oil Level switch, the PCM performs a test routine
based on time and engine coolant temperature
to ensure that the engine oil has drained back into the
sump. To test for low oil level at startup, one of the
following conditions must be present:
If the engine coolant temperature was
between 15C (59F) and 130C (266F) at the
last key OFF, the engine coolant temperature
at key ON must be at least 12C (22F) cooler
than the engine coolant temperature at the last
key OFF.
If the engine coolant temperature was higher
than 100C (212F) at the last key OFF, the time
between last key OFF and the present key ON
must be sufficient to allow the oil to drain back to
the sump. The PCM will remain powered up
for 10 seconds to ensure that the oil has drained
back to the sump. If the key is turned back
ON while the PCM is still powered up the oil level
'
will not be tested.
The Low Oil Level Lamp will be illuminated for
approximately 7 minutes when the PCM checks for
low oil level and the Engine Oil Level switch indicates
that a low oil level condition exists (Engine Oil
Level switch circuit not grounded). When the ignition is
first turned ON, the PCM commands the Low Oil
Level lamp ON for a brief period of time to
test the bulb.

For diagnosis of the instrument panel, perform the

System Check in the Instrument Cluster section
of Electrical Diagnosis.
Check for the following conditions:
Poor connection at PCM or oil level sensor.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wire connection.
Damaged harness. Inspect the wiring harness for
damage. If the harness appears to be OK,
disconnect the PCM and turn the ignition ON.
Observe a voltmeter connected to the affected
PCM output circuit while moving connectors and
wiring harnesses related to the PCM output
circuit. A change in voltage will indicate the
location of the fault.
Engine Oil Level Switch circuit: If the problem with
the Low Oil Level lamp can not be isolated using
the Engine Oil Level Switch Diagnostic table,
use the PCM Controlled Lamps Diagnostic table.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
10. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.
11. For the PCM to check engine oil level, startup
engine coolant temperature must be at least 12 C
(22 F) cooler than the engine coolant temperature
was last time the ignition was turned OFF.
Allowing the engine to warm and then cool
ensures that the PCM checks the engine oil level
switch and that the information displayed on
the scan tool is current.

6-1134

Engine

Engine Controls - 3.SL

Engine Oil Level Sensor/Switch Diagnosis

Step

Action
Important: Ensure that engine oil level is not low (as
indicated on the engine oil level indicator) before
continuing diagnosis.
Was the On-Board Diagnostic (OBD) System Check
performed?

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 6

Go to Step 3

Go to Step 7

Go to Step 4

Go to Step 8

Go to Step 5

Go to Step 11

Go to
Diagnbstic Aids

Go to Step 11

Go to Step 10

Go to Step 11

Go to Step 9

1. Turn OFF the ignition switch.

2. Disconnect the PCM.
2

3. With a J 34142-8 Unpowered Test Light to B+, probe

the engine oil level switch signal circuit at the PCM
harness connector.

Is the test light ON?

1. Reconnect the PCM.
2. Turn ON the ignition switch.

3. Raise the vehicle.

3

4. Disconnect the engine oil level switch connector.

B+

5. Connect a J 39200 Digital Multimeter to measure

voltage .between the engine oil level switch harness
connector terminals.
Is the voltage near the specified value?
4

Connect the digital multimeter between the engine oil level

switch signal circuit and chassis ground.

B+

Is the voltage near the specified value?

1. Check the engine oil level switch signal circuit for

an open.
5

2. If a problem is found, repair as necessary. Refer to

Wiring Repairs.

Was a problem found?

1. Check for poor terminal connections at the PCM.

2. If a problem is found, repair as necessary. Refer to

Wiring Repairs.

Was a problem found?

1. Check for poor terminal connections at the engine oil
level switch.

2. If a problem is found, repair as necessary. Refer to

Wiring Repairs.

Was a problem found?

Locate and repair open in the engine oil level switch

ground circuit (CKT 451 ). Refer to Wiring Repairs.

Replace the engine oil level switch. Refer to Engine Oil

Pressure Sensor/Switch Replacement.

10

11

Start the engine.

Is the low oil light off?

Go to Step 11

Is action complete?
Replace the PCM.
Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming.
Is action complete?

Go to Step 11

Is action complete?

Go to Step 11

System OK

Go to Step 2

Engine Controls - 3.SL

Engine

6-1135

Fuel System Pressure Test

9

12822

Legend

(1)
(2)
(3)
(4)
(5)

Fuel
Fuel
Fuel
Fuel
Fuel

Pressure Regulator Assembly

Return Pipe
Pump
Pump Flex Pipe
Feed Pipe

(6)
(7)
(8)
(9)

Fuel
Fuel
Fuel
Fuel

Filter
Pipe Shut Off Adapters J 37287
Pressure Gauge J 34730-1A
Rail Assembly

Circuit Description

Test Description

When the ignition switch is turned ON, the Powertrain

Control Module (PCM) will turn ON the in-tank fuel
pump. The in-tank fuel pump will remain ON as long as
the engine is cranking or running and the PCM is
receiving reference pulses. If there are no reference
pulses, the PCM will turn the in-tank fuel pump OFF
2 seconds after the ignition switch is turned ON or
2 seconds after the engine stops running. The in-tank
fuel pump is an electric pump within an integral
reservoir. The in-tank fuel pump supplies fuel through
the fuel feed pipe, and in-line fuel filter to the fuel
rail assembly. The fuel pump is designed to provide
fuel at a pressure above the pressure needed by
the fuel injectors. A fuel pressure regulator, attached
to the Fuel Rail, keeps the fuel available to the
fuel injectors at a regulated pressure. Unused fuel is
returned to the fuel tank by a separate fuel return pipe.
The fuel pressure gauge J 34730-1A and fuel pipe
shut off adapters J 37287 are used for fuel system
diagnosis.

The numbers below refer to the step numbers on the

diagnostic table.
2. To relieve the fuel pressure, refer to Fuel Pressure
Relief Procedure. With the ignition switch ON and
the fuel pump running, the fuel pressure
indicated by the fuel pressure gauge should read
333-376 kPa (48-55 psi). The spring pressure
inside the fuel pressure regulator controls
this pressure.
3. A fuel system that drops more than 5 psi
in 1o minutes has a leak in one or more of the
following areas:
The fuel pump check valve.
The fuel pump flex pipe.
The valve or valve seat within the fuel pressure
regulator.
The fuel injector(s).

6-1136

Engine Con.trols - 3.St

5. Fuel pressure that drops-off during acceleration,

cruise, or hard cornering may cause a lean
condition. A lean condition can cause a loss of
power, surging, or misfire. You can diagnose
a lean condition using a scan tool. If an extremely
lean condition occurs, the oxygen sensors(s)
will stop toggling. The oxygen sensor output
voltage(s) will drop below 500 mV. The fuel
injector width will increase.
Important: Make sure the fuel system is not operating
in the Fuel Cut-Off Mode. This can cause false
indications by the scan tool. Refer to Engine Scan
Tool Data List.

8. When the engine is at idle, the manifold pressure

is low (high vacuum). This low pressure (high
vacuum) is applied to the fuel pressure regulator
diaphragm. The low pressure (high vacuum)
offsets the pressure being applied to the
fuel pressure regulator diaphragm by the spring
inside the fuel pressure regulator. When this
happens, the result is lower fuel pressure. The
fuel pressure at idle will vary slightly as the
barometric pressure changes, but the fuel
pressure at idle should always be less than the
fuel pressure noted in step 2 with the engine OFF.
12. A rich condition may result from the fuel pressure
being above 376 kPa (55 psi). A rich condition
may cause a OTC P0132 or a OTC P0172 to set.
Driveability conditions associated with rich
conditions can include hard starting followed by
black smoke and a strong sulfur smell in the
exhaust.
13. This test determines if the high fuel pressure is
due to a restricted fuel return pipe or if the
high fuel pressure is due to a faulty fuel pressure
regulator.
15. A lean condition may result from the fue.1 pressure
being below 333 kPa (48 psi). A lean condition
may cause a OTC P0131 or a OTC P0171 to set.
Driveability conditions associated with lean
conditions can include hard starting (when the
engine is cold), hesitation, poor driveability, lack of
power, surging, and misfiring.

Engine
16. Restricting the fuel return pipe with the J 37287
Fuel Pipe Shut-Off Adapter causes the fuel
pressure to rise above the regulated fuel pressure.
Using a scan tool to pressurize the system, the
fuel pressure should rise above 376 kPa (55 psi)
as the valve on the Fuel Pipe Shut-Off Adapter
connected to the fuel return pipe becomes partially
closed.
Notice: Do not allow the fuel pressure to exceed
450 kPa (65 psi). Fuel pressure in excess of 450 kPa
(65 psi) may damage the Fuel Pressure Regulator.

22. Check the spark plug associated with a particular

fuel injector for fouling or saturation in order to
determine if that particular fuel injector is leaking.
If checking the spark plug associated with a
particular fuel injector for fouling or saturation does
not determine that a particular fuel injector is
leaking, use the following procedure:
1. Remove the fuel rail, but leave the fuel pipes
connected to the fuel rail. Refer to Fuel Rail
Assembly Replacement.
2. l,.ift the fuel rail just enough to leave the fuel
injector nozzles in the fuel injector ports.
Caution: In order to reduce the risk of fire and
personal injury that may result from fuel spraying
on the engine, verify that the fuel rail is positioned
over the fuel injector ports. Also verify that the
fuel injector retaining clips are intact.
3. Pressurize the fuel system by using a
scan tool.
4. Visually and physically inspect the fuel injector
nozzles for leaks.

Engine

Engine Gontrols - 3.SL

6-1137

Fuel System Pressure Test .

Action

Step

Value(s)

Yes

No

Go to Step2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Step 12

Go to Step 10

Go to Step 4

Go to Step 19

Go to Step 5

Go to Step 6

Go to Step B.

Go to Step 24

Go to Step 7

Go to Step 24

Go to Step 19

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

1. Turn the ignition OFF.

2. Turn the air conditioning system OFF.

Caution: Wrap a shop towel around the fuel pressure

connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel leakage
that occurs during the connection of the fuel pressure
gauge. Place the towel in an approved container when
the connection of the fuel pressure gauge is complete.
3. Install the J 34730-1A fuel pressure gauge.
4. Place the bleed hose of the fuel pressure gauge into
an approved gasoline container.
5. Turn the ignition ON.
6. Bleed the air out of the fuel pressure gauge into an
approved gasoline container.
7. Turn the ignition OFF for 1O seconds.
8. Turn the ignition ON.
Important: The fuel pump will run for approximately
2 seconds. Cycle the ignition as necessary in order to
achieve the highest possible fuel level
9. Observe the fuel pressure indicated by the fuel
pressure gauge with the fuel pump running.
Is the fuel pressure within the specified limits?

333-376 kPa
(48-55 psi)

Important: The fuel pressure may vary slightly when the

fuel pump stops running, the fuel pressure should stabilize
and remain constant.
Note the fuel pressure after the fuel pump stops running.
Does the fuel pressure drop more than the specified value
in 1O minutes?

34 kPa (5 psi)

Relieve the fuel pressure to the first specified value.

Does the fuel pressure drop more than the second
specified value in 1O minutes?

69 kPa (10 psi),

14 kPa (2 psi)

Do you suspect the fuel pressure of dropping-off during

acceleration, cruise, or hard cornering?

Visually and physically inspect the following items for a

restriction:
The in-line fuel filter.

The fuel feed pipe.

Did you find a restriction?

1. Remove the fuel sender assembly. Refer to Fuel

Sender Assembly Service.
2. Visually and physically inspect the following items:
The fuel pump strainer for a restriction.
The fuel pump strainer for correct position, and
installation on the fuel sender assembly
The fuel pump flex pipe for leaks.
Verify the fuel pump is the correct fuel pump for
this vehicle.
Did you find a problem in any of these areas?

6-1138

Engine

Engine Controls - 3.8L

Fuel System Pressure Test (cont'd)

Step

10

11

12

Action

Value(s)

1. Turn the ignition OFF for 10 seconds.

2. Turn the ignition ON.
Important: The fuel pump will run for approximately
2 seconds. Cycle the ignition as necessary in order to
achieve the highest possible fuel pressure. Note this
pressure.
3. Start the engine.
4. Allow the engine to idle at normal operating
temperature.
Is the fuel pressure less than the noted fuel pressure by
the amount specified?

21-69 kPa
(3-10 psi)

1. Disconnect the vacuum hose from the fuel pressure

regulator.
2. With the engine idling, apply 12-14 inches of vacuum
to the fuel pressure regulator.
Does the fuel pressure drop by the amount specified?

21-69 kPa
(3-10 psi)

1. Relieve the fuel pressure. Refer to Fuel Pressure

Relief Procedure.
2. Disconnect the fuel feed pipe and the fuel return pipe
from the fuel rail. Refer to Quick Connect Fitting(s)
Service (Metal Collar).
3. Install the J 37287 fuel pipe shut-off adapters
between the fuel feed pipe and the fuel return pipe
and the fuel rail.
Notice: Do not allow the fuel pressure to exceed 450 kPa
(65 psi). Fuel pressure in excess of 450 kPa (65 psi) may
damage the Fuel Pressure Regulator.
4. Open the valves on the Fuel Pipe Shut-Off Adapters.
5. Turn the ignition OFF.
6. Pressurize the fuel system by using a scan tool.
7. Place the bleed hose of the fuel pressure gauge into
an approved gasoline container.
8. Bleed the air out of the fuel pressure gauge.
9. Wait for the fuel pressure to build.
10. Close the valve in the fuel pipe shut-off adapter that
is connected to the fuel feed pipe.
Does the fuel pressure remain constant?

1. Open the valve in the fuel pipe shut-off adapter that

is connected to the fuel feed pipe.
2. Pressurize the fuel system by using a scan tool.
3. Wait for the fuel pressure to build.
4. Close the valve in the fuel pipe shut-off adapter that
is connected to the fuel return pipe.
Does the fuel pressure remain constant?

Is the fuel pressure above the specified limit?

376 kPa
(55 psi)

Yes

No

Go to Symptoms

Go to Step 9

Go to Step 20

Go to Step21

Go to Step 19

Go to Step 11

Go to Step 21

Go to Step 22

Go to Step 13

Go to Step 15

Engine

s. 1139

Engine Controls - 3.SL

Fuel System Pressure Test (cont'd)
Action

Step

Value(s)

Yes

No

1. Relieve the fuel pressure. Refer to Fuel Pressure

Relief Procedure.

2. Disconnect the fuel return pipe from the. fuel rail.

Refer to Quick Connect Fitting(s) Service (Metal
Collar).
3. Attach a length of flexible fuel hose to the fuel rail
return outlet passage

13

4. Place the open end of the flexible hose into an

..

333-376 kPa
(48-55 psi)

approved gasoline container.

5. Turn the ignition OFF for approximately 1O seconds.
6. Turn the ignition ON.
7. Observe the fuel pressure gauge with the fuel pump
running.
Is the fuel pressure within the specified limits?
14

Visually and physically inspect the fuel rail outlet passages

for a restriction.

'

Go to Step 23

15

16

Is the fuel pressure above the specified value?

1. Relieve the fuel pressure. Refer to Fuel Pressure
Relief Procedure.
2. Disconnect the fuel return pipe from the fuel rail.
Refer to Quick Connect Fitting(s) Service (Metal
Collar).
3. Install the J 37287 fuel pipe shut-off adapter between
the fuel return pipe and the fuel rail.
4. Open the valve on the fi.Jel pipe shut-off adapter.
5. Turn the ignition OFF.
6. Pressurize the fuel system by using a scan tool.
Notice: Do not allow the fuel pressure to exceed 450 kPa
(65 psi). Fuel pressure in excess of 450 kPa (65 psi) may
damage the Fuel Pressure Regulator.

Did you find a restriction?

O kPa (0 psi)

Go to Step 14

Go to Step 24

Go to Step 21

Go to Step 16

Go to Step 17

Go to Step 21

Go to Step 7

Go to Step 24

Go to Step 18

Go to Step 24

Go to Step 19

333-376 kPa
(48-55 psi)

7. Place the bleed hose of the fuel pressure gauge into

an approved gasoline container.
8. Bleed the air out of the fuel pressure gauge.
9. Slowly close the valve in the Fuel Pipe Shut-Off
Adapter that is connected to the fuel return pipe.
Does the:fuel pressure rise above the specified value?

17

Perform Fuel System Electrical Test. Refer to Fuel Pump

Relay Circuit Diagnosis.
Did you find a problem with the fuel pump electrical
circuit?

Visually and physically inspect the following items:

The in-line fuel filter for obstructions.

18

19

The fuel feed pipe for a restriction.

The fuel pump strainer for obstructions.
The fuel pump flex pipe for leaks.
Important: It will be necessary to remove the fuel sender
assembly in order to inspect the fuel pump strainer and
the fuel pump flex pipe. Refer to Fuel Sender Assembly
Service.
Did you find a problem in any of these areas?
Replace the fuel sender assembly.
Is the action complete?

Go to Step 25

6-1140

Engine Controls - 3.SL

Engine

Fuel System Pressure Test (cont'd)

Step

Action

Value(s)

Locate and repair the loss of vacuum to the fuel pressure

regulator.
Is the action complete?

21

Replace the fuel pressure regulator.

Is the action complete?

22

Locate and replace any leaking fuel injector(s).

Is the action complete?

23

Locate and correct the restriction in the fuel return pipe.

Is the action complete?

24

Repair the problem as necessary.

Is the action complete?

25

1. Turn the ignition OFF.

2. Turn the air conditioning system OFF.
Caution: Wrap a shop towel around the fuel pressure
connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel leakage
that occurs during the connection of the fuel pressure
gauge. Place the towel in an approved container when
the connection of the fuel pressure gauge is complete.
3. Install the J 34730-1A fuel pressure gauge.
4. Place the bleed hose of the fuel pressure gauge into
an approved gasoline container.
5. Turn the ignition ON.
6. Bleed the air out of the fuel pressure gauge into an
approved gasoline container.
7. Turn the ignition OFF for 10 seconds.
8. Turn the ignition ON.
Important: The fuel pump will run for approximately
2 seconds. Cycle the ignition as necessary in order to
achieve the highest possible fuel pressure.
9. Observe the fuel pressure indicated by the fuel
pressure gauge with the fuel pump running.
Is the fuel pressure within the specified limits?

333-376 kPa
(48-55 psi)

Important: The fuel pressure may vary slightly when the

fuel pump stops running, the fuel pressure should stabilize
and remain constant.
1. Note the fuel pressure after the fuel pump stops
running.
2. Does the fuel pressure drop more than the specified
value in 1O minutes?

34 kPa (5 psi)

20

26

Yes

No

Go to Step 25
Go to Step 25
Go to Step25
Go to Step 25
Go to Step25

Go to Step 26

Go to Step 11

Go to Step 10

System OK

Engine

Engine Controls - 3.SL

6-1141

Fuel Injector Balance Test

1
FUEL INJECTOR
- - TESTER+

LOWVEHICLEBATIERY

READY TO TEST

TEST IN PROGRESS

AMPERAGE SUPPLY SELl:CTOR SWITC

Balance Test
4amp

Coil Test
4amp
2.Samp
0.Samp

0.5-2.5
amp

B+

PUSH TO START TEST

J 39021
17713

Legend
(1) First Reading

(2) Second Reading

Injector Balance Test, Example

Cylinder

1st Reading

330 kPa
(48 psi)

330 kPa
(48 psi)

330 kPa
(48 psi)

330 kPa
, (48 psi)

330 kPa
(48 psi)

330 kPa
(48 psi)

2nd Reading

165 kPa
(24 psi)

124 kPa
(18 psi)

152 kPa
(22 psi)

186 kPa
(27 psi)

165 kPa
(24 psi)

165 kPa
(24 psi)

Amount of Drop

165 kPa
(24 psi)

206 kPa
(30 psi)

179 kPa
(26 psi)

145 kPa
(21 psi)

165 kPa
(24 psi)

165 kPa
(24 psi)

Average Range:
162-183 kPa
(23.5-26.5 psi)

Injector OK

Faulty injector too much

fuel drop

Injector OK

Faulty injector too little

fuel drop

Injector OK

Injector OK

Test Description
Caution: Wrap a shop towel around the fuel
pressure connection in order to reduce the risk of
fire and personal injury. The towel will absorb
any fuel leakage that occurs during the connection
of the fuel pressure gauge. Place the towel in an
approved container when the connection of
the fuel pressure gauge is complete.
4. The engine coolant temperature must be below
the operating temperature in order to avoid
irregular fuel pressure readings due to Hot Soak
fuel boiling.
5. The fuel pressure should be within the specified
range. If the fuel pressure is not within the
specified range, go to Fuel System
Pressure Test.

6. The fuel pressure should reach a steady value. If

the fuel pressure does not reach a steady value,
go to Fuel System Pressure Test.
7. If the pressure drop value for each fuel injector is
within 10 kPa (1.5 psi) of the average pressure
drop value, the fuel injectors are flowing properly.
Calculate the pressure drop value for each fuel
injector by subtracting the second pressure
reading from the first pressure reading. Refer to
the Injector Balance Test Example.

6-1142

Engine Controls - 3.SL

Engine
Fuel Injector Balance Test

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Fuel lnj
Coil Test - ECT
Between
10-35 Degrees C

Go to Step 4

Go to Step 5

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Did you perform the Fuel Injector Coil Test Procedure?

'

Is the engine coolant temperature above the

specified value?

94C (201 F)

Allow the engine to cool below the specified value.

Is the engine coolant temperature below the
specified value?

94C (201F)

Caution: Wrap a shop towel around the fuel pressure

connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel leakage
that occurs during the connection of the fuel pressure
gauge. Place the towel in an approved container when
the connection of the fuel pressure gauge is complete.
1. Install the fuel pressure gauge.
2. Energize the fuel pump using the scan tool.
3. Place the bleed hose of the fuel pressure gauge into
an approved gasoline container:
4. Bleed the air out of the fuel pressure gauge.
5. Using a scan tool pressurize the fuel system.
6. Wait for the fuel pressure to build.
Important: The fuel pump will run for approximately
2 seconds. Repeat Step 5 as necessary in order to
achieve the highest possible fuel pressure.
7. Observe the reading on the fuel pressure gauge.
Is the fuel pressure within the specified limits?

333-376 kPa
(48-55 psi)

Turn the fuel pump OFF.

Does the fuel pressure remain constant?

Go to Step 5

(
Go to Step 6

Go to Fuel
System
Pressure Test

Go to Step 7

Go to Fuel
System
Pressure Test

Engine Controls - 3.8L

Engine

6-1143

Fuel Injector Balance Test (cont'd)

Step

Action

Value(s)

Yes

No

1. Connect the J 39021 fuel injector tester to a fuel

injector.
2. Set the amperage supply selector switch on the fuel
injector tester to the Balance Test 0.5-2.5 amp
position.
3. Turn the fuel pump ON then OFF in order to
pressurize the fuel system.
4. Record the fuel pressure indicated by the fuel
pressure gauge after the fuel pressure stabilizes. This
is the 1st pressure reading.
5. Energize the fuel injector by depressing the Push to
Start Test button on the fuel injector tester.

6. Record the fuel pressure indicated by the fuel

pressure gauge after the fuel pressure gauge needle
has stopped moving. This is the 2nd pressure
reading.

10 kPa (1.5 psi)

7. Repeat steps 1 through 6 for each fuel injector.

8. Subtract the 2nd pressure reading from the 1st

pressure reading for one fuel injector. The result is
the pressure drop value.
9. Obtain a pressure drop value for each fuel injector.
10. Add all of the individual pressure drop values. This is
the total pressure drop.
11. Divide the total pressure drop by the number of fuel
injectors. This is the average pressure drop.
Does any fuel injector have a pressure drop value that is
either higher than the average pressure drop or lower than
the average pressure drop by the specified value?

Go to Step B

Go to Symptoms

Go to Step 9

Go to Symptoms

Notice: Do Not repeat any portion of this test before

running the engine in order to prevent the engine from
flooding.

Re-test any fuel injector that does not meet the

specification. Refer to the procedure in step 7.
Does any fuel injector still have a pressure drop value that
is either higher than the average pressure drop or lower
than the average pressure drop by the specified value?
Replace the faulty fuel injector(s). Refer to Fuel Injector
Replacement.
Is the action complete?

10 kPa (1.5 psi)

System OK

6-1144

Engine Controls - 3.8L

Engine

Fuel lnj Coil Test - ECT Between 10-35 Degrees C.

J 39200 DMM

CJCJCJ

LOW VEHICLE BAnERY

READY TO TEST

TEST IN PROGRESS

mvn......
V-DCe.m.A
v:..Ac

A.

AMPERAGE SUPPLY SELECTOR SWITCH

Coll Test
411fflp

OFF

Balance Test
4amp

2.Samp
0.Samp

c:::i CJ CJ CJ

FUEL INJECTOR
- TESTER +

oo

0.5-2.5
amp

PUSH TO START TEST

j.J.A

B+

J 39021

17707

Test Description
Caution: Wrap a shop towel around the fuel
pressure connection in order to reduce the risk of
fire and personal injury. The towel will absorb
any fuel leakage. that occurs during the connection
of the fuel pressure gauge. Place the towel in an
approved container when the connection of
the fuel pressure gauge is complete.
2. The engine coolant temperature affects the ability
of the fuel injector tester to detect a faulty fuel
injector. If the engine coolant temperature is NOT
Between 10C-35C (50F-95F), go to Fuel
lnj Coil Test - ECT Outside 10-35 Degrees C.
3. The first second of the voltage displayed by the
DMM may be inaccurate due to the initial
current surge. Therefore, record the lowest voltage
displayed by the DMM after the first second of
the test. The voltage displayed by the DMM should
be within the specified range (refer to the
Example). The voltage displayed by the DMM

may increase throughout the test as the fuel

injector windings warm and the resistance. of the
fuel injector windings changes .. An erratic
voltage reading (large fluctuations in voltage that
do not stabilize) indicates an intermittent
connection within the fuel injector.
Resistance
Ohms
11.4-12.6
Fuel Injector
Number
1
2
3

Voltage Specification at 10C-35C

(50F-95F)
5.7-6.6

Voltage Reading
6.3
5.9
6.2
6.1

Pass/Fail
p
p
p
p

5
6

4.8
6.0

F
p

Engine Controls 3.SL

Engine

6;.1145

Fuel lnj Coil Test - ECT Between 10-35 Degrees C

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Fuel lnj
Coil Test - ECT
Outside
10-35 Degrees C

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

1. Connect the scan tool.

2. Check the engine coolant temperature.

10C-35C
(50F-95F)

Is the engine coolant temperature between the specified

limits?
1. Turn the ignition OFF.
Notice: In order to prevent flooding of a sin~le cylinder and
possible engine damage, relieve the fuel pressure before
performing the fuel injector coil test procedure.
2. Relieve the fuel pressure. Refer to Fuel Pressure
Relief Procedure.
3. Access the fuel injector electrical connectors as
required.

'

4. Connect the J 39021 fuel injector tester to B+ and

ground.
5. Set the amperage supply selector switch on the fuel
injector tester to the Coil Test 0.5 amp position.

6. Connect the leads from the J 39200 Digital Multi

Meter (DMM) to the fuel injector tester. Refer to the
illustration.
7. Set the DMM to the tenths scale (0.0).
8. Connect the fuel injector tester to a fuel injector.
Important: Check the engine coolant temperature again in
order to ensure that the correct chart is being used.
9. Press the Push to Start Test button on the fuel
injector tester.
10. Observe the voltage reading on the DMM.

5.7-6.6 volts

Important: The voltai;ie reading may rise during the test.

11.. Record the lowest voltage observed after the first
second of the test.
12. Repeat the procedure for the remaining fuel injectors.

Did any fuel injector.have an erratic voltage reading or a

voltage reading out.side of the specified limits?

Replace the fuel injector(s).

Refer to Fuel Injector Replacement.
Is the action complete?

Goto Step 4
!

Go to Fuel
Injector
Balance Test

Go to Fuel
Injector
Balance Test

6-1146

Engine Controls - 3.SL

Engine

Fuel lnj Coil Test - ECT Outside 10-35 Degrees C

J 39200 DMM

ec:Joo

LOWVEHICLEBATTERY

READY TO TEST

TEST IN PROGRESS

mvn...
V-DC.emA
V-AC
A
OFF
.A

AMPERAGE SUPPLY SELECTOR SWITCH

Coil Test
4amp
2.Samp

CJCJCJC]

FUEL INJECTOR
- TESTER+

Balance Test
4amp

0.5-2.5

o.samp

00

amp

PUSH TO START TEST

B+

J 39021

17707

Test Description
Caution: Wrap a shop towel around the fuel
pressure connection in order to reduce the risk of
fire and personal injury. The towel will absorb
any fuel leakage that occurs during the connection
of the fuel pressure gauge. Place the towel in an
approved container when the connection of
the fuel pressure gauge is complete.
2. The engine coolant temperature affects the ability
of the fuel injector tester to detect a faulty fuel
injector. If the engine coolant temperature is NOT
Outside 10C-35C (50F-95F), go to Fuel
Injector Coil Test Procedure - Engine Coolant
Temperature Between 10C- 35C (50F-95F).
3. The first second of the voltage displayed by the
DMM may be inaccurate due to the initial
current surge. Therefore, record the lowest voltage
displayed by the DMM after the first second of
the test. The voltage displayed by the DMM may
increase throughout the test as the fuel injector
windings warm and the resistance of the fuel
injector windings changes. An erratic voltage
reading (large fluctuations in voltage that do not
stabilize) indicates an intermittent connection
within the fuel injector. From the voltages

recorded, identify the highest voltage, excluding

any voltages above 9.5 volts. Subtract each
voltage that is not above 9.5 volts from the highest
voltage. Record each subtracted value (refer to
the Example). The subtracted value for any
fuel injector must not exceed 0.6 volt. A fuel
injector with a subtracted value that is greater
than 0.7 volt is faulty. Replace the fuel injector. A
fuel injector with a recorded voltage above
9.5 volts is also faulty. Replace the fuel injector.

Highest Voltage Reading

7.1 Volts
Injector
Voltage
Number
1
9.8
6.6
2
6.9
3
5.8
4
7.0
5
7.1
6

Acceptable Subtracted
Value Above/Below
10C-35C
(50F-95F)
0.6 Volts
Subtracted
Value
Pass/Fail
F
p
0.5
p
0.2
1.3
F
p
0.1
p
0.0

Engine

Engine Controls - 3.SL

6-1147

Fuel lnj Coil Test - ECT Outside 10-35 Degrees C

Step

Action

Value(s)

Yes

No

Go to Step 2

Goto A
Powertrain On
Board Diagnostic
(080) System
Check

Did you perform the Powertrain OnBoard Diagnostic

(OBD) System Check?

1. Connect the scan tool.

2. Check the engine coolant temperature.
Is the engine coolant temperature outside the specified
limits?

Go to Fuel lnj
Coil Test - ECT
Between
10-35 Degrees

10C-35C
(50F-95F)

Go to Step 3

c.

1. Turn the ignition OFF.

Notice: In order to prevent flooding of a single cylinder and
possible engine damage, relieve the fuel pressure before
performing the fuel injector coil test procedure.

2. Relieve the fuel pressure. Refer to Fuel Pressure

Relief Procedure.

3. Access the fuel injector electrical connectors as

required.
4. Connect the J 39021 fuel injector tester to B+ and
ground.
5. Set the amperage supply selector switch on the fuel
injector tester to the Coil Test 0.5 amp position.
6. Connect the leads from the J 39200 Digital Multi
Meter (DMM) to the fuel injector tester. Refer to the
illustration.
7. Set the DMM to the tenths scale (0.0).
8. Connect the fuel injector tester to a fuel injector.
Important: Check the engine coolant temperature again in
order to ensure that the correct chart is being used.
9. Press the Push to Start Test button on the fuel
injector tester.

0.6 volts

10. Observe the voltage reading on the DMM.

Important: The voltage reading may rise during the test.

11. Record the lowest voltage observed after the first

second of the test.
12. Repeat the procedure for the remaining fuel injectors.
13. Identify the highest voltage reading recorded other
than those above 9.5 volts.
14. Subtract any other voltage reading recorded from the
highest voltage reading recorded.
15. Repeat step 14 for all the remaining fuel injectors.
Is any value that resulted from subtraction greater than the
specified value?

Replace any fuel injector that had any of the following:

A subtracted value exceeding 0.6 volts.
An initial reading above 9.5 volts.
An erratic reading.
Refer to Fuel Injector Replacement.
Is the action complete?

Go to Step 4

Go to Fuel
Injector
Balance Test

Go to Fuel
Injector
Balance Test

6-1148

Engine Controls - 3.8L

Fuel Tank Leak Check

Caution: Place a dry chemical (Class BJ fire
extinguisher near the area before performing a
Fuel Tank Leak Check. Before removing the
fuel tank for a suspected leak, make sure that the
fuel pipes or the tubes are not leaking onto the
tank. Once removed, make sure that the fuel is not
leaking around the fuel sender 0-ring. Failure to
follow these precautions may result in personal
injury.
Important: This check requires a fuel sender
.
assembly, a fuel tiller cap, and a fuel sender gasket to
be installed in the fuel tank.
1. Relieve fuel system pressure. Refer to Fuel
Pressure Relief Procedure.
2. Remove the fuel tank. Refer to Fuel Tank
Replacement.
3. Cap the fuel teed pipe, the fuel return pipe, and
the EVAP pipe on the fuel sender assembly.
4. Install a piece of fuel line on vent pipe.
5. Submerge tt1e fuel tank in water or apply a soap
solution to the outside of the fuel tank.
6. Apply 31-38 kPa (4112-5112 psi) air pressure to fhe
piece of hose on the fuel tank vent pipe. Air
bubbles appearing from the fuel tank indicate
a leak.
7. Replace the fuel tank it it is leaking. Refer to Fuel
Tank Replacement.

Fuel Tank Vent Valve Diagnosis

The fuel tank vent valve is located in the rear of the
vehicle near the fuel tank. The fuel tank vent valve is a
pressure/vacuum relief valve. If the valve is not
functioning properly it could cause excessive pressure
or vacuum to build up in the fuel tank. The result
may be possible fuel discharge when removing the fuel
tiller cap or possible damage to the fuel tank or the
fuel sender.
1 . Loosen the fuel filler cap in order to relieve the
tank pressure.
2. Remove the tank vent valve from the vehicle.
3. Wrap the vent valve in a shop towel and shake out
any remaining fuel.
4. Connect the vent valve to a radiator pressure
check device using the appropriate adapters.
5. Slowly apply pressure to the vent valve. The valve
should open at approximately 1112 psi. It not,
replace the vent valve.
6. Disconnect the vent valve from the pressure
tester.

Engine
7. Connect the vent valve to a hand operated
vacuum pump using the appropriate adapters.
8. Slowly apply vacuum to the vent valve. The valve
should open at approximately 1-2" Hg. If not,
replace the vent valve.

Alcohol/Contaminants-in-Fuel Diagnosis
Alcohol concentrations greater than 10% in fuel can be
detrimental to fuel system components and may
cause driveability problems such as hesitation, lack of
power, stall, no start, etc.
The problems may be due to fuel system corrosion
and subsequent fuel filter plugging, deterioration
of rubber components, and/or air-fuel mixture leaning.
Various types and concentrations of alcohOI are
useq in commercial fuel. Some alcohol is more
detrimental to fuel system components than others. It
an excessive amount of alcohol in the fuel is
suspected as the cause of a driveability condition, the
following procedure may be used to detect the
presence of alcohol in the fuel.

Testing Procedure
The fuel sample should be drawn from the bottom of
the tank so that any water present in the tank will
be detected. The sample should be bright and .clear. If
the sample appears cloudy, or contaminated with
water (as indicated by a wate'r layer at the bottom of
the sample), this procedure should. not be used,
and the fuel system should be.cleaned.
1. Using a 100 ml specified cylinder with 1 ml
graduation marks, till the cylinder with fuel to
the 90 ml mark.
2. Add 1O ml of water in order to bring the total fluid
volume to 100 ml and install a stopper.
3. Shake the cylinder vigorously tor
10 to 15 seconds.
4. Carefully loosen the stopper in order to release
the pressure.
5. Re-install the stopper and shake the cylinder
vigorously again tor 10 to 15 seconds.
6. Put the cylinder on a level surface tor
approximately 5 minutes in order to allow
adequate liquid separation.
It alcohol is present in the fuel, the volume of the
lower layer (which would now contain both alcohol and
water) will be greater than 10 ml. For example, it the
volume of the lower layer is increased to 15 ml,
this indicates at least 5 percent alcohol in the fuel.
The actual amount of alcohol may be somewhat
greater because this procedure does not extract all of
the alcohol from the fuel.

Engine Controls - 3.8L

Engine

6-1149

EVAP Control System Diagnosis

!Hot In Run, Bulb Test And Start!
~

- - - - - - - - - - - - -:- - -

- - - -

ENG EMIS

Fuse
10A

I
I

I
I

' '

Fuse Block
Details
Cell11
<II

Underhood (U/H)

Electrical
Center

t
.

L-------------------------J
F2IC2

AS C1

PNK 339
PCM

PN:1339
Evaporative
Emission

PNK 339
[]

A
Evaporative
Emission

C1=BLU
C2=CLEAR

BI

~i:~~i~ent

Valve

WHT 1310

[ ] (EVAP)

Purge
Valve

WHTI1310
A11 C2
r

DK
GRN/WHT 428

I
I

-I ,I Underhood
(UH)
I Electrical

IC1

Center
010
WHT 1310

76
~
I

-----------------

2 C2

- ~v~P - - - - - - - - - - - - - E;A;- - - Purge

Valve
Control

Vent
Solenoid
Valve

Powertrain
"'
Control
,.
I
Module (PCM) ~

L---------------------J
154561

Circuit Description
The evaporative system includes the following
components:
The fuel tank.
The EVAP vent solenoid.
The fuel tank pressure sensor.
The fuel pipes and hoses.
The vapor lines.
The fuel cap.
The evaporative emission canister.
The purge lines.
The EVAP purge solenoid.
The EVAP purge solenoid valve allows manifold
vacuum to purge the canister. The Powertrain Control
Module (PCM) supplies a ground to energize the
solenoid valve (purge ON). The EVAP purge solenoid
control is Pulse Width Modulated (PWM) or turned
ON and OFF several times a second. The duty cycle
(pulse width) is determined by engine operating

conditions including load, throttle position, coolant

temperature and ambient temperature. The duty cycle
is calculated by the PCM and the output is
commanded when the appropriate conditions have
been met.
The EVAP Vent solenoid is used to seal the EVAP
system during the EVAP leak diagnostic tests. The fuel
tank pressure sensor is used to monitor vacuum in
the system during the diagnostic tests.
A stuck closed EVAP purge solenoid, stuck open
EVAP vent solenoid, disconnected or damaged EVAP
purge line or vent hose, leaking fuel cap, or fill
neck should set a OTC P0440. A small leak in the
EVAP system should set a OTC P0442. An EVAP vent
solenoid stuck closed, a restricted vent hose, or a
blocked EV AP canister should set a OTC P0446. A
continuous purge condition with no purge commanded
by the PCM (EV AP purge solenoid stuck open or
leaking) should set a OTC P1441. Refer to the OTC
tables for further diagnostic procedures regarding
the EVAP system.

6-1150

Engine

Engine Controls - 3.8L

Diagnostic Aids

Test Description

Check for the following conditions:

Poor connection at PCM.
Inspect harness connectors for backed out
terminals, improper mating, broken locks,
improperly formed or damaged terminals, and
poor terminal to wire connection.
Damaged harness.
Inspect the wiring harness for damage. If the
harness appears to be OK, observe the Fuel Tank
Pressure display on the scan tool while moving
connectors and wiring harnesses related to
the sensor. A change in the display will indicate
the location of the malfunction.
Incorrect EVAP purge or vacuum source line
routing.
Verify that the source vacuum and EVAP purge
lines to the canister purge valve are not switched.

Number(s) below refer to the step number(s) on the

Diagnostic Table.
5. The PCM will command the EVAP purge and
EVAP canister vent valves closed with the
scan tool Seal System EVAP output control
function activated. Fuel tank pressure should not
decrease under this condition.
6. The PCM commands the EVAP purge valve OFF
(open) and the EVAP canister vent valve ON
(closed) with the scan tool System Pert. EVAP
output control function activated. Engine vacuum
should cause fuel tank pressure to decrease
when System Pert. is activated.

Important: Although these diagnostics are considered

type A, they act like type B diagnostics under
certain conditions. Whenever the EVAP diagnostics
report that the system has passed, or if the battery has
been disconnected, the diagnostic must fail during
two consecutive cold start trips before setting a DTC.
The initial failure is not reported to the diagnostic
executive or displayed on a scan tool. A passing
system always reports to the diagnostic executive
immediately.

Engine Controls - 3.8L

Engine

6-1151

EVAP Control System Diagnosis

Step

Action

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Value(s)

Go to Step 2

No
Go to the A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to
OTC P0453 Fuel
Tank Pressure
Sensor Circuit
High Voltage

Go to Step 4

Go to
OTC P0452 Fuel
Tank Pressure
Sensor Circuit
Low Voltage

Go to Step 5

Go to
OTC P0446
Evaporative
Emission (EVAP)
Vent System ..
Performance

Go to
OTC P1441
Evaporative
Emission (EVAP)
System Flow
During
Non-Purge

Go to Step 6

System OK

Go to
OTC P0440
Evaporative
Emission (EVAP)
System

Yes

Important: Visually/physically inspect for the following

conditions:
Vacuum or purge lines disconnected. Refer to
Emission Hose Routing Diagram.
Loose or missing fuel cap.
1. Turn OFF the ignition switch.
2. Remove the fuel cap.
3. Turn ON the ignition switch.
4. Observe Fuel Tank Pressure on the scan tool.
Is Fuel Tank Pressure at the specified value?

O in. H20

Important: Before continuing with diagnosis, zero the

EVAP Pressure and Vacuum (inches of H20) gauges on
the J 41413 EVAP pressure/purge diagnostic station (refer
to tool operating instructions).
1. Replace the fuel cap.
2. Using the scan tool, command the EVAP canister
vent valve ON (Closed).
3. Connect the EVAP pressure/purge diagnostic station
to the EVAP service port.
4. Pressurize the EVAP system to the specified value
using the J 41413 EVAP pressure/purge diagnostic
station (monitor pressure 'using gauge on the EVAP
pressure/purge diagr1ostic station).
5. Observe Fuel Tank Pressure on the scan tool.
Is Fuel Tank Pressure at the specified value?

5 in. H20

Monitor the EVAP Pressure gauge on the EVAP

pressure/purge diagnostic station while commanding the
EVAP canister vent valve OFF (Open).
Does EVAP Pressure decrease to the specified value
within 5 seconds?

O in. H20

1. Start the engine.

2. Remove the fuel cap.
3. Using the scan tool output tests function, select Seal
System and activate.
4. Replace the fuel cap.
5. Switch the rotary switch on the EVAP pressure/purge
diagnostic station to .PURGE.
6. Run the engine at idle while monitoring the Vacuum
(inches of H20) gauge on the EVAP pressure/purge
diagnostic station.
Is vacuum increasing to a value greater than the
specified value?

O in. H20

1. Using the scan tool output tests function, select

System Pert. and activate.
2. Switch the rotary switch on the EVAP pressure/purge
diagnostic station to PURGE.
3. Run the engine at 2500 RPM while monitoring the
Vacuum (in. of H20) gauge on the EVAP
pressure/purge diagnostic station for at least
10 seconds.
Did vacuum increase to a value greater than the
specified value?

-5 in H20

6-1152

Engine Controls - 3.SL

Engine

Idle Air Control System Diagnosis

Idle Air
Control (IAC)
Valve

Stepper
Motor

11
1

LT

GRN /WHT 1749

LT

12

Bl

lj

i'
I

Coil
A

.,

PCM
C1=BLU
C2=CLEAR

DI

BLU/BLK
1748
LT
LT

- ~-R_N!~}~ 4~ - - - - _1J

~~~~~;

1747
C1

,. - - - - - - - - - - - - - - - - - - - -:I IAC
IAC
IAC
IAC
can B
eon B
Coil A
con A
I High
Low
Low
High
1

., Powertrain
IC
ontrol
I Module i,
1
(PCM)~

L--------------------J

22679

Circuit Description
The PCM controls engine idle speed by adjusting the
position of the Idle Air Control (IAC) motor pintle.
The IAC is a bi-directional motor driven by two coils.
The PCM pulses current to the IAC coils in steps
(counts) to extend the IAC pintle into a passage in the
throttle body to decrease air flow. The PCM reverses
the current pulses to retract the pintle, increasing
air flow. This method allows highly accurate control of
idle speed and quick response to changes in
engine load.

Diagnostic Aids
Check for the following conditions:
Poor connection at PCM or IAC motor. Inspect
harness connectors for backed out terminals,
improper mating, broken locks, improperly formed
or damaged terminals, and poor terminal to
wire connection.
Damaged harness. Inspect the wiring harness for
damage.
Restricted air intake system. Check for a possible
collapsed air intake duct, restricted air filter
element, or foreign objects blocking the air intake
system.

Throttle body. Check for objects blocking the IAC

passage or throttle bore, excessive deposits in
the IAC passage and on the IAC pintle, and
excessive deposits in the throttle bore and on the
throttle plate.
Check tor a sticking throttle plate. Also inspect the
IAC passage tor deposits or objects which will
not allow the IAC pintle to fully extend.
Vacuum leak. Check for a condition that causes a
vacuum leak, such as disconnected or damaged
hoses, leaks at EGR valve and EGR pipe to
intake manifold, leaks at throttle body, faulty or
incorrectly installed PCV valve, leaks at intake
manifold brake booster hose disconnected, etc.
Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed may help determine how
often the condition that caused the OTC to be
set occurs. This may assist in diagnosing the condition.

Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
11. This vehicle is equipped with a PCM which utilizes
an Electrically Erasable Programmable Read Only
Memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.
Refer to PCM Replacement and Programming
Procedures in Powertrain Control Module (PCM)
and Sensors.

Engine Controls . 3.SL

Engine

6-1153

ld1e Air Control System Diagnosis

Action

Step

Value(s)

Yes

No

Go to Step 2

Go to the A
Powertrain On
Board Diagnostlc
(080) System
heck

System OK

Go to Step 3

Go to Step 5

Go to Step 4

Go to Step 12

Go to Step 10

Go to Step 6

Go to Step 7

Refer to
appropriate
section for
on-vehicle
service

Go to Step B

Refer to
appropriate
section for
on-vehicle
service

Go to Step B

Go to Step 12

Go to Step 9

Was the On-Board Diagnostic (OBD) System Check

performed?

1. Start engine.

2. All accessories OFF (A/C, Rear defroster etc.)

3. Using a scan tool, command RPM up to 1500, down
to 650, and then up to 1500 while monitoring Engine
Speed on the scan tool.
Does Engine Speed remain within 50 RPM of the RPM
commanded?
1. Disconnect the IAC.
2. Install J 37027-A IAC System Monitor.
3. With the engine running, command RPM up to 1500,
down to 650, and then up to 1500 while observing
the IAC System Monitor node lights.

Does each node light cycle red and green (never OFF)?
1. Check the following circuits for an open, short to
voltage, or short to ground:

IAC A Low.
IAC A High.
IAC B Low.
IAC B High.
2. If a problem is found, repair as necessary. Refer to
Wiring Repairs.

Was a problem found?

Was a low idle symptom or rich condition noticed?

Visually/physically inspect for the following conditions:

Throttle body tampering (throttle lever stop screw

turned).
Restricted air intake system.
Check for a possible collapsed air intake duct,
restricted air filter element, or foreign objects blocking
the air intake system.
Throttle body. Check for objects blocking the IAC
passage or throttle bore, excessive deposits in the IAC
passage and on the IAC pintle, and excessive
deposits in the throttle bore and on the throttle plate.

Was a problem found?

Visually/physically inspect for the following conditions:
Vacuum leaks.
Throttle body tampering (throttle lever stop screw
turned).

Throttle plate or throttle shaft binding.

Accelerator and cruise Control cables for being
misadjusted or for binding.
Faulty, missing, or incorrectly installed PCV valve.

Was a problem found?

1. Check for a poor connection at the IAC harness

connector.
2. If a problem is found, replace faulty terminals as
necessary. Refer to Wiring Repairs.
Was a problem found?

6-1154

Engine Controls - 3.8L

Engine

Idle Air Control System Diagnosis (cont'd)

Action

Step

Value(s)

Replace IAC valve. Refer to /AC Valve Replacement.

Is the action complete?

10

1. Check for a poor connection at the PCM harness

connector.
2. If a problem is found, replace faulty terminals as
necessary. Refer to Wiring Repairs.
Was a problem found?

Replace the PCM.

Important: The replacement PCM must be programmed.
Refer to PCM Replacement/Programming
Is. action complete?

11

12

1.
2.
3.
4.

Clear DTCs.
Start engine.
All accessories OFF (A/C, Rear defroster etc.)
Using a scan tool, command RPM up to 1500, down
to 650, and then up to 1500 while monitoring Engine
Speed on the scan tool.
Does Engine Speed remain within 50 RPM of the RPM
commanded?

Yes

Go to Step 12

Go to Step 12

No

Go to Step 11

Go to Step 12

System OK

Go to Step3

Engine

Engine Controls - 3.8L

6-1155

Repair Instructions
PCM Replacement/Programming
Notice: In order to prevent possible electrostatic
discharge damage to the PCM, do not touch
the connector pins or soldered components on the
circuit board.
Service of the PCM should normally consist of either
replacement of the PCM or EEPROM programming.
If the diagnostic procedures call for PCM Replacement,
check the PCM first to see if it is the correct part. If
the PCM is faulty, remove it and install the
new service PCM.
The new service PCM will not be programmed. You
must program the new PCM. OTC P0602 indicates the
EEPROM is not programmed or has malfunctioned.
Notice: In order to prevent possible electrostatic
discharge damage to the PCM, do not touch
the connector pins or soldered components on the
circuit board.
Notice: Turn the ignition OFF when installing or
removing the PCM connectors and disconnecting or
reconnecting the power to the PCM (battery cable,
PCM pigtail, PCM fuse, jumper cables, etc.) in order
to prevent internal PCM damage.

Important: When replacing the production PCM with a

service PCM (controller), it is important to transfer
the broadcast code and production PCM number to the
service PCM label. Do not record on PCM cover.
This will allow positive identification of PCM parts
throughout the service life of the vehicle.

Notice: Turn the ignition OFF when installing or

removing the PCM connectors and disconnecting or
reconnecting the power to the PCM (battery cable,
PCM pigtail, PCM fuse, jumper cables, etc.) in order
to prevent internal PCM damage.

Removal Procedure
1.
2.
3.
4.

Disconnect the negative battery cable.

Remove the PCM from the mounting hardware.
Disconnect the harness connectors from the PCM.
Remove the PCM from the engine compartment.

21745

6-1156

Engine

Engine Controls - 3.8L

Installation Procedure

1. Avoid Electrostatic Discharge. Do not touch

terminals.with your finQers.
2. Connect the harness connectors to the PCM.
3. Position and install the PCM into the vehicle.
4. Connect the negative battery cable.
5. If you are installing a new PCM, program the new
PCM EEPROM.

21745

EEPROM Programming
1. Set-up - E;nsure that the following conditions have
been met
The battery is fully charged.
The ignition is ON.
The Vehicle Interface. Module cable connection
at the DLC is secure.
2. Program the PCM using the latest software
matching the vehicle. Refer to up~to-date Techline
equipment user's instructions.
3. If the PCM fails to program, proceed as follows:
Ensure that all PCM connections are .OK ..
Check the Techline equipment for the latest
software version.
Attempt to program the PCM. If the PCM still
cannot be programmed properly, replace the
PCM. You must program the
replacement PCM.

Functional Check
1. Perform the On-Board Diagnostic System Check.
2. Start the engine and the engine run for one
minute.
3. Use the scan tool in order to scan for the DTCs.

Engine
CKP System Variation Learn Procedure
\

Crankshaft Position System Variation

Learn Procedure
The crankshaft position system variation compensating
values are stored in the PCM non-volatile memory
after a learn procedure has been performed. If
the actual crankshaft position. system variation does
not match the crankshaft position system variation
compensating values stored in the PCM, DTC P0300
may set (refer to Diagnostic Aids for DTC P0300).
The Crankshaft Position System Variation Learn
Procedure should be performed if any of the following
conditions are true:
DTC P1336 is set.
The PCM has been replaced.
The engine has been replaced.
The crankshaft has been replaced.
The crankshaft harmonic balancer has been
replaced.
The crankshaft position sensor has been replaced.

Caution: Set the vehicle parking brake and

block the drive wheels when performing the
Crankshaft Position System Variation Learning
Procedure in order to prevent personal injury.
Release the throttle immediately when the engine
starts to decelerate. Once the learn procedure
is completed, the PCM will return the engine
control to the operator and the engine will respond
to the throttle position.
Important: Begin the crankshaft position' system
variation learn procedure with the ignition switch OFF.
Do not turn ON the ignition switch or start the
vehicle unless instructed to do so by the scan tool.
The scan tool crankshaft position system variation
learn function will be inhibi.ted if any powertrain DTCs
other than DTC P1336 are set before or during the
crankshaft position system variation learn procedure.
Clear DTCs before attempting to perform the
crankshaft position system variation learn procedure. If
any DTCs reset, the DTCs must be diagnosed and
repaired before the crankshaft position system
variation learn procedure can be sucessfully
completed.
The crankshaft position system variation learn function
will be inhibited if the PCM detects a malfunction
involving the camshaft position signal circuit,
the 3X reference circuit, or the 18X reference circuit.
If the scan tool indicates that a problem with the
camshaft position signal exists, refer to
OTC P0341 Camshaft Position (CMP) Sensor
Performance.

Engine Controls - 3.SL

6-1157

If the scan tool indicates that a problem with the

3X crank signal exists, refer to OTC P1374
Crankshaft Position (CKP) High to Low Resolution
Frequency Correlation.
If the scan tool indicates that a problem with the
18X crank signal exists, refer to OTC P0336
1BX Reference Signal Circuit.
The scan tool crankshaft position system variation
!eari:, function wilt not be enabled. until engine coolant
temperature is greater than 70 C (158 F).
Selecting the crankshaft position system variation
learn procedure on the scan tool will command
the PCM to enable CKP system variation learn fuel
cutoff and allow the crankshaft position system
compensating values to be stored in the PCM. The
PCM must detect an engine speed of 5150 RPM (CKP
system variation learn fuel cutoff) during the
crankshaft position system variation learn procedure to
store the crankshaft position system compensating
values and complete the procedure.
1. Set the parking brake.
2. Block the drive wheels.
3. Close the hood.
4. Start the engine and allow engine coolant
temperature to reach at least 70C (158F).
5. Turn OFF the ignition switch.
6. Select and enable the crankshaft position variation
learn procedure with the scan tool.
7. Start the vehicle
8. Ensure that the transaxle is in Park.
9. Apply and hold the service brake pedal firmly.
10. Increase accelerator pedal position until CKP
system variation learn fuel cutoff is reached.
CKP system variation learn fuel cutoff is reached
at 5150 RPM. Immediately release the
accelerator pedal when fuel cutoff is reached.
11. The crankshaft position system variation
compensating values are learned when RPM
decreases back to idle. If the procedure
terminates, refer to Important above for
instructions.
12. Observe DTC status for .OTC P1336.
13. If the scan tool indicates that DTC P1336 ran and
passed, the crankshaft position system variation
learn' procedure is cornplete. lf the scan tool
indicates DTC P1336 failed or not run, check for
other DTCs. If no DTCs other than P1336 are
set, repeat the crankshaft position system variation
learn procedure as.necessary.

61'158

Engine

Engine Controls 3.SL

ECT Sensor Replacement
Removal Procedure

Important: Care must be taken when handling the

Engine Coolant Temperature sensor. Damage to the
engine coolant temperature sensor will affect
proper operation of the fuel injection system.
1. Drain the. radiator coolant.
2. Dis9onnect the elect.rical connector.
3. Using a 19 mm deep well socket, remove the
sensor.

21671

(
Installation Procedure
1. Coat engine coolant temperature sensor threads
with sealer P/N 1052080 or equivalent.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Hand start the ECT sensor into the engine.

3.
4.

5.
6.

21671

Tighten
Tighten the ECT sensor to 12.5 Nm (9.2 lb ft).
Connect the electrical connector.
Refill radiator with coolant.
Start the engine and check for leaks.
Check coolant level.

Engine

Engine Controls - 3.SL

6-1159

MAF Sensor Replacement

The MAF sensor on this engine is attached to the
throttle body assembly.

Removal Procedure
1. Disconnect the MAF sensor electrical connector.
2. Remove the screws holding MAF sensor to
throttle body.
3. Remove the MAF sensor from the throttle body.

15006

Installation Procedure
1. Carefully position the MAF sensor to the
throttle body.
2. Install 3 screws holding the MAF sensor to the
throttle body.
3. Connect the electrical connector.

\\

15006

6"'.1160

Engine

Engine Controls - 3.SL

MAP Sensor Replacement

The MAP sensor is mounted to the intake manifold

vacuum source.

Removal Procedure

1. Remove the MAP sensor electrical connector.

2. Carefully bend the locking tabs that hold the MAP
sensor to the manifold vacuum source just
enough to remove the MAP sensor.
3. Pull the MAP sensor straight out of vacuum
source.

21663

(
Installation Procedure
1. Ensure that the seal is installed on MAP sensor
and that the seal is not damaged.
2. Install the MAP sensor to the manifold vacuum
source. Ensure that the locking tabs engage to
hold the MAP sensor to the vacuum source.
3. Connect the MAP sensor electrical connector.

21663

'

Engine

Engine Controls :- 3.SL

~ 161

H025 Replacement
Bank 1 H02S 1 and Bank 2 H02S. 1
Notice: The .Heated Oxygen Sensors each use a'
permanently attached pigtail qnd connector. This pigtail
should not be removed from the heated. oxygen .
sensor. Damage or remova:1,of the pigtajl or connector
could affect proper operation of the heated oxygen .
sensor.
,
'

Removal Procedure
Important: Take care wh.en handling the' heated
oxygen sensor. The in-line electrical connector and
louvered end must be kept free of grease, dirt or other
contaminants. Also, avoid using cleaning solvents of
any type. Do not drop or roughly handle the heated
oxygen sensor/catalyst monitor. A dropped ,sen~or is a
bad sensor.
The heated oxygen sensor may be difficult to remove
when the engine tel'T)perature i~ below 48C (120F).
Excessive force may damage threads in the exhaust
manifold or exhaust pipe.
1 . Disconnect the H02S electrical connector.
2. Carefully back out the heated oxygen sensor.

28514

187262

6-1162

Engine Controls - 3.8L

Engine
Installation Procedure
Important: A special anti-seize compound is used on
the heated oxygen sensor threads. The compound
consists of graphite suspended in fluid and glass
beads. The graphite will burn away, but the glass
beads will remain, making the sensor easier to
remove. New or service sensors will already have the
compound applied to the threads. If a sensor is
removed from an engine and if for any reason is to be
reinstalled, the threads must have anti-seize
compound applied before reinstallation.
1. Coat threads of heated oxygen sensor/catalyst
monitor with anti-seize compound P/N 5613695,
or equivalent if necessary.
2. Hand start the Heated Oxygen Sensor.

(.

Tighten
Tighten the Heated Oxygen Sensor to
42 N-m (31 lb ft).
107252

Notice: Refer to Fastener Notice in Cautions and

Notices.
3. Connect the electrical connector.

Bank 1 H02S 3
Notice: The Heated Oxygen Sensors each use a
permanently attached pigtail and connector. This pigtail
should not be removed from the heated oxygen
sensor. Damage or removal of the pigtail or connector
could affect proper operation of the heated oxygen
sensor.

Removal Procedure

19542s

Important: Take care when handling the heated

oxygen sensor. The in-line electrical connector and
louvered end must be kept free of grease, dirt or other
contaminants. Also, avoid using cleaning solvents of
any type. Do not drop or roughly handle the heated
oxygen sensor/catalyst monitor. A dropped sensor is a
bad sensor.
The heated oxygen sensor may be difficult to remove
when engine temperature is below 48C (120F).
Excessive force may damage threads in exhaust
manifold or exhaust pipe.
1. If you are replacing Bank 1 H02S 3, raise the
vehicle.
2. Disconnect the electrical connector.
3. Carefully back out the heated oxygen sensor.

Engine

Engine Contr()ls - 3.SL

s. 1163

Installation Procedure
Important: A special anti-seize compound is used on
the heated oxygen sensor threads. The compound
consists of graphite suspended in fluid and glass
beads. The graphite will burn away, but the glass
beads will remain, making the sensor easier to
remove. New or service sensors will already have the
compound applied to the threads. If a sensor is
removed from an engine and if for any reason is to be
reinstalled, the threads must have anti-seize
compound applied before reinstallation.
1. Raise the vehicle if you are replacing Bank 1
H02S 2 or Bank 1 H02S 3.
2. Coat threads of heated oxygen sensor/catalyst
monitor with anti-seize compound P/N 5613695,
or equivalent if necessary.

Notice: Refer to Fastener Notice in Cautions and

Notices.
3. Hand start the Heated Oxygen Sensor.

196434

Tighten
Tighten the Heated Oxygen Sensor to
42 N,m (31 lb ft).

4. Connect the electrical connector.

TP Sensor Replacement
Removal Procedure
Notice: The TP sensor is an electrical component. Do
not soak the TP sensor in any liquid cleaner or
solvent as damage may result.
1. Disconnect the TP sensor electrical connector.

~
178680

6-1164

Engine Controls - 3.SL

.

.c

Engine

2. Remove the two TP sensor attaching screws.

(
\

178693

3. Remove the TP. sensor.

178694

Installation Procedure
1. Install the TP sensor to the throttle body assembly.

178694

Engine

Engine Controls - 3.8L

Ei~1165

Notice: Refer to Fastener Notice in Cautions and

Notices.

2. Install the two TP sensor attaching screws, using

a thread-locking compound on the screws. Loctite
262, GM P/N 1052624, or equivalent should
be used.

Tighten
Tighten the TP sensor attaching screws to
2.0 N-m (18 in lb).

178693

3. Install the TP sensoF electrical connector.

~
178680

IAT Sensor. Replacement

Intake Air Temperature (IAT) Sensor
The IAT sensor is mounted in the Air Intake Resonator.

Removal Procedure
1. Disconnect the IAT sensor electrical connector.
2. Carefully remove the IAT sensor
(snaps into place).

21677

6-1166

Engine

Engine ~ontrols - 3.SL

Installation Procedure

1. Install the IAT Sensor into the Air Intake

Resonator (snaps into place).
2. Connect the IAT Sensor electrical connector.

21677

IAC Valve Replacement

Removal Procedure
1. Remove the electrical connector from the idle air
control valve.

155466

2. Remove the idle air control valve attaching

screws.

185614

Engine Controls - 3.SL

Engine

6-1167

3. Remove the idle air control valve.

185583

4. Remove the idle air control valve 0-ring.

185626

Installation Procedure
Notice: The IAC valve may be damaged if installed
with the cone (pintle) extended more than 28 mm
(1-1/8 in). Measure the distance that the valve
is extended before installing a new valve. The distance
from the idle air control valve motor housing to the
end of the idle air control valve pintle should be 1.ess
than 28 mm (1-1/8 in). Manually compressing the
pintle until the extension is less than 28 mm (1-1/8 in).
1. Install the new idle air control 0-ring.

{rt
lij

185626

6-1.168

Engine controls -3.st.

Engine
2. Install the idle air control valve in the intake
manifold.

185583

Notice: Refer to Fastener Notice in Cautions and

Notices.

3. Install the idle air control valve attaching screws.

Tighten
Tighten the idle air control valve attaching screws
to 3.0 N-m (27 lb in).

185614

4. Install the electrical connector to the idle air

control valve.
5. The PCM will reset the idle air control valve
whenever the ignition switch is turned ON,
then OFF. Turn the ignition switch ON, then OFF.
6. Start the engine and allow the engine to reach
,,
operating temperature.

155466

Engine

Engine Controls - 3.8L

6-1169

Accelerator Controls Cable Replacement

Removal Procedure
1. Remove the left instrument panel insulator. Refer
to Instrument Panel Insulator in Instrument Panel,
Gages and Console.
2. Remove the aqcelerator cable (3) from the
accelerator pEldal lever (2).
3. Squeeze the accelerator cable cover tangs (1)
and push the accelerator cable through the
bulkhead.

--12613

4. Disconnect the accelerator cable from the

retaining clip.
5. Disconnect the accelerator cable from the throttle
body lever.
6. Disconnect the accelerator cable from the
accelerator cable bracket.
7. Remove the accelerator cable.

12816

Installation Procedure
Notice: Do not route flexible components (hoses,
wires, conduits, etc.) within 50 mm (2 in) of moving
parts unless flexible compbnents can be securely
fastened. This is necessary in order to prevent
possible interference and damage to the component.
1. Slide the accelerator cable (3) through the
bulkhead.
2. Snap the retainer (1) through the bulkhead.
3. Connect the accelerator cable (3) through the slot
in the accelerator pedal lever (2).
4. Seat the retainer (4) in the accelerator pedal
lever (2).

--12613

6-1170

Engine

Engine Controls - 3.8L

5. Connect the accelerator cable to the throttle

body lever.
6. Connect the accelerator cable to the accelerator
cable bracket.
7. Connect the accelerator cable into fhe
retaining clip.
8. Check for complete throttle opening and closing
positions by operating the accelerator pedal. Also
check for poor carpet fit under the accelerator
pedal. The throttle should operate freely, without
binding, between full closed and wide open
throttle.
9. Reinstall the left instrument panel insulator. Refer
to Instrument Panel Insulator in Instrument Panel,
Gages and Console.

Accelerator Controls Pedal Replacement

Removal Procedure
1. Remove the left instrument panel insulator. Refer
to Instrument Panel Insulator in Instrument Panel,
Gages and Console.
2. Disconnect the accelerator cable from the
accelerator pedal lever.
3. Remove the retainer clip from the accelerator
pedal pivot pin.
4. Remove the accelerator pedal from the accelerator
pedal lever.

Installation Procedure
1. Install the accelerator pedal to the accelerator
pedal lever.
2. Reinstall the retainer clip to the accelerator pedal
pivot pin.
3. Connect the accelerator cable to the accelerator
pedal lever.
4. Check for complete throttle opening and closing
positions by operating the accelerator pedal. Also
check for poor carpet fit under the accelerator
pedal. The throttle should operate freely without
binding between full closed and wide open throttle.
5. Reinstall the left instrument panel insulator. Refer
to Instrument Panel Insulator in Instrument Panel,
Gages and Console.

Engine

Engine Controls - 3.8L

6-1171

Throttle Body Assembly Replacement

Removal Procedure
Notice: Do Not use solvent of any type when cleaning
the gasket surfaces on the intake manifold and the
throttle body assembly, as damage to the gasket
surfaces and throttle body assembly may result.
Use care in cleaning the gasket surfaces on the intake
manifold and the throttle body assembly, as sharp
tools may damage the gasket surfaces.
1. Drain the radiator coolant.
2. Remove the air intake tube.
3. Disconnect the TP sensor electrical connector.

178680

4. Disconnect the MAF sensor electrical connector.

5. Disconnect the ECT sensor electrical connector.

155464

6. Disconnect the accelerator control and cruise

control cables.

12816

6-1172

Engine Controls - 3.8L

. Engine
7. Remove the accelerator control cable bracket.

215499

8. Remove the nuts and the bolt holding the throttle

body to the iotake manifold.
9. Remove the throttle body assembly.

12814

Installation Procedure
1. Install a new throttle body gasket if necessary.
2. Reinstall the throttle body assembly.
Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Reinstall the throttle body retaining nuts and bolt.
Tighten
Tighten the throttle body retaining nuts and the
bolt to 1O Nm (89 lb in).

12814

Engine

Engine Controls - 3.SL

6-1173

4. Connect the TP sensor electrical connector.

178680

5. Connect the MAF sensor electrical connector.

6. Connect the ECT sensor electrical connector.

155464

7. Reinstall the accelerator control cable bracket.

\
)

215499

6-1174

Engine

Engine Controls - 3.8L

8. Connect the accelerator control and cruise control

cables.
9. Check for complete throttle opening and closing
positions by operating the accelerator pedal. Also
check for poor carpet fit under the accelerator
pedal. The throttle should operate freely without
binding between full closed and wide open throttle.
10. Reinstall the air intake tube.
11 . Refill the radiator in order to replace the lost
coolant.

12816

Throttle Body Air Inlet Screen

Replacement
Removal Procedure
1. Remove the air intake tube.
2. Remove the snap ring (3).
3. Remove the throttle body air inlet screen (2) from
the throttle body ( 1).

180140

Installation Procedure
1. Install the throttle body air inlet screen (2) to the
throttle body (1 ).
2. Reinstall the snap ring (3).
3. Reinstall the air intake tube.

180140

Engine

Engine Controls - 3.SL 6-1175

Fuel Pressure Relief Procedure

Caution: Relieve the fuel system pressure before

servicing fuel system components in order to
reduce the risk of fire and personal injury.
After relieving the system pressure, a small
amount of fuel may be released when servicing
the fuel lines or connections. In order to reduce the
chance of personal injury, cover the regulator
and the fuel line fittings with a shop towel before
disconnecting. This will catch any fuel that
may leak out. Place the towel in an approved
container when the disconnection is complete.

Tools Required:
J 34730-1A, Fuel Pressure Gauge
Caution: Refer to Battery Disconnect Caution in
Cautions and Notices.
1. Disconnect the negative battery terminal.
2. Loosen the fuel fill cap in order to relieve tank
vapor pressure.
~- Connect Fuel Pressure <3auge J 34730-1A to the
fuel pressure connection. Wrap a shop towel
around the fuel pressure connection while
connecting the fuel pressure gauge in order to
avoid spillage.
4. Install the bleed hose of the gauge into an
approved container.
5. Open the valve in order to bleed the fuel system
pressure. The fuel connections are now safe for
servicing.
6. Drain any fuel remaining in the fuel pressure
gauge into an approved container.

I
~b--...J~?
180378

Quick Connect Fitting(s) Service

(Metal Collar)
Removal Procedure
Tools Required
J 37088-A Tool Set, Fuel Line Quick-Connect
Separator
Notice: Cap the fittings and plug the holes when
servicing the fuel system in order to prevent dirt and
other contaminants from entering the open pipes
and passages.

Important: Always maintain cleanliness when

servicing fuel system components.
1. Relieve the fuel system pressure. Refer to Fuel
Pressure Relief Procedure.
2. Slide the dust cover from the quick connect fitting.
12773

6-1176

Engine Controls - 3.SL

Engine
3. Grasp both sides of the fitting. Twist the female
connector 1/4 turn in each direction to loosen any
dirt within the fitting.

12775

Caution: Wear safety glasses when using

compressed air, as flying dirt particles may cause
eye injury.

4. Blow dirt out of the fitting using compressed air.

\ I

)m~

\l

c=:

.....

'\

12776

5. Choose the correct tool from J 37088-A Tool Set

for the size of the fitting. Insert the tool into the
female connector, then push inward to release the
locking tabs.

12780

Engine

Engine Controls - 3.SL

6-1177

6. Pull the connection apart.

Notice: If it is necessary to remove rust or burrs from

a fuel pipe, use emery cloth in a radial motion with
the fuel pipe end in order to prevent damage to
the 0-ring sealing surface.
7. Using a clean shop towel, wipe off the male
pipe end.
8. Inspect both ends of the fitting for dirt and burrs.
Clean or replace the components as required.

12782

Installation Procedure
Caution: In order to reduce the risk of fire and
personal injury, before connecting fuel pipe
fittings, always apply a few drops of clean engine
oil to the male pipe ends.
This will ensure proper reconnection and prevent
a possible fuel leak.
During normal operation, the 0-rings located in
the female connector will swell and may prevent
proper reconnection if not lubricated.
1. Apply a few drops of clean engine oil to the male
pipe end.

12784

2. Push both sides of the fitting together to cause

the retaining tabs to snap into place.

12786

6-1178

Engine

Engine Controls - 3.8L

3. Once installed, pull on both sides of the fitting to

make sure the connection is s~cure.
4. Tighten the fuel fill cap.

Caution: Refer to Battery Disconnect Caution in

Cautions and Notices.
5. Reconnect the negative battery cable.
6. Inspect for leaks.
7. Inspect for fuel leaks.
7. 1. Turn the ignition switch ON for 2 seconds.
7.2. Turn the ignition switch OFF for
10 seconds.
7.3. Turn the ignition switch ON.
7.4. Check for fuel leaks.

12787

8. Reposition the dust cover over the quick connect

fitting.

r=: )] __

____...a

+12789

Quick Connect Fitting(s) Service

(Plastic Collar)
Removal Procedure
Caution: Relieve the fuel system pressure before
servicing fuel system components in order to
reduce the risk of fire and personal injury.
After relieving the system pressure, a small
amount of fuel may be released when servicing
the fuel lines or connections. In order to reduce the
chance of personal injury, cover the regulator
and the fuel line fittings with a shop towel before
disconnecting. This will catch any fuel that
may teak out. Place the towel in an approved
container when the disconnection is complete.

157703

Engine

Engine Controls - 3.8L 6-1179

Notice: Cap the fittings and plug the holes when

servicing the fuel system in order to prevent dirt and
other contaminants from entering the open pipes
and passages.
Notice: Before attempting any On-Vehicle Service,
place a dry chemical (Class B) fire extinguisher near
work area.
Important: Always maintain cleanliness when
servicing fuel system components.
1. Relieve the fuel system pressure. Refer to Fuel
Pressure Relief Procedure
2. Grasp both sides of the quick-connect fitting.
Twist quick-connect fitting 1/4 turn in each
direction in order to loosen any dirt within fitting.

Caution: Wear safety glasses when using

compressed air in order to prevent eye injury.
3. Blow out any dirt from the quick-connect fittings at
both ends using compressed air.

.. .
. ..

c=:::J}~~!<:::

155410

4. Squeeze the plastic tabs of the male end

connector.

12777

6-1180

Engine

Engine Controls - 3.8L

5. Pull connection apart.

6. Wipe off the male pipe end using a clean
shop towel.
7. Clean or replace components/assemblies as
required.

12778

Installation Procedure
Caution: In order to reduce the risk of fire and
personal injury, before connecting fuel pipe
fittings, always apply a few drops of clean engine
oil to the male pipe ends.
This will ensure proper reconnection and prevent
a possible fuel leak.
During normal operation, the 0-rings located in
the female connector will swell and may prevent
proper reconnection if not lubricated.
1. Apply a few drops of clean engine oil to the male
pipe end.

155425

2. Push both sides of the quick-connect fitting

together in order to cause the retaining
tabs/fingers to snap into place.

155771

(
\

Engine

Engine Controls - 3.8L

6-1181

3. Pull on both sides of the quick connect fitting in

order to make sure the connection is secure ..
4. Tighten the fuel fill cap.
Caution: Refer to Battery Disconnect Caution in
Cautions and Notices.
5. Reconnect the negative battery cable.
6. Inspect for leaks.
6.1. Turn the ignition switch ON for 2 seconds.
6.2. Turn the ignition switch OFF for
10 seconds.
6.3. Turn the ignition switch ON.
6.4. Check for fuel leaks.

155399

In-Line Fuel Filter Replacement

Removal Procedure
Notice: Cap the fittings and plug the holes when
servicing the fuel system in order to prevent dirt and
other contaminants from entering the open pipes
and passages.
Important: Always maintain cleanliness when
servicing fuel system components;
Important:
There is no service interval for fuel filter
replacement. Only replace a restricted fuel filter.

Inspect the fuel tank internally and clean the fuel

tank if you find a restricted fuel filter.
1. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
2. Raise the vehicle. Refer to Lifting and .jacking the
Vehicle in general information.
3. Clean all the fuel filter connections and the
surrounding areas before disconnecting the
fuel pipes in order to avoid possible contamination
of the fuel system.
4. Disconnect the quick-connect fitting at the fuel
filter inlet (3). Refer to Quick Connect Fitting(s)
Service (Plastic Collar).
5. Disconnect the threaded fitting (1) from the fuel
filter outlet.
6. Slide the fuel filter (2) from the bracket (4).
7. Inspect the fuel pipe 0-ring for cuts, nicks,
swelling, or distortion. Replace the 0-ring if
necessary.

'

12603

6-1182

Engine

Engine Controls .. 3.8L

Installation .Procedure

Notice: Always re-attach the fuel lines and fuel filter

with all original type fasteners and hardware.

Do not repair sections of fuel pipes.

Important: If fuel line bundle attaching hardware is
damaged or broken replace it.
1. Slide the fuel filter (2) into the bracket (4).
2. Connect the threaded fitting (1) to the fuel filter
outlet.

'

Notice: Refer to Fastener Notice in Cautions and

Notices.
Tighten

12603

Tighten the fuel filter fitting to 30 N,m (22 lb ft).

3. Connect the quick-connect fitting to the fuel filter
inlet (3). Refer to Quick Connect Fitting(s) Service
(Plastic Collar).
4. Lower the vehicle.
5. Tighten the fuel fill cap.
Caution: Refer to Battery Disconnect Caution in
Cautions and Notices.
6. Reconnect the negative battery cable.
7. Inspect for leaks.
7.1. Turn the ignition switch ON for 2 seconds.
7.2. Turn the ignition switch OFF for
10 seconds.
7.3. Turn the ignition switch ON:
7.4. Check for fuel leaks.

Fuel Tank Draining Procedure

Caution:
Never drain or store fuelin an open container
due to the possibility of fire or explosion.
When draining the. fuel tank, slowly insert the
h~nd operated pump device in the fuel tank.
Do Not force the hand operated pump device in
the fuel tank. Forcing the pump device can
cause the fuel pump to dislocate from the fuel
sender assembly.
1. Remove the fuel filler cap.
2. Use a hand operate~ pump device in order to
drain as much fuel through thefuel filler pipe

as possible.
3. Reinstall the fuel fiU cap.

Engine

Engine Controls - 3.8L

6-1183

Fuel Tank Replacement

Removal Procedure
\
'

Caution: Provide additional support when a

vehicle is on a hoist in the following ways:
Before removing parts, support the opposite
end. This helps prevent the vehicle from
slipping off.
Before removing major components, chain the
vehicle frame to the hoist pads at the same
end as the removal. This helps avoid a tip-off.
Failure to follow these precautions could cause
vehicle damage, serious personal injury, or death.
1. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining
Procedure.
3. Remove the fuel tank filler pocket.
4. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in general information.
5. Remove the fuel filler pjpe shield.
6. Remove the exhaust system from the catalytic
converter back. Refer to Muffler Replacement in
Engine Exhaust.
7. Remove the exhaust pipe heat shield and the
exhaust muffler heat shield.
8. Remove the rear axle assembly. Refer to Rear
Axle Replacement in Rear Drive Axle.
9. Clean all fuel pipe connections and surrounding
areas before disconnecting the fuel pipes in order
to avoid possible contamination of the fuel
system.
10. Disconnect the EVAP pipes (1) at the EVAP
canister (2).
11. Disconnect the fuel return pipe (4).
12. Disconnect the EVAP purge pipe (3).
13. Disconnect the fuel feed pipe at the fuel filter inlet.
14. Disconnect the fuel tank vent valve from the
rec:ir brake hose bracket.
15. Remove the rear pipe clip.

21288

183854

6-1184

Engine Controls - 3.SL

Engine
16. Disconnect the fuel sender and the fuel pressure
sensor electrical connectors.
17. Disconnect the electrical harness clip (2) from the
fuel tank flange (1 ).

2
173809

18. With the aid of an assistant, support the fuel tank.

19. Remove the left fuel tank strap attaching bolt (3)
from the underbody bracket (1 ).
Notice: Do not bend the fuel tank straps. Bending the
fuel tank straps may damage the straps.
20. Lower the left fuel tank strap (2).
21. Remove the EVAP canister vent valve and
bracket (4).

173855

22. Remove the right fuel tank strap attaching bolt.

23. Lower the right fuel tank strap.
24. Remove the fuel tank.

174089

Engine

Engine Controls - 3.8L

6-1185

25. Place the fuel tank in a suitable work area.

26. Remove the fuel tank insulators if necessary.

183852

27. Remove the fuel sender assembly (3) and the

rear fuel and EVAP pipes from the fuel tank.
Refer to Fuel Sender Assembly Replacement.

172721

Installation Procedure
1. Reinstall the fuel sender assembly (3) and the
rear fuel and EVAP pipes to the fuel tank. Refer
to Fuel Sender Assembly Replacement.

172721

6-1186

Engine Controls - 3.8L

Engine
2. Reinstall the right fuel tank insulator.

183852

Important: The fuel sender pipes must route below

the left fuel tank insulator.

3. Align the insulator (2) on the top of the fuel tank

with 15-25 mm (0.6-1.0 in) of the insulator
extending beyond the edge of the fuel tank front
flange (3).
4. Fold the insulator down.
5. Secure the insulator to the flange (4). The
alignment notch on the insulator lines up with the
fuel tank flange edge (1).

183856

6. With the aid of an assistant, position and support

the fuel tank.
7. Position the right fuel tank strap up ..
8. Reinstall the front right fuel tank strap
attaching bolt.

174089

(
\

Engine

Engine Controls - 3.SL

6-1187

9. Position the EVAP canister vent valve bracket (4)

between the left fuel tank strap (2) and the
underbody bracket (1).

Notice: Refer to Fastener Notice in Cautions and

Notices.
10. Reinstall the front left fuel tank strap attaching bolt.

Tighten
Tighten the front fuel tank strap attaching bolts to
33 N-m (24 lb ft).

173855

11. Connect the fuel sender and the fuel pressure

sensor electrical connectors.
12. Connect the electrical harness clip (2) to the fuel
tank flange (1 ).

2
173809

13. Connect the fuel tank vent valve to the rear brake
hose bracket.
14. Connect the fuel feed pipe at the fuel filter inlet.
15. Connect the EVAP purge pipe (3).
16. Connect the fuel return pipe (4).
17. Connect the EVAP pipes (1) at the EVAP
canister (2).

)
183854

6-1188

Engine Controls - 3.8L

Engine
18. Install the fuel and EVAP pipes into the pipe clip.
19. Align the fuel and EVAP pipes in a flat position.
20. Reinstall the pipe clip bolt.
Tighten
Tighten the pipe clip bolt to 5.5 N-m (49 lb in).
21. Reinstall the rear axle assembly. Refer to Rear
Axle Replacement in Rear Drive Axle.
22. Reinstall the exhaust system heat shields and
attaching screws.
23. Reinstall the exhaust system. Refer to Muffler
Replacement in Engine Exhaust.

175268

Reinstall the fuel tiller pipe shield.

Lower the vehicle.
Reinstall the fuel tank tiller pocket.
Refill the fuel tank and reinstall the fuel till cap.
Reconnect the negative battery cable. Refer
to Battery Disconnect Caution.
29. Inspect tor leaks.
29.1. Turn the ignition switch ON tor 2 seconds.
29.2. Turn the ignition switch OFF for
10 seconds.
29.3. Turn the ignition switch ON.
29.4. Check tor fuel leaks.

24.
25.
26.
27.
28.

21288

Fuel Tank Vent Valve Replacement

Removal Procedure
Caution: Refer to the Battery Disconnect Caution
in Cautions and Notices.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining
Procedure.
4. Remove the fuel tank. Refer to Fuel Tank
Replacement.
5. Disconnect the fuel tank vent valve hose (1) from
the fuel sender pipe.
6. Remove the fuel tank vent valve (2) and hose (1 ).

12605

Engine

Engine Controls - .3.SL

6-1189

Installation Procedure
1. Connect the fuel tank vent valve hose (1) to the
fuel sender pipe.
2. Install the fuel tank. Refer to Fuel Tank
Replacement.
3. Install the fuel tank vent valve (2) to the rear
brake hose bracket (3).
4. Refill the fuel tank.
5. Install the fuel filler cap.
6. Connect the negative battery cable.
7. Inspect for leaks.
7.1. Turn the ignition switch ON for 2 seconds.
7.2. Turn the ignition switch OFF for
10 seconds.
7.3. Turn the ignition switch ON.
7.4. Check for fuel leaks.
8. Perform the Idle Learn Procedure. Refer to PCM
Idle Learn Procedure.
12605

Fuel Tank Pressure Sensor Replacement

Removal Procedure
1. Relieve the fuel system pressure. Refer to Fuel
Pressure Relief Procedure
2. Drain fuel tank. Refer to Fuel Tank Draining
Procedure.
3. Remove the fuel tank. Refer to Fuel Tank
Replacement.
4. Disconnect the electrical connector from the fuel
tank pressure sensor.
5. Remove the fuel tank pressure sensor (10) from
the modular fuel sender.

215749

Installation Procedure
1. Install the new fuel tank pressure sensor {10) to
the modular fuel sender.
2. Connect the electrical connector to the fuel tank
pressure sensor.
3. Reinstall the fuel tank. Refer to Fuel Tank
Replacement.
4. Refill the fuel tank and reinstall the fuel fill cap.
Caution: Refer to Battery Disconnect Caution
in Cautions and Notices.
5. Reconnect the negative battery cable.

)
215749

6-1190

Engine Controls - 3.8L

Engine
Fuel Sender Assembly Replacement
Removal Procedure
Caution: In order to reduce the risk of fire and
personal injury that may result from a fuel
leak, always replace the fuel sender gasket when
reinstalling the fuel sender assembly.
Notice: Do Not handle the fuel sender assembly by
the fuel pipes. The amount of leverage generated
by handling the fuel pipes could damage the joints.
Notice: Cap the fittings and plug the holes when
servicing the fuel system in order to prevent dirt and
other contaminants from entering the open pipes
and passages.

112121

Important: Always maintain cleanliness when

servicing fuel system components.
1. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining
Procedure.
3. Remove the fuel tank. Refer to Fuel Tank
Replacement.
4. Remove the fuel sender assembly retaining
nuts (1), the retaining ring (2), the fuel sender
assembly (3), and the gasket (4). Discard
the gasket.

Caution: Drain the fuel from the fuel sender

assembly into an approved container in order to
reduce the risk of fire and personal injury.
Never store the fuel in an open container.
5. Clean the gasket sealing surfaces.

Installation Procedure
1. Position the new gasket on the fuel tank.
Important: The fuel pump strainer must be in a
horizontal position when the fuel sender is installed in
the tank. When installing the fuel sender assembly,
assure that the fuel pump strainer does not block full
travel of the float arm.
2. Carefully fold the strainer to allow it to fit through
the opening in the fuel tank. Make sure the
strainer unfolds once .it is placed in the tank.
3. Install the fuel sender assembly into the fuel tank.

172942

Engine

Engine Controls - 3.8L

6-1191

4. Reinstall the fuel sender retaining ring (2):

Notice: Refer to Fastener Notice in Cautions and
Notices.
5. Reinstall the fuel sender assembly retaining
nuts (1 ).
Tighten
Tighten the fuel sender assembly retaining nuts
alternately and evenly to 6.5 N,m (58 lb in).
6. Reinstall the fuel tank. Refer to Fuel Tank
Replacement.
7. Add fuel and reinstall the fuel filler cap.
Caution: Refer to Battery Disconnect Caution in
Cautions and Notices.
8. Reconnect the negative battery cable.
9. Inspect for leaks.
9.1. Turn the ignition switch ON for 2 seconds.
9.2. Turn the ignition switch OFF for
10 seconds.
9.3. Turn the ignition switch ON.
9.4. Check for fuel leaks.

172721

Fuel Sender Assembly Service

Removal Procedure
Important: Always maintain cleanliness when
servicing fuel system components.
1. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining
Procedure.
3. Remove the fuel tank. Refer to Fuel Tank
Replacement.
4. Remove the fuel sender assembly. Refer to Fuel
Sender Assembly Replacem<3nt.
5. Note the position ~f the fuel strainer (5) on the
fuel pump.
6. Support the fuel sender assembly with one hand
and grasp the strainer (5) with the other hand.
7. Rotate the strainer in one direction and pull the
strainer off the pump. Discard the strainer after
inspection.
8. Inspect the strainer. Replace a contaminated
strainer and clean the fuel tank.
9. Inspect the fuel pump inlet for dirt and debris. If
found, replace the fuel pump and reservoir.
10. If the fuel pump and reservoir is being replaced,
proceed to step 12.
11. Disconnect the vent hose (1) and the fuel return
hose (3) from under the cover (9).
12. Disconnect the quick-connect fitting on the fuel
pump flex pipe (2).
13. Disconnect the electrical connector (7) from the
fuel pump.
14. Pry the locking tabs (6) on the bottom of the fuel
sender, lift the reservoir to clear the locking tabs
and pull the reservoir downward to clear the
guides on the fuel sender.

215749

6-1192

Engine

Engine Controls - 3.SL

Installation Procedure

1. Align the tabs on the reservoir with the guide on

the fuel sender, push the reservoir upward to the
stop on the top of the reservoir and snap the
locking tabs (6) over the ramps on the bottom of
the reservoir.
2. Connect the fuel vent hose (1) and the fuel return
hose (3).
3. Connect the quick-connect fitting on the fuel pump
flex pipe (2).
4. Connect the fuel pump electrical connector (7).

215749

Important: Always install a new pump strainer

when replacing the fuel pump.
5. Install the new fuel pump strainer in the same
position as noted during disassembly. Push on
the outer edge of the strainer ferrule until the
strainer is fully seated.
6. Reinstall the fuel sender assembly. Refer to Fuel
Sender Assembly Replacement.
7. Reinstall the fuel tank. Refer to Fuel Tank
Replacement.
8. Add fuel and reinstall the fuel fill cap.

Caution: Refer to Battery Disconnect Caution in

Cautions and Notices.
9. Reconnect the negative battery cable.
10. Inspect for leaks.
10.1. Turn the ignition switch ON for 2 seconds.
10.2. Turn the ignition switch OFF for
10 seconds.
10.3. Turn the ignition switch ON.
10.4. Check for fuel leaks.

Fuel Pump Strainer Replacement

Removal Procedure
Important: Always maintain cleanliness when
servicing fuel system components.
1. Relieve fuel system pressure. Refer to Fuel
Pressure Relief Procedure.
2. Remove the fuel sender assembly. Refer to Fuel
Sender Assembly Replacement.
3. Note the position of the strainer (5) for aid in
installation.

215749

Engine

Engine Controls - 3.SL

6-1193

4. Support the reservoir with one hand and grasp

the strainer with the other hand.
5. Use a screwdriver to pry the strainer ferrule off
the reservoir.
6. Discard the strainer.

54511

Installation Procedure
1. Install the new strainer (5) to the reservoir.
2. Support the reservoir with one hand and grasp
the strainer with the other hand twisting the
strainer into position.
3. Reinstall the fuel sender assembly. Refer to Fuel
Sender Assembly Replacement.
4. Add fuel and reinstall the fuel fill cap.
Caution: Refer to Battery Disconnect Caution in
Cautions and Notices.
5. Reconnect the negative battery cable.
6. Inspect for fuel leaks:
6.1. Turn the ignition switch ON for 2 seconds.
6.2. Turn the ignition switch OFF for
10 seconds.
6.3. Turn the ignition switch ON.
6.4. Check for fuel leaks.

215749

Fuel Level Sensor Replacement

Removal Procedure
Important: Always maintain cleanliness when
servicing fuel system components.
1. Relieve fuel system pressure. Refer to Fuel
Pressure Relief Procedure.
2. Remove the fuel sender assembly. Refer to Fuel
Sender Assembly Replacement.
3. Remove the fuel level sensor (8) from the
modular fuel sender.

215749

6-1194

Engine

Engine Controls - 3.8L

Installation Procedure

1. Install the fuel level sensor (8) to modular fuel

sender.
2. Reinstall the fuel sender assembly. Refer to Fuel
Sender Assembly Replacement.
3. Add fuel and reinstall the fuel fill cap.

Caution: Refer to Battery Disconnect Caution in

Cautions and Notices.
4. Reconnect the negative battery cable.
5. Inspect for fuel leaks:
5.1. Turn the ignition switch ON for 2 seconds
5.2. Turn the ignition switch OFF for 1O seconds.
5.3. Turn the ignition switch ON.
5.4. Check for fuel leaks.

215749

Fuel Hose/Pipes Replacement

(Filter to Engine)
Removal Procedure

215517

Caution: In order to Reduce the Risk of Fire and

Personal Injury:
If nylon fuel pipes are nicked, scratched or
damaged during installation, Do Not attempt to
repair the sections of the nylon fuel pipes.
Replace them.
When installing new fuel pipes, Do Not
hammer directly on the fuel harness body clips
as it may damage the nylon pipes resulting
in a possible fuel leak.
Always cover nylon vapor pipes with a wet
towel before using a torch near them. Also,
never expose the vehicle to temperatures
higher than 115C (239F} for more than one
hour, or more than 90C (194F) for any
extended period.
Before connecting fuel pipe fittings, always
apply a few drops of clean engine oil to
the male pipe ends. This will ensure proper
reconnection and prevent a possible fuel leak.
(During normal operation, the 0-rings
located in the female connector will swell and
may prevent proper reconnection if not
lubricated.)
Notice: Replace the EVAP pipes and hoses with the
original equipment or parts that meet the GM
specifications for those parts. The replacement EVAP
pipe must have the same type of fittings as the
original pipe in order to ensure the integrity of the
connection. When replacing EVAP hoses, use
only reinforced fuel-resistant hose identified with the
word Fluoroelastomer or GM 6163-M on the hose. The
inside hose diameter must match the outside pipe
diameter. Do not use rubber hose within 100 mm (4 in)
of any part of the exhaust system or within 254 mm
(1 O in) of the catalytic converter.

Engine

Engine Controls - 3.SL

6-1195

Notice: Cap the fittings and plug the holes when

servicing the fuel system in order to prev~nt dirt and
other contaminants from entering the open pipes
and passages.

Important: Always maintain cleanliness when

servicing fuel system components.
1. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining
Procedure.
3. Clean all the fuel and EV AP pipe and hose
connections and the surrounding areas before
disconnecting in order to avoid possible
contamination of the fuel system.
4. Disconnect the engine compartment connecting
fuel feed pipe (4) from the chassis fuel and
EV AP pipes. Refer to Quick Connect Fitting(s)
Service (Metal Collar).
5. Disconnect the engine compartment connecting
return pipe (3) from the chassis fuel and
EVAP pipes.
6. Disconnect the engine compartment connecting
EVAP pipe (5) from the chassis fuel and
EVAP pipes.
7. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in general information.
8. Remove the rear fuel pipe shield attaching
nuts (3) and bolt (6).
9. Remove the rear fuel pipe shie.ld (4).
10. Remove the front fuel pipe shield attaching
nuts (1 ).
11. Remove the front fuel pipe shield.

7C!J
173551

6-1196

Engine

Engine Controls - 3.8L

12. Disconnect the fuel feed pipe from the outlet

side (4) of the fuel filter (3). Discard the 0-ring.
13. Disconnect the fuel return pipe (1) and the
EVAP (2) pipe from the rear fuel and EVAP pipes.
14. Remove the fuel pipe attaching hardware and the
fuel pipes. Note the position of the fuel pipes for
installation.
15. Inspect the pipes for bends, kinks, and cracks.
Repair or replace the pipes as required.

215524

Repair Procedure
When repairing the fuel or EVAP pipes with hoses,
always replace them with original equipment or parts
meeting GM specifications. Use only reinforced
fuel resistant hose which is identified with the word
Fluoroelastomer or GM 6163-M on the hose.
The inside hose diameter must match the outside pipe
diameter.
Do Not use rubber hose within 100 mm (4 in) of any
part of the exhaust system or within 254 mm (1 O in) of
the catalytic converter.
A minimum of 13 mm (112 in) clearance must be
maintained around sharp edges such as flanges, pinch
welds, etc., in order to prevent contact and chafing.
A minimum of 19 mm (% in) clearance must be
maintained around all moving parts.
Cut the ends of the pipe remaining on the car square
with a tube cutter. Using the first step of a double
flaring tool, form a bead on the end of both pipe
sections. If the pipe is too corroded to withstand the
beading operation without damage, the pipe should be
replaced. If a new section of pipe is used, form a
bead on both ends of the pipe also.
Use screw type hose clamps. Slide the clamps onto
the pipe and push the hose 51 mm (2 in) onto
each portion of the fuel pipe.
If more than a 6 in length of pipe is removed, use a
combination of steel pipe and hose so that the
total hose lengths, including the 100 mm (4 in)
additional length will not be more than 254 mm (10 in)
long. Follow the same routing as the original pipe.

Engine

Engine Controls - 3.8L 6-1197

Installation Procedure
Important:

Always re-attach the fuel lines and the fuel filter

with all original type fasteners and hardware.
When replacing the fuel or EV AP pipes, always
replace them with original equipment or parts
that meet the GM specifications for those parts.
The replacement pipes must have the same
type of fittings as the original pipes in order to
ensure the integrity of the connection.
Do Not use copper or aluminum tubing to
replace steel tubing. Only tubing meeting the
124-M specification or its equivalent is capable of
meeting all pressure, corrosion and vibration
characteristics necessary to ensure the durability
standard required.
1. Position the fuel and EVAP pipes to the frame rail.
2. Loosely install the number 1 position pipe
clip stud.

173403

3. Loosely install the number 2 position pipe

clip stud.

173409

4. Loosely install the number 3 position pipe

clip stud.

173412

6-1198

Engine

Engine Controls - 3.SL

5. Align the fuel and EVAP pipes to the number 5

and number 6 position.

Notice: Refer to Fastener Notice in Cautions and

Notices.
6 .. Install the pipe clip bolts.
Tighten
Tighten the pipe clip bolts to 4.5 N-m (40 lb in).

173417

7. Align the fuel and EVAP pipes to the number 4

position clamp.

8. Install the pipe clamp stud.

Tighten
Tighten the pipe clamp stud to 5 N-m (44 lb in).

173416

9. Connect the fuel return pipe (1) at the rear quick

connect fitting.

10. Connect the EVAP purge pipe (2) at the rear

quick connect fitting.
11. Connect the fuel feed pipe (4) to the fuel filter (3).
Tighten
Tighten the fuel feed pipe fitting to
30 N-m (22 lb ft).

215524

Engine

Engine Controls - 3.8L

6-1199

12. Install the fuel and EVAP pipes into the pipe clip.
13. Align the fuel and EVAP pipes in a flat position.
14. Install the pipe clip bolt.

Tighten
Tighten the pipe clip bolt to 5.5 N-m (49 lb in).

175268

15. Position the front fuel pipe shield (2) to the 3 fuel
pipe clip studs and the brake pipe clip stud (7).
16. Install the pipe shield nuts (1 ).

Tighten
Tighten the pipe shield nuts to 5 Nm (44 lb in).
17. Position the rear fuel pipe shield (4) to the fuel
pipe stud and the fuel pipe clip stud (5).
18. Loosely install the pipe shield nuts.
19. Install the pipe shield bolt.
Tighten
19.1. Tighten the pipe shield bolt to
5 N-m (44 lb in).
19.2. Tighten the pipe shield nuts to
5 N-m (44 lb in).
20. Lower the vehicle.

7~

173551

21. Connect the engine compartment EVAP pipe (5)

to the chassis EV AP pipe.
22. Connect the engine compartment fuel feed
pipe (4) to the chassis fuel feed pipe.
23. Connect the engine compartment fuel return
pipe (3) to the chassis fuel feed pipe.
24. Add fuel and reinstall the fuel fill .cap.

Caution: Refer to Battery Disconnect Caution in

Cautions and Notices.
25. Reconnect the negative battery cable.
26. Inspect for leaks.
26.1. Turn the ignition switch ON for 2 seconds.
26.2. Turn the ignition switch OFF for
10 seconds.
26.3. Turn the ignition switch ON.
26.4. Check for fuel leaks.

215517

6;.1200

Engine

Engine Controls - 3.SL

Fuel Hose/Pipes Replacement
(Filter to Tank)
Removal Procedure

215497

Caution: In order to Reduce the Risk of Fire and

Personal Injury:
If nylon fuel pipes are nicked, scratched or
damaged during installation, Do Not attempt to
repair the sections of the nylon fuel pipes.
Replace them.
When installing new fuel pipes, Do Not
hammer directly on the fuel harness body clips
as it may damage the nylon pipes resulting
in a possible fuel leak.
Always cover nylon vapor pipes with a wet
towel before using a torch near them. Also,
never expose the vehicle to temperatures
higher than 115C (239F) for more than one
hour, or more than 90C (194F) for any
extended period.
Before connecting fuel pipe fittings, always
apply a few drops of clean engine oil to
the male pipe ends. This will ensure proper
reconnection and prevent a possible fuel leak.
(During normal operation, the 0-rings
located in the female connector will swell and
may prevent proper reconnection if not
lubricated.)
Notice: Do not attempt to straighten any kinked nylon
fuel lines. Replace any kinked nylon fuel feed or
return pipes in order to prevent damage to the vehicle.
Notice: Replace the EVAP pipes and hoses with
the original equipment or parts that meet the
GM specifications for those parts. The replacement
EVAP pipe must have the same type of fittings as the
original pipe in order to ensure the integrity of the
connection. When replacing EVAP hoses, use
only reinforced fuel-resistant hose identified with the
word Fluoroelastomer or GM 6163-M on the hose. The
inside hose diameter must match the outside pipe
diameter. Do not use rubber hose within 100 mm (4 in)
of any part of the exhaust system or within 254 mm
(1 O in) of the catalytic converter.
Notice: Cap the fittings and plug the holes when
servicing the fuel system in order to prevent dirt and
other contaminants from entering the open pipes
and passages.
Important: Always maintain cleanliness when
servicing fuel system components.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
3.. Drain the fuel tank. Refer to Fuel Tank Draining
Procedure.
4. Raise the vehicle.
5. Clean all fuel and EVAP pipe and hose
connections and the surrounding areas before
disconnecting in order to avoid possible
contamination of the fuel system.

(
\

Engine

Engine Controls - 3.SL

6-1201

6. Remove the fuel tank. Refer to Fuel Tank

Replacement.
7. Disconnect the rear fuel feed pipe (4) and the
return pipe (3) from the chassis fuel pipe and
the fuel filter (5).
8. Disconnect the EV AP hoses from the chassis
EVAP pipe (2) and the EVAP canister (1 ).

Installation Procedure
Important:
Always re-attach the fuel lines and fuel filter with
all original type fasteners and hardware.
If fuel line bundle attaching hardware is damaged
or broken replace it.
1. Connect the EVAP hoses to the chassis EVAP
pipe (2) and the EVAP canister (1 ).
2. Connect the rear fuel feed pipe (4) and the return
pipe (3) to the chassis fuel pipe and the fuel
filter (5).
3. Install the fuel tank. Refer to Fuel Tank
4.
5.
6.
7.
8.

Replacement.
Lower the vehicle.
Refill the fuel tank.
Connect the negative battery cable.
Tighten the fuel filler cap.
Inspect for leaks.
8.1. Turn the ignition switch ON for 2 seconds.
8.2. Turn the ignition switch OFF for
10 seconds.
8.3. Turn the ignition switch ON.
8.4. Visually inspect the fuel system for
fuel leaks.

215497

Fuel Hose/Pipes Replacement

(Engine Compartment)
Removal Procedure

Caution: In order to Reduce the Risk of Fire and

Personal Injury:
If nylon fuel pipes are nicked, scratched or
damaged during installation, Do Not attempt to
repair the sections of the nylon fuel pipes.
Replace them.
When installing new fuel pipes, Do Not
hammer directly on the fuel harness body clips
as it may damage the nylon pipes resulting
in a possible fuel leak.
Always cover nylon vapor pipes with a wet
towel before using a torch near them. Also,
never expose the vehicle to temperatures
higher than 115C {239F) for more than one
hour, or more than 90C (194F) for any
extended period.
Before connecting fuel pipe fittings, always
apply a few drops of clean engine oil to
the male pipe ends. This will ensure proper
reconnection and prevent a possible fuel leak.
(During normal operation, the 0-rings
located in the female connector will swell and
may prevent proper reconnection if not
lubricated.)

215517

6-1202

Engine Controls - 3.SL

Engine
Notice: Do not attempt to straighten any kinked nylon
fuel lines. Replace any kinked nylon fuel feed or
return pipes in order to prevent damage to the vehicle.
Notice: Replace the EVAP pipes and hoses with
the original equipment or parts that meet the
GM specifications for those parts. The replacement
EVAP pipe must have the same type of fittings as the
original pipe in order to ensure the integrity of the
connection. When replacing EVAP hoses, use
only reinforced fuel-resistant hose identified with the
word Fluoroelastomer or GM 6163-M on the hose. The
inside hose diameter must match the outside pipe
diameter. Do not use rubber hose within 100 mm (4 in)
of any part of the exhaust system or within 254 mm
(10 in) of the catalytic converter.

Notice: Cap the fittings and plug the holes when

servicing .the fuel system in order to prevent dirt and
other contaminants from entering the open pipes
and passages.
Important: Always maintain cleanliness when
servicing fuel system components.
1. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Draining
Procedure.
3. Disconnect the fuel feed pipe (1) at the engine.
Refer to Quick Connect Fitting(s) Service
(Metal Collar).
4. Disconnect the fuel return pipe (2) at the engine.
5. Disconnect the EVAP pipe (6) at the engine.
6. Disconnect the EV AP pipe (5) at the chassis fuel
and EVAP pipes.
7. Disconnect the fuel feed pipe (4) at the chassis
fuel and EV AP pipes.
8. Disconnect the fuel return pipe (3) at the chassis
fuel and EVAP pipes:
9. Remove the fuel feed, return, and EVAP pipes.

Installation Procedure

215517

Important:
Always re-attach the fuel lines and fuel filter with
all original type fasteners and hardware.
If fuel line bundle attaching hardware is damaged
or broken replace it
1. Install the fuel feed, return, .and EVAP pipes.
2. Connect the fuel feed pipe (4) at the chassis fuel
and EVAP pipes.
3. Connect the fuel return pipe (3) at the chassis fuel
and EVAP pipes.
4. Connect the EVAP pipe (5) at the chassis fuel
and EV AP pipes.
5. <::onnect the fuel feed pipe (1) to the engine.
6. Connect the fuel return pipe (2) to the engine.
7. Connect the EVAP pipe (6) to the engine.
8. Add fuel and reinstall the fuel fill cap.

(
\

Engine
Caution: Refer to Battery Disconnect ,Caution in
Cautions and Notices.
9. Reconnect the negative battery cable.
10. Inspect for leaks.
10.1. Turn the ignition switch ON for 2 seconds.
10.2. Turn the ignition switch OFF for
10 seconds.
10.3. Turn the ignition switch ON.
10.4. Check for fuel leaks.

Fuel System Cleaning

Important:
Only use oil free compressed air to blow out the
fuel pipes.
Inspect the fuel tank internally and clean, the fuel
tank if you find a plugged fuel filter.
Important: Always maintain cleanliness when
servicing fuel system components.

1. Relieve the fuel system pressure. Refer to the

Fuel Pressure Relief Procedure.
2. Drain the fuel tank. Refer to Fuel Tank Oraining
Procedure.
3. Remove the fuel tank. Refer to Fuel Tank
Replacement.
4. Remove the fuel sender assembly. Refer to Fuel
Sender Assembly Replacement.
5. Inspect the fuel pump strainer. Replace a
contaminated strainer and inspect the fuel pump.
6. Inspect the fuel pump inlet for dirt and debris.
Replace the fuel pump and 'reservoir if you find
dirt or debris in the fuel pump inlet.
Important: When flushing the fue! tank, handle the
fuel and water mixture as a hazardous material.
Handle the fuel and water mixture in accordance with
all applicable local, state, and federal laws and
regulations.
7. Flush the fuel tank with hot water.
8. Pour the water out of the:fuel,sender assembly
opening. Rock theJank to, be sure that removal
of the water from the tank is comp~ete.
9. Reinstall the fuel sendet assembly: Refer to Fuel
Sender, Assembly Replacement.,
1O. Reinstall the fuel tank. Refer to Fuel Tank
Replacement.
11. Add fuel and reinstall the fuel fill cap.

Caution: Refer to Battery Disconnect Caution in

Cautions and Notices.
12. Reconnect the negative battery cable.
13. Inspect for leaks.
13.1 . Turn the ignition switch ON for 2 seconds.
13.2. Turn the ignition switch OFF for
10 seconds.
13.3. Turn the ignition switch ON.
13.4. Check for fuel leaks.

Engine Controls,".': ,3.SL

6-1203

6-1204

Engine Controls - 3,SL

Engine
Fuel Rail Assembly Replacement
Removal Procedure
Tools Required
J 37088-A Tool Set, Fuel Line Quick-Connect
Separator
Notice: Cap the fittings and plug the holes when
servicing the fuel system in order to prevent dirt and
other contaminants from entering the open pipes
and passages.

12815

Important: Always maintain cleanliness when

servicing fuel system components.
1. Bleed fuel pressure from the fuel system. Refer to
Fuel Pressure Relief Procedure.
2. Clean the fuel rail assembly and connections.
3. Remove the fuel feed and fuel return pipes from
the fuel rail tubes. Refer to Quick Connect
Fitting(s) Service (Metal Collar).
4. Disconnect the fuel injector coil wires.
5. Disconnect the vacuum line from the vacuum
source to the fuel pressure regulator.
6. Disconnect the MAP sensor electrical connector.
7. Remove the vacuum line to the vacuum switch
from the fuel pipe bundle.
8. Disconnect the vacuum source from the intake
manifold.
9. Disconnect the fuel injector electrical connectors.
10. Remove the fuel injector harness fasteners.
11. Remove the fuel rail hold-down bolts.
12. Remove the fuel rail with equal force on both
sides of the fuel rail.
13. Remove the front fuel injector retaining clips on
each side of the fuel rail.
14. Remove the front fuel injector on each side of the
fuel rail. The fuel rail will now clear the intake
manifold.

Installation Procedure
Caution: In order to reduce the risk of fire and
personal injury that may result from a fuel
leak, always install the fuel injector 0-rings in the
proper position. If the upper and lower 0-rings
are different colors (black and brown}, be sure to
install the black 0-ring in the upper position
and the brown 0-ring in the lower position on the
fuel injector. The 0-rings are the same size but
are made of different materials.
Notice: Always re-attach the fuel lines and fuel filter
with all original type fasteners and hardware.
Do not repair sections of fuel pipes.

12815

Engine
Notice:
Use care when servicing the fuel system
components, especially the fuel injector electrical
connectors, the fuel injector tips, the injector
0-rings. Plug the inlet and the outlet ports of the
fuel rail in order to prevent contamination.
Do not use the compressed air to clean the fuel
rail assembly as this may damage the fuel rail
components.
Do not immerse the fuel rail assembly in a solvent
bath in order to prevent damage to the fuel rail
assembly.
1. The 0-rings must be replaced on all components
that are replaced.
2. Lightly oil the fuel injector 0-rings with clean
engine oil.
3. Place the fuel rail assembly {WITHOUT the front
fuel injectors on each side of the fuel rail) on the
intake manifold.
4. Reinstall the front fuel injector on each side of the
fuel rail.
5. Reinstall the fuel injector retaining clips on the
front fuel injector on each side of the fuel rail.
6. Seat the fuel injectors by HAND.
Notice: Refer to Fastener Notice in Cautions and
Notices.
7. Reinstall the fuel rail hold-down bolts.
Tighten
Tighten the fuel rail hold-down bolts to
10 N-m (89 lb in).
8. Reinstall the fuel injector harness fasteners.
9. Connect the fuel injector electrical connectors.

10. Connect the vacuum source to the intake manifold.

11. Reinstall the vacuum line to the vacuum switch
into the fuel pipe bundle.
12. Connect the vacuum line from the vacuum source
to the fuel pressure regulator..
13. Connect the fuel feed and fuel return pipes by
pushing the pipes onto the fuel rail tubes.
14. Connect the MAP sensor electrical connector.
15. Reconnect the fuel injector coil wires.
Caution: Refer to Battery Disconnect Caution in
Cautions and Notices.
16. Reconnect the negative battery cable.
17. Inspect for leaks.
17 .1 . Turn the ignition switch ON for 2 seconds.
17.2. Turn the ignition switch OFF for
10 seconds.
17.3. Turn the ignition switch ON.
17.4. Check for fuel leaks.
\\
/

Engine Controls - 3.8L

6-1205

6-1206

Engine Controls - 3.SL

Engine
Fuel Pressure Regulator Replacement
Removal Procedure

12686

Notice: Cap the fittings and plug the holes when

servicing the fuel system in order to prevent dirt and
other contaminants from entering the open pipes
and passages.
Important: Always maintain cleanliness when
servicing fuel system components.
1. Relive the fuel pressure. Refer to Fuel Pressure
Relief Procedure.
2. Remove the fuel rail. Refer to Fuel Rail Assembly
Replacement.
3. Clean any dirt from the fuel pressure regulator
retaining ring.
4. Remove the snap ring (1 ).
5. Using a shop towel to catch any spilled fuel, lift
and twist the fuel pressure regulator in order to
remove the fuel pressure regulator (2) from
the fuel pressure regulator housing.
6. Remove the pressure regulator small 0-ring (6).
7. Remove the pressure regulator filter screen (5).
8. Remove the pressure regulator large 0-ring (4).
9. Remove the pressure regulator 0-ring back up (3).
10. Cover the fuel pressure regulator housing in
order to prevent contamination from entering
the fuel system.

Installation Procedure

12686

Notice:
Do not use compressed air in order to test or
clean a fuel pressure regulator as damage to the
fuel pressure regulator may result.
Clean the fuel pressure regulator filter screen with
gasoline if necessary.
Do not immerse the fuel pressure regulator in a
solvent bath in order to prevent damage to the
fuel pressure regulator.
1. Install new 0-rings on the fuel pressure regulator.
Lubricate the 0-rings lightly with clean engine oil.
2. Install pressure regulator 0-ring back up (3).
3. Install pressure regulator large 0-ring (4).
4. Install pressure regulator filter screen (5).
5. Install pressure regulator small 0-ring (6).
6. Install the fuel pressure regulator (2) in the fuel
pressure regulator housing.
7. Install the snap ring (1 ).
8. Reinstall the fuel rail. Refer to Fuel Rail Assembly
Replacement.
9. Tighten the fuel fill cap.

(
'

Engine

Engine Controls - 3.SL

6-1207

Caution: Refer to Battery Disconnect Caution in

Cautions and Notices.
10. Reconnect the negative battery cable.
11. Inspect for leaks.
11.1. Turn the ignition switch ON for 2 seconds.
11.2. Turn the ignition switch OFF for
10 seconds.
11.3. Turn the ignition switch ON.
11.4. Check for fuel leaks.

Fuel Injector Replacement

Removal Procedure
Notice: Cap the fittings and plug the holes when
servicing the fuel system in order to prevent dirt and
other contaminants from entering the open pipes
and passages.
Notice: Use care in removing the fuel injectors in
order to prevent damage to the fuel injector electrical
connector pins or the fuel injector nozzles. Do not
immerse the fuel injector in any type of cleaner. The
fuel injector is an electrical component and may
be damaged by this cleaning method.

Important: The fuel injector is serviced as a complete

assembly only. If the fuel injectors are found to be
leaking, the engine oil may be contaminated with fuel.
Always maintain cleanliness when servicing fuel
system components.
1. Remove the fuel rail. Refer to Fuel Rail Assembly
Replacement.
2. Remove the fuel injector retaining clip (2).
3. Remove the fuel injector (3).

12687

4. Remove the fuel injector upper 0-ring (1).

5. Remove the fuel injector lower 0-ring (5).
6. Remove the fuel injector 0-ring back up (4).

Installation Procedure
Important: Each fuel injector is calibrated for a
specific flow rate. Be sure to use the correct part
number when ordering replacement fuel injectors.

When replacing the fuel injector 0-rings, be sure to

install the brown 0-ring in the lower position.
The fuel injector lower 0-ring uses a nylon collar,
called the 0-ring backup, to properly position
the 0-ring on the fuel injector. Be sure to reinstall the
0-ring backup, or the sealing 0-ring may move on
the fuel injector when installing the fuel rail. If
the sealing 0-ring is not seated properly, a vacuum
leak is possible and driveability complaints may occur.
1. Coat all new 0-rings with clean engine oil
before installing.
2. Install the fuel injector 0-ring back up (4).
3. Install the fuel injector lower 0-ring (5).
4. Install the fuel injector upper 0-ring (1 ).
5. Install the fuel injector (3).
6. Install the fuel injector retaining clip (2).

12687

6-1208

Engine Controls - 3.SL

Engine
7. Reinstall the fuel rail. Refer to Fuel Raif Assembly
Replacement.

Caution: Refer to Battery Disconnect Caution ;n

Cautions and Notices.
8. Reconnect the negative battery cable.
9. Inspect for leaks.
9.1. Turn the ignition switch ON for 2 seconds.
9.2. Turn the ignition switch OFF for
10 seconds.
9.3. Turn the ignition switch ON.
9.4. Check for fuel leaks.

Fuel Pump Relay Replacement

Removal Procedure
1. Remove the cover from the relay center (2).
2. Remove the fuel pump relay by pulling upward.

255043

Installation Procedure
1. Push the relay into the relay center socket.
2. Reinstall the cover on the relay center (2).

255043

Engine

Engine Controls - 3.8L

6-1209

Engine Oil Pressure Sensor/Switch

Replacement

Removal Procedure
1. Raise the vehicle.
2. Drain the engine oil.
3. Disconnect the electrical connector from Engine
Oil Level Switch
4. Remove the Engine Oil Level Switch from the
oil pan.

227971

Installation Procedure
1. Install the Engine Oil Level Switch.
Tighten
Torque the Engine Oil Level Switch to
20 N-m (15 lb ft).

Notice: Refer to Fastener Notice in Cautions and

Notices.
2. Lower the vehicle.
3. Add the engine oil to the correct level. For the
crankcase oil capacity, refer to General
Information.

227971

EVAP Canister Purge Solenoid Valve

Replacement
Removal Procedure
1. Disconnect the electrical connector and hoses
from the EVAP Canister Purge Solenoid.
2. Bend the tab on the mounting bracket and
remove the EVAP Canister Purge Solenoid.

187246

6-1210

Engine

Engine Controls - 3.SL

Installation Procedure

1. Position the EVAP Canister Purge Solenoid on

the mounting bracket.
2. Connect the hoses and electrical connector to the
EVAP Canister Purge solenoid.

(
'

21690

EVAP Vent Valve Replacement

Removal Procedure
1. Detach the EV AP canister vent valve from the
EV AP canister vent valve bracket.
2. Disconnect the EVAP canister vent valve electrical
connector.
3. Loosen the vent hose clamp and remove the vent
hose from the EV AP vent valve.
4. Remove the EVAP canister vent valve from the
vehicle.

228634

Installation Procedure
1. Connect the vent hose to the EV AP canister vent
valve and tighten the hose clamp.
2. Connect the EV AP canister vent valve electrical
connector.
3. Install the EVAP canister vent valve to the EV AP
canister vent valve bracket.

228634

Engine Controls - 3.SL

6-1211

EVAP Canister Replacement

Removal Procedure
1. Raise the vehicle. Refer to Vehicle Lifting and
Jacking in General Information.
2. Remove the left rear tire.
3. Remove the left rear inner wheel well shield.

229123

4. Disconnect the hoses from the canister.

5. Remove the canister from the canister bracket.
6. Remove the canister from the vehicle.

187227

Installation Procedure
1.
2.
3.
4.
5.

Install the new canister to the. canister bracket.

Connect the hoses to the canister.
Install inner wheel well shield.
Install wheel and tire assembly.
Lower the vehicle.

187227

6-1212

Engine

Engine Controls - 3.8L

Ignition Control Module Replacement

Removal Procedure
1. Disconnect the 14-way connectoF at ignition
control module.
2. Disconnect the spark plug wires from the
ignition coils.
3. Remove the 6 screws securing coil assemblies to
ignition control module.
4. Disconnect the ignition coils from ignition control
module.
5. Remove the ignition control module.

187266

Installation Procedure
1. Position the ignition control module onto the
bracket.
2. Position the ignition coils onto the ignition control
module.
3. Hand start 6 screws through the ignition coils and
module to the bracket.

Tighten
Tighten screws to 4-5 N-m (40 lb in).
Notice: Refer to Fastener Notice in Cautions and
Notices.
4. Connect the spark plug wires to the ignition coils.
5. Connect the 14-way connector to the ignition
control module.

12299

Ignition Coil(s) Replacement

1

Removal Procedure
1. Disconnect the 14-way connector from the ignition
control module.
2. Disconnect the spark plug wires from the coil
assemblies.
3. Remove 6 screws (1) securing the coil assemblies
to the ignition control module.
4. Remove the coils (2) from the ignition control
module (3).
5. Remove the ignition control module.

12299

Engine

Engine Controls - 3.8L

6-1213

Installation Procedure
1. Attach the coils to the ignition control module.
Refer to Ignition Control Module. Replaceme.nt
(Ignition Coils) Ignition Coil(s).
2. Install 6 ignition coil attaching screws
Tighten:
Tighten the screws to 4-5 N-m (40 lb. in.).
3. Install the nuts and washers securing the ignition
control module assembly to the mounting bracket.
Tighten:
Tighten the nuts to 8 N-m (70 lb. in.).
4. Connect the spark plug wires.
5. Connect the 14-way connector to module.

187266

Crankshaft Position Sensor Replacement

Removal Procedure
1. Remove the negative battery cable.
2. Remove the serpentine belts from crankshaft
pulley.
3. Raise the vehicle on a hoist.
4. Using 28 mm socket, remove the crankshaft
harmonic balancer retaining bolt.
5. Remove the crankshaft harmonic balancer
using J 38197
6. Remove the crankshaft position sensor shield. Do
Not use a pry bar.
7. Disconnect the sensor electrical connector.
8. Remove the sensor from the block face.

187269

Installation Procedure
1. Position the Crankshaft Position Sensor onto the
engine block face.
2. Install the bolts to hold the sensor to the engine
block face.
3. Tighten
Tighten bolts to 20-40 N-m (14-28 lb ft).

Notice: Refer to Fastener Notice in Cautions and

Notices.
4. Position and install the Crankshaft Position
Sensor Shield.
5. Connect the electrical connector.
6. Position the Balancer onto the Crankshaft.
7. Apply thread sealer GM-1052080 or equivalent to
threads of Crankshaft Balancer bolt.

Tighten
Tighten bolt to 150 N-m +76 (110 lb ft +76).
187288

6-1214

Engine Controls - 3.SL

Engine
8. Lower the vehicle from the hoist.
9. Install the Serpentine accessory drive belt.
10. Connect the negative battery cable.

Camshaft Position Sensor Replacement

Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect .the electrical connector from camshaft
position sensor.
3. Remove the camshaft position sensor
retaining screw.
4. Remove the camshaft position sensor.

187294

Installation Procedure
1. Position the camshaft position sensor.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Hand start the camshaft position sensor
retaining bolt.

Tighten
Tighten the retaining bolt to 5 N,m (44 lb in).
3. Connect the electrical connector.
4. Connect the negative battery cable.

187294

Engine

Engine Controls - 3.8L

6-1215

Knock Sensor Replacement

Removal Procedure
)

1. Disconnect the negative battery cable.

2. Raise the vehicle.
3. Drain the cooling system. Refer to Cooling and
Radiator.
4. Disconnect the wiring harness connector from the
Bank1 Knock Sensor.

187243

5. Disconnect the wiring harness connector from the

Bank2 Knock Sensor.

187239

6. Remove the Knock Sensor from engine block.

21707

6-1216

Engine

Engine Controls - 3.SL

Installation Procedure

Important: Do Not apply thread sealant to sensor

threads. Sensor is coated at the factory and applying
additional sealant will affect the sensor's ability to
detect detonation.
1. Hand start the Knock Sensor into the
engine block.
Tighten
Tighten the Knock Sensor to 19 N-m (14 lb ft).
Notice: Refer to Fastener Notice in Cautions and
Notices.

21707

2. Connect the wiring harness connector to the

Bank1 Knock Sensor.

187243

3. Connect the wiring harness connector to the

Bank2 Knock Sensor.
4. Lower the vehicle.
5. Fill the cooling system. Refer to Cooling and
Radiator.
6. Connect the negative battery cable.

187239

Engine

Engine Controls .. 3.8L

6-1217

EGR Valve Replacement

Removal Procedure
1. Disconnect the electrical connector at the
EGR valve.
2. Remove the 2 base to flange nuts.
3. Remove the linear EGR valve assembly.

187211

Installation Procedure
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Position the Linear EGR valve assembly and
hand start the two nuts holding the EGR Valve
to the adapter.
Tighten
Tighten the nuts to 29 N-m (21 lb ft).
2. Connect the electrical connector.

187211'

6-1218

Engine

Engine Controls - 3.8L

Clutch Anticipate Switch Replacement

Removal Procedure
The Clutch Anticipate Switch is located on the
Brake/Clutch Pedal Bracket.
1. Remove the left side hush panel.
2. Disconnect the electrical connectors.
3. Grasp and pull the Clutch Anticipate Switch
straight out of the retainer.

'

.
21679

Installation Procedure
1. Position the Clutch Anticipate Switch into the
Brake/Clutch Pedal Bracket.
Hold the clutch pedal depressed while installing
the switch.
The switch should bottom in the retainer. Note
that audible clicks can be heard as the switch
is pressed into the retainer.
2. Slowly pull the clutch pedal rearward against the
pedal stop.
3. Release the clutch pedal and pull back on it again
to ensure proper switch adjustment.
4. Connect the electrical connector.
5. Install the left side hush panel.

'

.
21679

Engine

Engine. Controls - 3.8L

6-1219

Crankcase Ventilation System Inspection

Removal Procedure
1. While holding down the PCV Valve cover, remove
the two (2) cover retaining bolts.
2. Remove the PCV Valve cover.
3. Remove the PCV Valve, spring, and 0-ring.

21764

Installation Procedure
1. Install the PCV Valve, spring, and 0-ring.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Position the PCV Valve cover (use a new gasket
if necessary) and hand start the two (2) cover
retaining bolts.
Tighten
Tighten the 2 cover retaining bolts to
12 N-m (106 lb-in.).

21764

Air Cleaner Element Replacement

Removal Procedure (Air Cleaner Element)
Notice: If the Mass Air Flow (MAF) sensor is installed
backwards, the system will go rich. An arrow cast
into the plastic portion of the sensor indicates proper
air flow direction. The arrow must point toward the
engine.
1. Release the fasteners located at the front of the
air cleaner duct assembly.
2. Remove the air cleaner element from the air
cleaner duct assembly.

229388

6-1220

Engine Controls - 3.SL

Engine
Installation Procedure (Air Cleaner Element)
Notice: Verify that the radiator air deflector is in
position before installing an air cleaner assembly.
Improper installation may allow water intrusion which
could damage the engine.
1. Install a new air cleaner element into the air
cleaner assembly.
2. Position and lock the fasteners located at the front
of the air cleaner duct assembly.

229388

Air Cleaner Intake Duct Replacement

Removal Procedure (Air Cleaner Intake Duct)
Notice: If the Mass Air Flow (MAF) sensor is
installed backwards, the system will go rich. An arrow
cast into the plastic portion of the sensor indicates
proper air flow direction. The arrow must point toward
the engine.
1. Release the fasteners located at the front of the
air cleaner duct/resonator assembly.
2. Release the button fasteners located at the rear
of the air cleaner duct assembly.
3. Loosen the hose clamp from the air intake duct at
the air cleaner duct assembly ..
4. Loosen the hose clamp from the air intake duct at
the throttle body assembly
5. Remove the air intake duct from the air cleaner
duct/resonator assembly.
229388

Installation Procedure
(Air Cleaner Intake Duct)
Notice: Verify that the radiator air deflector is in
position before installing an air cleaner assembly.
Improper installation may allow water intrusion which
could damage the engine.
1. Position the air intake duct at the front of the air
cleaner assembly.
2. Position the air intake duct onto the front of the
throttle body unit.
3. Securely fasten the hose clamp at the air cleaner
assembly.
4. Securely fasten the hose clamp at the throttle
body assembly
5. Position the air cleaner assembly onto the radiator
support.
6. Install the button fasteners located at the rear of
the air cleaner assembly.
229388

(
\

Engine

Engine Controls - 3.8L

6-1221

Description and Operation

Powertrain Control Module Description

18X Reference PCM Input

From the ignition control module, the PCM uses this
signal to calculate engine RPM and crankshaft position
at engine speeds below 1200 RPM. The PCM also
uses the pulses on this circuit to initiate injector pulses.
If the PCM receives no pulses on this circuit,
OTC P0336 will set and the PCM will use the
3X reference signal circuit at all times for fuel and
ignition control. The engine will continue to start and
run using the 3X reference signal only.
Refer to Electronic Ignition System for further
information.

A/C Refrigerant Pressure Sensor

187237

The Powertrain Control Module (PCM) is the control

center of the vehicle. It controls the following items:
Fuel metering system.
Transaxle/transmission shifting.
Ignition timing.
On-board diagnostics for powertrain functions.
It constantly looks at the information from various
sensors, and controls the systems that affect vehicle
performance. The PCM also performs the diagnostic
function of the system. It can recognize operational
problems, alert the driver through the MIL, and store
diagnostic trouble codes which identify the problem
areas to aid the technician in making repairs.
The type of PCM used is a PCM 32U. The knock
sensor system is no longer a separate component. The
PCM contains integrated knock sensor (KS) diagnostic
circuitry. For further information, refer to Knock
Sensor System Description.

Information Sensors/Switches Description

3X Reference PCM Input

From the ignition control module, the PCM uses this

signal to calculate engine RPM and crankshaft position
at engine speeds above 1200 RPM. The PCM also
uses the pulses on this circuit to initiate injector pulses.
If the PCM receives no pulses on this circuit,
OTC P1374 will set and the PCM will use the
18X reference signal circuit for fuel and ignition control.
The engine will continue to start and run using the
18X reference signal only.
'

Refer to Electronic Ignition System for further

information.

The A/C refrigerant pressure sensor signal indicates

high side refrigerant pressure to the PCM. The
PCM uses this information to adjust the idle air control
valve to compensate .for the higher engine loads
present with high A/C refrigerant pressures and to
control the cooling fans. A fault in the A/C refrigerant
pressure sensor signal will cause OTC P0530 to
set. Refer to Heater, Ventilation, and Air Conditioning
for a complete description and on-vehicle service.

A/C Request PCM Input

The A/C request signal indicates to the PCM that an
A/C mode is selected at the A/C control head.
The PCM uses this information to adjust the idle
speed before turning ON the A/C clutch. If this signal
is not available to the PCM, the A/C compressor
will be inoperative.

Crankshaft Position (CKP) Sensor

The crankshaft position sensor provides a signal used
by the ignition control module to calculate ignition
sequence. The ignition control module also uses the
crankshaft position sensor signals to initiate 18X and
3X reference pulses which the PCM uses as
reference to calculate RPM and crankshaft position.

Camshaft Position (CMP) Sensor and

CAM Signal
The camshaft position sensor sends a cam signal to
the PCM which uses it as a sync pulse to trigger
the injectors in proper sequence. The ('.;AM signal is
passed through the ignition control module. It is filtered
and buffered by the ignition control module, but the
signal is not processed in any other way. The
PCM uses the CAM signal to indicate the position of
the #1 piston during its power stroke. This allows
the PCM to calculate true Sequential Fuel Injection
(SFI) mode of operation. If the PCM detects an
incorrect CAM signal while the engine is running,
OTC P0341 will set.
If the CAM signal is lost while the engine is running,
the fuel injection system will shift to a calculated
sequential fuel injection mode based on the last fuel
injection pulse, and the engine will continue to run. The
engine can be restarted and will run in the calculated
sequential mode as long as the fault is present
with a 1 in 6 chance of injector sequence being correct.
Refer to OTC P0341 for further information.

6-1222

Engine

Engine Controls - 3.8L

Clutch Anticipate Switch (Manual Transaxle)

The Clutch Anticipate Switch input allow the PCM
to adjust the IAC when the manual transmission clutch
is being disengaged. The PCM monitors the Clutch
Anticipate Switch input; if a low voltage is monitored,
the PCM considers the Clutch Anticipate Switch
closed to ground (clutch pedal released). When the
ground at the Clutch Anticipate Switch input is
interrupted (clutch pedal applied), the PCM will
immediately decrease IAC counts. This is done to
avoid a possible RPM flare caused by the sudden
change in engine load.

Electronic Brake Control Module (EBCM) PCM Serial Data (CKT 800)
The PCM uses the UART serial data line (CKT 800) to
communicate with various other components and
systems within the vehicle. The PCM receives rough
road information from the EBCM on the serial data
circuit. The PCM uses the rough road information to
enhance the misfire diagnostic by detecting crankshaft
speed variations caused by driving on rough road
surfaces. This allows false misfire information to be
rejected. The EBTCM I EBCM calculates rough
road information by monitoring the ABS wheel speed
sensors. If a malfunction occurs occurs which does
not allow the EBTCM I EBCM to transmit correct rough
road information to the PCM while a misfire DTC is
requesting the MIL, DTC P1380 will set. If a loss
of communications occurs which causes the PCM to
not receive rough road information while a misfire DTC
is requesting the MIL, DTC P1381 will set.
Refer to ABS/TCS in Antilock Brake System for
information regarding ABS operation.

Engine Coolant Temperature (ECT) Sensor

--42212

The engine coolant temperature sensor is a thermistor

(a resistor which changes value based on temperature)
mounted in t~e engine coolant stream. Low coolant
temperature produces a high resistance
(100,000 ohms at -40C/-40F) while high temperature
causes low resistance (70 ohms at 130C/266F).
The PCM supplies a 5 volt signal to the engine coolant
temperature sensor through a resistor in the PCM
and measures the voltage. The voltage will be
high When the engine is cold, and lowwhen the engine
is hot. By measuring the voltage, the PCM calculates
the engine coolant temperature., The scan tool
displays engine coolant temperature in degrees. After
engine startup, the temperature should rise steadily
to about 90C (194F) then stabilize when thermostat
opens. lfthe engine. has not been run for several
hours (overnight), the engine. coolant temperature and
intake air temperature displays should be close to
each other;
Engine coolant temperature affects most systems the
PCM controls. A hard fault in the engine coolant
sensor circuit should set DTC P0117 or DTC P0118;
an intermittent fault should set a DTC P1114 or P1115.
This section also contains a specification table to
check for sensor resistance values relative to
temperature.

EGR Pintle Position Sensor

The PCM monitors the EGR valve pintle position input
to ensure that the valve responds properly to
commands from the PCM and to detect a fault if the
pintle position sensor and control circuits are open
or shorted. If the PCM detects a pintle position signal
voltage outside the normal range of the pintle
position sensor, or a signal voltage that is not within a
tolerance considered acceptable for proper EGR
system operation, the PCM will set DTC P1406: Refer
to EGR System Description for a complete description
of the EGR system.

Engine

Engine Controls - 3.8L

Heated Oxygen Sensors

14490

The fuel control Heated Oxygen Sensors (Bank 1

H02S 1 and Bank 2 H02S 1) are mounted in
the exhaust manifolds where they can monitor the
oxygen content of the exhaust gas stream. The oxygen
present in the exhaust gas reacts with the sensor to
produce a voltage output. This voltage should
constantly fluctuate from approximately 1OOmV (high
oxygen content - lean mixture) to 900mV (low
oxygen content - rich mixture). The heated oxygen
sensor voltage can be monitored with a scan tool. By
monitoring the voltage output of the oxygen sensor,
the PCM can calculate what fuel mixture command to
send the injectors (lean mixture-low H02S
voltage = rich command, rich mixture-high H02S
voltage= lean command).
An open Bank 1 H02S 1 circuit should set a
DTC P0134; an open in Bank 2 H02S 1 circuit should
set a DTC P0154. With an open H02S signal, the
scan tool will display a constant voltage between
400 500mV. A constant voltage below 300mV in the
Bank 1 H02S 1 sensor circuit (circuit grounded)
should set DTC P0131. A constant voltage below
300mV in the Bank 2 H02S 1 sensor circuit (circuit
grounded) should set DTC P0151. A constant
voltage above 800mV in the Bank 1 H02S 1 circuit
hould set DTC P0132, while a constant voltage above
800mV in the Bank 2 H02S 1 circuit should set
DTC P0152. A fault in the Bank 1 H02S 1 heater
circuit should cause DTC P0135 to set. A fault in the
Bank 2 H02S 1 heater circuit should cause
DTC P0155 to set.The PCM can also detect H02S
response problems. If the response time of an H02S is
determined to be too slow, the PCM will store a
DTC that indicates degraded H02S performance.
To control emissions of Hydrocarbons (HC), Carbon
Monoxide (CO), and Oxides of Nitrogen (NOx), a
three-way catalytic converter is used. The catalyst
within the converter promotes a chemical reaction
which oxidizes the HC and CO present in the exhaust
gas, converting them into harmless water vapor
and carbon dioxide. The catalyst also reduces NOx,

6-1223

converting it to nitrogen. The PCM has the ability to

monitor this process using the Bank 1 H02S 2 and the
Bank 1 H02S 3 heated oxygen sensors.
The Bank 1 H02S 2 sensor produces an output signal
which indicates the amount of oxygen present in the
exhaust gas entering the three-way catalytic converter.
The Bank 1 H02S 3 sensor produces an output
signal which indicates the oxygen storage capacity of
the catalyst; this in turn indicates the catalyst's
ability to convert exhaust gases efficiently. If the
catalyst is operating efficiently, the Bank 1 H02S 2
signal will be far more active than that produced by the
Bank 1 H02S 3 sensor.
Although the Bank 1 H02S 3 sensors' main function is
catalyst monitoring, they also plays a limited role in
fuel control. If the sensor output indicates a voltage
either above or below the 450 millivolt bias voltage for
an extended period of time, the PCM will make a
slight adjustment to fuel trim to ensure that fuel
delivery is correct for catalyst monitoring.
A problem with the Bank 1 H02S 2 signal circuit
should set DTC P0137, P0138 or P0140, depending
on the specific condition. A problem with the
Bank 1 H02S 3 signal circuit should set DTC P0143,
P0144, or P0146. A fault in the heated oxygen
sensor heater element or its ignition feed or ground
will result in slower oxygen sensor response. This may
cause erroneous catalyst monitor diagnostic results.
A fault in the Bank 1 H02S 2 heater circuit should
cause DTC P0141 to set. A fault in the Bank 1 H02S
2 heater circuit should cause DTC P0147 to set.

Intake Air Temperature Sensor

21677

The Intake Air Temperature (IAT) sensor is a

thermistor which changes value based on the
temperature of air entering the engine. Low
temperature produces a high resistance
(100,000 ohms at -40C/-40F), while high temperature
causes low resistance (70 ohms at 130C/266F).

6-1224

Engine Controls - 3.8L

The PCM supplies a 5 volt signal to the sensor

through a resistor in the PCM and measures the
voltage. The voltage will be high when the incoming
air is cold, and low when the air is hot. By measuring
the voltage, the PCM calculates the incoming air
temperature.

Engine
Mass Air Flow Sensor

The IAT sensor signal is used to adjust spark timing

according to incoming air density. The scan tool
displays temperature of the air entering the engine,
which should read close to ambient air temperature
when engine is cold, and rise as underhood
temperature increases. If the engine has not been run
for several hours (overnight) the IAT sensor
temperature and engine coolant temperature should
read close to each other. A failure in the IAT
sensor circuit should set OTC P0112 or OTC P0113.

Reference Low
This is a ground circuit for the digital RPM counter
inside the PCM, but the wire is connected to engine
ground only through the ignition control module.
Although this circuit is electrically connected to the
PCM, it is not connected to ground at the PCM. The
PCM compares voltage pulses on the 18X and
3X reference input circuits to any on this circuit,
ignoring pulses that appear on both. If the circuit is
open, or connected to ground at the PCM, it may
cause poor engine performance and possibly a MIL
with no OTC set.

Knock Sensors
The knock sensors detect abnormal vibration (spark
knocking) in the engine. The sensors are mounted
in the engine block near the cylinders. The knock
sensors produce an AC voltage signal under all engine
operating conditions. The PCM adjusts the Ignition
Control (IC) spark timing based on the amplitude and
frequency of. the KS signal being received.
The PCM contains integrated Knock Sensor (KS)
diagnostic circuitry. The PCM uses the circuitry
to diagnose the KS sensors and related wiring. The
PCM calculates an average voltage of each knock
sensor's signals and takes instantaneous signal
voltage readings. The PCM uses the instantaneous
signal voltage readings to determine the state of
the knock sensor circuitry. If the knock sensor system
is operating normally, the PCM should monitor
instantaneous KS signal voltage readings varying
outside a voltage range above and below the
calculated average voltage. If the PCM malfunctions in
a manner which will not allow proper diagnosis of
the KS circuit OTC P0325 will set. OTCs P0327 and
P0332 are designed to diagnose the knock sensors,
and related wiring, so problems encountered with
the KS system should set a OTC.
For further information, refer to Knock Sensor System
Description.

15006

The Mass Air Flow (MAF) sensor measures the

amount of air which passes through the throttle body.
The PCM uses this information to determine the
operating condition of the engine, to control fuel
delivery. A large quantity of air indicates acceleration,
while a small quantity indicates deceleration or idle.
The scan tool displays the MAF value in grams
per second (gm/s). At idle, MAF should read
between 4 gm/s -7 gm/s on f;l. fully warmed up engine.
Values should change rather quickly on acceleration,
but values should remain fairly stable at any given
RPM. A MAF sensor rnalfuction or MAF signal circuit
problem should set OTC P0101, OTC P0102, or
OTC P0103.

Engine

Engine Controls - 3.8L

Manifold Absolute Pressure Sensor

6-1225

Transmission Temperature Sensor

The transmission fluid temperature sensor is a
thermistor which changes value based on the
temperature of the transmission fluid. A high
transmission fluid temperature may cause the vehicle
to operate in Hot Mode. While in Hot Mode, shift
points may be altered, 4th gear disabled, and TCC
forced ON in 2nd gear.
A failure in the TFT sensor or associated wiring
should cause OTC P0712 or P0713 to set. In this case,
engine coolant temperature will be substituted for
the TFT sensor value, and the transmission will
operate normally. Refer to 4L60-E Automatic
Transmission for a complete description and on-vehicle
service.

Throttle Position Sensor

21663

The Manifold Absolute Pressure (MAP) sensor

responds to changes in intake manifold pressure
(vacuum). The MAP sensor signal voltage to the PCM
varies from below 2 volts at idle (high vacuum) to
above 4 volts with the key ON, engine not running or
at wide-open throttle (low vacuum). The MAP
sensor is used to determine manifold pressure
changes while the linear EGR flow test diagnostic is
being run (refer to OTC P0401 ), to determine
engine vacuum level for other diagnostics and to
determine barometric pressure (BARO).
If the PCM detects a voltage that is lower than the
possible range of the MAP sensor, OTC P0107 will be
set. A signal voltage higher than the possible range
of the sensor will set OTC P0108. An intermittent
low or high voltage will set OTC P1107 or P1106
respectively. The PCM can also detect a shifted MAP
sensor. The PCM compares the MAP sensor signal
to a calculated MAP base.d on throttle position
and various engine load factors If the PCM detects a
MAP signal that varies excessively above or below
the calculated value, OTC P0106 will set.

TCC Brake Switch

The TCC brake switch signal indicate.s when the brake
pedal is applied. The TCC brake switch information
is used by the PCM mainly to control the transmission
torque converter clutch. Refer to 4L60-E Automatic
Transmission for a complete description, diagnosis,
and on-vehicle service.

14476

The Throttle Position {TP) sensor is a potentiometer

connected to the throttle shaft on the throttle body. By
monitoring the voltage on the signal line, the PCM
calculates throttle position. As the throttle valve angle
is changed (accelerator pedal moved), the TP
sensor signal also changes. At a closed throttle
position, the output of the TP sensor is low. As the
throttle valve opens the TP sensor voltage increases
so that at Wide Open Throttle (WOT}, the TP
sensor voltage should be above 4 volts. The PCM
calculates fuel delivery based on throttle valve angle
(driver demand}.
A broken or loose TP sensor may cause intermittent
bursts of fuel from an injector and unstable idle
because the PCM thinks the throttle is moving. A hard
failure in the TP sensor 5 volts reference or signal
circuits should set either a OTC P0122 or OTC P0123.
A hard failure with the TP sensor ground circuit
may set OTCs PO 123 and PO 117. Once a OTC is set,
the PCM will use an artificial default value based
on engine RPM and mass air flow for throttle position
and some vehicle performance will return. A high
idle may result when either OTC P0122 or OTC P0123
is set.

6-1226

Engine Controls - 3.8L

The PCM can detect intermittent TP sensor faults.

DTC P1121 or DTC P1122 will set if an intermittent
high or low circuit failure is being detected. The PCM
can also detect a shifted TP sensor. The PCM
monitors throttle position and compares the actual TP
sensor reading to a predicted TP value calculated
from engine speed. If the PCM detects an out of range
condition, DTC P0121 will be set.

PCM Controlled Warning Lamps

Description
MIL Operation
The Malfunction Indicator Lamp (MIL) is located on
the instrument panel (CHECK ENGINE) or (SERVICE
ENGINE SOON). The MIL performs the following
functions:
It informs the driver that a problem has occurred
and that the vehicle should be taken for service
as soon as possible.
As a bulb check and system check, the MIL will
illuminate with the ignition switch ON and the
engine not running. when the engine is started, the
MIL will turn OFF. If the MIL remains ON, the
self-diagnostic system has detected a problem. If
the problem goes away, the MIL will turn OFF
in most cases, but a diagnostic trouble code will
remain stored.
If the MIL is illuminated, then the engine stalls, the
MIL will remain Illuminated so long as the ignition
switch is ON.
Now, if the MIL is not illuminated and the engine
stalls, the MIL will not illuminate until the ignition
switch is cycled OFF, then ON.
Perform the Powertrain On-Board Diagnostic System
Check first, when the following conditions are
present:
When the MIL does not turn ON when the the
ignition switch is turned to the RUN position
When the MIL remains ON while the engine is
running
When you suspect a driveability problem

Low Oil Level Lamp

The PCM commands the Low Oil Level Lamp ON if
the engine oil level sensor indicates that a low oil level
condition exists. The PCM determines whether or
not to test for low oil level based on the difference
between engine coolant temperature at the last
shutdown and engine coolant temperature at startup.
This is to ensure that the oil has drained back into
the oil pan before testing.
The engine oil level switch is a simple float switch that
is grounded when the engine oil level is OK. When
the ignition is first turned ON, the PCM commands the
Low Oil Level lamp ON for a brief period of time to
test the bulb (approximately 3 seconds). The PCM also
checks the engine oil level switch circuit at startup.

Engine
If the engine has been running, the PCM performs a
test routine based on engine coolant temperature
to ensure that the engine oil drained back into
the sump before checking the state of the engine oil
level switch. If the engine coolant temperature is
between 15C (59F) and 130C (266F), the PCM
compares the engine coolant temperature at the
last key OFF to the engine coolant temperature at the
current key ON. If the difference.between the
recorded temperature values is at least 12C (54F),
the PCM will test the engine oil level.

Generator Lamp
The PCM commands the generator lamp ON under
the following conditions:
When the engine speed is greater than 1200 rpm
and system voltage falls below 10 volts for
longer than 10 seconds. The PCM commands the
generator lamp OFF when system voltage
rises to above 12 volts.
When the generator control circuit (L terminal)
remains low for longer than 1O seconds.

Second Gear Lamp (4L60E Transaxle Only)

The PCM supplies 12 volts to the second gear
start switch through a pull-up resistor. The second
gear start switch is a normally open switch. The PCM
senses a high input voltage, commands normal
transaxle shifting, and the second gear start lamp is
not illuminated. When the second gear start switch
is closed, the input voltage to the PCM is pulled low.
The PCM turns the second gear lamp ON and
commands the to vehicle begin in second gear (the
following gears shift in normal sequence).

PCM Controlled Air Conditioning

Description
Operation
The air conditioning system uses a compressor with
variable displacement. This compressor is referred
to as the V-5 type compressor. The V-5 compressor
meets A/C requirements without cycling. The A/C
compressor operation is controlled by the Powertrain
Control Module (PCM) for the following reasons:
Improved idle quality during compressor
clutch engagement.
Improved wide open throttle performance (WOT).
Protects the A/C compressor from operation
with incorrect refrigerant pressures.
The A/C clutch electrical system consists of the
following components:
The A/C control head and/or the A/C programmer.
The A/C refrigerant pressure sensor.
The A/C compressor clutch.
The A/C compressor clutch relay.
The PCM.

Engine
When an A/C mode is selected at the A/C control
head, the A/C programmer provides a 12 volt signal to
the A!C request circuit. The PCM monitors the A/C
request circuit and controls the A/C compressor relay
based on the A/C request signal. This allows the
PCM to increase the engine idle speed just prior to
A/C clutch engagement for better idle quality. In
addition, the PCM will command the cooling fans ON
during A/C operation. The PCM also monitors the
A/C refrigerant pressure sensor circuit. If the A!C
refrigerant pressure is too high or low, the PCM will
disable the A/C compressor .relay.
The PCM will enable the A/C compressor clutch
whenever the engine is running and the A/C has been
requested unless one or more of the following
conditions are present:
Throttle angle is greater than 90%.
A/C head pressure is greater than 414 psi
(4.27 volts) or less than 34 psi (0.35 volt)
as determined by the A/C refrigerant pressure
sensor.
Ignition voltage is less than 10.5 volts.
Engine speed is greater than 5400 RPM for any
amount of time.
Engine speed is greater than 4500 RPM for longer
than 5 seconds.
ECT is greater than 125C (257F).
IAT is less than sC (41F).,
Any of the conditions described above will inhibit A/C
compressor relay operation.

Diagnosis
DTC P0530, P0560, P1639, or P1641 can affect A/C
operation. Refer to the DTC tables if any DTCs
are set.
The A/C Clutch Control Circuit Diagnosis table should
be used for diagnosing the electrical portion of the
A/C compressor clutch circuit if a DTC is not set. To
diagnose the refrigerant portion of the HVAC
system, refer to the Heater, Ventilation, and Air
Conditioning (HVAC) section. A scan tool will be used
in diagnosing the system. The scan tool has the
ability to display the A/C request and refrigerant
pressure inputs to the PCM. The scan tool can display
when the PCM has commanded the A/C clutch ON.
The scan tool also has the ability to override the
A/C request signal and energize the A/C control relay.

Engine Cooling Fan Description Electric

EngineControls - 3.8L

6-1227

coils. The cooling fan relays are energized when

current flows through the relay coils to ground at the
PCM. The cooling fan relay #1 control circuit is
used for low speed cooling fan operation. The cooling
fan relay #1 control circuit and the cooling fan
relay #2 and #3 control circuit are both grounded for
high speed fan operation. The cooling fan relay control
circuits are monitored by the PCM. Before using the
Electric Cooling Fans diagnostic tables be sure to
perform the Powertrain On-Board Diagnostic System
Check. If diagnostic trouble codes P1651 or P1652
are present, use the appropriate DTC diagnostic tables
prior to performing Electric Cooling Fans diagnostics.
Important: When certain Diagnostic Trouble Codes
(DTCs) are present, the PCM may command the
cooling fans to run all the time. It is important
to perform the Powertrain On-Board Diagnostic System
check prior to diagnosing the engine cooling fans.
The PCM will complete the ground path for cooling fan
relay #1 under any of the following conditions:
When engine coolant temperature exceeds
105C (221 F).
When A/C is requested and ambient temperature
is greater than 10c (50F).
When A/C refrigerant pressure is greater
than 190 psi (2 volts).
For high speed cooling fans operation, the PCM will
delay control of the cooling fan #2 and #3 relays for
6 seconds. The 6 second delay ensures that the
cooling fan electrical load will not exceed the capacity
of the system. The PCM will complete the ground
paths for cooling fan relays #1 , #2, and #3 under any
of the following conditions:
When engine coolant temperature
exceeds 113C (235F).
When A/C refrigerant pressure is greater
than 275 psi (2.9 volts).

Diagnosis
If a problem that involves the low speed cooling fan
relay control circuit (cooling fan relay #1 control) exists,
Dl"C P1651. should set. If the problem affects the
high speed cooling fan relay control circuit (cooling fan
relay #2 and #3 control), DTC P1652 should"set. A
problem with the ECT sensor should set DTC P0117,
P0118, P1114, or P1115. Any of these DTCs will
affect cooling fan operation and should be diagnosed
before using the Electric Cooling Fan Diagnosis
table. The Electric Cooling Fan Diagnosis table should
be used to diagnose the PCM controlled cooling
fans only if no DTC is set.

Operation

The Powertrain Control Module (PCM) controls the

operation of the cooling fans. This is accomplished by
providing a ground path for the cooling fan relay
coils within the PCM. The relay contacts will close and
complete the circuit between the fusible link at the
battery junction block and the fan motors. Whenever
there is a fan ON request both fans will be running.
Power.for the fan motors is supplied through a fusible
link at the battery junction block. Battery positive
voltage is applied to the cooling fan relay contacts and

Fuel Supply Component Description

The fuel tank stores the fuel supply. An electric fuel
pump, located in the fuel tank with the fuel level sensor
assembly, pumps fuel through an in-line fuel filter to
the fuel rail assembly. The pump provides fuel at
a pressure greater than is needed by the injectors. The
fuel pressure regulator, part of the fuel rail assembly,
keeps fuel available to the injectors at a regulated
pressure. A separate pipe returns unused fuel to the
fuel tank.

6-1228

Engine Controls - 3.SL

Engine

Fuel Tank Vent Valve

Fuel Sender Assembly

The fuel tank vent valve is located in the rear of the

vehicle near the fuel tank. The fuel tank vent valve is a
pressure/vacuum relief valve. When the fuel tank
pressure exceeds a specified pressure, the valve
opens allowing the tank pressure to bleed off. When
the fuel tank is in a vacuum condition, the vent
valve opens when the vacuum is within a specified
range allowing fresh air to be pulled in.

Fuel Tank

The fuel tank stores the fuel supply. The fuel tank is
located in the rear of the vehicle. The fuel tank is held
in place by two metal straps that attach to the frame.
The fuel tank is made of steel and is coated internally
with a special corrosion inhibitor.

Fuel Tank Filler Pipe

4

The fuel tank filler pipe has a built-in restrictor and

deflector in order to prevent refueling with leaded fuel.
21295

Fuel Filler Cap

The fuel sender assembly (5) is inside the fuel tank

and attaches to the top of the fuel tank. The fuel
sender assembly consists of the following major
components:
The fuel sender (3).
The fuel pump and reservoir assembly (8).
The fuel pump strainer (4).

Fuel Sender

5
173450

Notice: If a fuel tank filler cap requires replacement,

use only a fuel tank filler cap with the same features.
Failure to use the correct fuel tank filler cap can
result in a serious malfunction of the fuel and EV AP
system.
The fuel tank filler neck is equipped with a tethered
fuel filler cap. The cap requires a quarter of a
turn to remove it. A built in torque-limiting device
prevents over tightening. In order to install the cap,
turn the cap clockwise until you hear three audible
clicks. This signals that the correct torque has been
reached and the cap is fully seated. A fuel filler
cap that is not fully seated may cause a malfunction in
the emission system.

21295

The fuel sender consists of a float (6), a wire float

arm (7), a sensor (2), and a roll-over valve (1 ).
The position of the float arm indicates the fuel level
and a signal is sent to the display in the vehicle
instrument cluster. The EVAP pipe of the fuel sender
has a pressed in roll-over valve. The roll-over
valve prevents fuel from entering the evaporative
emission canister if the vehicle rolls over by shutting
OFF the EVAP pipe to the canister.

Engine Controls - 3.8L

Engine
Fuel Pump

6-1229

Fuel Tank Vapor Pressure Sensor

12607

The fuel pump is mounted inside the fuel reservoir in

the fuel tank. The fuel pump is an electric high
pressure roller vane pump. The fuel pump pumps fuel
to the fuel rail assembly at a specified flow and
pressure. Excess fuel returns to the fuel tank by the
return pipe. The fuel pump delivers a constant flow of
fuel to the engine even during low fuel conditions
and aggressive vehicle maneuvers. The PCM controls
the electric fuel pump operation through a fuel
pump relay. Three hoses are permanently attached to
the fuel pump and reservolr assembly (4). The fuel
pump flex pipe (2) has a quick-connect fitting. The fuel
return hose (3) has a square end. The fuel vapor
hose (1) is cut on an angle. The fuel pump flex pipe
acts to dampen the fuel pulses and noise generated by
the fuel pump.

Fuel Pump Strainer

The fuel pump strainer attaches to the lower end of
the fuel pump and reservoir assembly. The fuel pump
strainer is made of woven plastic. The functions of
the fuel pump strainer are to filter contaminants and to
wick fuel. The fuel pump strainer is self-cleaning
and normally requires no maintenance. Fuel stoppage
at this point indicates that the fuel tank contains an
abnormal amount of sediment or water. Clean the fuel
tank and replace a plugged fuel pump strainer with
a new one.

The fuel tank pressure sensor is used to detect small

leaks in the evaporative emission system. The fuel
tank pressure sensor is a three wire strain gauge
sensor much like that of the common GM MAP sensor.
However, this sensor has very different electrical
characteristics due to its pressure differential design.
The sensor measures the difference between the
air pressure {or vacuum) in the fuel tank and
the outside air pressure. The sensor mounts at the top
of the fuel tank. A three wire electrical harness
connects it to the Powertrain Control Module (PCM).
The PCM supplies a five volt reference voltage
and ground to the sensor. The sensor will return a
voltage between 0.1 and 4.9 volts. When the air
pressure in the fuel tank is equal to the outside air
pressure, such as when the fuel fill cap is removed, the
output voltage of the sensor will be 1.3 to 1.7 volts.
Refer to Information Sensors/Switches Description for
further information and diagnosis of the enhanced
EVAP system.

6-1230

Engine Controls - 3.8L

Engine

Enhanced Evaporative Emission (EVAP)

Service Port

threaded outlet fitting. The threaded fitting is sealed

with an 0-ring. There is no service interval for fuel filter
replacement. Replace a restricted fuel filter.

Fuel Feed and Return Pipes

The fuel feed pipe carries fuel from the fuel tank to the
fuel rail assembly. The fuel return pipe carries fuel
from the fuel rail assembly back to the fuel tank. The
fuel feed and return pipes consist of three sections:
The rear fuel pipe assemblies are located from
the top of the fuel tank to the chassis fuel
pipes. The rear fuel pipes are constructed
of nylon.
The chassis fuel pipes are located under the
vehicle and connect the rear fuel pipes to
the engine compartment connecting fuel pipes.
These pipes are constructed of steel.
The engine compartment connecting fuel pipes
connect the chassis pipes to the engine fuel
rail. These fuel pipes are constructed of nylon.

Nylon Fuel Pipes

21046

The enhanced EV AP service port is located in the

evaporative purge hose in the engine compartment
near the purge solenoid. The service port is identified
by a green colored cap. The port contains a
schrader valve and fittings to allow the connection of
the J 41413 EVAP Pressure/Purge Diagnostic
Station. Refer to EVAP control system diagnosis for
further information and diagnosis of the Enhanced
EVAP system.

In-Line Fuel Filter

:~~Jffml~C~~~~~~
, _____________________
:~.~~~~~--

12628

The fuel feed pipe has a steel fuel filter installed

ahead of the fuel injection system. The paper filter
element (2) traps particles in the fuel that may damage
the injection system. The filter housing (1) is made
to withstand maximum fuel system pressure, exposure
to fuel additives, and changes in temperature. The
fuel filter has a quick-connect inlet fitting and a

Caution: In order to Reduce the Risk of Fire and

Personal Injury:

If nylon fuel pipes are nicked, scratched or

damaged during'ihsta/lation, Do Not attempt to
repair the sections of the nylon fuel pipes.
Replace them.
When installing new f1,1el pipes, Do Not
hammer directly on the fuel harness body clips
as it may damage the nylon pipes resulting
in a possible fuel leak.

Always. cover nylon vapor pipes with a wet

towel before using a torch near them. Also,
never expose the vehicle to temperatures
higher than 115.C (239F) for more than one
hour, or more than 90C (194F} for any
extended period.
Before connecting fuel pipe fittings, always
apply a few drops of clean engine oil to
the male pipe ends. This will ensure proper
reconnection and prevent a possiJ;,le fuel leak.
(During normal operation, the 0-rings
located in the female connector will swell and
may prevent proper reconnection if not
lubricated.)
Nylon fu,el pipes are designed to perform the same job
as the steel or flexible fuel pipes or hoses that they
replace. Nylon pipes are constructed to withstand
maximum fuel system pressure, exposure to
fuel additives, and changes in temperature. There are
three sizes of nylon fuel pipes used: 3/8 in ID for
the fuel feed, 5/16 in ID for the fuel return, and 1/2 in
ID for the vent.
The fuel feed and return pipes are assembled as a
harness. Retaining clips hold the pipes together
and provide a means for attaching the pipes to the
vehicle. Heat resistant rubber hose and/or corrugated
plastic conduit protect the sections of the pipes
that are exposed to chafing, high temperature or
vibration.

Engine

\!

Nylon fuel pipes are somewhat flexible and can be

formed around gradual turns under the vehicle.
However, if nylon fuel pipes are forced into sharp
bends, the pipes will kink and restrict the fuel
flow. Also, once exposed to fuel, nylon pipes may
become stiffer and are more likely to kink if bent too
far. Take special care when working on a vehicle with
nylon fuel pipes.

Quick-Connect Fittings
Quick-connect fittings provide a simplified means of
installing and connecting fuel system components. The
fittings consist of a unique female connector and a
compatible male pipe end. 0-rings, located inside the
female connector, provide the fuel seal. Integral
locking tabs or fingers hold the fittings together.

Fuel Pipe 0-Rings

An 0-ring seals the threaded connection at the fuel
filter. Fuel system 0-ring seals are made of special
material. Service the 0-ring seals with the
correct service part.

EVAP Pipes and Hoses

The EV AP pipes extend from the fuel sender assembly
and the EVAP canister vent solenoid to the
evaporative emission canister. The EVAP purge pipe
extends from the EV AP canister to the EVAP
purge valve in the engine compartment. The rear
pipes and the engine compartment pipe are
constructed of nylon. The chassis EVAP purge pipe is
constructed of steel.

Fuel Metering Modes of Operation

Purpose
The basic function of the air/fuel metering system is to
control air/fuel delivery to the engine. The best
air/fuel mixture to minimize exhaust emissions is
14.7 to 1, which allows the catalytic converter
to operate most efficiently. Fuel is delivered to the
engine by individual fuel injectors mounted in
the intake manifold near each intake valve.
The main control sensor is the Heated Oxygen Sensor
(H02S), located in the exhaust manifold. The H02S
tells the Powertrain Control Module (PCM) how
much oxygen is in the exhaust gas and the PCM
changes the air/fuel ratio to the engine by controlling
the iuel injector on time. Because of the constant
measuring and adjusting of the air/fuel ratio, the fuel
injection system is called a Closed Loop system.

Modes of Operation
The PCM monitors voltages from several sensors to
determine the engine's fuel needs. Fuel is delivered
under one of several conditions called modes.
All modes are controlled by the PCM and are
described below.

Starting Mode
When the ignition is first turned ON the PCM energizes
the fuel pump relay for two seconds, allowing the
fuel pump to build up pressure. The PCM then checks
the Engine Coolant Temperature (ECT) sensor and

Engine Controls - 3.8L

6-1231

the Throttle Position (TP) sensor. During cranking, the

PCM checks the crankshaft position signal in order
to determine the proper air/fuel ratio for starting.
The PCM controls the amount of fuel delivered in the
starting mode by changing how long the fuel
injectors are energized. This is done by pulsing the
fuel injectors for very short times.

Run Mode
The run mode has two conditions called Open Loop
and Closed Loop.
When the engine is first started and engine speed is
above 725 RPM, the system is in Open Loop
operation. In Open Loop the PCM ignores the signal
from the Heated Oxygen Sensor (H02S), and
calculates the air/fuel ratio based on inputs from the
TP, ECT, and MAF sensors.
The system remains in Open Loop until the following
conditions are met:
The H02S has a varying voltage output showing
that it is hot enough to operate properly (this
depends on temperature).
The ECT has reached a specified temperature.
A specific amount of time has elapsed since
starting the engine.
The specific values for the above conditions vary with
different engines. When these conditions are met,
the system enters Closed Loop operation. In Closed
Loop the PCM changes fuel injector on-time based on
the signal from the H02S. This allows the air/fuel
ratio to stay very close to 14.7:1.

Acceleration Mode
The PCM provides extra fuel when it detects a rapid
increase in throttle position and air flow.

Deceleration Mode
The PCM reduces the amount of fuel injected when it
detects a decrease in throttle position and air flow.
When deceleration is very fast, the PCM may cut off
fuel completely for short periods.

Battery Voltage Correction Mode

When battery voltage is low, the PCM will compensate
for the weak spark in the following ways:
Increasing the amount of fuel delivered.
Increasing the idle RPM.
Increasing ignition dwell time.

Fuel Cut Off Mode

The PCM has the ability to shut OFF the fuel injectors
completely or selectively when certain conditions
are met. This fuel shut off mode allows the powertrain
to protect itself from damage and also improve its
driveability.

6-1232

Engine Controls - 3.SL

The PCM will disable the injectors under the following

conditions.

Engine
Fuel Rail

Ignition OFF (prevents engine run-on).

Ignition ON but no ignition reference signal

(prevents flooding or backfiring).

High engine speed (above red line).

High vehicle speed (above rated tire speed).
Extended high speed closed throttle coastdown
(reduce emissions and increases engine
braking).
Fuel RPM cut off ranges:
Important: These RPM cut off ranges may vary
according to PCM calibration, axle ratio, tire size, and
tire rating.
Park and Neutral - 4000 RPM
Reverse - 4000 RPM
Drive - 5950 RPM

Catalytic Converter Protection Mode

The PCM constantly monitors engine operation and
estimates conditions that could result in high catalytic
converter temperatures. If the PCM determines the
catalytic converter may overheat, it causes the system
to return to Open Loop operation and enriches the
fuel mixture.

Fuel Metering System Component

Description
Basic System Operation

12819

The fuel rail (1) is mounted to the top of the engine

and distributes fuel to the individual fuel
injectors (3). Fuel is delivered to the fuel inlet tube of
the fuel rail by the fuel pipes. The fuel then goes
through the fuel rail to the fuel pressure regulator (2).
The fuel pressure regulator maintains a constant
fuel pressure at the fuel injectors. Remaining fuel is
then returned to the fuel tank. Fuel pressure can
be observed using a fuel pressure gauge at the fuel
pressure gauge connection (4).

Fuel Injector

The fuel metering system starts with the fuel in the

fuel tank. An electric fuel pump, located in the fuel tank
with the gauge sending unit, pumps fuel to the fuel
rail through an in-pipe fuel filter. The fuel pump
is designed to provide fuel at a pressure above the
pressure needed by the fuel injectors. A fuel pressure
regulator in the fuel rail keeps fuel available to the
fuel injectors at a constant pressure. Unused fuel is
returned to the fuel tank by a separate pipe. For further
information on the fuel tank, in-pipe filter, and fuel
pipes, refer to Fuel Supply Component Description.

Accelerator Controls
The accelerator control system is cable-type. There
are no linkage adjustments. Therefore, the specific
accelerator control cable must be used.

Throttle Body Unit

The throttle body has a throttle plate to control the
amount of air delivered to the engine. The TP sensor,
and MAF sensor are also mounted on the
throttle body.
Vacuum ports located behind the throttle plate provide
the vacuum signals needed by various components.
Engine coolant is directed through a coolant cavity
in the throttle body to warm the throttle valve
and prevent icing.

2
13651

The Sequential Multiport Fuel Injection (SFI) fuel

injector is a solenoid operated device controlled by the
PCM. The PCM energizes the solenoid which opens
a valve to allow fuel delivery.

Engine

Engine Controls - 3.8L

The fuel is injected under pressure in a conical spray

pattern at the opening of the intake valve. Excess
fuel not used by the injectors passes through the fuel
pressure regulator before being returned to the
fuel tank.
A fuel injector which is stuck partly open will cause a
loss of fuel pressure after engine shut down,
causing long crank times to be noticed on some
engines.

Fuel Pressure Regulator

6-1233

CAM Signal (CKT 630)

The PCM uses this signal to determine the position of
the #1 piston during its power stroke, allowing the
PCM to calculate true Sequential Multiport Fuel
Injection (SFI). A loss of this signal will set a
OTC P0341. If the CAM signal is lost while the engine
is running, the fuel injection system will shift to a
calculated sequential fuel injection based on the last
fuel injection pulse and the engine will continue to run.
The engine can be restarted and will run in the
calculated sequential mode as long as the fault is
present with a 1 in 6 chance of being correct. Refer to
OTC P0341 Camshaft Position (CMP) Sensor
Performance.

Idle Air Control (IAC) Valve

12249

T.he cartridge type fuel pressure regulator (1) is a

diaphragm-operated relief valve (6) with fuel pump
pressure on one side, and. regulator spring (2)
pressure, and intake manifold vacuum on the other
side. The regulator's function is to maintain a constant
fuel pressure across the injectors at all times. The
pressure regulator compensates tor engine load
by increasing fuel pressure as engine vacuum drops.
The cartridge regulator is serviced as a separate
component. When servicing the fuel pressure
regulator, insure that the 0-ring backup (3), large
0-ring (4), filter screen (5), and smali 0-ring (7) are
properly placed on the pressure regulator.
If the fuel pressure is too low, poor performance and a
OTC P0171, could result. If the pressure is too high,
excessive odor and a OTC P0172, may result. Refer to
Fuel System Pressure Test for information on
diagnosing fuel pressure conditions.

(3X) Reference PCM Input (CKT 430)

From the electronic ignition module, the PCM uses

this signal to calculate engine speed and crankshaft
position. The PCM compares pulses on this circuit
to reference low CKT 453. The PCM also uses
the pulses on this circuit to initiate fuel injector pulses.
If the PCM receives no pulses on this circuit, no
fuel injection pulses will occur and the engine will
not run.

The purpose of the Idle Air Control (IAC) valve is to

control engine idle speed, while preventing stalls
due to changes in engine load. The IAC valve,
mounted in the upper intake manifold, controls bypass
air around the throttle plate. By moving a conical
valve, known as a pintle, in (to decrease air flow) or
out (to increase air flow), a controlled amount of
air can move around the throttle plate. If RPM is too
low, the PCM will retract the IAC pintle, resulting
in more air being bypassed around the throttle plate to
increase RPM. If RPM is too high, the PCM will
extend the IAC pintle, allowing less air to be bypassed
around the throttle plate, decreasing RPM.
The IAC pintle moves in small steps called counts.
During idle, the proper position of the IAC pintle
is calculated by the PCM based on battery voltage,
coolant temperature, engine load, and engine RPM. If
the RPM drops below a specified value, and the
throttle plate is closed (TP sensor voltage is
between 0.2-0.74), the PCM senses a near stall
condition. The PCM will then calculate a new
IAC pintle position in order to prevent stalls.
If the IAC valve is disconnected and reconnected with
the engine running, the idle RPM will be wrong. In
this case, the IAC has to be reset.
The IAC resets when the key is cycled ON then OFF.
When servicing the IAC, it should only be disconnected
or connected with the ignition OFF in order to keep
from having to reset the IAC.
The position of the IAC pintle affects engine start up
and the idle characteristics of the vehicle. If the
IAC pintle is open fully, too much air will be allowed
into the manifold. This results in high idle speed, along
with possible hard starting and a lean air/fuel ratio.
OTC P0507 may set. If the IAC pintle is stuck closed,
too little air will be allowed in the manifold. This
results in a low idle speed, along with possible hard
starting and a rich air/fuel ratio. OTC P0506 may set. If
the IAC pintle is stuck part way open, the idle may
be high or low and will not respond to changes in
engine load.

6-1234

Engine Controls - 3.SL

Engine

Fuel Pump Electrical Circuit

Diagnosis

When the key is first turned ON the PCM energizes

the fuel pump relay for two seconds to build up the fuel
pressure quickly. If the engine is not started within
two seconds, the PCM shuts the fuel pump OFF and
waits until the engine is cranked. When the engine
is cranked and the RPM signal has been detected by
the PCM, the PCM supplies 12 volts to the fuel
pump relay in order to energize the electric in-tank
fuel pump.

The evaporative leak detection diagnostic strategy is

based on applying vacuum to the EV AP system
and monitoring vacuum decay. Before the EVAP
system diagnostic tests are run the following conditions
must be present:
No VSS, TP, H02S, Misfire, IAT, MAP, Fuel Trim,
Injector circuit, EGR Pintle Position, ECT, or MAF
sensor DTCs set.
Engine coolant temperature is between 4C and
30C (40F and 86F).
Intake air temperature is between 4C and
30C (40F and 86F).
Fuel tank level is between 15% and 85%.
BARO is above 75 kPa.
The EVAP system diagnostic tests will be run following
a cold start, as indicated by the ECT and IAT
sensors. The fuel level sensor input to the PCM is
used to determine if the fuel level in the tank is
appropriate to run the EVAP diagnostic tests. To
ensure sufficient volume in the tank to begin the
various diagnostic tests, the fuel level must be
between 15% and 85%. The PCM monitors vacuum
level via the fuel tank pressure sensor input. At
an appropriate time, the EVAP purge valve and the
EV AP canister vent valve are turned ON, allowing
engine vacuum to draw a slight vacuum on the entire
evaporative emission system. After the desired
vacuum level has been achieved, the EVAP purge
valve is turned OFF, sealing the system. A leak
is detected by monitoring for a decrease in vacuum
level over a given time period. A small leak in the
system will cause DTC P0442 to be set. If the desired
vacuum level cannot be achieved in the test
described above, a large leak or a malfunctioning
EVAP purge valve is indicated. This can be caused by
the following conditions:
Disconnected or malfunctioning fuel tank pressure
sensor.
Missing, incorrect, or malfunctioning fuel cap.
Disconnected, damaged, pinched, or blocked
EVAP purge line.
Disconnected or damaged EVAP vent hose.
Disconnected, damaged, pinched, or blocked fuel
tank vapor line.
Disconnected or malfunctioning EV AP canister
vent valve.
Disconnected or malfunctioning EVAP canister
vent valve.
Open ignition feed circuit to the EVAP canister
vent or EVAP purge valve.
Damaged EVAP canister.
Any of the above conditions can set DTC P044;0.

An inoperative fuel pump relay can result in a no start

condition.
An inoperative fuel pump would cause a no start
condition. A fuel pump which does not provide enough
pressure can result in poor performance.

EVAP Control System Operation

Description
Enhanced EVAP System Operation
The basic Evaporative Emission (EVAP) Control
system used on all vehicles is the charcoal canister
storage method. This method transfers fuel vapor from
the fuel tank to an activated carbon (charcoal)
storage device (canister) to hold the vapors when the
vehicle is not operating. When the engine is running,
the fuel vapor is purged from the carbon element
by intake air flow and consumed in the normal
combustion process.
The EVAP purge valve allows manifold vacuum to
purge the canister. The Powertrain Control Module
(PCM) supplies a ground to energize the EV AP purge
valve (purge ON ). The EVAP purge valve control
is Pulse Width Modulated (PWM) or turned ON and
OFF several times a second. The PCM controlled
PWM output is commanded when the appropriate
conditions have been met:
Engine coolant temperature above 50C (77F).
After the engine has been running about 3 minutes
on a cold start or 30 seconds on a warm start.
The vehicle is operating in closed loop fuel control.
Canister purge PWM duty cycle varies according
to operating conditions determined by mass air flow,
fuel trim, and intake air temperature. Canister
purge will be disabled if TP angle increases to above
55%. Canister purge will be re-enabled when TP
angle decreases below 53%.
The evaporative leak detection diagnostic strategy is
based on applying vacuum to the EV AP system
and monitoring vacuum decay. The fuel level sensor
input to the PCM is used to determine if the fuel
level in the tank is correct to run the EVAP diagnostic
tests. To ensure sufficient volume in the tank to
begin the various diagnostic tests, the fuel level must
be between 15% and 85%. The PCM monitors
system vacuum level via the fuel tank pressure
sensor input.

Engine
A restricted or blocked EV AP canister vent path is
detected by drawing vacuum into the EVAP system,
turning OFF the EVAP canister vent valve and
the EVAP purge valve (EVAP. canister vent valve
Open, EVAP canister purge 0% ) and monitoring the
fuel tank pressure sensor input. With the EVAP
canister vent valve open, any vacuum in the system
should decrease qLlickly unless the vent path is
blocked. A blockage can l:)e caused by the following
conditions:
Malfunctioning EVAP canister vent valve (stuck
closed).
Plugged, kinked, or pinched vent hose.
Shorted EV AP canister vent valve control circuit.
Plugged evaporative canister.
If any of the above conditions are present, DTC P0446
will set.
The system checks for conditions that cause the
EVAP system to purge continuously by commanding
the EVAP canister vent valve ON and the EVAP purge
valve OFF (EVAP canister vent valve Closed, EVAP
canister purge 0%). If fuel tank vacuum level
decreases during the test, a continuous purge flow
condition is indicated. This can be caused by the
following conditions:
EVAP purge valve leaking.
EV AP purge and engine vacuum source lines
switched at the EV AP purge valve.
EVAP purge valve control circuit grounded.
If any of these conditions are present, DTC P1441 will
set. Refer to the DTC tables for further diagnostic
procedures regarding the EVAP system.

Engine Controls - a.SL

6-1235

Evaporative Emissions System

Purge/Pressure Diagnostic Station J 41413

6
2

20803

Legend
(1) Main Valve
(2) Evaporative Emission System Purge/Presure
Diagnostic Station J 41413
(3) Nitrogen Cylinder
(4) Black Connecting Hose
(5) Threaded Fitting
(6) Gauge Set

The EVAP system purge/pressure diagnostic station is

used to clear carbon released into the EV AP system
by the canister. Carbon released into the EV AP system
may cause EV AP system components to be
inoperative. If diagnosis indicates that an EVAP .
system component needs to be replaced, the system
should be checked for released carbon. A released

carbon condition must be corrected before replacing

any EV AP system component. Procedures for
checking the EV AP system for released carbon and
for correcting a released carbon condition are in
the Diagnostic Aids for the applicable DTC tables.

6;..1236

Engine Controls - 3.SL

Electronic Ignition System Description

Purpose
The electronic ignition system controls fuel combustion
by providing a spark to ignite the compressed
air/fuel mixture at the correct time. To provide optimum
engine performance, fuel economy, and control of
exhaust emissions, the PCM controls the spark
advance of the ignition system. Electronic ignition has
the following advantages over a mechanical
distributor system:
No moving parts.
Less maintenance.
Remote mounting capability.
No mechanical load on the engine.
More coil cool down time between firing events.
Elimination of mechanical timing adjustments.
Increased available ignition coil saturation
time. Increased available ignition coil
saturation time.

Operation
The electronic ignition system does not use the
conventional distributor and coil. The ignition system
consists of three ignition coils, an ignition control
module, a dual Hall-effect crankshaft position sensor,
an engine crankshaft balancer with interrupter
rings attached to the rear, related connecting wires,
and the Ignition Control (IC) and fuel metering portion
of the PCM.
Conventional ignition coils have one end of the
secondary winding connected to the engine ground. In
this ignition system, neither end of the secondary
winding is grounded. Instead, each end of a coil's
secondary winding is attached to a spark plug. Each
cylinder is paired with the cylinder that is opposite
it (1/4, 2/5, 3/6). These two plugs are on companion
cylinders, i.e., on top dead center at the same
time. When the coil discharges, both plugs fire at the
same time to complete the series circuit. The
cylinder on compression is said to be the event
cylinder and the one on exhaust is the waste cylinder.
The cylinder on the exhaust stroke requires very
little of the available energy to fire the spark plug. The
remaining energy will be used as required by the
cylinder on the compression stroke. The same process
is repeated when the cylinders reverse roles. This
method of ignition is called a waste spark ignition
system.
Since the polarity of the ignition coil primary and
secondary windings is fixed, one spark plug always
fires with normal polarity and its companion plug fires
with reverse polarity. This differs from a conventional
ignition system that fires all the plugs with the
same polarity. Because the ignition coil requires
approximately 30% more voltage to fire a spark plug
with reverse polarity, the ignition coil design is
improved, with saturation time and primary current
flow increased. This redesign of the system allows
higher secondary voltage to be available from
the ignition coils - greater than 40 kilovolts

Engine
(40,000 volts) at any engine RPM. The voltage
required by each spark plug is determined by the
polarity and the cylinder pressure. The cylinder on the
compression stroke requires more voltage to fire
the spark plug than the cylinder on the exhaust stroke.
It is possible for one spark plug to fire even though
a plug wire from the same coil may be disconnected
from its companion plug. The disconnected plug
wire acts as one plate of a capacitor, with the engine
being the other plate. These two capacitor plates
are charged as a spark jumps across the gap of the
connected spark plug. The plates are then discharged
as the secondary energy is dissipated in an oscillating
current across the gap of the spark plug that is still
connected. Secondary voltage requirements are very
high with an open spark plug or spark plug wire.
The ignition coil has enough reserve energy to fire the
plug that is still connected at idle, but the coil may
not fire the spark plug under high engine load. A more
noticeable misfire may be evident under load; both
spark plugs may then be misfiring.

System Components

12303

Crankshaft Position Sensor and Crankshaft

Balancer Interrupter Rings

The dual crankshaft position sensor is secured in an

aluminum mounting bracket and bolted to the front left
side of the engine timing chain cover, partially
behind the crankshaft balancer. A 4-wire harness
connector plugs into the sensor, connecting it to the
ignition control module. The dual crankshaft position
sensor contains two Hall-effect switches with one
shared magnet mounted between them. The magnet
and each Hall-effect switch are separated by an
air gap. A Hall-effect switch reacts like a solid state
switch, grounding a low current signal voltage when a
magnetic field is present. When the magnetic field
is shielded from the switch by a piece of steel placed
in the air gap between the magnet and the switch,
the signal voltage is not grounded.

Engine

Engine Controls .. 3.SL

5.. 1237

If the piece of steel (called an interrupter) is repeatedly

moved in and out of the air gap, the signal voltage
will appear to go ON - OFF - ON - OFF - ON - OFF. In
the case of the electronic ignition system, the piece
of steel is two concentric interrupter rings mounted to
.the rear of the crankshaft balancer.

12305

Camshaft Position {CMP) Sensor

12358

Legend
(1) Crankshaft Balancer
(2) Interrupter Rings

')

Each interrupter ring has blades and windows that

either block the magnetic field or allow it to close one
of the Hall effect switches. The outer Hall effect
switch produces a signal called the CKP 18X because
the outer interrupter ring has 18 evenly spaced
blades and windows. The CKP 18X portion of the
crankshaft position sensor produces 18 ON OFF pulses per crankshaft revolution. The Hall-effect
switch closest to the crankshaft, the CKP Sync
portion of the sensor, produces a signal that
approximates the inside interrupter ring. The inside
interrupter ring has 3 unevenly spaced blades
and windows of different widths. The CKP Sync portion
of the crankshaft position sensor produces 3 different
length ON - OFF pulses per crankshaft revolution.
When a CKP Sync interrupter ring window is between
the magnet and inner switch, the magnetic field will
cause the CKP Sync Hall effect switch to ground
the CKP Sync signal voltage supplied from the ignition
control module. The CKP 18X interrupter ring and
Hall-effect switch react similarly. The ignition control
module interprets the CKP 18X and CKP Sync
ON - OFF signals as an indication of crankshaft
position, and the ignition control module must have
both signals to fire the correct ignition coil. The ignition
control module determines crankshaft position for
correct ignition coil sequencing by counting how many
CKP 18X signal transitions occur, i.e.; ON - OFF or
OFF - ON, during a CKP Sync pulse.

The camshaft position sensor is located on the timing

cover behind the water pump near the camshaft
sprocket. As the camshaft sprocket turns, a magnet in
it activates the Hall effect switch in the camshaft
position sensor. When the Hall-effect switch is
activated, it grounds the signal line to the ICM, pulling
the camshaft position sensor signal circuit's applied
voltage low. This is interpreted as a CMP Sensor
signal. The CMP Sensor signal is created as piston #1
is approximately 25 degrees after top dead center
on the power stroke.

12299

Legend
(1) Screws
(2) Ignition Coil
(3) Ignition Control Module

6-1238

Engine Controls .. 3.SL

Ignition Coils

Engine
Powertrain Control Module (PCM)

Three twin-tower ignition coils are individually mounted

to the ignition control module. Each coil provides
spark for two plugs simultaneously (waste spark
distribution). Each coil is serviced separately. Two
terminals connect each .coil pack to the module. Each
coil is provided a fused ignition feed. The other
terminal at each coil is individually connected to the
module, which will energize one coil at a time by
completing and interrupting the primary circuit ground

path to each coil at the proper time.

Ignition Control Module (ICM)

The ignition control module performs the following
functions:
It powers the dual crankshaft position sensor
internal circuits.
It supplies the voltage signals that each respective
Hall effect switch pulses to ground to generate
the CKP Sync and CKP 18X signal pulses.
It determines the correct ignition coil firing
sequence, based on how many CKP 18X signal
transitions occur during a CKP Sync pulse.
This coil sequencing occurs at start-up. After the.
engine is running, the module remembers the
sequence; and continues triggering the ignition
coils in proper sequence.
It determines whether or not the crankshaft is
rotating in ,he proper direction, and cuts off
fuel delivery arid spark to prevent backfiring if
reverse rotation is detected.
It sends the 3X reference and 18X reference
signals to the PCM. The PCM determines engine
RPM from these signal. These signals used by
the PCM to determine crankshaft speed for
Ignition Control (IC) spark advance calculations.
The falling edge of each 3X reference
and 18X reference signal pulse occurs at a
specific time in relation to top dead center of any
cylinder stroke. The 3X reference signal sent
to the PCM by the ignition control module is an
ON - OFF pulse occurring 3 time per crp.nkshaft
revolution. This is nei.ther the CKP Sync pulse nor
the 18X crankshaft position sensor pulse, but
both of these are. required before the ignition
control module will generate the 3X reference
signal. The ignition control module generates the
3X reference signal by an internal divide-by-6
circuit. This divider circuit divides the CKP 18X
signal pulses by 6. The divider circuit is enabled,
or ready to begin dividing, only after it receives
a crankshaft position sensor CKP Sync pulse.
After beginning, the divider circuit does not need
the Sync pulses to continue operating. If either
the CKP 18X or CKP Sync pulses are missing at
start-up, the ignition control module will not
generate 3X reference or 18X reference signal
pulses and no fuel injector pulses will occur.

159242

The PCM is responsible for maintaining proper spark

and fuel injection timing for all driving conditions.
Ignition Control (IC) spark timing is the PCM method
of controlling spark advance and ignition dwell. To
provide optimum driveability and emissions, the PCM
monitors input signals from the following components
in calculating Ignition Control (IC) spark timing:
Ignition Control module (ICM).
Engine Coolant Temperature (ECT) sensor.
lnlake Air Temperature (IAT) sensor.
Mass Air Flow (MAF) sensor.
Trans Range or PNP inputs from Trans Range
switch or Park/Neutral Position switch.
Throttle Position (TP) sensor.
Vehicle Speed Sensor (VSS) I Trans Output
Speed Sensor (TOSS).
The ignition system uses many of the same ignition
module-to-PCM circuits as did previous Delco
engine management systems using distributor type
ignition. The following describes the PCM to ignition
control module circuits:
3X reference PCM input
From the ignition control module, the PCM uses
this signal to calct,1late engine RPM and crankshaft
position.The PCM compares pulses on this
circuit to any th;:tt are on the Reference Low
circuit, ignoring any pulses that appear on both.
The PCM .also uses the pulses on this circuit
to initiate injector pulses.
18X reference PCM input - The 18X reference
signal is used to accurately control spark timing at
low RPM and allow IC operation during crank.
Below 1200 RPM, the PCM is monitoring
the 18X reference signal and using it as the
reference for ignition timing advance. VVtJen engine
speed exceeds 1200 RPM, the PCM begins
using the, 3X reference signal to control spark
timing.

Engine

1/

Camshaft Position PCM input

The PCM uses this signal to determine the
position of the cylinder #1 piston during its power
stroke. This signal is used by the PCM to
calculate true Sequential Fuel Injection (SFI)
mode of operation. The PCM compares the
number of CAM pulses to the number of 18X and
3X reference pulses. If the number of 18X and
3X reference pulses occurring between CAM
pulses is incorrect, or if no CAM pulses are
received while the engine is running, the PCM will
set DTC P0341 . If the cam signal is lost while
th~ engine is running the fuel injection system will
shift to a calculated sequential fuel injection
mode based on the last cam pulse, and the engine
will continue to run. The engine can be re-started
and will run in the calculated sequential mode
as Ion g as the condition is present with a 1 in 6
chance of being correct.
Reference low PCM input
This is a ground circuit for the digital RPM
counter inside the PCM, but the wire is connected
to engine ground only through the ignition
control module. Although this circuit is electrically
connected to the PCM, it is not connected to
ground at the PCM. The PCM compares voltage
pulses on the 3X or 18X reference input to
those on this circuit, ignoring pulses that appear
on both.
Bypass signal PCM output
The ignition control module maintains a fixed
spark timing while the engine is cranking (Bypass
Mode). Once the PCM receives 3X reference
pulses, the PCM commands the ignition module
to allow the PCM to control the spark advance (IC
Mode). The ignition control module determines
correct operating mode based on the voltage level
that the PCM sends to the ignition control
module on the bypass circuit. The PCM provides
5 volts on the bypass circuit if the PCM is
going to control spark timing (IC Mode).
Ignition Control (IC) PCM output
The IC output circuitry of the PCM sends out
timing pulses to the ignition control module. When
in the Bypass Mode, the ignition control module
grounds these pulses. When in the IC Mode,
the ignition control module uses the timing pulses
for coil dwell and spark timing. Proper sequencing
of the 3 ignition coils, i.e.; which coil to fire, is
always the job of the ignition control module.

Modes of Operation
The ignition system uses the same four ignition
module-to-PCM circuits as did previous Delco engine
ma~~gement systems using distributor-type ignition.
Ignition Control (IC) spark timing is the PCM's method
of controlling spark advance and ignition dwell
when the ignition system is operating in the IC Mode.
There are two modes of ignition system operation:
Bypass Mode.
IC Mode.

Engine Controls - 3.SL

6-1239

In Bypass Mode, the ignition system operates

independently of the PCM, at a fixed spark timing. The
PCM switches to IC Mode (PCM controlled spark
advance) as soon as the engine begins cranking. After
the switch is made to IC Mode, it will stay in effect
until one of the following conditions occur:
The engine is turned off.
The engine quits running.
The IC output circuitry in the PCM generates IC output
pulses anytime crankshaft reference signal input
pulses are being received. When the ignition system is
operating in the Bypass Mode (no voltage on the
bypass control circuit), the ignition control module
grounds the IC pulses coming from the PCM.
The ignition control module will remove the ground
from the IC circuit only after switching to the IC Mode.
The PCM commands switching to IC Mode by
applying 5 volts on the bypass circuit to the ignition
control module. The PCM monitors the IC and Bypass
circuits for electrical malfunctions affecting proper
ignition system operation. If a malfunction occurs,
diagnosis is included in DTC P1351, P1352, P1361
and P1362 diagnostic tables. If diagnostic trouble
codes are encountered, go to the DTC tables
for diagnosis.
In the IC Mode, the ignition spark timing and ignition
dwell time is fully controlled by the PCM. IC spark
advance and ignition dwell is calculated by the PCM
using the following inputs:
Engine speed (18X reference or 3X reference).
Crankshaft position (18X reference or
3X reference and Camshaft position PCM input
signal).
Engine Coolant Temperature (ECT sensor).
Throttle Position (TP sensor).
Knock Signal (Knock sensor).
Park/Neutral Position (PRNDL input).
Vehicle Speed (Vehicle Speed Sensor).
PCM and ignition system supply voltage.
The following describes the PCM to ignition control
module circuits:
3X reference PCM input - From the ignition
control module, the PCM uses this signal to
calculate engine RPM and crankshaft position.
The PCM compares pulses on this circuit to any
that are on the Reference Low circuit, ignoring
any pulses that appear on both. The PCM
also uses the pulses on this circuit to initiate
injector pulses. If the PCM receives no pulses on
this circuit, the PCM will use the 18X reference
pulses to calculate RPM and crankshaft position.
The engine will continue to run and start
normally, but DTC P1374 will be set.

6-1240

Engine Controls - 3.8L

18X reference PCM input - The 18X reference

signal is used to accurately control spark timing
at low RPM and allow IC operation during crank.
Below 1200 RPM, the PCM is monitoring the
18X reference signal and using it as the reference
for ignition timing advance. When engine speed
exceeds 1200 RPM, the PCM begins using the,
3X reference signal to control spark timing. If the
1BX reference signal is not received by the
PCM while the engine is running, a DTC P0336
will be set and 3X reference will be used to control
spark advance under 1200 RPM, and Bypass
Mode will be in effect at under 400 RPM.
The engine will continue to run and start normally.
Reference low PCM input - This is a ground circuit
tor the digital RPM counter inside the PCM, but
the wire is connected to engine ground only
through the ignition control module. Although this
circuit is electrically connected to the PCM, it
is not connected to ground at the PCM. The PCM
compares voltage pulses on the 3X or
18X reference input to those on this circuit,
ignoring pulses that appear on both. If the circuit
is open, or connected to ground at the PCM,
it may cause poor engine performance and
possibly a MIL (Service Engine Soon) with
no DTC.
Bypass signal PCM output - The ignition control
module maintains a fixed spark timing while the
engine cranking (Bypass mode). Once the
PCM receives 3X reference pulses, the PCM
commands the ignition module to allow the PCM
to control the spark advance (IC Mode). The
ignition control module determines correct
operating mode based on the voltage level that
the PCM sends to the ignition control module
on the bypass circuit. The PCM provides 5 volts
on the bypass circuit if the PCM is going to control
spark timing (IC Mode).
Ignition Control (IC) PCM output - The IC output
circuitry of the PCM sends out timing pulses to
the ignition control module on this circuit. When in
the Bypass Mode, the ignition control module
grounds these pulses. When in the IC Mode, these
pulses are sent to the ignition control module to
control coil dwell and spark timing. Proper
sequencing of the 3 ignition coils, i.e., which coil
to fire, is always the job of the ignition control
module.
Knock Sensor (KS) PCM input - The PCM
contains integrated knock sensor (KS) diagnostic
circuitry. The KS system is comprised of A
knock sensor, PCM, and related wiring. The PCM
monitors the knock sensor signal to detect
engine detonation (spark knock). When the spark
knock occurs, the PCM retards the spark timing
(IC) to reduce detonation. Retarded timing
can also be a result of excessive valve lifter,
pushrod or other mechanical engine or
transaxle noise.

Engine
Camshaft Position PCM input (CAM signal) - The
PCM uses this signal to determine the position of
the cylinder #1 piston during its intake stroke.
This signal is .used by the PCM to calculate true
Sequential Fuel lnjectiqn (SFI) mode of operation.
The PCM compares the number of CAM pulses
to the number of 18X and 3X reference pulses. If
the cam signal is lost while the engfne is
running the fuel injection system will shift to a
calculated sequential fuel injection mode based on
the last cam pulse, and the engine will continue
to run. The engine can be re-started and will
run in the calculated sequential mode as long as
the fault is present with a 1 in 6 chance of
being correct.

Knock Sensor System Description

Purpose
Varying octane levels in today's gasoline may cause
detonation in some engines. Detonation is caused
by an uncontrolled explosion (burn) in the combustion
chamber. This uncontrolled explosion could produce
a flame front opposite that of the normal flame
front produced by the spark plug. The 'rattling sound
normally associc:1ted with detonation is the result of two
or more opposing pressures (flame fronts) colliding
,.
within the combustion chamber. Though light
detonation is sometimes considered normal, heavy
detonation could result in engine damage. To control
spark knock, a Knock Sensor (KS~ system is used.
This system is designed to retard spark timing
when spark knock is detected in the engine. The KS
system allows the engine to use maximam spark
advance tor optimal driveability and fuel economy.
'

',

Operation
The PCM contains integrated Knock Sensor (KS)
Diagnostic Circuitry. Input signals fmm the knock
sensors are used to detect engine detonation, allowing
the PCM to retard Ignition Control (IC) spark timing
based on the amplitude and frequency of the KS signal
being received. The knock sensors produce an AC
signal under all engine operating conditions. The PCM
calculates an average voltage of each knock
sensor's signal and takes instantaneous signal voltage
readings. The PCM uses the instantaneous signal
voltage readings to determine the state of the knock
sensor circuitry. If the knock sensor system is
operating normally, the PCM should monitor
instantaneous KS signal voltage readings varying.
outside a voltage range above and below the
calculated average voltage(as shown i,n the normal
knock sensor figure). It the PCM detects a knock
sensor signal voltage within the calculated average
voltage range, DTC P0327 or P0332 will set (as shown
in the abnormal knock sensor figure).

Engine

Engine Controls - 3.BL

Normal Knock Sensor Signal

6-1241

Abnormal Knock Sensor Signal

4
4

245257

245253

Legend

Legend
(1)
(2)
(3)
(4)

Upper
Knock
Knock
Lower

Fail Region
Sensor Calculated Average
Sensor Signal (Normal)
Fail Region

(1)
(2)
(3)
(4)

Upper Fail Region

Knock Sensor Calculated Average
Knock Sensor Signal (Failed)
Lower Fail Region

6-1242

Engine

Engine Controls - 3.8L

Diagnosis

Operation

If the PCM malfunctions in a manner which will not

allow proper diagnosis of the knock sensor system,
OTC P0325 will set.
DTCs P0327 and P0332 are designed to diagnose the
knock sensors, and related wiring. Problems
encountered with the KS system should set a OTC.
However, if the customer's complaint is
detonation/spark knock, use the tables for OTC P0327
or P0332 to diagnose the condition.

~---3

"'~---4

EGR System Description

Linear EGR Valve

11696

Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)

14441

Purpose
The Exhaust Gas Recirculation (EGA) system is used
to lower Oxides of Nitrogen (NOx) emission levels
caused by high combustion temperature. It does this
by decreasing combustion temperature.
The main element of the system is the linear EGR
valve. The EGA valve feeds small amounts of exhaust
gas back into the combustion chamber. With the
fuel/air mixture diluted by the exhaust gases,
combustion temperatures are reduced.

Cap-Sensor
Sensor-EGA Pintle Position
Pole Piece-Primary
Bobbin and Coil Assembly
Sleeve-Armature
Valve-Pintle
Armature and Base Assembly

The linear EGR valve is designed to accurately supply

EGA to an engine independent of intake manifold
vacuum. The valve controls EGA flow from the exhaust
to the intake manifold through an orifice with a PCM
controlled pintle. During operation, the PCM controls
pintle position by monitoring the pintle position
feedback signal. The feedback signal can be monitored
with a scan tool as ACTUAL EGA POS. ACTUAL
EGA POS should always be near the commanded
EGA position ( DESIRED EGA POS). The PCM uses
information from the following sensors to control
the pintle position:
Engine Coolant Temperature (ECT) sensor.
Throttle Position (TP) sensor.
Mass Air Flow (MAF).
The linear EGA valve is usually activated under the
following conditions:
Warm engine operation
Above idle speed

Engine

Engine Controls - 3.SL

Diagno$is

6-1243

Operation

+__

11699

Legend

(1)
(2)
(3)
(4)

Linear EGR Valve

Exhaust Gas
To Cylinders
Pintle

13561

The primary .control is through the crankcase

ventilation valve which metersthe flow at a rate
depending on inlet vacuum. To maintain idle quality,
the crankcase ventilation valve restricts the flow when
inlet vacuum is high.

Too much EGR flow at idle, cruise, or cold operation

may cause any of the following condftions to occur:
Engine stalls after cold start.
Engine stalls during closed throttle conditions.
Vehicle surges during cruise.
Rough idle.
DTC P0300 (misfire detected).
Too little or no EGR flow may allow combustion
temperatures to get too high. This could cause the
following symptoms:
Spark knock (detonation).
Engine overheating.
Emission test failure.
DTC P0401.
Poor fuel economy.
EGR flow diagnosis is included in the DTC P0401
diagnostic table. Pintle position error diagnosis
is covered in DTC P1406. If EGR diagnostic trouble
codes P0401 and/or P1406 are encountered, go to the
DTC tables for diagnosis.

Crankcase Ventilation System Description

Purpose
A crankcase ventilation system is used to consume
crankcase vapors in the combustion process instead of
venting them to atmosphere. Fresh air from the
throttle body is supplied to the crankcase, mixed with
blow-by gases and then passed through a crankcase
ventilation valve into the intake manifold.

21764

If abnormal operating conditions arise, the system is

designed to allow excessive amounts of blow-by gases
to back flow through the crankcase vent into the
throttle body to be consumed by normal combustion.

Air Intake System Description

The air induction system provides contaminant and
sound filtration of the outside air as it is drawn into the
engine. A remotely mounted air cleaner reduces
induction noise while preventing contaminants in the
air from entering the engine. The filtered air is
routed into an intermediate air duct assembly. The air
then enters the engine by flowing through the
throttle body, into the intake manifold, through the
cylinder head intake ports, and into the cylinders.

6-1244

Engine Controls - 3.8L

Special Tools and Equipment

Illustration

Engine
Illustration

Tool Number/Description

Tool Number/Description

(
J 34142-8
Test Light

J 34730-405
Injector Test Light
5382

385603

\\

J 23738-A
Vacuum Pump

J 39200
Digital Multi-meter
5386

3430

J 39194-8
Oxygen Sensor Wrench

J 34730-E
Fuel Pressure Gauge Kit
5388

5377

J 34730-1A
Fuel Pressure Gauge

J 26792
Spark Tester
5389

5381

Tech 2 Kit 7000081

50062

Engine Controls - 3.8L

Engine
Illustration

Tool Number/Description

Illustration

6-1245

Tool Number/Description

)
J 35689-A

J 33431-B

Metri-Pack Terminal Kit

Signal Generator and

Instrument Panel Tester

5395

9194

J 28742-A

J 37287
Inlet and Return Fuel Line
Shut-off Adapters

Weather Pack Terminal

Remover

5396

13541

J 37027-A

J 39021
Fuel Injector Coil/Balance
Tester

IAC Motor Analyzer

5399

5380

J 35616-A

J 39021-380
Fuel Injector Test Harness

Connector Test Adapter Kit

8917

385606

J 35314-A

J 37088-A

Exhaust Back Pressure

Tester

13544

Fuel Line Quick Connect

Separator

12366

6-1246

Engine Controls - 3.SL.;,

Illustration

Tool Number/Description

Engine
Tool Number/Description

Illustration

J 41413

J 41416

Pressure/Purge Diagnostic
Station

227620

Ultrasonic Leak Detector

69758

Engine

Engine Controls - 5.7L

6-1247

Engine Controls - 5.7L

~
1

Specifications
Temperature vs Resistance

oc

OF

OHMS

Temperature vs Resistance Values (Approximate)

100

212

177

90

194

241

80

176

332

70

158

467

60

140

667

50

122

973

45

113

1188

40

104

1459

35

95

1802

30

86

2238

25

77

2796

20

68

3520

15

59

4450

10

50

5670

41

7280

32

9420

-5

23

12300

-10

14

16180

-15

21450

-20

-4

28680

-30

-22

52700

-40

-40

100700

Fastener Tightening Specifications

Specifications
Application

Metric

English

Accelerator Control Cable Bracket Nut

10 Nm

89 Lb In

AIR Check Valves

23Nm

17 Lb ft

AIR Pipe To Exhaust Manifold Bolts

20 N-m

15 Lb ft

AIR Right Side Pipe Bracket to Cylinder Head Bolt

25Nm

18 Lb ft

AIR Pump to Bracket

9N-m

80 Lb In

Camshaft Position (CMP) Sensor Bolt

25 Nm

18 Lb ft

Crankshaft Position (CKP) Sensor Bolt

25N-m

18 Lb ft

Engine Coolant Temperature (ECT) Sensor

17 Nm

13 Lb ft

Fuel Filter Fitting

30N-m

22 Lb ft

Fuel Pipe Front Clip Bolts

4.5N-m

40 Lb In

Fuel Pipe Rear Clip Bolt

5.5 Nm

49 Lb In

Fuel Pipe Shield Bolt

5Nm

44 Lb In

Fuel Pipe Shield Nuts

5N-m

44 Lb In

Fuel Pipe Shield Studs

5N-m

44 Lb In

Fuel Rail Attaching Bolts

10 Nm

89 Lb In

Fuel Sender Assembly Attaching Nuts

6.5Nm

58 Lb In

6-1248

Engine

Engine Controls - 5.7L

Fastener Tightening Specifications (cont'd)
Specifications
Application

Fuel Tank Fill Pipe Shield Bolt

Metric

English

2.5 Nm

22 Lb In

Fuel Tank Strap Bolts

33N-m

24 Lb ft

Heated Oxygen Sensor (H02S)

41 N-m

30 Lb ft

Idle Air Control (IAC) Valve Attaching Screws

3N-m

27 Lb In

Knock Sensor (KS)

15 Nm

11 Lb ft

Powertrain Control Module (PCM) Connector End Bolts

8N-m

70 Lb In

Throttle Body Attaching Bolts

12 N-m

106 Lb In

Throttle Position (TP} Sensor Attaching Screws

2N-m

18 Lb In

Engine Scan Tool Data List

The Engine Scan Tool Data List contains all engine
related parameters that are available on the scan tool.
The list is arranged in alphabetical order. A given
parameter may appear in any one of the data lists, and
in some cases may appear more than once, or in
more than one data list in order to group certain
related parameters together.
Use the Engine Scan Tool Data List only after the
following is determined:
Powertrain On-Board Diagnostic System Check is
completed.
No Diagnostic Trouble Codes (DTCs).
On-board diagnostics are functioning properly.
Scan tool values from a properly running engine may
be used for comparison with the engine you are
diagnosing. The Engine Scan Tool Data List
represents values that would be seen on a normally
running engine.

Important: A scan tool that displays faulty data should

not be used. The scan tool concern should be
reported to the manufacturer. Use of a faulty scan tool
can result in misdiagnosis and unnecessary parts
replacement.
Only the parameters listed below are referenced in
this service manual for use in diagnosis. If all values
are within the typical range described below, refer
to Symptoms for diagnosis.
The column labeled Data List indicates where a
parameter can be located on the scan tool. Refer to
the scan tool operating manual for the exact locations
of the data lists. The following is a description of
each term listed:
All: The Parameter is in all data lists
indicated below.
Eng 1: Engine Data 1 List
Eng 2: Engine Data 2 List
EE: Enhanced EVAP Data
FF/FR: Freeze Frame/Failure Records
FT: Fuel Trim Data List
MF: Misfire Data List

Engine Scan Tool Data List

Scan Tool Parameter

Data List

Parameter Range/Units

Typical Data Values

Engine Idling/Radiator Hose Hot/Closed Throttle/Park or Neutral/Closed Loop/Accessories Off

A/C High Side Pressure

Eng 2

0-5 Volts

Varies

A/C High Side Pressure

Eng 2

kPa/psi

Varies

A/C Relay Command

Eng 1, 2, EE, MF

On/Off

Off

A/C Request

Eng 1, 2, EE, MF

Yes/No

No

A/C Status

Eng 1, 2, EE, MF

On/Off

Off

Actual EGR Position

Eng 1

0-100%

0%

AIR Pump Relay

Eng 1, 2, FT

On/Off

Off

AIR Solenoid Relay

Eng 1, 2, FT

On/Off

Off

Air Fuel Ratio

FF, FR

Ratio

14.7:1

kPa/Volts

65-104 kPa/3.5-4.9 Volts

(Varies w/Altitude)

BARO

Eng 1, FT, FF, FR

CAM Signal Input High to Low

Eng 1

Counts

Varies

CAM Signal Input Low to High

Eng 1

Counts

Varies

Clutch Pedal Position Switch

Eng1, 2, MF

Depressed/Released

Varies

Cold Startup

Eng1, 2, EE

Yes/No

Varies

Engine

Engine Controls - 5.7L

6-1249

Engine Scan Tool Data List (cont'd)

Scari Tool Parameter

Data List

Parameter Range/Units

Typical Data Values

Engine Idling/Radiator Hose Hot/Closed Throttle/Park or Neutral/Closed Loop/Accessories Off

Commanded EGR

Eng 1

Less than 1.3 volts

Cruise Requested

Eng1, 2

Yes/No

No

Cruise Control Inhibit

Eng1, 2

Yes/No

Yes

Current Gear

Eng 2, FF, FR

Transmission Gear
Position

Cycles of Misfire Data

MF

0-100 Counts

Varies

Cylinder Mode Misfire Index

MF

Counts

Varies

OTC Set This Ignition

Eng 1, 2, EE, FT

Yes/No

No

Desired IAC Airflow

Eng 1

0-64 g/s

Varies

Desired EGR Position

Eng 1

0-100%

0%

Desired Idle Speed

Eng 1, FF, FR

RPM

PCM Controlled

ECT

Eng 1, 2, EE, FT, MF,

FF, FR

-39 to 140C
(-38 to 284F)

85 to 113C
(185 to 235F)

EGR Closed Pintle Position

Eng 1

0-5.0 Volts

Less than 1.3 volts

EGR Pintle Position

Eng 1

0-5.0 Volts

Less than 1.3 Volts

Engine Load

MF, FF, FR

0-100%

1-4%@ Idle
5-9% @ 2500 RPM

Engine Run Time

Eng 1, 2, EE, FF, FR

Hrs, Min, Sec

Varies

Engine Speed

All

0-10,000 RPM

Varies

EVAP Canister Purge

Eng 1, 2, EE, FT, FR

0-100%

0-25%

EVAP Canister Vent Valve

Eng 1, 2, EE, FT

Not VentingNenting

Venting

Fail Counter

FR

Counts

Varies

Failures Since First Fail

FR

Counts

Varies

FC Relay 1

Eng 1, 2, EE

On/Off

Depends on engine
coolant temperature and
A/C Pressure

FC Relay 2 and 3

Eng 1, 2, EE

On/Off

Depends on engine
coolant temperature and
A/C Pressure
Varies

FT Diag. Inhibit

FT

Enabled/Disabled

Fuel Gauge Control

Eng 2, EE

0-100%

Varies

Fuel Level Sensor

Eng 2, EE

5-0 Volts

0. 7-2.5 Volts

Fuel Tank Level Remaining

Eng 2, EE, FT

0-16.6 gal./0-62.8 L

Varies

Fuel Tank Level Remaining

Eng 2, EE, FT

0-100%

Varies

Fuel Tank Pressure

Eng 1., 2, EE

-32.7 to 14.0 mm/Hg

(-17.5 to 7.5 in/H20)

Varies

Fuel Tank Pressure

Eng 2, EE

0-5.0 Volts

Varies

Fuel Tank Rated Capacity

Erig 2, EE, FT

16.6 gal./62.8 L

16.6 gal./62.8 L

Fuel Trim Cell

Eng 1, FT

0-23

16, 17, 20

Fuel Trim Learn

Eng 1, 2, EE, FT

Enabled/Disabled

Enabled (may Toggle)

Generator L Terminal
H02S Bank 1 Sensor 1

0-5 Volts

Eng 2, .

Active/Inactive

Active

Eng 1, FT

Millivolts

10-1,000 mV and Varying

H02S Bank 1 Sensor 2

Eng 1, FT

Millivolts

10-1,000 mV and Varying

H02S Bank 2 Sensor. 1

Eng 1, FT

Millivolts

10-1,000 mV and Varying

H02S Bank 2 Sensor 2

Eng 1, FT

Millivolts

10-1,000 mV and Varying

IAC Position

Eng 1

Counts

Varies

IAT

Eng 1, 2, EE, FT

-39 to 140C
(-38 to 284F)

Varies

IC Circuit Cylinder 1-8

MF

Ok/Fault

Ok

6-1250

Engine Controls - 5.7L

Engine

Engine Scan Tool Data List (cont'd)

Scan Tool Parameter

Data List

Parameter Range/Units

Typical Data Values

Engine Idling/Radiator Hose Hot/Closed Throttle/Park or Neutral/Closed Loop/Accessories Off

Ignition 1

Eng 2, EE

0-25 Volts

11.5-14.5 Volts

lnj. PWM Average Bank 1

Eng 2, EE, FT, FF, FR

Milliseconds

1-4

lnj. PWM Average Bank 2

Eng 2, EE, FT, FF, FR

Milliseconds

Knock Retard

Eng 1, EE, FT

0.0-16

1-4
oo

Long Term FT 1 Average

FT

Percentage

Near 0%

Long Term FT 2 Average

FT

Percentage

Near 0%

Long Term FT Bank 1

Eng 1, 2, EE, FT,

FF, FR

Percentage

Near 0%

Long Term FT Bank 2

Eng 1, 2, EE, FT,

FF, FR

Percentage

Near 0%

Loop Status

Eng 1, 2, EE, FT MF,

FF, FR

Open/Closed

Closed

Low Oil Lamp

Eng 2

On/Off

Off

Low Oil Level

Eng 2

Yes/No

No

Eng 1, 2, EE, FT, MF,

FF, FR

Grams Per
Seconds (g/s)

5-9 g/s@ Idle (depends

on altitude)
20-26 g/s @ 2,500 RPM
(depends on altitude)

MAF Frequency

Eng 2

0-31,999 Hz

Varies

MAP

Eng 1, 2, EE, FT,

FF, FR

kPa/Volts

20-48 kPa/1.0-2.0 Volts

(varies w/altitude)

MIL

Eng 1, 2, EE

Off/On

Off

Mileage Since OTC Cleared

Eng 2

km/Miles

Varies

Mileage Since First Failure

FF, FR

km/Miles

Varies

Mileage Since Last Failure

FR

km/Miles

Varies

Mileage Since MIL Request

FF

km/Miles

Varies

Misfire Current #1-#8

MF

0-200 Counts

Misfire History #1-#8

MF

0-65,535 Counts

Misfiring Cylinder

MF

Prim. Cyl# 0-8

Sec. Cyl# 0-8

00000000 Prim.

Misfire Revolution Status

MF

Reject/Accept

Varies

Not Run Counter

FR

Counts

Varies

PCM Reset

Eng 1, 2, MF

Yes/No

No

PNP (A/T only)

Eng 2

Park/Neutral
R-0321

Park/Neutral

MAF

00000000 Sec.

Pass Counter

FR

Counts

Varies

Reverse Inhibit (MIT only)

Eng 1, 2

Yes/No

No

Revolutions With Misfire

MF

Counts

SHRT FT Average 1

FT

Percentage

Near 0%

SHRT FT Average 2

FT

Percentage

Near 0%

Short Term FT Bank 1

Eng 1, 2, EE, FT,

FF, FR

Percentage

Near 0%

Short Term FT Bank 2

Eng 1, 2, EE, FT,

FF, FR

Percentage

Near 0%

Skip Shift Lamp (MIT only}

Eng 1, 2

On/Off

Off

Skip Shift Solenoid (MIT only)

Eng 1, 2

Enabled/Disabled

Disabled

Spark

Eng 1, 2, EE, FT, MF

Varies

Start Up ECT

Eng 1, FF, FR, EE

Degrees
co;Fo

TCC Brake Switch

Eng 1, 2, FF, FR

Applied/Released

Released

Varies

Engine Controls - 5.7L

Engine

6-1251

Engine Scan Tool Data List (cont'd)

Scan Tool Parameter

Parameter Range/Units

Data List

Typical Data Values

Engine Idling/Radiator Hose HoUClosed Throttle/Park or Neutral/Closed Loop/Accessories Off

TCC Duty Cycle

Eng 1, 2; MF, FF, FR

Enabled/Disabled

Disabled

TCC Enable Sol.

Eng 1, 2, MF, FF, FR

Enabled/Disabled

Disabled

Total Misfire Current Count

MF

Counts

Total Misfire Failures Since First Fail

MF

Total Misfire Passes Since First Fail

MF

0-65,535
0-65,535
0-5.0 Volts

0
0
0
.4-.9 Volts

TP Sensor

Eng 2

TP Angle

Eng 1, 2, EE, FT, MF,

FF, FR

0-100%

0%

Traction Control

Eng 1, 2, FF, FR

Active/Inactive

Inactive

Transmission OSS

FF, FR

RPM

Varies

Transmission Range

Eng 1, 2, FF, FR

0-4

Vehicle Speed

Eng 1, 2, EE, FT,

FF,FR

km/h
mph

VTD Fuel Disable

Eng 2, FF, FR

Active/Inactive

Inactive

Warm-Ups w/o Emission Faults

Eng 2

0,-255 Counts

Varies

Warm-Ups w/o Non-Emission Faults

Eng 2

0-255 Counts

Varies

Engine Scan Tool Data Definitions

The Engine Scan Tool Data Definitions contains a
brief description of all engine related parameters
available on the scan tool. The list is in alphabetical
order. A given parameter may appear in any one of the
data lists. In some cases, the parameter may appear
more than once or in more than one data list in
order to group certain related parameters together.

AIC High Side Pressure: The scan tool displays

15-452 psi/103-3116 kPa/0-5.0 Volts. This parameter
represents the A/C refrigerant pressure sensor
signal. The amount of pressure indicates the amount
of load that the A/C compressor places on the
engine. The PCM uses this information in order to
adjust idle and in order to control the cooling fans.
AIC Relay Command: The scan tool displays On or
Off. The A/C Relay Command parameter represents
the PCM commanded state of the A/C clutch relay
control circuit. When the scan tool displays ON,
the A/C clutch should be engaged.
AIC Request: The scan tool displays Yes or No,
The A/C Request displays the state of the A/C request
input circuit from the HVAC controls. The PCM uses
the A/C request signal in order to determine whether
the A/C compressor operation is being requested.
AIC Status: The scan tool displays On or Off. The
scan tool displays ON when the PCM detects a voltage
at the A/C status circuit.
Actual EGR Position: The scan tool displays
percentage. This parameter indicates the position of
the EGR pintle position in percentage. A fully
closed EGR displays 0%. A fully open EGR
displays 100%.

AIR Pump Relay: The scan tool displays On or Off.

The scan tool displays ON when the PCM grounds
the AIR pump relay control circuit. The scan tool
displays OFF when the PCM disables the ground
circuit.
AIR Solenoid Relay: The scan tool displays On or
Off. The scan tool displays ON when the PCM
grounds the AIR solenoid relay control circuit. The
scan tool displays OFF when the PCM disables
the ground circuit.
Air Fuel Ratio: The scan tool display indiqates the
Air to Fuel Ratio. The Air Fuel ratio is determined
from the Heated Oxygen sensor output. The PCM uses
the fuel trim to adjust fueling to attempt to maintain
an Air Fuel Ratio of 14. 7: 1.
BARO: The scan tool displays a range of
10-105 kPa/0.00-5.0 Volts. The Barometric Pressure
reading is determined from the MAP sensor signal.
The PCM monitors the MAP signal during key up and
Wide-Open Throttle (WOT) conditions. The
Barometric Pressure compensates for altitude
differences.
CAM Signal Input High to Low: The scan tool
displays 0-65,535 counts. The counts increment as
the PCM detects the Camshaft sensor signal voltage
going from high to low.
CAM Signal Input Low to High: The scan tool
displays 0-65,535 counts. The counts increment as
the PCM detects the Camshaft sensor signal voltage
going from low to high.
Clutch Pedal Position Switch (MIT only): The
scan tool displays depressed or released. This
parameter displays the position of the clutch pedal.

6-1252

Engine Controls - 5.7L

Cold Start Up: The scan tool displays Yes or No. A

cold start-up is when the engine coolant temperature
rises above a predetermined temperature during
an ignition cycle. The next ignition cycle the engine
coolant temperature should be below a predetermined
temperature. Also the engine coolant temperature
and the intake air temperature are less than 50 C
(122 F) and are within 3 C (5 F) of each other
at start-up. When the above is true the scan tool
displays Yes.
Commanded EGR: The scan tool displays
0-5.0 Volts. This parameter is the EGR pintle position
commanded by the PCM.
Current Gear: The scan tool displays 0-4. The scan
tool displays which gear the transmission is in. An
illegal transmission position displays 9.
Cycles of Misfire Data: The scan tool displays a
range of 0-100. The PCM Counts the number of
misfire tests during 200 revolutions.
Cylinder Mode Misfire Index: The scan tool
displays a range of 0-65,535. This parameter displays
the amount of crankshaft decelerations. When an
engine is operating without a misfire, the scan
tool displays less than 1,000 counts. When an engine
misfire occurs, the counter displays more than
1,000 counts.
DTC Set This Ignition: The scan tool displays Yes
or No. This parameter indicates if a Diagnostic
Trouble Code (DTC) set during the current ignition
cycle.
Desired IAC Airflow: The scan tool displays a
range of 0-64 Grams Per Second (g/s). This
parameter displays the calculated airflow in the IAC
passage.
Desired EGR Position: The scan tool displays
0-5.0 Volts. This parameter displays the desired
position of the EGR pintle as requested by the PCM.
This parameter should be very close to Actual
EGR position.
Desired Idle Speed: The scan tool displays a range
of 0-3,187 RPM. The PCM commands the desired
idle speed. The PCM compensates for various engine
loads based on engine coolant temperature in order
to keep the engine at the desired speed.
ECT: The scan tool displays a range of -39C to
140C (-38F to 284F). The Engine Coolant
Temperature (ECT) sensor is mounted in the cylinder
head of the left bank. The PCM applies 5.0 Volts
to the ECT sensor circuit. The sensor is a thermistor
which changes internal resistance as temperature
changes. When the sensor is cold (internal resistance
high), the PCM monitors a high signal voltage and
interprets the voltage as a cold engine. As the sensor
warms (internal resistance decreases), the voltage
signal decreases and the PCM interprets the
lower voltage as a warm engine.
EGR Closed Pintle Position: The scan tool displays
0-5.0 Volts. This display represents the voltage that the
PCM uses to determine whether or not the EGR valve is
closed. The voltage displayed will be the closed position
of the EGR pintle learned by the PCM.

Engine
EGR Pintle Position: The scan tool displays
0-5.0 Volts. This parameter displays the actual EGR
pintle position in voltage.
Engine Load: The scan tool displays a range of
0%-100%. The PCM calculates the Engine load from
engine speed and MAF sensor readings. The
Engine Load increases with an increase in RPM or
airflow.

Engine Run Time: The scan tool displays Hours,

Minutes, Seconds. This displays the amount of engine
run time for the current ignition cycle. When you
cycle the ignition off, the timer will reset to zero.
Engine Speed: The scan tool displays a range of
0-:10,000 RPM. The PCM computes Engine speed
from the ignition reference pulses. The Engine speed
should remain close to desired idle under various
engine loads with the engine idling.
EVAP Canister Purge: The scan tool displays a
range of 0%-100%. The PCM commands the
PWM duty cycle of the EVAP Purge Solenoid valve.
0% displayed indicates no purge; 100% displayed
indicates full purge.
EVAP Canister Vent Valve: The scan tool displays
venting or not venting. The scan tool displays
venting when the PCM commands the EV AP system
to purge. The scan tool will show not venting when
the valve is closed.
Fail Counter: This scan tool displays the amount of
times a OTC fails. This parameter is located in the
Failure Records list.
Failures Since First Fail: The scan tool displays
the number of times a DTC failed since the first failur~.
FC Relay 1: The scan tool displays On or Off. The
scan tool displays ON when the PCM commands
a coolant fan relay ON. Both fans are enabled on low
speed when the PCM commands the fan one relay
control ON.
FC Relay 2 and 3: The scan tool displays On or Off.
The scan tool displays ON when the PCM commands
a coolant fan relay ON. Both cooling fans are
enabled on high speed when the PCM commands
both fan control circuits ON.
FT Diag. Inhibit: The scan tool displays Enabled or
Disabled. The scan tool displays Disabled when
the PCM determines that certain parameters prohibit
the Fuel Trim diagnostic from running. The scan
tool displays Enabled when the PCM determines that
the Fuel Trim diagnostic is allowed to run.
Fuel Gauge Control: The scan tool displays
0-100%. This parameter indicates the fuel level that
the PCM is commanding the fuel gauge to. The
scan tool displays in percentage the fuel level in the
fuel tank.
Fuel Level Sensor: The scan tool displays
5.0-0 Volts. The PCM supplies a 5.0 Volt signal circuit
to the fuel level sensor. The float inside the fuel
tank controls a variable resistor which varies the
resistance based on fuel level. The scan tool displays
below 1.0 Volt for an empty tank, and close to
2.5 Volts for a full tank.

Engine

Engine Controls - 5.7L 6-1253

Fuel Tank Level Remaining: The scan.tool displays

0-62.6 L (0-16.8 gal). The scan tool displays in
Liters or Gallons the amount of fuel remaining in the
fuel tank.
Fuel Tank Level Remaining: The scan tool displays
0-100%. The scan tool displays in percentage the
amount of fuel remaining in the fuel tank.
Fuel Tank Pressure: The scan tool displays in
-32.7 to 13.96 mm/Hg or -17.4 to 7.5 (in/H20). This
parameter indicates the pressureNacuum inside of the
fuel tank. A negative value indicates a vacuum. A
positive value indicates a pressure.
Fuel Tank Pressure: The scan tool displays
0-5.0 Volts. The scan tool displays in voltage the
pressure inside of the fuel tank.
Fuel Tank Rated Capacity: The scan tool displays
62.6 L (16.8 gal). The scan tool displays the capacity
of the fuel tank in Liters or Gallons.
Fuel Trim Cell: The scan tool displays a range of
O to 23. The PCM determines from the MAP and RPM
inputs which fuel trim cell to operate the engine in.
The fuel trim cell displayed on the scan tool is the cell
that the engine is operating under.
Fuel Trim Learn: The scan tool displays Enabled or
Disabled. When conditions are appropriate for
enabling long term fuel trim corrections, the scan tool
displays Enabled. This indicates that the long term
fuel trim is responding to the short term fuel trim. If the
scan tool displays Disabled, then long term fuel trim
will not respond to changes in short term fuel trim.
H02S Bank 1 and Bank 2 Sensor 1: The scan tool
displays a range of 0-1,000 mV. The H02S Bank 1
and Bank 2 Sensor 1 parameter represents the
fuel control exhaust oxygen sensor output voltage.
The voltage fluctuates constantly within a range
between 1O mV (lean exhaust) and 1,000 mV (rich
exhaust) while operating in Closed Loop.
H02S Bank 1 and Bank 2 Sensor 2: The scan tool
displays a range of 0-1,000 mV. The H02S Bn1
and Bn2 Sensor 2 parameter represents the exhaust
oxygen sensor output voltage. The voltage fluctuates
constantly within a range between 1O mV (lean
exhaust) and 1,000 mV (rich exhaust) while operating
in Closed Loop.
IAC Position:

The scan tool displays counts from

Oto 1,024. The counts represent the commanded IAC

position by the PCM. The scan tool displays O
counts for a fully seated IAC pintle. The counts
increase as the idle increases. The counts vary
depending on the load placed on the engine at idle.
IAT: The scan tool displays a range of -39C
to 140C (-38F to 284F), The PCM converts the
resistance of the intake air temperature sensor
to degrees. The PCM uses the Intake Air Temperature
(IAT) in order to adjust fuel delivery and spark
timing according to incoming air density.
IC Circuit Cylinder 1-8: The scan tool displays OK
or Fault. If there is a problem with an ignition control
circuit, the scan tool displays Fault. The scan tool
displays OK under the normal operating conditions.

Ignition 1: The scan tool displays 0-25.5 Volts. The

Ignition 1 represents the system voltage measured
by the PCM at the ignition feed circuit.
lnj. PWM Average Bank 1 and Bank 2: The scan
tool displays a range of 0-1,000 m/sec. The Injector
average indicates the amount of time the PCM
commands each injector ON during each engine cycle.
A longer injector pulse width causes more fuel to be
delivered. The Injector Pulse Width increases with
an increased engine load.
Knock Retard: The scan tool displays a range of
0.0-16. Knock Retard indicates the amount of spark
the PCM removes from the IC spark advance in
response to the signal from the knock sensors.
Long Term FT Average Bank 1 and Bank 2: The
scan tool displays Percentage. This parameter
indicates the average of all long term fuel trim cells.
The short term fuel trim cells are rated (Weighted) for
the amount of which they are used. For example,
an idle cell is rated higher than a wide open cell. If a
fueling malfunction occurs in the idle cell and the
wide open cell, the average would be more affected
by the idle cell than the wide open cell. A negative
value significantly below 0% indicates that the
fuel system is rich and fuel delivery is being reduced
(decreased injector pulse width). A positive value
significantly greater than 0% indicates that a
lean condition exists and the PCM compensates by
adding fuel (increased injector pulse width). When the
average of the cells reach a predetermined high or
low, a fuel trim DTC sets.
Long Term FT Bank 1 and Bank 2: The scan tool
displays Percentage. The PCM derives the Long
Term Fuel Trim from the Short Term Fuel Trim value.
The Long Term Fuel Trim represents a long-term
correction of fuel delivery. A value of 0% indicates that
fuel delivery requires no compensation in order to
maintain the PCM commanded air/fuel ratio. A
negative value significantly below 0% indicates that
the fuel system is rich and the PCM is reducing
the fuel delivery (dE?creased injector pulse width). A
positive value significantly greater than 0% indicates
that a lean condition exists and the PCM compensates
by adding fuel (increased injector pulse width). Fuel
trim values at maximum authority indicates an
excessively rich or lean system.
Loop Status: The scan tool displays Open or
Closed. Closed Loop indicates that the PCM is
controlling fuel delivery according to oxygen sensor
voltage. In Open Loop, the PCM ignores the oxygen
sensor voltage and bases the amount of fuel to
be delivered on TP sensor, engine coolant, and MAF
sensor inputs only.
Low Oil Lamp: The scan tool displays On or Off.
The scan tool displays On when the PCM detects that
there is a low oil level condition. The Low Oil Lamp
is then commanded on by the PCM.
Low Oil Level: The scan tool displays Yes or No.
This parameter indicates when the engine oil level
is low. The scan tool displays YES when the
PCM detects the engine oil level is low.

6-1254

Engine Controls - 5.7L

MAF: The scan tool displays a range of 0.0-655 g/s.

The MAF (Mass Air Flow) is the MAF Input Frequency
converted to grams of air per second. This indicates
the amount of air entering the engine.
MAF Frequency: The scan tool displays a range of
0-31 ,999 Hz. The PCM converts current draw
needed by the MAF (to keep the hot wires at a
constant temperature) into a frequency signal. The
scan tool displays this frequency in Hertz signal.
MAP: The scan tool displays a range of
10-105 kPa/0.00-5.0 Volts. The Manifold Absolute
Pressure (MAP) sensor measures the change in
the intake manifold pressure from engine load, and
speed changes. As the intake manifold pressure
increc;1ses, the intake vac;uum decreases resulting in a
higher MAP sensor voltage and kPa reading. The
PCM uses the MAP sensor signal tor the following:
(1) Updating the BARO reading; (2) Enabling factor for
several of the diagnostics.
MIL:' The scan tool displays On or Ott. The scan tool
indicates if the PCM has commanded the Malfunction
Indicator Light (MIL) On.
Mileage Since DTC Cleared: The scan tool displays
Kilometer$ or Miles. This parameter indicates the
mileage accumulated since an emission Diagnostic
Trouble Code cleared. The PCM stores this mileage in
the Freeze Frame and Failure records butters.
Mileage Since First Failure: The scan tool displays
Kilometers or Miles. This parameter indicates the
mileage accumulated since an emission Diagnostic
Trouble Code first failed. The PCM stores this mileage
in the Freeze Frame and Failure records buffers.
Mileage Since Last Failure: The scan tool displays
Kilometers or Miles. This parameter indicates the
mileage accumulated since an emission Diagnostic
Trouble Code last failed. The PCM stores this mileage
in the Freeze Frame and Failure records buffers.
Mileage Since MIL Request: The scan tool displays
Kilometers or Miles. This parameter indicates the
mileage accumulated since the PCM requested the
MIL to illuminate. The PCM stores this mileage in the
Freeze Frame and Failure records buffers.
Misfire Current #1 - #8: The scan tool displays a
range of 0-200 Counts. The Misfire Current counters
increment at a rate according to the number of
possible misfires the PCM detects on each cylinder
during the last 200 cylinder firing events.
Mi!;fire History #1 - #8: The scan tool displays a
range of 0-65,535 Counts. The Misfire History
counters display the total level of misfire that has been
detected on each cylinder. The Misfire History
counters will not update or show any activity until a
misfire OTC (P0300) has become active. The
Misfire History counters will update every 200 cylinder
firing events.

Engine
Misfiring Cylinder: The sean tool displays Prim. Cyl
# 0-8 and Sec. Cyl # 0-8. When a multiple misfire
occurs, the scan tool displays the cylinder with
the most significant misfire under Prim. Cyl. The scan
tool displays the least significant misfire under
Sec. Cyl.
Misfire Revolution Status: The scan tool displays
Reject/Accept. This parameter,indicates the misfire
diagnostic is inhibited. The scan tool displays Reject
when the conditions for running the OTC are not
in range.
Not Run Counter: The scan tool displays counts
from O to 65,535. The scan tool displays the numb~r of
times a OTC diagnostic has not reached it's . .
predetermined criteria in order to run since it's first
failure.
PCM Reset: The scan tool displays Yes or No. This.
parameter indicates when the internal PCM resets.
The scan tool displays YES when an internal .
PCM reset occurred. The scan tool displays NO under
the normal operating conditions.
PNP: The scan.tool displays PARK/NEUTRAL or
R-0321. When the transmission is in park or neutral
the scan tool displays PARK/NEUTRAL. When
you place the gea:r se.lector into reverse or any forward
gear position, the scan tool displays R-0321.
Pass Counter: The scan tool displays the number
of times a OTC has passed.
Reverse Inhibit (MIT only): The scan tool displays
Yes or No. The PCM grounds the control circuit
when the conditions are.met for enabling the Reverse
Inhibit solenoid. Th.e scan tool displays Yes when
the PCM grounds the control circuit.
Revolutions with Misfire: The scan tool displays
the number of engine revolutions the engine is
misfiring.
SHRT FT Average 1 and 2: The scan tool displays
Percentage. This parameter indicates the average
of the short term fuel trim cells. The short term fuel trim
cells are rated (Weighted) for the amount of which
they are used. For example, the PCM rates an idle cell
higher than a wide open cell. If a fueling malfunction
is occurs in the idle cell and the wide open cell, the idle
cell would affect more than then the wide open cell.
A negative value significantly below 0% indicates that .
the fuel system is rich and th(;:l PCM is reducing the
fuel delivery (decreased injector pulse width). A
positive value significantly greater than 0% indicates
that a lean condition exists and the PCM is
compensating by adding fuel (increased injector pulse
width). When the average of the cells reach a
predetermined high or low, a fuel trim OTC sets.

Engine
Short Term FT Bank 1 and Bank 2: The scan tool
displays Percentage. The Short Term Fuel Trim
represents a short-term correction to fuel delivery by
the PCM in response to the amount of time the
fuel control oxygen sensor voltage spends above or
below the 450 mV threshold. If the oxygen sensor
voltage mainly remains less than 450 mV, indicating a
lean air/fuel mixture, short term fuel trim increases
into the positive range above 0%. The PCM adds fuel.
If the oxygen sensor voltage stays mainly above the
threshold, the short term fuel trim decreases below 0%
into the negative range. The PCM reduces the fuel
delivery in order to compensate for the indicated rich
condition. Under certain conditions such as an
extended idle and a high ambient temperature, the
canister purge may cause the Short Term FuelTrim to
read in the negative range during normal operation.
The Fuel trim values at maximum authority may
indicate an excessively rich or lean system.
Skip Shift Lamp (MIT only): The scan tool displays
On or Off. The PCM sends a message to the IPC
(via class 2) to enable the Skip Shift Lamp when the
Skip Shift Solenoid is enabled. The scan tool displays
On when the Skip Shift Lamp is On.
Skip Shift Solenoid (MIT): The scan tool displays
Enabled or Disabled. The PCM grounds the control
circuit when the conditions are met for enabling
the Skip Shift solenoid. The scan tool displays Enabled
when the PCM grounds the control circuit.
Spark: The scan tool displays a range of -64 to
64. The scan tool displays the amount of degrees the
PCM commands the spark advance on the IC
circuit. The PCM computes the desired spark advance
using the following: (1) Engine coolant temperature;
(2) Engine speed (RPM); (3) Load; (4) Vehicle speed.
The PCM adjusts the timing.
Start Up ECT: The scan tool displays a range of
-39C to 140C (-38F to 284F). The scan tool
displays the Engine Coolant Temperature at the time
the engine was started. The PCM uses Start Up
ECT for certain DTCs.
TCC Brake Switch: The scan tool displays Applied
or Released. This parameter indicates the state of
the TCC brake switch circuit input. The scan tool
displays Applied when you apply the vehicle brakes.
The torque converter clutch disengages. The scan tool
displays Released when you release the vehicle
brakes. This allows the torque converter clutch to
engage.
TCC Duty Cycle: The scan tool displays Disabled or
Enabled. This parameter is the commanded state of
the TCC PWM solenoid. The scan tool displays
Enabled when the commanded state of the solenoid is
ON. The scan tqol displays Disabled when the
solenoid is not on.
TCC Enable Sol.: The scan tool displays Enabled or
Disabled. The scan tool displays Enabled when the
electrical system supplies a voltage to the TCC Enable
solenoid.

Engine Controls - 5.7L

6-1255

Total Misfire Current Count: The scan tool

displays a range of 0-200. The Total Misfire Current
Count displays the total number of cylinder firing
events that the PCM detected as being misfires during
the last 200 crankshaft revolution sample period.
Total Misfire Failures Since First Fail: The scan
tool displays a range of 0-65,535. The Total
Misfire Failures Since First Fail displays the total
number of cylinder firing events that the PCM detected
as being misfires since the first failure.
Total Misfire Passes Since First Fail: The scan
tool displays a range of 0-65,535. The Total Misfire
Passes Since First Fail displays the total number
of cylinder firing events that the PCM detected
as being good since the first fail.
TP Angle: The scan tool displays 0-100 percent.
The scan tool displays the amount of throttle opening
in percentage. The scan tool displays about
O percent at closed throttle. The scan tool displays
about 100 percent at wide open throttle.
TP Sensor: The scan tool displays 0-5 Volts. The
scan tool displays the amount of throttle opening
in voltage. When the throttle is at a closed throttle the
voltage is between 0.4-0.9 Volts. When the throttle
is at wide open throttle the voltage is above 4.0 Volts.
Traction Control: The scan tool displays Active
or Inactive (If so equipped). The scan tool displays
active if the PCM receives a signal from the Electronic
Brake and Traction Control Module (EBTCM)
requesting torque reduction during a traction control
maneuver. The scan tool displays Inactive under
normal operating conditions.
Transmission OSS: The scan tool displays
transmission output speed. This parameter indicates
the rotational speed of the transmission output
shaft expressed as revolutions per minute.
Transmission Range: The scan tool displays the
transmission gear position.
Vehicle Speed: The scan tool displays km/h and
mph. The vehicle speed sensor signal is converted into
km/h and mph for display on the scan tool.
VTD Fuel Disabled: The scan tool displays
Active/Inactive. The PCM receives a 40-60 Hertz
signal from the Body Control Module. (BCM) when the
proper starting procedure occurs. When the PCM
receives this 40-60 Hertz signal the fuel system
is enabled and the engine starts. The scan tool
displays Active once the hertz signal is received by
the PCM. If an improper starting procedure occurs, the
BCM will not send the 40-60 Hertz signal to the
PCM and the PCM disables the fuel system. The scan
tool displays Inactive.
Warm-Ups w/o Emission Faults: The scan tool
displays a range of 0-255. This parameter counts the
number of warm up cycles without an emission
fault present. The counter increments to 255 and roll
back to O unless a fault occurs. If a fault occurs,
the counter reverts back to O until the fault is corrected.
Clearing the information with a scan tool or a loss of
power to the PCM also resets the counter to 0.

6-1256

Engine

Engine Controls - 5.7L

Warm-Ups w/o Non-Emission Faults: The scan

tool displays a range of 0-255. This parameter counts
the number of warm up cycles without a non-emission
fault present. The counter increments to 255 and
roll back to O unless a fault occurs. If a fault occurs,
the counter reverts back to O until the fault is corrected.
Clearing information with a scan tool or a loss of
power to the PCM also resets the counter to 0.

DTC List
Important: An export vehicle may have unrequired
emissions components removed.
Important: For Automatic Transmission DTC types,
refer to Diagnostic Trouble Code Identification (5. 7L) in
Automatic Transmission-4L60E.
llrThe service information contained in this manual
refers to the Federal calibration package. The export
change is NOT reflected in the service information
on the DTC's diagnostic support information page or in
the Repair Instructions. The DTC Type table
information refers to domestic and Export calibration
packages. Export vehicles may have differences
in DTC types that will affect Malfunction Indicator Lamp

(MIL) operation. Certain DTCs have been changed

from type A to type C or, in some cases, type X. When
a type A diagnostic fails, a DTC is set immediately
and the Malfunction Indicator Lamp (MIL) is
illuminated. When a type B DTC diagnostic fails, the
Malfunction Indicator Lamp (MIL) will illuminate if
the fault is present after two consecutive drive trips. A
type C DTC will set after one failure and be stored'
in history but will not illuminate the Malfunction
lndicatqr Lamp (MIL). Type X DTCs have been turned
off (the diagnostic does not run, no codes are
stored, and the Malfunction Indicator Lamp (MIL) will
not illuminate.
If a system is malfunctioning and the associated OTC
has been disabled (Type X), it may be beneficial to
use the diagnostic table as a guide to aid in diagnosis.
Many of the DTC tables include a functional test of
the system that may pinpoint a condition. However, it
is imRortant to remember that the DTC tables are
specifically designed for use only when a DTC is set.
Therefore, a thorough. understanding of the normal
operation of the system being diagnosed is necessary
and use of the tables for this purpose is. at the
discretion of the technician.

Diagnostic Trouble Code (OTC) Type Table

Export
Unleaded Fuel Export Leaded
Fuel
RPO K29,

OTC

Description

Domestic

and VE1

RPO NMB

P0101

Mass Air Flow (MAF) System Performance

P0102

Mass Air Flow (MAF) Sensor Circuit Low Frequency

B
B

P0103

Mass Air Flow (MAF) Sensor Circuit High Frequency

P0107

Manifold Absolute Pressure (MAP) Sensor Circuit

Low Voltage

P0108

Manifold Absolute Pressure (MAP) Sensor Circuit

High Voltage

P0112

Intake Air Temperature (IAT) Sensor Circuit Low

Voltage

P0113

Intake Air Temperature (IAT) Sensor Circuit High

Voltage

P0117

Engine Coolant Temperature (ECT) Sensor Low

Voltage

P0118

Engine Coolant Temperature (ECT) Sensor High

Voltage

P0121

TP Sensor Circuit Insufficient Activity

x
B

P0122

TP Sensor Circuit Low Voltage

P0123

TP Sensor Circuit High Voltage

13

P0125

Engine Coolant Temperature (ECT) Excessive Time

To Closed Loop Fuel Control

P0131

Heated Oxygen Sensor (H02S) Circuit Low Voltage

Bank 1 Sensor 1

P0132

Heated Oxygen Sensor (H02S) Circuit High Voltage

Bank 1 Sensor 1

P0133

Heated Oxygen Sensor (H02S) Slow Response

Bank 1 Sensor 1

P0134

Heated Oxygen Sensor (H02S) Circuit Insufficient

Activity Bank 1 Sensor 1

Engine

Engine Controls - 5.7L

6-1257

Diagnostic Trouble Code (OTC) Type Table (cont'd)

Domestic

Export
Unleaded Fuel
RPO K29,
and VE1

P0135

Heated Oxygen Sensor (H02S) Heater Circuit

Bank 1 Sensor 1

P0137

Heated Oxygen Sensor (H02S) Circuit Low Voltage

Bank 1 Sensor 2

P0138

Heated Oxygen Sensor (H02S) Circuit High Voltage

Bank 1 Sensor 2

P0140

Heated Oxygen Sensor (H02S) Circuit Insufficient

Activity Bank 1 Sensor 2

P0141

Heated Oxygen Sensor (H02S) Heater Circuit

Bank 1 Sensor 2

P0151

Heated Oxygen Sensor (H02S) Circuit Low Voltage

Bank 2 Sensor 1

P0152

Heated Oxygen Sensor (H02S) Circuit High Voltage

Bank 2 Sensor 1

P0153

Heated Oxygen Sensor (H02S) Slow Response

Bank 2 Sensor 1

P0154

Heated Oxygen Sensor (H02S) Circuit Insufficient

Activity Bank 2 Sensor 1

P0155

Heated Oxygen Sensor (H02S) Heater Circuit

Bank 2 Sensor 1

P0157

Heated Oxygen Sensor (H02S) Circuit Low Voltage

Bank 2 Sensor 2

),<

P0158

Heated Oxygen Sensor (H02S) Circuit High Voltage

Bank 2 Sensor 2

P0160

Heated Oxygen Sensor (t-102S) Circuit Insufficient

Signal Activity Bank 2 Sensor 2

P0161

Heated Oxygen Sensor (H02S) Heater Circuit

Bank 2 Sensor 2

P0171

Fuel Trim System Lean Bank 1

x
x
x
x
x
B

Description

DTC

P0172

Fuel Trim System Rich Bank 1

P0174

Fuel Trim System Lean Bank 2

P0175

Fuel Trim System Rich Bank 2

c
c
c
c
c

P0230

Fuel Pump Control Circuit

'

Export Leaded
Fuel
RPO NM8

P0300

Engine Misfire Detected

P0325

Knock Sensor (KS) Circuit

P0327

Knock Sensor (KS) Circuit Front

P0332

Knock Sensor (KS) Circuit Rear

c
c
c

c
c
c

P0335

CKP Sensor Circuit

P0336

CKP Sensor Circuit Performance

P0341

CMP Circuit Performance

P0342

CMP Sensor Circuit Low ,Voltage

P0343

CMP Sensor Circuit High Voltage

P0351

Ignition Control #1 Circuit

P0352

Ignition Control #2 Circuit

B.

P0353

Ignition Control #3 Circuit

P0354

Ignition Control #4 Circuit

P0355

Ignition Control #5 Circuit

B
,B

..

P0356

Ignition Control #6 Circuit

P0357

Ignition Control #7 Circuit

P0358

Ignition Control #8 Circuit

B
..

B
B

B
B

6-1258

Engine

Engine Controls - 5.7L

Diagnostic Trouble Code (DTC) Type Table (cont'd)

Export
Unleaded Fuel Export Leaded
Fuel
RPO K29,

OTC

Description

Domestic

and VE1

RPO NM8

x
x
x
x
x
x
x
x
x
x

P0401

EGR System Flow Insufficient

P0404

EGR System Performance

P0405

EGR Pintle Position Circuit Low Voltage

P0410

AIR System

P0412

AIR Solenoid Relay Control Circuit

c
c
c
c
c
c
c

P0418

AIR Pump Relay Control Circuit

P0420

TWC System Low Efficiency Bank 1

P0430

TWC System Low Efficiency Bank 2

P0440

EVAP System

P0442

EVAP Control System Small Leak Detected

P0443

EVAP Purge Solenoid Control Circuit

P0446

EVAP Canister Vent Blocked

P0449

EVAP Canister Vent Solenoid Valve Control Circuit

P0452

Fuel Tank Pressure Sensor Low Voltage

P0453

Fuel Tank Pressure Sensor High Voltage

x
x
x
x

P0461

Fuel Level Sensor Circuit Performance

P0462

Fuel Level Sensor Circuit Low Voltage

P0463

Fuel Level Sensor Circuit High Voltage

c
c
c

c
c
c
c
c

P0480

FC Relay 1 Control Circuit

P0481

FC Relay 2 and 3 Control Circuit

c
c
c
c
c
c
c
c
c

P0500

VSS Circuit (MIT)

P0506

Idle Speed Low

P0507

Idle Speed High

P0530

A/C Refrigerant Pressure Sensor Circuit

c
c
c

c
c
c
c
c

c
c
c
c
c

P0562

System Voltage Low

P0563

System Voltage High

P0601

PCM Memory

P0602

PCM Not Programmed

P0604

PCM RAM Performance

P0608

VSS Output Circuit

MIL Control Circuit

B
(No MIL)

c
c
c
c

c
c
c

P0650

P0801

Reverse Inhibit Solenoid Control Circuit (MIT)

c
c
c

P0803

Skip Shift Solenoid Control Circuit (MIT)

P0804

Skip Shift Lamp Control Circuit (MIT)

P1111

Intake Air Temperature (IAT) Sensor Circuit

Intermittent High Voltage

c
c

x
c

P1112

Intake Air Temperature (IAT) Sensor Circuit

Intermittent Low Voltage

c
c
c
c
c

c
c
c
c
c

c
c
c
c
c

P0654

Engine Speed Output Circuit

P0656

Fuel Gauge Output Control Circuit

P1114

ECT Sensor Circuit Intermittent Low Voltage

P1115

ECT Sensor Circuit Intermittent High Voltage

P1121

TP Sensor CKT Intermittent High Voltage

P1122

TP Sensor CKT Intermittent Low Voltage

x
x
x

I
\

Engine

Engine Controls - 5.7L 6-1259

Diagnostic Trouble.Code (DTC) Type Table (c.ont'd)
Export
Unleaded Fuel Export Lea~ed
Fuel
RPO K29,
and VE1
RPO NM8

Description

OTC

:~

P1133

P1134

Heated Oxygen Sensor (H02S) Transition Time

Ratio Bank 1 Sensor 1

8'

P1153

Heated Oxygen Sensor (H02S) Insufficient

Switching Bank 2 Sensor 1

/e'. .'

P1154

Heated Oxygen Sensor (H02S) Transition Time

Ratio Bank 2 Sensor 1

P1258

Engine Coolant Over Temperature-Fuel Disabled

P1336

CKP System Variation Not Learned

P1380

EB(T}CM OTC Detected - Rough Road Data

Unusable

P1404

EGR Valve Pintle Stuck Open

P1415

AIR System Bank 1

P1416

AIR System Bank 2

x
x

P1441

Evaporative Emissions (EVAP) System Flow During

Non-Purge

c
c
c
c
c
c
c

B .. '

"

c
c

P1539

NC Clutch Status C.ircuit High Voltage

P1545.

A/C Clutch Relay Control Circuit . .

P1546

NC Clutch Status. Circuit Low Voltage

P1626

Theft Deterrent System Fuel Enable Circuit

P1635

5 Volt Reference #1 Circuit

P1639

5 Volt Re.ference #2 Circuit ...

Fuel System Specifications

Fuel (Premium Recommended)
The following information appears in the General
Motors Owner's Manual for this vehicle.
Use premium unl.eaded gasoline rated at 91 octane or
higher for best performance. You may use middle
grade or regular unleaded gasolines, but your vehicle
may not accE::llerate as well.
At aminimum, the gasoline you use should meet
specifications ASTM 04814 in the United Stltes and
CGSB 3.5-M93 in Canada. Improved gasoline
specifications have been developed by the American
Automobile Manufacturers Association (AAMA) for
better vehicle performance and engine protection.
Gasolines meeting the AAMA specification could
provide improved driveability andemission control
system protection compared to other gasolines.
Be sure the posted octane for premium is at least
91 (at least 89 for middle grade and 87 for regular). 1f
the octane is less than 87, you may get a heavy
knocking noise when you drive. If it's bad enough, it .
~an damage your engine.

Domestic

Heated Oxygen Sensor (H02S) Insufficient

Switching Bank 1 Sensor 1

If you're using fuel rated a.t the recommended octane

or higher and you still hear a heavy knocking, your
engine needs service. But don't worry if you hear
a little pinging noise when you're accelerating
or driving up a hill. That's normal, and you don't have

.C

..

..
,,,

..

,s.,

,.

""

c
c
c
c

to buy a higher octan~ fuel to get rid of pinging. It's

the heavy, constant knock that means you have
a problem.

11 your vehicle is certified to meet California Emission

Standards (indicated on the underhood tune-up
label), it is designed to operate on fuels that meet
California specifications. If such fuels are not available
in states adopting California emissions standards,
your vehicle will operate satisfactorily on fuels meeting
.federal specifications, but emission control system
. performance may be c1ffected. The. malfunction
indicator lamp on your instrument panel may turn on
and/oryourvehicle may fail a smog-check test. If
this occurs; return-to a qualified service outlet
for diagnosis to determine the cause of failure. In the
event it is determined that the cause of the condition
is the type of fuels used, repairs may not be covered
by your warranty:
Some gasolines that are not r~formulated for low
emissions contain aR octane-enhancing additive called
methylcyclopentadlenyl manganese tricarbonyl
(MMT); ask your service station.operator whether or
not 'this fuel contains MMT. General Motors does
not recommendthe use of such gasolines. If fuels
containing MMT are used, spark.plug life may
be reduced and your emission control system
performance may be affected. The malfunction
indicator lamp on your instrument panel may turn on.
If this occurs, return to a qualified service outlet
for service.

6-1260

Engine Controls - 5.7L

Engine

To provide cleaner air, all gasolines in the United

States are now required to contain additives that will
help prevent deposits fr:om forming in your engine and
fuel system, allowing your emission control system
to function properly. Therefore, you should not have to
add anything to the fuel. 1n addition, gasolines
containing oxygenates, such as ethers and ethanol,
and reformulated gasolines may be available in
your area to help clean the air. General Motors
recommends that you use these gasolines if they
comply with the specifications described earlier.

Notice: Your.vehicle was not designed for fuel that

contains methanol. Don't use it. It can corrode
metal parts in your fuel system and also damage
plastic and rubber parts. That damage wouldn't
be covered under your warranty.

GM SPO Group Numbers

Application

GM SPO Group Number

Accelerator Control Cable

Accelerator Pedal
Air Cleaner Assembly
Air Filter
Camshaft Position (CMP) Sensor
Crankshaft Position (CKP) Sensor
Engine Coolant Temperature (ECT) Sensor
Engine Oil Level Sensor
EVAP Canister
EVAP Fuel Tank Pressure Sensor
EVAP Hoses and Pipes
EVAP Purge Solenoid
EVAP Vent Valve
Exhaust Gas Recirculation (EGR) Valve
Fuel Hoses and Pipes
Fuel Injectors
Fuel Pump
Fuel Pump Relay
Fuel Rail Assembly
Fuel Sender
Fuel Tank
Fuel Tank Straps
Heated Oxygen Sensor
Idle Air Control (IAC) Valve
Ignition Coil/Module

...

lnline Fuel Filter

Intake Air Duct
Intake Air Temperature (IAT) Sensor
Knock Sensors
Manifold Absolute Pressure (MAP) Sensor
Mass Air Flow (MAF) Sensor
Positive Crankcase Vent Valve
Powertrain Control Module (PCM)
Throttle Body Assembly
Throttle Position (TP) Sensor
Vehicle Speed (VSS) Sensor

3.430
3.451
3.402
3.410
2.383
2.383
3.682
1.516
3.130
3.140
3.145
3.140
3.140
3.670
3.163
3.300
3.900
3.900
3.330
3.107
3.001
3.022
3.682
3.338
2.170
3.890
3.417
3.682
2.383
3.682
3.682
1.745
3.670
3.335
3.339
3.682

Engine

Engine Controls - 5.7L

Schematic and Routing Diagrams

Emission Hose Routing Diagram

Emission Hose Routing

G
3
4
5
7
219151

Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)

To HVAC
To Power Brake Vacuum Boost
EVAP Service Port
To EVAP Canister
EVAP Canister Purge Solenoid Valve
Throttle Body
EGR Valve
Crankcase Ventilation Hose
PCV Valve

6-1261

E.nginEr
Controls
- 5.7L
.,
..' .
...
.
. . ,.1

Engine

Engine Controls Schematic References

Section Number Subsection Name

Reference on Schematic

Antilock Brakes Cell 44

5-ABS Brakes

BTSI Cell 138

2-Steering

Fuse Block Details Cell 11

8-Wiring Systems

Ground Distribution Cell 14

8-Wiring Systems

Power Distribution Cell 10

8-Wiring Systems

Supplemental Inflatable Restraints Cell 47

9-SIR

Release Systems Cell 134

8-Body Rear End

Engine Controls Schematic Icons

Icon

Icon Definition

Refer to ESD Notice in Cautions and No~ices.

19384

Refer to OBD II Symbol Description Notice ih'Cautiohs and Notices.

19385

m
:::,
c.a

Engine Controls Schematics (Power, Ground and MIL)

l Hot In RUN, BULB TEST And START !

lHot At All Times l

H10

'--------------J

L----- ----~
0.80RN 340

0.5 PNK/BLK

439

C101

T
CD

Lamp (MIL)

_r _

(SERVICE

E~G~':_S:_O~

(I)

~
I ~,.~

~~

A4

0.35 BRN/WHT 419

0.80RN 340

s1os-------~

:::,

" - - - - - "".' - - , Instrument

I
Malfunction
I Cl t
I
Indicator
I
us er

,. - - - - - - - - - ; - - - , Underhood
I
H7
PCM IGN
D~:~ution I Electrical
MiniFuse
ee1110
I Center 2
I
I
HS
15A
I

- - - - , Underhood
PCM BAT
I Electrical
MlnlFuse I Center 1
10 A
I

C230

0.5PNK 439
P110

0.80RN 340

0.80RN 340

0.35 BRN/WHT 419

19

20

61

" - - - - - - - &ltt-;ry- - - - - - -Bd;ry- - - - - - -

37

C2

"ig,;iiio';;" -

Positive

Positive

Positive

Voltage

Voltage

Voltage

C2=BLU

PCM Ground

~ - - - - - - - - - - - - G r o u n d - - - - - - G r o u n d - - - - - - Ground---- Ground_

- - - - - - - - - - - - 76

0.8BLK 451

C1

0.8 BLK 451

C1 = RED

Control

72

C1

-MIL - - - - - - "";,c~ -

21

- - - - - - - - - 60

0.8 BLK 451

C2

0.8BLK 451

PCM Ground

Jumper _ _ _ _ _ _ Jumper

24

C1

24

,Powertrain
I
Control
I Module
I (PCM)

-----~

C2

m
:::,
c.a
:::,

0.8 BLK/WHT

(I)

1704

Ground
Distribution
Gell14

-----

0
:::,

8110

" "I

'iii

..,

(J1

3BLK 451

=.....

a,

.....
I

G110

a,
192829

Engine Controls Schematics (Data Link Connector (DLC))

0)
I
..I,

!Loe I

!Hot At All Times!

'" - - - - - - - - I Power

03

I ~~~Ion
I
Fuse Block
C3
I
._ ___ Details
een 11_ _ _ _

- - - - ., IP
CIGAR ACCY I Fuse
Fuse 11
I Block
25 A
I
C4
I
_ _ _ _ .J

0.80RN 540

+- - - - - - -

S240

Cell11

0.80RN 540

'" - - - - - - - - - - - - - - - - - ., Powertrain
I Control

PCM

7V

Fuse Block
Details

!Esc
C1=RED I

C2=BLU

,Module
(PCM)

~-:~~L ,::-~-:::1-1:-~A
I

Serial Data

Serial Data

~
~

0)
~

m
:::,
ca
:::,
CD

:::,
" 'I

(II

:....

E C105

0.35TAN 800
5184
0.35
TAN 800
0.35TAN 800
P110

F C220

0.8 BLK/WHT 451 ,

S110

Antilock

A12

0.8 BLK/WHT 451

- -

- -Ill

Ground
DistribU1ion

........_ce__
111.....
4_

._ -

_. 11>- -,.

T
1

5215

' ' ,0.5 BLK/WHT

451

3BLK
S216 - - - - - - - S 2 1 7
650

P110
C230

0.35TAN 800
8225
0.35
TAN 800

0.35 BLK 650

0.35 PPL 1807

4
-=- G110

C200A
C200D

Supplemental
Inflatable
Restraints
(SIR)
Cell47

3 BLK 451
3 BLK 650

P100

Brakes
Cell44

16

0.35TAN 800

----------------2 -------------9

DataLink
Connector
(DLC)

m
:::,

-=- G200

(C

:::,
192s33

CD

Engine Controls Schematics {Bank 1 Ignition Coil/Modules)

IHot In AUN And START I

- - - , ~ -- - - - .,I Underhood
I'" Power
I Distribution
J9
INJ 1
I Electrical
Cell 10
MiniFuse
Center 2
I
JS
15A
I
I

L----------..1
0.8 P NK/WHT 639
A C100

r I
I
I

Ignition

~_

0_8 PNK 639

2
5~:;:; ______ ~-~

.-~=-~se-~...,,.~:

~ntrol

- -

_ _ _ _ _ _ _ =ence~ _

- I PCM
= RED
C2=BLU
Ignition

,Powertrain

1c1

Ignition
_ _ _ _ _ _ _ _ ~ntrol -

Ignition
_ _ _

~ntrol _ _ _ _ _ _ _ ~ntrol __ -

~;1~~:: : :~:~~~~;I~~:: : : : : -_ ~;1~~:_i ~;E~:: :::: ~

I
I Control
Module
I
1 (PCM)
,:~

1~~

:_C~ _":

0:~

[S]

s122~------------"1'----------------111'------------------11'1---.. . .
~--------If'--------.

D
Ignition
Feed

c
Ignition
Control
Signal

r . .____

rn~~

D
Reference
Low

:_ro_u_n_d_ _ __.

Ignition

Coil/

Ignition
Feed

Ignition
Control
Signal

r L------:. .

Module

rn~:~

c.

C.,
Ignition
Coil/
Module

Reference
Low

ro
...u_nd
________..

$126

Ignition
Control
Signal

rn~

Ground

L--------A-----'

550
0.8BLK 550

jVG112

Reference

Low

Ignition
Feed

____...

Ground

A'

Ignition
Control
Signal

Ignition
Coil/
Module
7

::::,
cg
::::,

mspark

WPlug

CD

0
::::,

A ,C106
0.8$100
BLK_550
_ _ _o_.8.....;;;;B..;;;L.;...K_ _ _, I

D.,
Ignition
Coil/
Module

~=~~Ion

.0..

;;
c.n

1 Cell14

....:....

1 BLK
450

0,

....
N
I

0,

192835

c.n
-.rfj

Engine Controls Schematics (Bank 2 Ignition Coil/Modules)

O')
I

...I,

"---,:1----!Hot In RUN And START

Distribution
I Cell 10
I

[S]

INJ 2
Electrical
1Center 2
MiniFuse
15 A
I

J11

J10

1
-

O')
O')

"'Underhood
I

I Power

.. -

.,

E_
-S

" - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - , Powertrain
I
I PCM 11 Control

f1

I
I

0. 8 PNK 839
B , C101

I
I

Ignition
Control

Ignition
Control

IC1=REDII
C2=BLU I
Ignition
Control

-=-

Reference

odule
I (PCM)

Ignition
Control

I+ I
I+ I

=~:r:;;~- - - -~~~F~~:~-:~:-~~~r: : - :-:-:-~~--~~E=:~~~E=:~:-~-:-:~~~:~~;; i, A

$124

::::s

CQ

::::s

-a
0

::::s

'ii

U1

:....

~
$125

D
Ignition
Feed

rn

c
Ignition
Control
Signal
Ground

A
Spark
Plug

sl
Reference
Low

c.

D ,,

Ignition
Coil/
Module
2

Ignition
Feed

BL

Ignition
Control
Signal

Reference
Low

Ground

[ITp&k

B
Ignition
Coil/
Module
4

Reference
Low

r
[I]Spak

A'

Plug

D ,,
Ignition
Feed
Ground

Plug

C,
Ignition
Control
Signal

Ignition
Coil/
Module
6

sl
Reference
Low

r
[I]Spa~

D ,,
Ignition
Feed
Ground

C,
Ignition
Control
Signal

Ignition
Coil/
Module

Plug

5127

A, C107

0.8 BLK 550

0.8 BLK
$100 ----------4~
550
0.8 BLK 550

1 BLK
450

Ground
Distribution
Ce1114

m
::::s

ce.
::::s
192844

Engine Controls Schematics (Engine Speed Output, CKP and CMP Sensors)
.- - - - , Instrument

Crankshaft
Position
(CKP)
Sensor

I Tachometerl Cluster
llnput
I ~

813--J ~

::::,

Camshaft

Position
(CMP)
Sensor

Hall Sensor
Trigger Circuit
Amplifier And
Voltage Reg
Electronics

jLoc

Traction
Control
Antilock
Brakes
Cell44

5
ff)

lS]

0.35 WHTI121 .
D C230
With

CQ

P110
0.35 WHT 121

[B

29

0.35
LTGRN 1867

0.35 YEL 573

__o_.3_5_W_H_T_S
120
121
0.35 WHT 121

I t

0.35
YELi 1868
BLK

Power

Gnd

o.35 PNK/BLK~2 A
oc~ RED
0.35
BRN/WHT 633
B
A
C

C108

0.35 PNK/BLK 632

0.35 RED 631
0.35
BRN/WHT 633
35

44

C2

Tachometer Output

C!<P Sensor Signal Input

Reference u1;V - - Low

Ignition

-1

C2

C1

Reference C~P Sensor _ Low

Signal Input
-

II

70

62

C1 22

4
-

C2

u12V -- ~ 60W~rtr81n
Ignition
I
Feed

on ro
Module

I~~
.._

I ~a

PCM

I
C1=REO
I
C2 = BLU
._ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

KS
KS
Signal
Signal
Front _ _ _ _ _ _ _ Rear _ _ _ _ _ _

---

. ____________

m
::::,

I~
I

CQ

.1

::::,

~~~:r~- -;~;11:6
Ar-------------~1

[I]
~

Front
Knock
Sensor
(KS)

[I]
-

(D

::::,

" 'I

in
(11

:....

Rear
Knock
Sensor
(KS)

I'""'

q,

.....

192845

0)

Engine Controls Schematics (Fuel System)

......
I

I
jesc I

S244

_ _ _ _ _I_ _ _ _ - I
ill
0.35 GAY 720

IL 0 c

0.35 GAY 720

GAY 120
83

F3

C405B

G3

1 F

1 ORN 1340

G C405A

1
BLI</
GAY 120
WHT 651
C ________ D
.

05
t_,
ORN/ 469
BLK

AS
I

fuDcJ~

Fuel
Level
Sensor

-------------

Er---~-~

O~;f
I
____ _. \,tk'J..-0

10

I
I

Fuel
Level
Input

52

C2

sv
Feed

SV

Fuel
Tank
Pressure

~~

~AS

---- __

C101

!n~ _

36

C210

~
S110

Gauge
Output
Control

PCM
C1 =flED
C2=BLU

.,
0

tn

U1

:....

r-

- -

!
Ground

C101

- Fuel
Pump
Relay
Control

,
I

0.35
P110
DK
GRN/WHT 465
0.35
DK
BLU 229
37 C2 11 C1

C1

0
::::,

>

C3

E C230

0.35 DK B.LU 1936

::::,
CD

~ Body

0.35
DK
BLU 229

0.35GRY 720

m
::::,

cc

Deterrent
Control
I
Fuel Enable Module
I
~6
.1 (BCM)

DB

P110

co

0.35 BLK/WHT 451

~htt-

0.35 DK BLU 1936

0)

Fuel
Ground

I
..I

0.35
DK GRN/WHT 465

A2

O.$BU<JWHT 451

-:

1Gauge1

75

~
~

., Underhood
I
.

086 I~~~p: 61:~:~~I

____

-fl;- - ------- -1- - - - - - - - - - - ------------- ~uel -

67

810

.. _.. >

0.35GRY 598

-TI-------

... - , Instrument
I Fuel I Cluster

~: .:~~~E::O:G;If$D~;;1~~----------~
r -

0.35GRY 720

HC405A

0.35 DK GAN 890

_87A_ls7
BB

1 GAY
120

~~~1300.5 GR: 41:.5 DK GRN 890

- A10

~:-----

I..

I
I

I )

Fuel Tank .: Tank

Pressure
Unit
I
Sensor

.. _

. - ------------A------,~~
Fuel
Pump

C200D
C200A

r I

- .Theft -

.,

Distrib!J1ion
Cell14.

3 BLK 451

Powertra1n

Deterrent I Control
Fuel
I Module
Enable
I (PCM)

.,,. G305~ _ _ _ _ _ _ . - ______ . ___ .,,. . _ _ _ _ _ . . _ .,,. _______________________ ~.

,!"

m
::::,

G110

192855

ca.::s
CD

,_,

,,-,\

Engine Controls Schematics {Injector Circuits)

l Hot In RUN, l!ULe Tl:ST Ana START I

:::,

l Hot In FIUN, BUI.a Tl:ST And START l

!L0c I

'" - p;~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,I Underhood

INJ 1

Electrical
1
Center 2

Mini Fuse

15A

Distribution

eeu 10

J11

J9

INJ 2

Mini Fuse
J10

JS

15A

0.8PNK 639

0.8PNK 839

Fuse Block
Details
Cell 11

Fuse Block
o,tails
Cell 11

0.5 PNK
839

0.5 PNK 839

0.5 PNK 839

..B

: II :~jector

..B

...

...

0.5PNK 639

0.5 PNK 639

.- ) ""Fuel

.-

.- ) ""Fuel

liij~jector l
B

----J.:.-. :
-T

.- -] ""Fuel

: II :Injector

..B
I

13

...

0.5 BLK 1744

18

.1

31

.A- 3

0.5 PNK 639

lJlj~' Jj~~
""Fuel

.- - "'Fuel

0.5
BLK/WHT 845

0.5
PNK/BLK 1746
33

F~;-.

Fuel .. .,,.

Fue;.,,.

Fuel

Injector 2
Driver

Injector 4
Driver

Injector 6
Driver

Injector 8
Driver

I
I

0.5 PNK 639

:::,

cc

.,,.

1
1

.9

.--1

:::,
CD

0.5
RED/BLK 877

=--/.:. --= =--.:. -..: ;..) .:.-.:. -..: :..: =-- =--:.:.,--= =--.:. -..: -=-- =-- .:. --= =-- .:..-.:.-..: -:..; } =-- =--.:. -..: :..: .:..-/.:. -..: :..: =--.:..-.:. ,- - - - -

12

-=-- =--.:. --=

31

0.5DK
BLU/WHT 878

0.5LT
BLU/BLK 844
~

j~'"' lJItector

0.5
YELJBLK 846

0.5LT
GRN/BLK 1745

23

111

,Fuel

O.SPNK
639

0.5PNK 839

0.5 PNK 839

.. -] ""Fuel

.- -] ""Fuel

: II :~jector

[B

A C100

C101

0.8 PNK/WHT 639

0.8PNK 839

CD

IDEsc!

-----------------------------------~

~-------

ce.
:::,

15

--1-=-

27

C1

--1

Fuel .,,.

Fuel .,,.

Fuel

Fuel

Injector 1
Driver

Injector 3
driver

Injector 5

Injector 7
Driver

Driver

.,,.

~ ~~~::ain

-a
g

'ii

I1 Module

(PCM)
I ~
I ~,.~
I~

UI

:.....
r

I
I

en

~--------------------------------------------------------------J

..a.
N

en

192858

CD

Engine Controls Schematics (Information Sensors)

r -

- -- - -

: MAF

._

0.8PNKf539
8104
- 0.8 PNK 539

- -

- -

- -

- - -

- - - - 5

- - -

- -

48

C1

------8 ----,.-----------43

64.

0.35 YEL 492

!Loe I

2!

jesc!

tn
::,
cc

::,
CD
(')

Powertrain

- - ,

~~j~
>
~

0.35 GRY 596

0.35 YEL 410
Antilock
Brakes
Cell44

0.35 GRY 416

I~J

0.35GRY
....
596---8116

Ignition
Power

-- - - -

~--------~,-:--~49 C2

0.35TAN 472

- -

V
Jsv IAT
Jsv
TP SensorI
ECT JSV
:
5V
.
Sensor
5V
sensor
.
(PCM)
_R_!fe!!n~ _. ....s!!!n~ _
_ _ ... ____ R,!1e~n:!' _ _ _ _ _ _ !g~'-
______ ~

Sensor

0.8 PNK 539

B C105

- - -

JSV MAP

~ S!)n~ _

_____ . ____ ..

- - - - -

[!]

Mass Air
Flow (MAF)
Sensor

MAF

sensor
Signal

Intake
Air
Te.mperature

(IAT)
Sensor

0
::,

....
"'I

0
tp
I

c.n
:....
r-

0.35 GRY 596

0.35 PPL 719

0.35 BLKIWHT 451

I 8={1E
B

- - _.
0.35
ORN/BLK 469

3 BLK 451
48

26

- - -

- -

- -

21 C1

- -

-=-

sensor

.,,. G110

C2

- - -;.._;-1-.- - - - - -_r- - - -. .

Signal

I
I
I

L -

-=-

ro,

C
B
0.35 BRN 718
0.35. BLK 452
0.35
DKBLU 417
$118 0.35 DK BLU
Antllock
Brakes
417 - $119 0.35 BLK =
- Cell44
452
0.35
DKBLU 417
0.35BLK 452

Sensor

0.35LTGRN 432
8110

1. lE
.

...._...1.:----_
. -_-_-_::. .

.________...-.. (MAP)

-=-

MAP

IAT

sensor
Ground

Sensor
Ground

;-1---12

23

'- -

- - -

- - -

Sensor

25

.. d ~-.. -

- -

- -

- -

Sensor
Ground

Signal

-=-

C2

-1- - - - - - - -.- -.;M - - - ~ Powertrain

-=-=Control
-

g1:~~~
-

ECT

Sensor
Ground

I Module
(PCM)

.
-

-:

I
I>
-

.J

m
:s
ca
192aso

sCD

.-_____/

Engine Controls Schematics (Heated Oxygen Sensors)

P;~

IHot Wrth lgn 1 Energized l

I Distribution
cen 10

J6

I
"-----

0;8PNK

., Underhood
: Electrical

ENG SEN
Fuse 10

20A

____
539

!L0c I

.. -

I
I

:
.

, .

Bank #1
,.. Left Front

H02S
High

' -

I
...

C105

~-

''

'ry. -

--- '

Baok #1

, ..

Left Rear
H02S
Low

Ho2s,
High

CD

~
~
~

Center 2

o:aPNK 539

... ---,

1s

H02S
Low

Bjlnk #2
Right Front

H02S
Low

PCM
C1 =RED
2
C =BLU

H02$
High.

Bank #2
Right Rear

H02S
Low

H02S
Hlgi

Powertrain
Control
I M(P'bt)le
I
I

- - - - - - - - - - - - - - - - - - ~ - - - -~ . - - - - - - -- - :. - - - - - - -- . - - - - - - - - ~ - - - - - - - - - ~ - - - - - - - - - - - - - - - - - - - _. ~
L---J11....___._ _
6-'T'------.
42
2
5
46
.
, :1
41 C2 ~
" 47

0~0
0.8
0.8
TAN/WHT 1669
PNK 539
Pf>UWHT 1665
0.8
0.8
0.8
PPUWHT 16(58
PNK 539
TAN/WHT 1653
A
B
A
D
B
D

0.8
PPL 1666
0.8
TAN 1667
A

0.8
PNK 539
B

0.8
TAN 1671

0.8
PPL 1670

0.8
PNK 539

:::,

cc

:::,
CD

0.8
BLK 450

Bank.1
Left Front
Heated Oxygen
Sensor (H02S) 1

c
0.8
BLK 450

Bank1
Left Rear
Heated Oxygen
Sensor (H02S) 2

Bank2
Right Front
Heated Oxygen
Sensor (H02S) 1

c
0.8
BLK 450

Bank2
Right Rear
Heated Oxygen
Sensor (H02S) 2

..a
0
0

:::,

0.8
BLK 450

iii"
(II

:....

r-

Ground
Distribution
Cell14

192863

Engine Controls Schematics (AIR and IAC)

0)
I

!Loe I
0
! Esc!

!Hot At All Times!

r P-;;w; -

I Distribution
I Cell 10

.. Underhood
AIR PUMP 1 Electrical
MinlFuse 1 Center 1
-

25A

L----- ----J
1 ORN

1 ORN 1440
F9
-.:..:.----....;,.;......, AIR
85

1 ORN 1440

r-E9

Sol
Relay

- - - .. Underhood
I Electrical
I Center 2
Pump
I
I
I
I
I

Relay

c lc101

[B

::,

(C

::,
CD

0
::,
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r;;
I

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:....

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0.35 LT
GRN/WHT 1749

0.35 LT

0.35 LT
BLU/WHT 1747

1 PNK/BLK 429

A
Secondary
-.;,,;...--.....;...._, Secondary
Air Injection (AIR)
Air
Injection
[ ] ] Bleed Valve
Solenoid
(AIR)
B
Pump

31

GRN/BLK 444

I
I
I
I

______ 57, c2
5 6- .'- ---- - _??., _- -- 30
Air- - - ; -;;; - - IAC - - - - iAc- - - - IAC - - - - iAc- - .. Powertrain
-~J

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I
I

1 BLK 150

Solenoid

----T

Relay

Control
-

Pump

----T Relay

con A
High

Coll A
Low

Coil B
Low

Coil B
High

Control

PCM

I Control
I Module
I (PCM)
I

I,:~

C1=RED I
C2=BLU

L-------------------------------J

5113

3 BLK 150

A'

......

1 RED 78
0.35 BAN 436
0.35 PPL 421

8159

' '

Coil
B

0.35 LT
BLU/BLK 1748

1 PNK/BLK 429

- - - - - 0.35 BR: 436 - " ----J

1 PNK/BLK 429

Coil
A

_E_s_ _ _ _F_s"T"--. AIR

85

Idle Air
Control
(IAC)
Valve

Stepper
Motor

1 ORN 1440
1 ORN 1440

.....

)
I...-~

Gromd
Distribution

Cell14

::,

G106

CD
192864

CD

~/

Engine Controls Schematics (TCS Retard Signal, VSS Output and VSS Signal)

[wiihl
~

res - ~ Electronic
Brake
spark

I
1
Retard
Control
I ___
Signal .,1 MOuUe
.., I
.,

19

C1 (EBCM)

CHEVROLETJ

r - ,Radio
I
I
I
I

r - ,cruise
I vss I Control
I Input I Module

...

_...

Kt

...

r- -

I vss I Cluster

>

11npuq

.....

P100

[B

0.35 DK GRN/WHT 817

0.35 GRY/BLK 1687

A1

CD

loEsc!

81._i_ ... ~

16 C3

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, Instrument

m
:::,
cc

C200A
C200D
0.35 DK GRN/WHT 817

0.35 DK GRN/WHT 817

0.35 DK GRN/WHT 817

8242

K C101

0.35 DK GRN/WHT 817

C220

~I
l

Vehicle Speed
_c:::::]_ Sensor
(VSS)

P110

B
0.35 DK GRN/WHT 817

:::,

cc

0.35YEL 400

:::,
CD
(')
0

0.35PPL 401

0.35 GRY/BLK 1687

-"'
:::,

30
r - - - -

I
I
I

55
~

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2.;

;;;..- .... -- - - - - - - - - - - - - - - - - - - - - - - - - - - , Powertrain

TCS Spark
Retard

Signal

VSS

output

PCM

C1=RED
C2=BLU

VSS
High

VSS
Low

Control _.
I Module ~
I (PCM) ~

(11

:.....
r-

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0,

.....
I

.......

192866

Engine Controls Schematics {EVAP and EGR)

<11
......

! Hot With lgn 1 Relay Energized I

~

P-;;w:; - - -

- - - -

...I

~ Underhood

[SJ

ENG CTRL : Electrical

MlniFuse Center 2
15A
I
.
....I

I Distribution
Cell 10
I

_________
0.5PNK 239
8182
0.5 PNK 239
G C100

0.5PNK
239

P100
02

[B

C200B
C200D

0.5 PNK 239

0.5 PNK 239

A2

0.5 PNK
239

$107

C405B

AIC405D
0.5 PNAK 239

0.5PNK 239

[]-

Emission
(EVAP)
Canister
Purge
Valve

IL c
0

0.35 DK GRN/WHT 428

BI

N
......

.,:.

::,

cc

::I

CD

0
0

::I

a
ci
1'

C.h

::.;.
r-

Evaporative
Emission
(EVAP)
Canister

Vent
Valve, .......
.
0.35BLK
0.5WHT 1310
0.35
GRY 705

B C405D

0.35
LTBLU 697 ,

B2IC405B
0.5 WHT 1310

0.35GRY 435

B C210
0.5WHT 1310

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3

45

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1

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Valve
Control

Vent

Valve
Control

62

C1 65

Ground "'"

...

C1 RED
C2 = BLU

__

,,

-----

5V
.Reference

,,,,,.,

..

....

---",

.....

----.

---

Ground =

PCM

34 C2

38

...

....

EGR
Pintle
Position

..

EGA Valve..
Control

..

Module

I (PCM)
.,..
I ~
I

--- -----,.--- -.

~~~:~rain

_____

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Engine Controls Schematics (Oil L&vel)

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s
CD

l ~cl
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rm
---,ls
n trument
1.Cli.Jster
I U:vel
I Indicator. I

Ul

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C C220
P110
0.35 BRN/WHT 1173

-----1 r----;--';'" ---. -,

0.35 BAN 1174

41 C1

76 C2

A
Oil
Level
Switch

B
Ground
Distribution

(I,.- -

I
I

0.35 BLKIWHT 451 .

~
.

I
I

I
I

Oil

Oil

Lev.el

'Switch
Input

Level

Lamp
Control

~PCM.

--T

C1=RED
C2=BLU

Powertrain

I Control
I

Module
1(PCM)
I
I

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I

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3 BLK 451

if

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192876

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.cp

Engine Controls Schematics (Reverse Inhibit and Skip Shift Solenoids)

..I,

jHot With Ignition Relay Energized !

Distribution

I Cell10

I
I....

IL

- - - - , Underhood
ENG SEN I Electrical
MlniFuse
I Center 2

I Power

O.SPNK 539
r -

IT
'

Instrument
I Cluster

.,

B C105

'<if:
~J __ ~

Skip
Shift

I>
I~

84

0.8 PNK 539

Fuse lock
Details
Cell 11

,... __

~
~
~

_________ ...
20A

0c

$104

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N
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8

I
1

II

0.35WHT 375

Reverse

I
I

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Inhibit
Solenoid

Shift
Solenoid

Transmission

I
I

L------------- ----J

0.5 LT GRN 1652

0.5GRY 587

0.35WHT 375

40
~
I

1
I
....I

C1
Lamp Control

7. ;v:s;n~;;- - - - - -,-si; ;.; ----

42

-, -;;; ;ill- - - - - - - - -

34

C1

Solenoid Control

Solenoid Control

~ Powetrain
Control
I
I Module

--1-=--1
--1
___________________________________ ... (PCM)
>
-=-

-=-

PCM
C1=RED
C2=BLU

I
I~

m
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192878

::::,
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Engine Controls Schematics (Transmission)

IHot Wtth lgn 1 Relay Energized t

r -

!Loe I

IHot With lgn 1 Relay Energized l

ENG SEN
MiniFuse
20A

P~r- . - - - - - - - - - - - - -

- - - - - - - - - ., Underhood

G9

Distribution

Cell 10
G8

ENG CTRL
MiniFuse
15A

_________

..I

[B

Fuse Block
Details
Cell 11

0.5 PNK
239

S182
0.5 PNK 239

0.8PNK 539

G
Fuse Block
Details
Cell11

--~

S104

CD.

0.5 PNK 239

C105

[SJ

I Electrical
I Center 2

L-

0.8 PNK 539

::s

(Q

C100

0.5 PNK 239

0.5PNK
239

S107
0.5 PNK 239

0.8PNK 539

Automatic
Transmission

r---------------- --------------------,

P110

C230

I=;t

I
II RED
o.s 839

0.8 PNK 539

C

C2

r -;- -

., Stop

.I

: f-:

olc
L

:~rr;~h

~~!=:
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0.35 PPL 420

H

0.5 RED 839

A

I
I
I

I ~.:i~r [ ]
II :er
Width

:
I

Clutch.
Solenoid

0.5
~;~SOL)
BU< 422

----T

C230

0.5 RED 839

A

BI. ~~!SOL)
Valve

0.STAN 418 -

81

(3-2SS)
Valve

Assembly

0.5WHT 687 -

0.5
TAN/BLK 422

0.5 RED 839

A

[]1 :;;n!'f []1 ~!n:'dNI []1 ~~n~:

ClutchPulse

0.5 RED 839

A

(2-3SS)
Valve

BI

(1-2SS)
Valve

Bl

0.5YEL 1223

0.5 WHT 687

0.5LTGRN 1222 -

::s
::s

(Q

0.5
LT GRN 1222

CD

::s

1
PPL :~ 0
4
08
C1

0.5 BRN 418

~iLJBLK 1223

Powe~:~
Control
Module(PCM)

ur

r----------------------------------------------------- ------,
I
I
I
I
I

TCC/Cruise Brake
Switch
Input

32

PCM
C1=RED
C2=BLU

-------~

TCC SOL
Valve
Control

C2

TCC PWM SOL

Valve
Control

34

--------~Q

3-2 SS
Valve Assembly
Control

-------~

2-3 SS
Valve
Control

C1

1- 2 SS
Valve
Control

(JI

I
I

r-

a,

:....
.....

~------------------------------------------------------------~

N
192883

~
~

Engine Controls Schematics (Transmission)

0)
I

Rear

" - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - , Powertram
1
Control
I
Transmission
Transmission
Transmission
.
TFT
Module (PCM)
I
I

1
I

I
.. _

Range A

Input

Range B

22

0.5 PNK 1224

61

0.5 DK BLU 1225

N
0.5PNKt224 -

01

0.5BRNT1227 -

AJ.

- .-

REV

04

. D3

Switch

--- Switch

(TFT)
Sensor

.... -

0.5 LT BLU 1229

BI

=
-

0.5GRY 452 -

" - ~ - - - - ,Park/
I
Neutral
I p
1 I Position

~.

'9.

0
0
j

..,.....

ur

U1
~

r-

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.

E3LK/WHT
J

451

C230

-----.,

$215

0.8 BLK/WHT 451

F C220

.!

--.,1

m
j

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/ ' Iswitch
I1 ~
-.N(D)D.-
I
- --...---
I
I
I

0.35

I
I
I

---i- -

0.5 PPL 1228

......

co

L-------..1

I
I
I
I

Temperaiure

.... Switeh

~
~

I ~ = .i I .':

(TFP)
Valve Manual
Position
Switch
Fluid

02

BTSI
Cell138

I
I

Transmission

LO
Switch

[SJ

1035

ORN/
434
BLK

Pressure
Automatic
Control Solenoid
Fluid Pressure {PC SOL.) Valve

Transmission

Switch

Release
Cell 134

Automatic
Transmission

--------------------------..--,

...... ~

!Loe

0,5 Ol;lN/BLK 434

0.35 ORN/BLK
8234
434

0.5 YEL/BLK 1227

Compartment
Lid

C2

0.50RNf;226 -

El

1
Signal _. _ ..1 ~

13

0.5DKBUJf;25 -

c,l

_ _ _ _ _ _

C1

0.5 RED 1226

Sensor

-= _-:: =-- ':" _-:: .!"'! .. _ ':" Input =--':"_-:: _-:. =-- Input _

25

I'

Range C

.....

0.8 BLK/WHT 451

T
--------

P110

0.5.
REO/BLK 1228
0.5 LT BLU/WHT 1229
0.35
ORN/BU< 434.

0.5 ORN/BLK 1057

39 C2
36
------------------- - - PCSOL.- - -PCSOL. -

14

Sensor Ground

I' -

I
I
I
L -

Valve Low

-- -

32
-

. ..;.. -

C1

PNP - Switch
Signal

Valve High

-----.J

- - - PCM
C1 =RED
C2=BLU
-

,Powertram
I Control

I Module (PCM)
I

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192884

CD

Engine Controls Schem~Ucs (NC $ystem)

:::,

ca

i Hot In l'IUN Or STAl'ITJ

r

G7

NC

Distribution

CRUISE,,.. ee111 o

G6

~ Underhood

Power

(D

Electri~I
I
Center 2

MiniFuse""

15A

_______ ...

"'--

- - - - ....
0.5 ____
PNK s_1_65
139 _ __,
Fuse Block
Details

CeU 11

0.5 PNK 139

0.5 PNK 139
r--DW ____ DS ---,Underhood
I
A/C
I Electrical
87
85
I
COMP I Center 2
I
I

Relay

------

86

I
l
I

~ __ca_!___ '.:01- ___ ~

0.5
DKGRN 59
0.35 DK GRN/WHT 459

---I ------------

C 0100

0.35DKGRNIW: 459

~
I
I

8105

g!:~~~

Relay
\
Controli

Refrigerant
Pressure Sensor

NC

Request _ _ _ _ Signal

0.35 DK GRN/W~~wC6~.
.

P110

, .FI

C230

0.35 DK GRN/WHT 762

A C2
r - - -,HVAC
I AIC
1

Reguest .ControL
I
1

.. ___ ....

O.S DKGAN'~

J =~:=r
GroundD :. . .
Clutch

J .

Pressure Sensor
_

__

5VReference

Status

A/C Refrigerant

_ _

1
63
0.35 RED/BL~r;8~- - - - - - - ~~;5-~-;~1~:4
C
C
B
-0.35 PPL 719

IT

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14

-r-N~ -----~6~~:~rain

SV

NC~

0.5 DKGRN
59

o.5DK~~ ~ 1

-;;M- - - - - ~~ - - - - - - - - - - - - - - - -

:I
~

0.5 DKGRN

I
.

<

1 ~~igerant
J,

Pressure
Sensor

I Module
I (PCM)

I~

[]A/C
Compressor

:::,

ca

Clutch

:::,
CD

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0
:::,

0;5 BLK 450

S115 _ _ _ _ _ ___,
0.5 BLK 450

A/C

Diode

81 OB

in

~ g~~~~on
Cell 14

a,

.....
I

G112

....

192885

co

0,

Engine Coi:,trQls Schematics (Engi11e Cooling Fan)

!Hot At AIITlmes

r-

1
I

- - - - - - - - - - - - - - - - Power

Lt
K1

Distribution

COOL FAN
MaxlFuse

co

J7
J6

10A

m
:::s

ce.:::s

I
L-

- - - - - - - - - - - - - ., Underhood
I
COOLING FAN
Electrical
1
MiniFuse
Center 1

ee1110

40A

......

-----------------

------

.------J

CD

3RED 402
0.35 ORN 1640
._. __ . . _ : S : : . . : 1 ~ 6 9 = - - - - - - - - - - - - - . l ' f \ - - - - - - - - - - - - - - - - - - - - ,

Power
Distribution
Cell10

0
0
:::s

$179

- ,:

;-

0.35 ORN 1640

0.35 ORN 1640

3RED 402

3 RED 402
3WHT 504
0.35 ORN 1640

r--C3

B8

B9

B3

--------'I

.......~......

~ - _!!! ;L;;~1.,;------ -;G-:; ~

0.35 DK GRN 335

~ Cooling
~ine .

C100

0.35 DK BLU 473 3 WHT 504

$166
0.35

B
Right
Engine
Cooling
Fan

DKBLU 473

C1

-t- "co;1;
I Fan

I ....f
I

Relay1
Control

3BLK 150
3 BLK 150
L----'l'--------------------$113
(
0.35 DK BLU 473

0.35 DK GRN 335

I
I
I
I

3WHT 504
.....__ _ _ _.....,..,.._______ $167

0.35
DKBLU 473

H C100

43

Cooling
Fan
Relay2

_____ !4 ____ !6 -----~

C10

Fan

- - - - ., Underhood
I Electrical
Engine
I Center 1

r--...---------.

Engine
Cooling
Fan
Relay3

Engine
Cooling
Fan
Relay1

C4

C6

28
-

C2

~~ - - - - - - - - - - - . / -

~
~

---f

,,
.

~"7in; , Powertrain
Fan Relay I
2And3 I
Control I

L-----------------------------J

Control
Module~
(PCM) ~

Ground
Distribution
Cell 14

.,_ -

"'

3BLK 150

m
:::s

= G106

cc

:::s

192886

CD

Engine Controls - 5.7L

Engine

6-1281

Cc:>mponent Locator
Engine Controls Components
Name

Location

1st-2nd Shift Valve

Solenoid

Inside the automatic transmission

2nd-3rd Shift Va.Ive

Solenoid

Inside the automatic transmission

3rd-2nd Shift Valve

Solenoid

Locator View

Connector End View

Inside the automatic transmission

In the front of the engine, on the lower

right side

A/C Compressor
Clutch Diode

Sealed in the engine harness,

approximately 17.0 cm (7.0 in) back from
the A/C compressor clutch connector

A/C Refrigerant
Pressure Sensor

Above right front wheelhouse, attached to

the refrigerant line

Engine Controls
Connector End Views

Automatic Transmission
Electronic Component
Views (Internal)

AT lnline Harness
Connector End View

Body Control Module

Component Views

Body Control Module

Connector End Views

A/C Compressor Clutch

Automatic Transmission Behind the engine

Body Control
Module (l3CM}

Under the. right side of the instrument

panel near the blower motor

Engine Controls
Connector End Views

Camshaft Position
(CMP) Sensor

Mounted in engine front cover

Engine Controls
Component Views

Engine Controls
Connector End Views

Crankshaft Position
Sensor

Lower front of engine

Engine Controls
Component Views

Engine Controls
Connector End Views

Cruise Control Module

Mounted to the left franie rail, forward bf

the wheelhouse

Cruise Control
Component Views

Cruise Control Connector

End Views

Data Link
Connector (DLC)

Under the instrument panel, right of th!;!

steering. column

Instrument Cluster
Component Views

Power.and Grovnding
Connector End Views
Anti/ock Brakes System
Connector End Views

Electronic Brake Control Mounted with brake pressure modulator

valve on the top of the left fr.ant frame rail
Module (EBCM)
Engine Coolant
Temperature (ECT)
Sensor
Engine Cooling Fans
Engine Oil Level Switch

Engine Controls
Component Views

Lower left side of engine, above generator

Behind the r~diator

Engine Controls
Component Views

On the lower right side of the engine, in

the oil pan

Engine Controls
Connector End Views

Engine Controls
Connector End Views

Engine Oil Pressure

Sensor

On the top rear 6f the engine, near the left.

cylinder head

Evaporative Emission
(EVAP) Canister. Purge
Solenoid Valve

On the right center of the engine, mounted

to the manifold

Engine Controls
Component Views

Engine Controls
Connector End Views

Evaporative Emis~ion
(EVAP) Canister Vent
Solenoid Valve

On the top right side. of the engine, part of

the EVAP canister

Engine Controls
Component Views

Engine Controls
Connector End Views

Left rear of engine,mounted to intake

manifold

Engine Controls
(;omponent Views

Engine Controls
Connector End Views

Fuel Injectors

Mounted on the intake manifold, part of

the fuel rail

Engine Controls
Component Views

Engine Controls
Connector End Views

Fuel Tank Unit

Under the rear of the vehicle

Harness Routing Views

.

...

Exhaust Gas
Recirculation (EGR)
Valve (VB VIN G)

'

Engine Controls
Connector End Views

Heated Oxygen Sensor

Bank 1, Sensor 1
Mounted in the left exhaust manifold
(Left Front)

Engine Controls
Component Views

f=ngine Controls
Connector End Views

Heated Oxygen Sensor

At the rear of the left catalytic converter
Bank 1, Sensor 2
(Left Rear)

Engine Controls
Component Views

Engine Controls
Connector End Views

5..12a2 Engine Controls - 5.7L

Engine

Engine Controls Components (cont'd)

Name

Location

Heated Oxygen Sensor

Mounted in the ,right exhaust manifold
Bank 2, Sensor 1
(Right Front)

..

Sj

HVAC Control

In the center of the instrum~nt panel,

above the radio

Idle Air Control

. (IAC) Valve

Right front on throttle body

Ignition Control
Coils/Modules

On the valve cover at the top of each

cylinder
.

Instrument Cluster

On the left side of the instrurnent panel

Intake Air Temperature .. Mounted on air duct, in front of intake

(IATJ Sensor
manifold

Connector End View

'

Heated Oxygen Sensor

At the rear of the right catalytic converter
Bank 2, Sensor 2
(Right Rear)

./

Locator View
-;Engine Controls
Component Views

Engine Controls
Connector End Views

'~''

''

. . Ef]gine (;gntrols
Component Views

Engine. Controls
Connector End. Views
..

HVAC Component Views

. Engir1e Con_trols
Component Views

Engine Controls
Connector End Views

Engine c_ont(ols
. Component Views

Engine Controls
Connector End. Views

Instrument Cluster
Component VieW:s

Instrument Cluster
Connector En,d Views

Engine Controls
Component Views

Engine Controls
Connector End VieWs

"

IP Fuse Block

On the left end of the instrument panel

carrier

Instrument Cluster
Component Views

Knock l:,ensor, Front

Center of the ehgine below the intake

manifold
..

Engine Controls
Component Views

Engine Controls
Connector End:Views

Knock Sensor, Rear

Center of the engine below the intake

.manifold..

Engine Controls
Compon~nt. Vfews

Engine Controls
Connector Erid Views ..

Engine Contr;ols
Component Views

Eng/rie Controls :
Connt:1ctor End .. ViEH'\"S ..

..

Manifold Absolute
Mounted to right side of intake manifold
Pressure. (MAP) Sensor

Mass Air Flow (MAF)

Sensor

Mounted on. the air duct, in front of the'

intake manifold

Engine Controls
Component Views

Engine Controls
Connector End Views

Park Neutral Position

Switch

Under the console, .on the base of the shift

control lever

Tilt Wheel/Column'
Component .. Views

Powertrain ,CQntrol
Module (PCM)

On the right side of the engine

compartment; rear of the wheelhouse

~ngfne Controis
Component Views

PCM Connector
End Views.

Radio

In the center of the instrum~nt, panel,

below the HVAC control

Instrument Cl11ster
Component Views

Entertainment Connector
End Views

Reverse Lockout
Solenoid (Manual)
Secondary Air Injection
Bleed Valve Solenoid
Secondary Air
Injection Pump

On the rear left side of the transmission

PCM Connector
End Views

Mounted to the right front frame rail

Engine Controls
..
Component Views

On the front left frame rail, in the engine

.
.
compartment

Engine Controls
Component Views

Engine Controls
Connector End Views

Engine Controls
Connector End Views

Skip Shih Solenoid.

. (Manual)

On the center left side of the transmission

Stop Lamp Switch

Mounted on the br~ke pedal bracket

Cruise Control
Component Views .

Throttle Position (TP)

Sensor

Mounted to the front of the throttle body

Engine Controls
Component. Views

Underhood Electrical
Center1

On the Left front corner of the engine

..
compartment

Underhood Electrical
Center 2

Engine Controls
Connector EncJ ,Views

, Antilock Brakes System

Connector End Views
Engine Controls
CormedtorEnd Views

Power and Grounding

Component Views

On the left front corner of the engine

compartment

Power and Grounding

component Views

Vehicle Speed Sensor

(Manual)

Rear left side of transmission

Power and Grounding'

Component Views

Engine Controls
ConnGctor End Views

Vehicle Speed Sensor

(Automatic)

Rear right side of transmission

Power and Grounding

Component Views

Engine Controls
Connector End Views

Harness Routing Views

lnline Harness Cpnnector

End Views

C100 (10 cavities)

Engine to forward lamp harness, in the

engine compartment, above the right
wheelhouse

Ehgine Controls - 5~7L 6-1283'

Engine

Engine Controls Components (contld)

Location

Name

Locator View

'

C101 (10 cavities)

Engine to forward lamp harness, in the

engine compartment, above the right
wheelhouse

Harness Routing Views

C102 (1 cavity)

Engine to forward lamp harness, in the

engine compartment, above the right
wheelhouse

Harness Routing Views

C105 (8 cavities)

Engine to forward lamp harness, in the

engine compartment, above the right
wheelhouse

Harness Routing Views

C106 (7 cavities)

Engine to engine jumper harness

Connector End View

lnline Harness Connector ,
End Views

lnline Harness Connector

End Views

C107 (7 cavities)

Engine to engir::ie jumper harness

C108 (3 cavities)

Engine to camshaft position sensor jumper

harness

C200A (17 cavities)

Forward lamp fo instrument panel harness,

behind the left kick panel and steering
column
"
.

Harness Routing Views

/nline Harness Connector

End Views

Forward lamp to instrument panel harness,

between the left kick panel and the
steering column

Harness Routing Views

lnline Harness Connector

End Views

..
C200B ( 18 cavities)

lnline Harness Connector

End Views

....

Part of the instrument panel

C200D (48 cavities)

harness, .,
between the left kick panel and the
steering column

Harness Routing Views

lnline Harness Connector

End Views

...

C21 o (8 cavities)

. instrument panel to engine harness,' under

the right side of the instrument panel,
behind the knee bolster

Hwness Routing Views

lnline Harness Connector

End Views

C220 ( 10 cavities)

fnstrument panel to engine harness, under

the right side of the instrument panel,
behind the knee bolster

Harness Routing Views

/nline Harness Connector

. ~ndViews ..

C230 ( 10 cavities)

Instrument panel to engine harness, under

the right side of the instrument panel,
behind the knee bolster

'
Harness Routing Views

tnline Harness Connector

End Views

C405A (7 cavities)

fuel tank harness to the instrument panel

harness pass through connector, forward
of the rear axle

C405B ( 16 cavities)

Instrument panel harness pass through

c;:onnector, forward of the rear axle

Harness Routing Views

G100 (V6 VIN K)

On the lower right side of the engine,

above the A/C compressor

Harness Routing Views

G100 (VB VIN G)

On the lower right side of the engine,

above the starter solenoid

Harness Routing Views

..

..

lnline Harness.Connector
End Views

lnline Harness Connector

End Views

G106

Attached to the top left side of the radiator

support

Harness Routing Views

G110

Attached to the rear of the left

cylinder head

Harness Routing Views.

G112

Attached to the rear of the left

cylinder head

Harness Routing Views

G200

Near the left A-pillar, bolted to the

instrument panel mounting stud behind the
kick panel

Harness Routing Views

.'

G305

Bolted to the left rocker panel at the floor

pan bar 3

Harness Routing Views

P100

Left side in the dash panel, engine to the

passenger compartment

Hwness 'Routing Vi~ws

P110

Right side in the dash panel, engine to the

passenger compartment

$100 (Manual
Transmission)

Engine harness, approximately 5 cm (2 in)

from the vehicle speed sensor breakout

..

;,

'

'
''

1.

1,

6-1284

Engine

Engine Controls - 5.7L

Engine Controls Components (cont'd)
Name

Location

Locator View

Connector End View

Engine harness, approximately 12 cm

(5 in) from the automatic transmission
breakout

S102

In the engine harness, main branch,

approximately 7 cm (3 in} from the engine
oil pressure sensor breakout

S104

Engine harness, approximately 14 cm

(6 in) from the powertrain control module
(PCM) breakout

S105

Engine harness at A/C refrigerant pressure

sensor breakout

S106

In the engine harness, main branch

approximately 4 cm (2 in) from the
powertrain control module (PCM) breakout

S107

In the engine harness, main branch,

approximately 7 cm (3 in) from the
powertrain control module (PCM) breakout

S108 (Automatic
Transmission)

In the engine harness, main branch,

approximately 5 cm (2 in) from the
automatic transmission breakout

S108 (Manual
Transmission)

In the engine harness, main branch,

approximately 12 cm (5 ln) from the
vehicle speed sensor breakout

8109

In the engine harness, approximately 8 cm

(3 in) from the fuel injector 4. breakout

S110

In the engine harness, main branch,

approximately 19 cm (7 in) from the
powertrain control module (PCM) breakout

S113

In the forward lamp harness approximately

7 cm (3 in) from the engine coolant
fans/cruise control

S114

Engine harness, approximately 17 cm

(7 in) back from A/C compressor clutch
connector

S115

In the engine harness, approximately

20 cm (8 in) back from the A/C
compressor clutch connector

S116

Engine harness, approximately 9 cm (4 in)

from manifold absolute pressure (MAP)
sensor breakout

S118

Engine harness, approximately 15 cm

(6 in) from manifold absolute pressure
(MAP) sensor breakout
'

Engine harness, main branch,

approximately 8 cm (3 in) from automatic
transmission breakout

Engine harness, main branch,

approximately 9 C(ll (4 in) from vehicle
speed sensor breakout

S120

Engine harness, main branch, 8 cm (3 in)

from powertrain control module (PCM)
breakout

S122

Engine jumper harness

8123

Engine jumper harness

8124

Engine jumper harness

S 100 (Automatic
Transmission)

S119 (Automatic
Transmission)
S119 (Manual
Transmission)

8125

Engine jumper harness

8126

Engine jumper harness

8127

Engine jumper harness

Engine Controls - 5.7L

Engine

6-1285

Engine Controls Components (cont'd)

Name

Location

Locator View

Connector End View

8159

Forward lamp harness, approximately

8 cm (3 in) into secondary air injection
bleed valve solenoid breakout

8165

In the forward lamp harness,

approximately 7 cm (3 in) from the main
branch into the UH electrical center 2
breakout

8166

Forward lamp harness, approximately

14 cm (6 in) from G105 breakout

8167

Forward lamp harness, approximately

7 cm (3 in) from electronic brake control
module (EBCM) breakout

8169

In the forward lamp harness,

approximately 6 cm (2 in) from the main
branch into the UH electrical center 1
breakout

8177

In the forward lamp harness,

approximately 4 cm (2 in) from the main
branch into the UH electrical center 1
breakout

8179

In the forward lamp harness,

approximately 25 cm (10 in) from the UH
electrical center 1 breakout

8182

In the forward lamp harness,

approximately 15 cm (6 in) from the UH
electrical center 1 breakout

8184

In the forward lamp harness,

approximately 5 cm (2 in) from the UH
electrical center 1 breakout

8215

In the instrument panel harness, main

branch, approximately 11 cm (4 in) from
the antenna cable breakout

8217

In the instrument panel harness, main

branch, approximately 18 cm (7 in) from
the body control module (BCM) breakout

8225

Instrument panel harness, approximately

6 cm (2 in) from blower motor breakout

S234 (Automatic)

Instrument panel harness, main branch,

approximately 5 cm (2 in) from body
control module (BCM) breakout

8240

In the instrument panel harness, main

branch, approximately 17 cm (7 in) from
the antenna cable breakout

8242

In the instrument panel harness, main

branch, approximately 4 cm (2 in) from
data link connector (DLC) breakout

S244 (Convertible)

Instrument panel harness, approximately

46 cm (18 in) from C405

8244 (Coupe)

Instrument panel harness, approximately

40 cm (16 in) back from C405

6-1286

Engine

Engine Controls - 5.7L

Engine Controls Component Views

Full Engine View LH Side

220990

Legend

(1)
(2)
(3)
(4)
(5)
(6)
(7)

EVAP Canister Purge Solenoid

Fuel Pulse Dampener
Fuel Rail with Injectors
Crankcase Vent
Left Bank Ignition Coils/Modules
Left Bank H02S Sensor 1
Engine Coolant Temperature (ECT) Sensor

(8)
(9)
(10)
(11)
(12)
(13)

Fuel Pressure Gauge Test Connector

Th.rattle Position (TP) Sensor
Idle Air Control {IAC)
Throttle Body Assembly
Exhaust Gas Recirculation (EGR) Valve
RighLBank Ignition Coils/Modules

Engine Cont,rols - f;.7L

Engine

6..1'287

Idle Air Control (IAC) Mott>r, Throttle Position ,(TP> Sensor, ,Generator

218886

Legend
(1) Idle Air Control (IAG) Motor
(2) Throttle Position (TP) Sensor

(3) Generator
(4) Throttle Body

6-1288

Engine Controls - 5~7L

Engine

Mass Air Flow Sensor and Intake Air Temperature Sensor

218744

Legend
(1) Mass Air Flow (MAF) Sensor
(2) Intake Air Temperature (IAT) Sensor

(3) Air Cleaner Housing

Engine

Engine ContrQls - S.7L 6~f289

Manifold Absolute Pressure (MAP) Sensor, Camshaft .Position (CMP) Sensor, Oil Pressure Switch

247435

Legend

(1) Manifold Absolute Pressure (MAP) sensor

(2) Camshaft Position (CMP) sensor

(3) Oil Pressure switch

(4) Connector to. Knock sensor jumper harness

e.:1~0 Engine Controls - ~;7L

Engine
Knock Sensors

198593

Legend
(1) Front Knock Sensor

(2) Rear Knock Serisor

Engine

Engine Controls~ 5.7L 6-1291

AIR, System
5

218767

Legend
(1) AIR System Crossover Hose
(2) Air Inlet From AIR Pump
(3) Left Bank Check Valve

(4) Left Bank AIR Tube

(5) Right Bank AIR Tube
(6) Right Bank Check Valve

6-1292

Engine Controls - 5;7L

Engine
AIR Pump Location

218771

Engine

Engine Controls ,5.7L 6-1298

Air Cleaner Housing .and Resonator

11

10

247788

Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

Air cleaner housing top cover

Seal
Air intake duct to resonator
Clamp
Air intake duct to top cover retainer
Intake Air Temperature (IAT) sensor
Clamp
Air intake resonator

(9)
(10)
(11)
(12)
(13)
(14)
(15)

Air intake duct to throttle body

Mass Airflow (MAF) sensor
Isolator
Air cleaner housing lower assembly
Front retaining clips
Air filter element frame
Air filter element

s.:.1294

Engine Controls - 5~7L

Engine
Air Cleaner Location.

218754

Legend
(1) Air Cleaner Housing

Engine

Engine Cootn>ls:~.5.7f.. 6-1.295

Crankshaft .Position Sensor Location

222858

Legend

(1) CKP Mounting .Bolt

(2) CKP Mounting Location.

(3) Crankshaft Position S~nsor (OKP)

6~1296

Engine Controls - 5.7L

Engine
H02S Location

218748

Legend

( 1) H02S Bank 2 Sensor 1

(2) H02S Bank 2 Sensor 2

(3) H02S Bank 1 Sensor 2

(4) H02S Bank 1 Sensor 1

Engine

Engine Controls - 5.7L 5..1297

PCM Location

218738

6-1298 . Engine

C,<>ntro.l s 5.7l ..

Engine

EVAP Canister Location

218758

Engine Controls - 5.7L

Engine

64299

Fuse Blocks #1 and #2

245570

Legend
(1) Fuse Block #1

(2) Fuse Block #2

61300

Engine

Engine Controls - 5.7L

PCM Connector End Views

PCM Connector C1 (Red)

(
I

r-,

,---,

J
~

41

60

20

@@@@@@@@@@@@@@@@@@@@
@@@@@@@@@@@@@@@@@@@@ [j

r-,

IQ}
-

r-,

61

BO

21

40

@@@@@@@@@@@@@@@@@@@@
O @@@@@@@@@@@@@@@@@@@@

cf

23346

Connector Part
Information
Pin
1-2

Wire Color

PCM Connector C1 (Red)

80 Pin Connector
Circuit No.

Function
Not Used

WHT

1310

EVAP Canister Vent Solenoid Valve Control

BRN/WHT

633

Camshaft Position Sensor Signal

5-6
7
8

9
10

YEL

PNK/BLK

Not Usd

400

VSS Signal High

1746

Not Used

229

VTD Fuel Enable

LT BLU/BLK

844

Injector #4 Control

RED/WHT

2122

Injector #2 Control

11

DKBLU

12
13
14

DKGRN

59

15

BLK/WHT

845

16-17
18
19-20
21

Not Used
Injector #3 Control

YEUBLK

846
-

A/C Status
Injector #5 Control
Not Used
Injector #6 Control
Not Used

PPL

719

IAT Sensor Ground

22

DKBLU

1225

Transmission Range Signal B

23

LT GRN/BLK

1745

Injector #2 Control

24

BLK/WHT

1704

Sensor Ground Jumper

25

PNK

1224

Transmission Range Signal A

26
27
28-29

RED/BLK

Not Used

877

Injector #7 Control

Not Used

1687

Spark Retard Signal

30

GRY/BLK

31

DK BLU/WHT

878

Injector #8 Control

32

ORN/BLK

434

PNP Switch Signal

33

BLK

1744

34

GRY or WHT

587 or 687

Injector #1 Control

35

LTGRN

1222

1-2 Shift Solenoid

36

DK/BLU

1936

Fuel Gauge Output Control

37

BRN/WHT

419

MIL Control

Skip Shift Solenoid (MIT) or 3-2 Shift Solenoid (A/T)

Engine

6-1301

Engine Controls - 5.7L

PCM Connector C1 (Red) (cont'd)

r-,

I .-,

J . 41@@@@@@@@@@@@@@@@@@@@60
~ :J@@@@@@@@O@@@@@@@@@@@D

'-'

.-,

[gt

20

I r-, I

61

80

.
@@@@@@@@@@@@@@@@@@@@
. D@@@@@@@@@@@@@@@@@@@@ Cf
21
40

23346

Connector Part
Information
Pin
38

Wire Color

PCM Connector C1 (Red)

80 Pin Connector
Circuit No.

39

DKGRN/WHT

459

40

WHTor
YEUBLK

375 or 1223

Function
Not Used
A/C Clutch Relay Control
Skip Shift Lamp Control (Mff) or 2-3 Shift Solenoid (A/T)

41

BRN/WHT

1173

Low Oil Level Indicator Lamp Control

42

LTGRN

1652

Reverse Inhibit.Solenoid Control

43

DK/GAN

335

Cooling Fan Relay #1 Control

44

YEL

573

Crankshaft Position Sensor Signal Input

45

DKGRN/WHT

428

EVAP Canister Purge Valve Control

Not Used

762

A/C Request Signal

46
47

DKGRN/WHT

492

MAF Signal

49

YEL
. PPL

2121

Ignition #1 Control

50-51

48

Not Used

52

PPUWHT

2128

Ignition #8 Control

53

RED

2127

Ignition #7 Control

54

LTBLU/WHT

2126

Ignition #6 Control

55

DKGRN/WHT

817

VSS Output Signal

56

DKGRN

2125

lgniti9n #5 Control

57

DKGRN/WHT

2124

Ignition #4 Control

58

LT BLU

2123

Ignition #3 Contrql

59

BRN/WHT

2130

Ignition Control Reference Low Bank 2

60

BAN

2129

Ignition Control Reference Low Bank 1

61

RED

1226

Transmission Range Signal C

62

BLK

552

EGA Pintle Position Ground

63

BLK

407

A/C Refrigerant Pressure Sensor Ground

Not Used

71

PPL

401

VSS Signal Low

72

BLK

451

PCM Ground

Not Used

64-70

73-74

75

GRY

720

Left and Right Fuel Tank Level Sensor Ground

76

BLK

451

PCM Ground

77

PPL

420

TCC/Brake Switch Signal

Not Used

78-80

6-1302

Engine Controls - 5.7L

Engine
PCM Connector C2 (Blue)

r-,

I ,---,

/'

I()}
c D

20

I ,---., I

,"I
61
@@@@@@@@@@@@@@@@@@@@eo

41
@@@@@@@@@@@@@@@@@@@@60

=I ::J @@@@@@@@@@@@@@@@@@@@

'

,---,

::J @@@@@@@@@@@@@@@@@@@@
21

40

cf

23346

Connector Part
Information
Pin

Wire Color

PCM Connector C2 (Blue)

80 Pin Connector
Functio.n

Circuit No.

TAN

1671

H02S Signal Low Bank 2 Sensor 2

TAN/WHT

1669

H02S Signal Low Bank 1 Sensor 2

TAN

800

Serial Data (UART)

RED

631

Camshaft Position Sensor B+ Supply

TAN

1667

H02S Signal Low Bank 2 Sensor 1

TAN/WHT

1653

H02S Signal Low Bank 1 Sensor. 1

RED/BLK

380

A/C Refrigerant Pressure Sensor Signal

TAN

472

IAT Sensor Signal

BRN

1456

EGR Pintle Position Sensor Signal

10

PPL

30

11
12

Fuel Level Sensor Signal

Not Used

DKBLU

417

TP Sensor Signal

13

YEUBLK

1227

Transmission Fluid Temperature Sensor Signal

14

ORN/BLK

1057

Transmission Fluid Temperature Sensor Ground

Not Used

19

PNK

439

PCM Ignition 1 Feed

15-18

20

ORN

340

PCM Battery Feed

21

BLK

451

PCM Ground

22

YEUBLK

1868

Crankshaft Position Sensor Ground

23

BLK

452

TP Sensor Ground

24

BLK/WHT

1704

Sensor Ground Jumper

25

BRN

718

ECT Sensor Ground

26

ORN/BLK

469

MAP Sensor Ground

27

Not Used

28

DKBLU

29

473

Engine Cooling Fan Relay #2 and #3 Control

Not Used

30

BRN

436

AIR Pump Relay Control

31

PPL

421

AIR Solenoid Relay Control

32

TAN/BLK

422

TCC Enable Solenoid

33

BRN

418

TCC (PWM) Solenoid Valve Control

34

GRY

435

EGR Valve Ground

35

WHT

121

Engine Speed (Tach} Output Signal

36

LT BLU/WHT

1229

Transmission Fluid Pressure Control Solenoid Control Low

37

DKGRN/WHT

465

Fuel Pump Relay Control

Engine Controls - 5.7l

Engine

6-1303

PCM Connector C2 (Blue) (cont'd)

~)

J
:;i

-,

l,-,I

::J

lr-i

i@@@@@@@@@@@@@@@@@@JO
@@@@@@@@@@@@@@@@@@@@
1
20

jfio~

c~ _

r-il

Ir-ii

6~@@@@@@@@@@@@@@@@@@JO

o21@@@@@@@@@@@@@@@@@@@@.40c r

'E

"/

23346

Connector Part
Information
Pin

Wire Color

PCM Connector C2 (Blue)

80 Pin Connector
Circuit No.

Function

38

LT BLU

697

EGR Valve Control Circuit

39

RED/BLK

1228

Transmission Fluid Pressure Control Solenoid Control High

40

Not Used

41

PPL

1670

42

PPUWHT

1668

H02S Signal High Bank 1 Sensor 2

43

GRY

596

TP Sensor 5V Reference

44-45

H02S Signal High Bank 2 Sensor 2

Not Used

46

PPL

1666

H02S Signal High Bank 2 Sensor 1

47

PPUWHT

1665

H02S Signal High Bank 1 Sensor 1

48

LT GRN

432

MAP Sensor Signal

49

YEL

410

50-51

ECT Sensor Signal

Not Used

52

DKGRN

890

Fuel Tank Pressure Sensor Signal

53

Not Used

54

LT GRN/BLK

444

IAC Coil B Low

55

LT BLU/BLK

1748

IAC Coil A Low

56

LT BLU/WHT

1747

IAC Coil A High

57

LT GRN/WHT

1749

IAC Coil B High

58

PPL

1807

Serial Data (Class 2)

59

Not Used

60

BLK

451

PCM Ground

61

ORN

340

PCM Battery Feed

62

LTGRN

1867

Crankshaft Position Sensor B+ Supply

63

Not Used

64

GRY

416

MAP Sensor 5.0 Volt Reference

65

GRY

705

5V Reference

66

GRY

474

A/C Refrigerant Pressure Sensor 5.0 Volt Reference

67

GRY

598

5V Reference

68

LT BLU

1876

Knock Sensor (KS) Rear

69

DKBLU

496

Knock Sensor (KS) Front

70

PNK/BLK

632

Camshaft Position Sensor Grou.nd

71-75

76

BRN

77-80

1174

Not Used
Oil Level Sensor Signal
Not Used

6-1304

Engine

Engine Controls - 5.7L

Camshaft Position (CMP) Sensor

Engine Controls Connector End Views

A/C Compressor Clutch

(
\

62453
62440

Connector Part
Information

Pin

A
B

Wire Color
DKGRN
BLK

1216-2017
2 Way F Metri-Pack
150 Series (GRY)
Circuit
No.

59
450

Connector Part
Information

Pin

Function
A/C Compressor Clutch
Control
A/C Compressor Clutch
Ground

Wire Color

1205-9595
.3 Way F Metri-Pack
.150 Seri!!~ (BLK)
Circuit
No.

BRN/WHT

633

PNK/BLK

632
631

R,ED

Function
Camshaft Position (CMP)
Sensor Signal - Input
Reference Low
Ignition Feed

Crankshaft Position (CKP) Sensor

A/C Refrigerant Pressure Sensor

62453
62485

Connector Part
Information

Pin

Wire Color
BLK

1211-0192
3 Way M Metri-Pack
150 Series Pull To Seat (BLK)
Circuit
No.

Function

407

A/C Refrigerant Pressure

Sensor Ground

GRY

474

A/C Refrigerant Pressure

Sensor 5.0V Reference

RED/BLK

380

A/C Refrigerant Pressure

, Sensor Signal

Connector Part
Information

1205-9595
3 Way Metri-Pack
150 Series (BLK)

Pin

Wire Color

Circuit
No.

YEL

573

YELJBLK

LTGRN

1868
,1867

Function
Crankshaft Position (CKP)
Sensor Signal - lnpuj
Reference Low
Ignition Feed

Engine

Engine Controls - 5.7L

Engine Coolant Temperature Sensor

6-1305

Evaporative Emission (EVAP} Canister

Purge Valve

62485

Connector Part
Information

Pin
A

Wire Color
BAN

YEL

DK GAN

1211-0192
3 Way F Metri-Pack
150 Series Pull to Seat (SLK)
>Circuit
No.

35437

Connector Part
Information

Function

1205-2643
2 Way Metri-Pack 150 Series
Sealed (RED)

Pin

Wire Color

Circuit
No.

718

Engine Coolant
Tenperature . (ECT}
Sensor Ground

PNK

239

Ignition Feed .

DKGRN/
WHT

428

410

Engine Coolant
Temperature (ECT)
Sensor Signal

EVAP Canister Purge

Valve Control

135

Engine Coolant
Temperature (ECT)
Sensor Outp.ut

Function

Evaporative Emis~ion (EVAP} Canister

Vent Valve

Engine Oil Level Switch .

35437

Connector Part
Information
35437

Connector. Part
Information

\,

Pin

Wire Color

BAN

BLK

1205-2641
2. Way F Metri-Pack
150 Series Sealed
Circuit
No.

1174
450

Function
Oil Level Switch Signal
Ground

1205.-2643
2 Way F. Metri~Pack
150 Series Sealed.(RED)

Pin

Wire Color

Circuit
No.

PNK

239

Ignition Feed

VVHT,.

1310

EVAP Canister Vent

Valve Control

Function

6-1306

Engine

Engine Controls - 5.7L

Fuel Injector #3

Exhaust Gas Recirculation (EGR) Valve

.I c:::::::J I

~ti!E~
154327

68773

Connector Part
Information

1218-6056
5 Way F Metri-Pack
150.2 Series Pull to
Seat (BLK)

Connector Part
. Information

Function

Pin

Wire Color

Circuit
No.

435

Exhaust Gas Recirculation

(EGR) Valve Ground

PNK

639

Ignition Feed

PNK/BLK

1746

Fuel Injector #3 Control

Pin

Wire Color

Circuit
No.

GRY

BLK

552

Exhaust Gas Recirculation

(EGR) Sensor Ground

BRN

1456

Exhaust Gas Recirculation

(EGR) Pintle 'Position

GRY

705

Exhaust Gas Recirculation

(EGR) 5V Reference

697

Exhaust Gas Recirculation

(EGR) Valve Control

LT BLU

1212-9140
2 Way F Metri-Pack
280.1 Series Pull To
Se~t (BLK)
Function

Fuel Injector #5

Fuel Injector #1

154327

Connector Part
Information

154327

Connector Part
Information

1212-9140
2 Way F Metri-Pack
280.1 Series Pull To
Seat (BLK)

Pin

Wire Color

Circuit
No.

PNK

639

Ignition Feed

BLK

1744

Fuel Injector #1 Control

Function

1212-9140
2 Way F Metri-Pack
280.1 Series Pull To
Seat (BLK)

Phi

Wire Color

Circuit
No.

PNK

639

Ignition Feed

BLK/WHT

845

Fuel Injector #5 Control

Function

Engine Controls.,. 5.7L

Engine
Fuel Injector #7

6-1307

Fuel Injector #4

154327

154327

1212-9140

1212-9140
Connector Part
Information

Connector Part
Information

2 Way F Metri-Pack
280.1 Series Pull To
Seat (BLK)

Pin

Wire Color

Circuit
No.

PNK

639

Ignition Feed

RED/BLK

877

Fuel Injector #7 Control

Function

2 Way F Metri-Pack
280.1 Series Pull To
Seat {BLK)

Pin

Wire Color

Circuit
No.

PNK

839

LT BLU/
BLK

844

Fuel Injector #2

Function
Ignition Feed
Fuel Injector #4 Control

Fuel Injector #6

154327
154327

Connector Part
Information

Pin

Wire Color

121.2-9140
2 Way F Metri-Pack
280.1 Series Pull To
Seat (BLK)
Circuit
No.

PNK

839

LT GRN/
BLK

1745

Connector Part
Information

Pin

Wire Color

Circuit
No.

PNK

839

Ignition Feed

YEUBLK

846

Fuel Injector #6 Control

Function
Ignition Feed
Fuel Injector #2 Control

1212-9140
2 Way F Metri-Pack
280.1 Series Pull To
Seat (BLK)
Function

6-1308

Engine Controls .. 5.7L

Engine

Fuel Injector #8

Heated Oxygen Sensor (H02S), Left Rear

40407

154327

Connector Part
Information

1212-9140
2 Way F Metri-Pack
280.1 Series Pull To

Connector Pa~
Information

Seat (BLK)
Pin

Wire Color

Circuit
No.

PNK

839

DK BLU/
WHT

878

Pin

Wire Color

1216-0825
4 Way Metri-Pack
150 Series (BLK)
Circuit
No.

Function
Ignition Feed
Fuel Injector #8 Control

Fuel Tank Pressure Sensor

Function

TAN/WHT

1669

LR Heated Oxygen.
Sensor (H02S) - Low

s.

PPUWHT

1668

LR Heated Oxygen
Sensor (H02S) - High

BLK

PNK

450
539

Grourid
Ignition Feed

Heated Oxygen Sensor (H02S), Right Front

62453

Connector Part
Information

1205-9595
3 Way F Metri-Pack
150 Series (BLK)

Pin

Wire Color

Circuit
No.

ORN/BLK

469

Fuel Sensor Ground

890

Fuel Tank Pressure

Signal

DKGRN
GRY/BLK

416

Function

5V Sensor Feed

40407

Connector Part
Information

Pin

Wire Color

121-60825
4 Way M Metri-Pack
150 Series Sealed(BLK)
Circuit
No.

Function

TAN

1667

Heated Oxygen Sensor

(H02S) - Low

PPL

1666

Heated Oxygen Sensor

(H02S) - High

BLK

PNK

450
539

Ground
Ignition Feed

Engine

Engine Controls - 5.7L 6-1309

Heated Oxygen Sensor (H02S), Right Rear

Intake Air Temperature (IAT) Sensor

40407

Connector Part
Information ;

Pin

1216~0825
4 Way M Metri-Pack
150 Series Series (BLK)

Circuit
No.

Wire Color

68719

Connector Part
Information

Function

TAN

1671

RR Heated Oxygen
Sensor (H02S) - Low

PPL

1670

RR Heated Oxygen
Sensor (H02S) ~ High

BLK

450

Grpund

PNK

539

Ignition Feed

Pin

Wire Color

1216-2199
2 Way F Metri Pack
150;2 Series Pull to
Seat (GRY)
Circuit
No.

Function

PPL

719

Intake Air Temperature

(IAT} Sensor Ground

TAN

472

Intake Air Temperature

(IAT) Sensor Signal

Knock Sensors (KS)

Idle Air Control (IAC) Valve

~lo le I I 1) i
B

35437

'

Connector Part
Information

Pin

1216~2190
4 Way F Metri-Pack
150.2 Series Pull to
Seat (BLK)
Circuit .
No.

Function

LT GRN/
BLK

444

I.die Air Control (IAC)

Valve Coil B Signal - Low

LT GRN
WHT

1749

Idle Air Control (IAC)

Valve Coil B Signal - High

LT BLU/
BLK

1748

Idle Air Control (IAC)

Valve Coil A Signal - Low

LT BLU/
WHT

1747

Idle Air Control (IAC)

Valve Coil A Signal - High

. A

Wire Color

38608

/\

Connector Part
Information

1205-2641
2 Way F Metri-Pack
150 Series Sealed (BLK)

Pin

Wire Color

Circuit
No.

DKBLU

496

Knock Sensor (KS)

Signal - Front

LT BLU

1876

Knock Sensor (KS)

Signal - Rear

Function

6-1310

Engine

Engine Controls - 5.7L

Reverse Inhibit Solenoid

Manifold Absolute Pressure (MAP) Sensor

68740

Connector Part
Information

1212-9946
3 Way F Metri Pack
150 Series (GRY)

35437

Connector Part
Information

Pin

Wire Color

Circuit
No.

ORN/BLK

469

Manifold Absolute
Pressure (MAP) Sensor
Ground

Function

LT GRN

432

Manifold Absolute
Pressure (MAP) Sensor
Signal

GRY

416

Manifold Absolute
Pressure (MAP)
Sensor 5.0V Reference

.1205-2646
2 Way F Metri-Pack
150 Series Sealed (WHT)

Pin

Wire Color

Circuit
No.

LTGRN

1652

Reverse Inhibit Solenoid

Control

PNK

539

Ignition Feed

Function

Secondary Air Injection (AIR) Bleed Valve

Solenoid

(
(

Mass Air Flow (MAF) Sensor

35437

Connector Part
Information

Pin

Wire Color

Circuit
No.

PNK/BLK

429

Secondary Air
Injection Bleed Valve
Solenoid - Feed

BLK

150

Ground

62453

Connector Part
Information

1205-9595
3 Way F Metri-Pack
150 Series (BLK)

Pin

Wire Color

Circuit
No.

YEL

492

Mass Air Flow (MAF)

Sensor Signal

BLK/WHT

451

Ground

PNK

539

Ignition Feed

Function

1205-2643
2 Way F Metri-Pack
150 Series Sealed (RED)

Function

Engine Controls - 5.7L

Engine

Throttle Position (TP) Sensor

Secondary Air Injection (AIR) Pump

_J

6-1311

OJ~~IH~IIGJ~ill
68730
62485

Connector Part
Information

1211-0293
3 Way F Metri-Pack
150 Series (BLK)

Connector Part
Information

1211-0192

3 Way F Metri-Pack
150 Series Pull To Seat (BLK)

Pin

Wire Color

Circuit
No.

RED

78

Secondary Air Injection

Pump Motor - Feed

GRY

596

Throttle Position (TP)

Sensor 5V Reference

BLK

452

Sensor Ground

DKBLU

417

Throttle Position Sensor

Signal

Function

Pin

PNK/BLK

429

Secondary Air Injection

Solenoid - Feed

BLK

150

Ground

Skip Shift Solenoid

Wire Color

Circuit
No.

Function

Vehicle Speed Sensor (VSS)

I ~
62471

35437

Connector Part
Information

Pin
A
B

Wire Color
GRY
PNK

1205-2643
2 Way F Metri-Pack
150 Series Sealed (BLK)
Circuit
No.

Connector Part
Information

Pin

Wire Color

Circuit
No.

PPL

401

Vehicle Speed Sensor

(VSS) Signal - Low

YEL

400

Vehicle Speed Sensor

(VSS) Signal - High

Function

587

Skip Shift Solenoid

Control

539

Ignition Feed

1216-2195
2 Way F Metri-Pack
150.2 Series Pull to
Seat (BLK)
Function

6-1312

Engine Controls - 5.7L

Engine

Diagnostic lnformatiof) and Procedures

A Powertrain On Board Diagnostic (OBD) System Check
Powertrain

I" -

Control II
Module I
~ (PCM)

J
-?V-

...

Serial Data

1 (Class 2)

(
-

PCM

C1=RED
C2 = BLU

. Serial Oat.a
(UART)
.I

~----~----------~
58

IP

I" -

I Power

!H~A:AIITi:e~ -

USe I Distribution
Cell 10
Fuse Block

Block I

Details
Cell11

03

ca

BLK/
WHT 451
-----<Ill

Ground
Distribution
Cell14

25 A

11

----------;~~1~~

TAN 800

----J
ORN 540

..,.. _____ _

TAN 800

PPL 1.807

ORN 540

BLK/WHT 451

TAN 800

Anti lock
Brakes.
Cell44

TAN 800

TAN 800

~-----

BLK!650 sCK[65o
-=-

Supplemental
Inflatable
Restraints
(SIR)
Cell 47

BLK/WHT 4,?1

BLK 451

.,

. CIGAR ACCY I
Fuse
I

L---------

Fuse Bloc
Details
Cell11

5
------

16

TAN 800
FiPL 1807
2
9 Data Link
----------------------

Connector

(DLC)
218492

Description
Important: Do not perform this check if no driveability
concern exists. A driveability condition includes all
PCM controlled systems and components.
The Powertrain OBD System Check is an organized
approach to identifying a condition created by an
electronic engine control system malfunction.
The Powertrain OBD System Check is the starting
point for any driveability complaint diagnosis.
The Powertrain OBD System Check directs.Joe
service technician to the next logical step in diagnosing
a complaint. Understanding and using the table
correctly will reduce the diagnostic time and prevent
'
the replacement of good parts.
Important: For automatic transmission DTCs, refer to
Diagno$tic Trouble Code 1dentificaflon (5. 7L) in

Automatic Transmission 4L60-E:. The DTCs associated

with the automatic transmission are:
DTCs P0502, P0503, and 560.
Any 700 and 1800 series DTCs (i.e. DTC P07XX
and P18XX).
Important: For Domestic and Export DTC Types, refer
to OTC List.

Important: This.vehicle is equipped with a Powertrain

Control Module (PCM) utilizing an Electric~lly
Erasable Progr~mmable Read Only Memory
(EEPROM). Program the new PCM when diagnostics
call for replacement of the PCM.
Refer to PCM Replacement/Programming.

Diagnostic Aids
Important: If an intermittent condition exists, inspect
the PCM wiring harnesses for improper installation
of electri.cal components. lhspect for aftermarket theft
deJerrent devices, llghts, .arid cellular phones.
.
Ensure that no aftermarket equipment is connected to
the Class 2 circuit. A cellular phone signal
comhiunication may cause an intermittent condition.
If multiple DTCs are set, inspect the IGN 'mini relay for
proper operation. Thisrelay prQtects the battery
from a parasitic draw. The following components are
powered by the IGN mini relay:
Injectors/Ignition coils
A/C system
Transmission
EVAP solenoid and EVAP Vent Valve
MAF sensor
Heated Oxygen Sensors

Engine
Test Description
The numbers below refer to the step numbers on the
diagnostic table.

1. Use a properly functioning scan tool with the

diagnostic tables in this section. DO NOT use the
Clear Info function unless instructed by a
diagnostic procedure.
3. An Ignition 1 voltage that is too low may cause
the following conditions:
A no start
Stalling
High idle
An inoperative scan tool
5. This step determines if a OTC is set for the
Vehicle Theft Deterrent (VTD} system. A VTD OTC
set causes the engine from starting.
6. If multiple DTCs are stored, diagnose in the
following order of priority:
1. PCM failure DTCs (P0601, P0602, P0604)
2. System Voltage DTCs
3. Component level DTCs (Sensors, Solenoids,
Relays etc.). Multiple DTCs within this
category should be diagnosed in numerical
order starting with the lowest numbered OTC.
4. System level DTCs (Misfire, Fuel Trim, etc.)

Engine Controls - 5.7L

6-1313

For Automatic Transmission DTCs, refer to Diagnostic

Trouble Code Identification (5. 7L) in Automatic
Transmission-4L60E.
It is beneficial to review the Freeze Frame Data and/or
Fail Records. Use the odometer information and the
fail counter in order to determine how frequently
and how recently the OTC set. This information and
the other operating conditions when the OTC set may
help diagnose an intermittent condition. Capturing
the stored info preserves data that the PCM will lose
when instructed to Clear Info at the .end of a
diagnostic table, or if you disconnect the PCM or
replace the PCM during a diagnostic procedure. The
scan tool stores the data in the scan tool's memory.
Review the captured info at the end of the diagnostic
procedure in order to catch the next OTC in the
event there are multiple DTCs stored. Follow the order
of priority as listed above.
7. Compare actual. control system data with the
values in the Engine Scan Tool Data List to
determine if any parameter is not within limits.
Keep in mind th~t a base engine condition
(i.e. advanced cam timing) may substantially alter
sensor values. If the actual data does not
correspond with the values in the Engine Scan
Tool Data List, refer to the appropriate
system/component diagnostic aids or test
descriptions.

6-1314

Engine Controls - 5.7L

Engine

A Powertrain On Board Diagnostic (OBD) System Check

Step

Action
Important:
Search for applicable service bulletins before
proceeding with diagnosis.
Do not turn the ignition OFF when performing this
diagnostic table.
Ensure the battery is fully charged before proceeding
with this diagnostic.

Value(s)

Important: Save or capture the Freeze Frame and/or

Failure Records information if the PCM displays data.
Does the scan tool display PCM data?

No

(
-

1. Connect a scan tool to the Data Link

Connector (DLC).
2. Turn ON the ignition leaving the engine OFF.
Does the scan tool power-up?
2

Yes

Go to Step 2

Go to Data Link
Connector
Diagnosis

Go to Step 3

Go to Data Link
Connector
Diagnosis

Go to Step 4

Go to
OTC P0562
System
Voltage Low

Important: If the starter does not engage, refer to Starting

System Check in Engine Electrical.
Monitor the Ignition 1 voltage using a scan tool while
cranking the engine or while the engine is operating?
Is the Ignition 1 voltage near the specified voltage?

B+

Does the engine start and continue to run?

Go to Step 6

Go to Step 5

Go to
OTC P1626 Theft
Deterrent Fuel
Enable
Signal Lost

Go to Engine
Cranks but Does
Not Run

Go to the
applicable
DTC table

Go to Step 7

Go to Symptoms

Go to Diagnostic
Aids and Test
Descriptions

Is DTC P1626 stored?

5

Monitor the DTC information using a scan tool.

Are any DTCs displayed?

Compare the scan tool data with the values shown in the
Engine Scan Tool Data List.
Are the values normal or within typical ranges?

Engine Controls - 5.7L

Engine

6-1315

Data Link Connector Diagnosis

IHot At All Ti mes !

'" - - - -

Hot In RUN, BULB TEST And START!

r - - - - - - - - ., Underhood
I
Power
I El t . I
H7
PCM IGN
Distribution
6C rlCa
I
MiniFuse
Cell 10
I Center 2
I He 15A
I

- - - - ., Underhood
PCM BAT
I Electrical
MiniFuse I Center 1
I

10 A

L----

________ J

439
~~~1439
L-

-.J

ORN 340

r---------,
I

PNK/BLK

::: =------ -~~~-=61

20

19

C2

\lJ

LJil

_I _E~G~:.s~o~ ~

A4

Instrument
Cluster

BRN/WHT 419

~
~

Powertrain
Control
Module
~ (PCM)

>

BRN/WHT 419
37 C1

Malfunction
Indicator
Lamp (MIL)
(SERVICE

T
ffi

,, r - - -Balte";y-------------- - - - - - -Biiii:e';y------ - -lg'nitiQn - - - - - - - - - - - - - - - -Mil - - - - - - - - - .,

I
I
I
I

Positive
Voltage

Positive
Voltage

V
7

Positive
Voltage

Serial Data

~ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ (Class II)

r _ _ _ _ _ _ lHotAtAIITimes! __

I Power
I Distribution
I Cell lO

IL

___

03

Fuse Black
C3
Details
Ce1111_ _ _ _

.,IP

PCM
C1=RED
C2=BLU
Ground

Ground

72
-~:: ~;/
BLK 451

Block

I
I
I

Ground ~

-~~~

~;

BLK 451

TAN 800

_ _ _ _ _.I

''

TAN 800
TAN 800

...----

Antila ck
Brakes
Cell44

PPL

' '- _..,.

Ground
Distribution
Cell14

BLK 451

TAN 800

1807
TAN 800 TAN 800
Supplemental
Inflatable
Restraints
(SIR)
Cell47

BLK/WHT 451
BLK 650

I Fuse

CIGAR ACCY
Fuse 11
I
25 A
I

ORN 540

_ _

ORN 540
Fuse Block
Details
Cell11

Serial Data
(UART) _ _ _ Ground

p:~ ~~~-- - - ~~~1~:

_

Control

16

____________ ~

Data Link Connector (DLC)

218506

Circuit Description
Use a properly functioning scan tool with the diagnostic
tables in this section. DO NOT use the Clear Info
function unless instr1;1cted by a diagnostic procedure.
Important: This vehicle, equipped with a Powertrain
Control Module (PCM), utilizes an Electrically Erasable
Programmable Read Only Memory (EEPROM).
Program the new PCM when the diagnostics call for
replacement of the PCM. Refer to PCM
Replacement/Programming.

5. A ground must be available at both terminals for

the scan tool to function properly.
8. A no start condition occurs when the fuse(s) for
the battery or ignition feed circuits is open. The
MIL is inoperative when the battery and ignition
feed circuit fuses open. Inspect the circuits
for being grounded when either of these
fuses open.

Test Description

13. If the test lamp does not illuminate for a circuit,

inspect the fuse for being open. If the fuse is
open, inspect the circuit for a short to ground.

The numbers below refer to the step numbers on the

diagnostic table.

15. Inspect for an open fuse that supplies the DLC. If

the fuse is open, repair the grounded circuit.

3. An engine that just cranks and does not attempt

to start indicates that the PCM is not powered-up.

6-1316

Engine Controls - 5.7L

Engine

Data Link Connector Diagnosis

Step

Action

Value(s)

Yes

No

Go to Step2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Step 4

Go to Step 10

Go to Step 8

Go to Step 5

Go to Step 15

Go to Step 6

Go to Step 7

'

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

Important: This table assumes that the scan tool you are
using is functional.

1. Turn ON the ignition leaving the engine OFF.

2. Connect the scan tool to the Data Link
Connector (DLC).
Does the scan tool power-up?

Does the engine start and continue to operate?

1. Disconnect the scan tool from the DLC.

2. Turn ON the ignition leaving the engine OFF.
3. Probe the DLC terminal 16 using the test lamp
J 34142-B connected to the battery ground. Refer to
Probing Electrical Connectors in Wiring Systems.
Is the test lamp illuminated?

Probe the DLC terminals 4 and 5 using the test lamp

J 34142-B connected to B+.
Does the test lamp illuminate for both of the circuits?

1. Inspect the scan tool connections to the DLC. Also

inspect the terminals for proper terminal tension at
the DLC. Refer to lntermittents and Poor Connections
Diagnosis in Wiring Systems.
2. If you find a poor connection, repair the condition as
necessary. Refer ro Repairing Connector Terminals in
Wiring Systems.
Is the action complete?

Repair the open ground circuit to the DLC terminals 4

and 5. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

1. Turn OFF the ignition.

2. Disconnect the PCM connector C1 located on the
opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.
3. Turn ON the ignition.
4. Probe the PCM Battery and the PCM ignition feed
circuits (C1-19, 20, and 57) in the PCM harness
connectors using the test lamp J 34142-B connected
to a battery ground.

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Does the test lamp illuminate for each circuit?

1. Turn OFF the ignition.
2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Measure the resistance between the battery ground
and the PCM ground circuits (C1-1, C1-40 and C2-1,
C2-40) in the PCM harness connectors using the
DMM J39200.
Does the DMM display the specified value (or lower) on
each circuit?

Goto A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 9

Go to Step 13

Go to Step 11

Go to Step 14

2n

Engine

Engine Controls - 5.7L

6-1317

Data Link Connector Diagnosis (cont'd)

Step

10

Action

Value(s)

1. Test the Class 2 circuit for being open, grounded, or

shorted to a voltage.
2. If a condition is found repair the circuit as necessary.
Refer to Wiring Repairs in Wiring Systems.

Did you find and correct the c9ndition?

11

1. Inspect for poor connections at the PCM. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection repair as necessary.
Refer to Repairing ConnectorTerminals in Wiring
Systems.
Did you find and correct the condition?

.13

14

Repair the faulty PCM ground circuit(s). Refer to Wiring

Repairs in Wiring Systems.
Is the action complete?

15

Repair the faulty B+ supply circuit. Refer to' Wiring Repairs

in Wiring Systems.
Is the action complete?

Go to Step 11

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 12

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

.-

Goto A
Powertrain On
Board Diagnostic
(OBD)System
Check

..

\.

Go to A
fowertrain On
Board Diagnostic
(080) System
Check

Replacement/Programming.
Replace the PCM.
Is the action complete?
Repair the circuit that did not illuminate the test lamp.
Refer to Wiring Repairs i.n Wiring Systems.
Is the action complete?

No

Go to A
Powertrain On
Boa.rd Diagnostic
(080) System
Check

Important: Program the replacement PCM. ~efer to PCM

12

Yes

6-1318

Engine

Engine Controls - 5.7L

Engine Cranks but Does Not Run

Description

Test Description

The Engine Cranks but Does Not Run diagnostic table

assumes that battery condition and engine cranking
speed are OK. If the battery condition and the cranking
speed are not OK, refer to Charging System Check
~nd/or Starting System Check in Engine Electrical for
diagnosis. Make sure that there is adequate fuel in
the tank.

The numbers below refer to the step numbers on the

diagnostic table.
2. Certain DTCs only set while cranking the engine.
This step verifies if a component is causing the
no start condition.
4. This step is testing for a grounded ignition feed
circuit for the crankshaft position sensor and
the camshaft position sensor. When the ignition
feed circuit is shorted, a no start occurs and
no DTCs are set. The ignition feed circuits are
connected internally within the PCM. The
PCM cannot detect that the engine is cranking
with a grounded ignition feed circuit If no engine
speed is displayed on the scan tool, inspect
the ignition feed circuit for a short to ground.
The scan tool may reset i.f the battery ;is at a low
state of charge. The battery may need to be
charged to perform this step.
5. This step verifies the IGN relay for proper
operation. The IGN relay supplies voltage to the
injectors and the ignition coils. When the IGN relay
is not operating properly, a no start condition
occurs. If the test lamp does not illuminate, this
indicates the IGN relay is not suppling a voltage to
the fuses.
6. The Crankshaft Position sensor is located near
the starter.
7. The Camshaft Position sensor is located at the
rear of the engine behind the intake manifold.
8. The ignition feed circuit for the Camshaft and
Crankshaft Position. sensors is internaUy
connected within the PCM. A short to ground on
either circuit causes a no start condition.
10. The fuel cap may need to be removed to hear if
the fuel pump is operating.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent water intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents damage to the harness connector
terminals. Refer to Using Connector Test Adapters
in Wiring Systems.
Inspect the duct work between the Mass Air Flow
(MAF) sensor and the throttle body for air leaks.
A malfunctioning MAF sensor may cause a
no start or a stall after start. If you suspect this,
disconnect the MAF sensor. The PCM will default
to the speed density (MAP, IAT, RPM) in order
to calculate the .load and the air flow. If this
corrects the condition and the connections are
OK, replace the MAF sensor.
If the steps above do not isolate the condition, refer to
Symptoms.

Engine Cranks but Does Not Run

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to the
applicable
OTC table

Go to Step 3

Go to
OTC P1626 Theft
Deterrent Fuel
Enable
Signal Lost

Go to Step4

Go to Step 5

Go to Step 6

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

Important: Refer to applicable OTC table if any of the

following DTCs are set: P0230, P0335, P0336, P0601,
P0602, P0604.
Crank the engine for the specified amount of time.
Does the scan tool display any DTCs that failed this
ignition?
Monitor the VTD Fuel Enabled status using a scan tool.
Does the scan tool display Active?

Monitor the engine speed while cranking the engine.

Is engine RPM indicated on the scan tool?

15 Seconds

Engine

Engine Controls - 5.7L

6-1319

Engine Cranks but Does Not Run (cont'd)

Step

Action

Value(s)

Yes

No

Go to Step 9

Go to Ignition
Relay Diagnosis

Go to Step 13

Go to Step 7

Go to Step 14

Go to Step 8

Go to Step 16

Go to Step 15

Go to Step 10

Go to
DTC P0118
Engine Coolant
Temperature
(ECT) Sensor
Circuit High
Voltage

Go to Step 11

Go to Fuel Pump
Relay Circuit
Diagnosis

Go to Step 12

Go to Fuel
System
Diagnosis

1. Turn ON the ignition leaving the engine OFF.

2. Probe both sides of the fuses (located in the
Underhood Electrical Center 2) listed below using the
test lamp J 34142-8 connected to ground.

INJ1
INJ2
ENG CTRL
ENG SEN
A/C CRUISE
Does the test lamp illuminate on both sides of all
the fuses?

1. Disconnect the Crankshaft Position (CKP) sensor

electrical connector. Refer to Crankshaft Position
Sensor Replacement.
2. Measure the voltage at the ignition feed circuit at the
CKP electrical connector using the DMM J 39200.
Does the DMM display near the specified value?

B+

1. Disconnect the Camshaft Position (CMP) sensor

electrical connector. Refer to Camshaft Position
Sensor Replacement.
2. Measure the voltage at the ignition feed circuit at the
CMP electrical connector using the DMM J 39200.
Does the DMM display near the specified value?

B+

1. Test the Camshaft and Crankshaft Position sensor

ignition feed circuits for a short to ground. Refer to
Testing for Short to Ground in Wiring Systems.

10

11

2. If you find a grounded circuit repair the circuit as

necessary. Refer to Wiring Repairs in Wiring
Systems.
Did you find and correct the condition?
Monitor the engine coolant temperature using the
scan tool.
Is the engine coolant temperature on the scan tool close to
the actual engine temperature?

Enable the fuel pump using the scan tool.

Does the fuel pump operate?
1. Turn OFF the ignition.
2. Install a fuel pressure gauge. Refer to Fuel System
Diagnosis.
3. Turn ON the ignition leaving the engine OFF.
4. Observe the fuel pressure.
Is the fuel pressure within the specified range when the
fuel pump is operating?

380-420 kPa
(55-61 psi)

61320

Engine Controls - 5.7L

Engine

Engine Cranks but Does Not Run (cont'd)

Step

Action

12

Perform the following additional inspections:

Inspect the duct work between the Mass Air Flow
(MAF) sensor and the throttle body for air leaks.
Inspect that the throttle angle is at 0% at a closed
throttle. If the throttle angle is not at 0%, refer to
DTC P0122 Throttle Position (TP) Sensor Circuit Low
Voltage and DTC P0123 Throttle Position (TP) Sensor
Circuit High Voltage.
A malfunctioning MAF sensor may cause a no start or
a stall after a start. If you suspect this, disconnect the
MAF sensor. The PCM will default to the speed
density (MAP, IAT, RPM) in order to calculate the
engine load and the intake air flow. If disconnecting
the MAF sensor corrects the condition and the
connections are OK, replace the MAF sensor. Refer to
MAF Sensor Replacement.
Inspect the spark plugs for being gas fouled. If the
spark plugs are gas fouled, determine what caused
the rich condition.
Inspect for an engine mechanical failure that causes
an engine not to start (i.e. timing chain, low
compression).
Compare MAP/BARO parameters to another vehicle.
The parameter values should be close to each other.
Did you find and correct the condition?

Replace the CKP sensor. Refer to Crankshaft Position

Sensor Replacement.
Is the action complete?

Replace the CMP sensor. Refer to Camshaft Position

Sensor Replacement.
Is the action complete?

13

14

15

16

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.

Replace the PCM.

Is the action complete?
1. Select the Diagnostic Trouble Codes (DTC) option
and the Clear DTC Information option using the
scan tool.
2. Attempt to start the engine.

Value(s)

Yes

No

Go to Step .16

Go to Hard Start
for diagnosis

Go to Step 16

Go to Step 16

Go to Step 16

Does the engine start and continue to run?

Go to Step 17

17

1. Idle the engine at the normal operating temperature.

2. Monitor the Diagnostic Trouble Code (DTC) option
using the scan tool.
Are any DTCs displayed?

18

Select the Capture Info option and the Review Info option
using the scan tool.
Are any DTCs displayed that you have not diagnosed?

. Go to Step 2

Go to the
applicable
DTC table

Go to Step 18

Go to the
applicable
DTC table

System OK

Engine,Controls- 5r7L

Engine

5.,1321

Ignition Relay Diagnosis

Power
Distribution
Cell10

1I
RED 2
B C2
... - - - ; - --.-., Ignition
I
.
I Switch
I

: Ac~'.

RED 2

r:1-Start :

I Lock-...
Off.....
I

Bulb I
un Test I

L----G

---.I

G2
PNK 3

PNK

...---------------,---------1...
3
PNK 3

Power
Distribution
Cell 10

PNK 3

Fuse Block
Details
Cell11

PNK 1039

PNK 1039

------------.,

Underhood ... Electrical 1

----------------------------------.
Center 2 I G9
ENG CTRL
G7
A/C CRUISE G11
J7
ENG SEN
J9
INJ 1
J11
I

I GB

Mini Fuse
15 A

G6

Mini Fuse
15 A

Not
Used

J6

Mini Fuse
2-0 A

JB

INJ 2
Mini Fuse

A
____________
..

Mini Fuse
15 A

J10

15

L-

EVAP Canister Purge Solenoid,

Vent Solenoid and Transmission

A/C Clutch
Relay

MAF Sensor, H02S, Reverse

Inhibit Solenoid and
Skip Shift Solenoid

Bank 1 Injectors and

Ignition Coil/Modules

Bank 2 Injectors and

Ignition Coil/Modules

218762

Circuit Description

Diagnostic Aids

The following components are powered by the

IGN relay:
Injectors/Ignition coils
Transmission
A/C system
EVAP solenoid and EVAP Vent Valve
MAF sensor
Heated Oxygen Sensors

Important: For any test that requires probing the PCM

or component harness connectors, use the Connector
Test Adapter Kit J 35616-A. Using this kit prevents
damage to the harness connector terminals. Refer to
Using Connector Test Adapters in Wiring Systems.
The following may cause an intermittent:
Poor connections. Test for adequate terminal
tension. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
Corrosion
Mis-routed harness.
Rubbed through wire insulation.
Broken wire inside the insulation.

61322

Engine Controls - 5.7L

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
4. For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.

Engine
5. This step isolates the circuit from the IGN relay.
All of the circuits at the relay are good if the
test lamp illuminates.
9. The open circuit will be between the splice and
the IGN relay.
11. Remove the underhood electrical center and
inspect the circuits that are supplied a voltage by
the IGN relay.

Engine Controls. - 5.7L

Engine

6-1323

Ignition Relay Diagnosis

Step

Action

Value(s)

Yes

Go to Step 2

Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to Step 8

Go to Step 4

Go to Step 9

Go to Step 5

Go to Step 10

Go to Step 6

Go to Step 11

System OK

Go to Step 7

No
Go to A

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

1. Turn OFF the ignition.

2. Remove the underhood electrical center cover.
2

3. Remove the IGN relay.

4. Probe the B+ feed circuit to the IGN relay harness
terminal with a test lamp J 34142-8 connected to a

ground.
Does the test lamp illuminate?
1. Turn ON the ignition leaving the engine OFF.

2. Probe the ignition feed circuit to the IGN relay

harness terminal with a test lamp J 34142-8
connected to a ground.

Does the test lamp illuminate?

1. Turn OFF the ignition.

2. Check the resistance of the IGN relay harness

terminal ground circuit using a DMM J 39200
connected to the battery ground.

o-5n

Is the resistance less than the specified value?

1. Turn OFF the ignition.
2. Jumper the IGN relay B+ feed circuit and the IGN
relay load circuit together using a fused jumper wire.

3. Probe the fuses for the following components with a

test lamp J 34142-8 connected to a ground.
5

ENG CTRL

A/C CRUISE
INJR1
INJR2
ENG SEN
Does the test lamp illuminate?

Check for poor terminal contact at the IGN relay harness

connector. Refer to Connector Repairs in Wiring Systems.

Did you find and correct the condition?

Replace the IGN relay.

Is the action complete?
Repair the open B+ supply to the IGN relay. Refer to
Wiring Repairs in Wiring Systems.

Is the action complete?

9

Repair the ignition feed circuit to the IGN relay. Refer to

Wiring Repairs in Wiring Systems.
Repair the open ground circuit for the IGN relay Refer to
Wiring Repairs in Wiring Systems.
Repair the IGN relay load circuit. Refer to Wiring Repairs
in Wiring Systems.
Is the action complete?

. System OK

Is the action complete?

11

System.OK

Is the action complete?

10

System OK

System OK

System OK

6-1324

Engine Controls - 5.7L

Engine

Fuel Pump Relay Circuit Diagnosis

IHot At All Times!

'" - - - - -

- - - - " Underhood
I
FUEL PUMP I Electrical
MlnlFuse Center 1

I Power
I Distribution
Cell 10
I

20A
____
.,I

L.-----

ORN 1340
- - " Underhood
. - - - - - - - - - . . - . Fuel I Electrical
Pump : Center 2
Relay

I
87A

'" -

...

- - - - " Fuel
Fuel
I Tank
Pump
: Unit

_
E

I
I

87

i.----B8 ----All

__

BLK!WHT 451

I
I
I
,1

GAY
120

DK GRNM'HT 465

- -- ;.. .,

BLK;WHT 451

1
Ground
Distribution

DK GRN/WHT 465

BLK 1050

Cell 14

BLK 451

Ground
Distribution
Cell14

37 AC2
'" - - - - - - - - - - - - - , Powertrain
I
I
PCM
Control
I
c1-RED
Fuel . ___
I Module
I
Pump
I
C2=BLU
Relay
(PCM)

I
L -

control
-

---- -

I
-

>

.I~:

218494

Circuit Description
When the ignition switch is ON, the PCM activates the
in-tank fuel pump. The fuel pump remains ON as
long as the PCM receives reference pulses from the
ignition system. If there are no reference pulses,
the PCM turns the fuel pump OFF after about
2-3 seconds. The pump delivers fuel to the fuel rail
and injectors, then to the pressure regulator, where the system pressure remains at 380-420 kPa
{55-61 psi). Excess fuel returns to the fuel tanks.
When the engine is stopped, a scan tool in the output
controls function can turn ON the fuel pump.

Improper fuel system pressure results in one or many

of the following symptoms:
Cranks but will not run
Cuts out, may feel like an ignition systElm concern
Poor fuel economy
Loss. of power
Hesitation
DTCs

Engine Controls - 5.7L 6-1325

Engine
Diagnostic Aids

Test Description

Important:

The numbers below refer to the step numbers on the

diagnostic table.

Remove any. debris from the PCM connector

surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent water intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents damage to the harness connector
terminals. Refer to Using Connector Test Adapters
in Wiring Systems.
The following conditions may have caused the
fuel pump fuse to open:

- The fuse was faulty

- There is an intermittent sbort in the fuel
pump power feed circuit.
- The fuel .pump has an intermittent internal
condition.
For an intermittent condition, refer to Symptoms.

3. Refer to the thumbnail wiring schematic for the

proper terminal identification.
5, The test lamp .only illuminates for two seconds
even though the scan tool commanded position is
ON. You will have to command the fuel pump
OFF then ON to re-enable the PCM fuel pump
contrql.
12. Inspect the fuel pump fuse for an open. If the fuse
is open, test the circuit for a short to ground.
20. Inspect the fuei pump fuse for an open. If the fuse
is open, test the circuit for a short to ground.

Fuel Pump Relay Circuit Diagnosis

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 9

Go to Step 3

Go to Step 4

Go to Step 12

Go to .Step 5

Go to Step 13

Go to Step 6

Go to Step 11

Did you perform the Powertrain On-Board Diagnostic

(080) System Check?

Inspect the fuel pump fuse for being open.

Is the fuse open?

Important: For terminal identification, refer to Electrical

Center Identification in Wiring Systems.

1. Install a sc~n tool.

2. Disconnect the fuel pump relay from the underho9d
electrical center 2.
3. Turn ON the ignition leaving the engine OFF.
4. Probe the fuel pump relay battery feed circuit at the
underhood electrical center 2 using the test lamp
J 34142-B connected to battery ground. Refer to
Probing Electrical Connectors in Wiring Systems.

Does the test lamp illuminate?

.
5

Probe the fuel pump relay ground circuit at the underhood

electrical center using the test lamp J 34142-8 connected
to B+.
Does the test lamp illuminate?

1. Probe the fuel pump relay control circuit at the

underhood electrical center 2 with the test lamp
J 34142-B connected to ground.
2. Enable the fuel pump using the scan tool.
Does the test lamp illuminate?

6-1326

Engine Controls - 5.7L

Engine

Fuel Pump Relay Circuit Diagnosis (cont'd)

Step

Action

Important: Ignition must be ON before performing

this step;
Jumper the fuel pump relay battery feed circuit to the fuel
pump relay load circuit at the underhood electrical
center 2 using a fused jumper wire. Refer to Using Fused
Jumper Wires in Wiring Systems.
Does the fuel pump operate?

Value(s)

Yes

No

(
Go to Step 18

Go to Step 7

Go to Step 8

Go to Step 14

Go to Step 25

Go to Step 15

Go to Step 20

Go to Step 10

Go to Step 16

Go to Step 21

Go to Step 17

Go to Step 22

1. Leave the fused jumper wire connected.

2. Raise the vehicle. Refer to Lifting and Jacking the

Vehicle in General Information.
3. Disconnect the fuel pump harness connector at the
Body Pass Through connector. Refer to Outside Left
of Rear Floor Pan, Fwd Rear of Axle 98 in Wiring
Systems.

4. Probe the fuel pump power feed circuit at the Body

Pass Through connector with the test lamp
J 34142-8 connected to ground.
Does the test lamp illuminate?

1. Leave the fused jumper wire connected.

2. Connect the test lamp J 34142-8 between the
battery feed circuit and the ground circuit at the
Body Pass Through connector. Refer to Outside Left
of Rear Floor Pan, Fwd Rear of Axle 98 in Wiring
Systems.
Does the test lamp illuminate?
1.
2.
3.
4.
5.

Turn OFF the ignition.

Remove the fuel pump relay.
Remove the fuel pump fuse.
Turn On the ignition leaving the engine OFF.
Probe the battery feed circuit for the fuel pump relay
at the underhood electrical center 2 with the test
lamp J 34142-8 connected to B+.
Does the test lamp illuminate?

1. Raise the vehicle. Refer to Lifting and Jacking the

10

11

Vehicle in General Information.

2. Disconnect the fuel pump harness connector at the
Body Pass Through connector. Refer to Outside Left
of Rear Floor Pan, Fwd Rear of Axle 98 in Wiring
Systems.
3. Probe the load circuit for the fuel pump relay at the
underhood electrical center 2 using the test lamp
J 34142-8 connected to B+.
Does the test lamp illuminate?

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the fuel pump relay control circuit for the
following conditions.

Did you

An open
A short to ground
A short to voltage
find any of the above conditions?

Engine

Engine Controls - 5.7L 6-1327

Fuel Pump Relay Circuit Diagnosis (cont'd)

step

Action

12

1. Repair the open or grounded battery feed circuit to

the relay. Refer to Wiring Repairs in Wiring Systems.
2. Replace the fuel pump fuse if the fuse is open.
Is the action complete?

!I

13

Repair the open relay ground circuit. Refer to Wiring

Repairs in Wiring Systems.

Value(s)

15

16

17

18

19

20

No

Go to Step 29

Is the action complete?

14

Yes

Go to Step 29

Repair the open circuit between the underhood electrical

center 2 and the Body Pass Through connector. Refer to
Wiring Repairs in Wiring System.
Is the action complete?

Repair the open fuel pump ground circuit. Refer to Wiring

Repairs in Wiring Systems.
Is the action complete?

Repair the short to ground in the fuel pump relay load

circuit between the relay and the Body Pass Through
connector. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Repair the fuel pump relay control circuit. Refer to Wiring

Repairs in Wiring Systems.
Is the action complete?

1. Inspect for poor connections atthe relay (underhood

electrical center). Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
2. If you find a poor connection repair the condition as
necessary. Refer to Repairing Connector Terminals
in Wiring Systems.
Did you find and correct the condition?

Replace the relay. Refer to Fuel Pump Relay

Replacement.
Is the action complete?

1. Repair the short to ground in the fuel pump relay

battery feed circuit between the relay and the fuse.
Refer to Wiring Repairs in Wiring Systems.
2. Replace the open fuse.
Is the action complete?

Go to Step 29

Go to Step29

Go to Step 29

Go to Step 29

Go to Step 29

Go to Step 19

Go to Step29

Go to Step 29

1. Turn OFF the ignition.

2. Re-install the fuel pump relay.
3. Install a new fuse.
21

4. Connect the fuel pump harness to the Body Pass

Through connector.

5. Turn ON the ignition leaving the engine OFF.

6. Command the fuel pump relay ON using a scan tool.
Is the Fuel Pump fuse open?

22
'

1. Inspect for a poor connection at the PCM. Refer to

lntermittents and Poor .Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection, repair the c.ondition as
necessary. Refer to Repairing Connector Terminals
in Wiring Systems.
Did you find and correct the condition?

Go to Step 24

Go to
Diagnostic Aids

Go to Step 29

Go to Step 23

6-1328

Engine Controls - 5.7L

Engine

Fuel Pump Relay Circuit l>iagnosis (cont!d)

Step.

23

..

Value(s),

Action1 ..
}.
..
.. ..
Important: Program the replacement PCM. Refer to PCM
Replacement/Programming.
Replace the PCM.
.
Is the action comple~e?

Yes

.,,,

No

..

Go to Step 29

i:

24

..

Lower the fuel tank. Refer to Fuei Tank

Replacement.
2. Test the f\Jef pump harness between the Body Pass
. Through connector and the fuel pump (sending unit)
for short to ground.
3. If y9u find a grounded circuit, repair the circuit as
necessary. Refer to Wiring Repairs in Wiring

Systems.

Did you find and correct the condftion?

25

I"'"

1. Inspect for poor connections at the Body Pass

Throu'gh connector. Refer to lntermittents. and Poor
Connection Diagnosis in Wiring Systems.
2. If you find a poor connection repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
. ,.
Did you find and correct the condition?
..

Go to Step27

Go toStep29

Go to Step26

..

1. Lower the fuel tank. Refer to Fuel Tank

ReP,lac(;]men.t.
2. Remove the fuel sending unit jumper harness;
3. Inspect the harness for damage.
4. If you find a damaged harness, repair as necessary.
Refer to Wiring Repairs in Wiring Systems.
Did you find and correct the condition?

Go.to siep~9

'

('

'

~-~

26

..

27

28

1. Inspect for poor connections at the fuel tank sending

unit. Refer .to lntermittents and Poor Conhections
Diagnosis ih Wiring Systems.
2. If you find a poor connection repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systemi,. '
. ;
.
.
.
Did you find and correct the,condition?
Important: Inspect for poor electrical connections (within
the fuel tank) at the fuel pur/,p/sending unit harness
connector before replacing the fuel pump. Refer to
lntermittents and Poor Connections Diagnosis in Wiring
Systems'..

.,.

J
,

..

,_

Select the Capture Info option and the Review Info option
using the scan tool.
3J ;'
. Ooes the .scan tdbl display any DTCs that you have not
diagnosed?

Go to Step27

Go to Step29

. Go to Step 28

,.
.

Replace the fuel pump. Refer to Fuel Sender Assembly

Service.
Is the action complete?
1. Select the Diagnostic Trouble Code (OTC) option
and the Clear OTC Information option using the
scan tool.
29
. 2. Attempt to start the engine .
.. DoesJhe engine.start and continue to run?
..
'"'~
.
1. Idle the engine until the normal operating
temperature is reached.
30
2. Select the Diagnostic Trouble Code (OTC) option.
!
;
Are any DTCs displayed?

Go to Step 29

Goto Step 29
..

Go to Step 30

..

..

..

Go to Step2

..

.
-

Go to the
applicable
OTC table

Go to $tep 31

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5.7L

6-1329

Fuel System Diagnosis

218096

Legend
(1) J 37287 Fuel Line Shut-off Adapters
(2) Rear Fuel Return Pipe
(3) T-connector

(4) Fuel Return Pipe

(5) Fuel Feed Pipe
(6) J 34730-1A Fuel Pressure Gauge

Circuit Description

Test Description

When you turn ON the ignition switch, the Powertrain

Control Module (PCM) turns ON the in-tank fuel
pump. The in-tank fuel pump remains ON as long as
the engine is cranking or running and the PCM
receives reference pulses. If there are no reference
pulses, the PCM turns the in-tank fuel pump OFF
2 seconds after the ignition switch is turned ON
or 2 seconds after the engine stops running.

The numbers below refer to the step numbers on the

diagnostic table.

The electric fuel pump attaches to the fuel sender

assembly inside the fuel tank. The in-tank fuel pump
supplies fuel through an in-pipe fuel filter to the fuel rail
assembly. The fuel pump provides fuel at a pressure
above the pressure needed by the fuel injectors.
The fuel pressure regulator keeps the fuel available to
the fuel injectors at a regulated pressure. The fuel
pressure regulator attaches to the fuel sender
assembly return pipe. Unused fuel returns to the fuel
tank by a separate fuel return pipe. The fuel return
pipe attaches to a T-connector in the fuel feed pipe on
the outlet side of the fuel filter.

2. When the ignition switch is ON and the fuel pump

is running, the fuel pressure indicated by the fuel
pressure gauge should read 380-410 kPa
(55-60 psi). The spring pressure inside the fuel
pressure regulator controls the fuel pressure.
3. A fuel system that drops more than 34 kPa (5 psi)
in 1O minutes has a leak in one or more of the
following areas:
The fuel pipes.
The fuel pump check valve.
The fuel pump flex pipe.
The valve or valve seat within the fuel pressure
regulator.
The fuel injector(s).
4. A fuel system that drops more than 14 kPa (2 psi)
in 1O minutes after being relieved to 69 kPa
(10 psi) indicates a leaking fuel pump check valve.

6-1330

Engine Controls - 5.7L

5. Fuel pressure that drops-off during acceleration,

cruise, or hard cornering may cause a lean
condition. A lean condition can cause a loss of
power, surging, or misfire. You can diagnose
a lean condition using a scan tool. If an extremely
lean condition occurs, the heated oxygen
sensors(s) will stop toggling. The heated oxygen
sensor output voltage(s) will drop below
300 mV. The fuel injector pulse width will increase.

Important: Make sure the fuel system is not operating

in the Fuel Cut-Off Mode. This can cause false
indications by the scan tool.
10. A rich condition may result from the fuel pressure
being above 410 kPa (60 psi). A rich condition
may cause DTC P0132, DTC P0152, DTC P0172
or DTC P0175 to set. Driveability conditions
associated with rich conditions can include hard
starting followed by black smoke and a strong
sulfur smell in the exhaust.
11. This test determines if the high fuel pressure is
due to a restricted fuel return pipe or if the
high fuel pressure is due to a faulty fuel pressure
regulator.

12. A lean condition may result from the fuel pressure

being below 380 kPa (55 psi). A lean condition
may cause OTC P0131 , DTC P0151, DTC P0171
or DTC P0174 to set. Driveability conditions
associated with lean conditions can include hard
starting (when the engine is cold), hesitation,
poor driveability, lack of power, surging, and
misfiring.

Engine
Notice: Do not allow the fuel pressure to exceed
500 kPa (72 psi). Fuel pressure in excess of 500 kPa
(72 psi) may damage the fuel pressure regulator.
13. Restricting the fuel return pipe with the J 37287
fuel pipe shut-off adapter causes the fuel
pressure to rise above the regulated fuel pressure.
Using a scan tool to pressurize the fuel system,
the fuel pressure should rise above 41 O kPa
(60 psi) as the valve on the fuel pipe shut-off
adapter connected to the fuel return pipe becomes
partially closed.
18. Check the spark plug associated with a particular
fuel injector for fouling or saturation in order to
determine if that particular fuel injector is leaking.
If checking the spark plug associated with a
particular fuel injector for fouling or saturation does
not determine that a particular fuel injector is
leaking, use the following procedure:
1. Remove the fuel rail, but leave the fuel pipe
connected to the fuel rail. Refer to Fuel Rail
Assembly Replacement.
2. Lift the fuel rail just enough to leave the fuel
injector nozzles in the fuel injector ports.
Caution: In order to reduce the risk of fire and
personal injury that may result from fuel spraying
on the engine, verify that the fuel rail is positioned
over the fuel injector ports. Also verify that the
fuel injector retaining clips are intact.
3. Pressurize the fuel system by using the scan
tool fuel pump enable.
4. Visually and physically inspect the fuel injector
nozzles for leaks.

Engine

Engine Controls - 5.7L

5.. 1331

Fuel. System Diagnosis

Step.

Action

Value(s)

Did you perform the Powertrain On-Board Diagnostic (OBD)

System Check?

No

Yes

Go to Step 2

Go to A
Powertrain On
Board
Diagnostic
(080) System
Check

1. Turn the ignition OFF.

2. Turn the air conditioning system OFF.

Caution: Wrap a shop towel around the fuel pressure

connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel leakage
that oqcurs during the connection of the fuel pressure
gauge. Place the towel in an approved container when
the connection of the fuel pressure gauge is complete.
3. l11stall the J 34730-1A fuel pressure gauge (6).
4. Place the bleed hose of the fuel pressure gauge into
an approved gasoline container.
5. Turn the ignition ON.

380-410 kPa
(55-60 psi)

6. Bleed the air out of the fuel pressure gauge.

7. Turn the ignition OFF for 10 seconds.
8. Turn the ignition ON.
Important: The fuel pump will run for approximately
2 seconds. Cycle the ignition as necessary in order to
achieve the highest possible fuel pressure.
9. Observe the fuel pressure with the fuel pump running.
Is the fuel pressure within the specified limits?

Important: The fuel pressure may vary slightly when the

fuel pump stops running. After the fuel pump stops running
the fuel pressure should stabilize and remain constant.
Does the fuel pressure drop more than the specified value
in 1O minutes?

Relieve the fuel pressure to the first specified value.

Does the fuel pressure drop more than the second specified
value in 1O minutes?
Do you suspect the fuel pressure of dropping-off during
acceleration, cruise, or hard cornering?

Go to Step 3

Go to Step 10

Go to Step B

Go to Step 4

Go to Step 17

Go to Step 5

Go to Step 6

Go to
Symptoms

Go to Step 21

Go to Step 7

Go to Step 21

Go to Step 17

34 kPa (5 psi)

69 kPa (10 psi)

14 kPa (2 psi)

""

Visually and physically inspect the following items for a

restriction:

The fuel filter.

The fuel feed pipe (5).
Did you find a restriction?

1. Remove the fuel sender assembly. Refer to Fuel

Sender Assembly Replacement.
2. Visually and physically inspect the following items:
~ The fuel pump strainer for a restriction

The fuel pump flex pipe for leaks

The fuel pressure regulator for leaks
The fuel pressure regulator fuel return flex pipe
for leaks
Verify the fuel pump is the correct fuel pump for this
vehicle
Did you find a problem in any of these areas?

6-1332

Engine Controls - 5~7L

Engine

Fuel'System Diagnosis (cont'd)

Step

Action

1. Relieve the fuel pressure. Refer to the Fuel Pre~sure

Relief Procedure.
2. Disconnect the fuel feed pipe (5) from the fuel rail.
Refer to Quick Connect Fitting(s) Service (Metal
Collar).
3. Install the J 37287 fuel pipe shut-off adapter (1)
between the fuel feed pipe and the fuel rail.
4. Open the valve on the fuel feed pipe shut-off adapter.
5. Pressurize the fuel system using a scan tool.
6. Place the bleed hose of the fuel pressure gauge (6)
into an approved gasoline container.
7. Bleed the air out of the fuel pressure gauge.
8. Wait for the fuel pressure to build.
9. Close the valve in the fuel feed pipe shut-off adapter.
Does the fuel pressure remain constant?

Value(s)

Yes

No

Go to Step 9

Go to Step 18

"

Important: This step requires the aid of an assistant.

1. Open the valve in the fuel feed pipe shut-off
adapter (1 ).
2. Relieve the fuel pressure. Refer to the Fuel Pressure
Relief Procedure.
3. Raise the vehicle.
4. Disconnect the steel fuel return pipe (4) at the nylon
rear return pipe (2). Refer to Quick Connect Fitting(s)
Service (Plastic Collar).

10

11

12

5. Drain any remaining fuel from the pipes into an

approved gasoline container.
6. Install the J 37287 fuel pipe shut-off adapter (1)
between the steel fuel return pipe and the rear nylon
return pipe.

7. Pressurize the fuel system using a scan tool.

8. Wait for the fuel pressure to build.
9. Close the valve in the fuel pipe shut-off adapter that is
connected to the fuel return pipe (4).
Does the fuel pressure remain constant?
Is the fuel pressure above the specified limit?
1. Relieve the fuel pressure. Refer to the Fuel Pressure
Relief Procedure.
2. Disconnect the steel fuel return pipe (4) at the nylon
rear return pipe (2). Refer to Quick Connect Fitting(s)
Service (Plastic Collar).
3. Drain any remaining fuel from the fuel pipes into an
approved gasoline container.
4. Attach a length of flexible fuel hose to the steel fuel
return pipe attached to the T-connector (3).
5. Place the open end of the flexible fuel hose into an
approved gasoline container.
6. Turn ON the fuel pump using a scan tool.
7. Observe the fuel flow with the fuel pump running.
Is there fuel flow?
Is the fuel pressure above the specified value?

410 kPa
(60 psi)

Go to Step 16

Go to Step 17

Go to Step 11

Go to Step 12

Go to Step 20

Go to step 19

Go to Step 13

Go to Step 14

o kPa (0 psi)

Engine Controls - 5.7L

Engine

6-1333

Fuel System Diagnosis (cont'd)

Action

Step

Value(s)

Yes

No

'

Important: This step requires the aid of an assistant.

13

1. Relieve the fuel pressure. Refer to the Fuel Pressure

Relief Procedure.
2. Raise the vehicle.
3. Disconnect the steel fuel return pipe (4) from the nylon
rear return pipe (2). Refer to Quick Connect Fitting(s)
Service (Plastic Collar).
4. Drain any remaining fuel from the fuel pipes into an
approved gasoline container.
5. Install the J 37287fuel pipe shut-off adapter (1)
between the steel fuel return pipe and the nylon rear
fuel return pipe.
6. Open the valve on the fuel pipe shut-off adapter.
7. Pressurize the fuel system using a scan tool.

410 kPa
(60 psi)

8. Place the bleed hose of the fuel pressure gauge (6)

into an approved gasoline container.
9. Bleed the air out of the fuel pressure gauge.
Notice: Do not allow the fuel pressure to exceed 500 kPa
(72 psi). Fuel pressure in excess of 500 kPa (72 psi) may
damage the fuel pressure regulator.
10. Slowly close the valve in the fuel pipe shut-off adapter
that is connected to the fuel return pipe.
Does the fuel pressure rise above the specified value?
14

Turn ON the fuel pump using a scan tool.

Does the fuel pump run?

Go to Step 16

Go to Step 7

Go to Step 15

Go to Fuel
Pump Relay
Circuit
Diagnosis

Go to Step 21

Go to Step 17

Visually and physically inspect the following items:

The fuel filter for obstructions.
15

The fuel feed pipe (5) for a restriction.

the fuel pump strainer for obstructions.

The fuel pump flex pipe for leaks.

Did you find a problem in any of .these areas?
16

17

Replace the fuel pressure regulator. Refer to Fuel Sender

Assembly Service.
Is the action complete?

Replace the fuel pump. Refer to Fuel Sender Assembly

Service.
Is the action complete?

18

Locate and replace any leaking fuel injector(s).

Is the action complete?

19

Locate and correct the restriction in the steel fuel return

pipe (4) or the T-connector (3).
Is the action complete?

20

Visually and physically inspect the nylon re'.3-r fuel return

pipe (2) for a restriction.

21

System OK
System OK

System OK

Did you find a re,striction?

Repair the problem as necessary.
Is the action cqmplete?

System OK

Go to Step 21

System OK

Go to Step 16

6-1334

Engine

Engine Controls - 5.7L

OTC P0101 Mass Air Flow {MAF) Sensor Performance

IHot With lgn 1 Relay Energized I

'" Power
- - - - I Distribution
I Cell 10

J7

MinlFuse I

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Sensor

Center 2

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PCM
C1 = RED
C2=BLU

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Powertrain
Control
Module
(PCM)

j.

[M;'1

LJil

YEL 492

PNK 539

5 39
PNKf _ _ _._
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PNK 539

Fuse Block
Details
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AA

Ignition
Power

MAF

Mass Air

Sensor
Signal

Flow (MAF)
Sensor

Ground

B
BLKIWHT 451
-

__.,.

Ground
Distribution
Cell 14

BLK 451

218496

Circuit Description
The Mass Air Flow (MAF) sensor measures the
amount of air ingested by the engine. The direct
measurement of the air entering the engine is more
accurate than calculating the airflow from the MAP, the
IAT and the engine speed (speed/density). The
MAF sensor has a battery feed, ground, and a signal
circuit.
The MAF sensor used on this engine is a hot wire
type. This engine uses the MAF sensor to measure air
flow rate. The MAF output frequency is a function of
the power required to keep the air flow sensing
elements (hot wires) at a fixed temperature above the
ambient temperature. Air flowing through the sensor
cools the sensing elements. The amount of cooling is
proportional to the amount of air flow. The MAF
sensor requires a greater amount of current in order to
maintain the hot wires at a constant temperature as
the air flow increases. The MAF sensor converts
the changes in current draw to a frequency signal read
by the PCM. The PCM calculates the air flow (grams
per second) based on this signal.
The PCM monitors the MAF sensor frequency. The
PCM can determine if the sensor is stuck low,
stuck high, not providing the airflow value expected for
a given operating condition, or that the signal
appears to be stuck based on a lack of signal variation
expected during the normal operation. This diagnostic
tests the range/performance of the MAF sensor.

The MAF system performance or rationality diagnostic

uses the MAP, the IAT, and the engine speed to
calculate an expected airflow rate. The PCM then
compares the rate to the actual measured airflow from
the MAF sensor. The PCM only compares the
actual MAF value and the calculated value during
conditions where the values are likely to match. This
DTC sets if the actual MAF reading is not within a
predetermined range of the calculated reading.

Conditions for Running the DTC

DTCs P0102, P0103, P0107, P0108, P0121,
P0122, P0123 not set.
The engine is running.
The TP sensor angle is less than 50% and the
engine vacuum (BARO-MAP) is greater
than 65 kPa.
The system voltage is greater than 10 volts but
less than 16 volts.
The change in TP sensor is less than 3%.
All above conditions stable for 2.0 seconds.

Conditions for Setting the DTC

The MAF frequency is 50% different from the
speed density calculation.
All conditions met for 5.0 seconds.

Engine
Action Taken When the DTC Sets
The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive Ignition
Cycle that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive Ignition Cycle,
the PCM records the operating conditions at
the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.
The PCM utilizes speed density (RPM, MAP, IAT)
for fuel management.

Conditions for Clearing the MIL/DTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent water intrusion into the PCM.
For. any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents damage to the harness connector
terminals. Refer to Using Connector Test Adapters
in Wiring Systems.
The following may cause an intermittent:
- Mis-routed harness
- Rubbed through wire insulation
- Broken wire inside the insulation
Any un-metered air may cause this DTC to set.
Inspect for the following:
- An engine vacuum leak
- The PCV system for vacuum leaks
- An incorrect PCV valve
- The engine oil dip stick not fully seated
For an intermittent, refer to Symptoms.

Engine Controls - 5.7L 6-1335

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. The MAF system performance or rationality
diagnostic uses the MAP sensor signal along with
other inputs in order to calculate an expected
airflow rate. The PCM then compares the
expected flow rate to the actual measured airflow
from the MAF sensor. The first few steps of
this table verify that the MAP sensor is working
properly. Correct any MAP sensor DTCs first.
Refer to OTC P0107 Manifold Absolute Pressure
(MAP) Sensor Circuit Low Voltage if the MAP
sensor voltage is less than 0.8 volts. Refer
to OTC PO 108 Manifold Absolute Pressure (MAP)
Sensor Circuit High Voltage if the MAP sensor
voltage is greater than 4.0 volts.
3. Twist the sensor towards the front of the vehicle
and lift upward in order to remove the MAP
sensor.
6. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the DTC failed.
7. Any un-metered air causes this DTC to set.
Inspect the PCV system for vacuum leaks. Also
inspect the dip stick for being pulled out.
Inspect the oil fill cap for being loose.
8. This step verifies the signal circuit from the MAF
sensor electrical connector to the PCM.
9. This step verifies whether a ground and B+ circuit
is available.
10. This step tests the signal circuit for an open.
11. This step tests the signal circuit for a short to B+.

6-1336

Engine

Engine Controls - 5.7L

DTC P0101 Mass Air Flow (MAF) Sensor Performance

Step

Action

Did you perform the Powertrain On-Board Diagnbstic

(OBD) System Check?
1

Value(s)

1. Turn OFF the ignition.

2. Remove the MAP sensor from the intake manifold
leaving the electrical harness connected.
3. Connect a hand operated vacuum pump to the MAP
sensor.
4. Turn ON the ignition leaving the engine OFF.
5. Observe the MAP sensor display while slowly
applying vacuum up to 20 inches Hg as indicated on
the pump gauge. Each 1 inch of vacuum applied
should result in a 3 to 4 kPa drop in the MAP sensor
value on the scan tool and the value should change
smoothly with each increase in vacuum.
Did the MAP sensor value change smoothly through the
entire range of the test without any erratic readings?
Apply 20 inches Hg vacuum to the MAP sensor.
Is the MAP sensor reading on the scan tool the same or
less than the specified value?
Disconnect the vacuum source from the MAP sensor.
Does the MAP sensor reading return to the original value?

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to
DTCP0107
Manifold Absolute
Pressure (MAP)
Sensor:Circuit
Low Voltage or
OTC P0108
Manifold Absolute
Pressure (MAP)
Sensor Circuit
High Voltage

Go to Step 3

If any MAP sensor DTCs are set, refer to the applicable

OTC before proceeding.
1. Idle the engine.
2. Monitor the MAP sensor voltage parameter using a
scan tool.
Is the MAP sensor voltage outside of the specified range?

Yes

0.8-4 volts

Goto Step 4

Go to Step 19

Go to Step 5

Go to Step 19

Go to Step 6

Go to Step 19

Go to Step 7

Go to
Diagnostic Aids

34 kPa

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records

data for this OTC and observe the parameters.

3. Turn OFF the ignition for 15 seconds.

4. Re-install the MAP Sensor.

5. Start the engine.

6. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in the Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.
7. Select the Diagnostic Trouble Code (OTC) option, the
Specific OTC option, then enter the OTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

Engine Controls - 5.7L

Engine

6-1337

OTC P0101 Mass Air Flow (MAF) Sensor Performance (corit'd)

Action.

Step

Value(s)

Yes

No

Go to Step 21

Go to Step B

1. Inspect for the following conditions:

Objects blocking the MAF sensor inlet screen

Intake manifold vacuum leaks
Vacuum leaks at the throttle body
Crankcase ventilation valve faulty, missing, or
incorrectly in.stalled

..

2. If you find a condition, repair as necessary.

Did you find and correct the condition?

Turn OFF the ignition.

Disconnect the MAF sensor connector.
Turn ON the ignition leaving the engine OFF.
Measure the voltage between the MAF sensor signal
circuit and the battety ground using the DMM
J39200.
Is the voltage near the specified value?

Connect the test lamp J 34142-8 between the MAF sensor

ignition feed and the ground circuit at the MAF sensor
harness connector.
Is the test lamp illuminated?

10

Is the voltage less than the specified value?

11

1. Turn OFF the ignition.

2. Disconnect the PCM connector C1 located on the
opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.
3. Turn ON the ignition leaving the engine OFF.
4. Measure the voltage between the MAF sensor signal
circuit and ground.
Does the voltage measure near the specified value?

12

1.
2.
3.
4.

Connect the test lamp J 34142-8 between the MAF sensor

ignition feed circuit and the battery ground.

.,

5.0V

14

15

4.5V

16

Go to Step 11

Go to Step 20

Go to Step 17

Go to Step 15

Go to Step 16

Go to Step 21

Go to Step 18

Go to Step 21

Go to Step 20

1. Test the MAF sensor signal circuit between the PCM

and the MAF sensor for the following:
An open circuit
A short to ground
A short to the MAF sensor ground circuit.
2. Repair the circuit if the MAF sensor signal circuit is
open or shorted. Refer to Wiring Repairs in Wiring
Systems.
Did you find and correct the condition?

Locate and repair the open in the ignition feed circuit to

the MAF sensor. Refer to Wiring Repairs in Wiring
Systems.
Is the action complete?

Go to Step 12

Go to Step 14

o.ov

Go to Step 21

Is the action complete?

Go to Step 13

1. Inspect for a poor connection at the MAF sensor.

Refer to lntermittents and Poor Connections
Diagnosis in Wiring Systems.
2. If you find a poor connection, repair the condition as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and correct the condition?

Locate and repair the open in the ground circuit to the

MAF sensor. Refer to Wiring Repairs in Wiring Systems.

Go to Step 10

Is the test lamp illuminated?

13

Go to Step 9

Go to Step 21

6-1338

Engine Controls - 5.7L

Engine

DTC P0101 Mass Air Flow (MAF) Sensor Performance (cont'd)

Step

Action

Value(s)

17

Locate and repair the short to voltage in the MAF sensor

signal circuit. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

18

Replace the MAF sensor. Refer to MAF Sensor

Replacement.
Is the action complete?

Replace the MAP sensor. Refer to MAP Sensor

Replacement.
Is the action complete?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

19

20

Yes

No

Go to Step 21

Go to Step 21

Go to Step 21

Go to Step 21

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.

21

2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.

Does the scan tool indicate that this test ran and passed?
22

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 22

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls .. 5.7L

6-1339

DTC P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency

:J

!Hot With lgn 1Relay Energized !

~ P-;;-wer

I Distribution
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rv1AF
Sensor
Signal

Ignition
Power

Mass Air
Flow (MAF)
Sensor

Ground

8
BLKtv'VHT 451
-

Ground
Distribution
Cell 14

BLK 451

218496

Circuit Description
The Mass Air Flow (MAF) sensor measures the
amount of air ingested by the engine. The direct
measurement of the air entering the engine is more
accurate than calculating the airflow from the MAP, the
IAT, and the engine speed (speed/density). The
MAF sensor has a battery feed, a 'ground, and signal

circuit.
The MAF sensor used on this engine is a hot wire
type. This engine uses the MAF sensor in order
to measure air flow rate. The MAF output frequency is
a function of the power required to keep the air flow
sensing elements (hot wires) at a fixed temperature
above the ambient temperature. Air flowing through the
sensor cools the sensing elements. The amount of
cooling is proportional to the amount of air flow. The
MAF sensor requires a greater amount of current
in order to maintain the hot wires at a constant
temperature as the air flow increases. The MAF sensor

converts the changes in current draw to a frequency

signal read by the PCM. The PCM calculates the
air flow (gmms per second) based on this signal.
The PCM monitors the MAF sensor frequency. The
PCM determines if the sensor is stuck low, stuck high,
not providing the airflow value expected for a given
operating condition, or that the signal appears to
be stuck based on a lack of signal variation expected
during the normal operation. This diagnostic tests
for too low an airflow rate, This DTC sets when the
PCM detects that the MAF sensor frequency is below a
predetermined value.

Conditions for Running the DTC

The engine speed is greater than 300 RPM.
The system voltage is at least 8.0 volts.

Conditions for Setting the DTC

The MAF frequency is less than 1O Hz.
All conditions met for 1 second

6-1340

Engine

Engine Controls - 5.7L

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive Ignition
Cycle that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive Ignition Cycle,
the PCM records the operating conditions at
the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.
The PCM utilizes speed density (RPM, MAP, IAT)
for fuel management.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent water intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents damage to the harness connector
terminals. Refer to Using Connector Test Adapters
in Wiring Systems.
.The following may cause an intermittent:
- Mis-routed harness
- Rubbed through wire insulation
- Broken wire inside the insulation

Any un-metered air may cause this DTC to set.

Inspect for the following:
- An engine vacuum leak
- The PCV system for vacuum leaks
- An incorrect PCV valve
- The engine oil dip stick not fully seated
- The engine oil fill cap loose or missing
For an intermittent, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Monitoring the MAF sensor frequency will
determine if the fault is present or the malfunction
is intermittent.
3. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
isolates when the DTC failed.
4. This step tests whether the MAF sensor ignition
feed circuit is shorted to a ground. If the fuse is
open, repair the circuit as necessary and
replace the fuse.
5. This step tests whether the 5.0 volts is available
to the MAF sensor signal circuit.
6. This step tests if the signal circuit is shorted to
another 5.0 volt reference circuit. If another
OTC sets, repair the circuits that are shorted
together. If no DTCs set it may be necessary to
road test the vehicle.
10. Inspect the fuse 19 for being open. If the fuse is
open, inspect the MAF sensor ignition feed
circuit for a short to ground.
11. This step verifies whether B+ is available to the
MAF sensor.

Engine Controls - 5.7L

Engine

6-1341

DTC P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency
Action

Step

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

)
1

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 19

Go to Step 5

Go to Step 6

Go to Step 7

Go to Step 20

Go to Step 11

Go to Step 14

Go to Step 8

1. Install a scan tool.

2. Idle the engine.

3. Monitor the MAF sensor frequency display on the
Engine 2 Data List of the scan tool.
Is the MAF sensor frequency below the specified value?

10 Hz

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this DTC and observe the parameters.

3. Turn OFF the ignition for 15 seconds.

4. Start the engine.

5. Operate the vehicle within the conditions required for

this diagnostic to run, and as close to the conditions
recorded in the Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the DTC.
6. Select the Diagnostic Trouble Code (DTC} option, the
Specific DTC option, then enter the DTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?
Is the ENG SEN fuse open?

1. Turn OFF the ignition.

2. Disconnect the MAF sensor connector.
3. Turn ON the ignition leaving the engine OFF.

4. Measure the voltage between the MAF sensor signal

5V

circuit and the battery ground using the DMM

J 39200. Refer to Measuring Voltage in Wiring
Systems.
Is the voltage near the specified value?

Important: If the engine does not start when the MAF

sensor signal circuit is grounded, and no additional DTC
sets, monitor the scan tool parameters for a sensor value
that is not within range. This will aid in locating a short to
another 5.0 volt circuit.
1. Turn OFF the ignition.
2. Jumper the MAF sensor signal circuit to battery
ground using a fused jumper wire. Refer to Using
Fused Jumper Wires in Wiring Systems.

3. Start the engine.

Do any additional DTCs set?

1. Turn OFF the ignition.

2. Disconnect the PCM. Refer to PCM
Replacement/Programming.
3. Turn ON the ignition leaving the engine OFF.
4. Measure the voltage at the MAF sensor signal circuit
at the PCM harness connector using the DMM
J 39200. Refer to Probing Electrical Connectors in
Wiring Systems.
Does the DMM display a voltage?

6-1342

Engine Controls - 5.7L

Engine

OTC P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency (cont'd)
Step

Action

.,

Value(s)

1. Turn OFF the ignition.

2. Test for continuity of the MAF sensor signal circuit
, using the DMM J 39200. Refer to Testing for
Continuity in Wiring Systems.
Does the DMM display OL?

Test for continuity of the MAF sensor signal circuit to

battery ground using the DMM J 39200. Refer to Testing
for Continuity in Wiring Systems.
Does the DMM display OL?

10

Test for continuity at the PCM harness between the MAF,

sensor signal circuit and all other circuits at both PCM
connectors using the DMM J 39200. Refer to T~sting for
Continuity in Wiring Systems.
Does the DMM display OL?

11

Connect the test lamp J 34142-B between the MAF sensor

ignition feed circuit and the ground at the MAF sensor
harness connector.
Does the test lamp illuminate?

12

Connect the test lamp J 34142-B between the MAF sensor

ignition feed circuit and the battery ground.
Does the test lamp illuminate?

1. Inspect for a poor connection at the MAF sensor

harness terminals. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
2. If you find a poor connection, repair the cor,dition as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and correct the c9ndition? _

Repair the short to voltage in the MAF sensor signal

circuit. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Repair the open in the MAF sensor signal circuit. Refer to

Wiring Repairs in Wiring Systems.
Is the action complete?

Repair the short to ground in the MAF sensor signal

circuit. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Repair the circuits that are shorted together. Refer to

Wiring Repairs in Wiring Systems.
Is the action complete?

Repair the MAF sensor groun'd circuit for an open. Refer

to Wiring Repairs in Wiring Systems.
Is the action complete?

1. Repair the open or grounded ignition feed circuit to

the MAF sensor. Refer to Wiring Repairs in Wiring
Systems.
2. Replace the fuse if necessary.
Is the action complete?

Repair the circuits that are shorted together between the

MAF sensor signal circuit and the circuit for which the DTC
set. Refer to Wiring Repairs in Wiring Systems
Is the action complete?

_,

14

15

16

17

18

19

20

21

Replace the MAF sensor. Refer to MAF Sensor

Replacement.
Is the action complete?

No

>',

13

Yes

Go to Step 15

Go to Step 9

Go to Step 10

Go to Step 16

Go to Step 17

Go to Step22

' Go to Step 13

Go to Step 12

Go to Step 18

Go to Step 19

Go to Step 24

Go to Step 21
-

Go to Step 24

Go to Step 24

Go to Step 24

Go to Step 24

Go to Step 24

Go to Step 24

Go to Step 24

Go to Step 24

Engine

Engine Controls - 5. 7L

6-1343

OTC P0102 Mass Air Flow (MAF) Sensor Circuit Low Frequency (cont'd)
Action

Step

Value(s)

Yes

No

Go to Step 24

Go to Step 23

1. Inspect for a poor connection at the PCM. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.

)
22

2. If you find a poor connection, repair the condition as

necessary. Refer to Repairing Connector Terminals in
Wiring Systems.

Did you find and correct the condition?

Important: Program the replacement PCM. Refer to PCM

23

Replacement/Programming.
Replace the PCM.
Is the action complete?

Go to Step 24

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
24

3. Select the Diagnostic Trouble Code (OTC) option and

the Specific DTC option, then enter the DTC number
using the scan tool.

4. Operate the vehicle within the Conditions for Running

the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

25

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 25

Go to Step 2

Go to the
applicable
DTC table

System OK

6-1344

Engine

Engine Controls .. s~7L

OTC P0103 Mass Air Flow (MAF) Sensor Circuit High Frequency
r -

sv >

: MAF
Sensor.

.. _________ ..

~S.'.!!n~ _

48

I Control

C1:~~D
G2=BLU

_ -

C1

Powertrain

Module
(PCM)

~ ~

YEL 492

PNK 539
PNKI 5_39_ ___._ Fuse Block
Details
PNK 539
........_Ge_n_n_ _
----p'

AA

Ignition
Power

rviAF

Mass Air

Sensor
Signal

Flow (MAF)
Sensor

Ground

B
BLK/WHT 451
-

--4

Ground
Distribution
Cell 14

BLK 451

(
218496

Circuit Description
The Mass Air Flow (MAF) sensor measures the
amount of air ingested by the engine. The direct
measurement of the air entering the engine is more
accurate than calculating the airflow from the MAP, the
IAT, and the engine speed (speed/density). The
MAF sensor has a battery feed, a ground, and a signal
circuit.
The MAF sensor used on this engine is a hot wire
type. This engine uses the MAF sensor in order
to measure air flow rate. The MAF output frequency is
a function of the power required to keep the air flow
sensing elements (hot wires) at a fixed temperature
above the ambient temperature. Air flowing through the
sensor cools the sensing elements. The amount of
cooling is proportional to the amount of air flow. The

MAF sensor requires a greater amount of current

in order to maintain the hot wires at a constant
temperature as the air flow increases. The MAF sensor
converts the changes in current draw to a frequency
signal read by the PCM. The PCM calculates the
air flow (grams per second) based on this signal.
The PCM monitors the MAF sensor frequency. The
PCM determines if the sensor is stuck low, stuck high,
not providing the airflow value expected for a given
operating condition, or that the signal appears to
be stuck based on a lack of signal variation expected
during the normal operation. This diagnostic tests
for too high an airflow rate. This DTC sets when the
PCM detects that the MAF sensor frequency is above
a predetermined value.

Engine
Conditions for Running the OTC

The engine speed is greater than 300 RPM.

The system voltage is greater than 8.0 volts.

Conditions for Setting the OTC

The MAF frequency is greater than 14,000 Hz.
All conditions met for.less than 1 second.

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive Ignition
Cycle that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive Ignition Cycle,
the PCM records the operating conditions at
the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.
The PCM utilizes speed density (RPM, MAP, IAT)
for fuel management.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diaghostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent water intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents damage to the harness connector
terminals. Refer to Using Connector Test Adapters
in Wiring Systems.

Engine Controls - 5.7L

6-1345

Water entering the air intake system that reaches

the MAF sensor could cause this DTC to set.
The water rapidly cools the hot wires in the sensor,
causing a false indication of excessi_ve airflow.
Inspect the following areas for evidence (witness
marks) of water intrusion:
- AIR system
- Intake air system
The following may cause an intermittent:
- Mis-routed harness
- Rubbed through wire insulation
- Broken wire inside the insulation
- A poor connection in the ignition feed circuit
to the MAF sensor can cause a DTC P0103
to set.
For an intermittent, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Monitoring the MAF sensor frequency determines
if the fault is present or the malfunction is
intermittent. A poor connection at the MAF sensor
or at the fuse causes this DTC to set.
3. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the OTC failed.
4. This step tests for electro-magnetic interference
on the MAF sensor signal circuit. There should
be no signal indicated on the scan tool with
the sensor disconnected.

6-1346

Engine Controls - 5.7L

Engine

OTC P0103 Mass Air Flow (MAF) Sensor Circuit High Frequency
Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

1. Idle the engine.

2. Monitor the MAF sensor display on the Engine 2 Data
List of the scan tool.
Is the MAF sensor frequency above the specified value?
1. Turn ON the ignition leaving the engine OFF.
2. Review the Freeze Frame and/or Failure Records
data for this DTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and a$ close to the conditions
recorded in the Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the DTC.
6. Select the Diagnostic Trouble Code (DTC) option, the
Specific DTC option, then enter the DTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

Value(s)

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

14,000 Hz

1. Turn OFF the ignition.

2. Disconnect the MAF sensor connector.
3 . .Idle the engine.
4. Monitor the MAF sensor frequency using the
scan tool.
Does scan tool indicate a MAF sensor frequency?

1. Inspect for a poor connection at the MAF sensor

harness terminals. Refer to lntermittents and Poor
Connections Diagnosis in Wiring' Systems.
2. If you find a poor connection, repair the condition as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and correct the condition?

Replace the MAF sensor. Refer to MAF Sensor

Replacement.

Yes

Go to Step 7

Go to Step 5

Go to Step 10

Go to Step 6

Is the action complete?

Go to Step 10

1. Inspect the MAF sensor harness for incorrect routing

at the following locations:

Near secondary ignition wires or components.

Other high current components. Such as
solenoids, relays, and motors.
2. Correct the harness routing if you find incorrect
routing.
Did you find and correct the condition?

Go to Step 10

Go to Step 8

Engine Controls - 5.7L

Engine

6-1347

DTC P0103 Mass Air Flow (MAF) Sensor Circuit High Frequency (cont'd)
Step

Action

Value(s)

1. Inspect the MAF sensor signal circuit terminal

connections at the PCM connector C1 located on the
opposite side of the manufacturer's logo. Refer to
lntermittents and Poor Connections Diagnosis in
Wiring Systems.

Yes

No

Go to Step 10

Go to Step 9

2. If you find a poor connection, repair the condition as

necessary. Refer to Connector Repairs in Wiring
Systems.
Did you find and correct the condition?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

Go to Step 10

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear DTC Information option using the scan tool.

2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (DTC) option and
10

the Specific DTC option, then enter the DTC number

using the scan tool.

4. Operate the vehicle within the Conditions for Running

the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

11

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 11

Go to Step 2

Go to the
applicable
DTC table.

System OK

6-1348

Engine Controls - 5.7L

Engine

DTC P0107 Manifold Absolute Pressure {MAP) Sensor Circuit Low Voltage
Powertrain
Control
Module
(PCM)

J.

"sv - - - I Reference

";; 5

511

I A/C Refrigerant
-

.:-_ ::"-

EGA
Valve
Control

I ~I

Refrige~~
Pressure
~
Sensor ...._......._ _ _ _.....,
C
A

GAY 705

LT BLU 697

GRY 416

I - c<S

63

~ A/C-R;;g';,a";;i , - - - - -

BAN 1456

Pressure

GRY 435

I -~

~~~=br

LTGRN 432
ORN/BLK 469

Sensor
Ground

tJ

5; - - - -1- - - -MAP -1------ -r -~ Powertrain

62 C1 9
-------;,R- - - -

Sensor
Ground

-,Manifold
Absolute

BLK 407

66 C2

I
J

BLK 552

RED/BLK 380

1
I

64 C2

Exhaust Gas
Recirculation
(EGR)
,_______......._________. Valve

"'

MAP
SV
Reference

38

- ;,. -

-= _-: ::- ":"-":' --: ::_ =-- ::"-"':' -- "": =-- ::"-"':' _-: ;-_ ':" --= _-: =-- ::"--= _-: 65

GRY 474

EGR
5V

I Pressure
Sensor
L

Pressure
Sensor
Signal

I
I
I

- -

48

34

26
---------

-----------

EGA
Valve
Ground

C2

Sensor
Signal

MAP
Sensor
Ground

PCM
EGA
Pintle
Position

C1=RED
C2 = BLU

I
I
I

Control
Module
(PCM)

I
I ~

L-----------------------------------------J
218502

Circuit Description
The Manifold Absolute Pressure (MAP) sensor is
mounted to the rear of the intake manifold. The MAP
sensor measures the pressure changes within the
intake manifold w;hich is an indication of the engine
load. The MAP sensor has a 5.0 volt reference,
a ground, and a signal circuit.
The MAP sensor contains a diaphragm which changes
the resistance based on pressure. When the manifold
pressure is low (high vacuum) the sensor output
voltage is low. When the manifold pressure is high
(low vacuum) the sensor output voltage is high.
The MAP sensor voltage (depending on altitude) can
range from 1.0-1.5 volts at idle (high vacuum) to
4.0-4.9 volts at wide open throttle (low vacuum).

When the PCM senses a signal voltage lower than the

normal operating range of the sensor, this DTC
will set.

Conditions for Running the DTC

No TP sensor DTCs set.
The engine is running.
The TP angle is no more than 20% when the
engine speed is greater than 1200 RPM.
OR
The TP angle is no more than 0% when the
engine speed is no more than 1200 RPM.

Conditions for Setting the DTC

The MAP sensor voltage is less than 0.1 O volts.
All conditions met for greater than 2 seconds.

Engine
Action Taken When the DTC Sets
The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids:
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent water intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents damage to the harness connector
terminals. Refer to Using Connector Test Adapters
in Wiring Systems.
The following may cause an intermittent:
- Mis-routed harness
- Rubbed through wire insulation

- Broken wire inside the insulation

The PCM 5.0 volt reference circuits are internally
connected within the PCM. If all the MAP sensor
circuits are OK, inspect the following
cdmponent/circuits for malfunctions:
- A/C Refrigerant Pressure sensor
- EGR Valve
For an intermittent, refer to Symptoms.

~I

Engine Controls - 5.7L

6-1349

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. If OTC P1635 sets at the same time, this indicates
that the 5.0 volt reference circuit is either shorted
to a ground or shorted to a voltage. The 5.0 volt
reference circuit is internally connected within the .
PCM. The A/C Refrigerant Pressure sensor or
the EGR valve may be causing this OTC to
set. Refer to OTC P1635 for further diagnosis.
3. This step determines if the malfunction is present.
4. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the OTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the OTC failed.
5. If the scan tool displays 5.0 volts, the MAP sensor
signal, 5.0 volt reference circuit, and the PCM are
OK. For any test that requires probing the
PCM or component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using
this kit prevents any damage to the harness
connector terminals.
6. If the scan tool displays 5.0 volts, the MAP sensor
signal circuit and the PCM are OK. For any test
that requires probing the PCM or component
harness connectors, use the Connector Test
Adapter Kit J 35616-A. Using this kit prevents any
damage to the harness connector terminals.
7. Disconnecting the PCM allows using the OMM
J 39200 in order to test the continuity of the
circuits. This aids in locating an open or a shorted
circuit.

6-1350

Engine Controls - 5.7L

Engine

DTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage
Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

1. Install a scan tool.

2. Idle the engine.
3. Monitor the Diagnostic Trouble Code (OTC)
Information using the scan tool.

Value(s)

Monitor the MAP sensor voltage on Engine 1 Data List on

the scan tool.
Is the MAP sensor voltage below the specified value?
1. Turn ON the ignition leaving the engine OFF.
2. Review the Freeze Frame and/or Failure Records
data for this OTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in the Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.
6. Select the Diagnostic Trouble Code (OTC) option, the
Specific OTC option, then enter the OTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to
DTCP1635 5
Volt Reference 1
Circuit

Go to Step 3

Go to Step 5

Go to Step 4

0.10V

1. Disconnect the MAP sensor electrical connector.

2. Jumper the 5.0 volt reference circuit and the MAP
sensor signal circuit together at the MAP sensor
harness connector.
3. Observe the MAP sensor voltage display on the
scan tool.
Is the MAP sensor voltage near the specified value?

5.0V

1. Connect the test lamp J 34142-8 between B+ and the

MAP sensor signal circuit at the MAP sensor harness
connector.
2. Observe the MAP sensor voltage display on the
scan tool.
Is the MAP sensor voltage near the specified value?

5.0V

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the 5.0 volt reference circuit for an open or short
to a ground.
4. If you find the 5.0 volt reference circuit is open or
shorted to a ground, repair the circuit as necessary.
Refer to Wiring Repairs in Wiring Systems.
Did you find and correct the condition?

No

Did OTC P1635 fail this ignition cycle?

3

Yes

Go to Step 5

Go to
Diagnostic Aids

Go to Step 11.

Go to Step 6

Go to Step 7

Go to Step 9

Go to Step 13

Go to Step B

Engine Controls - 5.7L

Engine

6-1351

OTC P0107 Manifold Absolute Pressure (MAP) Sensor Circuit Low Voltage (cont'd)
Step

Action

Value(s)

Yes

No

Go to Step 13

Go to Step 12

Go to Step 13

Go to Step 10

Go to Step 13

Go to Step 12

1. Inspect the 5.0 volt reference circuit for a poor

connection at the PCM. Refer to lntermittents and
Poor Connections Diagnosis in Wiring Systems.

2. If you find a poor connection repair the condition as

necessary. Refer to Repairing Connector Terminals in
Wiring Systems.

Did you find and correct the condition?

1. Turn OFF the ignition.
2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the MAP sensor signal circuit for the following:
9

Open circuit
Short to a ground

Short to sensor ground circuit

4. If you find the MAP sensor signal circuit is open or
shorted to a ground, repair the circuit as necessary.
Refer to Wiring Repairs in Wiring Systems.
Did you find and correct the condition?
1. Inspect the MAP sensor signal circuit for a poor
connection at the PCM. Refer to lntermittents and
Poor Connections Diagnosis in Wiring Systems.
10

2. If you find a poor connection repair the condition as

necessary. Refer to Repairing Connector Terminals in
Wiring Systems.

Did you find and correct the condition?

11

Replace the MAP sensor. Refer to MAP Sensor

Replacement.

12

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

Go to Step 13

Is the action complete?

Go to Step 13

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
13

3. Select the Diagnostic Trouble Code (DTC) option and

the Specific DTC option, then enter the OTC number
using the scan tool.

4. Operate the vehicle within the Conditions for Running

the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

14

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 14

Go to Step 2

Go to the
applicable
OTC table

System OK

6-1352

Engine Controls - 5.7L

Engine

OTC P0108 Manifold Absolute Pressure (MAP) Sensor Circuit High Voltage

"sv - - -sv - - - - -

Powertrain
~
Control : Reference
Module I A/C Refrigerant

(~M)

;; 5

- ;:, -

.,
:

.
EGR

EGR

;f~n~e~ _

65

GRY 474

38

GRY 705

64 C2

LT BLU 697

MAP

.:-};~~~~\-"'-:-_-::_-=_-:::-_:=-_};:~ _--- __ --- _

~:;;e_ _ _

GRY 416

E
Exhaust Gas
Recirculation

O
I
I
h
I r4==i I
1-~----.. ., .,
. (EGR)

.__B__,.___C......::;_ _ _A....,.____, Valve

Refrige~~ ...
Pressure

Sensor

II

~1~

Absolute
Pressure

GRY 435

BLK 552

RED/BLK 380

Manifold

~-~~

LT GRN 432

ORN/BLK 469

BLK 407

1-----1 ~~-~~.;; ~l- -tJ

66

~
I
I
I

A/CR.;1g";ra;;
Pressure
Sensor
Signal

C2

63

62 C1

Sensor
Ground

Sensor

Sensor
Ground

;
5

34

-1- - -

26

48

-----------

EGA
Valve
Ground

-M;:-P - , --

Sensor
Signal
=

EGA

C1=RED

Position

~-

a=BW

C2

---------

-f - ~ Powertrain

MAP
Sensor
Ground

I
I
I

Control
Module
(PCM)

I~

I~

L-------------------------~---------------~
218502

Circuit Description
The Manifold Absolute Pressure (MAP) sensor is
mounted to the rear of the intake manifold. The MAP
sensor measures the pressure changes within the
intake manifold which is an indication of the engine
load. The MAP sensor has a 5.0 volt reference,
a ground, and a signal circuit.
The MAP sensor contains a diaphragm which changes
the resistance based on pressure. When the manifold
pressure is low (high vacuum) the sensor output
voltage is low. When the manifold pressure is high
(low vacuum) the sensor output voltage is high.
The MAP sensor voltage (depending on altitude) can
range from 1.0-1.5 volts at idle (high vacuum) to
4.0 - 4.9 volts at wide open throttle (low vacuum).
When the PCM senses a signal voltage higher than the
normal operating range of the sensor, this DTC sets.

Conditions for Running the DTC

No TP sensor DTCs set.
The engine is operating.
The TP sensor angle is less than 5% when the

engine speed is n<> more than 1,000 RPM.

OR
The TP sensor angle is less than 18% when
engine speed is greater than 1,000 RPM.

Conditions for Setting the DTC

The MAP sensor voltage is greater than 4.3 volts.
All conditions met for greater than 4 seconds.

Engine
Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator

Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic tails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM rec.ords the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test tailed (current DTC} clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycjes, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
The following may cause an intermittent:
- Mis-routed harness
- Rubbed through wire insulation
- Broken wire inside the insulation
The PCM 5.0 volt reference circuits are internally
connected within the PCM. If all the MAP sensor
circuits are OK, inspect the following
component/circuits for malfunctions:
- A/C Refrigerant Pressure sensor
- EGA Valve
For an intermittent, refer to Symptoms.

Engine Controls - 5.7L

6-1.353

Test Description
The numbers below refer to the step numbers on.the
diagnostic table.
2. If DTC P1635 sets at the same time, this indicates
that the 5.0 voltage reference circuit is either
shorted to a ground or shorted to a voltage. The
5.0 volt reference circuit is internally connected
within the PCM. The A/C Refrigerant Pressure
sensor or the EGA valve may be causing this DTC
to set. Refer to DTC P1635 for further diagnosis.
3. This step determines if the malfunction is present.
4. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how 'many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a tail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the DTC failed. For any test
that requires probing the PCM or component
harness connectors, use the Connector Test
Adapter Kit J 35616-A. Using this kit prevents any
damage to the harness connector terminals.
5. This step tests whether the signal circuit is
shorted to a voltage.
6. This step verifies whether a ground circuit is
available at the MAP sensor. For any test
that requires probing the PCM or component
harness connector~. use the Connector Test
Adapter Kit J 35616-A. Using this kit will prevent
any damage to the harness connector terminals.
9. Remove the MAP sensor and verify if vacuum is
available to the sensor. Also, inspect the MAP
sensor seal for nicks and cuts.

5..1354

Engine Controls - 5.7L

Engine

OTC P0108 Manifold Absolute Pressure (MAP) Sensor Circuit High Voltage
Step

Action

Did you perform the Powertrain .on-Board Diagnostic

(OBD) System Check?
1

1. Install. a scan tool.

2. Idle the engine.
3. Monitor the Diagnostic Trouble Code (DTC)
Information using the scan tool.
Did DTC P1635 fail this ignition cycle?
Important: If the engine idle is rough, unstable or
incorrect, repair the idle condition before using this table;
refer.to Symptoms.
Monitor the MAP sensor voltage on the Engine 1 Data List
on the scan tool.
Is the MAP sensor voltage above the specified value?

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this DTC and opserve the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in the Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the DTC.

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to
OTC P1635 5
Volt Reference 1
Circuit

Go to Step 3

Go to Step 5

Go to Step 4

Go to Step 5

Go to
Diagnostic Aids

Go to Step 6

Go to Step 7

Go to Step B

Go to Step 10

Go to Step 16

Go to Step 12

Go to Step 9

Go to Step 15

Go to Step 13

Go to Step 14

4.3V

6. Select the Diagnostic Trouble Code (DTC) option, the

Specific DTC option, then enter the DTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

1. Disconnect the MAP sensor electrical connector.

Refer to MAP Sensor Replacement.
2. Observe the MAP sensor voltage displayed on the
scan tool.

1.0V

Is the MAP sensor voltage below the specified value?

6

Probe the sensor ground circuit with the test lamp

J 34142-8 to B+.
Is the test lamp illuminated?

1. Test the MAP sensor signal circuit for a short to

voltage or a short to the 5.0 volt reference circuit.
2. Repair the MAP sensor signal circuit if the circuit is
shorted. Refer to Wiring Repairs in Wiring Systems.
Is the MAP sensor signal circuit shorted?

Measure the voltage at the 5.0 volt reference circuit to the

battery ground using the DMM J 39200.
Is the voltage near the specified value?
Inspect for a plugged or leaking vacuum supply to the
MAP sensor.
Is the vacuum supply OK?

5.0V

Engine Controls - 5.7L

Engine

6-1355

DTC P0108 Manifold Absolute Pressure (MAP) Sensor Circuit High Voltage (cont'd)
Action

Step

Value(s)

Yes

No

Go to Step 16

Go to Step 11

Go to Step 16

Go to Step 12

1. Inspect for a poor sensor ground terminal connection

at the PCM. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.

10

2. If you find a poor connection repair the condition as

necessary. Refer to Connector Repairs in Wiring

Systems.
Did you find and correct the condition?

1. Test the continuity of the MAP sensor ground circuit.

Refer to Testing for Continuity in Wiring Systems.

11

12

2. Repair the open or the poor connection if the MAP

sensor ground circuit measures over the specified
value. Refer to Wiring Repairs in Wiring Systems.
Did you find and correct the condition?
Important: Program the replacement PCM. Refer to PCM
Replacement/Programming.

Replace the PCM.

Is the action complete?

5Q

Go to Step 16

Replace the MAP sensor. Refer to MAP Sensor

Replacement.
Is the action complete?

14

Repair the faulty vacuum supply.

Is the action complete?

15

Repair the 5.0 volt reference circuit for a short to voltage.

Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

13

Go to Step 16
Go to Step 16

Go to Step 16

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear DTC Information option using the scan tool.

2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (DTC) option and

16

17

the Specific DTC option, then enter.the DTC number

using the scan tool.
4. Operate the vehicle within the Conditions for Running
the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 17

Go to Step 2

Go to the
applicable
DTC table

System OK

6-1356

Engine

Engine Controls - 5.7L

DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage
r -

I
I
I

IAT
Sensor

~v- - - - , Powertrain

'Control

I Module
1

(PCM)

~ig!_al _ _ _ _ _ _

~ ~

8IC2
TAN 472

rn
A

Intake
Ai
T~mperature
(IAT)
Sensor

PPL 719

21 C1
'" - - - - - - "- - - - - - - - - ., Powertrain
I
..
PCM
I Control
I

IAT

1
1

Sensor
Ground

C1 =RED
C2=BLU

M d I
O U0
(PCM)

L---------------J ~
218499

Circuit Description
The Intake Air Temperature (IAT) sensor contains a
semiconductor device which changes the resistance
based on the temperature (a thermistor). The IAT
sensor is located in the air intake passage of
the engine air induction system. The IAT sensor has a
signal circuit and a ground circuit. The PCM applies
5.0 volts on the signal circuit to the sensor. The
PCM monitors the changes in this voltage caused by
changes in the resistance of the sensor in order to
determine intake air temperature.
When the intake air is cold, the sensor (thermistor)
resistance is high. The PCMs signal voltage is
only pulled down a small amount through the sensor
to a ground; therefore, the PCM senses a high
signal voltage (low temperature). When the intake air
is warm, the sensor resistance is low,, The signal
voltage is pulled down a greater amount; therefore,
the PCM senses a low signal voltage (high
temperature).
When the PCM senses a signal voltage lower than the
normal operating range of the sensor, this OTC sets.

Conditions for Running the DTC

OTCs P0101, P0102, P0103, P0117, P0118,
P0125, P0500, P0502, P0503 not set.
The engine run time is greater than 30 seconds.
The vehicle speed at least 40 km/h (25 mph).

Conditions for Setting the OTC

The Intake Air Temperature is greater than
139C (282F).
All conditions met for 5.0 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

Engine Controls - 5.7L

Engine

Test Description

Diagnostic Aids
Important:

6-1357

Remove any debris from the PCM connector

surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents any damage to the harness
connector terminals.
The following may cause an intermittent:
- Mis-routed harness
- Rubbed through wire insulaUon
- Broken wire inside the insulation
If the engine has sat overnight, the engine coolant
temperature and the engine intake air temperature
values should display within a few degrees of
each other. If the temperatures are not within 3C
(5F), refer to Temperature vs Resistance.
If you determine that the DTC occurs
intermittently, performing the P1112 diagnostic
table may isolate the cause of the fault.
For an intermittent, refer to Symptoms.

The numbers below refer to the step numbers on the

diagnostic table.
2. This step determines if the malfunction is present.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.
3. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the DTC failed. For any test
that requires probing the PCM or component
harness connectors, use the Connector Test
Adapter Kit J 35616-A. Using this kit prevents any
damage to the harness connector terminals.
4. An intake air temperature below -30C (-22F)
indicates the PCM and the IAT wiring are OK.
5. Disconnecting the PCM allows using the DMM
J 39200 in order to test continuity of the
circuits. This aids in locating an open or a shorted
circuit.

DTC P0112 Intake Air Temperature (IAT) Sensor Circuit Low Voltage
Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

1. Install a scan tool.

2. Turn ON the ignition leaving the engine OFF.

3. Monitor the IAT display on the Engine 1 Data List of

the scan tool.
Is the IAT above the specified value?

139C (282F)

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records

data for this OTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in the Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.
6. Select the Diagnostic Trouble Code (OTC) option, the
Specific OTC option, then enter the OTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

6-1358

Engine Controls - 5.7L

Engine

DTC P0112 Intake Air Temperature'(IAT) Sensor Circuit Low Voltage (cont'd)
Action

Step

1. Disconnect,the IAT sensor electrical connector.

2. Observe the lAT display on the scan tool.
Is the IAT at the specified value?

Value(s)

Yes

No

Go to Step 6

Go to Step 5

Go to Step 8

Go to Step 7

-39C (-38F)

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
5

Replacement/Programming.
3. Test the IAT signal circuit for a shori: to a ground.
4. If you find the IAT sensor signal circuit is grounded,
repair the circuit as necessary. Refer to Wiring
Repairs in Wiring Systems.
Is the IAT signal circuit grounded?'

Replace the IAT sensor. Refer to /AT Sensor

Replacement.
Is the action complete?
Important: Program the replacement PCM. Refer to PCM
Replacement/Programming.

Replace the PCM.

Is the action complete?

Go to Step 8

Go to Step 8

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (DTC) option and
the Specific DTC option, then enter the DTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

(
Go to Step 9

Go to Step 2

Go to the
applicable
DTC table

System OK

\,

Engine

Engine Controls - 5.7L

6-1359

OTC P0113 Intake Air Temperature (IAT) Sensor Circuit High Voltage

,. - - - sv- - - - , Powertrain
I
I
I

IAT

I
I

Sensor

Control
Module
(PCM)

8IC2
TAN 472

~~ig!,a1 _ _ _ _ _ _ ..

LliJ

~,

rn
A ..,

Intake
Air
Temperature
(IAT)
Sensor

PPL 719

21, C1
,. - - - - - - - - - - - - - - - , Powertrain
I Control
I
PCM
I
!AT
C1 =RED
I M d I
C2=BLU
O U0

I
I

Sensor

Ground

I (PCM)
I
I

L---------------..1

~
218499

Circuit Description
The Intake Air Temperature (IAT) sensor contains a
semiconductor device which changes the resistance
based on the temperature (a thermistor). The IAT
sensor is located in the air intake passage of
the engine air induction system. The IAT sensor has a
signal circuit and a ground circuit. The PCM applies
5.0 volts on the signal circuit to the sensor. The
PCM monitors the changes in this voltage caused by
changes in the resistance of the sensor in order to
determine intake air temperature.
When the intake air is cold, the sensor (thermistor)
resistance is high. The PCMs signal voltage is
only pulled down a small amount through the sensor
to a ground; therefore, the PCM senses a high
signal voltage (low temperature). When the intake air
is warm, the sensor resistance is low. The signal
voltage is pulled down a greater amount; therefore,
the PCM senses a low signal voltage (high
temperature).
When the PCM senses a signal voltage higher than
the normal operating range of the sensor, this
DTC sets.

Conditions for Running the DTC

DTC(s) P0101, P0102, P0103, P0117, P0118,
P0125, P0500, P0502, P0503 not set.
The engine coolant temperature is greater
than 0C (32F).
The vehicle speed is less than 11 km/h (7 mph).
The mass air flow is less than 15 g/s.

Conditions for Setting the DTC

The Intake Air Temperature is less
than -35C (-31 F).
All conditions met for greater than 5.0 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

5.. 1350

Engine Controls .. 5.7L

Engine

Diagnostic Aids

Test Description

Important:
Remove any debris from the PCM connector
. surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents any damage to the harness
connector terminals.
The PCM terminals C1-24 and C2-24 are the
Sensor Ground Jumper terminals. This DTC sets if
the jumper is open or the connection between
the jumper and the PCM is faulty. Inspect
for proper terminal tension/connections at the
PCM harness connector before replacing
the PCM.
The following may cause an intermittent:
- Mis-routed harness
- Rubbed through wire insulation
- Broken wire inside the insulation
If the engine has sat overnight, the engine coolant
temperature and the intake air temperature
values should display within a few degrees .of
each other. It the temperatures are not within 3C
(5F), refer to Temperature vs Resistance.
If you determine that the DTC occurs
intermittently, performing the P1111 diagnostic
table may isolate the cause of the fault.
For an intermittent, refer to Symptoms.

The numbers below refer to the step numbers on the

diagnostic table.
2. This step determines if the malfunction is present.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit will prevent any damage to the harness
connector terminals.

3. Using the Freeze Frame and/or Failure Records

data may aid in locating an intermittent condition.
It you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the DTC failed. For any test
that requires probing the PCM or component
harness connectors, use the Connector Test
Adapter Kit J 35616-A. Using this kit prevents any
damage to the harness connector terminals.
4. An intake air temperature above 139C (282F)
indicates that the PCM and IAT wiring are OK.
5. An intake air temperature above 139C (282F)
indicates that the PCM and IAT signal circuit
is OK.
6. Disconnecting the PCM allows using the DMM
J 39200 in order to test continuity of the
circuits. This aids in locating an open or a shorted
circuit.

8. Disconnecting the PCM allows using the DMM

J 39200 in order totest continuity of the
circuits. This aids in locating an open or a shorted
circuit.
10. The PCM terminals C1 -24 and C2-24 are the
Sensor Ground Jumper terminals. This DTC sets if
the jumper is open or the connection between
the jumper and the PCM is faulty. Inspect
tor proper terminal tension/connections at the
PCM harness connector before replacing
the PCM.

Engine

Engine Controls - 5.7L

6-1361

OTC P0113 Intake Air Temperature (IAT) Sensor Circuit High Voltage
Action

Step

Value(s)

Yes

No

Go to Step 2

Go to A
Powerlrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 9

Go to Step 5

Go to Step 8

Go to Step 6

Go to Step 7

Go to Step 12

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

1. Install a scan tool.

2. Turn ON the ignition leaving the engine OFF.

3, Monitor the IAT display on the Engine 1 Data List of
the scan tool.

-39C (~38F)

Is the IAT at the specified value?

1. Turn ON the ignition leaving the engine OFF.
2. Review the Freeze Frame and/or Failure Records
data for this OTC and observe the parameters .
3. .Turn OFF the ignition for 15 seconds.

..

4 . Start the engine.

5. Operate the vehicle within the conditions required for

this diagnostic to run, and as close to the conditions
recorded in the Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the DTC.

6. Select the Diagnostic Trouble Code (DTC) option, the

Specific OTC option, then enter the DTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?
1. Disconnect the IAT sensor electrical connector.

2. Jumper the IAT harness terminals together.

3. Observe the IAT parameter on the scan tool.

140C (284F)

Is the IAT at the specified value?

Jumper the IAT sighal circuit to a known good ground.

Is the IAT at the specified value?

140C (284F)

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the

same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.

3. Test the IAT sensor signal circuit for an open.

Is the IAT sensor signal circuit open?

Repair the IAT sensor signal circuit. Refer to Wiring

Repairs in Wiring Systems.

Go to Step 15

Is the action complete?

1. Turn OFF the ignition.
2. Disconnect both PCM connectors. Refer to PCM
Replacement/Programming.

3. Test the IAT sensor ground circuit for an open

between the IAT sensor and the PCM.

4. If you find an open circuit repair the condition as

necessary. Refer to Wiring Repairs in Wiring
Systems.

Go to Step 15

Did you find and correct the condition?

Replace the IAT sensor. Refer to /AT Sensor

Replacement.
Is the action complete?

Go to Step 10

Go to Step 15

6-1362

Engine

Engine Controls - 5.7L

DTC P0113 Intake Air Temperature (IAT) Sensor Circuit High Voltage (cont'd)

Step

10

Action

Test the resistance between PCM connector

terminals C1-24 and C2-24.
Is the resistance within the specified range?

Value(s)

12

Test for a short to voltage on the signal circuit.

Did you find and correct the condition?

13

1. Inspect for faulty connections at the PCM. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection repair the condition as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and correct the condition?

14

15

16

Important: Program the replacement PCM. Refer to PCM

ReplacemenVProgramming.

Replace the PCM.

Is the action complete?
1. Select the Diagnostic Trouble Code (DTC) option and
the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (DTC) option and
the Specific DTC option, then enter the DTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

No

Go to Step 12

Go to Step 11

0-50

Repair the circuit with the open or high resistance. Refer

to Wiring Repairs in Wiring Systems.
Is the action complete?

11

Yes

Go to Step 15
Go to Step 15

Go to Step 13

Go to Step 15

Go to Step 14

Go to Step 15

Go to Step 16

Go to Step 2

Go to the
applicable
DTC table

System OK

(
\

Engine

Engine Controls - 5.7L

6-1363

DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage

J
---;~~r- ------

,. - - - - - - sv - - - - - - , Powertrain
I
I

ECT

I Control

I Module

~ (PCM) ~

49 C2
r- -

I
I

., Instrument

I Cluster
I~

At7_I . . ~

YEL 410

DKGRN 135

C rGRN J135

~~~ii~~.
Temperature
[ ]
(ECT)
A

-=-

Sensor

BRN 718
25

C2

'" - - - - 'f" - - - - - - - , Powertrain

I

...

I
I
I
I

ECT
Sensor
Ground

PCM

g:~i~

I Control

I Module ~
I (PCM) ~
I

1.------------..1
218500

Circuit Description

Conditions for Running the DTC

The Engine Coolant Temperature (ECT) sensor

contains a semiconductor device which changes the
resistance based on the temperature (a thermistor).
The ECT sensor is mounted in the left bank cylinder
head near the front of the engine. The ECT sensor has
a signal circuit. and a ground circuit. The PCM
applies a voltage (about 5.0 volts) on the signal circuit
to the sensor. The PCM monitors the changes in
this voltage caused by changes in the resistance of
the sensor in order to determine the coolant
temperature.

The engine run time is greater than 1O seconds.

When the coolant is cold, the sensor (thermistor)

resistance is high. The PCMs signal voltage is only
pulled down a small amount through the sensor
to a ground; therefore, the PCM senses a high signal
voltage (low temperature). When the coolant is
warm, the sensor resistance is low. The signal voltage
is pulled down a greater amount; therefore the PCM
senses a low signal voltage (high temperature).
At normal operating temperature, the voltage should
measure about 1.5-2.0 volts at the PCM.
'i

When the PCM senses a signal voltage lower than the

normal operating range of the sensor, this DTC sets.

Conditions for Setting the DTC

The Engine Coolant Temperature is greater
than 139C (282F).
All conditions met for 20.0 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

6-1364

Engine Controls - 5.7L

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents any damage to the harness
connector terminals.
The following may cause an intermittent:
- Mis-routed harness
- Rubbed through wire insulation
- Broken wire inside the insulation
If the engine has sat overnight, the engine coolant
temperature and the intake air temperature
values should display within a few degrees of
each other. If the temperatures are not within 3C
(5F), refer to Temperature vs Resistance.
If you determine that the DTC occurs
intermittently, performing the P1114 diagnostic
table may isolate the cause of the fault.
For an intermittent, refer to Symptoms.

Engine
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step determines if the malfunction is present.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.

3. Using the Freeze Frame and/or Failure Records

data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the DTC failed.
4. An engine coolant temperature below
-30C (-22F) indicates the PCM and the ECT
sensor wiring are OK.
5. Disconnecting the PCM allows using the DMM
J 39200 in order to test continuity of the
circuits. This aids in locating an open or a shorted
circuit.
7. Inspect for proper terminal tension/connections at
the PCM harness before replacing the PCM.

DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage
Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Important: If the engine is overheating, correct the

overheating condition before proceeding with this table.
1. Install a scan tool.
2. Turn ON the ignition leaving the engine OFF.
3. Monitor the ECT sensor display on the Engine 1 Data
List of the scan tool.
Is the ECT sensor above the specified value?

139C (282F)

Engine Controls - S.7L

Engine

6-1365

DTC P0117 Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage (cont'd)
Action

Step

Value(s)

Yes

No

Go to Step 4

Go to
Diagnostic Aids

Go to Step 6

Go to Step 5

Go to Step B

Go to Step 7

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this OTC and observe the parameters.

3. Turn OFF the ignition for 15 seconds.

4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in the Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.

6. Select the Diagnostic Trouble Code (OTC) option, the

Specific OTC option, then enter the OTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this .
ignition?
:

1. Disconnect the ECT sensor electrical connector.

2. Observe the ECT sensor display on the scan tool.
Is the ECT sensor below the specified value?
.:
1. Turn OFF the ignition.
2. Disconnect the PCM connectorC2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the ECT sensor signal circuit for a short to a
ground.
4. If you find the ECT sensor signal circuit is grounded,
repair the circuit as necessary. Refer to Wiring
Repairs in Wiring Systems.
Did you find the ECT sensor signal circuit grounded?
Replace the ECT sensor. Refer to ECT Sensor
Replacement.

-30C (-22F)

Is the action complete?

Go to Step B

Important: Program the replacement PCM. Refer to PCM

7

Replacement/Programming.
Replace the PCM.
Is the action complete?

Go to Step B

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.

2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.

4. Operate the vehicle within the Conditions for Running

the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

Select the Captu~e Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 9

Go to Step 2

Go to the
applicable
OTC table

System OK

6-1366

Engine Controls - 5.7L

Engine

OTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit High Voltage

J- ------i

,. - - - - - - sv - - - - - - , Powertrain
I Control

I
I

ECT

~ ---~;~~r

I Module

(PCM)

>
~

49 C2
.. - ., Instrument
I
I Cluster
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A17-I . . ~

YEL 410

DKGRN 135

B CrGRNJ1as

[l]
I
A

-=-

6~~jl;~t
Temperature
(ECT)
Sensor

BRN 718
25

C2

'" - - - - f - - - - - - - , Powertrain
I

I
I

Eci-

Grou~

Sensor

PCM

lg1:~i~ I

I Control
I

Module

I (PCM)
I

>

1.------------..1
218500

Circuit Description

Conditions for Running the DTC

The Engine Coolant Temperature (ECT) sensor

contains a semiconductor device which changes the
resistance based on the temperature (a thermistor).
The ECT sensor is mounted in the left bank cylinder
head near the front of the engine. The ECT sensor has
a signal circuit and a ground circuit. The PCM
applies a voltage (about 5.0 volts) on the signal circuit
to the sensor. The PCM monitors the changes in
this voltage caused by changes in the resistance of
the sensor in order to determine the coolant
temperature.
When the coolant is cold, the sensor (thermistor)
resistance is high. The PCMs signal voltage is only
pulled down a small amount through the sensor
to a ground; therefore, the PCM senses a high signal
voltage (low temperature). When the coolant is
warm, the sensor resistance is low. The signal voltage
is pulled down a greater amount; therefore, the
PCM senses a low signal voltage (high temperature).
At normal operating temperature, the voltage
should measure about 1.5-2.0 volts at the PCM.
When the PCM senses a signal voltage higher than
the normal operating range of the sensor, this
DTC sets.

The engine run time is greater 60 seconds.

Conditions for Setting the DTC

The Engine Coolant Temperature is less
than -39C (-38F).
All conditions met for 20 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

En'gine Controls - .?.7L ,,,6.;1367

Engine
Conditions for Clearing the MIUDTC .

The PCM turns the. MIL OFF 'after three,

consecutive ignition cycles that the diagnostic
runs and does not fail.
, A.last test failed (current DTC) clears when the
diagnostic runs and does not fail.
. AHistory OTC clears afterforty cons~cuJiY!?
warm-up cycles, if this or any other emission
related diagnostic does not report any failures\
Use a scan tool in order to clear the MIUDTC.

Test. Description
The numbers below refer to the step numbers 'on the
diagnostic table.
2. This step determines if the malfunction is present.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.

3.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM co,hnector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent coniaminate intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the

Connector Test Adapter Kit Jl35616-A. Using this, .

kit prevents any damage to the harness

connector terminals.
The following may cause an intermittent:
- Poor Connections
Mis-routed harness
- Rubbed throu~h wire insulation
- Br-0ken wire-inside theinsulation
If the engine has sat overnight, the engine coolant
temperature and intake air temperature values
should display within a few d~grees of each other.
If the temperatures are not within 3C (5F),
refer tq Tempe(ature vs Resi[$tance.
If you determine tharthe DTC
intermittently, performing the P1115 diagnostic
table. may isolate the cause of the fault.
For an intermittent, refer to Symptoms.

,recurs

'

',,

'

Usir,gthe Freeze Frame and/or.Failure Records_

data may aid in locating anlnterrhittent cqndition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/Qr Failure
Records data. can help determine how many miles
since the OTC set. rhe Fail Counter and Pass ,
Counter'can also help.determine how'many
ignition cycles the diagnostic reported a pass
and/or a fail'. Operate the vehicle within the samei
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that.you observed. This
will isolate When the DTC failed.

4: An engi~e toolanf temperature ~ove 1390

(282.F) indicates th~ .PCM _and !;CJ sensor wiring
is OK.
5. An engine coolant temperature above 139C
(282-P:") indicates the PCM and ECT sensor signal
circuit is OK.
6. Disconnecting the P.CM allow~ using the DMM
J 39200 in order to test continuity of.the
circuits. This a1ds in locating an op'en or a shorted
circuit.

a.

Disconnecting the PCM allows using the DMM

J 39200 in order-to test,continuity of the .
circuits. This aids in locating .an,open or shorted
circuit.

1 t. inspect for prope,r: termlnal tension/connections at

the PCM harness before replacingthe PCM.

Eng hie

6-1368 .Engine Controls- 5.7L

OTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit,!'iigh Voltage
Step

Value(s)

Action

''

Yes

No:

'

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Goto A
Powertrain On
Board Diagnostic
(OBD) System
Cher;k

'.

,'

GotoStep 2

1. 'Install a scan tool.

2. Turn ON the ignition leaving the engine OFF.
2
3. Monitor the ECT sensor display oh the Engine 1 Data
List of the scan tobl.
,
Is \he ECT sensor at the specified value?'

-39C (-38F)
.,

Go to Step 4

1. Turn ON the. ignition lea,ving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this OTC and obs~fve the parameters.
3. Turn OFF the ignition for, 1'.5 seconds.
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as,close to the conditions
recorded in the Freeze Frame/Failure Records as
possible. Special operating conditions that you need ,
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.
6. Select the DiagnosticTrouble Code (OTC) option, the
Specific OTC option, then enter the OTC number
using the scan tool.
Does the .scan tool indicate mat this diagnostic failed this
ignition?

Go to Step 3

,,

,,
'

,,,

,,,

.
-

,.\'
'

.,

Go to Step 4
..

Go to
Diag11ostic Aids

1. Disconnect the ECT sensor electrical connector.

2. Jumper theECT sensor harness terminals together.
3. Observe the engine coolant temperature parameter
on the scan tool.
Is the ECT sensor at the specified value?

140;C.(284F)

Jumper the ECT sensor signal circuit to a known good

grouhd.
Is the ECT sensor at the specified value?

140C'(284F)

,,

",

"

'!,

.,

.'.

'>

Goto Step 9

Ge to.Btep 5

Go to Step B

Go to Step 6

Go to Step 7

Go to Step 11

1. Turn OFF the ignition.

6

2. Disconnect the PCM connector C2 located on the

same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the ECT sensor signal circuit for an open.

Is the ECT sensor signal circuit open?

Repair the ECT sensor signal circuit. Refer to Wiring

Repairs in Wiring Systems.
Is the action complete?

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the ECT sensor ground circuit for an open.
Is the ECT sensor ground circuit open?

Replace the ECT sensor. Refer to ECT Sensor

Replacement.
Is the action complete?

Go to Step 14

Go to Step 10

Go to Step 11

Go to Step 14

Engine

Engine Controls - S.7L

6-1369

DTC P0118 Engine Coolant Temperature (ECT) Sens'or Circuit High Voltage (cont'd)
Action

Step

10

Value(s)

Yes

No

Repair the ECT sensor ground circuit. Refer to Wiring

Repairs in Wiring' Systems.
Is the action complete?

Go to Step 14

1. Test for a short to voltage on the signal circuit

2. If you find the signal circuit shorted to a voltage repair
11

the condition as necessary. Refer to Wiring Repairs

in Wiring Systems.
Did you find and correct the condition?

Go to Step 14

Go to Step 12

Go to Step 14

Go to Step 13

1. Inspect for faulty connections at the PCM. Refer to

12

13

14

lntermittents and Poor Connections Diagnosis in

Wiring Systems.
2. If you find a poor connection repair the condition as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and correct the condition?
Important: Program th.El replacement PCM. Refer to PCM
Replacement/Programming.

Replace the PCM.

Is the action complete?
1. Select the Diagnostic Trouble Code (OTC) option and
the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Se'fect the Diagnostic Trouble Co~e.(DTC) option anq
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the DTC as specified .in the supporting text, if
applicable.

Does the scan tool indicatei that this test ran and passed?

15

Go to Step 14.

Select the Capture Info option and the. Review Info.option

using the scan toot.
:: , .
Do~s the scan tool displiw ariy DTCs that you ha.ve not
dia,gr:\Osed?'

..

Go to Step 15
Go to the
applicable
OTC table ..

Go to Step 2

System OK

6-137-0

engine

Engine, eontrols - 5;7L

DTC P0121 TP Sensor Circuit Insufficient Actiyity,

r - --- - - - - - - - - -:..-- - - - - - - - - - - - - - ., Powertrain
I
sv
'
I Contr9l
I
TP Sensor
Fuel Tank
J, Module'

'1

_ ____________ ___
5V

~~n~:

Pressure Sensor

s~~e~~~ E0

GAY 596
Antilock
Brakes
Cell 44

~
:

I
I

-:~so~12.-

Sensor

Sensor

BLK 452

ORN/BLK '469
Anti lock

D!( ~RN, BEl

Brakes ',,
,, ......

BLK
452

Cell 14,

, dRN/BLK 469

BLK 452

~~.-= -;. - ; .-~

, ;} ;

--= -;...- ;;.--= --= ;;..-

Groun

Ground
_ _ _.,. Distribution

Cel144

Sensodr
,

'' .>: c ' ,, '

~ Pressure
Fliel Tank..

~ --= ~ ;;..-

Signal

'

ffnrottle
, : Posrnon (TP)

DKBLU
417

DKBLU 417

~; .~ :.... .

596

DKBLU 417

UiJ

,, '

596

[M;'l

(PC!'A).

GAY 598

GRY

GAY

I1

,I

'
,

-.-=~l1gg~-" ~ ~ .c~ -c~:~:-; ;.

7.-.5..

Sensor
.

;' ,' "~

Signal

,,,

Sensdr
Grour_i.d

~o.o~fr~fa!n

1
C2 =BLU ''.
'Modul~
. .
. 1 (PCM)

I
I

~--------------------------------------J~
218503

Circuit Description
The Throttle Position (TP) sensor is a potentiometer.
The TP sensor is mounted to the left side of the
throttle body. The TP sensor provides a voltage signal
that changes relative to throttle blade angle. This
signal voltage is one of the most important inputs used
by the PCM. The TP sensor has a 5.0 volt reference,
a ground and a signal circuit.
The TP sensor signal voltage should be about 0.6 volt
at idle. The TP sensor voltage should increase to
above 4.0 volts at wide open throttle (WOT).
This diagnostic compares actual throttle position from
the TP sensor to a predicted throttle position value.
The predicted throttle position is calculated from
engine speed and other inputs. If the PCM detects the
predicted throttle position is below the actual TP
sensor value, this OTC sets.

Conditions for Running the DTC

No MAP sensor or TP sensor DTCs set.
The engine run time is greater than 10 seconds.
The engine coolant temperature is greater
than 0C (32F).
The IAC is between O and 255 counts.
The MAP is less than 55 kPa.

OR
The MAP is greater than 65 kPa.
MAP steady.

Conditions for Setting the DTC

The predicted throttle angle does not match the
actual throttle angle.
All conditions present for 20 seconds.

Engine

Engine Controls - 5.7L

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditi.ons at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not tail.
A last test tailed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

6-1371

The PCM 5.0 volt reference circuits are internally

connected within the PCM. If all the TP sensor..
circuits are OK, inspect the Fuel Tank Pressure
Sensor for malfunctions.
If it is determined that the DTC occurs
intermittently, performing the DTC P1121
diagnostic table may isolate the cause of the fault:
For an intermittent, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. If OTC P1639 sets at the same time, th.is indicates
that the 5..0 volt reference circuit is either shorted
to a ground or shorted to a voltage. The 5.0 volt
reference circuit is internally connected
within the PCM.
3. The MAP value should change with the engine
speed. If a MAP sensor voltage changes,
there is no malfunction with the MAP sensor.
4. This step tests for an intermittent connection at
the sensor.
8. If the TP sensor voltage changes, there is no
malfunction with the TP sensor wiring or the PCM.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the .
.
Connector Test Adapter Kit J 35616-A. Using this
kit prevents any damage to the harness
connector terminals.
The following may cause an intermittent:
- Mis-routed harness
- Rubbed through wire insulation
- Broken wire inside the insulation

9. Using Freeze Frame and/or Failure Records data

may aid in locating an intermittent condition. If
you cannot duplicated the OTC, the information
included in the Freeze Frame and/or Failure
Records data can help d.etermine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine. how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the DTC failed. For an
intermittent condition, refer to Symptoms.
11. This tests the 5.0 volt reference circuit, signal
circuit, and the PCM. If the scan tool displayed
5.0 volts, the TP sensor circuits are OK.

DTC P0121 TP Sensor Circuit Insufficient Activity

Step

Action
Did you perform the Powertrain On-Board Diagnostic
(OBD) System Check?

1. Install the scan tool.

2. Idle the engine.
3. Monitor the Diagnostic Trouble Code (DTC)
information using the scan tool.
Did DTC P1639 fail this ignition?

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to
OTC P16395
Volt Reference 2
Circuit

Go to Step 3

6-1372

Engine

Engine Controls - 5.7L

OTC P0121 TP Sensor Circuit Insufficient Activity (cont'd)

Step

Action

Value(s)

Yes

No

1. Start the engine.

2. Monitor the MAP sensor voltage.
3

3. Increase the engine speed to the specified value.

Does the MAP sensor voltage change when the engine
speed changed?

2000 RPM
Go to Step 8

Go to Step 4

Go to Step 16

Go to Step 5

Go to Step 6

Go to Step 17

Go to Step 7

Go to Step 17

Go to Step 8

Go to Step 17

Go to Step 9

Go to Step 10

Go to Step 10

Go to
Diagnostic Aids

1. Turn ON the ignition leaving the engine OFF.

2. Move the MAP sensor electrical connector, the
4

harness and the PCM connectors (by hand only)

while observing the scan tool display.

Is the MAP value affected by moving the harness or

connectors?

1. Remove the MAP sensor from the intake manifold but

leave the electrical harness connected.

2. Connect a hand operated vacuum pump to the MAP

sensor.

3. Observe the MAP display while slowly applying

vacuum up to 20 inches Hg as indicated on the pump
gauge. Each 1 inch of vacuum applied should result
in a 3 to 4 kPa drop in the MAP sensor value on the
scan tool and the value should change smoothly with
each increase in vacuum.
Did the MAP value change smoothly through the entire
range of the test without any erratic readings?
Apply 20 inches Hg vacuum to the MAP sensor.
Is the MAP sensor reading the same or less than the
specified value?
Disconnect the vacuum source from the MAP sensor.
Does the MAP sensor reading return to its original value?

1. Turn ON the ignition leaving the engine OFF.

2. Monitor the TP sensor voltage while moving the
8

accelerator pedal from a closed throttle to a wide

open throttle.
Does the TP sensor voltage go from below the specified
value to above the specified value?

34kPa

Below 1.0 V to
above 4.0V

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records

data for this OTC and record the parameters.

3. Turn OFF the ignition for 15 seconds.
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.

6. Select the Diagnostic Trouble Code (OTC) option, the

Specific OTC option, then enter the OTC number
which was set using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

10

1. Disconnect the TP sensor.

2. Observe the TP sensor display on the scan tool.
Is the TP sensor voltage near the specified value?

o.ov

Go to Step 11

Go to Step 13

Engine Controls .. 5.7L 6-1373

Engine

DTC P0121 TP. Sensor Circuit Insufficient Activity (cont'd)

Step

Value(s)

11

12

Replace the TP sensor. Refer to TP Sensor Replacement.

Is the action complete?

13

Test for the following conditions:

TP signal circuit for a short to voltage.
TP sensor ground circuit for high resistance between
the PCM and the TP sensor. Refer to Testing for
Continuity in Wiring Systems.
TP sensor ground circuit for a poor connection. Refer
to lntermittents and Poor Connections Diagnosis in
Wiring Systems.
If you find a condition, repair the wiring harness as
necessary. Refer to Wiring Repairs in Wiring Systems.
Did you find and correct the condition?

Action
Jump the TP sensor 5.0 volt reference circuit to the TP
sensor signal circuit using a fused jumper wire.
Is the TP sensor voltage near the specified value?

Yes

No

Go to Step 12

Go to Step 14

5.0V

Go to Step 18

Go to Step 18

Go to Step 15

Go to Step 18

Go to Step 15

Test for the following conditions:

14

TP signal circuit or 5 volt reference circuit for a poor

connection. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
TP signal circuit or 5 volt reference circuit for high
resistance between the f>CM and the TP sensor.
Refer to Testing for Continuity in Wiring Systems.

If you find a condition, repair the wiring harness as

necessary. Refer to Wiring Repairs in Wiring Systems.
Did you find and correct the condition?

Important: Program the replacement PCM. Refer to PCM

15

16

17

Replacement/Programming.
Replace the PCM.
Is the action complete?

Go to Step 18

Locate and repair the affected circuits. Refer. to Wiring

Repairs in Wiring Systems.
Is the action complete.?

Replace the MAP Sensor. Refer to MAP Sensor

Replacement.

Go to Step 18
Go to Step 18

1. S~lect the Diagnostic Trouble Code (IJTC) option and

the Clear OTC Information option using the scan tool.

18

2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (OTC) option and
the Specific DTC option; then enter the DTC number
using the scan tool.

4. Operate the vehicle within the Conditions for Running

the OTC as specified in the supporting text, if
applicable:
Does the scan tool indicate that this test ran and passed?

19

Select the Capture Info option and the Review Info using
the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 19

Go to Step 2

Go to the
applicable
OTC table

System OK

6-1374

Engine

Engine Controls . - 5.7L

OTC P0122 Throttle Position (TP) Sensor Circuit Low Voltage

'" - - - - - - - - - - - - - - - - - - - - - - - - - - - - ., Powertrain
~

I
I

TP Sensor

5V
L

~fe_::>n_:e
43

________________
.r

Module
1 (PCM)

Fuel Tank
Pressure Sensor
5,:'._ R:;e'.:.n~ _

_ J1

67 C2

GAY 596
Antilock
Brakes
Cell 44

!Loe

I~~~
I

[S]

'

..

GRY 598

GRY

596
GRY 596

C'
DKBLU 417

IIThroille

, _: Position [TP)
Sensor

8"'
BLK 452
DKBLU
417

DKBLU 417
12

'

ORN/BLK 469

BLK
452

Anti lock
Brakes
Cell44

DKGRN 890

Ground
- - - - Distribution
Cell14

23

52 C2

75 C1

~~--------- ~-------------------------

~ TP- - - - - - - - - - .- - - - - - - - - - F:e1Ta;1- - - - I
:

Sensor1
Signal
.~

Sensor
Ground

ORN/BLK 469

BLK 452

Pressure
Sensor
Signal

I - - -P;M - - ; Powertrain
~

Sensor
Ground

= RED

c12 =BLU

I
:

Control
Module
(PCM)

..

L--------------------------------------J~
218503

Circuit Description
The Throttle Position (TP) sensor is a potentiometer.
The TP sensor is mounted to the left side of the
throttle body. The TP sensor provides a voltage signal
that changes .relative to throttle blade angle. This
signal voltage is one of the most important inputs used
by the PCM. The TP sensor has a 5.0 volt reference,
a ground and a signal circuit.
The TP sensor signal v,eltage should be about 0.6 volt
at idle. The TP ::;ensor voltage should increase to
above 4.0 volts at wide open throttle (WOT).
When the PCM senses a signal voltage lower than the
normal operating range of the sensor, this OTC sets.

Conditions for Running the OTC

The ignition switch is in the ON position or the engine
is operating.

Conditions for Setting the OTC

The TP sensor signal voltage is less than 0.2 volts.
The above conditions present for 10.0 seconds.

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive ignition
cycle that the diagnostic runs and fails.
The PCM records the operating. conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.
The PCM uses a default TP sensor value.

Engine Controls S~7L 61375

Engtne,
The Transmission TCC Vlfill not:apply.
High Jransmission line pressure:
Fixed transmission shift points, hard shifts ahd
fourth gear in hot mode.

Tsest Description , .
..,

no

Conditions for Clearing the MIL/DTC

The PCM turris the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Oiagnostic Aids
Important:
.
..
! Remove any debris. fr.om the PCM connec.t.or
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Corinector Test Adapter Kit J 35616-A. Using this
kit prevents any damage to the harness
connect9r te,rminals.

The following may cause an intermittent:

- M.is-routed Harness:
- Rubbed through wire insulation
- Broken wire inside the insulation
The PCM 5.0 volt reference circuits are ipternally
connected within the PCM. If all the TP sensor ;
circuits are OK, inspect the Fuel Tank Pressure,
Sensor for malfunctions.
If it is determinedJhat the DJC occurs.
intermittently, performing the DTC P1122
diagnostic table may isolate the cause of the fault.
For an intermittent, refer to Symptoms.

'

The numbers below. refer to the step numbers on the

diagnostic ta:ble.
.
,

2. .If. DTC P1639 sets at .the same time, this indicates

that ,the
volt.reference circuit is e.ither shorted
to a ground or shorted to avoltage. The 5.0 volt
reference circuit is internally connected,
within the PCM.

5.0

3. This step verifies that a malfunction is present.

4. LJ~jng 'FreeteJr~me a.nd/or Failure Records data
may aid in. locating ~n intermiltent condition. If
you cannot,duplicated the DTC, the information
included in the Freeze Frame a.nd/orFailure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles ihe diagnostic reported a pass
. and/or fail. Operate vehicle Vlfithinthe sarrie
freeze frame .conditions (RPM, load, vel)ic.le
. _speed, 1empera.ture' etc.) that you .observed. This
will isolate when the OTC.failed. For an
intermittent condition, refer to $ympt9ms.

a.

5. This determines if the short is caused from the

Accelerator and Servo Control Module. After
repairs are made, reconnecUhe Accelerator and
Servo Cantrol Module and clear any DTCs
that set when the Accelerator and Servo Control
Module was disconnected.
6. If the scan tool indicates 5.0 volts, indicates the
TP sensor.circu.its and PCM are OK.
7. Disconnecting the PCM will allow using the DMM
,J 39200 to test continuity of. the circuits. This will
aid in locating an openor shorted circuit.
8. Disconnecting the PCM will allow using the DMM
' J.'.39200 totest continuity of the circuits. This will
aid in locating an open or shorted circuit. Refer
to Wiring Aepairsin Wiring Systems. .
10. Disconnecting the PCMwill allow using the DMM
J 39200 to test continuity of the circuits. This will
aid in locating an open or shotted circuit.

DTC P0122 Throttle Position (TP) Sensor Circ~it Low Voltage

'

Step

Action

"

Val.ue(s)

Yes

No

Go<to Step 2

~o to A
Powertrain On
Board Diagnostic
(080)
System Check

Did you perform the Powertrain On-Board Diagr)ostic

(080) System Check?
1

.,

1. lnsta)I the scan tool.

2. Idle the engine.
'
3. Monitor the Diagnostic Trouble Code (OTC)
information using the scan tool.

D.id OTC P1639tail this.ignition?

1. Turn ON the ignition leaving the engine OFF.
2. With the throttle closed, monitor the TP sensor
display on the scan tool.
Is the TP sensor voltage below the specified value?

'-\

"

Go to
DTCP1639
5'Vo/(
Reterimce 2
Circuit.

. Go to.,Step 3

Go to Step 5

Go to Step 4

0.2V

6-1376

Engine Controls "' s. 7LJ

Engine

DTC P0122 Throttle Position (JP) Sensor Circuit Low Voltage (cont'd)
Action

Step

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Fraine and/or Failure Records
data for this OTC and record the parameters.
3. Turn OFF the ignition for 15 seconds.
"
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
.. recorded in Freeze Frame/Failure Records as
possibl~. Special operating'i::onditions that you need
to meet before thePCM Will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.
6. Setect the Diagnostic Trouble Code (OTC) option, the
Specific DTC option, then enter the OTC number
wh.ich WijS set using the scan tool.
Does the scan tool. indicate that this diagnostic failed this
ignition?
'

4,

..

Value(s)

'

Yes

No

'

',

'

'

'

Go to Step 5

'

'

Go to
DiagnosUc Aids

'

Important: After you cornplete this diagn<1sis reconnect

the Accelerator and Servo Control Module. Also, clear the
Accelerator and Servo Contrbl Module DTCs that set when
the Accelerator and Servo Control Module was
disconnected.
1. Turn OFF the ignition.
2. Disconnect the;Accelerator and Servo Control
Module. Refer to Accelerator ar,d Servo Control
Module (ASM) Replacement in Antiloc~ Brake
System.
3. Turn ON the ignition leaving the engine OFF.

o.2v ,. '.!
'

Is the TP sensor .voitage .still'. .below

the specified
value?
,,
,
'

Go toBtep6

'

1. Disconnect the TP sensor electrical connector.

2. Jumper the 5.0 volt reference circuit and the TP
signal circuit together at the TP sensor harness
connector.

''c

,,

4.7V

3. Observe.the TP sensor voltage display on the

scan tool.

'

"

'.

Is the TP sensor voltage above the specified ~alue?

Go to A.
Diagnostic
System Check in
Antilock Brake
S,ystem

1, Connect the test lamp J 34142-B between B+ and the

TP. sensor signal circuit at the TP sensor harness
. , c:onnector.

Go to Step 7

4.7V

2. Observe the TP .sensor voltage display on the

scan tool.

..

Is the TP sensor voltage above the specified value?

1. Turn OFF the ignition.

Go to.Step 1i ,

'

Go to Step B

Go to Step 10

Go to Step 14

Go.to Step 9

2. Disconnect the PCM C2 connector located on the

same side of the manufacturer's logo. Refer to PCM
Replacement/Programming.

'3. Test the 5.0 volt reference circuitfor an open or short

to ground.
4. If the 5.0 volt reference circuit is open or shorted to
ground, repair the circuit as necessary. Refer to
Wiring Repairs in Wiring Systems.
Did you find and correct the c:ondition?

Engine Controls - 5.7L

Engine

6-1377

DTC P0122 Throttle Position {TP) S.ensor Circuit'Low Voltage (cont'd)

Yes

No

Go to Step 14

Go to Step 13

Go to Step 14

Go to Step 11

connection at the PCM. Refer to lntermittents and

Poor Connections Diagnosis in Wiring Systems.
2. If you find a poor connection, repair as necessary.
Refer to Repairing Connector; Terminals in Wiring
Systems.
Did you find and correct the condition?

Go to Step 14

Go to Step 13

Replace the TP sensor. Refer to TP Sensor Replacement.

Is the action complete?

Go to Step 14

Action

Step

Value(s)

1. Test the 5.0 volt reference circuit for a poor

connection at the PCM. Refer to lntermittents and
Poor Connections Diagnosis in Wiring Systems.
g

2. If you find a poor connection, repair as necessary.

Refer to REJpairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

1. Turn OFF the ignition.

10

2. Disconnect the PCM connector C2 located on the

same side of the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the TP signal circuit for an open, short to
ground, or for a short to the sensor ground circuit.
4. If you find the TP sensor signal circuit is open or
shorted to ground, repair the circuit as necessary.
Refer to Wiring Repairs in Wiring Systems.
Did you find and correc~ the condition?

1. Test the TP sensor signal circuit for a poor,

11

12

13

14

15

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.

Replace the PCM.

Is the action complete?

Go to Step 14

L Select the Diagnostic Trouble Code {DTC} option and

the pear DTC Information option using the scan tool.
2. Idle the ehgine atthe normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
1~ Specific DTC option, then enter the DTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
appli_cable.
Does the scan tool indicate that this test ran and passed?

Go to Step 15

Go to Step 2

Go to the
applicable
DTC table

'System OK

Select the Capture 1nfci option and the R~vfew Info using
'
the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

6-1378

Engine

Engine Controls - 5~7L

DTC ~0123. Throttle Po$ition (Tl?) Sen:5or Circuit HighVoltage:

jLocl

,. - - - - - - - - - - - - - - - -- - - - - - - - - -- - ., Powertrain
~

I~~~

TP Sensor

5V

Fuel Tank
Pressure Sensor
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ S~R::e'.:.n~ _

~ _ ~l~n.:_e

GRY 596
Antilock
Brakes
Cell 44

IM\I

I (PCM)

----------------------------------67

43

Module

C2

GR;:Y 598

GRY

596
GRY 596

tlThrome
, -- Sensor
Position (Tl'J

DKBLU 417

BLK 452

ORN/BLK 469

DKBLU

41'7"

Anti lock
Brakes
Cell44

BLK

452
DKBLU 417

TP-

Cell14

ORN/BLK 469 .

-1-----1- - - - - - - - - 23

Sensor
Signal

52 C2

~ Fuel-:;:~; , Pressure
sensor
Signal

Sensor
Ground

Ground

_ ___,.....,. Di!ltribution

BLK 452

12

DKGRN 890

75 C1
-

- - -

I - . . . -P;M - - ~ Power1rain
Control
~

C1= RElil
c 2 =BLU
.

Sensor
Ground

I Module
:

I
L

I
-

'-' ,;;,., -

'-'

\.,.. -

(PCM)

~
218503

Circuit Description

,Conditi9ns for Runnh'lg The DTC

The Throttle Position (TP) sensor is a potentiometer.

The TP sensor is mounted to the left side of the
throttle body. The .TP s.ensor provides a voltage signal
that chang13s relative to throttle blade angle. This
signal voltage is one of the most important inputs used
by the PCM. The TP sensor has a 5.0 volt reference,
a ground and a signal circuit.
The TP sensor signal voltage should be about 0.6 volt
at idle. The TP sensor voltage should increase to
above 4.0 volts at wide open throttle (WOT).
When the PCM senses a signal voltage higher than
the normal operating range of the sensor, this
OTC sets.

The ignit1Qrl switch is. in

is operating.

tne ON position or thE:1 engine

Conditions for Setting The OTC

The TP sensor signal voltage is greater
than 4.8 volts.
Condition present for 10.0 seconds.

Engine
Action Taken When the OTC Sets
The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
. Failure records.
The PCM uses a default TP sensor value.
The Transmission TCC will not apply.
High transmission line pressure.
Fixed transmission shift points, hard shifts and no
fourth gear in hot mode.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.

For any test that requires probing the PCM or

component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents any damage to the harness
connector terminals.

Engine Controls - 5.7L

6-1379

The following may cause an intermittent:

- Mis-routed harness
- Rubbed through wire insulation
- Broken wire inside the insulation
The PCM 5.0 volt reference circuits are internally
connected within the PCM. If all the TP sensor
circuits are OK, inspect the Fuel Tank Pressure
Sensor for malfunctions.
If it is determined that the DTC occurs
intermittently, performing the OTC P1121
diagnostic table may isolate the cause of the fault.
For an intermittent, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. If DTC P1639 sets at the same time, this indicates
that the 5.0 volt reference circuit is either shorted
to a ground or shorted to a voltage. The 5.0 volt
reference circuit is internally connected
within the PCM.
3. This step verifies if the fault is present.
4. Using Freeze Frame and/or Failure Records data
may aid in locating an intermittent condition. If
you cannot duplicated the OTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the OTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc,) that you observed. This
will isolate when the OTC failed. For an
intermittent condition, refer to Symptoms.
5. Vehicles equipped with traction control will have to
disconnect the Accelerator and Servo Control
Module. This will determine if the short is caused
from the Accelerator and Servo Control Module.
After repairs are made, reconnect the Accelerator
and Servo Control Module and clear the DTCs
that set when the Accelerator and Servo Control
Module was disconnected.
7. This tests whether the ground circuit is available
to the TP sensor. Test for poor electrical
connections at the TP sensor. Refer to Repairing
Connector Terminals in Wiring Systems.

6-1380

Engine Controls - 5.7L

Engine

DTC P0123 Throttle Position (TP) Sensor Circuit High Voltage

Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

1. Install the scan tool.

2. Idle the engine.
3. Monitor the Diagnostic Trouble Code (OTC)
information using the scan tool.
Did DTC P1639 fail this ignition?
1. Turn ON the ignition leaving the engifte OFF.
2. With the throttle closed, observe the TP sensor
voltage and percentage display on the scan tool.
Is the TP sensor voltage or the Throttle Angle above the
specified values?
1.. Turn ON the ignition leaving the engine OFF.
2. Review the Freeze Frame and/or Failure Records
data for this DTC and record the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the DTC.
6. Select the Diagnostic Trouble Code (DTC) option, the
Specific DTC option, then enter the OTC number
which was set using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

Value(s).

Go to
DTCP1639
5 Volt
Reference 2
Circuit

Go tq Step3

';

Goto Step 5

Go to Step 4

'

1. Disconnect the TP sensor electrical connector.

2. Observe the TP sensor voltage display on the
scan tool.
Is the TP sensor voltage below the specified value?

0.20V

Replace the TP sensor. Refer to TP Sensor Replacement.

Is the action complete?

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

4.7V, 0%

4.7V

Measure the voltage at the 5.0 volt reference circuit to

ground using the DMM J 39200.
Is the voltage greater than the specified value?

No

Important: After you complete this diagnosis reconnect

the Accelerator and Servo Control Module. Also, clear the
Accelerator and Servo Control Module DTCs that set when
the Accelerator and Servo Control Module was
disconnected.
1. Turn OFF the ignition.
2. Disconnect the Accelerator and Servo Control
Module. Refer to Accelerator and SeNo Control
Module (ASM) Replacement in Antilock Brake
System.
3. Turn ON the ignition.
Is the TP sensor voltage above the specified value?

Probe the sensor ground circuit at the TP sensor harness

connector with the test lamp J 34142-8 connected to B+.
Does the test lamp illuminate?

Yes

Go to Step 5

Go to
Diagnostic Aids

Go to Step 6

Goto A
Diagnostic
System Check in
Antilock Brake
System

Go to Step 7

Go to Step 10

Go to Step 8

Go to Step 11

Go to Step 14

Go to Step 9

5.0V

Go to Step 15

Engine Controls"'. 5.7L

Engine

6-1381

DTC P0123 Throttle Position (TP) Sen.sor Circuit High Voltage (cont'd)
Step

Action

Value(s)

10

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side of the manufacturer's logo. Refer to PCM
Replacement/Programming:
3. Test for a short to voltage on the TP sensor signal
circuit; also test for a short circuit between the TP
sensor signal circuit and the Accelerator and Servo
Control Module.
4. If you find the TP sensor signal circuit shorted, repair
the circuit as necessary. Refer tg Wiring Repairs in
Wiring Systems.
Did you find and correct the condition?'

Yes

No

Go to Step 15

Go to Step 13

Go to Step 15

Go to Step 12

Go to Step 15

Go to Step 13

1. Test for an open TP sensor ground circuit Refer to

Testing for Continuity in Wiring Systems.
11

12

2. If you find the TP sensor ground circuit open, repair

the circuit as necessary. Refer to Wiring Repairs in
Wiring Systems.
Did you find and correct the condition?

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side of the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the TP sensor ground circuit for a .poor
connection at the PCM. Refer to lntermittents. and
Poor Connections Di~gnosis in Wiring Systems.
4. If you find a poor con!J.f3~tion at the TP sensor ground
circuit, repair as necessary. Refer to Repairing
Connector Terminals in Wiring Systems.
Did you find and correct the condition?

Important: Program the replacement PCM. Refer to PCM

13

14

Replacement/Programming.
Replace the PCM.
Is the action complete?

Go to Step 15

Repair the 5 volt reference circuit for a short to voltage.

Refer to Wiring Repairs in Wiring Systems.i
Is the action complete?

Go to Step 15

1. Select the Diagnostic Trouble Code (OTC) option and

15

16

the Clear DTC Information option using the scan tool.

2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific DTC option, then enter ,he DTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info using
the scan tool.
Does the scan tool display any DTCs that you have not .
diagnosed?

.,

Go to Step 16

Go to Step 2

Go to the
applicable
DTC table

System OK

6-1382

Engine Controls ... 5.7L

Engijne

DTC P0125 Engine Coolant Temperature (ECT) Excessive Time to Closed

Loop Fuel Control

J
- ------

,. - - - - - - - - - - - - - , Powertrain
I Control
sv
I
ECT
I Module /.

~ ---~;~~r

~ (PCM) ~

L'..tiJ

49 C2
.- - ., Instrument
I
I Cluster
I
I }.

A17-I

YEL 410

.J

DKGRN 135

CrGRNJ135
B

~~~il~~t
Temperature
[ ]
(ECT)

-=-

Sensor

BRN 718
25

C2

,. - - - - -f" - - - - - - - , Powertrain
~

I
I

ECT

Sensor

Ground

PCM
c1 = RED
c2=BLU

I
I Control
I

Module /.
(PCM) ~

L------------.1

(
218500

Circuit Description

Conditions for Setting the OTC

Th.e PCM monitors the ECT sensor in order to

determine how long it takes the engine to reach the
coolant temperature required for Closed Loop
operation. DTC P0125 sets if the PCM determines that
the engine does not reach Closed Loop temperature
in a specified amount of time. This test will not
run if either the intake air or engine coolant
~emperature is too low at start-up. The PCM will only
run this DTC on a cold start and only once per
cold start.

The closed. loop coolant temperature of 34C (93F) is

not reached within a predetermined time. The
maximum allowable time depends on the start-up
coolant temperature and the amount of airflow into the
engine. The range for the time is from 2 minutes
and 20 seconds to 22 minutes and 30 seconds.

Conditions for Running the DTC

DTCs P0112, P0113, P0117, P0118 not set
The engine is operating.
The engine coolant temperature is between -36C
(-33F) and 40C (104F) at engine start-up.
The intake air temperature is greater
than -7C (19F).
The vehicle speed is greater than
1.6 km/h (1 mph).

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Engine:Controls - 5.7L
Conditions for Clearing the MIL/DTC
The PCM. turns th.e MIL OFF after three
consecutive ignition cycles that the diagnostic
runs arid does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
.AHistory OTC clears after forty consecutive
warm-up cycles, if this or any ot~er emission
related diagnostic does. not report any failures.
Us.e scan tool in order to clear the MIUDTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before sent.icing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A Using this
kit prevents any damage td the 'harness
connector terminals.
Using the Freeze Frame and/or Failure Records
data.may lid in lo.eating an intermittent condition.
If you cannot duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the OTC set. The Fail Counter and Pass
C6't'.mter can also help determine how many .
ignition cycles the diagnostic reported a pass
and/or a tail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the OTC failed.
If the engine has sat overnight, the eng1ne coolant
temperature and intake air temperature values
should display within a few degrees of each other.
If the temperatures are not within 3C (5F),
refer to Temperature vs Resistance.
If you determine tha.t the OTC occurs
intermittently, 'performing the P1114 or P1115
diagnostics table may isolate the cause
of the fault.

6~1383

An,engine coolant temperature exceeding 34C

(93F}, indicates that the engine is capable of
reaching the proper temperature, but not
necessarily in the correct amount of time. Re.peat
this diagnostic table oh a cold engine, and
measure the time required to reach the
temperature threshold; When starting a cold
engine, measure the amount of time it taKes the
engine to reach the specified temperature.
The engine shoyld reach the specified temperature
within 5 minutes or'less, If the engine does not
reach the specified temperature within 5 minutes,
inspect the following:
- Coolant level. Refer to Draining and Filling
Cooling System (VB) in Engine Cooling.
- Thermostat operation. Refer to Thermostat
Diagnosis in Engine Cooling.
- Are the tans on at all times? Refer to Electric
Cooling Fan Diagnosis. .
For an intermittent condition, refer to Symptoms.

Test Description
The numbers below refer to the. step numbers on the
diagnostic table.
2. An ECT failure could c::ause a. OTC P0125 to set,
so correct any ECT DTCs that are set. For any
test that requires probing the PCM or acomponent
harness connector, use the Connector Test
Adapter Kit J35616-A. Using this kit prevents
damage to the harness'conriector terminals.
6. If it is obvious that the engine is not reaching full
operating temperature, tor example the radiator
hoses never get very warm, or there is a complaint
. of little or no heat from the heater, you can skip
this step.
9. This OTC will not repo'rt a pass. The scan tool
status tor this OTC will never report a pass.
The scan tool wiO only display when the diagnostic
fails. The repair is not complete if the scan tool
indicates. that the dia,gnostic ran and failed.

OTC P0125 -=ngine Coolant Temperature (ECT) Excessive Time to Closed Loop Fuel Control
Step

Action

yalue(s).

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Go to Step2
Go to applicable
OTC table

Go to Step 3

'

Are any engine coolant temperature DTCs set?

"

NO
Goto A
Powertrain On
Board Diagnostic
(OBD) System
Check

'

Yes

6-1384

Engine Controls - 5.7L

Engi:Ae~

OTC P0125 Engine Coolant Temperature (ECT) Excessive Time\to'Closed Loop Fuel Control:,
(cont'd)
.'
Step

Action

Value(s)

Yes

No

Go to Step 4

Go to
, OTC P0117
Engine Coolant
Temperature
(ECTJ S~nsor
Circuit
Voltage

1. Install a scan tool.

2. Turn ON the ignition leaving the engine OFF.
3. Disconnect the ECT sensor.

-35C (-31 F)

Does scan tool indicate the ECT sensor is less than the
specified value?

4
:

Jumper the terminals of the ECT sensor harness

conne.ctor together using a jumper wire.
Does the scan tool indicate the ECT is greater than the
specified valu,e?

Low

139C (282F)

Gb to Step 5

Go to
OTCP01W.
Engine Coolant
Temperatvre
(ECT) Sensor
Circuit High
Voltage

'

.,

1. Reconnect the ECT sensor.

2. Idle the engine.
3. Observe the ECT .sensor display on the Engine 1
Data List of the scan tool.
5

Important: Allow the engine to warm up if it has not

already reached the specified temperature. 5 minutes is
the maximum amount of time it should take to reach this
temperature from a cold start. Less time is required if the
engine is already warm.

The coolin!;)
system must be
retested on a
cold start. Go to
!;)iagnostic Aids.

Does the scan tool ind.icate the engine coolant

temperature reache'd the specified value?

Measure the resistance of the ECT se'nsor using the DMM

J 39~00. Refer to Temperature vs Resistance,
Is the ECT resistance close to the value indicated in the
Ternperature Vs Resistance Table?
Inspect the following for an engine cooling system
condition:
Thermostat operation. Refer to Thermostat Diagnosis
in Engine Cooling.
Coolant level. Refer to Draining and Filling Cooling
System (VB) in Engine Cooling.
Coolant to water ratio. Refer to Coolant Concentration
. Testing in Engine Cooling.

Replace the ECT sensor. Refer to ECT Sensor

Replacement.
Is the action complete?

10

.,

Go to Step 6

",

Go to Step 7

' S(epB
Gd.to
,'

f-

Go to Step 9 ..

Go to Step 9

'

'

Go to Step 2

Does the scan tool indicate that t~is test failed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

'

\ .J

1. Select the Diagnostic Trouble CodE:l (OTC) option ar:,d

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the DT.C number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.

..

. Cooling fan operation etc. Refer to Electric Cooling

Fan Diagnosis.
Is the action complete?

r,

34C (93F)

Go to the
applicable
OTC table

Go to Step 10

(
System OK

Eng.ine Controls - 5. 7L

Engine

6-1385

DTC P0131 H02S Circuit Low Voltage Bank 1 Sensor 1

rr:-,

!Hot With lgn 1 Energized f

r---

Power
Distribution
Cell 10

J7

ENG SEN.

L'.:'.J

...;. ., Underhood
I Electrical
: center 2

(M;'""1

.. ____________ .
J6

Fusl:i 10
20.A

LJ:U

PNK 539
Fuse Block
Details
Cell11

PNK 539

. - - - - - - - - - - - - - - - - - - - - - - - - - - - ' , I t - - - - - - - .-. -,
.l

;e,-;;-k:;1"":' - - - - - - - - - - - - - B-;;n;;-#-;- -

PNK 539

r I
Lett Front
I
I H02S
H02S
High

PCM
C1=.RED
C2=BLU

H02S
High

Low

Powertrain
I Control
I Module
I (PCM)

.,

Lett Rear

H02S
Low

PP~::.:~~~ 1~;- ~~~~~:~:h: ~H:i.: t.~

D

Bank #2
flight,Front H02S #1
RighfRear H02S #2

B~nk #1
Left Front

BLK 450

Heated Oxygen
Sensor (H02S} # 1

Bank #1
Lett Rear

c
BLK 450

Heated Oxygen
Sensor (H02S) # 2

I
'--------------------------- -

BLK

_J

'
450' ' - - - - - - - ,-.,c
-----------....

Grouno.
Distribution
Cell14
218508

Circuit Description
The PCM supplies a voltage of about 450 mV between
the H02S high and tow signal circuits. The mcygen
sensor varies the Voltage over a.range frqm about
1,000 mV when the exhaust is rich, down through
about 10 mV when the exhaust is lean.
The PCM monitors and stores the heated oxygen
sensor (H02S) voltage information. The PCM
evaluates the H02S voltage samples in order to
determine the amount of time the H02S voltage was

out of range. The PCM compares the stored H02S

voltage samples taken within each sample period and
determines if majority of the samples are out of the
operating range.
The PCM monitors the H02S voltage for beirigfixed
below a predetermined yoltage. If the PCM detects the
a DTC sets.
voltage
is below a predeterminedvoltage,
.
.
'

''

6.. 1386

Eng,ine

Engine Controls .. 5.7L

Conditions for Running the DTC

Critei"ia1
DTCs P0101 , .P0102, P0103, P0112, P01 l3,
PQ,117, P0118, P0121, 1;>0122, P0123, P0125,,"
P0335, P0336, P035l-P0358, P1258 not set.
The AIR, EGR, and the Catalyst diagnostics are.
not active.
The engine coolant temperature is greater
than 48C (118F).
The ignition voltage is greater than 9.0 volts.
The fuel system is operating in Closed Loop.
The fuel trim learn is enabled.
The air/fuel ratio is between 14.5:1 and 14.7:1.
The TP angle is between 3% and 20%.

9R
Criteria 2
OTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0335, P0336, P0351-P0358, P1258 not set.
The ignition voltage is greater than 9.0 volts.
The AIR, EGR, and the Catalyst diagnostics are
not active.

The Power Enrichment mode is enabled for

0.5 seconds.

Conditions for Setting the DTC

Criteria 1
The H02S signal voltage remains below 200 mV.
The Criteria 1 conditions are present for
33 seconds.
OR
Criteria 2

The. HO?S signal voltage remains below 360 mV.

: The Criteria 2 conditions are present for
5.0 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second c<;msec1,Ative ignition cycle
that the: diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
..diagnostic fails, the PCM stores this information i.n
the Failure ~ecords. If the diagnostic reports a
failure.
t~e. second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.
Open Loop Fueling

on

Conditions for Clearing the MILIDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the. PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion irlto the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using 1his
kit prevents any damage to the harness
connector terminals.
The PCM sets this OTC when the vehicle runs out
of fuel.

Heate.d Oxygen Sensor (H02S) wire: Sensor

pigtail may be in ;contact with the exhaust manifold
or the exhaust system.
An oxygen supply inside the H02S is necessary
for proper operation. The H02S wires provides
the supply of oxygel'). Inspect the H02S yVires and.
connections for breaks or contamination. Refe'r
to H02S Wiring Repairs in Wiring Systems.
Test for intermittent ground in signal wire between
connector and sensor. Refer to lntermittents and
Poor Connections Diagnosis in Wiring Systems.
Lean injector(s): Perform the Injector Balance
Test. Refer to Fuel Injector Balance Test.
Fuef contamination: Water near the in::..tank fuel
pump inlet can be delivered to the injectors.
The water causes a lean exhaust and can- set a
OTC. Refer to Alcohol/Contaminarits-
in-FuelDiagndsis. . . .
'
,
.
Fyel pressure: System will. be 1ec;:ih if Juel pres~ure
is,IQ\'V. Refer to Fuel System Diagnosif. c .. .
Exhaust leaks: An exhaust leak neacthe H02$
can cause a lean condition.
Vacuum or e::rankcase leaks can c~use a leaq,,
congition.
If the above are OK; the H02S may be at fault.
For an intermittent condition, refer to Symptoms.

\.

'

Engine

Engine Controls - 5.7L

Test Description
The nu.mbers below refer fo the step numbers on the
diagnostic table.
2. If the H02S voltage is fixed well below 200 mV,
this indicates a short to battery ground or
chassis ground. If the voltage is fixed near or
above 200 mV, this indicates a short to a PCM
ground. When the H02S voltage is fixed near
200 mV, indicates the DTC s~t when the
fuel system was in a Power Enrichment mode of
operation. This DTC sets if the H02S voltage
is less than 360 mV during a Power Enrichment
mode of operation. For any test that requires
probing the PCM or a component harness
connector, use the Connector Test Adapter Kit
J 35616-A. Using this kit prevel)ts damage to the
harness connector terminals.. ;

The engine must be at the normal operating

temperature before performing this test.

6...1387.

3. Using the Freeze Frame and/or Failure Records

data may aig in. locating an intermittent condition.
1.f you can not duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also aid in determining how
many ignition cycles the diagnostic reported a
pass and/or a faiL Operate the vehicle within the
same freeze. frame conditions (RPM, load,
vehicle speed, temperature etc.) that the PCM
recorded. This will isolate when the DTC failed.
4. Grounding the low side circuit of the H02S should
cause the H02S voltage to display a bias voltage.
A voltage staying.near 0.0 volts indicates the
low circuit is open, or the high circuit is open or
grounded.
5. Disconnecting the PCM allows using the DMM
J39200 in order.to test continuity of the
circuits. This aids in locating an open or shorted
circuit.

DTC P0131 H02S Circuit Low Voltage Bank 1 Sensor 1

Step

Action

Value(s)

Yes

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Go to Step 2
\

Important: Inspect the H02S for being secure before

proceeding with this OTC. A sensor that is loose could
cause this DTC to set.
1. Install a scan tool.
2. Idle the engine at the normal operating temperature.
3. Operate the vehicle within parameters specified under
Conditions for Running the OTC in the
supporting text.
4. Monitor the H02S voltage display on the Engine 1
Data List using the scan tool.
Is the H02S voltage less than the specified value?
1. Turn ON the ignition leaving the engine OFF.
2. Review the Freeze Frame and/or Failure Records
data for this OTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Idle the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in the Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.

No
Go to A
Powertrain On
Board Diagnostic .
(080) System
Check

200mV

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to
Diagnostic Aids

Go to Step 5

6. Select the Diagnostic Trouble Code (OTC) option, the

Specific DTC option, and then enter the OTC number

using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?
\

1. Disconnect the H02S.

2. Jumper the H02S low circuit (PCM side) to a ground.
Is the H02S voltage within the specified range?

350-550 mV

6-1388

Engine

Engine Controls - 5.7L

DTC P0131 H02S Circuit Low Voltage Bank 1 Sensor 1 (cont'd}
Action '

Step

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the H02S signal circuit for a short to ground or
a short to the sensor ground Circuit.
Is the H02S signal circuit shorted?
Repair the H02S signal circuit. Refer to Wiring Repairs in
Wiring Systems.

Value(s)

No

Go to Step 6

Go to Step 7

Go to Step 8

Is the action complete?

Important: Program the replacement PCM. Refer to PCM
Replacement/Programming,
Replace the PCM.
Is the action complete?

Yes

Go to Step 8

1. Select the Diagnostic Trouble Code {DTC) option and

the Clear DTC Information option using the scan tool.

2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code {DTC) option'and
the Specific DTC option, then enter the DTC number
using the scan tool.

4. Operate the vehicle within the Conditions for Running

the DTC as specified in the supporting text, if
applicable.

Does the scan tool indicate that this test ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 9

Go to Step 2

Go to the
applicable
OTC table

System OK

EngineControls - 5.7L

Engine

6-1389

OTC P0132 H02S Circuit High Voltage Bank 1 Sensor 1

lHot With lgn 1 Energized !

. . - P:;-~ - - - - - - - - - ., Underhood

Distribution .. J7
Cett 10
J6.

I Electrical
I Center 2

ENG SEN
Fuse 10
20 A

L.------ ---~- ..
PNK 539
Fuse Block
Details
CeH11

...--- '

.....

PNK 539

.--------------------------'- - - - - - - ..,.. ..,

I

r - "'iia-;;-k :;1- -

PNK 539

~ ~

I
I.Bit Front
I
.
I H02S
H02S
High

Low

I
I

- - - - - - - - - - ;n;#-; - - ., Powertrain
.PCM
C1=RED
C2 = BLU

Left Rear
H02S
High

.
H02S
Low

I Control
I Module
I (PC&')

PP~:,;~ ,~- ~~:~~=:r~:N~:c. ~~

B

IYI

I
I

Bank #2
Right Front H02S #1
Righi Flear H02S #2

c
BLK 450

Bank #1
Left Front
Heated Oxygen
Sensor (H02S) # 1

c
BLK 450

Bank #1
Left Rear
Heated Oxygen
Sensor (H02S) # 2

.____ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ -

I
I

_J

----------<Ill

218508

Circuit Description
The PCM supplies a voltage of about 450 mV between
the H02S high and low signal circuits. The oxygen
sensor varies the voltage over a range from about
1,000 mV when the exhaust is rich, down through
about 1O mV when .the exhaust is lean.
The PCM monitors and stores the heated oxygen
sensor (H02S) voltage information. The PCM
evaluates the H02S voltage samples in order to
determine the amount of time the H02S voltage was

out of rang~. The PCM compares the stored H02S

voltage. samples taken within each sample period and
determines if majority of the samples are out of the
operating range.
The PCM monitors the H02.S voltage for being fixed
above a predetermined voltage. If the PCM detects the
voltage ,is above a predetermined. voltage, a DTC sets.

6..;1390

Engine Controls~5~7L

Conditions for Running the OTC

Criteria.1

DTCs P0101, P0102, P0103, P0112, P0113,

P0117, P0118, P0121, P0122, P0123, P0125,
P0335, P0336, P0351-P0358, P0410, P0412,
P0418, P0420, P0430, P1258, P1415,.
P1416 not set
The ignition voltage is greater than 9.0 volts.

Engine
CondiUons for Clearing the MIUDTC
The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use scan tool in order to clear the MIUDTC.

The fuel system is operating in Closed Loop.

Diagnostic Aids

The fuel trim learn is enabled.

Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents any damage to the harness
connector terminals.
Inspect the H02S electrical connections for
evidence of water intrusion. Water present in the
connector causes the B+ supply to the heater
to bleed over to the signal circuit.
Fuel pressure: The system goes rich if the
pressure is too high. The PCM compensates for
some increase. However, if the fuel pressure is too
high, a OTC may set. Refer to Fuel System
Diagnosis.
Rich injector(s): Perform the Injector Balance
Test. Refer to Fuellnjector Balance Test.
Leaking injector: Refer to the Fuel System
Diagnosis.
Evaporative emissions (EVAP) canister purge.
Inspect for fuel saturation. If full of fuel, inspect the
canister control and hoses. Refer to EVAP
Control System Operation Description.
MAF sensor: Disconnect the MAF sensor and see
if the rich condition is corrected. If so, inspect for
proper installation. If installed OK, replace the
MAF sensor. If the MAF sensor is installed
backwards, the system goes rich. The plastic
portion of the sensor has arrows cast into
it indicating proper air flow direction. The arrows
must point towards the engine.
An oxygen supply inside the H02S is necessary
for proper operation. The H02S wires provides
the supply of oxygen. Inspect the H02S wires and
connections for breaks or contamination. Refer
to H02S Wiring Repairs in Wiring Systems.
TP sensor: An intermittent TP sensor output
causes the system to go rich, due to a false
indication of the engine accelerating.
For an intermittent condition, refer to Symptoms.

The air/fuel ratio is between 14.5:1 and 14.7:1.

OR
Criteria 2

DTCs P0101, P0102, P0103, P0112, P0113,

P0117, P0118, P0125, P0335, P0336,
P0351-P0358, P1258 not set.
The ignition voltage is greater than 9.0 volts.
The AIR, EGR, and the Catalyst diagnosttcs are
not active.
Deceleration Fuel Cut~off mode is enabled for
greater than 1.0 second.

Conditions for Setting the OTC

Criteria 1

The H02S signal voltage remains above 775 mV.

The Criteria 1 conditions are present for
33 seconds.
OR
Criteria 2

The H02S signal voltage remains above 540 mV.

The Criteria 2 conditions are present for
50 seconds.

Action Taken When the OTC Sets

The PCM illumlnates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first ti(lle the
diagnostic fail 9, the PCM stores this information iri
the Failure Records. If the diagnostic.reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.
Open Loop Fueling

(
\

Engine

Engine Controls,- 5.7L

Test Description

6".1391

Records data: can help determine how many miles

since the OTC set. The Fail Counter and Pass
Counter can also aid in determining how
many ignition cycles the diagnostic teported a
pass and/or a fail. Operate the vehicle within the
same freeze frame conditions (RPM, load,
vehicle speed, temperature etc,) that the PCM
recorded. This will isolate when the OTC failed.
Refer to Symptoms.

The numbers below refer to the step numbers on the

diagnostic table.
2. This step tests for a rich condition. For any test
that requires probing the PCM or a component
harness connector, use the Connector Test
Adapter Kit J 35616-A. Using this kit prevents
damage to the harness connector terminals.
This OTC also s_ets during a deceleration
fuel cut-off. Inspect items which could cause arich
exhaust during a deceleration (leaking injectors,
stuck injectors etc.). Refer to Conditions for Setting
the OTC.

4. If the voltage remains high, this indicates the

signal circuit is shorted to a voltage; If the voltage
goes low, this indicates a rich condition.

5. This step isolates the condition. If the voltage

remains high, this indicates the signal circuit is not
shorted to the heater feed circuit. '

The engine must be at the normal operating

temperature before performing this test.

3. Using the Freeze Frame and/or Failure Records

data may aid in locating an intermittent condition.
If you can not duplicate the OTC, the information
included in the Freeze Frame and/or Failure

8. Review the system mechanization. Test for a

short between the H02S signal circuit and
a,ny other wires powered by this fuse that. run
together inside the same harness.

DTC P0132 H02S Circuit High.Voltage Bank 1 Sensor-1

'.

.Step

Action

Value(s)

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
'

1
..

Yes

Go, to Step 2 .

l
:

.
2

,.

1. Install a scan tool.

2. Idle the engif.)e at the normal operating temperature.
3 . Operate th~ engine:above 1,200 RPM for two
minutes.

Go to A
Powertrain On
Boa,rd Diagnostic
(OBD) System
,. Ct,eck

775m\/

4 ..Mopitor the H02S volta,ge display on the Engine 1

1
Data List using a scan tool.

'

Is the H02S voltage greater than the specified value?

1. Turn ON the ignition leE1ving the engine OFF.
2. Review the Freeze Fraine and/or Failure Records
data for this DTC and qbserve the parameters.
3. Turn OFF the ignition for 15 seconds.
"
4. Idle the engine.
5. Operate the vehicle within the conditions required for
.
this: di&gnm;tic to run, and as close to the conditi9ns
recorded in the Freeze Frame/Failure Records as
3
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running ,
..
,,-,
the;DTC.
6. Select the Diagnostic Trouble Code (DTC) option, the
Specific OTC option, and then enter the DTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

No

Go toStep 4

Go to Step 3

'

A.

1. Turn ON the ignition leaving the engine OFF.

2. Monitor the H02S voltage.
Is the H02S voltage greater than the specified value?
Remove the H02S heater fuse while monitoring the H02S
voltage.
Does the voltage drop to within the specified range when
the power to the heater is disconnected?

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to
Diagnostic Aids

Go to Step 6

Go to Step 7

775mV

350-550 mV

6...1392

Engine Controls - 5.7L

Engine

DTC P0132 H02S Circuit High Voltage Bank 1 Sensor 1 (cont'd)

Action

Step

1, Reinstall the fuse.

2. Qisconnect the H02S.
1 3: Jumper the H02S low circuit (PCM side) to a known
good gro.und.
4. Monitor the H02Svoltage using the scan tool.
Does the scan tool indicate the H02S voltage within the
specified range?

Important: Disconnecting the PCM may .eliminate the

short to voltage if the signal circuit is shorted to another
C2 circuit.
1. Turn OFF the ignition.
2. Disconnect the PCM connector C2 located on the
same side as the manufacture(s logo. Aefer to PCM
Replacement/Programming.
3. Disconnect the H02S.
4. Turn ON the ignition leaving the'engine OFF.
5. Test for a voltage on the H02S sensor signal
circuit at the PCM harl]e$s conn~ctpr using th(;), ..
DMM J 39200.
.
.
'
"

Value(s)

'

Repair the short to voltage in the H02S signal circuit.

Refer to Wiring Repairs in Wiring Systems.

__;

.Go to Step 8

Go to Step 9

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.

Replace the PCM.

Is the action complete?

Go to Step 11

1.

11

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle_ the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions ,for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you 1havE! not
diagnosed?

'

Go to Step 11

10

12

Go to Step B

Replace the H02S. Refer to H02S Replacement - Bank

Is the action complete?

'

Go to Step 10

Is the action complete?

No

350-550 mV

Is a voltage pre$ent?

Yes

Go to Step 11

Go to Step 12

Go to the
applicable
OTC table

Go to Step 2

System OK

Engine

Engine Controls - s~7L

DTC P0133 H02S Slow Response Bank 1 Sensor 1

!Hot With lgn 1 Energized !

.. - P-;;-w;

- - - - - - - - ., Underhood

Distribution
Cell 10

J7

.ENG SEN
Fuse 10

J6

20 A

I Electrical
I Center 2
I

1.------------.1

6-1393

I I
L OC

l_..:i:J

PNK 539
Fuse.Block
Details
Cell11

PNK 539

,---..,_..--------------------~- -

-'

- - -

- - -,
I

r' -

PNK 539

~a-;;-k :;1- - - - - - - -..;.. - - - - - 0-;;n;#-;-.:.;;; ... ., Powertrain

Left Front
'PCM
Left Rear '
I Control

I
I H02S
High

C1=.RED
C2=BLU

H02S
Low

H02S
. High

H02S
Low

I Module
I (PCM)

pp~~ ~::-~r ::~:::r;N:1:'.g ~

1

~~:-~

Bank #2
Righi Front H02S #1
Right Rear H02S #2

BLK 450

Bank #1'
Left Front
Heated Oxygen
Sensor (H02S) # 1

c
BLK 450

Bank #1
Left Rear
Heated Oxygen
Sensor (H02S) # 2

I
I

~------------------------ '

'

_J

'

BLK 450' ' - ______ -<Ill

- -

. - -

- -

Ground
Distribution
-<Ill ~Ce=ll"'-'14_...,

218508

Circuit Description
The f=>CM continubu~;ly monitors the Heated Oxygen
Sensor (H02S) activlty for .1 QO 'seconds. During
the monitor period the, PCM counts the numbe'r of
times that the HQ2S respbnds from rlc~ to lean and
from lean to rich and adds the amount of time it took to
complete all transitions. With 'this .information, the
PCM can detEfrmine the average t!me for all transitions.
If the average response time is too slow, a DTC sets.
The PCM determines the lean to rich transition
when the H02S voltage changes from less than 300
mV to greater than 600 mV. The PCM determines
the rich to lean transition when the H02S voltage
changes from more than 600 mV to less than 300 mV.
An H02S that responds too slowly is most likely
defective. Replace the H02S.

Conditions for Running the DTC

DTCsP0101, P0102,P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, PQ125,
P0335, P0336, P0351-P0358, P1120, P1220,
P1221, P1258, not set.
The engine coolant temperature is greater
than 65C (149F).

The, ignition voltage is greater than 9.0 volts.

The AIR, EGR, and the Catalyst diagnostics are
not active.
The fuel system is operating in Closed Loop.
The engine speed between 1,000 RPM and
2,300 RPM.
The engine air flow is between 15 g/s and 35 g/s.
The EVAP canister purge duty cycle is greater
than 0%.
The engine run time is greaterthan 120 seconds.

5.;1394

IEngine Controls .,; 5;7l

Conditions for Setting the OTC

The lean to rich response (below 300 mV to
above 600 mV) average time is greater
than 100 milliseconds.
The rich to lean response (above 600 mV to
below 300 mV) average time is greater
than 100 milliseconds.
the above conditions are met for 100 seconds.

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports 1'.3.
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame anq updates the

Failure records.

Conditions for Clearing the MIL/OTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail:
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.

A History OTC clears after forty consecutive

warm-up cycles, if this or any other emissio.n
related diagnostic does not report any failure~,
Use a scan tool in order to clear the MIUOTC:

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets a:re installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test \hat requires 1:>r.obing the.PQM;.or
component ha,rness co1:1nector~. use.th.e
,
Conne.ctor Test Adapter Kit J 3561,6-A. Using this
kit prevents any damage to the harne.ss
conhectOr terminals.
This cjiagnostic only runs o~c(;l per igr,ition cycle.
A malfunction in the H02S he~ter circuits
causes a OTC to set. Test Hf)2S heater. circuits
for intertnittant opens/connections. Refer to
lntermittents and Poor Connections Diagnosis In
Wiring Systems.

Engine
An o'>c'ygen supply inside1the H02S is necessary,
for proper operation. The H02S wires provides
the supply of oxygen. Inspect the H02S wires and
connections for breaks or contamination. Refer
to H02S Wiring Repairs in Wiring Systems.
Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since. the OTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
wilt isotate when the DTC failed.
For an intermittent condition, refer to Symptoms.

. Test Description
The numbers below refer to the step numbers on the
dia~nostic table.
2. This step determines if the fault is present. This ,
test may take 5 minutes for the diagnostic to
run. For any test that requires probing the PCM or
a component harness connector; use the 1
Connector Test Adapter Kit J 35616-A. Using this
kit prevents damage to the harness connector
terminals.

at

3. When DTCs P01'33 and P0153 are set

the
same time, it is a good indication that a fuel

cohtamination condition is' present.

4. An exhaust leak 6-12 inches away from the
H02S can cause a DTC to set.
5. This step verifies whether a good ground circuit is
available.
6. This step tests the integrity of the signal circuit to
the. PCM ...
7. This step tests the integrity of the signal circuit to
the PCM.
8. Certain RTV .silicone gasket materials give off
vapors that can contaminate the Hb2S.' There
is also a possibility of 9ilicone contamination
caused by silicone in tt:ie fueL If tl;le sensors
.appear Jo be co~tamir:iated by silicpne and all the
silicone sealant is'a;non silicone bas.e, advise
thEl cu'stom'er to try different fuel company ...
A missing .fuel filler rElstrictor indicates the
customer may have used leaded fuel.

Engine

Engine Controls - 5.7L 6-1395

OTC P0133 H02S Slow Response Bank 1 Sensor 1

Step

Action

'
Did you perform the Powertrain On-Board Diagnostic
(OBD) System Check?

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic'
(OBD) System
Check

Go to Step 3

Go to
Diagnostic Aids

Go to Step 8

Go to Step 4

Go to Step 2

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 7

Go to Step 10

Go to Step 12

Go to Step 11

Important: If any DTCs are set (except P0153), refer to

those DTCs before proceeding with this diagnostic table.

1. Install a scan tool.

2. Idle the engine at the n.ormal operating temperature.
3. Operate the vehicle within the parameters specified
under Conditions for Running the DTC in the
supporting text.
4. Monitor the Diagnostic Trouble Code (OTC)
information using the scan tool.

Did DTG P0133 fail this ignition?

Did DTC P0153 also fail this ignition?

1. Inspect for an exhaust system leak. Refer to Exhaust
Leakage in Engine Exhaust. After you inspect the
exhaust system, return to this diagnostic.
2. If you find an exhaust leak, repair the exhaust leak as
necessary.

Did you isolate an exhaust leak?

Visually/physically inspect the following items:
Ensure that the H02S is securely-installed.
\

Inspect for corrosion on the terminals.

Inspect the terminal tension at the H02S and at
the PCM.

Inspect for damaged wiring.

Did you find a concern in any of the above areas?
1. Disconnect the Bank 1 H02S 1.
2. Jumper the H02S low (PCM side) signal circuit to a
ground.

3. Monitor the Bank 1 H02S 1 voltage on the Engine 1

Data List using the scan tool.

350-550 mV

Does the scan tool indicate a voltage within the

specified range?
1. Jumper the Bank 1 H02S 1 high and low (PCM side)
signal circuits to a ground.

2. Monitor the Bank 1 H02S 1 voltage using the

scan tool.

200mV

Does the scan tool indicate a voltage below

specified value?

Important: Determine and correct the cause of the

contamination before replacing a sensor. Inspect for the
following conditions:
Fuel contamination

Use of improper RTV sealant

Engine oil/coolant consumption

Replace the affected Heated Oxygen sensor. Refer to
H02S Replacement - Bank 1 and/or H02S
Replacement - Bank 2.
Is the action complete?

Repair the condition as necessary.

Is the action complete?

Go to Step 13

Go to Step 13

6-1396

Engine Controls - 5.7L

Engine

OTC P0133 H02S Slow Response Bank 1 Sensor 1 (cont'd)

Step

Value(s)

Action

Yes

No

'

10

Repair the open Bank 1 H02S 1 low signal circuit or the

grounded Bank 1 H02S 1 high signal circuit. Refer to
Wiring Repairs in Wiring Systems.
Is the action complete?

11

Repair the open Bank 1 H02S 1 high signal circuit or the

faulty PCM connections. Refer to Wiring Repairs in Wiring
Systems.
Is the action complete?

12

Replace the Bank 1 H02S 1. Refer to H02S

Replacement - Bank 1.
Is the action complete?

13

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the sGan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

14

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 13

Go to Step 13

Go to Step 13

Go to Step 14

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5.7L

6-1397

DTC P0134 H02S Circuit Insufficient Activity Bank 1 Sensor

....

lHot With lgn 1 Energized !

-- - -...
Power
Distribution
Cell10

J7

ENG SEN
Fuse 10
20 A ,

J6
I. -

-,- -

.. -

- , Underhood
I Electrical
: Center 2
-

...

PNK 539
Fuse Block
Details
Cell11

PNK 539

- - - - - -

---,

Bank #2
Right Front H02S #1
Right Rear H02S #2

c
BLK 450

Bank #1
Left Front
Heated Oxygen
Sensor (H02S) # 1

c
BLK 450

Bank #1
Left Rear
Heated Oxygen
Sensor (H02S) # 2

,,

' - - - - - - - - - - - " ' - - - - - - - - - - - - - - - - - - -

_J

_________ _.,.

BLK 450' ' - - - - - - - ..::...

Ground
Distribution
Cell14

218508

Circuit Description
The PCM supplies a voltage of about 450 mV between
the H02S high and low signal circuits. The oxygen
sensor varies the voltage over a range from.about
1,000 mV when the exhaust is rich, down through
about 10 mV when the exhaust is lean.
The PCM monitors and stores the heated oxygen
sensor (H02S) voltage information. The PCM
evaluates the H02S voltage samples in order to
determine the amount of time the H02S voltage was
out of range. The PCM compares the stored H02S
voltage samples taken within each sample period and
determines if majority of the samples are out of the
operating range.
The PCM monitors the H02S voltage and detects if
the voltage goes out of the bias range. If the PCM
does not detect the voltage went out of the bias range,
a OTC sets.

Conditions for Running the OTC

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0335, P0336, P0351-P0358, P1258 not set.
The ignition voltage is greater than 9.0 volts.
The AIR, EGR, and the Catalyst diagnostics are
not active.
The fuel system is operating in Closed Loop.
The engine run time is greater than 70 seconds.
The engine coolant temperature is greater
than 48C (118F).

Conditions for Setting the OTC

The H02S signal voltage is steady between
350 mV and 550 mV.
The conditions are present for 60 seconds.

6":"1398

Engine Controls - 5.7L

Engine

Action Taken When the DTC Sets

Using the Freeze Frame and/or Failure Hecords

data may aid in locating an intermittent condition.
If you cannot duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the OTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) t~at you observed. This
will isolate when the OTC failed.
For an intermittent condition, refer to Symptoms.

The PCM illuminates the Malfunction Indicator

Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.
Open Loop Fueling

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents any damage to the harness
connector terminals.
An oxygen supply inside the H02S is necessary
for proper operation. The H02S wires provides
the supply of oxygen. Inspect the H02S wires and
connections for breaks or contamination. Refer
to H02S Wiring Repairs in Wiring Systems.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. The engine rnust be at the normal operating
temperature before performing this test. For any
test that requires probing the PCM or a component
harness connector, use the Connector Test
Adapter KitJ 35616-A. Using this kit prevents
damage to the harness connector terminals.
3. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you can not duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the OTC set. The Fail Counter and Pass
Counter can ~lso be used to determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that the PCM recorded.
This will isolate when the OTC failed. Refer to
Syrrptoms.

4. If the scan tool indicates the H02S voltage goes

below 200 mV, this indicates the H02S circuits
and PCM are OK.

5. This step tests whether the signal circuit from the

PCM is OK.
6. Disconnecting the PCM allows using the OMM
J 39200 in order to test continuity of the
circuits. This aids in locating an open or shorted
circuit.
7. Disconnecting the PCM allows using the OMM
J 39200 in order to test continuity of the
circuits. This aids in locating an open or shorted
circuit.

Engine Controls - 5;7L 6-1399

Engine

DTC P0134 H02S Circuit Insufficient Activity Bank 1 Sensor

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to Step 4

Go to Step 4

Go to
Diagnostic Aids

Go to Step B

Go to Step 5

Go to Step 6

Go to Step 7

Go to Step 13

Go to Step 9

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Important: Inspect the H02S for being secure before

proceeding with this OTC. A sensor that is loose could
cause this OTC to set.

1. Install a scan tool.

2. Idle the engine at the normal operating temperature.
3. Operate the engine above 1,200 RPM for two
min~tes.
4. Monitor the H02S voltage display on the Engine 1
Data List using the scan tool.
Does the scan tool indicate the Bank 1 H02S 1 voltage
varying outside the specified range?

350-550 mV

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this DTC and observe the parameters.
3. Turlil OFF ffie' ignition for 15 seconds.

4. Idle the engine.

5. Operate the vehicle within the conditions required for
this.,diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that need to be
met before the PCM will run this diagnostic, where
applicable, are Hste.d in conditions for Running
the DTC.
6. Select the Diagnostic Trouble Code (DTC) option and
the Specific DTC option, then enter the DTC number.
usir19 the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

l. Turb ON the ignition leaving the engine OFF.

2. Disconnect the Bank 1 .H02S 1.
3. Jumper the H02S high and low (PCM side) signal
circits to a ground.
4. Monitor the Bank 1 H02S 1 voltage usin~ the
scan tool.
Is the Bank 1 H02S 1 voltage below the specified value?

200mV

1. Remove the jumper wire.

"
2. Measure the voltage between the Bank 1 H02S 1
high signal circuit (PCM side) and the Bank 1 H02S
1 heater ground circuit using the DMM J 39200.
Does the Bank 1 H02S 1 voltage measure above the
specified value?

375mV

1. Turn' OFF the ignition.

2. Disconnect the PCM connector C2 located on the
sarrie side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
Test
the continuity of the Bank 1 H02S 1,low circuit
3.
Refer to Testing for Continuity in Wiring System's.
4. Repair the open or the poor connection if the Bank 1
H02S 1 low circuit measures over the specified
value. Refer to Wiring Repairs in Wiring Systems.
Did you find and correct the Bank 1 H02S 1 low circuit
condition?

2Q

6-1400

Engine Controls - 5.7L

Engine

OTC P0134 H02S Circuit Insufficient Activity Bank 1 Sensor (cont'd)

Step

Action

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the continuity of the Bank 1 H02S 1 signal
circuit. Refer to Testing for Continuity in Wiring
Systems.
4. Repair the open or the poor connection if the Bank 1
H02S 1 signal circuit measures over the specified
value. Refer to Wiring Repairs in Wiring Systems.
Did you find and correct the Bank 1 H02S 1 signal circuit
condition?

2n

1. Inspect for a poor Bank 1 H02S 1 signal or low

circuit terminal connection at the Bank 1 H02S 1
harness connector. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
2. If you find a poor connection repair the condition as
necessary. Refer to Connector Repairs in Wiring
Systems.
Did you find and correct the condition?

1. Inspect for a poor Bank 1 H02S 1 low circuit terminal

connection at the PCM. Refer to lntermittents and
Poor Connections Diagnosis in Wiring Systems.
2. If you find a poor connection repair the condition as
necessary. Refer to Connector Repairs in Wiring
Systems.
Did you find and correct the condition?

Value(s)

11

Replace the Bank 1 H02S 1. Refer to H02S Replacement

- Bank 1.
Is the action complete?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

14

Go to Step 13

Go to Step 10

Go to Step 13

Go to Step 11

Go to Step 13

Go to Step 12

10

13

No

1. Inspect for a poor Bank 1 H02S 1 signal circuit

terminal connection at the PCM. Refer to lntermittents
and Poor Connections Diagnosis in Wiring Systems.
2. If you find a poor connection repair the condition as
necessary. Refer to Connector Repairs in Wiring
Systems.
Did you find and correct the condition?

12

Yes

Go to Step 13

Go to Step 12

Go to Step 13

Go to Step 13

Go to Step 14

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5.7L

6-1401

DTC P0135 H02S Heater Performance Bank 1 Sensor 1

!Hot With lgn 1 Energized !

,. - P:;-w; - - - - - - - - - , Underhood

I
I

Distribution
Cell 10

J7

ENG SEN
Fuse 10

I Electrical
I Center 2
I

~------ _____ .,
J6

20 A

PNK 539
Fuse Block
Details
Cell11

PNK 539

--------,
I

,. - ;a-;;-k :;, - - - - - - - - - - - - - - B-;-n~#~ - - , Powertrain

PNK 539

I
Left Front
I
I H02S
H02S
High

Low

PPVW:~ ,:-~~

PCM

Lett Rear

c1~RED
C2=BLU

H02S

H02S

I Control
I Module
I (PCM)

~;--~~~~::r:~:]~ t.~
High

Low

Bank #2

Right Front H02S #1

Right Rear H02S #2

c
BLK 450

Bank #1
Left Front
Heated Oxygen
Sensor (H02S) #1

c
BLK 450

Bank #1
Left Rear
Heated Oxygen
Sensor (H02S) # 2

I
I

._____ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _.._ - - - - - - - .J

' ' - ______ -<111

BLK 450'
----------<111

218508

Circuit Description
The PCM supplies a bias voltage (approximately
450 mV) on the Heated Oxygen Sensor (H02S) signal
high and low circuits. When you turn the ignition to
the ON position, battery voltage is supplied to
the H02S heater. As the heater reaches the operating
temperature, the H02S voltage responds by
changing from a bias voltage range to the normal
operation. Typically, as the H02S reaches the
operating temperature, the H02S voltage goes from a
bias voltage to a voltage below 300 mV. Depending
on the exhaust gas content, it is possible for the H02S
voltage to go above 450 mV.

The PCM runs the heater test only on a cold start

(depends on the cumulative air flow) and only once an
ignition cycle. When you start the engine the PCM
monitors the H02S voltage. When the H02S voltage
goes above or below the bias range threshold, the
PCM determines how much time it took. If the
PCM detects that the process took too much time for
the H02S to enter into normal operating range, a
OTC sets. The time the process takes the H02S to
reach operating temperature is based on the amount of
air that flows into the engine.

6-1402

Engine Controls - 5.7L

Conditions for Running the DTC

OTCs P0101, P0102, P0103, POH2, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0335, P0336, P0351-P0358, P1258 not set.
The intake air temperature and the engine coolant
temperature are less than 50C (122F) and are
within 8C (14.5F) of each other at engine
start-up.
The ignition voltage is between 10.0 volts and
16.0 volts.
The AIR, EGR, and the Catalyst diagnostics are
not active.
The engine air flow is less than 23 g/s.
The TP sensor angle is less than 20%.

Conditions for Setting the DTC

The H02S voltage remains between 300 mV and 700
mV for a predetermined amount of time (depends
on engine coolant temperature and air flow).

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition qycle
that the diagnostic runs and fails.
The PCM records the operating conditio.ns at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writesJhe
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecut.ive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
Important:

Remove any debris from the PCM connector

surfaces .before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents any damage to the harness
connector terminals.

Engine
Usirig the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the OTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
fre.eze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isqlate when the OTC failed.
The heater diagnostic will only run on a cold start
and run once per ignition cycle.
An oxygen supply inside the H02S is necessary
for proper operation. The H02S wires provides
the supply of oxygen. Inspect the H02S wires and
connections for breaks or contamination. Refer
to H02S Wiring Repairs in Wiring Systems.
For an intermittent condition, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Allow the engine to cool before performing this
test. If the sensor is at the operating temperature
the.H02S voltage will stay high or lqvv. If the
H02S voltage stays between 300-700 mV
.
indicates the H02S heater is inoperative. For any
test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.
3. If more than one H02S OTC is set, this is a good ,
indication that the H02S fuse is open. Test all

the related circuits going to all the heated oxygen

sensors for a short to ground. If all of the wiring
is OK, it may be necessary to disconnect
each H02S one at a time to locate a shorted
sensor.
4. This step verifies whether a B+ supply is available
at the sensor.
5. This step verifies whether a ground is available at
the sensor.
6. This step tests whether the H02S heater element
is internally open.
'
7. Inspect the ignition feed circuits at the Underhood
Electrical Ce.nter for poor connections:
8. Test the ground circuits for an open if more then
one heater OTC sets.

Engine

Engine Controls - 5.7L 6-1403

DTC P0135 H02S Heater Performance Bank 1 Sensor 1
Action

Step

Value{s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to
Diagnostic Aids

Go to Step 3

Go to Step 11

Go to Step 4

Go to Step 5

Go to Step 7

Go to Step 6

Go to Step B

Go to Step 9

Go to Step 10

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Important: Allow the engine to cool for about one half

hour before proceeding with this table.
1. Turn OFF the ignition.
2, Install the scan tool.
3. Turn ON the ignition leaving the engine OFF.
4. Monitor the H02S voltage display on the Engine 1
Data List of the scan tool.
.Does the H02S voltage go from a bias voltage to above or
below the specified range?

Inspect the H02S fuse for an open.

Is the H02S fuse open?

300-700 mV

1. Raise the vehicle. Refer to Lifting and Jacking the

Vehicle in General Information.

2. Disconnect the H02S electrical connector.

3. Probe the ignition feed circuit at the H02S electrical
connector (PCM side) using the test lamp J 34142-B
connected to ground (a known good ground. Do not
use the H02S heater ground or the H02S low
circuits).
Does the test lamp illuminate?
Connect the test lamp J 34142-8 between the H02S
ignition feed and the H02S heater ground.
Does the test lamp illuminate?
Measure the resistance between the H02S ignition feed
and the H02S heater ground at the H02S pigtail using a
DMM J39200.
Is the H02S resistance within the specified range?
Repair the open in the H02S ignition feed circuit to the
H02S. Refer to Wiring Repairs in Wiring Systems.

3.5-14.0Q

Is the action complete?

Repair the open in the H02S heater ground circuit. Refer
to Wiring Repairs in Wiring Systems.
Is the action complete?

1. Inspect for a poor connection at the H02S harness

terminals. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
2. If you find a poor connection, replace the terminals.
Refer to Connector Repairs in Wiring Systems.
Did you find and correct the condition?

10

Replace the H02S. Refer to H02S Replacement - Bank 1.

Is the action complete?

11

1. Locate and repair the short to ground in the H02S

ignition feed circuit. Refer to Wiring Repairs in Wiring
Systems.
2. Replace the faulty fuse.
Is the action complete?

Go to Step 12

Go to Step 12

Go to Step 12
Go to Step 12

Go to Step 10

Go to Step 12

6-1404

Engine Controls - 5.7L

Engine

DTC P0135 H02S Heater Performance Bank 1 Sensor 1 (cont'd)

Step

12

Action

1. Select the Diagnostic Trouble Code {OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the D.TC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.

Value(s)

13

Does the scan tool display any DTCs that you have not
diagnosed?

No

(
-

Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.

Yes

Go to Step 13

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine Controls - 5.7L

Engine

6-1405

OTC P0137 H02S Circuit Low Voltage Bank1 Sensor 2

IHot With lgn 1 Energized !

I"' -

P:;-wer

J7

Distribution

Cell 10

J6

ENG SEN
Fuse 10
20 A

Underhood
Electrical
1' Center 2

L.------------.1

UI

PNK 539

Fuse Block
Details

PNK 539

Cell 11

.-----------------------------,.- - -

- -

- - --,
I

r - ;a-;;-k :;;1- - - - - - - - - - - - - - ;n;;-,,;; - - , Powertrain

PCM
Lett Rear
I Control

PNK 539

I
Lett Front
I
I H02S
H02S
High

).
BLK 450

H~2S
High

Low

PP~~ ,:~~H;
D

C1=REo
C2=BLU

H02S
Low

I Module
I (PCM)

1~;--pN~~~:~:h:N-~:J,:~ t.~

Bank #1
Left Front
Heated Oxygen
Sensor (H02S) # 1

Bank #2
Right Front H02S #1
Righi Rear H02S #2

Bank #1
Left Rear
Heated Oxygen
Sensor (H02S) # 2

BLK 450

I
I

~--------------------------<-- - - - - - - BLK

_J

'
450' ' - - - - - - - _,..
-----------...
218508

Circuit Description
The PCM supplies a voltage of about 450 mV between
the H02S high and low signal circuits. The oxyg~n
sensor varies the voltage over a range from about
1,000 mV when the exhaust is rich, down through
about 10 mV when the exhaust is lean.
The PCM monitors and stores the heated oxygen
sensor (H02S) voltage information. The PCM
evaluates the H02S voltage samples in order to
determine the amount of time the H02S voltage was

out of range. The PCM compares the stored H02S

voltage samples taken within each sample period and
determines if majority of the samples are out of the
operating range.
The PCM monitors the H02S voltage for being fixed
below a predetermined voltage. If the PCM detects the
voltage is below a predetermined voltage, a OTC sets.

6-1406

Engine Controls .. 5.7L

Conditions for Running the DTC

Criteria 1
DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0335, P0336, P0351-P0358, P1258 not set.
The engine coolant temperature is greater
than 48C (118F).
The ignition voltage is greater than 9.0 volts.
The fuel system is operating in Closed Loop.
The AIR, EGR, and the Catalyst diagnostics are
not active.
The fuel trim learn is enabled.
The air/fuel ratio is between 14.5:1 and 14.7:1.
The TP angle is between 3% and 20%.
OR
Criteria 2
DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0125, P0335, P0336,
P0351-P0358, P1258 not set.
The ignition voltage is greater than 9.0 volts.
The AIR, EGR, and the Catalyst diagnostics are

not active.
The Power Enrichment mode is enabled for
greater than 1.0 second.

Conditions for Setting the DTC

Criteria 1
The H02S signal voltage remains below 90 mV.
The Criteria 1 conditions are present for
80 seconds.
OR
Criteria 2
The H02S signal voltage remains below 420 mV.
The Criteria 2 conditions are present for
5.0 seconds during the Power Enrichment mode.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp when the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Freeze Frame and/or the Failure
Records.
Open Loop Fueling.

Engt11e
Conditions for Clearing the MtUDTC
The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusioQ into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents any damage to the harness
connector terminals.
The P,CM sets this DTC when the vehicle runs out
of fuel.
Heated Oxygen Sensor (H02S) wire: Sensor
pigtail may be in contact with the exhaust manifold
or the e?(haust system.
An oxygen supply inside the H02S is necessary
for proper operation. The H02S wires provides
the supply of oxygen. Inspect the H02S wires and
connections for breaks or contamination. Refer
to H02S Wiring Aepairs in Wiring Systems.
Test for intermittent ground in signal wire between
connector and sensor. Refer to lntermittents and
Poor Connections Diagnosis in Wiring Systems.
Lean injector(s): Perform the Injector Balance
Test. Refer to Fuel Injector Balance Test.
Fuel cdntarnination: Water near the in~tank fuel
pump inlet can be delivered to the injectors.
The water causes a lean exhaust and can set.a
DTC. Refer to Alcohol/Contaminants
in-Fuel Diagnosis~
Fuel pressure: System will be l~ari if fuel pressw~
is low. Refer t9 Fel System Diagnosis.

Exhaust leaks: An exhaust leak near the H02S
can cause a lean condition.
Vacuum .or crankcase leaks can cause a lean .
condition.
If the above are OK, the H02S may be at fault
For an intermittent condition, refer to Symptoms.

Engine

Engine Controls - 5.7L

Test Description

included in the Freeze Frame and/or Failure

Records data can help determine how many miles
since the OTC set. The Fail Counter and Pass
Counter can also be used to determine how many
ignition cycles the diagnostic reported a pass
and/or a .fail. Operate the vehicle within the same
freeze frame conditi.ons (RPM, load, vehicle
speed, temperature etc.) that the PCM recorded.
This will isolate when the OTC failed.

The numbers below refer to the step numbers on the

diagnostic table.

'. 2. If the H02S voltage is fixed well below 200 mV,

this indicates a short to battery ground or
chassis ground. If the voltage is fixed near or
above 200 mV, this indicates a .short to a PCM
ground. When the H02S voltage is fixed near
200 mV, indicates the OTC set when the
fuel system was in a Power Enrichment mode of
operation. This OTC sets if the H02S voltage
is less than 420 mV during a Power Enrichment
mode of operation. For any test that requires
probing the PCM or a component harness
connector, use the Connector Test Adapter Kit
J 35616-A. Using this kit prevents damage to the

harness connector terminals.

The engine must be at the normal operating
temperature before performing this test.
3. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you can not duplicate the OTC, the information

6-1407

4. Lower the exhaust sy$tem to gain sufficient

access to the H02S and/or the H02S connector if
necessary. Refer to Catalytic Converter
Replacement in Engine Exhaust. Grounding the
low side circuit of the H02S should cause
the H02S voltage to display a bias voltage. A
voltage staying near 0.0 volts indicates the
low circuit is open, or the high circuit is open or
grounded.
5. Disconnecting the PCM allows using the DMM
J 39200 in order in order to test continuity of
the circuits. This aids in locating an open
or shorted circuit.

DTC P0137 H02S Circuit Low Voltage Bank1 Sensor 2

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

'

1
.,.

1,

Important: Inspect the H02S for being secure before

proceeding with this OTC. A sensor that is loose could
cause this OTC to set.

1. Install a scan tool.

2. Idle the engine at the normal operating temperature.
3. Operate the vehicle within the parameters specified
under Conditions for Running the OTC in the
supporting text.

90mV

4. Monitor the H02S voltage display on the Engine 1

Data List using the scan tool.
Is the H02S voltage fixed below the specified value?

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this OTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Idle the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that need to be
met before the PCM will run this diagnostic, where
applicable, are listed in Conditions for Running
the OTC.
6. Select the Diagnostic Trouble Code (DTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

6-1408

Engine Controls - 5.7L

Engine

DTC P0137 H02S Circuit Low Voltage Bank1 Sensor 2 (cont'd)

Step

Action

Value(s)

1. Disconnect the H02S.

2. Jumper the H02S low circuit (PCM side) to a ground.
Does the scan tool indicate the H02S voltage is within the
specified range?

350-550 mV

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the H02S signal circuit for a short to ground or
a short to the sensor ground circuit.
Is the H02S signal circuit shorted?

Repair the H02S signal circuit. Refer to Wiring Repairs in

Wiring Systems.
Is the action complete?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Yes

No

(
Go to
Diagnostic Aids

Go to Step 5

Go to Step 6

Go to Step 7

Go to Step 8

Go to Step 8

Go to Step 9

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine Controls - 5.7L

Engine

6-1409

OTC P0138 H025 Circuit High Voltage Bank 1 Sensor 2

!Hot With lgn 1 Energi2ed !

,.--Power
..

Distribution
Cell10

J7

ENG SEN
Fuse 10
20 A

, Underhood
I Electrical

____________ ..:center 2
J6

PNK 539
Fuse Block
Details
Cell11

PNK 539

~-----------------------'~ -

PNK 539

,. - - - - - - - - - - - - - - - - - - - - - - Bank #1
Bank #1
I
Left Front
PCM
Lett Rear
I
C1=RED
I ~~~s
~~:s
C2=BLU
~~~s
~~s

- - - -,

, Powertrain
IC
ontrol
I Module
I (PCM)

PP~~~=~ ,~- ~N-K-~~~E:~J:: t.

D

- -

Bank #2
Right Front H02S #1
Right Rear H02S #2

c
BLK 450

Bank #1
Left Front
Heated Oxygen
Sensor (H02S) # 1

c
BLK 450

Bank #1
Left Rear
Heated Oxygen
Sensor (H02S) # 2

L---------------------~ - - - - - - '

_J

BLK 450' ' - - - - - - - _.,.

----------<Ill

Ground
Distribution
Cell14

218508

Circuit Description
The PCM supplies a voltage of about 450 mV between
the H02S high and low signal circuits. The oxygen
sensor varies the voltage over a range from about
1,000 mV when the exhaust is rich, down through
about 1O mV when the exhaust is lean.

The PCM monitors and stores the heated oxygen

sensor (H02S) voltage information. The PCM
evaluates the H02S voltage samples in order to
determine the amount of time the H02S voltage was
out of range. The PCM compares the stored H02S
voltage samples taken within each sample period and
determines if majority of the samples are out of the
operating range.
The PCM monitors the H02S voltage for being fixed
above a predetermined voltage. If the PCM detects the
voltage is above a predetermined voltage, a DTC sets.

5.;1410

Engine Controls - 5.7L

Engine

Conditions for Running the OTC

Diagnostic Aids

Criteria 1
DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0335, P0336, P0351-P0358, P1258 not set.
The ignition voltage is greater than 9.0 volts.
The fuel system is operating in Closed Loop.
The AIR, EGR, and the Catalyst diagnostics are
not active.
The fuel trim learn is enabled.
The air/fuel ratio is between 14.5: 1 and 14.7: 1.
The TP angle is between 0% and 100%.
OR

Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents any damage to the harness
connector terminals.
Inspect the H02S electrical connections for
evidence of water intrusion. Water present in the
connector causes the B+ supply to the heater
to bleed over to the signal circuit.
Fuel pressure: The system goes rich if the
press,ure is .too high. The PCM compensates for
some increase. However, if the fuel pressure is too
high, a DTC may set. Refer to Fuel System

Criteria 2
DTCs P0101, P0102, P0103, P0112; P0113,
P0117, P0118, P0125, P0335, P0336,
P0351-P0358, P1258 not set.
The ignition voltage is greater than 9.0 volts.
The AIR, EGR, and the Catalyst diagnostics are
not active.
The Deceleration Fuel Cut-off mode is enabled for .
greater than 3.0 seconds.

Conditions for Setting the OTC

Criteria 1
The H02S signal voltage remains above 930 mV.
The Criteria 1 conditions are present for
40 seconds.
OR
Criteria 2
The H02S signal voltage remains above 480 mV
for 4.5 seconds.
The Criteria 2 conditions are present for
5.0 seconds during the Deceleration Fuel
Cut-off mode.

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp when the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Freeze Frame and/or the Failure.
Records.
Open Loop Fueling.

Conditions for Clearing the MIL/DTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnosis.
Rich injector(s): Perform the Injector Balance
Test. Refer to Fuel Injector Balance Test.
Leaking injector: Refer to the Fuel System
Diagnosis.
Evaporative emissions (EV AP) canister purge.
Inspect for fuel s.aturation. If full of fuel, inspect the
canister control and hoses. Refer to EVAP
Control System Operation Description.
MAF sensor: Disconnect the MAF sensor and see
if the rich condition is corrected. If so, inspect for
proper installation. If installed OK, replace the
MAF sensor. If the MAF sensor is installed
backwards, the system goes rich. The plastic
portion of the sensor has arrows cast into
it indicating proper air flow direction. The arrows
must point towards the engine.
An oxygen supply inside the H02S is necessary
for proper operation. The H02S wires provides
the supply of oxygen. Inspect the H02S wires and
connections for breaks or contamination. Refer
to H02S Wiring Repairs in Wiring Systems.
TP sensor: An intermittent TP sensor output
causes the system to go rich, due to a false
indication of the engine accelerating.
For an ihtermittent condition, refer to Symptoms.

Engine

Engine Controls - 5.7L

Test Description

since the DTC set. The Fail Counter and Pass

Counter can also be used to determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the DTC failed. Refer to
Symptoms.

The numbers below refer to the step numbers on the

diagnostic table.
2. This DTC also sets during a deceleration fuel
cut-off. Inspect items which could cause a
rich exhaust during a deceleration (leaking
injectors, stuck injectors etc.). Refer to Conditions
for Setting the DTC. For any test that requires
probing the PCM or a component harness
connector, use the Connector Test Adapter Kit
J 35616-A. Using this kit prevents damage to the
harness connector terminals.
The engine must be at the normal operating
temperature before performing this test.
3. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicated the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles

6-1411

4. If the voltage remains high, this indicates the

signal circuit is shorted to a voltage. If the voltage
goes low, this indicates a rich condition.
5. This step isolates the condition. If the voltage
remains high, this indicates the signal circuit is not
shorted to the heater feed circuit.
8. Review the system mechanization. Test for a
short between the H02S signal circuit and
any other wires powered by this fuse that run
together inside the harness.

OTC P0138 H02S Circuit High Voltage Bank 1 Sensor 2

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to
Diagnostic Aids

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Important: Inspect the front H02S voltage before

proceeding with this OTC. If the front H02S voltage is
fixed below 300 mV, refer to OTC P0131 H02S Circuit
Low Voltage Bank 1 Sensor 1.
1. Install the scan tool.
2. Idle the engine until the normal operating temperature
is reached.
3. Raise the engine speed to 1,200 RPM.
4. Monitor the H02S voltage display on the Engine 1
Data List using the scan tool.
Is the H02S voltage greater than the specified value?

930mV

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this OTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.
6. Select the Diagnostic Trouble Code (DTC) option, the
Specific OTC option, and then enter the OTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

1. Turn ON the ignition leaving the engine OFF.

2. Monitor the H02S voltage.
Is the H02S voltage greater than the specified value?

930mV

6-1412

Engine

Engine Controls - 5.7L

OTC P0138 H02S Circuit High Voltage Bank 1 Sensor 2 (cont'd)

Step

Action

Value(s)

Remove the H02S heater fuse while monitoring the H02S

voltage.
Does the voltage drop to within the specified range when
the'power to the heater is disconnect.ed?

350-550 mV

1. Reinstall the fuse.

2. Disconnect the H02S.
3. Jumper the H02S low circuit (PCM side) to a known
good ground.
4. Monitor the H02S voltage using the scan tool.
Does the scan tool indicate the H02S voltage within the
specified range?

350-550 mV

10

Important: Disconnecting the PCM may eliminate the

short to voltage if the signal circuit is shorted to another
C2 circuit.
1. Turn OFF the ignition.
2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Disconnect the H02S.
4. Turn ON the ignition leaving the engine OFF.
5. Test for voltage on the H02S sensor signal circuit at
the PCM harness connector using the DMM J 39200.
Is there any voltage present?

Repair the short to voltage in the H02S signal circuit.

Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

Replace the H02S. Refer to H02S Replacement - Bank 1.

Is the action complete?

Yes

No

Go to Step 6

Go to Step 7

Go to Step 10

Go to Step B

Go to Step B

Go to Step 9
-

Go to Step 11

(
Go to Step 11

Go to Step 11

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
11

3. Select the Diagnostic Trouble Code (OTC) option and

the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.

Does the scan tool indicate that this test ran and passed?
12

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 12

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5.7L

6-1413

DTC P0140 H02S Circuit Insufficient Activity Bank 1 Sensor 2

\

r -

!Hot \Mth lgn 1 Energized !

P:;w;
- - - ., Underhood
Distribution
Cell 10

J7

I Electrical

ENG SEN
Fuse 10
20 A

.. ____________ .I Center 2
J6

U:!J

PNK 539
Fuse Block
Details
Cell11

PNK 539
...._

'" - ;a;k:;1- - - - - - - - - - - - - - B-;ni:-#~ -

PNK 539

I
Lett Front
1~

I H02S
High

H02S
.Low

PPWW:~ ,;-~
D

PCM
C1=RED
C2= BLU

Powertrain
I Control
I Module

.,

Lett Rear

H02S
High

--------,

H02S
Low

I (P.CM)

~;- ~~:~~=:r~: ~:1: ~

Bank #2
Right Front H02S #1
Right Rear H02$.#2

c
BLK 450

Bank #1
Left Front
Heated Oxygen
Sensor (H02S) # 1

c
BLK .450

Bank #1
Left Rear
Heated Oxygen
Sensor (H02S) # 2

I
I

'--------------,--------..,..---- -

BLK

'
450'

_J

'-- _ - - - - - _.,.

----------<Ill

218508

Circuit Description
The PCM supplies a voltage of about 450 mV between
the H02S high and low signal circuits. The oxygen
sensor varies the voltage over a range from about
1,000 mV when the exhaust is rich, down through
about 10 mV when the exhaust is lean.
The PCM monitors and stores the heated oxygen
sensor (H02S) voltage information. The PCM
evaluates the H02S voltage samples in order to
determine the amount of time the H02S voltage was
out of range. The PCM compares the stored H02S
voltage samples taken within each sample period and
determines if majority of the samples are out of the
operating range.
The PCM monitors the H02S voltage and detects if
the voltage goes out of the bias range. If the PCM
does not detect the voltage went out of the bias range,
a DTC sets.

Conditions for Running the OTC

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122,P0123, P0125,
P0335, P0336, P0351-P0358, P1258 not set.
The engine run time is greater than 70 seconds.
The fuel system is operating in Closed Loop.
The AIR, EGR, and the Catalyst diagnostics are
not active.
The engine coolant temperature is greater
than 48C (118F).

Conditions for Setting the OTC

The H02S signal voltage is steady between 409 mV
and 489 mV for 2.5 minutes.

6-1414

Engine

Engine Controls - 5.7L

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp when the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Freeze Frame and/or the Failure
Records.
Open Loop Fueling.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents any damage to the harness
connector terminals.
An oxygen supply inside the H02S is necessary
for proper operation. The H02S wires provides
the supply of oxygen. Inspect the H02S wires and
connections for breaks or contamination. Refer
to H02S Wiring Repairs in Wiring Systems.
For an intermittent condition, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. The engine must be at the normal operating
temperature before performing this test. For any
test that requires probing the PCM or a component
harness connector, use the Connector Test
Adapter Kit J 35616-A. Using this kit prevents
damage to the harness connector terminals.
3. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicated the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
. Counter can also be used to determine how many
ignition cycles the diagnostic reported a pass
and/or .a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature ete.) that you observed. This
will isolate when the DTC failed. Refer to
Symptoms for further diagnosis.
4. Lower the exhaust system in order to gain
sufficient access to the H02S and/or it's
connector. Refer to Catalytic Converter
Replacement in Engine Exhaust. If the scan tool
indicates the H02S voltage goes below 200 mV,
indicates the H02S circuits and PCM are OK.
5. This step tests whether the signal circuit from the
PCM is OK.
6. Disconnecting the PCM allows using the DMM
J 39200 in order to test continuity of the
circuits. This aids in locating an open or shorted
circuit.
'

7. Disconnecting the PCM allows using the DMM

J 39200 in order to test continuity of the
circuits. This aids in locating an open or shorted
circuit.

Engine

Engine Controls - 5.7L

6-1415

DTC P0140 H02S Circuit Insufficient Activity Bank 1 Sensor 2

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to Step 4

Go to Step 4

Go to
Diagnostic Aids

Go to Step 8

Go to Step 5

Go to Step 6

Go to Step 7

Go to Step 13

Go to Step 9

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Important: Before proceeding with this DTC, inspect the

H02S for being secure. A sensor that is loose could cause
this DTC to set.
1. Install the scan tool.
2. Idle the engine until the normal operating temperature
is reached.
3. Operate the engine above 1,200 RPM for two
minutes.
4. Monitor the H02S voltage display on the Engine 1
Data List using the scan tool.
Does the scan tool indicate the H02S voltage varying
outside the specified range?

409-489 mV

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this DTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Start the engine.

5. Operate the vehicle within the conditions required for

this diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.
6. Select the Diagnostic Trouble Code (OTC) option, the
Specific OTC option, and then enter the OTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

1. Turn ON the ignition leaving the engine OFF.

2. Disconnect the H02S.
3. Jumper the H02S high and low (PCM side) signal
circuits to ground.
4. Monitor the H02S voltage using the scan tool.
Is the H02S voltage below the specified value?

200mV

1. Remove the jumper wire.

2. Measure the voltage between the H02S high signal
circuit (PCM side) and the H02S heater ground
circuit using the DMM J 39200.
Does the H02S voltage measure above the
specified value?

375mV

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the continuity of the H02S low circuit. Refer to
Testing for Continuity in Wiring Systems.
4. Repair the open or the poor connection if the H02S
low circuit measures over the specified value. Refer
to Wiring Repairs in Wiring Systems.
Did you find and correct the condition?

2Q

6-1416

Engine Controls - 5.7L

Engine

DTC P0140 H02S Circuit Insufficient Activity Bank 1 Sensor 2 (cont'd)

Step

Action

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the continuity of the H02S signal circuit. Refer
to Testing for Continuity in Wiring Systems.
4. Repair the open or the poor connection if the H02S
signal circuit measures over the specified value.
Refer to Wiring Repairs in Wiring Systems.
Did you find and correct the condition?

Value(s)

Yes

No

(
2Q

Go to Step 13

Go to Step 10

Go to Step 13

Go to Step 11

Go to Step 13

Go to Step 12

1. Inspect for a poor connection at the H02S signal or

low circuit.. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.

2. If you find a poor connection, repair/replace the

terminal(s) as necessary. Refer to Connector Repairs
in Wiring Systems.

Did you find and correct the condition?

10

11

12

1. Test for a poor connection at the H02S low circuit

terminal at the PCM. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
2. If you find a poor connection, repair/replace the
terminal(s) as necessary. Refer to Connector Repairs
in Wiring Systems.
Did you find and correct the condition?

1. Test for a poor connection at the H02S signal circuit

terminal at the PCM. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
2. If you find a poor connection, repair/replace the
terminal(s) as necessary. Refer to Connector Repairs
in Wiring Systems.
Did you find and correct the condition?

Replace the H02S. Refer to H02S Replacement - Bank 1.

Is the action complete?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.

Replace the PCM.

Is the action complete?

(
Go to Step 13
Go to Step 13

Go to Step 12

Go to Step 13

13

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

14

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 14

Go to Step2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5. 7L

6-1417

OTC P0141 H02S Heater Performance Bank 1 Sensor 2

!Hot With lgn 1 Energized !

'" - p:;-111;

I
I
I..

J7

ENG SEN
Cell 10
Fuse 10
______
__
J6
20_
A___
Distribution

Underhood
I Electrical
I Center 2

.,

,1

Ll:!J

PNK 539
Fuse Block
Details
Cell11

PNK 539

--------,

Bank #2

Right Front H02S #1

Right Rear H02S #2

c
BLK 450

Bank #1
Left Front
Heated Oxygen
Sensor (H02S) # 1

c
BLK 450

Bank #1
Left Rear
Heated Oxygen
Sensor (H02S) # 2

~------------------------j-- - - - - - - BLK

'
450' "-

_J

______ __.,.

-----------

Ground
Distribution
Cell14

218508

Circuit Description
The PCM supplies a bias voltage (approximately
450 mV) on the Heated Oxygen Sensor (H02S) signal
high and low circuits. When the ignition is turned to
the ON position, battery voltage is supplied to the
H02S heater. As the heater reaches operating
temperature, the H02S voltage responds by changing
from a bias voltage range to normal operation.
Typically, as the H02S reaches operating temperature,
the H02S voltage goes from a bias voltage to a
voltage below 300 mV. Depending on the exhaust gas
content, it is possible for the H02S voltage to go
above 450 mV.

The PCM will run the heater test only on a cold start
(depends on cumulative air flow) and only once
an ignition cycle. When the engine is started the PCM
will monitor the H02S voltage. When the H02S
voltage goes above or below the bias range threshold,
the PCM will determine how much time it took. If
the PCM detects that it took too much time for the
H02S to enter into normal operating range, a
DTC sets. The time it takes the H02S to reach the
operating temperature is based on the amount
of air that flows into the engine.

6-1418

Engine

Engine Controls - 5.7L

Conditions for Running the DTC

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0125, P0335, P0336,
P0351-P0358, P1258 not set.
1he intake air temperature and engine coolant
temperature are less than 50C (122F) and
are within 8C (14.5F) of each other at engine
start-up.
The ignition voltage is between 10.0 volts and
16.0 volts.
The AIR, EGR, and the Catalyst diagnostics are
not active.
The engine air flow is less than 30 g/s.
The engine coolant temperature is greater
than 48C (118F).

Conditions for Setting the DTC

The H02S voltage remains between 300 mV and
700 mV for a predetermined amount of time (depends
on engine coolant temperature and air flow).

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIL/DTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents any damage to the harness
connector terminals.

Using the Freeze Frame and/or Failure Records

data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the DTC failed.
The heater diagnostic only runs on a cold start
and run once per ignition cycle.
An oxygen supply inside the H02S is necessary
for proper operation. The H02S wires provides
the supply of oxygen. Inspect the H02S wires and
connections for breaks or contamination. Refer
to H02S Wiring Repairs in Wiring Systems.
For an intermittent condition, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Allow the engine to cool, before proceeding with
this diagnostic table. The H02S may be at the
operating temperature and no drop .or rise in the
H02S voltage would occur. If the H02S voltage
stays between 300-700 mV indicates the
H02S heater is inoperative. For any test that
requires probing the PCM or a component harness
connector, use the Connector Test Adapter Kit
J 35616-A. Using this kit prevents damage to the
harness connector terminals.
3. If more then one H02S heater DTC is set, this is
good indication that the H02S fuse is open.
Test all the related circuits going to all of the
heated oxygen sensors for a short to ground. If all
wiring is OK, it may be necessary to disconnect
each H02S one at a time to locate a shorted
sensor.
4. This step verifies whether B+ supply is available
at the sensor.
5. This step verifies whether a ground is available at
the sensor.
6. This step tests whether the H02S heater element
is internally open.
7. Inspect the ignition feed circuits at the Underhood
Electrical Center for poor connections.
8. Test the ground circuits for an open if more then
one heater OTC sets.

Engine

Engine Controls - 5.7L

6-1419

DTC P0141 H02S Heater Performance Bank 1 Sensor 2

Step

Action

Value(s)

..

Yes

No

Go to Step2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to
Diagnostic Aids

Go to Step 3

Go to Step 11

Go to Step 4

Go to Step 5

Go to Step 7

Go to Step 6

Go to Step 8

Go to Step 9

Go to Step 10

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Important: If the engine has just been operating, allow the

engine to cool for about one half hour before proceeding.
1. Turn OFF the ignition.
2. Install the scan tool.

3. Turn ON the ignition leaving the engine OFF.

4. Monitor the H02S voltage display on the Engine 1

300~700 mV

Data List of the scan tool.

Does the H02S voltage go from a bias voltage to above or
below the specified range?

Inspect the fuse for the H02S ignition feed circuit.

Is the H02S fuse open?

1. Raise the vehicle. Refer to Lifting and Jacking the

Vehicle in General Information.
2. Disconnect the H02S electrical connector.

3. Probe the ignition feed circuit at the H02S electrical

connector (PCM side) using the test lamp J 34142-8

connected to a known good ground. Do Not use the

H02S heater ground or the H02S low circuit.
Does the test lamp illuminate?

Connect the test lamp J 34142-8 between the H02S

ignition feed and the H02S heater ground.
Does the test lamp illuminate?
Measure the resistance between the H02S ignition feed
and the H02S heater ground at the H02S pigtail using the
DMM J39200.
Is the H02S resistance within the specified range?

3.5-14.0Q

Repair the open in the H02S ignition feed circuit to the

H02S. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Repair the open in the H02S heater ground circuit. Refer

to Wiring Repairs in Wiring Systems.
Is the action complete?

Go to Step 12
-

Go to Step 12

1. Inspect for a poor connection at the H02S harness

terminals. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.

2. If you find a poor connection, replace the terminals.

Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

Go to Step 12

10

Replace the H02S. Refer to H02S Replacement - Bank 1.

Is the action complete?

11

Locate and repair the short to ground in the H02S ignition

feed circuit and replace the fuse. Refer to Wiring Repairs
in Wiring Systems.
Is the action complete?

Go to Step 12

Go to Step 10

Go to Step 12

s:.1420

Engine Controls - 5.7L

Engine

DTC P0141 H02S Heater Performance Bank 1 Sensor 2 {cont'd)

Step

Action

12

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (DTC) option and
the Specific OTC option, then enter the DTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

13

Value(s)

Yes

No

Go to Step 13

Go to Step 2

Go to the
applicable
DTC table

System OK

Engine

Engine Controls - 5. 7L

6-1421

DTC P0151 H02S Circuit Low Voltage Bank 2 Sensor 1

!Hot With Ign 1 Energized !

r--------Power
Distribution
Cell 10

J7
J6

- , Underhood
I Electrical
: Center 2

ENG SEN
Fuse 10
20 A

L2w

L------ -----J
PNK 539
Fuse Block
Details
Cell 11

'

' , PNK 539

' '

r - - - - - - -'
r -

I
I
I
I
I
I
I

Bank #1
Left Front H02S #1
Left Rear H02S #2

1.
I
I H02S

-~k-;. 2- - - - - - - - - - - - - - ;n; #-; Right Front

High

-------

c2=BLU

H02S

Low

H02S
Law

------------------

46

- , Powertrain

I Control
I Module
H02S I (PCM)

Right Rear

PCM
c1=RED

High

-------

41 C2 ~

PPL 1666

TAN 1667

PNK 539

B"'

A"'

TAN 1671

A"'

PPL 1670

B"'

PNK 539
D

r
)

Bank #2
Right Front
Heated Oxygen
Sensor (H02S) #1

BLK 450

Bank #2
Right Rear
Heated Oxygen
Sensor (H02S) # 2

c
BLK 450

L - - - - - - - ---------------------------

'

BLK 450' .....__ ______ ~

-

Ground
Distribution
Cell 14

218509

Circuit Description
The PCM supplies a voltage of about 450 mV between
the H02S high and low signal circuits. The oxygen
sensor varies the voltage over a range from about
1,000 mV when the exhaust is rich, down through
about 1O mV when the exhaust is lean.

The PCM monitors and stores the heated oxygen

sensor (H02S) voltage information. The PCM
evaluates the H02S voltage samples in order to
determine the amount of time the H02S voltage was
out of range. The PCM compares the stored H02S
voltage samples taken within each sample period and
determines if majority of the samples are out of the
operating range.
The PCM monitors the H02S voltage for being fixed
below a predetermined voltage. If the PCM detects the
voltage is below a predetermined voltage, a DTC sets.

6-1422

Engine Controls - 5.7L

Conditions for Running the OTC

Criteria 1
OTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0335, P0336, P0351-P0358, P1258 not set.
The engine coolant temperature is greater
than 48C (118F).
The ignition voltage is greater than 9.0 volts.
The fuel system operating in Closed Loop.
The AIR, EGR, and the Catalyst diagnostics are
not active.
The fuel trim learn is enabled.
The air/fuel ratio is between 14.5:1 and 14.7:1.
The TP angle is between 3% and 20%.
OR
Criteria 2
OTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0335, P0336, P0351-P0358, P1258 not set.
The ignition voltage is greater than 9.0 volts.
The AIR, EGR, and the Catalyst diagnostics are
not active.
The Power Enrichment mode is enabled for
greater than 0.5 second.

Conditions for Setting the OTC

.Criteria 1
The H02S signal voltage remains below 200 mV.
The Criteria 1 conditions are present for
33 seconds.
OR
Criteria 2
The H02S signal voltage remains below 360 mV.
The Criteria 2 conditions are present for
5.0 seconds during the Power Enrichment mode.

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.
Open Loop Fueling

Engine
conditions for Clearing the MIL/OTC:
The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents any damage to the harness
connector terminals.
The PCM sets this OTC when the vehicle runs out
of fuel.
Heated Oxygen Sensor (H02S) wire: Sensor
pigtail may be in contact with the exhaust manifold
or the exhaust system .
An oxygen supply inside the H02S is necessary
for proper operation. The H02S wires provides
the supply of oxygen. Inspect the H02S wires and
connections for breaks or contamination. Refer
to H02S Wiring Repairs in Wiring Systems.
Test for intermittent ground in signal wire between
connector and sensor. Refer to lntermittents and '
Poor Connections Diagnosis in Wiring Systems.
Lean injector(s}: Perform the Injector Balance
Test. Refer to Fuel Injector Balance Test.
Fuel contamination: Water near the in-tank fuel
pump inlet can be delivered to the injectors.
The water causes a lean exhaust. and can set a
OTC. Refer to Alcohol!Contatninants-in-F'uel
Diagnosis.
Fuel pressure: System will be lean if fuel pressure
is low. Refer to Fuel System Diagnosis.
Exhaust leaks: An exhaust leak near the H02S
can cause a lean condition.
Vacuum or crankcase leaks can cause a lean
condition.
If the above are OK, the H02S may be at fault.
For an intermittent condition, refer to Symptoms.

Engine

Engine Controls - 5.7L

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. If the H02S voltage is fixed well below 200 mV,
this indicates a short to battery ground or
chassis ground. If the voltage is fixed near or
above 200 mV, this indicates a short to a PCM
ground. When the H02S voltage is fixed near
200 mV, indicates the DTC set when the
fuel system was in a Power Enrichment mode of
operation. This DTC sets if the H02S voltage
is less than 360 mV during a Power Enrichment
mode of operation.
The engine must be at the normal operating
temperature before performing this test. For any
test that requires probing the PCM or a component
harness connector, use the Connector Test
Adapter Kit J 35616-A. Using this kit prevents
damage to the harness connector terminals.

6-1423

3. Using the Freeze Frame and/or Failure Records

data may aid in locating an intermittent condition.
If you can not duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also be used to determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that the PCM recorded.
This will isolate when the DTC failed.
4. Grounding the low side circuit of the H02S should
cause the H02S voltage to display a bias voltage.
A voltage staying near 0.0 volts indicates the
low circuit is open, or the high circuit is open or
grounded.
5. Disconnecting the PCM allows using the DMM
J 39200 in order to test continuity of the
circuits. This aids in locating an open or shorted
circuit.

DTC P0151 H025 Circuit Low Voltage Bank 2 Sensor 1

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids.

Go to
Diagnostic Aids

Go to Step 5

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

Important: Inspect the H02S for being secure before

proceeding with this DTC. A sensor that is loose could
cause this DTC to set.

1. Install a scan tool.

2. Idle the engine at the normal operating temperature.
3. Operate the vehicle within the parameters specified
under Conditions for Running the DTC in the
supporting text.
4. Monitor the H02S voltage display on the Engine 1
Data List using the scan tool.
Is the H02S voltage less than the specified value?
1. Turn ON the ignition leaving the engine OFF.
2. Review the Freeze Frame and/or Failure Records
data for this DTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Idle the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that need to be
met before the PCM will run this diagnostic, where
applicable, are listed in Conditions for Running
the DTC.
6. Select the Diagnostic Trouble Code (DTC) option and
the Specific DTC option, then enter the DTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?
1. Disconnect the H02S.
2. Jumper the H02S low circuit (PCM side) to a ground.
Does the scan tool indicate H02S voltage within the
specified range?

200mV

350-550 mV

6-1424

Engine Controls - 5.7L

Engine

OTC P0151 H02S Circuit Low Voltage Bank 2 Sensor 1 (cont'd)

Step

Action

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the H02S signal circuit for a short to ground or
a short to the sensor ground circuit.
Is the H02S signal circuit shorted?

Repair the H02S signal circuit. Refer to Wiring Repairs in

Wiring Systems.
Is the action complete?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Value(s)

Yes

No

Go to Step 6

Go to Step 7
-

Go to Step 10

Go to Step 10

Go to Step 9

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5.7L

6-1425

DTC P0152 H02S Circuit High Voltage Bank 2 Sensor 1

!Hot With lgn 1 Energized !

r------Power
Distribution
Cell 10

J7
J6

ENG SEN
Fuse 10
20 A

- ., Underhood
I Electrical
'center 2
I

L------------J
PNK 539
Fuse Block
Details
Cell 11

-<111- ---,...

.....
' , PNK 539

'

.....

r - - - - - - - '~----------------------------,

I
I
I
I
I
I

Bank #1
Left Front H02S # 1
Left Rear H02S #2

'" - - - - - - - - - - - - - - - - - - - - - - - Bank #2
Bank #2
I
Right Front
PCM
Right Rear
I
C1=RED
I H02S
H02S
C2=BLU
H02S
H02S
Low

High

Low

High

., Powertrain
I
Control
I Module
I (PCM)

L------------------------J
5 - - - - - 46 - -- -- -- - --- -- 1 - - - - - - 41 C2

PPL 1666
TAN 1667

PNK 539

BA

TAN 1671

AA

PPL 1670

BA

PNK 539
D

T
Bank #2
Right Front
Heated Oxygen
Sensor {H02S) #1

I
I

c
BLK 450

Bank #2
Right Rear
Heated Oxygen
Sensor (H02S) # 2

c
BLK 450

L - - - - - - - 4 - - - - - - - - - - - - - - - - - - - - - - -........

'

BLK 450' ..._ ___ - - _ _...,.

-----------<Ill

Ground
Distribution
Cell14

218509

Circuit Description
The PCM supplies a voltage of about 450 mV between
the H02S high and low signal circuits. The oxygen
sensor varies the voltage over a range from about
1 000 mV when the exhaust is rich, down through
about 1O mV when the exhaust is lean.

The PCM monitors and stores the heated oxygen

sensor (H02S) voltage information. The PCM
evaluates the H02S voltage samples in order to
determine the amount of time the H02S voltage was
out of range. The PCM compares the stored H~2S
voltage samples taken within each sample period and
determines if majority of the samples are out of the
operating range.
The PCM monitors the H02S voltage for being fixed
above a predetermined voltage. If the PCM detects the
voltage is above a predetermined voltage, a OTC sets.

6-1426

Engine

Engine Controls - 5.7L

Conditions for Running the DTC

Diagnostic Aids

Criteria 1
DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0335, P0336, P0351-P0358, P1258 not set.
The fuel system operating in Closed Loop.
The fuel trim learn is enabled.
The AIR, EGR, and the Catalyst diagnostics are
not active.
The air/fuel ratio is between 14.5: 1 and 14. 7: 1.
OR

Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents any damage to the harness
connector terminals.
Inspect the H02S electrical connections for
evidence of water intrusion. Water present in the
connector causes the B+ supply to the heater
to bleed over to the signal circuit.
Fuel pressure: The system goes rich if the
pressure is too high. The PCM compensates for
some increase. However, if the fuel pressure is too
high, a DTC may set. Refer to Fuel System
Diagnosis.
Rich injector(s): Perform the Injector Balance
Test. Refer to Fuel Injector Balance Test.
Leaking injector: Refer to the Fuel System
Diagnosis.
Evaporative emissions (EV AP) canister purge.
Inspect for fuel saturation. If full of fuel, inspect the
canister control and hoses. Refer to EVAP
Control System Operation Description.
MAF sensor: Disconnect the MAF sensor and see
if the rich condition is corrected. If so, inspect for
proper installation. If installed OK, replace the
MAF sensor. If the MAF sensor is installed
backwards, the system goes rich. The plastic
portion of the sensor has arrows cast into
it indicating proper air flow direction. The arrows
must point towards the engine.
An oxygen supply inside the H02S is necessary
for proper operation. The H02S wires provides
the supply of oxygen. Inspect the H02S wires and
connections for breaks or contamination. Refer
to H02S Wiring Repairs in Wiring Systems.
TP sensor: An intermittent TP sensor output
causes the system to go rich, due to a false
indication of the engine accelerating.
For an intermittent condition, refer to Symptoms.

Criteria 2
DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0335, P0336, P0351-P0358, P1258 not set.
The ignition voltage is greater than 9.0 volts.
The AIR, EGR, and the Catalyst diagnostics are
not active.
The Deceleration Fuel Cut-off mode is enabled for
greater than 1.0 second.

Conditions for Setting the DTC

Criteria 1
The H02S signal voltage remains above 775 mV.
The Criteria 1 conditions are present for
33 seconds.
OR
Criteria 2
The H02S signal voltage remains above 540 mV.
The Criteria 2 conditions are present for
5.0 seconds during the Power Enrichment mode.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.
Open Loop Fueling

Conditions for Clearing the MIL/DTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Engine

Engine Controls - 5.7L

Test Description

Records data can help determine how many miles

since the DTC set. The Fail Counter and Pass
Counter can also be used to determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that the PCM recorded.
This will is.olate when the DTC failed. Refer to

The numbers below refer to the step numbers on the

diagnostic table.

2. This step is verifying the condition is present. This

DTC also sets during a deceleration fuel cut-off.
Inspect items which could cause a rich ex.haust
during a deceleration (leaking injectors, stuck
injectors etc.). Refer to Conditions for
Setting the DTC.
The engine must be at th'e normal operating
temperature before performing this test. For any
test that requires probing the PCM or a component
harness connector, use the Connector Test
Adapter Kit J 35616-A. Using this kit prevents
damage to the harness connector terminals.
3. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you can not duplicate the DTC, the information
included in the Freeze Frame and/or Failure

5.. 1427

SyfT!ptoms.
4. If the voltage remains high, this indicates the
signal circuit is shorted to a voltage. If the voltage
goes low, this indicates a rich condition.
5. This step isolates the condition. If the voltage
remains high, this indicates the signal circuit is not
shorted to the heater feed circuit.
8. Review the system mechaniz.ation. Test for a
short between the H02S signal circuit and
any other wires powered by this fuse that run
together inside the same harness.

DTC P0152 H02S Circuit High Voltage Bank 2 Sensor 1

Step

Action

Value(s)

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

'
1. Install a scan tool.
2. Idle. the engine at the normal operating temperature.
3. Operate the engine above 1,200 RPM for two
minutes.
4. Monitor the H02S voltage display on the l=ngine 1.
Data List using the scan tool.

1. Turn ON the ignition leaving the engine OFF.

2. Monitor the H02S voltage.
Is the H02S voltage greater than the specified value?
Remove the H02S heater fuse while monitoring the H02S
voltage.
Does the voltage drop to within the specified range when
the power to the heater is disconnected?

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to
Diagnostic Aids

Go to Step 6

Go to Step 7

'

775mV

Is the H02S voltage greater than the specified value?

1. Turn ON the ignition leaving the engine OFF.
2. Review the Freeze Frame and/or Failure Records
data for this DTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Idle: the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that need to be
met before the PCM will run this diagnostic, where
applicable, are listed in Conditions for Running
the DTC.
6. Select the Diagnostic Trouble Code (DTC) option and
the Specific DTC option, then enter the DTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

Yes

775mV

350-550 mV

6-1428

Engine

Engine Controls - 5.7L

DTC P0152 H02S Circuit High Voltage Bank 2 Sensor 1 (cont'd)

Step

Action

1. Reinstall the fuse.

2, Disconnect the H02S.
3. Jumper the H02S low circuit (PCM side) to a known
good ground.
4. Monitor the H02S voltage using the scan tool.
Does the scan tool indicate the H02S voltage within the
specified range?

Value(s)

No

(
350-550 mV

Important: Disconnecting the PCM may eliminate the

short to voltage if the signal circuit is shorted to another
C2 circuit.
1. Turn OFF the ignition.
2. Disconnect the PCM connector C2 located on the
same side as t,he manufacturer's logo. Refer to PCM
Replacement/Programming
3. Disconnect the H02S.
4. Turn ON the ignition.
5. Test for a voltage on the H02S sensor signal circuit
at PCM harness connector using the DMM J 39200.
Is a voltage present?

Repair the short to voltage in the H02S signal circuit.

Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

10

Replace the H02S. Refer to H02S Replacement - Bank 2.

Is the action complete?

11

1. Select the Diagnostic Trouble Code (OTC} option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC} option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

12

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Yes

Go to Step 10

Go to Step 8

Go to Step 8

Go to Step 9

Go to Step 11

Go to Step 11
Go to Step 11

Go to Step 12

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine Co.ntrols, .. 5.7L

Engine

6-1429

OTC P0153 H02S Slow Response Bank 2 Sensor 1

IHot With lgn 1 Energized !

.. -P:;w;;; - - - - - - - - - ,Underhood
I
I
Distribution
Cell 10

I
I

Fuse Block
Qetails
Cell 11

,,.._ -

J7

Electrical
I Center 2
I

ENG SEN
Fuse 10

JG

20A

jM';:-1

Llil

--,...

'

':.: PNK 539

' '

r-------'

. I

. ,

- - - - - - -: - - --;- - ;an:#-; - - , Powertrajn

- -:-- -lil;k;?- Right Front

I
I H02S

H02S

, Low
L -

:5,

PCM

C2=BLU

High

-----46

I
I
I

..
-

t Control
I Module
. H02~ I

Right Rear

..
..

~ ~ -

, H02S
lqlN . _ .
_,,..,.... -::~

.
,....i.,

High
-

~ .J

{PCM)

-----------,------1, ,----.-,-41 C2

J;'
J:i4.

PPL 1666

PNK 539

TAN 1667

Bank.#1
Left Froni H02S #1
Left Rear H02$ ,!' 2.

TAN 1671

AA

PPL 1670

PNK 539

BA

T
)

Bank #2
Rigt,t Frcint .
He~ted Oxygen
' S~nsor (H02S) # 1

I
I
I

I
L - - - - ...:. - -

BLK 450

Bank#2
Right Rear
Heated Oxygen
Sensor (H02S) # 2

c
BLK 450

-------'--------------------....J
'
.,

BLK 450"' '-: _

-

.T" _ _ _ _ __..,.
-

__..,.

Ground
Distribution
Cell 14

218509

Circuit Description

Conditions for Running

the DTC
,,
'

The PCM contfriu6'.usly ~on.itors the Heated :oxy~Jn

Sensor (H02S) activity for 100 se9orids. During
the monitor period the PCM counts the number ot
times that the H02S responds from rich to lean .and
from lean to rich and adds the amount of time it took to
complete all transitions. With this inform'ation, the:
PCM can determine the average time for aH transitions.
If the average response time is too slow, a, OTC.sets.
The PCM determines the lean to rich transition
when the H02S voltage changes from less than
300 mV to greater than 600 mV. The PCM determines
the rich to lean transition when the H02S voltage
changes from more than 600 mV to less than 300 mV.
An H02S that responds too slowly is most likely
defective. Replace the H02S.

'

',

DJCs P0101,P0102, POio3, P0112,.P0113,

P0117, P0118, P0121, P0122, Po1i3; P0125,
P0335, P0336, P0351-P0358, P1258 not set
The eAgin~ coolant temperature is greater
than 65C (149F) ..
The ignition voltage is greater than 9.0 Volts.
The AIR, EGR, and the Catalyst diagnostics are
not active.
The fuel system is operating in Closed Loop.
The engine speed is between 1,000 RPM
and 2,300 RPM.
The engine air flow between 15 g/s and 35 g/s.
The EVAP canister purge duty cycle is
greater than 0%.
The engine run time is greater than 120 seconds.

6-1430

Engine

Engine Controls .. 5~7L

Conditions for Setting the OTC

The lean to rich response {below 300 mV to
above 600 mV) average time is greater
than 100 milliseconds.
The rich to lean response {above 600 mV to
below 300 mV) average time is greater
than 100 milliseconds.
The above conditions are met for 100 seconds.

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records .the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed {current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any othe.r emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Conn~ctor Test Adapter Kit J 35616-A. Using this
kit prevents any damage to the harness
connector terminals.
A malfunction in the H02S heater circuits will
cause a DTC to set. Test the H02S heater circuits
for intermittent opens/connections. Refer to
lntermittents and Poor Connections Diagnosis in

Wiring Systems.

An oxygen supply. inside the H02S is necessary

for proper operation. The H02S wires provides
the supply of oxygen. Inspect the H02S wires and
connections for breaks or contamination. Refer
to H02S Wiring Repairs in Wiring Systems.
Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freezetrame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the DTC failed.
For an intermittent condition, refer to Symptoms.

Test Description
The numbers. below refer to the step numbers on the
diagnostic table.
2. This step determines if the fault is present. This
test may take 5 minutes for the diagnostic to
run. For any test that requires probing the PCM or'
a component harness connector, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents damage to the harness connector
terminals.
3. When DTCs P0133 and P0153 are set at the
same time, this is a good indication that a
.fuel cont~mination condition is present.

4. An exhaust leak 6-12 inches away from the

H02S can cause a DTC to set.
5. This step verifies whether a good ground circuit is
available.
6. This step tests the integrity of the signal circuit to
the,PCM.

7. This step tests the integrity of the signal circuit to

the PCM.
8. Certai,n ATV silicone gasket materials. give off
vapors that can contaminate the H02S. There
is al~o a possibility of silicone contamination
caused by silicone in the fuel: If the sensors
appear to be contaminated by silicone and all the
silicone sealant is a non silicone base, advise
the customer to try a different fuel company.
A missing fuel filler restrictor indicates the
customer may have used leaded fuel.

Engine Controls -.5.7L

Engine

6-1431

OTC P0153 H02S Slow Response Bank 2 Sensor 1

Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

)
i

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Important: If any DTCs are set (except P0133), refer to

those DTCs before proceeding with this diagnostic table.

1. Install a scan tool.

2. Idle the engine at the normal operating temperature.
3. Operate the vehicle within parameters specified under
2 ..
Conditions for Running the flTC in the
supporting text.
4. Monitor the Diagnostic trouble Code (OTC)
Information using the scan tool.
Does the scan tool indicate that OTC P0153 test failed this
ignition?

.,

Did the scan tool also indicate that P0133 failed this
ignition?

1. Inspect the exhaust system for leaks. Refer to

Exhaust Leakage in Engine Exhaust. After you
inspect the exhaust system return to this diagnbstic.
2. If you find an exhaust leak repair the exhaust as
necessary.
Did you find and correct the condition?

Visually/physically inspect the following items:

Ensure that the H02S is securely installed.
Inspect for .corrosion on the terminals.
Test the terminal tension at the H02S and at the
PCM. Refer to lntermittents and Poor Connections
Diagnosis in Wiring Systems.

Go to
Diagnostic Aids

Go to Step 8

Go to Step 4

Go to Step 2

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 7

Go to Step 10

Go to Step 12

Go to Step 11

Inspect for damaged wiring.

Did you find a concern in any of the above areas?
1. Disconnect the Bank 2 H02S 1.
2. Jumper the H02S low (PCM side) signal circuit to a
ground.
3. Monitor the Bank 2 H02S 1 voltage on the Engine 1
Data List using a scan tool.
Does the scan tool indicate a voltage within the
specified range?

Go to Step 3

350-550 mV

1. Jumper the Bank 2 H02S 1 high and low (PCM side)

signal circuits to a ground.

2. Monitor the Bank 2 H02S 1 voltage using a

scan tool.
Does the scan tool indicate a voltage below the
specified value?

200mV

Important: Determine and correct the cause of the

contamination before replacing a sensor.
1. Inspect for the following conditions:

Fuel contamination. Refer to

Alcohol/Contaminants-in-Fuel Diagnosis.

Use of improper RTV sealant

Engine oil/coolant consumption
2. Replace the affected H02S. Refer to H02S
Replacement - Bank 1 and/or H02S Replacement Bank 2.
Is the action complete?

Go to Step 13

6-1432

Engine Controls - 5.7L

Engine

DTC P0153 H02S Slow Response Bank 2 Sensor 1 (cont'd)

Step

Action

Value(s)

Repair condition as necessary.

Is the action complete?

10

Repair the open Bank 2 H02S 1 low signal circuit or, the
grounded Bank 2 H02S 1 high signal circuit. Refer to
Wiring Repairs in Wiring Systems.
Is the action complete?

11

Repair the open Bank 2 H02S 1 high signal circuit or, the
faulty PCM connections. Refer to Wiring Repairs in Wiring
Systems.
Is the action complete?

12

Replace the Bank 2 H02S 1. Refer to H02S Replacement

- Bank 2.
Is the action complete?

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (DTC) option and
the Specific DTC option, then enter the DTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

13

14

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Yes

Go to Step 13

No

Go to Step 13

Go to Step 13

Go to Step 13

Go to Step 14

Go to Step 2

Go to the
applicable
DTC table

System OK

Engine

Engine Controls - 5.7L

6-1433

OTC P0154 H02S Circuit Insufficient Activity Bank 2 Sensor 1

\

!Hot With lgn 1 Energized !

-P-;;w;;; - - - - - - - - -

Distribution
ce1110

I
I

J7
J6

ENG SEN
Fuse 10
20 A

,Underhood
I Electrical
I Center 2

DJ

1.----- _______ . .
PNK 539
Fuse Block
Details
Cell 11

.,._ -

---..
'

' , PNK 539

'

,-------' '
r- -

I
I
I
I
I
I

+
Bank #1
Left Front H02S #1
Left Rear H02S #2

I
I
I

-B;k -; 2

HO;!S

Low

PCM
C1=RED
C2=BLU

Right Front

H02S

High

;n; #-; - - , Powertrain

Right Rear

H02S
Low

H02S

High

.. - - - - - . - ::-_ ::-_-: --= _:-_ =---::- --= _:-_ ::-_ - -: .:-_ =---=- _- 5

-----46

I Control
I Module
I (PCM)
.I

41 C2 ~

PPL 1666
TAN 1667

AA

PNK 539

BA

TAN 1671

PPL 1670

PNK 539

I
I
I
I

Bank #2
Right Front
Heated Oxygen
Sensor (H02S) #1

c
BLK 450

Bank #2
Right Rear
Heated Oxygen
Sensor (H02S) # 2

c
BLK 450

L - - - - - - - -------------------------~

' '-- ______ __..,.

BLK 450'
----------<Ill

Ground
Distribution
Cell 14

218509

Circuit Description
The PCM supplies a voltage of about 450 mV between
the H02S high and low signal circuits. The oxygen
sensor varies the voltage over a range from about
1,000 mV when the exhaust is rich, down through
about 10 mV when the exhaust is lean.
The PCM monitors and stores the heated oxygen
sensor (H02S) voltage information. The PCM
evaluates the H02S voltage samples in order to
determine the amount of time the H02S voltage was
out of range. The PCM compares the stored H02S
voltage samples taken within each sample period and
determines if majority of the samples are out of the
operating range.
The PCM monitors the H02S voltage and detects if
the voltage goes out of the bias range. If the PCM
does not detect the voltage went out of the bias range,
a OTC sets.

Conditions for Running the DTC

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0335, P0336, P0351-P0358, P1120, P1220,
P1221, P1258, not set.
The AIR, EGR, and the Catalyst system
diagnostics are not active.
The fuel system is operating in Closed Loop.
The ignition voltage is greater than 9.0 volts.
The engine run time is greater than 70 seconds.

Conditions for Setting the DTC

The H02S signal voltage is steady between
350 mV and 550 mV.
All conditions present for 60 seconds.

6-1434

Engine

Engine. Controls .. 5.7L

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.
Open Loop Fueling

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents any damage to the harness
connector terminals.
An oxygen supply inside the H02S is necessary
for proper operation. The H02S wires provides
the supply of oxygen. Inspect the H02S wires and
connections for breaks or contamination .. Refer
to H02S Wiring Repairs in Wiring Systems.
For an intermittent condition, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. The engine must be at the normal operating
temperature before performing this test. For any
test that requires probing the PCM or a component
harness connector, use the Connector Test
Adapter Kit J 35616-A. Using this kit prevents
damage to the harness connector terminals.

3. Using the Freeze Frame and/or Failure Records

data may aid in locating an intermittent condition.
If you can not duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the OTC set. The Fail Counter and Pass
Counter can also aid in determining how
many ignition cycles the diagnostic reported a
pass and/or a fail. Operate the vehicle within the
same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that the PCM
recorded. This will isolate when the OTC failed.
For an intermittent refer to Symptoms.
4. If the H02S voltage goes below 200 mV this
indicates that the H02S circuits and PCM are OK.
5. This step verifies whether the signal circuit from
the PCM is OK.
6. Disconnecting the PCM allows using the DMM
J 39200 in order to test continuity of the
circuits. This aids in locating an open or shorted
circuit.
7. Disconnecting the PCM allows using the DMM
J 39200 in order to test continuity of the
circuits. This aids in locating an open or shorted
circuit.

Engine

Engine Controls - 5.7L

6-1435

DTC POt54 H02S Circuit Insufficient Activity Bank 2 Sepsor 1

Step.

Action
Did you perform the Powertrain On-Board Diagnostic
(OBD) System Check?

Important: Inspect the H02S for being secure before

proceeding with this DTC. A sensor that is loose could
cause this DTC to set.
1. Install a scan tool.
2. Idle the engine at the n9rmal operating temperature.
3. Operate the engi11e above 1,200 RPM for two

minutes.
4. Mon'.itor the H02S voltage display on the Engine 1
Data List using the scan tool.
Does the.scan tool indicate the Bank 2 H02S 1 voltage
varying outside the specified range?
'
1. Turn ON the ignition leaving the engine OFF.
2. Review the Freeze Frame and/or Failure Records
data for this DTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Idle the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible'..Special operating conditions that need to be
met before the PCM will run this diagnostic, where
applicable, are listed in Conditions for Running
the lt>TC.
6. Select the Diagnostic Trouble Code (DTC) option and
the Specific DTC option; then enter the DTC number
usin\;l the scan tool..
D~es the scan tool indicate that this diagnostic failed this
ignition?

Value(s)

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Goto Step 3

Go to Step 4

Go to Step 4

Go to
Diagnostic Aids

Go to Step B

Go to Step 5

Go to Step 6

Go to Step 7

Go to Step 10

Go to Step 9

350:-550 mV

_,

1. Turri ON toe ignition leaving the engine OFF.

2. Disconnect the Bank 2 H02S 1.
3. Jumper the H02S high and low (PCM side) signal
circuits to a ground.
4. Monitor the Bank 2 H02S 1 voltage using a
scan tool.
Is the Bank 2 H02S 1 voltage below the specified value?

200mV

1. Remove the jumper wire.

2. Measure the voltage between the Bank 2 H02S 1
high signal circuit (PCM side) and the Bank 2
H02S 1 heater ground circuit using the
DMM J39200.
Does the Bank 2 H02S 1 voltage measure above the
specified value?

375mV

1.. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the continuity of the Bank 2 H02S 1 low circuit.
Refer fo Testing for Continuity in Wiring Systems.
4. If the Bank 2 H02S 1 low circuit measures over the
specified value, repair the open or the poor
connection as necessary. Refer to Wiring Repairs in
Wiring Systems.
Did you find and correct the Bank 2 H02S 1 condition?

Yes

2Q

6-1436

Engine Controls - 5.7L

Engine

DTC P0154 H02S Circuit Insufficient Activity Bank 2Sensor 1 (cont'd)

Step

10

11

12

13

14

Value(s).,

Action

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the continuity of the Bank 2 H02S 1 signal
circuit. Refer to Testing for Continuity in Wiring
Systems.
4. Repair the open or the poor connection if the Bank 2
H02S 1 signal circuit measures over the specified
value. Refer to Wiring Repairs in Wiring Systems.
Did you find and correct a Bank 2 H02S 1 signal circuit
condition?

'

1. Inspect for a poor Bank 2 H02S 1 low circuit terminal

connection at the PCM. Refer to lntermittents and
Poor Connections Diagnosis in Wiring Systems.
2. Replace the terminal if necessary. Refer to Connector
Repairs in Wiring Systems.
Did you find and correct the condition?

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (DTC) option and
the Specific DTC option, then enter the DTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 13

Go to Step 10

Go to Step 13

Go to Step 11

Go to Step 13

Go to Step 12

Go to Step 13

Go to Step 12

'

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

No

2n

1. Inspect for a poor Bank 2 H02S 1 signal or low

circuit terminal connection at the Bank 2 H02S 1
harness connector. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
2. Replace the terminal(s) if necessary. Refer to
Connector Repairs in Wiring Systems.
Did you find and correct the condition?

1. Inspect for a poor Bank 2 H02S 1 signal circuit

terminal connection at the PCM. Refer to lntermittents
and Poor Connections Diagnosis in Wiring Systems.
2. Replace the terminal if necessary. Refer to Connector
Repairs in Wiring Systems.
Did you find and correct the condition?
Replace the Bank 2 H02S 1. Refer to H02S Replacement
- Bank 2.
Is the action complete?

Yes

Go to Step 13

Go to Step 13

Go to Step 14

Go to Step 2

Go to the
applicable
DTC table

System OK

Engine Controls - 5.7L

Engine

6-1437

DTC P0155 H02S Heater Performance Bank 2 Sensor 1

!Hot With lgn 1 Energized !

.- -P-;;v; - - - - - - - - - ,I Underhood
I
I
I

J7

Distribution
ce1110

J6

Electrical

ENG SEN
Fuse 10
20 A

I Center 2
I ..

L------------..1
PNK .539

Fuse Block
Details
Cell11

.....

--~

'

' , PNK 539

' '

r-------'
1

.- - - -Ba-;:;k:;, 2-: - - - - - - - - - - - - - ; 11, ; #-; -

I
I
I
I
I
I
I
I

+
Bank #1
Left Front H02S #1
Left Rear H02S # 2

Right Froni

H02S
Low

L -

PCM
c1=RED
c2 = BLU

H02S
High
-

-----46

- , Powertrain

Right Rear

H02S
Low

H02S
High

:-_:-_-:_-:__:-_:-_-:_-::_:-_:-_- -::_:-_:-_:-_- -

I Control
I Module
I (P M)
.I

41 C2

C
>

PPL 1666

TAN 1667

AA

PNK 539

BA

TAN 1671

AA

PPL 1670

PNK 539

BA

r
I
1.
I
I
I

Bank #2
Right Front
. Heated Oxygen
Sensor (H02S) #1

BLK 450

Bank #2
Right Rear
Heated Oxygen
Sensor (H02S) # 2

c
BLK 450

L - - - - - - - -------------------------__,

'

BLK 450' '-- ______ __.,.

------------

Ground
Distribution
Cell 14

218509

Circuit Description
The PCM supplies a bias voltage (approximately
450 mV) on the Heated Oxygen Sensor (H02S) signal
high and low circuits. When you turn the ignition to
the ON position, battery voltage is supplied to
the.H02S heater. As the heater reaches the operating
temperature, the H02S voltage responds by
changing from a bias voltage range to the normal
operation. Typically, as the H02S reaches the
operating temperature, the H02S voltage goes from a
bias voltage to a voltage below 300 mV. Depending
on the exhaust gas content, it is possible for the HQ2S
voltage to go above 450 mV.
The PCM runs the heater test only on a cold start
(depends on the cumulative air flow) and only once an
ignition cycle. When you start the engine the PCM
monitors the H02S voltage. When the H02S voltage
goes above or below the bias range threshold, the
PCM determines how much time it took. If the

PCM detects that the process took too much time for
the H02S to eriter into normal operating range, a
OTC sets. The time the process takes the H02S to
reach operating temperature is based on the amount of
air that flows into the engine.

Conditions for Setting the OTC

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0335, P0336, P0351-P0358, P1258 not set.
The intake air temperature and the engine coolant
temperature are less than 50C (122F) and are
within 8C (14.5F) of each other at engine
start-up.
The ignition voltage is between 10.0 volts and
16.0 volts.
The AIR, EGR, and the Catalyst diagnostics are
not active.

6-1438

Engine

Engine Controls - 5.7L

Conditions for Setting the DTC

The H02S voltage remains between 300 mV and
700 mV for a predetermined amount of time (depends
on engine coolant temperature and air flow).

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp when the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Freeze Frame and/or the Failure
Records.
Open Loop Fueling.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagndstic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
.
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into tne PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents any damage to the harness
connector terminals.
Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help .determine how many miles
since the DTC set. The Fail Counter and Pass

Counter can also help getermtne.,how !fl~ny

ignition cycles the. diagnostic reported a pass
and/or a fail. Operate the. vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the OTC failed. For an
intermittent condition, refer to Symptoms.
The heater diagnostic will only run on a cold start
and run once per ignition cycle.
.
An oxygen supply inside the H02S ls necessary
for proper operation. The H02S wires provides
the supply of oxygen. Inspect the H02S wires and
connections for breaks or contamination. Refer
to H02S Wiring Repairs in Wiring Systems.
For an intermittent condition, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. The engine must be allowed to cool. The H02S
maybe at operating temperature and no drop
or rise in H02S voltage will occur. If the H02S
voltage stays between 300-700 mV indicates
the H02S heater is inoperative. For any test that
requires probing the PCM or a component
harness connector, use the Connector Test
Adapter Kit J 35616-A. Using this kit prevents
damage to the harness connector terminals.
3. An open H02S fuse causes multiple H02S DTCs
to set. Test all of the related circuits going to all
of the heated oxygen sensors for a short to
ground. If all of the wiring is OK, it may be
necessary to disconnect each H02S one at a time
to locate a shorted sensor.
4. This step ve.rifies whether the B+ supply is
available at the sensor.
5. This step verifies whether a ground is available at
the sensor.
6. This step test s whether the H02S heater element
is internally open.
7. Inspect the ignition feed circuits at the Underhood
Electrical Center for poor connections.
8. Test the ground circuits for an open if more ,then
one heater OTC sets.
'
''

DTC P0155 H02S Heater Performance Bank 2 Sensor 1

Step

Action
Did you perform the Powertrain On-Board Diagnostic
(OBD) System Check?
'

Value(s)

Yes

No

Go to Step2

Go to A
Powehrain On
Board Diagnostic
(OBD) System
Check

Important: Allow engine to cool tor about one halt hour

before proceeding.
1. Turn OFF the ignition.
2. Install a scan tool.
3. Turn ON the ignition leaving the engine OFF.
4. Monitor the H02S voltage display on the Engine 1
Data List of the scan tool.
Does the H02S voltage go from a bias voltage to above or
below the specified range?

300-700 mV

Go to
Diagnostic Aids

. Go to Step~

Engine

Engine Controls - 5.7L

6-1439

OTC P0155 H02S Heater Performance Bank 2 Sensor 1 (cont'd)

Step
3

Action

Inspect the fuse for H02S ignition feed.

Is the H02S fuse open?

Value{s)

'

Yes

No

Go to Step 11

Go to Step 4

Go to Step 5

Go to Step 7

Go to Step 6

Go to Step B

Go to Step 9

Go to Step 10

1. Raise the vehicle. Refer to Lifting and Jacking the

Vehicle in General Information.
2. Disconnect the H02S.

10

11

3. Probe the ignition feed circuit at the H02S electrical

connector (PCM side) using the test lamp J 34142-B
connected to a known good ground. Do not use the
H02S heater ground or the H02S low circuit.
Is the test lamp illuminated?
Connect the test lamp J 34142-B between the H02S
ignition feed and the H02S heater ground.
Is the test lamp illuminated?
Measure the resistance between the H02S ignition feed
and the H02S heater ground at the H02S pigtail using the
DMM J39200.
Is the H02S resistance within the specified range?
Repair the open H02S ignition feed circuit to the H02S.
Refer to Wiring Repairs in Wiring Systems.
Is the action complete?
Repair the open H02S heater ground circuit. Refer to
Wiring Repairs in Wiring Systems.
Is the action complete?

1. Inspect for a poor connection at the H02S harness

terminals. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
2. If you find a poor connection, replace the terminals.
Refer to Connector Repairs in Wiring Systems.
Did you find and correct the condition?
Replace the H02S. Refer to H02S Replacement - Bank 2.
Is the action complete?
Locate and repair the short to ground in the H02S ignition
feed circuit and replace the faulty fuse. Refer to Wiring
Repairs in Wiring Systems.
Is the action complete?

3.5-14.0Q

Go to Step 12

Go to Step 12

Go to Step 12

Go to Step 12

Go to Step 10

Go to Step 12

1. Select the Diagnostic Trouble Code (OTC} option and

12

13

the Clear OTC Information option using the scan tool.

2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific DTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle witl')in the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 13

Go to Step 2

Go to the
applicable
OTC table

System OK

6-1440

Engine

Engine Controls .. 5.7L,

DTC P0157 H02S Circuit Low Voltage Bank 2 Sensor 2

!Hot With lgn 1 Energized l

- - , Underhood

'" - P:;-wer
Distribution
ce1110

J7

I Electrical
I Center 2
I

ENG SEN
Fuse 10
20 A

.. ____________ .
J6

L.:1il

PNK 539
Fuse Block
Details

Cell11

...- ---. .....

' , PNK 539
.....

.....

r - - - - - - - '~ - - - - - - - - - - - - - - - - - - - - - - ~
~ -

-B;k -;2- -

I
I
I
I
I
I

+
Bank #1
Left Front H02S #1
Left Rear H02S #2

I H02S
1.

PCM

Right Front

C1 = RED

H02S
High

C2=BLU

;n; #-; - - , Powertrain

I Control

Right Rear

H02S
Low

H02S
High

IM d I

--------------~---------.!
46 --- -- --- ------ -- -- --- - --41
Low

-----

C2

O LI

(PCM)

PPL 1666

TAN 1667

PNK 539

TAN 1671
A

PPL 1670
B

PNK 539
D

T
c

Bank #2
Right Front
Heated Oxygen
Sensor (H02S) #1
L - - - - - - -

BLK 450

Bank #2
Right Rear
Heated Oxygen
Sensor (H02S) # 2

c
BLK 450

-._------------------'------_J
-

Ground
Distribution

Cell 14

218509

Circuit Description
The PCM supplies a voltage of about 450 mV between
the H02S high and low signal circuits. The oxygen
sensor varies the voltage over a range from about
1,000 mV when the exhaust is rich, down through
about 10 mV when the exhaust is lean.

The PCM monitors and stores the heated oxygen

sensor (H02S) voltage information. The PCM
evaluates the H02S voltage samples in order to
determine the amount of time the H02S voltage was
out of range. The PCM compares the stored H02S
voltage samples taken within each sample period and
determines if majority of the samples are out of the
operating range.
The PCM monitors the H02S voltage for being fixed
below a predetermined voltage. If the PCM detects the
voltage is below a predetermined voltage, a DTC sets.

Engine
Conditions for Running the OTC
Criteria 1

DTCs P0101, P0102, P0103, P0112, P0113,

P0117, P0118,P0121, P0122, P0123, P0125,
P0335, P0336, P0351-P0358, P1258 not set.
The engine coolant temperature is greater
than 48C (118F).
The fuel system is operating in Closed Loop.
The fuel trim learn is enabled.
The ignition voltage is greater than 9.0 volts. ,
The AIR, EGR, and Catalyst diagnostics are not
active.
The TP angle is between 3% and 20%.
OR
Criteria 2
DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122,P0123, P0125,
P0335, P0336, P0351-P0358, P1258 not set.
The ignition voltage is greater than 9.0 volts.
The AIR, EGR, and Catalyst diagnostics are not
active.
The Power Enrichment mode is enabled for
greater than 1.0 seconds.

Conditions for Setting the OTC

Criteria 1
The H02S signal voltage remains below 90 mV.
The Criteria 1 conditions are present for
80 seconds.
OR
Criteria 2
The H02S signal voltage remains below 420 mV.

The Criteria 2 conditions are present for

5.0 seconds during the Power Enrichment mode.

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Engine Controls - 5.7L

6-1441

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit prevents any damage to the harness
connector terminals.

The PCM sets this DTC when the vehicle runs out
of fuel.
Heated Oxygen Sensor (H02S) wire: Sensor
pigtail may be in contact with the exhaust manifold
or exhaust system.
An oxygen supply inside the H02S is necessary
for proper operation. This supply of oxygen is
provided through the H02S wires. All H02S wires
and connections should be inspected for breaks
or contamination. Refer to H02S Wiring Repairs in
Wiring Systems.
Test for an intermittent ground in the signal wire
between connector and sensor. Refer to
lntermittents and Poor Connections Diagnosis in
Wiring Systems.
Lean injector(s): Perform the Injector Balance
Test. Fuel Injector Balance Test.
Fuel contamination: Water near the in-tank fuel
pump inlet can be delivered to the injectors.
The water causes a lean exhaust and can set a
OTC. Refer to Alcohol/Contaminants-in-Fuel
Diagnosis.
Fuel pressure: System will be lean if fuel pressure
is low. Refer to Fuel System Diagnosis.
Exhaust leaks: An exhaust leak near the H02S
can cause a lean condition.
Vacuum or crankcase leaks can cause a lean
condition.
If the above are OK, the H02S may be at fault.
For an intermittent condition, refer to Symptoms.

61442

Engine Controls 5.7L

Engine

Test Description

Records data can help determine how many miles

since the OTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail: Operate .the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the OTC failed. For an
intermittent condition, refer to Symptoms.

The numbers below refer to the step numt,ers on the

diagnostic table;
2. If the H02S voltage is fixed well below 200 mV,
this indicates a short to battery ground or
chassis ground. If the voltage is fixed near or
above 200 mV, this indicates a short to a PCM
ground. When the H02S voltage is fixed near
200 mV, indicates the OTC set when the
fuel system was in a Power Enrichment mode of
operation.
Idle the engine at the normal operating
temperature before performing this test. For any
test that requires probing the PCM or a component
harness connector, use the. Connector Test
Adapter Kit J 35616-A. Using this.kit prevents
damage to the harness connector terminals.
3. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the OTC, the information
included in the Freeze Frame and/or Failure

4. Lower the exhaust system to gain sufficient

access to the H02S and/or the H02S connector if
necessary. Refer to Catalytic Converter
Replacement in Engine Exhaust. Grounding the
low side circuit of the H02S causes the H02S
voltage to display a bias voltage. If the voltage
stays near 0.0 volts, this indicates the low circuit 1s
open, or the high circuit is open or grounded.
5. Disconnecting the PCM allows using the DMM
J 39200 in order to test continuity of the
circuits . This aids in locating an open or shorted
circuit.

DTC P0157 H02S Circuit Low Voltage Bank 2 Sensor 2

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

1. Install the scan tool.

2. Idle the engine at the normal operating temperature.
3. Operate the vehicle within the Conditions for Running
the DTC as specified in the supporting text, if
applicable.
4. Monitor the H02S voltage display on the Engine 1
Data List using the scan tool.
Is the H02S voltage less than the specified value?
1. Turn ON the ignition leaving the engine OFF.
2. Review the Freeze Frame and/or Failure Records
data for this OTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame and/or Fai11,1re Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the DTC.
Does the scan tool indicate that this diagnostic failed this
ignition?
1. Disconnect the H02S.
2. Jumper the H02S low circuit on the PCM side to a
ground.
Is the H02S voltage within the specified range?

(
90mV

Go to Step 3

Go to Step 4

Go to Step 4

Go to
Diagnostic Aids

Go to
Diagnostic Aids

Go to Step 5

350-550 mV

Engine

Engine Controls - 5.7L 6-1443

DTC P0157 H02S Circuit Low Voltage Bank 2 Sensor 2 (cont'd)

Step

Action

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturers logo. Refer to PCM
Replacement/Programming.

Value(s)

Repair the H02S signal circuit. Refer to Wiring Repairs in

Wiring Systems.
Is the action complete?

No

Go to Step 6

Go to Step 7

3. Test the H02S signal circuit for a short to ground or

a short to the sensor ground circuit.
Is the H02S signal circuit shorted?

Yes

Go to Step 8

..

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

Go to Step 8

1. Select the Diagnostic .Trouble Code (OTC) option and

the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate, that this test ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 9

Go to Step 2

Go to the
applicable
OTC table

System OK

6~1444

Engine

Engine Controls - 5i7L

OTC P0158 H02S Circuit High Vdltage Bank 2 Sensor 2

...

!Hot \Mth lgn i ,Energized !

- Power
- -

Distribution

J7

ENG SEN
Fuse 10

J6

20 A

Cell 10

- , Underhood
I Electrical
: Center 2

L------------.l
PNK 539
Fuse Block
Details
Cell 11

'

' , PNK 539

' ,,

r - - - - - - . ;, . '-*:::--...:..__...;;___...:,._...:,.__--'-'--"---'-'-~-'---'---'--------'---'----'---.
I
~

Bank #1

I
I

I
I

I
I
I
I
I

Left Front H02S #1

Left Rear H02S #2

- - -B,;k-;2- - - - - - - - - - - - - - ;;;m;
Right Front
H02S
Low

1'102S
High

PCM
C1 = RED
c.2 = BLLl
.
,

#-; - - , Powe.rtrain

Right Rear
.

H02S
Low

I Control

, , IM d I
H02S I O U e
High {PCM)

------------------------.l
5 -----46 _, . ,
- 1 --'~"'--41 C2
PPL

1666
.. ,,,.,, .
PNK 539,

TAN 1667

AA

D, ,;

TAN 1671

AA

PPL 1670

B."

PNK 539

I
I

Bank #2
RightFront
Heated Oxygen
Sensor (H02S) #1

BLK 450

Bank #2
Right Rear
Heated Oxygen
Sensor (H02S) # 2

c,
BLK 450

L - - - - - - - ..,.__ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __1

' ' - ______ ~

BLK 450'
---------~

Ground
Distribution
Cell14

218509

Circuit Description
The PCM supplies a voltage of about 450 mV between
the H02S high and low signal circuits. The oxygen
sensor varies the voltage over a range from about
1,000 mV when the exhaust is rich, down through
about 10 mV when the exhaust is lean.

The PCM monitors and stores the heated oxygen

sensor (H02S) voltage information. The PCM
evaluates the H02S voltage samples in order to
determine the amount of time the H02S voltage was
out of range. The PCM compares the stored H02S
voltage samples taken within each sample period and
determines if majority of the samples are out of the
operating range.
The PCM monitors the H02S voltage for being fixed
above a predetermined voltage. If the PCM detects the
voltage is above a predetermined voltage, a DTC sets.

Engine

Engine Controls - 5.7L

6-1445

Conditions for Running the OTC

Diagnostic Aids

Criteria 1
DTCs P0101 , P0102, P0103, P0112, P0113,
P0117, P0118, P012l; P0122, P0123, P0125,
P0335, P0336, P0351-F>0358, P1258 not set.
The fuel system is operating in Closed Loop.
The fuel trim learn is enabled.
The ignition voltage is greater than 9.0 volts.
The AIR, EGA, and the Catalyst diagnostics are
not active.
OR

Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM; Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.
Inspect the H02S. electrical connections for
evidence of water intrusion. Water present in the
connector causes the B+ supply to the heater
to bleed over to the signal circuit.
Fuel pressure: The system goes rich if the
pressure is too high. The PCM compensates for
some increase. However, if the fuel pressure is too
high, a OTC may set. Refer to Fuel System
Diagnosis.
Rich injector(s): Perform the Injector Balance
Test. Refer to Fuel Injector Balance Test.
Leaking injector: Refer to Fuel System Diagnosis.
Evaporative emissions (EVAP). canister purge.
Inspect for fuel saturation. If full of fuel, inspect the
canister control and hoses. Refer to EVAP
Control System Operation Description.
MAF sensor: Disconnect the MAF sensor and see
if the rich condition is corrected. If so, inspect for
proper installation. If instafled OK, replace the
MAF sensor. If 'the MAF sensor is installed
backwards, the system goes rich. The plastic
portion of the sensor has arrows cast into
it indicating proper air flow direction. The arrows
must point towards the engine.
An oxygen supply inside the H02S is necessary
for proper operation. The H02S wires provides
t.he supply of oxygen. Inspect the H02S wires and
connections for breaks or contamination. Refer
to H()2S Wiring Repairs in Wiring Systems.
TP sensor: An intermittent TP sensor output
causes the system to go rich, due to a false
indication of the engine accelerating.
For an intermittent condition, refer to Symptoms.

Criteria 2
DTCs P0101, P0102, P6103, P0112;POt13,
P0117; P0118, P0121, P0122, P0123, P0125,
P0335, P0336, P0351-P0358, P1258 not set.
The ignition voltage is greater than 9.0 volts.
The AIR, EGR, and the Catalyst diagnostics are
not active.

The Deceleration Fuel Cut-off mode is enabled for

greater than 3.0 seconds.

Conditions for Setting the OTC

Criteria 1
The H02S signal voltage remains above 930 mV.
, The Criteria 1 conditions are present for
40 seconds.
OR
Criteria 2
The H02S signal voltage remains above 480 niV.
The Criteria 2 conditions are present for
5.0 seconds during Deceleration Fuel
Cut-off mode.

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC} clears when the
diagnostic runs and does not faif.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This OTC also sets during a deceleration fuel
cutsoff. Inspect items which could cause a
rich exhaust during a deceleration (leaking
injectors, stuck injectors etc.). Refer to Conditions
for Setting the. OTC.
The engine must be at.the normal operating
temperature before performing this test. For any
test that requires probing the PCM or a component
harness connector, use the Connector Test
Adapter Kit J 35616-A. Using this kit prevents
damage to the harness connector terminals.

5,.1445

Engine

EnSjine Controls - ~-7L.

3. Using the Freeze Frame and/or Failure:Records

data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the inforniation
included. in the Freeze Frame 'and/or Failure
Records data can: help determine how many miles
since the DTC set. 'f'hEHfail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
, and/or a fail.. O~rate the vehicle within the same
freeze frame'i:::onditions (RPM, load, vehicle
speed, temperature etc.).that you observed. This
will isolate.when.the DTC failed. For an
intermittent condition, refer to Symptoms.

4. If the voltage remains high, ,this indicates the.

signal circuit is shorted to a voltage. If the voltage
goes low, this indicates a rich condition.
5. This. step isolates, the.~ondition. If the voltage
remaif)S high, this indicates the signal circuit is not
shqrted .i~ Jhe t,eat~r! feeq, circu.it. . .

8. Review the system rnechani~tic;m. Test for a

short .between the H()2S. signal circuit and
any 'other wires powered by this fuse that run
togetner inside the harness:
.

OTC P0158 H02S Circuit High Voltage Bank 2 Sensor 2

(v~ue<s>;

Step

Yes

No

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
Go to Step

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Important: Inspect the front H02S voltage before

proceeding with this DTO. If the front H02S voltage is

fixeo below 3.00 .rnV, refer to DTC P0151 H02S Circuit
Lo~ Voltage Bank 2 Sensor 1.
1. Install the scan tool.
2. Start the ~ngirle .
.3 .. lncrea~ the engine speed to 1,200 RPM.
4. Monitor the H02S voltage display on the Engine 1
.Data List using the scan tool.,
Is the. tJ02$ voltage greater than. the specified value?

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to
Diagnostic Aids

Go toStepB

Go to Step 1

1. TurnON the ignitjon IE!a~jng the engine OFF.

2 .. Review the Freeze Fram'e and/or Failur~ Records
.
data for this [)JC and observe the parameters.
3. Turn OFF the ignitionJor 15 s.econds ..
4. Start the engine.
5. Or:,erate the vehige within the conditions. required for
. this diagnostic to run, and as close to the conditions
recorded in Freeze Frame and/or Failure Records as
possible. Special operating conditiqo.s that you need
to.meet before the PCM will q.m this diagnostic,
where applicable, are listed iri Conditions for Running
the DTC.

6. Select the Diagnostic Trouble Code (OTC) option and

the Specific OTC option, then enter the OTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?
'

; 5

1. Turn ON the ignition leavin'g t!1~,en~ine Off;.

2 .. Monitor the HQ2S voltage.
,
,
Is the 1-102~ Voltage. 'great~r tt,~n tile specified value?
Remove the H02S heater rose vvhile monitoring the H02S
voltage.
Does the voltage drop to withih the specified range when
.the power to tl;l.e heater is disconnecie,d?

930 n,v

350-550 mV

Engine Controls - 5.7L

Engine

6-1447

OTC P0158 H02S Circuit High Voltage Bank 2 Sensor 2 (cont'd)

Action

Step

Value(s)

Yes

No

Go to Step 10

.Go to Step B

Go to Step B

Go to Step 9

1. Reinstall the fuse.

2. Disconnect the H02S.

3. Jumper the H02S low circuit (PCM side) to a known

6

good ground.
4. Monitor the H02S voltage using the scan tool.
Does the scan tool indicate the H02S voltage within the
specified range?

350-550 mV

Important: Disconnecting the PCM may eliminate the

short to voltage if the signal circuit is shorted to another
C2 circuit.
1. Turn OFF the ignition.

10

2. Disconnect the PCM connector C2 located on the

same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Disconnect the H02S.
4. Turn ON the ignition.
5. Test for,a voltage on the H02S sensor signal
circuit at the PCM harness connector using the
DMM J39200
Is a voltage present?
Repair the short to voltage in the H02S signal circuit.
Refer to Wiring Repairs in Wiring Systems.
Is the action complete?
Important: Program the replacement PCM. Refer to PCM
Replacement/Programming.

Replace the PCM.

Is the action complete?
Replace the H02S. Refer to H02S Replacement - Bank 2.
Is the action complete?

Go to Step 11

Go to Step 11

Go to Step 11

1. Select the Diagnostic Trouble Code (OTC) option and

11

12

the Clear OTC Information option using the scan tool.

2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 12

Go to the
applicable
OTC table .

:.

Go to Step 2

System OK

6-1448

Engine Controls - 5.7L

Engine

OTC P0160 H02S Circuit Insufficient Activity Bank 2 Sensor 2

IHot With lgn 1 Energized. !

'" - P:;~ - - - - - - - - - , Underhood

I
I

Distribution
ee1110

J7
J6

I Electrical
I Center 2

ENG SEN
Fuse 10
20 A

ITT
L'.w

L------------.1
PNK 539
Fuse Block
Details
Cell 11

-4- - --,..,

'

' , PNK 539

' '

r - - - - - - - '- - = - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,
I

I
I
I

I
I
I
I

Bank #1
Left Front H02S #1
Left Rear H02S #2

'" - - -Ba-;;k-;2- - - - - - - - - - - - - - ;n; #-; - - , Powertrain

I
I
I

Right Front
H02S
Low

L -

PCM
c1 = RED
2 =BLU

H02S
High

Right Rear
H02S
Low

H02S
High

_:-::-_:-_-:- ::-_::-_-:_-_-::-_::-_:-_-:_:-_:-_- -:_:-_::-_:-_- -

I Control
I Module
I (PCM}
.I

41 C2 ~

46
PPL 1666

TAN 1667

PNK 539

AA

TAN 1671

AA

PPL 1670

PNK 539

BA

Bank #2
Right Front
Heated Oxygen
Sensor (H02S) # 1

I
I
I
I

BLK 450

Bank #2
Right Rear
Heated Oxygen
Sensor (H02S) # 2

(
BLK 450

L - - - - - - - --------------------------"

' '--- ______ __,..

BLK 450'
-

-"111

.Ground
Distribution
Cell 14

218509

Circuit Description
The PCM supplies a voltage of about 450 mV between
the H02S high and low signal circuits. The oxygen
sensor varies the voltage over a range from about
1,000 mV when the exhaust is rich, down through
about 10 mV when the exhaust is lean.
The PCM monitors and stores the heated oxygen
sensor (H02S) voltage information. The PCM
evaluates the H02S voltage samples in order to
determine the amount of time the H02S voltage was
out of range. The PCM compares the stored H02S
voltage samples taken within each sample period and
determines if majority of the samples are out of the
operating range.
The PCM monitors the H02S voltage and detects if
the voltage goes out of the bias range. If the PCM
does not detect the voltage went out of the bias range,
a DTC sets.

Conditions for Running the DTC

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0335, P0336, P0351-P0358, P1120, P1220,
P1221, P1258, not set.
The engine run time is greater than 70 seconds.
The fuel system operating in Closed Loop.
System voltage is greater than 9.0 volts.
The AIR, EGA, and the Catalyst diagnostics are
not active.
The engine coolant temperature is greater
than 48C (118F).

Conditions for Setting the DTC

The H02S signal voltage is steady
between 409 mV and 489 mV.
All conditions present for 2 minutes and
30 seconds.

Engine
Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator

Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Important:

Remove any debris from the PCM connector

surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.
An oxygen supply inside the H02S is necessary
for proper operation. This supply of oxygen is
provided through the H02S wires. All H02S wires
and connections should be inspected for breaks
or contamination. Refer to H02S Wiring Repairs in
Wiring Systems.
For an intermittent condition, refer to Symptoms.

Engine Controls - 5.7L

6-1449

Test Description
The numbers below refer to the step numbers on the
diagnostic tabl.e.
2. Idle the engine at the normal operating
temperature before performing this test. For any
test that requires probing the PCM or a component
harness connector, use the ConnectorTest
Adapter Kit J 35616-A. Using this kit prevents
damage to the harness connector terminals.
3. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the OTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the DTC failed. For an
intermittent condition, refer to Symptoms.

4. Lower the exhaust system to gain sufficient

access to the H02S and/or the H02S connector if
necessary. Refer to Catalytic Converter
Replacement in Engine Exhaust. If the scan tool
indicates the H02S voltage goes below
200 mV, indicates the H02S circuits and the PCM
are OK.

5. This step verifies whether the signal circuit from

the PCM is OK.
6. Disconnecting the PCM allows using the DMM
J 39200 in order to test continuity of the
circuits. This alds in locating an open or shorted
circuit.
7. Disconnecting the PCM allows using the DMM
J 39200 in order to test continuity of the
circuits. This aids in. locating an open or shorted
circuit.

6-1450

Engine

Engine Controls - 5.7L

DTC P0160 H02S Circuit Insufficient Activity Bank 2 Sensor 2

Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Important: Before proceeding with this DTC, inspect the

H02S for being secure. A sensor that is loose could cause
this OTC to set.
1. Install the scan tool.
2. Idle the. engine at the normal operating temperature.
3. Operate the engine above 1,200 RPM for 2 minutes.
4. Monitor the H02S voltage display on the Engine 1
Data List using the scan tool.
Does the scan tool indicate the Bank 2 H02S 2 voltage
varying outside the specified range?

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this DTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Start the engine.
5. Operate the vehicle within the cond.itions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame and/or Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.
6. Select the Diagnostic Trouble Code (DTC) option and
the Specific DTC option, then enter the DTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

Value(s)

No

Go to Step2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Step 4

Go to Step 4

Go to
Diagnostic Aids

Go to Step 8

Go to Step 5

Go to Step 6

Go to Step 7

Go to Step 13

Go to Step 9

409-489 mV

1. Turn ON the ignition leaving the engine OFF.

2. Disconnect the Bank 2 H02S 2.
3. Jumper the H02S high and the H02S low signal
circuits on the PCM side to a ground.
4. Monitor the Bank 2 H02S 2 voltage using the
scan tool.
Is the Bank 2 H02S 2 voltage below the specified value?

200mV

1. Remove the jumper wire.

2. Measure the voltage between the Bank 2 H02S 2
high signal circuit on the PCM side and the Bank 2
H02S 2 heater ground circuit using the
DMM J39200.
Does the Bank 2 H02S 2 voltage measure above the
specified value?

375mV

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturers logo. Refer to PCM
Replacement/Programming.
3. Test the continuity of the Bank 2 H02S 2 low circuit.
Refer to Testing for Continuity in Wiring Systems.
4. Repair the open or the poor connection as necessary
if the Bank 2 H02S 2 low circuit measures over the
specified value. Refer to Wiring Repairs in Wiring
Systems.
Did you find and correct the Bank 2 H02S 2 low circuit
condition?

Yes

2Q

Engine

Engine Controls - 5.7L

6-1451

DTC P0160 H02S Circuit Insufficient Activity Bank 2 Sensor 2 (cont'd)

Step

Action

Value(s)

Yes

No

Go to Step 13

Go to Step 10

Go to Step 13

Go to Step 11

Go to Step 13

Go to Step 12

Go to Step 13

Go to Step 12

1. Turn OFF the ignition.

)
7

2. Disconnect the PCM connector C2 located on the

same side as the manufacturers logo. Refer to PCM
Replacement/Programming.
3. Test the continuity of the Bank 2 H02S 2 signal
circuit. Refer to Testing for Continuity in Wiring
Systems.
4. Repair the open or the poor connection if the Bank 2
H02S 2 signal circuit measures over the specified
value. Refer to Wiring Repairs in Wiring Systems.
Did you find and correct the Bank 2 H02S 2 signal circuit
condition?

2n

1. Test for a poor Bank 2 H02S 2 signal or low circuit

terminal connection at the Bank 2 H02S 2 harness

connector. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
2. If you find a poor connection, repair the condition as
necessary. Refer to Connector Repairs in Wiring
Systems.
Did you find and correct the condition?

1. Test for a poor PCM terminal connection at the

9

Bank 2 H02S 2 low circuit. Refer to lntermittents and

Poor Connections Diagnosis in Wiring Systems.
2. If you find a poor connection, repair the condition as
necessary. Refer to Connector Repairs in Wiring
Systems.
Did you find and correct the condition?

1. Test for a poor Bank 2 H02S 2 signal circuit terminal

I

10

11

12

connection at the PCM. Refer to lntermittents and

Poor Connections Diagnosis in Wiring Systems.
2. If you find a poor connection, repair the condition as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and correct the condition?
Replace the Bank 2 H02S 2. Refer to H02S
Replacement - Bank 2.
Is the action complete?
Important: Program the replacement PCM. Refer to PCM
Replacement/Programming.
Replace the PCM.
Is the action complete?

Go to Step 13

Go to Step 13

1. Select the Diagnostic Trouble Code (OTC) option and

13

14

\
)

the Clear DTC .Information option using:the scan tool.

2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
_4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
'.
using the scan tool.
Does the scan tool display any DTCs thatyou have not
diagnosed?

Go to Step 14

Go to Step 2

Go to the
applicable
DTC table

System OK

6-1452

Engine Controls - 5.7L

Engine

DTC P0161 H02S Heater Performance Bank 2 Sensor 2

!Hot With lgn 1 Energized !

r - P;wer

Distribution
ce1110

J7

J6

ENG SEN
Fuse 10
20 A

Underhood
I Electrical
1Center 2
1

L------------..1
PNK 539
Fuse Block
Details
Cell 11

.,._ -

--,,_

'

' , PNK 539

' '

r - - - - - - - '- - = - - - - - - - - - - - - - - - - - - - - - - - - - ~

- - -B;;k-;2- - - - - - - - - - - - - - ;n; #-; - - , Powertrain

PCM

Right Front

I
I
I
I
I
I

H02S

H02S

Low

High

------- -

c1 - RED

c2;::, BLU

H02S

H02S

Low

High

-------------------

46

Right Rear

-------

I Control
I Mod I
I
Ue
(PCM)
.I

41 C2 ~

PPL 1666

'f

TAN 1667

Bank #1
Left Front H02S #1
Left Rear H02S #2

PNK 539

BA

TAN 1671

PPL 1670

PNK 539

Bank #2
Right Front
Heated Oxygen
Sensor {H02S) #1
L - - - - - - -

BLK 450

Bank #2
Right Rear
Heated Oxygen
Sensor (H02S) # 2

BLK 450

-------------------------......1
'

BLK 450' '-- ______ _,,.

-

_,,.

Grouno
Distribution
Cell 14

218509

Circuit Description
The PCM supplies a bias voltage (approximately
450 mV) on the Heated Oxygen Sensor (H02S) signal
high and low circuits. When you turn the ignition to
the ON position, battery voltage is supplied to
the H02S heater. As the heater reaches the operating
temperature, the H02S voltage responds by
changing from a bias voltage range to the normal
operation. Typically, as the H02S reaches the
operating temperature, the H02S voltage goes from a
bias voltage to a voltage below 300 mV. Depending
on the exhaust gas content, it is possible for the H02S
voltage to go above 450 mV.
The PCM runs the heater test only on a cold start
(depends on the cumulative air flow) and only once an
ignition cycle. When you start the engine the PCM
monitors the H02S voltage. When the H02S voltage
goes above or below the bias range threshold, the
PCM determines how much time it took. If the

PCM detects that the process took too much time for
the H02S to enter into normal operating range, a
DTC sets. The time the process takes the H02S to
reach operating temperature is based on the amount of
air that flows into the engine.

Conditions for Running the OTC

DTCs P0101, P0102, P0103, P0112, P0113,
P0117, P0118, P0121, P0122, P0123, P0125,
P0335, P0336, P0351-P0358, P1258 not set.
The intake air temperature and the engine coolant
temperature are less than 50C (122F) and are
within 8C (14.5F) of each other at engine
start-up.
The ignition voltage is between 10.0 volts and
16.0 volts.
The engine air flow is less than 30 g/s.
The AIR, EGA, and the Catalyst diagnostics are
not active.

Engine
Conditions for Setting the OTC

The H02S voltage remains between 300 mV and

700 mV for a predetermined amount of time (depends
on engine coolant temperature and air flow).

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
.Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector

terminals.
Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the OTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the OTC failed.

Engine Controls - 5.7L

6-1453

The heater diagnostic will only run on a cold start

and run once per ignition cycle.
An oxygen supply inside the H02S is necessary
for proper operation. The H02S wires provides
the supply of oxygen. Inspect the H02S wires and
connections for breaks or contamination. Refer
to H02S Wiring Repairs in Wiring Systems.
For an intermittent condition, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. The engine must be allowed to cool, as the H02S
may be at operating temperature and no drop or
rise in H02S voltage would occur. If the H02S
voltage stays between 300-700 mV indicates the
H02S heater is inoperative. For any test that
requires probing the PCM or a component harness
connector, use the Connector Test Adapter Kit
J 35616-A. Using this kit prevents damage to the
harness connector terminals.
3. If more than one H02S heater OTC is set, this is
a good indication that the H02S fuse is open.
Test all the related circuits going to all of the
heated oxygen sensors for a short to ground. If all
of the wiring is OK, it may be necessary to
disconnect each H02S one at a time to locate a
shorted sensor.
4. Lower the exhaust system to gain sufficient
access to the H02S and/or the H02S connector if
necessary. Refer to Catalytic Converter
Replacement in Engine Exhaust. This step verifies
whether the B+ supply is available at the sensor.
5. This step verifies whether a ground is available at
the sensor.
6. This step tests whether the H02S heater element
is internally open.
7. Inspect the ignition feed circuits at the Underhood
Electrical Center for poor connections.
8. Test the ground circuits for an open if more then
one heater OTC sets.

6-1454

Engine Controls - S.7L

Engine

OTC P0161 H02S Heater Performance Bank 2 Sensor 2

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagn9stic
(OBD) System
Check

Go to
Diagnostic Aids

Go to Step 3

Go to Step 11

Go to Step 4

Go to Step 5

Go to Step 7

Go to Step 6

Go to Step 8

Go to Step 9

Go to Step 10

Did you perform the Powertrain On-Board Diagnostic

(080) System Check?

Important: If you have been operating the engine, allow

the engine to cool for about one half hour before
proceeding.
1. Turn OFF the ignition.
2. Install the scan tool.
3. Turn ON the ignition leaving the engine OFF.
4. Monitor the H02S voltage display on the Engine 1
Data List of the scan tool.
Does the H02S voltage go from a bias voltage to above or
below the specified values?

300-700 mV

Inspect the fuse for the H02S ignition feed.

Is the H02S fuse open?

1. Raise the vehicle. Refer to Lifting and Jacking the

Vehicle in General Information.
2. Disconnect the H02S electrical connector.
3. Using the test lamp J 34142-8 connected to a
ground, probe ignition feed circuit at H02S electrical
connector on the PCM side. Use a known good
ground. Do not use the H02S heater ground or the
H02S low.
Is the test lamp illuminated?

Connect the test lamp J 34142-8 between the H02S

ignition feed and the H02S heater ground.
Is the test lamp illuminated?

Measure the resistance between the H02S ignition feed

and the H02S heater ground at the H02S pigtail using the
DMM J39200.
Is the H02S resistance within the specified values?

Repair the open in the H02S ignition feed circuit to the

H02S. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Repair the open in the H02S heater ground circuit. Refer

to Wiring Repairs in Wiring Systems.
Is the action complete?

1. Inspect for a poor connection at the H02S harness

terminals. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
2. If you find a poor connection repair the condition as
necessary. Refer to Connector Repairs in Wiring
Systems.
Did you find and correct the condition?

Replace the H02S. Refer to H02S Replacement - Bank 2.

Is the action complete?

10

3.5-14.on

Go to Step 12

Go to Step 12

Go to Step 12
Go to Step 12

Go to. Step 10

1. Repair the short to ground in the H02S ignition feed

11

circuit. Refer to Wiring Repairs in Wiring Systems.

2. Replace the faulty fuse.
Is the action complete?

Go to Step 12

Engine

Engine Controls - 5.7L

6-1455

DTC P0161 H02S Heater Performance Bank 2 Sensor 2 (cont'd)

Step

Action

12

1. Select the Diag[lostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test. ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

13

Value(s)

Yes

No

Go to Step 13

Go to Step 2

Go to the
applicable
OTC table

System OK

6-1456

Engine Controls - 5.7L

Engine

DTC P0171 Fuel Trim System Lean Bank 1

Circuit Description
The PCM controls a Closed Loop air/fuel metering
system in order to provide the best possible
combination of driveability, fuel economy, and emission
control. The PCM monitors the heated oxygen
sensor signal voltage and adjusts the fuel delivery
based on the signal voltage while in Closed Loop. A
change made to the fuel delivery changes the
Long and Short Term Fuel Trim values. The Short
Term Fuel Trim values change rapidly in response to
the H02S signal voltages. These changes fine
tune the engine fueling. The Long Term Fuel Trim
values change in response to trends in Short
Term Fuel Trim. The Long Term Fuel Trim makes
coarse adjustments to fueling in order to re-center and
restore control to Short Term Fuel Trim. You can
use a scan tool in order to monitor the Short and Long
Term Fuel Trim. The ideal fuel trim values are
around 0%. A positive Fuel Trim value indicates that
the PCM is adding fuel in order to compensate for
a lean condition. A negative Fuel Trim value indicates
that the PCM is reducing the amount of fuel in
order to compensate for a rich condition. If the PCM
detects an excessively Rich or Lean condition,
the PCM sets a DTC. The long term fuel trim
diagnostic parameter is an average of several of the
long term speed load learn cells which the PCM
selects based on the engine speed and the
engine load.

Conditions for Running the OTC

DTCs P0101, P0102, P0103, P0107, P0108,
P0112, P0113, P0117, P0118, P0121, P0122,
P0123, P0125, P0300, P0335, P0336,
P0351-P0358, P0401, P0404, P0405, P0410,
P0412, P0418, P0443, P0500, P0502, P0503,
P1111, P1112, P1258, P1404, P1415,
P1416 not set.
The engine coolant temperature is between 50C
(122F) and 115C (239F).
The barometric pressure is greater than 74 kPa.
The mass air flow is between 5.0 g/s and 90 g/s.
The manifold absolute pressure is between 26 kPa
and 90 kPa.
The intake air temperature is between
-20C (-4F) and 90C (194F).
The engine speed is between 400 RPM and
3,000 RPM.
The TP sensor angle is less than 90%.
The vehicle speed is less than 137 km/h (85 mph).
The fuel level is greater than 10%.

Conditions for Setting the OTC

The average Long rerm Fuel Trim cell values are
above a predetermined threshold.
All the above co11ditions are present for 6 seconds.

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive ignition
cycle that the diagnostic runs and fails, if the
diagnostic fails under the same conditions (load,
RPM, temperature, etc.) as the previous
ignition cycle that the test ran and failed.
The first time the diagnostic fails, the PCM
records the operating conditions in Failure
Records.
The second consecutive ignition cycle that this
diagnostic fails [under the same conditions
(load, RPM, temperature, etc.) as the previous
ignition cycle that the test ran and failed], the PCM
stores this information in Freeze Frame. The
PCM copies any data previously stored in Freeze
Frame and copies the data into the Failure
Records. The PCM then overwrites the Freeze
Frame. The only exception to this is if a Misfire
DTC was already recorded in Freeze Frame.
In this case, the Misfire data stays in Freeze
Frame and the PCM updates the Fuel Trim data
in the Failure Records.

Conditions for Clearing the MIL/OTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail within the same conditions
that the DTC last failed.
Important: If the last failure was during a non-typical
driving condition, the MIL may remain ON longer
than the three ignition cycles. Review the Freeze
Frame/Failure Records for the last failure conditions.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
A last test failed (Current DTC) clears when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
This DTC sets if the engine runs out of fuel.
A fuel delivery malfunction causes this DTC to
set. Thoroughly inspect all items that cause a lean
condition.
For an intermittent condition, refer to Symptoms.

Engine Controls - 5.7L

Engine

6-1457

ignition cycles the diagnostic reported a pass

and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the DTC failed. For an
intermittent condition, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step determines whether the fault is present.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.

4. If DTC 174 is also set indicates both banks of the

engine are operating lean. Inspect the items that
would cause both banks to operate lean.

3. Using the Freeze Frame and/or Failure Records

data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many

5. A vacuum leak causes DTCs P0171 and P0174 to

set at the same time. Inspect all areas of the
engine for a vacuum leak. Also inspect the PCV
valve for being the correct one for this application.
Make sure the engine oil fill cap is in place and
that it is tight. Ensure that the .engine oil dip stick is
fully seated.

DTC P0171 Fuel Trim System Lean Bank 1

Action

Step

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

Important: If any DTCs are set, except P0171 and P0174,

refer to those DTCs before proceeding with this diagnostic.
1. Install the scan tool.
2. Idle the engine at the normal operating temperature.
3. Fuel system in Closed Loop.
4. Monitor the LT FT Bn 1 display on the Fuel. Trim Data
List using the scan tool.
Is the LT FT less than the specified value indicated?

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Step 4

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 6

23% LT

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this OTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.

4. Start the engine.

5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame and/or Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.
6. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?
Is OTC P0174 also set?

6-1458

Engine. Controls - 5.7L

Engine

DTC P0171 Fuel Trim System Lean Bank 1 (cont'd)

Step

Action

Value(s)

Yes

No

Visually/physically inspect the following items:

\.

Vacuum hoses for splits, kinks, and proper

corinections, i::tefer toEmission Hose Routing
Diagram.
Crankcase ventilation valve and/or system for leaks.
Refer to Ctankcas(? Ventilation System Description.

Contaminated fuel. Refer to '

Alcohol/Contaminants-in-Fuel Diagnosis.

PCM and sensor grounds are clean, tight and in the

proper locations.
Air induction system after MAF sensor for
vacuum leaks.
Engine mechanical failure. Refer to Base Engine
Misfire Diagnosis in Engine Mechanical 5. 7L.
Was a concern found in any of the above areas?

Go to Step 7

Go to Fuel
System
Diagnosis

Go to Step 7

Refer to Fuel
System
Diagnosis

Go to Step B

Go to Step 9

Go to Step 2

Go to the
applicable
OTC table

.System OK

Visually/physically inspect th.e following items:

Bank 1 exhaust leaks, missing or loose exhaust
hardware.

Bank 1 H02S 1 is installed securely and the electrical

connector not contacting exhaust system or
ignition wires.

Engine mechanical failure. Refer to Base Engine

Misfire Diagnosis in Engine Mechanical 5. 7L.
Vacuum leaks that will ohly affect bank 1, such as the
intake manifold, the injector O rings, etc.
Was a concern found in any of the above areas?
7

Repair or replace any faulty items found.

Is the action complete?

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (OTC) option and

8

the Specific OTC option, then enter the OTC number

using the scan tool.

4. Op~rate the vehicle within the Conditions for Running

the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Engine

.Engine Controls - '5.7L 6~1459

OTC P0172 Fuel Trim System Rich Bank 1

Circuit Description

Conditions for Setting the OTC

'

The PCM controls a Close~ Lc>0p a,ir/fuel metering

system in order to. provi,de the .best possit,le , .
combination of driveability, fueteconomy, and emission
control. The PC_M monitors the heated oxygen
sensor signal voltage and adjusts the fuel .delivery
based on the signal voltage while in Closed Loop. A
change made to the fuel delivery cha~es the
Long and ShortTerm fuel Trim values. The Short
Term Fuel Trim values change rapidly in,response to
the H02S signal voltages. These changes'fine1
tune the engine fueling, The LOAg Term Fuel Trim
values change in response to trends in :Short
Term Fuel Trim. The Long Term Fuel Trim makes. . . . .
coarse adjustme~ts to fueling in ~rd~r fo. re~~n_t~r :.a_nd.' '.
restore control to Short Term Fuel Trim . Y~ucan
use a scan tool ir1 order to monitorthe Short and t.ongT erm Fuel Trim. The ideal fuel trim values are
'around 0%. A positive Fuel Trim value indicates that
,the PCM is adding fuel in order to compensate for
a lean condition. A negative Fuel lirim value indicates
.that the PCM is reducing the amount oHueHn

order to compensate for a rich condition. If the PCM .

detects an excessively Rich or Lean condition,
the PCM sets a OTC. The long term fuel trim
diagnostic parameter is an average of seve,ral of the
long term speed load learn cells which the PCM
selects based on the engine speed and the
.engine load.

Conditions for Running the DTC

DTCs P0101, P0102, P0103, P0107, Pofoa,
P0112, P0113, P0117, P0118, ,P0121, P0122,
P0123, P0125, P0300, P0335, P0336,
P0351-P0358, P0401, P0404, P0405, P0410, .
P0412, P041'8, P0443, P0500, P0502, P0503,
P1111, P1112, P1258, P1404, P1415,
P1416 not set.
The engine c.oolant temperature is between 50C
(122F) and 115C (239F}.
The barometric pressure is greater than 74 kPa.
The mass air, flow is between 5.0 g/s and 90 g/s.
The manifold absolute pressure is between 26 kPa
and 90 kPa.
The intake air temperature is between
-20C {-4F) and 90C (194F).
The engine speed is between 400 RPM and
. 3,000 RPM.
..
:
The TP sensor angle is less tl'iah 90%.
The vehicle speed is less than 137 km/h (85 mph).

\
)

,'

'

The average Long Term Fuel Trim cell values are

. below a predetermined threshold.
the above .conditions are present for
'' 49 seconds.

~, All
..

Action Taken When the OTC Sets

' The PCM illuminates the Malfunction Indicator
Eamp (MIL} on the second conseciutive ignition
cycle that the diagnostic runs and fails, if the
diagnostic fails under the same conditions (load,
RPM, temperature, etc;) as the previous
ignition cycle that the test ran and failed;
l"he first time the diagnostic fails, the PCM
records the operating conditions in Failure
.Recqrds.
.,The second consecutive ignition cycle t~at this
diagnostic fails [under the same conditions
(load, RPM, temperature, etc.) as the previous
ignition cycle that the test ran and failed], the PCM
stores this information in Freeze Frame. The
PCM copies any data previously stored in Freeze
Frame and copies the data into the Failure
Records. The PCM then. overwrites the Freeze
Frame. The only exception to this. is if a Misfire
titC was already recorded in Freeze Frame.
In this case, the Misfire data stays in Freeze
Frame and the PCM updates the Fuel Trim data
in the Failure Records.

'c6nditions for Clearing the Mll/DTC

' The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
1runs and does not fail within the same conditions
that the DTC last failed.
Important: If the last failure was during a non~typical
, driving condition, the MIL may remain ON longer
than the three ignition cycles. Review the Freeze
Fra:'me/Failure Records. forthe last failure conditions.
, A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
A last test failed (Current OTC) clears When the
diagnostic runs.and does not fail.
Use a scan tool in order to clear the MIUOTC.

. Diagnostic Aids
For an intermittent condition, refer to Symptoms.

61460

Engine Controls -.5.7L

Engine

Test Description

speed, temperatt,1re etc.) that you observed. This

will isolate when the DTC failed. For an
intermittent condition, refer to Symptoms.

The numbers below refer to the step r,umbers on the

diagnostic table.
2. This step determines whether the fault .is present.
3. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine. how many miles
since the OTC set. The. Fail Counter and Pass
Counter.can also help determine how many
ignition cycles the di~gnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle.

4. If DTC 1?5 is also set, then both banks are

operating rich. lnspectitemsthat would cause both
banks to operate rich.

5. Excessive fuel. in ttle.oH will cause DTCs P0172

and P0175 to set at the,same time. Remove .
the PCV valve from the .intake manifold and plug
with a suitable stopper. Also disconnect the
fresh air .pipe from the rocker cover and plug with
a suitable stopper. If the long term and short
term fuel trim .values increase;, indicates there is
fuel in the oil.

DTC P0172 Fuel Trim Syste{ll Rich Bank 1

Step

Action

Value(s)

Did you perform the Powertrain On,Board Diagnostic

(OBD) System Check?
1

Yes

No

Go to Step 2

Go to A
Power:train On
Board Diagnostic
(OBD) System
Check

,.

.
....

Important: It any DTCs are set, except P0172 and P0175,

refer to those DTCs before proceeding with this diagnostic.
1. Install the scan tool.
2. ldl~ the engioe at the normal operating temperature.
3. Fuel system in Closed Loop.
4. Monitor the LT FT 8111 display on the Fuel Trim Data
List using the sc.an tool.
Is th.e LT FT greater than the specified. value in.9icated?

-13% LT
.

Go to Step 3

Go to Step 4

... ,

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data tor this OTC and observe the parameters.
3. Turn OFF the ignition tor 15 seconds.
4. 1Start the engine.
5. Operate the vehicle within the conditions required tor
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame and/or Failure Re.cords as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions tor Running
the OTC.
6. Select the Diagnostic Trouble Code (OTC) option and
the Specific DTC option, then enter the OTC number
using the scan tool.
Does the scan tool indicate that this diagnostic tailed this
ignition?

Is OTC P0175 also set?

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 6

Engine Controls - 5.7L

Engine

6-1461

DTC P0172 Fuel Trim System Rieb Bank 1 (cont'd)

Step

Action

Visually/physically inspect the following items:

Collapsed air intake duct.
The air filter element for being restricted. Refer to Air
Cleaner Element Replacement.
MAF .sensor for being installed in the proper direction
and for foreign objects blocking the inlet screen. Refer
to MAF Sensor Replacetnent.
For fuel in the pressure regulator line. Refer to Fuel
System Diagnosis.
Inspect fpr the .incorrect MAP/BARO display. Compare
to another vehic.le.
For excessive fuel in the crankcase. Change oil as
necessary.
Was a concern found in any of the above areas?

Important: When the fuel system test is finished, return to

this table.
Inspect the Bank 1 injectors for leaking, refer to Fuel
System Diagnosis.
Are any injectors leaking?

Repair or replace any faulty items found.

Is the action complete?

Replace the. faulty H02S. Refer to H02S R~placement Bank 1.

Is the action complete?

Value(s)

Yes

No

Go to Step 7

Go to Fuel
System
Diagnosis

Go to Step 7

Go to Step 8

Go to Step 9

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.

10

)
/

3. Select the Diagnostic Trouble Code (DTC) option and

the Specific OTC option, then enter the DTC number
using the scan tool.
4. Operate the vehicle within the Co.nditions for Running
the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.

Does the scan tool display any DTCs that you nave not
diagnosed?

Go to Step 9

";

Go to Step 10

Go to Step 2

Go to the
applicable
DTC table

System OK

61462

Engine Controls - 5.7L

Engine

DTC P0174 Fuel Trim System Lean Bank 2

Circuit Description
The PCM controls a Closed Loop air/fuel metering
system in order to provide the best possible
combination of driveability, fuel economy, and emission
control. The PCM monitors the heated oxygen
sensor signal voltage and adjusts the fuel delivery
.based on the signal voltage while in Closed Loop. A
change made to the fuel delivery changes the
Long and Short Term Fuel Trim values. The Short
Term Fuel Trim values change rapidly in response to
the H02S signal voltages. These changes fine
tune the engine fueling. The Long Term Fuel Trim
values change in response to trends in Short
Term Fuel Trim. The Long Term Fuel Trim makes
coarse adjustments to fueling in order to re-center and
restore control to Short Term Fuel Trim. You can
use a scan tool in order to monitor the Short and Long
Term Fuel Trim. The ideal fuel trim values are
around 0%. A positive Fuel Trim value indicates that
the PCM is adding fuel in order to compensate for
a lean condition. A negative Fuel Trim value indicates
that the PCM is reducing the amount of fuel in
order to compensate for a rich condition. If the PCM
detects an excessively Rich or Lean condition;
the PCM sets a OTC. The long term fuel trim
diagnostic parameter is an average of several of the
long term speed load learn cells which the PCM
selects based on the engine speed and the
engine load.

Conditions for Running the DTC

DTCs P0101, P0102, P0103, P0107, P0108,
P0112, P0113, P0117, P0118, P0121, P0122,
P0123, P0125, P0300, P0335, P0336,
P0351-P0358, P0401, P0404, P0405, P0410,
P0412, P0418, P0443, P0500, P0502, P0503,
P1111, P1112, P1258, P1404, P1415,
P1416 not set.
The engine coolant temperature is between 50C
(122F) and 115C (239F).
The barometric pressure is greater than 74 kPa.
The mass air flow is between 5.0 g/s and 90 g/s.
The manifold absolute pressure is between 26 kPa
and 90 kPa.
The intake air temperature is between
-20C (-4F) and 90C (194F).
The engine speed is between 400 RPM and
3,000 RPM.
The TP sensor angle is less than 90%.
The vehicle speed is less than 137 km/h (85 mph).
The fuel level is greater than 10%.

Conditions for Setting the DTC

The average Long Term Fuel Trim cell values are
above a predetermined threshold.

All the above conditions are present for 6 seconds:

Action Taken When the DTC Sets

' The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive ignition
cycle that the diagnostic runs and fails, if the
diagnostic f~ils under the same conditions (load,
RPM, temperature, etc.) as the previous
ignition cycle that the test ran and failed.
The firsttime the diagnostic fails, the PCM
records the operating conditions in Failure
.. Records.
The second consecutive ignition cycle that this
diagnostic fails [under the same conditicms
(load, RPM, temperature, etc.) as the previous
ignition cycle that the test ran and tailed], the PCM
stores this information in Freeze Frame. The
PCM"copies any data previously stored in Freeze
Frame and copies the data into the Failure
Records. The PCM then overwrites the Freeze
Frame. The only exception to this is if a Misfire
DTC was already recorded in Freeze Frame.
In. this case, the Misfire data stays in Freeze
Frame and the PCM updates the Fuel Trim data
in the Failure Records..

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail within the same conditions
that the DTC last failed.
Important: If the last failure was during a non-typical
driving condition, the MJL may remain ON longer
than the three ignition cycles. Review the Freeze
Frame/Failure Records for the last failure conditions.
A History OTC: clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
A last test failed (Current DTC) clears when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
This DTC sets if the engine runs out of fuel.
A fuel delivery malfunction causes this DTC to
set. Thoroughly inspect all items that cause a lean
condition.
For an intermittent condition, refer to Symptoms.

(
\

Engine Controls - 5.7L

Engine
Test Description

ignition cycles the diagnostic reported a pass

and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the DTC failed. For an
intermittent condition, refer to Symptoms.

The numbers below refer to the step numbers on the

diagnostic table.

6-1463

2. This test determines whether the fault is present.

For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.

4. If DTC 171 is also set indicates both banks of the

3. Using the Freeze Frame and/or Failure Records

data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Count~r can also help determine how many

5. A vacuum leak will cause DTCs P0171 and

P0174 to set at the same time. Inspect all areas
of the engine for a vacuum leak. Also inspect PCV
valve for being the correct one for this application.
Make sure the engine oil fill cap is in place and
that it is tight. Ensure that the engine oil dip stick is
fully seated.

engine are operating lean. Inspect items that

would cause both banks to operate lean.

DTC P0174 Fuel Trim System Lean Bank 2

Action

Step

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Step 4

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 6

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Important: If any DTCs are set, except P0171 and P0174,

refer to those DTCs before proceeding with this diagnostic.

1.
2.
3.
4.

lnst~II the scan tool.

Idle the engine at the normal operating temperature.
Fuel system in Closed Loop.
Monitor the LT FT Bn 2 display on the Fuel Trim Data
List using the scan tool.
Is the LT FT less than the specified value indicated?

23%LT

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this OTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.

4. Start the engine.

5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded .in Freeze Frame and/or Failure Reco.rds as
possible. Special operating conditions that, you need
to meet before the PCM will run this diagnostic,
where applicable are listed in Conditions for Running
the OTC.
6. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?
Is OTC P0171 also set?

6-1464

Engine

Engine Controls - 5.7L

DTC P0174 Fuel Trim System Lean Bank 2 (cont'd)

Step

Action

Value(s)

Yes

No

Visually/physically inspect the following items:

The vacuum hoses for splits, kinks and proper
connections. Refer to Emission Hose Routing
Diagram.

The crankcase ventilation valve and/or system

for leaks.
The fuel system for contamination. Refer to
Alcohol/Contaminants-in-Fuel Diagnosis.
Ensure that the PCM and sensor grounds are clean,
tight and in proper locations.
The air induction system after the MAF sensor for
vacuum leaks.

The engine for signs of mechanical failure. Refer to

Base Engine Misfire Diagnosis in Engine
Mechanical 5.7L.
Was a concern found in any of the above areas?

Go to Step 7

Refer to Fuel
System
Diagnosis.

Go to Step 7

Refer to Fuel
System
Diagnosis.

Visually/physically inspect the following items:

Bank 2 exhaust leaks, missing or loose exhaust
hardware.

Bank 2 H02S #1 is installed securely and electrical

connector not contacting exhaust system or
ignition wires.
Engine mechanical failure. Refer to Base Engine
Misfire Diagnosis in Engine Mechanical 5. 7L.

Vacuum leaks that will only affect bank 2 such as the

intake manifold, the injector O rings, etc.
Was a concern found in any of the above areas?
7

Repair or replace any faulty items found.

Is the action complete?

Go to Step 8

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.

2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 9

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5.7L

6-1465

OTC P0175 Fuel Trim System Rich Bank 2

Circuit Description
The PCM controls a Closed Loop air/fuel metering
system in order to provide the best possible
combination of driveability, fuel economy, and emission
control. The PCM monitors the heated oxygen
sensor signal voltage and adjusts the fuel delivery
based on the signal voltage while in Closed Loop. A
change made to the fuel delivery changes the
Long .and Short Term Fuel Trim values. The Short
Term Fuel Trim values change rapidly in response to
the H02S signal voltages. These changes fine
tune the engine fueling. The Long Term Fuel Trim
values change in response to trends in Short
Term Fuel Trim. The Long Term Fuel Trim makes
coarse adjustments to fueling in order to re-center and
restore control to Short Term Fuel Trim. You can
use a scan tool in order to monitor the Short and Long
Term Fuel Trim. The ideal fuel trim values are
around 0%. A positive Fuel Trim value indicates that
the PCM is adding fuel in order to compensate for
a lean condition. A negative Fuel Trim value indicates
that the PCM is reducing the amount of fuel in
order to compensate for a rich condition. If the PCM
detects an excessively Rich or Lean condition,
the PCM sets a OTC. The long term fuel trim
diagnostic parameter is an average of several of the
long term speed load learn cells which the PCM
selects based on the engine speed and the
engine load.

Conditions for Running the DTC

DTCs P0101, P0102, P0103, P0107, P0108,
P0112, P0113, P0117, P0118, P0121, P0122,
P0123, P0125, P0300, P0335, P0336,
P0351-P0358, P0401, P0404, P0405, P0410,
P0412, P0418, P0443, P0500, P0502, P0503,
P1111, P1112, P1258, P1404, P1415,
P1416 not set.
The engine coolant temperature is between 50C
(122F) and 115C (239F).
The barometric pressure is greater than 74 kPa.
The mass air flow is between 5.0 g/s and 90 g/s.
The manifold absolute pressure is between 26 kPa
and 90 kPa.
The intake air temperature is between
-20C (-4F) and 90C (194F).
The engine speed is between 400 RPM and
3,000 RPM.
The TP sensor angle is less than 90%.
The vehicle speed is less than 137 km/h (85 mph).

Conditions for Setting the DTC

The average Long Term Fuel Trim cell values are
below a predetermined threshold.
All the above conditions are present for
49 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive ignition
cycle that the diagnostic runs and fails, if the
diagnostic fails under the same conditions (load,
RPM, temperature, etc.) as the previous
ignition cycle that the test ran and failed.
The first time the diagnostic fails, the PCM
records the operating conditions in Failure
Records.
The second consecutive ignition cycle that this
diagnostic fails [under the same conditions
(load, RPM, temperature, etc.) as the previous
ignition cycle that the test ran and failed], the PCM
stores this information in Freeze Frame. The
PCM copies any data previously stored in Freeze
Frame and copies the data into the Failure
Records. The PCM then overwrites the Freeze
Frame. The only exception to this is if a Misfire
OTC was already recorded in Freeze Frame.
In this case, the Misfire data stays in Freeze
Frame and the PCM updates the Fuel Trim data
in the Failure Records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail within the same conditions
that the OTC last failed.
Important: If the .last failure was during a non-typical
driving condition, the MIL may remain ON longer
than the three ignition cycles. Review the Freeze
Frame/Failure Records for the last failure conditions.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
A last test failed (Current OTC) clears when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUOTC.

6-1466

Engine

Engine Controls - 5.7L

Diagnostic Aids

free~e frame conditions (RPM, load, vehicle

speed, temperature etc.) that you observed. This
will isolate when the OTC failed. For an

intermittent condition, refer to Symptoms.

For an intermittent condition, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This test determines whether the fault is present.
3. Using the Freeze Frame and/or Failure Records ...
data may aid in locating an intermittent c.ondition.
If you cannot duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the OTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle with_in the same

4. If DTC 172 is also set, then both banks are

operating rich. Inspect items that would cause both
banks to ope(aJe rich.
5. Excessive fuel in the oil will cause OTCs P0172
and P0175 to set at the same time. Remove
the PCV valve from the intake manifold and plug
with a suitable stopper. Also disconnect the
fresh air pipe from the rocker cover and plug with
a suitable stopper. If the long term and short
term fuel trim vatues increase, indicates there is
fuel in the oil.

DTC P0175 Fuel Trim System Rich Bank 2

Step

Action
Did you perform the Powertrain OnsBoard Diagnostic
(OBD) System Check?

Value(s)

Yes

No

Go to Step 2

Goto A
Powertrain On
Board Diagnostic
(OBD) System
Check

'-.

Important: If any DTCs are set, except P0172 and P0175,

refer to those DTCs before proceedingwith this diagnostic.
1. Install the scan tool.
2. Idle the engine at the normal operating temperature.
3. Fuel system in Closed Loop.

-13% LT

4. Monitor the LT FT Bn 2 display on the Fuel Trim Data

List using the scan tool.

_,

Is the LT FT greater than the specified values indicated?

Go to Step 3

Go to Step 4

Go to Step 4

Go to
Diagnostic Aid.s

Go to Step 5

Go to Step 6

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Fai.lure Records
data for this DTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Start the engine.

5. Operate the vehicle within the conditions required for

this diagnostic to run, and as close to the conditions
recorded in Freeze Frame and/or Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.

6. Select the Diagnostic Trouble Code (DTC) option and

the Specific OTC option, then enter the DTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

Is DTC P0172 also set?

Engine Controls - 5.7L

Engine

6-1467

OTC P0175 Fuel Trim System Rich-Bank 2 (cont'd)

Step

Action

'-~-

Value(s)

'

Yes

No

Visually/physically inspect the following items:

Collapsed air intake duct.
The air filter element for being restricted. Refer to Air
Cleaner Element Replacement.

The MAF sensor for being installed in the proper

direction and for foreign objects blocking the inlet
screen. Refer to MAF Sensor Replacement.
For fuel in the pressure regulator hose. Refer t_o Fuel
System Diagnosis.
Inspect for .the incorrect MAP/BARO display. C0mpare
to another vehicle.
For excessive fuel in the crankcase. Change oil as
necessary.
Was a concern found in any of the above areas?

Important: When the fuel system test is finished, return to

this table.
Inspect the Bank 2 injectors for leaking, refer to Fuel
System Diagnosis.
Are any injectors leaking?

Repair or replace any faulty items found.

Is the action complete?

Replace the faulty H02S. Refer to H02S Replacement f.3ank 2.

Is the action complete?
.,

Go to Step 7

Go to Fuel
System
Diagnosis

Go to Step 7

Go to Step B

Go to Step 9

Go to Step 9

1. Select the Diagnostic Trouble Code (OTC) option and

\I
9

'

10

the Clear OTC Information option using the scan tool.

2. Idle t~e ~ngine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the DTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran ai:id passed?
Select the Capture. Info option and the Review Info option
using the scan tool.
Does the scan tool display.any DTCs that you have not
diagnosed?

Go to Step 10

Go to Step 2

Go to the
applicable
OTC table

System OK

6~1468

Engine

Engine Controls - 5.7L

DTC P0230 Fuel Pump Relay Control Circuit

!Hot Al All Times!

'" - - - - -

- - - - , Underhood
I
FUEL PUMP I Electrical
MiniFuse Center 1

I Power
I Distribution
ce1110
I

Uil

20A
I
~----- ____
...

GRY{,20

ORN

GRJ120
.. -

BLK!WHT 451

- - - - ., Fuel
Fuel
I Tank
Pump
: Unit
I
I

. - - - -BS

- _..

AB

GRY
120
BLK/WHT 451

DK GRN/WHT 465

____ J

- -

,
I

1
Ground
Distribution
Cell 14

DK GRN/WHT 465

BLK 1050

BLK 451

Ground
Distribution
Cell14

37 A C2
.- ..,.. - - - - - - - - - - - - ., Powertrain
I

I
I

PCM
C1=RED
C2=BLU

Fuel ----
Pump
Relay
Control

Control
I Module
I
(PCM)

}Ii
1.-------------"'~
I

218494

Circuit Description
When you turn the ignition switch to the ON position,
the PCM activates the in-tank fuel pump. The fuel
pump remains on as long as the PCM receives
reference pulses from the electronic ignition system. If
there are no reference pulses, the PCM turns the
fuel pump off after about 2-3 seconds. The PCM
controls the fuel pump relay by applying B+ to the
control circuit via an internal switch called a driver. The
primary function of the driver is to supply a voltage
to the fuel pump relay. The driver has a fault line which
the PCM monitors. When the PCM commands the
fuel pump on, the voltage of the control circuit should
be high (near battery voltage). When the PCM
commands the control circuit to the fuel pump OFF,
the voltage potential of the circuit should be low (near
O volts). This OTC sets when the PCM detects the
fuel pump control circuit is shorted to ground.

Conditions for Running the DTC

The engine speed is greater than 600 RPM.
The ignition voltage is between 6.0 volts
and 16.0 volts.

Conditions for Setting the DTC

The PCM detects that the commanded state of
the driver and the actual state of the control
circuit do not match.
All the above conditions present for a minimum of
10 seconds.

Engine
Action Taken When the DTC Sets
The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Important:

Remove any debris from the PCM connector

surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.

Engine Controls - 5.7L

6~1469

The following may cause an intermittent:

- Poor connections: Test for adequate terminal
tension. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
- Corrosion
- Mis-routed harness
- Rubbed through wire insulation
- Broken wire inside the insulation
Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the DTC failed.
For an intermittent condition, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Listen for an audible click when the relay operates.
Command both the ON and the OFF states.
Repeat the commands as necessary.
3. This test can detect a partially shorted coil which
would cause excessive current flow. Leaving the
circuit energized for 2 minutes allows the coil
to warm up. When warm, the coil may short (goes
above 0.75 Amp).
5. Identify and test the correct relay terminals in
order to avoid improper diagnosis.
12. If you do not find any trouble in the control circuit
or the connection at the PCM, the PCM may be
malfunctioning. However, this is an extremely
unlikely failure. Before replacing the PCM, inspect
for poor connections at the PCM harness
connectors.
13. The repair is not complete if the scan tool
indicates that the diagnostic ran and failed.

&-1470

Engine

Engine Controls - 5.7L

DTC P0230 Fuel Pump Relay Control Circuit

Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

Value(s)

No

Yes

..

Go to Step 2

1. Turn ON the ignition leaving the engine OFF.

2. Comman.d the fuel pump relay ON and OFF using a
.scan tool.
Does the fuel pump relay .turn ON and OFF when
. commanded?
1. Turn OFF the ignition.
2. Disconnect the PCM .connector C2 located on the
same side as. the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Turn 9N thei ignition leaving the engine OFF.
Important:. Replace the relay .if the DMM goes to O Amps

during the current draw test.

4. Measure the current from the relay control circuit in
the PCM harness connector to B+ for 2 minutes
using the DMM J 39200 on the 40 Amp scale.
Does the current draw measure less than the specified
value shown (but not O)?

..

Go: to A.
Powertrain On
Board Diagnostic
(080) System
Check

'

'

Go to Step 3

Go to Step 5

.
'

0.75A

t",i

Go to
Diagnostic Aids

.'

\;

Go to $tep 4

Important: For underhood relay terminal identification

refer to Electrical Center Identification in Wiring Systems.

1. Turn OFF the ignition.

2. Remove the fuel pump relay from the un.derhood
electrical center..
3. Measure the resistance from the relay control circuit
in the PCM harness connector to a ground using the
DMM J39200.
Does the DMM display infinite resistance?

.,

..
Go to Step 11

Goto Step 10

Go to Step B

Go to Step 6

Go to Step 7

Go to Step 9

Important: For underhood relay terminal identification

refer to Electrical Center Identification in Wiring Systems.
1. Turn OFF the ignition.

2. Remove the fuel pump relay from the underhood

electrical center.
3. Connect the test lamp J 34142-8 between the ground
circuit and the control circuit at the underhood
electrical center. Refer to the thumbnail wiring
schemat.ic for terminal identification.
4. Turn ON the ignition leaving the engine OFF.
5. Command the fuel pump relay ON and OFF using a
scan tool.
Does the test lamp turn ON and OFF when commanded?
Test the resistance of the fuel pump relay ground circuit at
the underhood electrical center to the battery ground using
the DMM J 39200. Refer to Testing for Continuity in Wiring
Systems.
Is the resistance within the specified range?

o-sn

Engine

Engine Controls - 5.7L

6-1471

DTC P0230 Fuel Pump Relay Control Circuit (cont'd)

Step

Action

1. Turn OFF the ignition.

2. Reconnect the relay.
3. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
4. Turn ON the ignition leaving the engine OFF.
5. Momentarily probe the relay control circuit in the PCM
harness connector with a fused jumper wire
connected to B+.
Does the relay turn ON when the circuit is grounded and
OFF when the circuit is opened?

Inspect the connections at the relay. Refer to lntermittents

and Poor Connections Diagnosis in Wiring Systems.
If you find a poor connection, repair the condition as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and correct the condition?

Repair the open fuel pump relay ground circuit. Refer to

Wiring Repairs in Wiring Systems.
Is the action complete?

Repair the fuel pump relay control circuit. Refer to Wiring

Repairs in Wiring Systems.
Is the action complete?

Replace. the relay. Refer to Fuel Pump Relay

Replacement.
Is the action. complete?

10

11

12

13

14

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.

Replace the PCM.

Is the action complete?

1.. Select the. Diagnostic Troubl.e Codes (OTC) option

and the Clear OTC Information option using the
scan tool.
2. Idle the engine .at.the nO.rmal operating temperature.
3. S.elect the Specific OTC and the Diagnostic Trouble
Code (OTC) qption using a ~can tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable .
. Does the scan tool indicate, that this test passed?
Select the Capture Info option and the Review Info option
.using the scan :tool.
Are any DTCs displayed that you have not diagnosed?

Value(s)

Yes

No

Go to Step 12

Go to Step 10

Go to Step 13

Go to Step 11

Go to Step 13

Go to Step 13

Go to Step 13

Go to Step 13

Go to Step 14

Go to Step 2

Go to the
applicable
.OTC table

System OK

6-1472

Engine

Engine Controls - 5.7L

DTC P0300 Engine Misfire Detected

Circuit Description
The Crankshaft Position sensor is mounted through
the side of the engine block at the rear of Bank 2
behind the starter assembly. The Crankshaft Position
sensor works in conjunction with a 24X reluctor
wheel on the crankshaft. The reluctor wheel is inside
the engine immediately in front of the rear main
bearing. The PCM provides a 12 volt power supply to
the CKP sensor as well as a ground and a signal
circuit.
A misfire causes a change in crankshaft speed. The
PCM times the interval between each pulse and
compares each new time interval with the previous
one in order to determine when an excessive change
in crankshaft speed has occurred. You can expect
a certain amount of acceleration/deceleration between
each firing stroke, but if the crankshaft speed
changes are greater than an expected amount, the
PCM interprets this as a misfire.
The PCM uses the Crankshaft Position sensor for
both spark and fueling. As the crankshaft rotates, the
reluctor wheel teeth interrupt a magnetic field
produced by a magnet within the sensor. The sensors
internal circuitry detects this and produces a signal
which the PCM reads. The PCM uses this 24X signal
in combination with the Camshaft Position sensor
1X signal in order to accurately .determine crankshaft
position. The PCM also calculates a 4X signal
from this information. The PCM uses the 4X signal for
internal calculations. The 4X signal also provides a
tach signal for any device which requires one.
Observe that as long as the Crankshaft Position
sensor 24X signal is available, the engine will start.
The PCM can determine top dead center for all
cylinders by using the Crankshaft Position sensor 24X
signal alone. The Camshaft Position sensor 1X
signal is used by the PCM to determine if the cylinder
at top dead center is on the firing stroke, or the
exhaust stroke. The system attempts synchronization
and looks for an increase in engine speed indicating
the engine started. If the PCM does not detect
an increase in engine speed, the PCM incorrectly
synchronized to the exhaust stroke and will re-sync to
the opposite cam position. A slightly longer cranking
time may be a symptom of this condition.

Conditions for Running the OTC

DTCs P0101, P0102, P0103, P0107, P0108,
P0117, P0118, P0121, P0122, P0123, P0125,
P0335, P0336, P0341, P0342, P0343, P0500,
P0502, P0503, P1258 not set.
The engine speed is between 450 RPM
and 3,001 RPM.
The ignition voltage is between 11.0 volts
and 16.0 volts.

The engine coolant temperature is between -7C

(19F) and 130C (266F).
Fuel level greater than 10%
The TP sensor angle is steady within 1%.
The ABS and Traction Control systems are not
active.
The transmission is not changing gears.
The AIR diagnostic test is.not in progress
The A/C clutch is not changing states.
The PCM is not in fuel shut-off or decel fuel
cut-off mode.
The ABS signals not exceeding rough road
thresholds.

Conditions for Setting the OTC

The PCM determines that an emission type
Misfire is present.
The PCM determines that a catalyst damaging
Misfire is present.

Action Taken When the OTC Sets

The PCM will illuminate the Malfunction Indicator
Lamp (MIL) under the following conditions:
The PCM illuminate the Malfunction Indicator
Lamp (MIL) on the second consecutive ignition
cycle that the diagnostic runs and fails, if the
diagnostic fails under the same conditions (load,
RPM, temperature, etc.) as the previous
ignition cycle that the test ran and failed.
The first time the diagnostic fails, the PCM
records the operating conditions in Failure
Records.
The second consecutive ignition cycle that this
diagnostic fails [under the same conditions
(load, RPM, temperature, etc.) as the previous
ignition cycle that the test ran and failed], the PCM
stores this information in Freeze Frame. The
PCM copies any data previously stored in Freeze
Frame and copies the data into the Failure
Records. The PCM then overwrites the Freeze
Frame. The only exception to this is if a Misfire
OTC was already recorded in Freeze Frame.
In this case, the Misfire data stays in Freeze
Frame and the PCM updates the Fuel Trim data
in the Failure Records.
The PCM determines the percent of misfire over a
1,000 revolution period is high enough to cause
excessive tail pipe emissions. The PCM
illuminates the Malfunction Indicator lamp the next
consecutive ignition cycle that the diagnostic
runs and fails, if the diagnostic fails under
the same conditions (load, RPM, temperature,
etc.) as the previous ignition cycle that the test ran
and failed.

Engine
Conditions for Clearing the MIUDTC
Important: If the last failure was during a non-typical
driving condition, the MIL may remain ON longer
than the three ignition cycles. Review the Freeze
Frame/Failure Records for the last failure conditions.
The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail within the same conditions
that the DTC last failed.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
A last test failed (Current DTC) clears when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Important:

Remove any debris from the PCM connector

surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.
Running the vehicle out of fuel causes sufficient
misfire to set DTC P0300. A vehicle that is out
of fuel may have DTC P0461 also set.
A restricted fuel filter can cause sufficient misfire
to set DTC P0300. Refer to Fuel System
Diagnosis.
Observe, if more than one cylinder is mis-firing,
the scan tool may only display one cylinder
mis-firing. This will not be apparent until the repair
is complete.Also, if an ignition coil/module
ground circuit is open for one side of the engine,
the scan tool may only display 2 or 3 cylinders
mis-firing. Inspect the ground circuit for the ignition
coil/modules on the cylinder bank of the engine
that has more than one cylinder mis-firing.
~ Excessive vibration from sources other than the
engine could cause a misfire DTC. The following
are possible sources of vibration:
- Variable thickness brake rotor
- Drive shaft not balanced
- Certain rough road conditions

Engine Controls - 5.7L

6-1473

Using the Freeze Frame and/or Failure Records

data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the DTC failed.
For an intermittent condition, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. The misfire current counters will not increment
when engine load is low.
Wetting down the secondary ignition system with
water from a spray bottle may help locate
damaged or deteriorated components. Look/listen
for arcing or misfiring as you apply the water.
If the Misfire Cur counters are incrementing and
there is no apparent misfire, an erratic CKP sensor
signal could be the cause. Perform the diagnostic
table for DTC P0335 first if this condition is
suspected.
If a misfire is present and you suspect a fuel
control condition, force the fuel system into Open
Loop using the scan tool and allow the engine
to run for a few minutes. If this eliminates
the misfire, refer to any fuel control related DTCs
which are set. If no other DTCs are set, refer
to the Engine Scan Tool Data List.
4. The cylinder with the more significant misfire may
cause another cylinders counter to increment
only by a small amount.
10. If the engine misfire moves with the spark plug,
this is good indication that you should replace
the spark plug.
12. If you cannot find any fuel system conditions, refer
to Engine Mechanical. An engine mechanical
condition can cause a spark plug to foul. Inspect
the engine for loose rockers, collapsed lifters
or worn camshaft lobes.
17. If the customers concern is the MIL is flashing,
this indicates that a Catalyst Misfire has
occurred. Drive the vehicle in the conditions to run
the catalyst diagnostic. Refer to OTC P0420
Catalyst System Low Efficiency Bank 1 and/or
OTC P0430 Catalyst System Low
Efficiency Bank 2.

6-1474

Engine Controls -,5.7L

Engine

OTC P0300 Engine Misfire Detected

Step

Action

Value(s)

Yes

No

Go to Stfrp 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Important:
You must perform the CKP System Variation Learn
Procedure before proceeding with this diagnostic
table. Refer to CKP System Variation Learn
Procedure.
If any DTCs are set, refer to those DTCs before
proceeding with this diagnostic:

Ensure that the ABS and Traction Control systems are

functioning properly before proceeding with this
diagnostic. Automatic Transmission
1. Install the scan tool.
2. Idle the engine.

3. Turn all the accessories ON (i.e. lights, A/C, rear

defogger).
4. Set the Park Brake.
5. Transmission in drive.

6. Monitor all of the Misfire Cur. counters on the misfire

2

data list (one counter per cylinder) using the

scan tool.
Manual Transmission
1. Install the scan tool.
2. Idle the engine.
3. Turn all the accessories ON (i.e. lights, A/C, rear
defogger).

4. Set the Park Brake.

5. Transmission in neutral.
6. Select the special functions and RPM control using
the scan tool.
7. Lower the engine speed to the specified value.
8. Select the misfire data list while in the RPM control
portion of the scan tool. You can sele.ct.the misfire lis.t
by pressing the More and then the Next List/Previous
list soft key on the scan tool. The Soft Key will have
to be selected a few times to reach the misfire
data list.
9. Monitor all of the Misfire Cur. counters on the misfire
data list (one counter per cylinder) using the
scan tool.
Are any of the Misfire Cur. counters incrementing?

Go to Step 4

Go to Step 3

Engine

Engine Controls - 5.7L

6-1475

OTC P0300 Engine Misfire Detected (cont'd)

Action

Step

Value(s)

Yes

No

Go to Step 4

Go to
Diagnostic Aids

Go to Step 6

Go to Step 5

Go to Step 17

Go to Step 6

Go to Step 7

Go to Fuel
lnjectqr Circuit
Diagnosis

Go to Step 9

Go to Step B

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records

data for this OTC and observe the, parameters.

3. Turn;OFF the ignition for 15 seconds.
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.
6. Select the Diagnostic Trouble Code (OTC) option, the
Specific OTC option, and then enter the OTC numbe~ ,
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

Is only one Misfire counter incrementing?

Visually/physically inspect the following items:
Vacuum hoses for splits, kinks and proper
connections.
Throttle body arid intake manifold for vacuum leaks.
Crankcase venUlation valve and/or system for
vacuum leaks.
PCM grounds for being clean and secure. Refer to
Ground Distribution Schematics in Wiring Systems.

'

Verify that all injector harness connectors are

connected to the proper injector/cylinder.
Inspect the injector and Ignition Control fuses for being
open. If you find an open fuse, locate and repair the
shorted circuit. Refer to Wiring Repairs in Wiring
Systems.
Test for low fuel pressure or restricted fuel flow. Refer
to Fuel System Diagnosis.
Inspect for a restricted exhaust.
Poor fuel quality. Refer to
Alcohol/Contaminants-in-Fuel Diagnosis.

,.

Did any of the above steps isolate a condition requiring a

repair?
1. Tum OFF the ignition.

2. Disconnect the injector that corresponds to the Misfire

Cur counter(s) that was jncrementing.

3. Connect the injector test lamp J34730-405 to the

injector electrical connector.

4. Idle the engine.

Is the injector test lamp flashing?
1. Turn OFF the ignition.

2. Reconnect the injector harness electrical connector.

3. Disconnect the ignition wire(s) from the spark plug
7

that correspond$ to the Misfire Cur counter(s) that

was incrementing. Refer to Spark Plug Wire Harness
Replacement (VB) in Engine Electrical.
4. Install spark tester J 26792 to a ground.
5. Start and idle the engine.
Does the spark jump the tester gap and is the spark
consistent?

6-1476

Engine

Engine Controls~ 5.7L:

OTC P0300 Engine Misfire Detected (cont'd)

Step

10

Action

Value(s)

1. Remove the ignition wire for the cylinder that is

Mis-firing.
2. Measure the resistance of the ignition wire using the
DMM J39200.
Is the ignition wire resistance less than the specified
resistance?

700Q

1. Exchange the suspected spark plug with another

cylinder that is operating properly.
2. Operate the vehicle under the same conditions that
the misfire occurred.
Important: If the Injector Coil Test Procedure fails to
locate the cause of the fault, refer to Base Engine Misfire
Diagnosis in Engine Mechanical 5.7L.
Did the misfire move with the spark plug?

Are the spark plugs oil or coolant fouled?

12

13

14

15

16

Important: If no concern can be located with the fuel

system, refer to Base Engine Misfire Diagnosis in Engine
Mechanical 5.7L.
'
Are the spark plugs gas fouled?

Important: If the Injector Coil Test Procedure fails to

locate the cause of the fault, refer to Base Engine Misfire
Diagnosis in Engine Mechanical 5.7L.
Do the spark plugs show any signs of being cracked,
worn, or improperly gapped?

Replace or re-gap spark plugs. If improper gap is

found, be.sure to re-gap spark plugs using a wire type
gauge, J 41319.
Is the action complete?

Replace the faulty spark plug(s). Refer to Spark Plug

Replacement in Engine Electrical.
Is the action complete?

Replace the faulty ignition wire(s). Refer to Spark Plug

Wire Harness Replacement (VB) in Engine Electrical.
Is the action complete?

Go to Electronic
Ignition System
Diagnosis

Go to Step 16

Go to Step 10

Go to Step 11

Go to Step 15

Go to Fuel lnj
Coil Test - ECT
Between
10-35 Degrees C

Go to Base
Engine Misfire
Diagnosis in
Engine
Mechanical 5.7L.

Go to Step 12

Go to Fuel
System
Diagnosis

Go to Step 13

Go to Step 14

Go to Fuel lnj
Coil Test - ECT
Between
10-35 Degrees C

Go to Step 17

Go to Step 17

'

Go to Step 17

Was the customers concern that the MIL was flashing?

17

No

1. Remove the spark plug(s) from the cylinder(s) tha:t

indicated a misfire. Refer to Spark Plug Replacement
in Engine Electrical.
2. Visually inspect the spark plug(s) for the affected
cylinder(s).
Does the spark plug appear to be OK?

11

Yes

Go to
DTCP0420
Catalyst System,
Low Efficiency
Bank.1 or
DTG P0430
Catalyst System
Low Efficiency
Bank 2.

Goto Step 18

Engine Controls - 5.7L

Engine

6-1477

OTC P0300 Engine Misfire Detected (cont'd)

Step

Action

Value(s)

Yes

No

Go to Step 19

Go.to Step 2

Go to the
applicable
OTC table

System OK

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.

)
18

19

2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the DTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does. the scan tool display any DTCs.that you have not
diagnosed?

6-1478

Engine

Engine Controls .. ,s.7L

DT.C::: P0325 Knock Sensor'. Syst~m .

Circuit Description

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and tails.
Tfie PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stbres this information in
th~ Failure Records. If the diagnostic reports a
fa.ilure en the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure: The PCM writes the
cond.itions to the Freeze Frame and updat~s the
Failure records.

The KS system monitors both knoc~ sensors in order

to determine if detonation is present. If the KS
system determines that excessive knock (detonation) .....
is present, the PCM retards the spark timing based
on the signals frorr, the KS system. When knock
is present, the KS system voltage input signal to the
PCM goes low. The PCM then retards timing until
no knock is present. When the KS ~ystem is
malfunctioning, the KS> circ:uit voltage going to the
PCM goes low. The PCM interprets this low signal as
spark knock.

, Conditions for Clearing,theMIUDTC

Conditions.for Running the OTC

The PCM turns the MIL OFF after.three

consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

The engine speed is between 1,500 RPM and

3,000 RPM.
The MAP is less than 60 kPa.
The engine coolant temperature is greater
than 70C (158F).
The throttle angle is greater than 0.5%.
The engine run time is greater than 20 seconds.

Diagnostic Aids
If the diagnostic test does not run, review the
Conditions for Running the OTC.
For an intermittent condition, refer to Symptoms.

Conditions for Setting the OTC

A malfunction with the KS system or circuits within
the PCM are faulty.
All above conditions present for 3.0 seconds.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This OTC indicates an internal PCM condition.

DTC P0325 Knock Sensor System

Step

Action

Value(s)

Yes

No

Go to Step2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Did you perform the Powertrain On-Board Diagnostic

(OBO) System Check?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate vehicle within the Conditions for Running the
OTC as specified in the supporting text, if applicable.
Does the scan tool indicate that this test ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 3

Go to Step 4

Go to Step2

Go to applicable
OTC table

System OK

Engine Controls - 5.7L

Engine

6-1479

OTC P0327 Knock Sensor (KS) 1 Circuit

'" - - - - - - - - - - - - - - - ., Powertrain
I
I PCM I I Control
c1=RED
I Module
C2=BLU
I (PCM)

KS

KS

Signal

Signal

:
I

~--~~-------~~--J

>

Uil

DKB~l4Q6- B~~F:
.LT

Ar-------------~1

[!]

Front
Knock
Sensor
(KS)

-:::"

[!]
...

Rear
Knock
Sensor
(KS)

-=218517

Circuit Description
The Knock Sensor (KS) system detects engine
detonation. The PCM retards the spark timing based
on the signals from the knock sensors. The knock
sensors produce an AC voltage. The knock sensor
voltages are an input to the PCM. The amount of AC
voltage produced is proportional to the amount
of knock.
An operating engine produces a normal amount of
engine mechanical vibration (noise). The knock
sensors produce an AC voltage signal from this noise.
When an engine operates, the PCM learns the
minimum and maximum frequency of the noise the
engine produces. When the PCM determines that this
frequency is less than or greater than the expected
amount, a knock sensor DTC sets.

Conditions for Running the DTC

The engine run time is greater than 20 seconds.
The engine coolant temperature is greater
than 70C (158F).
The engine speed is between 1,500 and
3,500 RPM.
The TP sensor angle is greater than 0.5%.
The MAP is less than 60 kPa.

Conditions for Setting the DTC

The PCM determines that this frequency is less than
or greater than the expected amount for less
than 3 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating. conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIL/DTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

6-1480

Engine

Engine Controls - 5.7L

Diagnostic Aids

Test Description

Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.
Inspect the knock sensor for proper installation. A
knock sensor that is loose or over torqued may
cause the OTC P0327 to set.
Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the OTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the OTC failed.
For an intermittent, refer to Symptoms.

The numbers below refer to the step numbers on the

diagnostic table.
2. This verifies the malfunction is present. The scan
tool will display OTC Ran=Yes and Pass=lnt if
the failure is intermittent. This indicates the
diagnostic passed this ignition cycle and failed this
ignition cycle. At this point the resistance of the
knock sensors should be verified to be in the
correct range. If the knock sensor resistances are
correct, inspect the KS system wiring connections.
When inspecting the KS system connections,
start at the KS system jumper harness connector
located behind the intake manifold. Then
inspect the connections at the PCM. Refer to the
wiring schematic for the correct connector and
terminal. Then inspect the connections at
the appropriate knock sensor. Failure Records
data does not include the parameter KS Activity,
however other parameters may aid in locating
the conditions under which an intermittent
occurred.
3. This test will isolate the Knock S~nsor frolT} the
rest of the circuit.
4. Tap on the engine block near the appropriate
knock sensor.

Engine

Engine Controls - 5.7L

6-1481

DTC P0327 Knock Sensor (KS) 1 Circuit

Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

)
1

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to
Diagnostic Aids.

Go to Step 4

Go to Step 6

Go to Step 5

Go to Step 7

Go to Step 10

Go to Step B

Important: If an engine knock can be heard, repair the

engine mechanical condition before proceeding with this
diagnostic.

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this DTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame and/or Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.
6. Select the Diagnostic Trouble Code (DTC) option and
the Specific DTC option, then enter the OTC number
using the scan tool.

Does the scan tool indicate that this diagnostic failed this
ignition?

1. Disconnect the knock sensor electrical connector

located behind the intake manifold.
2. Measure the resistance of the appropriate knock
sensor by connecting the DMM J 39200 between the
knock sensor signal circuit on the sensor side and the
engine block.
3. Set the DMM to the 400K ohm scale.
Is the resistance of the knock sensor within the
specified range?

93-107KQ

1. Connect the DMM J 39200 between the front knock

sensor signal circuit on the sensor side and the
engine block.
2. Set the DMM to the AC voltage scale.

Important: Do not tap on any plastic components.

3. Tap on the engine near the appropriate knock sensor

while observing the signal indicated on the DMM.
Is any signal indicated on the DMM while tapping on the
engine near the Knock Sensor?

1. Disconnect the PCM connector C2 located on the

same side as the manufacturers logo. Refer to PCM
Replacement/Programming.
2. Test the KS signal circuit between the PCM and the
knock sensor connector for the following:
An open.
A short to voltage.
A short to ground.
3. If you find a condition repair the circuit as necessary.
Refer to Wiring Repairs in Wiring Systems.
Did you find and correct the condition?

6-1482

Engine

Engine Controls - 5.. 7L

DTC P0327 Knock Sensor (KS) 1 Circuit (cont'd)

Step

Action

Value(s)

Yes

No

1. Remove the intake manifold. Refer to Intake Manifold

Replacement in Engine Mechanical-5.?L for.

2. Test for an open or a short to ground in the signal

6

circuit between th.e knock sensor jumper harness

connector, located at the back of the intake manifold,
and the knock sensor connector.
3. If you find a condition repair the circuit as neces1?ary.
Refer to Wiring Repairs in Wiring Systems.

Did you find and correct the condition?

Go to Step 10

Replace the appropriate Knock Sensor. Refer to Knock

Sensor Replacement.
Is the action complete?

1. Inspect the KS signal circuit for a poor terminal

connection at the PCM. Refer to lntermittents and
Poor Connections Diagnosis in Wiring Systems.
2. If you find a poor connection repair, the condition as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and correct the condition?

lmportarit: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

Go to Step 7

Go to Step 10

Go to Step 10

Go to Step 9

Go to Step 10

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
10

11

3. Select the Diagnostic Trouble Code (OTC) option and

the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 11

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5 . 7L

6-1483

DTC P0332 Knock Sensor Circuit Rear

'" - - - - - - - -- - - - - - - - ., Powertrain
PCM
I Control
I
I
C1=RED
I Module
I
C2=BLU
I (PCM)
I

Signal
Front

Signal
Rear

I~

D(~~F------ F6

JJ4.

L---------------J
~TB~

r-------------~1

.
[!]
A

Front

Knock
Sensor

rn

Knock
.. Sensor

(KS)

'-::::-

Rear
(KS)

-=218517

Circuit Description
The Knock Sensor (KS) system d.etects engine
detonation. The PCM retards the spark timir,g based
on the signals from the knock sensors. The knock
sensors produce an AC voltage. The knock sensor
voltages are an input to the PCM. The amount of AC
voltage produced is proportional to the amount
of knock.
An operating engine produces a normal amount of
engine mechanical vibration (noise). The knock
sensors produce an AC voltage signal from this noise.
When an engine operates, the PCM learns the
minimum and maximum frequency of the noise the
engine produces. When the PCM determines that this
frequency is less than or greater than the expected
amount, a knock sensor OTC sets.

Conditions for Running the OTC

The engine run time is greater than 20 seconds.
The engine coolant temperature is greater
than 70C (158F).
The engine speed is between 1,500 and
3,500 RPM.
The TP sensor angle is greater than 0.5%.
The MAP is less than 60 kPa.

Conditions for Setting the OTC

The PCM determines that this frequency is less than
or greater than the expected amount for less
than 3 seconds.

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

6-1484

Engine

Engine Controls - 5.7L

Diagnostic Aids

Test Description

Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.
Inspect the knock sensor for proper installation. A
knock sensor that is loose or over torqued may
cause the OTC P0332 to set.
Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the OTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the OTC failed.
For an intermittent, refer to Symptoms.

The numbers below refer to the step numbers on the

diagnostic table.
2. This verifies the malfunction is present. The scan
tool will display OTC Ran=Yes and Pass=lnt if
the failure is intermittent. This indicates the
diagnostic passed this ignition cycle and failed this
ignition cycle. At this point the resistance of the
knock sensors should be verified to be in the
correct range. If the knock sensor resistances are
correct, inspect the KS system wiring connections.
When inspecting the KS system connections,
start at the KS system jumper harness connector
located behind the intake manifold. Then
inspect the connections at the PCM. Refer to the
wiring schematic for the correct connector and
terminal. Then inspect the connections at
the appropriate knock sensor. Failure Records
data c;loes not include the parameter KS Activity,
however other parameters may aid in locating
the conditions under which an intermittent
occurred.

3. This test will isolate the Knock Sensor from the

rest of the circuit.
4. Tap on the engine block near the appropriate
knock sensor.

Engine Controls - 5.7L

Engine

6-1485

DTC P0332 Knock Sensor Circuit Rear

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to
Diagnostic Aids.

Go to Step 4

Go to Step 6

Go to Step 5

Go to Step 7

Go to Step 10

Go to Step 8

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

)
3

Important: If an engine knock can be heard, repair the

engine mechanical condition before proceeding with this
diagnostic.
1. Turn ON the ignition leaving the engine OFF.
2. Review the Freeze Frame and/or Failure Records
data for this DTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame and/or Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the DTC.
6. Select the Diagnostic Trouble Code (DTC} option and
the Specific DTC option, then enter the DTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

1. Disconnect the knock sensor electrical connector

located behind the intake manifold.
2. Measure the resistance of the appropriate knock
sensor by connecting the DMM J 39200 between the
knock sensor signal circuit on the sensor side and the
engine block.
3. Set the DMM to the 400K ohm scale.

93-107KQ

Is the resistance of the knock sensor within the

specified range?

1. Connect the DMM J 39200 between the front knock

sensor signal circuit on the sensor side and the
engine block.
2. Set the DMM to the AC voltage scale.
Important: Do not tap on any plastic components.
3. Tap on the engine near the appropriate knock sensor
while observing the signal indicated on the DMM.
Is any signal indicated on the DMM while tapping on the
engine near the Knock Sensor?

1. Disconnect the PCM connector C2 located on the

same side as the manufacturers logo. Refer to PCM
Replacement/Programming.
2. Test the KS signal circuit between the PCM and the
knock sensor connector for the following:

An open.
A short to voltage.
A short to ground.
3. If you find a condition repair the circuit as necessary.
Refer to Wiring Repairs in Wiring Systems.
Did you find and correct the condition?

6-1486

Engine Controls - 5.7l

Engine

DTC P0332 Knock Sensor Circuit Rear (cont'd)

Step

Action

Value(s)

;_:,

..

Yes

No

1. Remove the intake manifold. Refer to Intake Manifold

Replacement in Engine Mechanical-5.?L for.

2. Test for an open or a short to ground in the signal
circuit between the knock sensor jumper harness
connector, located at the back of the intake manifold,
and the knock sensor connector.
3. If you find a condition repair the circuit as necessary ..
Refer to Wiring Repairs in Wiring Systems.
Did you find and correct the .condition?

'

'

Go to .Step 1.0

Replace the appropriate Knock Sensor. Refer to Knock

Sensor Replacement.
Is the action complete?

Go to Step 7

Go to Step 10

1. Inspect the KS signal circuit for a poor terminal

connection at the PCM. Refer to lntermittents and

Poor Connections Diagnosis in Wiring Systems.
2. If you find a poor connection repair, the condition as
necessary. Refer to Repairing Connector .Terminals in
Wiring Systems.

Did you find and correct the condition?

Go to Step 10

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

Go to Step 9

Go to Step 10

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear DTC Information option using the scan tool.

2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (DTC) option and
10

the Specific DTC option, then enter the DTC number

using the scan tool.

'

4. Operate the vehicle within the Conditions ,for Running

the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran (;l.nd,pa~sed?

11

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Str3p 11

Go.to Step2

Go to the
applicable
DTC table

System OK

Engine Controls - 5.7L

Engine

6-1487

DTC P0335 Crankshaft Position (CKP) Sensor Circuit.

Crankshaft

I.......J_--So->al. .

I~~r

S_tate-~-
-

YEL 573

44

LT GRN 1867

YEL/ 1868
BLK
C1 22

62 C2

. . - cKPSe-;;scir - .. _-.;;..-....;; ~ - - - - - - - - - - - .,
I

Signal Input

I
I

ReferenceD:2v

~Low

CMP Sensor

PCM

..
Ignition

Feed

C1=RED
C2-BLU

Powertrain

I Control
I
I

Module

1 (PCM)

~ . ~
Alillli.'.'

~-----------------~----J

218514

Circuit Description
The Crankshaft Position Sensor CKP is mounted in
the right rear of the engine block behind the starter.
The CKP sensor works in conjunction with a
24X reluctor wheel mounted on the rear of the
crankshaft. The CKP sensor has a B+ power supply, a
ground, and a signal circuit.
As the crankshaft rotates, the reluctor wheel teeth
interrupt a magnetic field produced by a magnet within
the sensor. The sensor's internal circuitry detects
this and produces a signal which the PCM reads. The
PCM uses this signal to accurately measure
crankshaft velocity which is a variable used in order to
detect misfire, spark and, fueling.

Conditions for Running the DTC

DTCs P0101, P0102, P0103, P0341 , P0342,
P0343 are not set.
The CMP sensor is transitioning.
The ignition voltage is between 5.0 and 17.0 volts.
The MAF is greater than 3 g/s.
The ignition switch in the crank mode.

Conditions for Setting the DTC

The PCM determines no signal from the CKP sensor
for less than 3 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIL/DTC

A last test failed (current DTC) clears.when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit prevents
damage tothe harness connector terminals.
The following conditions may cause this DTC
to set:
- Poor qonnections/terminal tension at the
sensor. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
- Crankshaft reluctor wheel damage or
improper installation
- The sensor coming in contact with the
reluctor wheel
- The engine running out of fuel.
.
Excess crankshaft end play will cause the CKP
sensor reluctor wheel to move out of alignment with
the CKP sensor. This could result in any one of the
following:
- A no start
- A start and stall
- Erratic performance

6-1488

Engine

Engine Controls - 5.7L

An improperly installed propeller shaft could cause

excess crankshaft end play. Refer to Propeller
Shaft Diagnosis (Runout Measurement) or
Propeller Shaft Diagnosis (Drive Gear Pinion Yoke
Runout) in Engine Mechanical 5. 7L.
Using Freeze Frame and/or Failure Records data
may aid in locating an intermittent condition. If you
cannot duplicate the OTC, the information included
in the Freeze Frame and/or Failure Records data
can aid in determining how many miles since the
OTC set. The Fail Counter and Pass Counter can
also aid determining how many ignition cycles the
diagnostic reported a pass and/or a fail. Operate
the vehicle within the same freeze frame conditions
(RPM, load, vehicle speed, temperature etc.) that
you observed. This will isolate when the OTC failed.
For an intermittent, refer to Symptoms.

7. This test determines if the CKP sensor signal

circuit or if the PCM is faulty.

11. The CKP System Variation Learn Procedure must

be performed anytime the relationship between
the CKP sensor and the CKP reluctor wheel
is changed.

(
\

13. To inspect the reluctor wheel, remove the starter

and rotate the crankshaft while viewing the
reluctor wheel through the CKP sensor hole. If
you cannot determine if the reluctor wheel
is damaged, the oil pan may have to be removed.

14. The CKP System Variation Learn Procedure must

be performed anytime the relationship between
the CKP sensor and the CKP reluctor wheel
is changed.

15. Before replacing the PCM, inspect the PCM

Test Description

harness connections.

The numbers below refer to the step numbers on the

diagnostic table.

16. The repair is not complete if the scan tool

3. This step determines if the fault is present.

indicates that the diagnostic ran and failed.

6. This step simulates a CKP sensor signal to the

PCM. If the PCM receives the signal, the fuel
pump will operate for about two seconds. If the
fuel pump operates, the condition is either terminal
contact at the CKP sensor, the CKP sensor or,
the CKP sensor reluctor wheel.

OTC P0335 Crankshaft Position (CKP) Sensor Circuit

Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to Step 4

Go to Step 4

Go to
Diagnostic Aids

Does the engine start and continue to run?

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this OTC and record or document the
parameters.
3. Turn OFF the ignition for 15 seconds.
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.
6. Select the Specific OTC option under the Diagnostic
Trouble Code (OTC) option using a scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

Engine

Engine Controls - 5.7L

6-1489

OTC P0335 Crankshaft Position (CKP) Sensor Circuit (cont'd)

Action

Step
\

Caution: Before proceeding, remove the fuses forthe

ignition coil and fuel injector feed circuits in order to
prevent personal injury from engine rotation, sparks,
and excessive engine fueling.
1. Turn ON the ignition leaving the engine OFF.
2. Lift the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
3. Disconnect the Crankshaft Position (CKP) sensor.
4. Measure the voltage from the CKP sensor ignition
feed circuit using the DMM J 39200 connected to
ground.
Does the DMM display the specified voltage?
Connect the DMM J 39200 between the CKP sensor
ignition feed circuit and the CKP sensor ground circuit.

Value(s)

.. 6.

No

Go to Step 5

Go to Step 8

Go to Step 6

Go to Step 9

Go to Step 11

Go to Step 7

Go to Step 15

Go to Step 10

Go to Step 16

Go to Step 15

Go to Step 16

Go to Step 15

Go to Step 16

Go to Step 11

B+

B+

Does the DMM display the specified voltage?

Momentarily connect the test lamp between the CKP
sensor signal circuit and the CKP sensor ignition feed
circuit.

Yes

Does the fuel pump operate when ignition voltage was

applied to the CKP sensor signal circuit?
...

1. Connect the CKP sensor.

2. Disconnect the PCM connector C1 located on the

opposite side of the manufacturer's logo. Refer to

PCM Replacement/Programming

3. Probe the CKP sensor signal circuit using the DMM

J 39200 set to the 40V AC scale.
4. Crank the engine.

4.0-6.0V

Is the voltage within the specified range?

1. Test for 13.n open or a short to ground in the CKP
ignition feed circuit.

2. If you find the CKP ignition feed circuit open or

shorted to ground repair the condition as necessary.
Refer to Wiring Repairs in Wiring Systems.

Did you find and repair the condition?

1. Test for an open or a poor connection in the CKP
ground circuit. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.

2. If you find thE:: CKP ground circuit open or a poor

connection, repair the condition as necessary. Refer
to Wiring Repairs or Repairing Connector Terminals
in Wiring Systems.

Did you find and repair the condition?

Test the CKP sensor signal circuit for the following:
An open
A short to ground
10

A short to voltage

If you find a condition repair the circuit as necessary.

Refer to Wiring Repairs in Wiring Systems.
Did you find and repair the condition?

6-1490

Engine Controls - 5.7L

Engine

DTC P0335 Crankshaft Position (CKP) Sensor Circuit (cont'd)

Action

Step

11

Important: The CKP System Variation Learn Procedure

must be performed anytime the relationship between the
CKP sensor and the CKP reluctor wheel is changed.
1. Remove the CKP sensor and visually inspect the
CKP Sensor for the following conditions:
Physical damage
Loose or improper installation
Wiring routed too closely to secondary ignition
components
2. If you find a condition, repair as necessary.
Did you find and correct the condition?

Value(s)

Yes

No

Go to Step 16

Go to Step 12

Go to Step 16

Go to Step 13

Go to Step 16

Go to Step 14

1. Inspect for poor connections/terminal tension at the

12

13

CKP sensor. Refer to lntermittents and Poor

Connections Diagnosis in Wiring Systems.
2. If you find a poor connection repair the condition as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and correct the condition?
Visually inspect the CKP sensor reluctor wheel for
damage.
Did you find and correct the condition?

1. Replace the CKP Sensor. Refer to Crankshaft

14

Position Sensor Replacement.

2. Perform the CKP System Variation Learn Procedure.

Is the action complete?

15

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

Go to Step 16

Go to Step 16

1. Select the Diagnostic Trouble Codes (DTC) option

16

17

and the Clear DTC Information option using the

scan tool.
2. Idle the engine at the normal operating temperature.
3 .. Select the Specific DTC option under the Diagnostic
Trouble Code (DTC) option using a scan tool.
4. Operate vehicle within the Conditions for Running the
DTC as specified in the supporting text, if applicable.
Does the scan tool indicate that this test passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Are any DTCs displayed that you have not diagnosed?

Go to Step 17

Go to Step 2

Go to the
applicable
DTC table

System OK

Engine,Controls - p.7L

Engine

6-149.1

OTC P0336 Crankshaft ,Position (CKP) 'Sensor Performance

ILPc'f

. LT GAN 1867

YEL 573

YEL/ 1868
BLK .

44 ' C1 22
62 C2
.....:. . . eKP.;..S;s;;-::--:: __-.;;;.-. . ;;-:.. ;' - - - - - - - - - - - ,

l.Reference1f:

,I

. Signal
. :Input
.: . ... =Low

L ,- -

..:,

.. -

-, ;

-",

..

POM
C1=RED
_
2
.C -BLU

Ignition

. CM)'Semsor
-

Feed
-

Powertrain

Co.ntrol
I.Md
I ......
I

1
..

O Ue

(PCM) ~

..I

218514

Action Taken When the DTC Sets

Circuit Description
The Crankshaft Position Sehsor is mounted in the
right rea:r of theengirie biock behind the sta.rter.The
CKP sensor.works in conjunctibnwith a 24X .
reluctqr wheel mounted on the. rear <:>i .tfte :cra~k~~aft.
The CKP sensor has a
power supply, a grOuhd,
and a signal circuit.
'
.
As the crankshaft rotates, the reluctor wheel feeth
interrupt ~ magnetic field produced by a magn~~ within
the sensor. The sensor's internal circuitry detects
this and proquces a. signal which the PCM reads. The
PCM uses this signal to accurately measure

crankshaft velocity which is a variable used.in order to

detec.t misfire, spark and, fueling.
i .

e+

Conditions for Running the DTC

The engine speed is..beJween 500 anJ:lJ,QOO.f:,:tPM.,
The ignition voltage is between 5.0 and 17.0-volts.
<,

, , . , , ,

'

Conditions for: Setting the OTC

The PCM detern,ines that the CKP sensor signal is
out of range for less than 1 second.

The PCM ill'umihates the Malfunction Indicator

Lamp on thesecori'd consecutive ignition cycle
that the diagnostic runs and fails.
The PCMJet:ordsthe operating conditions at the
time the diagnostic fail,s. The. first time the
diagnostic fails, the PCM stores this information in
the Failure Records. lfthe diagnostic reports a
faih..ire or\ the"second consecutive ignition'
,;cycle,. the PCM records the operating' conditions
. , at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
, c,onse.c;tive ignitio,n ~ycles that the diagnostic
runs and \;!be$ not faiL .
~ A. lastJ~.st fail~.d (crrent DTC) clears when the
. ,diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Engine

6-1492 . Engine Controls - 5.7L

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.
The following conditions may cause this DTC
to set:
- Poor connections/terminal tension at the
sensor. Refer to lntermittents and Poor
Connections Diagnosis In Wiring Systems.
- Crankshaft reluctor wheel damage or
improper installation.
- The sensor coming in contact with the
reluctor wheel.
- The engine running out of fuel.
- If the crankshclft rotates backwards, this DTC
sets. This condition is only with vehicles
equipped with a manual transmission. This
condition can occur when a vehicle is
on an 'incline and the clutch is released and
an engine stall occurs.
Excessive crankshaft end play will cause the CKP
sensor reluctor wheel to move out of alignment
with the CKP sensor. This could result in any one
of the. following:
- A no start
- A start and stall
- Erratic performance

An improperly instaHed propeller shaft could cause

excess crankshaft end play. Refer to Propeller
Shaft Diagnosis (Runout Measurement) or
Propeller Shaft Diagnosis (Drive Gear Pinion Yoke
Runout) in Engine Mechanical.
Using Freeze Frame and/or Failure Records data
mayaid in locating an intermittent condition. If
you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can aid in determining how many
miles since the DTC set. The Fail Counter
and Pass Counter can also aid determining how
many ignition cycles the diagnostic reported a
pass and/or a fail. Operate the vehicle within the
same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you
observed. This will isolate when the DTC failed.
For an intermittent, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step verifies that the malfunction is present.
3. This step tests for EMI (Electro Magnetic
Interference) on the CKP sensor circuits.
6. Vertical lines across the face of the sensor could
indicate foreign material passing between the
CKI? sensor and the refuctor wheel. Non vertical
line5, ,across the face of the sensor may indicate a
crack in the CKP sensor. Either of these
conditions
causes this DTC to set.
'i"
,.,
7. Damage to the reluctor wheel would affect the
CKP sensor output. To inspect the reluctor wheel,
re,move the starter and rotate the crankshaft
while viewing the reluctor wheel through the CKP
s~nsor hole. It you cannot determine if the
reluctor wheel is damaged, the oil pan may have
to be removed. If this condition exist, refer to
Oil Pan Replacement in Engine Mechanical 5. 7L.

OTC P0336 Crankshaft Position {CKP) Sensor Performance

Step

Action
Did you perform the Powertrain On-Board Diagnostic
(OBD) System Check?

Important: If OTC P0335 is also set, diagnose DTC P0335

before proceeding with this OTC.
1. Install a scan tool.
2. Idle the engine for 2 minutes.
Does the scan tool indicate that OTC P0336 failed this
ignition?

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to
Diagnostic Aids

Engine Controls.- 5.7L

Engine

6-1493

OTC P0336 Crankshaft Position (CKP) .Sensor Performance (cont'd)

Step

Action

Value(s)

Yes

No

Go to Step 9

Go to Step 4

Go to Step 9

Go to Step 5

Go to Step 9

Go to Step 6

Go to Engine
Mechanical

Go to Step 7

Go to Engine
Mechanical

Go to Step 8

1. Visually/Physically inspect all circuits going to the

)

Crankshaft Position sensor for the following:

Routed to close to secondary ignition wires or
components
Routed to close to after-market add on electrical
equipment
Routed to close to solenoids, relays and motors
2. If you find incorrect routing, correct the harness
routing.
Did you find and correct the condition?

1. Test the terminal contact at the CKP sensor. Refer to

lntermittents and Poor Connections Diagnosis in

Wiring Systems.
2. If you find a poor connection, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

1. Test the terminal contact at the PClvt for the CKP

sensor circuits. Refer to lntermittents and Poor

Connections Diagnosis in Wiring Systems.
2. If you find a poor connection, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

Important: The CKP System Variation Learn Procedure

must be preformed anytime the relationship between the
CKP sensor and the CKP reluctor wheel is changed. Refer
to CKP System Variation Learn Procedure.
6

1. Remove the CKP sensor. Refer to Crankshaft

Position Sensor Replacement.

2. Inspect the CKP sensor for signs of damage.
Is the CKP. sensor da.maged?

Inspect the CKP reluctor wheel for damage.

Is the CKP reluctor wheel damaged?

'

1. Replace the CKP Sensor. Refer to Cr:an[<shaft

8

Position Sensor Replacement.

2. Perform the CKP System Variatlon Learn Procedure.
Is the action complete?

-.
Go to Step 9

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC option using the scan tool.

2. Idle the engine at the normal operating temperature.

g

10

.,

3. Select the Diagnostic Trouble Code (OTC) option and

the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate vehicle within the Conditions for Running the
OTC as specified in the supporting text, if applicable.
Does the scan tool indicate that this test Hj.n and passed?
Select the Capture Info option and the Review Info option
using the scan tool.
'
Does the scan tool display any DTCs that you have not
diagnosed?

-.

Go to Step 10

Go to Step 2

Go to applicable
OTC table

System OK

6-1494

Engine

Engine Controls - 5.7L

DTC P0341 Camshaft Position (CMP),Sensor Performance

rtl

Camshaft
Position
(CMP)
Sensor

L.J

BRNJWHT 633
PNK/BLK 632

RED 631

BRN/WHT 633

PNK/BLK 632

70
r -

I
1

1
I

RED 631

C2
-

4
-

Re1erence C_MP Sensor

_ Low

C1
-

Signal Input

C2
-

, 2V

I
I

..,

. Ignition

Feed
PCM
.
.
C1=RED., .
C2,;., BLU
CKP Sensor

Powertrain
'

I Control

Module
I
1 (PCM)

>

I
I ,,..~

~------------------J

218515

Circuit Description
The Camshaft Position sensor is mounted through the
top of the engine block at the rear of the valley
cover. The CMP sensor works in conjunction with a
1X .reluctor wheel on the camshaft. The rel.uctor wheel
is inside the engine immediately in front of the rear
cam bearing. The PCM provides a 12 volt power
supply to the CMP sensor as well as a ground and a
~ignal circuit.
The CMP sensor determines whether a cylinder is on
a firing stroke or on an exhaust stroke. As the
camshaft rotates, the reluctor wheel interrupts a
magnetic field produced by a magnet within the
sensor. The sensors internal circuitry detects this and
produces a signal which the PCM reads. The PCM
uses this 1X signal in combination with the Crankshaft
Position sensor 24X signal in order to determine
crankshaft position and stroke. This diagnostic for the
Camshaft Position sensor tests for a loss of
Camshaft Position sensor signal.
Observe that as long as the Crankshaft Position
sensor 24X signal is available, the engine will start.
The PCM can determine top dead center for all
cylinders by using the Crankshaft Position sensor 24X
signal alone. The Camshaft Position sensor 1X
signal is used by the PCM to determine if the cylinder
at top dead center is on the firing stroke, or the
exhaust stroke. The system attempts synchronization
and looks for an increase in engine speed indicating

the engine started. If the PCM does not detect an

increase in engine speed, the PCM incorrectly
synchronized to the exhaust stroke and will re-sync to
the opposite cam position. A slightly longer cranking
time may be a symptom of this condition.

Conditions for Running the. DTC.

The ignition voltage is between 5.0 volts and
17.0 volts.
The engiQe speed is less than 4;000 RPM.

Conditions for Setting the DTC

The PCM detects that a CMP to CKP mis-match has
occurred for 10 second.
,

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the 'second consecutive ignition cycle
that the diagnostic rems and fails.
,.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

(
\

Engine Controls - p.7-L 6-1495

Engine
Conditions for Clearing the MIUDTC

Using Freeze Frame andfor Failure Records data

may aid in locating an Ihtermittent condition .. If
you cannot duplicate the OTC, the information
included in the Freeze Frame and/or Failure
R~cords data can ,aid in determining how many
miles since the OTC set. The Fail Counter
. and Pass Counter can also aid determining how
many ignition cycles the diagnostic reported a
pass and/or a fail. Operate the vehicle within the
same freeze frame conditions (RPM, load,
vehicle speed, temperature etc,) that you
obseNed. This will isolate when the OTC failed.

The,PCM turns the MIL OFF after three

consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
. related diagnostic does net report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids

Important:
Remove any debris from the PCM connector
surfaces before seNicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
.,
terminals.
The following mechanical conditions may cause
this OTC to set: ...
- Poor conriectionslterminal tension afthe
sensor. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
- Carnshaft reluctor wheel damage
- The sensor coming in contact with the
reluctor wheel

For an intermittent, refer to Symptoms.

Test Description
',

'

The numbers be.low refer to the step numbers on the

diagnostic table.
2. This step verifies that the: malfunction is present.
,3. This step tests for EMI (Electro Magnetic
Interference) on the CMP sensor circuits.
6. Vertical lines across the face of the sensor could
indicate foreign material passing between the
CMP sensor and the reluctor wheel. This condition
would cause this OTC to set.
7. Damage to the reluctor wheel would affect the
. CMP sensor output If this condition exists, refer
Camshaft Replacement in Engine
Mechanical 5.7L.

tq

DTC P0341 Camshaft Position (CMP)'Sensor Performance

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On ,,
Board Diagnostic:
(OBD) System
Check

Go to Step 3

Go to
Diagnostic Aids

Go to Step 9

Go to Step 4

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

.,

--'"

1. Install a 'Scan tool.

2. Idle the engine for 2 minutes.
Does the scan tool indicate that OTC P0341 failed this
ignition?

1. Visually/Physically inspect all circuits going to the

Camshaft Position sensor for the following:

Routed to close to secondary ignition wires or

components
Routed to close to after-market add on electrical
equipment
Routed to close to solenoids, relays and motors
2. If you find incorrect routing, correct the harness
routing
Did you find and correct the condition?

6-1496

Engine Controls - 5.7L

Engine

DTC P0341 Camshaft Position {CMP) Sensor Performance {cont'd)

Step

Action

Value(s)

Yes

No

1. Test the terminal contact at the PCM for the CMP

sensor circuits. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.

2. If you find a poor connection, repair as necessary.

(
-

Refer to Repairing Connector Terminl;lls in Wiring

Systems.
Did you find and correct the. condition?

1. Remove the Intake Manifold. Refer to Intake Manifold

Replacement in Engine Mechanical 5. 7L.
2. Test the terminal contact at the CMP sensor. Refer to
lntermittents and Poor Connections Diagnosis in
Wiring Systems.
3. If you find a poor connection, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

1. Remove the CMP sensor. Refer to Camshaft Position

Sensor Replacement.
2. Inspect the CMP sensor for signs of damage.
Did you find the CMP sensor damaged?

Inspect the CMP reluctor wheel for damage.

Did you find the CMP reluctor wheel damaged?

Replace the CMP sensor. Refer to Camshaft Position

Sensor Replacement.

1
'

Go to Step 9

Go to Step 5

Go to Step 9

Go to Step 6

Go to Camshaft
Replacement in
Engine
Mechanical 5.7L.

Go to Step 7

Go to Camshaft
Replacement in
Engine
Mechanical 5.7L.

Go to Step 8

Is the action complete?

Go to Step 9

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC option using the scan tool.
2. Idle the engine at the normal operating temperature.

10

3. Select the Diagnostic Trouble Code (OTC) option anq

the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate vehicle within the Conditions for Running the
OTC as specified in the supporting text, if applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 10

Go to Step2

Go to applicable
OTC table

System OK

Engine

Engine Controls - 5.7L

6-1497

DTC P0342 Camshaft Position (CMP) Sensor Circuit Low Voltage

BRNJWHT 633
PNK/BLK 632

RED 631

BRN/WHT 633

PNK/BLK 632

70
~

1
I
I

C2

RED 631

C1

C2

- - - - - - cMPS;,;s; - - - - - - - - ., Powertrain

~!erence Signal Input

2v Ignition : Control

Feed

PCM

C1=RED
C2 = BLU

Module

I
1 (PCM)
I

CKP Sensor

>

I ~

~------------------J
218515

Circuit Description

The Camshaft Position sensor is mounted through the

top of the engine block at the rear of the valley
cover. The CMP sensor works in conjunction with a
1X reluctor wheel on the camshaft. The reluctor wheel
is inside the engine immediately in front of the rear
cam bearing. The PCM provides a 12 volt power
supply to the CMP sensor as well as a ground and a
signal circuit.
The CMP sensor determines whether a cylinder is on
a firing stroke or on an exhaust stroke. As the
camshaft rotates, the reluctor wheel interrupts a
magnetic field produced by a magnet within the
sensor. The sensors internal circuitry detects this and
produces a signal which the PCM reads. The PCM
uses this 1X signal in combination with the Crankshaft
Position sensor 24X signal in order to determine
crankshaft position and stroke. This diagnostic for the
Camshaft Position sensor tests for a loss of
Camshaft Position sensor signal.
Observe that as long as the Crankshaft Position
sensor 24X signal is available, the engine will start.
The PCM can determine top dead center for all
cylinders by using the Crankshaft Position sensor 24X
signal alone. The Camshaft Position sensor 1X
signal is used by the PCM to determine if the cylinder
at top dead center is on the firing stroke, or the
exhaust stroke. The system attempts synchronization
and looks for an increase in engine speed indicating

the engine started. If the PCM does not detect an

increase in engine speed, the PCM incorrectly
synchronized to the exhaust stroke and will re-sync to
the opposite cam position. A slightly longer cranking
time may be a symptom of this condition.

Conditions for Running the DTC

The ignition voltage is between 9.0 volts and
17.0 volts.
The engine speed is less than 4,000 RPM.

Conditions for Setting the DTC

The PCM detects the Cam signal is stuck low when
the signal should be high for 5.0 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

6-1498

Engine

Engine Controls - 5.7L

Using Freeze Frame and/or Failure Records data

may aid in locating an intermittent condition. If
you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can aid in determining how many
miles since the DTC set. The Fail Counter
and Pass Counter can also aid determining how
many ignition cycles the diagnostic reported a
pass and/or a fail. Operate the vehicle within the
same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you
observed. This will isolate when the DTC failed.
For an intermittent, refer to Symptoms.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles tha:t the diagnostic
runs and does not fail.

A last test failed (current DTC) clears when the

diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Test Description

Diagnostic Aids
Important:

Remove any debris from the PCM connector

surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit

prevents damage to the harness connector

terminals.
The following mechanical conditions may cause
this DTC to set:
- Poor connections/terminal tension at the
sensor. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
- Camshaft ~eluctor wheel damage
- The sensor coming in contact with the
reluctor wheel

The numbers below refer to the step numbers on the

diagnostic table.
2. This step verifies that the fault is present.
4. This step tests the Camshaft Position sensor B+
reference circuit from the PCM to the CMP
jumper harness.
5. This step tests the Camshaft Position sensor
ground circuit from the PCM to the CMP jumper
harness.
6. This step tests the Camshaft Position sensor
signal circuit. Applying a voltage causes the CAM
signal input - High to Low and Low to High
parameter to increase if the circuit and the PCM
are operating properly.
8. A duty cycle that is present, indicates the condition
is intermittent. Inspect the jumper harness for
poor. connections.
9. This step tests the Camshaft Position sensor B+
reference circuit from the CMP jumper harness
to the CMP sensor.
10: This step tests the Camshaft Position sensor
ground circuit from the CMP jumper harness to the
CMP sensor.

DTC P0342 Camshaft Position (CMP) Sensor Circuit Low Voltage

Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

Vatue(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to Step 4

1. Install a scan tool.

2. Idle the engine.

3. Monitor the CAM signal input - High to Low and Low
to High transition parameter in the Engine Data List 1
using the scan tool.
Does the scan .tool parameter. increment?

Engine Controls - 5.7L

Engine

6-1499

DTC P0342 Camshaft Position (CMP) Sensor Circuit Low Voltage ,{cont'd)
Step

Action

Value(s)

Yes

No

Go to Step 4

Go to
Diagnostic Aids

Go to Steps

Go to Step 14

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this DTC and observe the parameters.

3. Turn OFF the ignition for 15 seconds.

4. Idle the engine.
5. Operate the yehJcle within the conditions required for
,.
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic, .
where applicable, are listed in Conditions for Runriing
the DTC.
6. Select the Diagnostic Trouble Code (DTC) option', the
Specific DTC option, then enter the DTC number
'
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

'

.,

1. Turn OFF the ignition.

2. Disconnect the Camshaft Position sensor (CMP)
-,~
jumper harness connector located near the
EGR valve.
3. Turn ON the ignition leaving the engine OFF.
4. Probe the Camshaft Position sensor ignition feed
circuit (PCM h,l;irness side) with one. led of the DMM
and connect the other lead to battery ground.
Does the DMM display near the specified value?
i
'
Measure the voltage from the Camshaft Position sensor
ignition feed circuit to the Camshaft Position sehsor
ground circuit using the DMM J 39200.
Does.the DMM display riear the specified voltage?

1. Start the engine.

2. Monitor the CAM signal input - High to Low and Low.
to High transition in the Engine Data List 1 using the
scan tool.
3;
Momentarily and repeatedly probe the signal circuit
6
,.,,.,.
(PCM side of connector) using a fused jumper
..
connected to B+.
Does the CAM signal input - High to Low and Low tOHigh '
transition counters increment when the jumper contacts
the signal circuit?

B+

'

B+
.Go to Step 6

. Go to Step 16

Go to Step 7

Go to Step 17

1. At the CMP Jumper harness, jumper the ignition feed

and the ground 9ircuit between the PCM side of the
harness to the camshaft position sensor side of the
harness.
2. Connect a third jumper to the signal circuit of the
camshaft position sensor side of the harness.

3.. Idle the engine.

4. Connect the DMM J 39200 to the signal circuit (CMP
side) and ground.
5. Set the DMM to DC voltage and to the duty cycle
position.
Does the DMM display a percentage within the
specified range?

45-55%

'

,,

'

Go to Step B'

Go to Step 9

6..;1500

Engine Controls - 5.7L

Engine

DTC P0342 Camshaft Position (CMP) Sensor Circuit Low Voltage (cont'd)
Value(s).

Step

Action

1. Inspect the PCM to CMP jumper harness for poor

connections. Refer to lrltermittents and Poor
Connections Diagnosis in Wiring Systems.
2. If you find a poor connection repair the condition as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and correct the condition?

1. Turri OFF the ignition.

2. Remove the intake manifold in order to gain access
to the Camshaft Position sensor. Refer to Intake
Manifold Replacement in Engine Mechanical 5.7L.
3. Disconnect the Camshaft Position sensor electrical
connector.
4. Reconnect the CMP jumper harness connector.
5. Turn ON the ignition leaving the engine OFF.
6. Measure the voltage from the Camshaft Position
sensor B+ reference circuit to the battery ground
using the DMM J 39200.
Does the DMM display near the specified voltage?

B+

Measure the voltage from the Camshaft Position sensor

ignition feed circuit to the Camshaft Position sensor
ground circuit using the DMM J 39200.
Does the DMM display near the specified voltage?

B+

1. Disconnect the CMP jumper harness connector.

2. Test the continuity of the CMP signal circuit Gumper
harness) using the DMM J 39200.

Is there continuity and is the resistance within the

specified range?

0-50

Probe the CMP signal circuit with the DMM J 39200

connected to ground.
Is the voltage less than the specified value?

1.0V

10

11

12

13

14

15

16

Probe the CMP signal circuit with the Test Lamp

J 34142-8 connected to B+.
Does the test Lamp illuminate?

Yes

No

Go to Step 35

Go to
Diagnostic Aids

Go to Step 10

Go to Step 19

Go to Step 11

Go to Step 21

Go to Step 12

Go to Step 23

Go to Step 13

Go to Step 25

Go to Step26

Go to Step 31

Go to Step 15.

.Go to Step 28

Go to Step 27

Go to Step 33

Go to Step 33

Go to Step29

'

1. Disconnect the PCM connector C2 located on the

same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
2. Test the continuity of the CMP ignition feed circuit
using the DMM J 39200.
Is there continuity and is the resistance within the
specified range?
Test the CMP ignition feed circuit for the following:
a short to ground.
a short to voltage.
Did you find the condition?
1. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
2. Test the continuity of the CMP ground circuit using
the DMM J 39200.
Is there contfnuity and is the resistance within the
specified range?

0-50

0-5Q

Engine

Engine Controls - 5.7L

6-1501

OTC P0342 Camshaft Position (CMP) Sensor Circuit Low Voltage (cont'd)
Step

Acticm

Value(s)

17

1. Disconnect the PCM connector C1 located on the

opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.
2. Test the continuity of the CMP signal circuit using the
DMM J39200.
Is there continuity and is the resistance within the
specified range?

0-5Q

Yes

No

Go to Step 18

Go to Step 30

Go to Step 35

Go to Step 33

Go to Step35

Go to Step 20

Test the CMP signal circuit for the following:

A grounded circuit
18

A circuit shorted to a voltage

If you find a condition, repair as necessary. Refer to
Wiring Repairs in Wiring Systems.
Did you find and correct the condition?

,.

19

20

21

22

23

24

25

26

1. Inspect the connection at the CMP and at the Jumper

harness connector for poor connections. Refer to
lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

Repair the CMP ignition feed circuit for an open or a short

to ground. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

1. Inspect the connection at the CMP and at the jumper

harness connector for poor connections. Refer to
lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

Repair the CMP ground circuit for an open. Refer to Wiring

Repairs in Wiring Systems:
Is the action complete?

1. Inspect the connection at the CMP and at the jumper

harness connector for poor connections. Refer to
lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

Repair the CMP signal circuit for an open. Refer to Wiring

Repairs in Wiring Systems.
Is the action complete?

Repair the CMP signal circuit for a short to voltage. Refer

to Wiring Repairs in Wiring Systems.
Is the action complete?

Repair the CMP signal circuit for a short to ground. Refer

to -Wiring Repairs in Wiring Systems.
Is the action complete?

Go to Step 35

Go to Step 35

Go to Step 22

Go to Step 35

Go to Step 35

Go to Step 24
-

Go to Step 35

Go to Step 35
-

Go to Step 35

6-1502

Engine Controls - 5.7L

Engine,

DTC. P9342 Camshaft Position (CMP) Sensor OirQuit Low Voltage. ,(cont'd)
Step

27

..

,,

Action

Repair the CMP ignition feea circuirfor:

a short to ground.
a short to voltage.
Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Yes

Value(s)

N~ . '

'

Go to Step 35
'

1. Inspect the. pMP ignition feed circuit for an open

circuit.

28

29

30

2. If you find the circuit open, repair the CMP ignition

feed circuit. Refer to Wiring Repairs in Wiring
Systems.
Did you find and correct the condition?

..
Go to Step 35 .

Repair the CMP ground circuit for an open. Refer to Wiring

Repairs in Wiring Systems.
Is the action complete?

Repair the CMP signal circuit for an open. Refer to Wiring

Repairs in Wiring Systems.
Is the action complete?

Go .to Step 35 ..

31

32

Replace the Camshaft Position sensor. Refer to Camshaft

Position Sensor Replacement.
Is the action complete?

Go to Step 35

1. Inspect the connection at the CMP harness connector

for poor connections. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
2. If you find a poor connection repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

Go to Step 33

. ~}

\"'

Goto Step 35

Go to Step 32

Go to Step 35

1. Inspect the connection at the PCM harness connector

33

34

for poor connections. Refer to lntermittents and Poor

Connections Diagnosis in Wiring Systems.
2. If you find a poor connection repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?
Important: Program the replacement PCM. Refer to PCM
Replacement/Programming.
Replace the PCM.
Is the action complete?

"

Go to Step35

Go toBtep 34

Go to Step 35

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear DTC Information option using the scan tool.

2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (DTC) option and
35

36

t.he Specific DTC option, then enter the DTC number

usintJ the scan tool.
4. Operate the vehicle within the Conditions for Running
the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed? '
Select the Capture Info option and the Review Info option
using thei; scan tool. .. .
..
Does the scan tool display any DTCs that you have not
diagnosed?

_.J:

Go to Step 36

Goto Step 2
\

Go to applicable
DTC Table.

' . ,,'

System OK

Engine

Engine Controls - 5.7L

6-1503

DTC P0343 Camshaft Position (CMP) Sensor Circuit High Voltage

Solid State

Camshaft
Position
(CMP)

Sensor
B

BRN/WHT 633
PNK/BLK 832

RED 631

BRN/WHT 633

PNK/BLK 632

RED 631

4 C1
4 C2
70 C2.
... - - - - - - - - - - - - - - - - - - ., Powertrain
I
Reference C~AP Sensor
2V
I
_ Low
Signal Input
Ignition Control
I
1
I
Feed
I Module
I
PCM
1 (PCM)

I
I

C1=RED
C2 = BLU

CKP Sensor

I )I ~

~------------------J

218515

Circuit Description
The Camshaft Position sensor is mounted through the
top of the engine block at the rear of the valley
cover. The CMP sensor works in conjunction with a
1X reluctor wheel on the camshaft. The reluctor wheel
is inside the engine immediately in front of the rear
cam bearing. The PCM provides a 12 volt power
supply to the CMP sensor as well as a ground and a
signal circuit.
The CMP sensor determines whether a cylinder is on
a firing stroke or on an exhaust stroke. As the
camshaft rotates, the reluctor wheel interrupts a
magnetic field produced by a magnet within the
sensor. The sensors internal circuitry detects this and
produces a signal which the PCM reads. The PCM
uses this 1X signal in combination with the Crankshaft
Position sensor 24X signal in order:to determine
crankshaft position and stroke. This diagnostic for the
Camshaft Position sensor tests for a loss of
Camshaft Position sensor signal. .
Observe that as long as the Crankshaft Position
sensor 24X signal is available, the engine will start.
The PCM can determine top dead center for all
cylinders by using the Crankshaft Position sensor 24X
signal alone. The Camshaft Position sensor 1X
signal is used by the PCM to determine if the cylinder
at top dead center is on the firing stroke, or the
exhaust stroke. The system attempts synchronization
and looks for an increase in engine speed indicating

the engine started. If the PCM does not detect an

increase in engine speed, the PCM incorrectly
synchronized to t11e exhaust stroke and will re-sync to
the opposite cam position. A slightly longer cranking
time may be a symptom of this condition.

Conditions for Running the OTC

The ignition voltage is between 5.0 volts and
17.0 volts.

The engine speed is less than 4,000 RPM.

Conditions for Setting the OTC

The PCM detects the Cam signal is stuck high when
the signal should be low for 5.0 seconds.

Action Taken When the OTC Sets

The PCM illuminates the Malfuriction Indicator
Lamp on the second com,ecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

61504

Engine Controls 5.7L

Engine

Conditions for Clearing the MIUDTC

Using Freeze Frame and/or Failure Records data

may aid in locating an intermittent condition. If
you cannot duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data can aid in determining how many
miles since the OTC set. The Fail Counter
and Pass Counter can also aid determining how
many ignition cycles the diagnostic reported a
pass and/or a fail. Operate the vehicle within the
same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you
observed. This will isolate when the OTC failed.
For an intermittent, refer to Symptoms.

The PCM turns the MIL OFF after three

consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

Test Description

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.
The following mechanical conditions may cause
this OTC to set:
- Poor connections/terminal tension at the
sensor. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
- Camshaft reluctor wheel damage
- The sensor corning in contact with the
reluctor wheel

The numbers below refer to the step numbers on the

diagnostic table.
2. This step verifies that the fault is present.
4. This step tests the Camshaft Position sensor B+
reference circuit from the PCM to the CMP
jumper harness.
5. This step tests the Camshaft Position sensor
ground circuit from the PCM to the CMP jumper
harness.
6. This step tests the Camshaft Position sensor
signal circuit. Applying a voltage causes the CAM
signal input - High to Low and Low to High
parameter to increase if the circuit and the PCM
are operating properly.
8. A duty cycle that is present, indicates the condition
is intermittent. Inspect the jumper harness for
poor connections.
9. This step tests the Camshaft Position sensor B+
reference circuit from the CMP jumper harness
to the CMP sensor.
10. This step tests the Camshaft Position sensor
ground circuit from the CMP jumper harness to the
CMP sensor.

DTC P0343 Camshaft Position {CMP) Sensor Circuit High Voltage

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to Step 4

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

1. Install a scan tool.

2. Idle the engine.

3. Monitor the CAM signal input - High to Low and Low
to High transition parameter in the Engine Data List 1
using the scan tool.
Does the scan tool parameter increment?

Engine Controls - 5. 7L

Engine

6-1505

OTC P0343 Camshaft Position (CMP) Sensor Circuit High Voltage (cont'd)
Action

Step

Value(s)

Yes

No

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 14

Go to Step 6

Go to Step 16

Go to Step 7

Go to Step 17

Go to Step 8

Go to Step 9

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records

data for this DTC and observe the parameters.

3. Turn OFF the ignition for 15 seconds.

4 . Idle the engine.

5. . Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the DTC.
6. Select the Diagnostic Trouble Code (DTC) option, the
Specific DTC option, then enter the DTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

1. Turn OFF the ignition.

2. Disconnect the Camshaft Position sensor (CMP)

4

jumper harness connector located near the

EGR valve.
3. Turn ON the ignition leaving the engine OFF.
4. Probe the Camshaft Position sensor ignition feed
circuit (PCM harness side) with one lead of the DMM
and connect the other lead to battery ground.
Does the DMM display near the specified value?
Measure the voltage from the Camshaft Position sensor
ignition feed circuit to the Camshaft Position sensor
ground circuit using the DMM J 39200.
Does the DMM display near the specified voltage?

B+

B+

1. Start the engine.

2. Monitor the CAM signal input - High to Low and Low

to High transition in the Engine Data List 1 using the

scan tool.
3. Momentarily and repeatedly probe the signal circuit
(PCM side of connector) using a fused jumper
connected to B+.
Does the CAM signal input - High to Low and Low to High
transition counters increment when the jumper contacts
the signal circuit?

1. At the CMP Jumper harness, jumper the ignition feed

and the ground circuit between the PCM side of the
harness to the camshaft position sensor side of the
harness.
2. Connect a third jumper to the signal circuit of the
camshaft position sensor side of the harness.

3. Idle the engine.

4. Connect the DMM J 39200 to the signal circuit (CMP
side) and ground.
5. Set the DMM to DC voltage and to the duty cycle
position.
Does the DMM display a percentage within the
specified range?

45-55%

6-1506

Engine;Controls - 5.7L

Engine

DTC P0343 Camshaft Position (CMP) Sensor Circuit High Voltage (cont'd)
Step

Action

Value(s)

1. Inspect the PCM to CMP jumper harness for poor

connections. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.

No

Yes

(
,.

2. If you find a poor connection repair the condition as

necessary. Refer to Repairing Connector Terminals in
Wiring Systems.

Go to,Step 35

Did you find and correct the condition?

Go to
Diagnostic Aids

1. Turn OFF the ignition.

2. Remove the intake mani_fold in order to gai'n access .

to the Camshaft Position sensor. Refer to Intake
Manifold Replacement in Engine Mechanical 5.7L:
3. Disconnect the Camshaft Position sensor electrical
connector.

B+

4. Reconnect the CMP jumper harness connector.

5. Turn ON the ignition leaving the engine OFF.
6. Measure the voltage from the Camsh.aft Position
sensor B+ reference circuit to the battery ground
using the DMM J 39200.

..
'

..Go to Step

Does the DMM display near the specified voltage?

10

Measure the voltage from the Camshaft Position sensor

ignition feed circuit to the Camshaft Position sensor
ground circuit using the DMM J 39200.

10

Go to Step 19

Go to Step _11.
.

Go to Step 21

B+

Does the DMM display near the specified voltage?

'

'

1. DisconnecUhe CMP jumper harness connector.

'

,'

11

2. Test the continuity of.the CMP.. signal circuit (jumper

harness) using the DMM J 39200.
Is there continuity and is the resistance within the
specified range?

12

14

"

Probe the CMP signal .circuit with.theDMM.J 39200.

connected to ground.
Is the voltage less than the specified value?

13

0-50,

Probe the CMP signal circuit with the Test Lamp

J 34142-8 connected to B+.
Does the test Lamp illuminate?
1. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
,,
Replacement/Programming.
2. Test the continuity of the CMP igni!ion feed. circuit
using the DMM J 39200.

15

a short to voltage.

Go to Step23

Go to _Step 1.3

Go to Step25

Go to Step26

Go to Step 31

Go to Step 15

Go to Step28

Go to Step 27

Go to Step 33

Go to Step 33

Go to Step 29

1.0V
'

..

0-50

Is there continuity and is the resistance within the

specified range?
Test the CMP ignition feed circuit for the following:
a short to ground.

Go to Step 12

Did you find the condition?

1. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
16

2. Test the continuity of the CMP ground circuit using

the DMM .J 39200.
Is there continuity and is the resistance within the
specified range?

0-50

Engine

Engine Controls - S.7L

6-1507

.OTC P034a Camshaft Position (.CMP) Sensor Circuit High Voltage (cont'd)
Step

Action

Value(s)

17

1. Disconnect the PCM connector C1 located on the

opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.
2. Test the continuity of the CMP signal circuit using the
DMM J39200.
Is there continuity and is the resistance within the
specified range?

0-50

Yes

...

No

Go to Step 18

Go to Step 30

Go to Step 35

Go to Step 33

Go to Step 35

Go to Step20

Test the CMP signal circuit for the following:

18

19

20

21

A grounded circuit
A circuit shorted to a voltage
If you find a condition, repair as necessary. Refer to
Wiring Repairs in Wiring Systems.
Did you find and correct the condition?

1. rnspect the connection at the CMP and at the i\Jmper

harness connector for poor connections. Referto
lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

Repair the CMP ignition feed circuit for an open or a short

to ground. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

1. Inspect the connection at the CMP and at the jumper

harness connector for poor connections. Refer to
lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

Go to Step 35

Go to Sti'Jp 35

Go to Step 22

Repair the CMP ground circuit for an open. Refer to Wiring

Go to Step 35

Is the action complete?

23

'

24

1. Inspect the connection at the CMP and at the jumper

harness connector for poor connections. Refer to
lntermittents and Poor Connections Diagnosis in
Wirir:1g Systems.
2. If you find a poor connection repair as necessary.
Refer to Repairing Connector Terminals in Wiring.
Systems.
Did you find and correct the condition?
Repair the CMP signal circuit for an open. Refer to Wiring
Repairs in Wiring Systems.

Go to .Step 35
'.

26

Go to Step 24

Go to Step 35

Is the action complete?

25

22 Repairs in Wiring Systems.

Repair the CMP signal circuit for a short to voltage. Refer

to Wiring Repairs in Wiring Systems.
Is the action complete?

Repair the CMP signal circuit for a short to ground. Refer

to Wiring FJepairs rn Wiring Sy~tems:
Is the action complete?

.Go to Step 35

Go to Step 35

6-1508

Engine Controls - 5.7L

Engine

DTC P0343 Camshaft Position (CMP) Sensor Circuit High Voltage (cont'd)
Step

Action

Value(s)

Repair the CMP ignition feei'd circuit for:

a short to ground.
a short to voltage.
Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

-.

28

1. Inspect the CMP ignition feed circuit for an open

circuit.
2. If you find the circuit open, repair the CMP ignition
feed circuit. Refer-to Wiring Repairs in Wiring
Systems.
Did you find and correct the condition?

29

Repair the CMP ground circuit for an open. Refer to Wiring

Repairs in Wiring Systems.
Is the action complete?

27

30

Repair the CMP signal circuit for an open. Refer to Wiring

Repairs in Wiring Systems.

31

32

33

1. Inspect the connection at the PCM harness connector

for poor connections. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
2. If you find a poor connection repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.

34

35

36

Replace the PCM.

Is the action complete?
1. Select the Diagnostic Trouble Code (OTC) option and
the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go _to Step 33

Go to Step 35

Go to Step 35

Go to Step 35

Go to Step32

Go to Step 35

'\

Did you find and correct the condition?

Important: Program the replacement PCM. Refer to PCM
Replacement/Programming.

Go to Step 35

Did you find and correct the condition?

Replace the Camshaft Position sensor. Refer to Camshaft
Position Sensor Replacement.
Is the action complete?

No

Go to Step 35

Is the action complete?

1. Inspect the connection at the CMP harness connector
for poor connections. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
2. If you find a poor connection repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.

Yes

Go to Step 35

Go to Step34

Go to Step 35

Go to Step 36

Go to Step2

Go to applicable
OTC Table

System OK

Engine

Engine Controls - 5.7L

6-1509

DTC P0351 Ignition Coil 1 ControlCircuit

!Loe

)
- - -- ...

L-----

.-:" -

-:" .,.. -

Powertrain

-. ,

c1~c!o

PNK 639
Cell11

: Control

IJ
---- -~ ~: '~1:1 ~ ~ ~- ~B:1:~-----' ~

PNKM'HT 639

Fuse Block
Details

I"' -

+--

C2=BLU

Ignition

Control
#1

Reference

Low

Module

1 (PCM)
1

i,

...,..

PNK 639

Ignition Coil/ """ .... I\Aodules #3, 5 and 7

------,
D
Ignition
Feed

r ~ru:k

c
Ignition
Control
Signal

rn

Ignition

Ignition Coil/
Modules #3, 5 and 7

Coil/
Module
#1

L----------r---.~ -:-

-f--.....,..--~

Ground

.______A~..

....

BLK 550

,.
I
J

BLK

Ground
Distribution

550

Ce1114

BLK 550
BLK
450

218519

Circuit Description
The ignition system on this engine uses an individual
ignition coil/module for each cylinder. The PCM
controls the ignition system operation. The PCM
controls each coil using one of eight Ignition Control
(IC) circuits. The PCM commands the IC circuit
low when a spark event is requested. This causes the
IC module to energize the ignition coil to create a
spark at the spark plug. Each ignition coil/module has
the following circuits:
A power feed
A ground circuit

An ignition control (IC) circuit

A reference low circuit
Sequencing and timing are PCM controlled. This OTC
sets when the IC circuit is out of range.

Conditions for Running the DTC

The ignition voltage is between 9.0 volts and
17.0 volts.
The engine is operating.

Conditions for Setting the DTC

The PCM detects the ignition control circuit is
grounded, open or shorted to a voltage.
All conditions met for less than 1 second.

Engine Controls .. s,.7L

Engine

Action Taken When the DTC Sets

JheJOIIO'Ning FTisiY Ciluse an)nterfiF)lttent:

- Poorconnections. Test-for.adequate terminal
tension. Refer to fnterrriittents and Poor
'
.. ..Connections Diagnosis in Wiring Systems for
proper procedure.
2' Corrosion

6-1510

The PCM illuminates the Malfunction Indicator

Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
tt:i~ Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Free1e Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that tne
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM' or a
component harness connector, use the Connector
Test Adapte-r Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.

- Mis-ro,uted hr::irness
- Rubbed thro~,9~ -wjr~ in~ulation
.... - Broken wire inside the insulation
Using Freeze Frame and/pr Failure Records data
may aid in locating an intermittent condition. If
you cannot duplicate the OTC_, the 'information
included in the Freeze Frame and/or, Failure
R_ecords data can .aid in determining how many
miles since the OTC set. The Fail Counter
and Pass Counter can also aid determining how
many ignition cycles the diagnostic reported a
pass and/or a fail. Operate the vehicle within the
same freeze frame cooditions (RRM, load,
vehicle speed, temperature etc.) thatyou
observed. This will isolate when the OTC failed.
For an intermittent condition, refer to Symptoms.

.. Test Descr_iption
The numbers below refer to the step numbers on the
diagnostic tablei. - '
'!.

,)

',

:,

?,.,rlhis step verifies that the fault is present.

4. This step tests,. the integrity of the IC circuit and

the PCM but~CJt.
5. This step tests for a short to grpund on the IC
control circuit.

Engine

Engine Controls - 5.7L 6-1511

OTC P0351 Ignition Coil 1 Control Circuit

Step

Action
Did you perform the Powertrain On-Board Diagnostic
(OBD) System Check?

Important: If ail the Ignition Control (IC) DTCs are set at

the same time, inspect the IC ground circuits for an open.
1. Install a scan tool.
2. Idle the engine.
3. Monitor the (IC) Ignition Control status for the cylinder
with the ignition control DTC using the scan tool in
the Misfire Data List.

Value(s)

1. Turn OFF the engine.

2. Disconnect the ignition coil electrical harness.
3. Idle the engine.
4. Measure the frequency at the ignition control signal
circuit using the DMM J 39200 on the DC Hertz
setting.

Measure the voltage at the ignition control signal circuit

using the DMM J 39200.
Is the voltage greater than the specified value?

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 8

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 7

Go to Step 10

Go to Step 11

Go to Step 10

3.0-20 Hz

1.0 volts

Test the resistance from the IC circuit (at the ignition coil
harness connector) to ground using the DMM J 39200.
Does the DMM indicate OL?

Is the action complete?

Go to Step 4

1. Turn OFF the ignition.

2. Disconnect the PCM connector C1 located on the
opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.
3. Test the continuity from the IC circuit (at the ignition
coil harness connector) to the PCM connector using
the DMM J 39200.
Does the DMM indicate continuity?

Replace the ignition coil. Refer to Ignition Coil

Replacement in Engine Electrical.

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Is the frequency within the specified range?

No

Does the scan tool in9icate Fault?

1. Turn ON the ignition leaving the engine OFF.
2. Review the Freeze Frame and/or Failure Records
data for this DTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the DTC.
6. Select the Diagnostic Trouble Code (DTC) option, the
Specific DTC option, then enter the DTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

Yes

Go to Step 13

6-1512

Engine Controls - 5.7L

Engine

DTC P0351 Ignition Coil 1 Control Circuit (cont'd)

Step

10

Action

Value(s)

Repair the Ignition Control circuit for a short to voltage.

Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Repair the Ignition Control circuit for an open or grounded

circuit. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Yes

No

Go to Step 13

Go to Step 13

1. Inspect for a poor connection at the PCM. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.

11

2. If you find a poor connection repair the condiUon as

necessary. Refer to Repairing Connector Terminals in

Wiring Systems.
Did you find and correct the condition?

12

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

Go to Step 13

Go to Step 12

Go to Step 13

1. Select the Diagnostic Trouble Code (OTC) option and

13

the Clear OTC Information option using the scan tool.

2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.

Does the scan tool indicate that this test ran and passed?

14

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tob1 display any DTCs that you have not
diagnosed?

Go to Step 14

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5.7L

6-1513

DTC P0352 Ignition Coil 2 Control Circuit

!Hot In RUN And START I

'" - - - - -

- - - - , Underhood
1
INJ 2
Electrical
MiniFuse . 1 Center 2

I Power
Distribution
I Cell 10
I

15A

~ _ _ _ _ _

_ ___

~ - - - - - - - - - - - - - - ~M- - ~ Powertrain
I

PNK 839

PNK 839

Ignition
Control
#2

Reference
Low

LJ:J

I Control

C1=RED
C2=BLU

Fuse Block
Details
Cell11

p:;r;:-,

Module
1 (PCM)
i,
1
I

_
-

+-BRN/WHT 2130

PNK 839

Ignition Coil/ - Modules # 4, 6 and 8

....---------- - - - - - D
Ignition
Feed

r ~ru:k

c
Ignition
Control
Signal

Ignition
Coil/
Module

Ignition Coil/
Modules #4, 6 and 8

.,.

# 2

'-------------r------

......___!'3round
_

rn

Reference
Low

____.

Af

BLK 550

BLK
550

Ground
Distribution
Cell14

BLK 550
BLK
450

218521

Circuit Description
The ignition system on this engine uses an individual
ignition coil/module for each cylinder. The PCM
controls the ignition system operation. The PCM
controls each coil using one of eight Ignition Control
(IC) circuits. The PCM commands the IC circuit
low when a spark event is requested. This causes the
IC module to energize the ignition coil to create a
spark at the spark plug. Each ignition coil/module has
the following circuits:
A power feed
A ground circuit
An ignition control (IC) circuit
A reference low circuit
Sequencing and timing are PCM controlled. This DTC
sets when the IC circuit is out of range.

Conditions for Running the DTC

The ignition voltage is between 9.0 volts and
17.0 volts.
The engine is operating.

Conditions for Setting the DTC

The PCM detects the ignition control circuit is
grounded, open or shorted to a voltage.
All conditions met for less than 1 second.

6-1514

Engine Controls - 5.7L

Engine

Action Taken When the OTC Sets

The following may cause an intermittent

- Poor connections. Test for adequate terminal
tension. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems for
propsr procedure.
- Corrosion
- Mis-routed harness
- Rubbed through wire insulation
- Broken wire inside the insulation
Using Freeze Frame and/or Failure Records data
may .aid in locating an intermitte.nt condition. If
you cannot duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data can aid in determining how many
miles since the OTC set. The Fail Counter
and Pass Counter can also aid determining how
many ignition cycles the diagnostic reported a
pass and/or a fail. Operate the vehicle within the
same freeze frame conditions (RPM, load;
vehicle speed, temperature etc.) that you
observed. This will isolate when the OTC failed.
For an intermittent condition, refer to Symptoms.

The PCM illuminates the Malfunction Indicator

Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test thatrequires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step verifies that the fault is present.
4. This step tests the integrity of the IC circuit and
the PCM output.
5. This step tests for a short to ground on the IC
control circuit.

Engine Controls - 5.7L

Engine

6-1515

OTC P0352 Ignition Coil 2 Control Circuit

Step

Action

..

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 8

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 7

Go to Step 10

Go to Step 11

Go to Step 10

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

Important: If an the clgnition Qontrol (IC) DTCs are set at

the same time, inspect the IC ground circuits for an open.
1. Install a scan tool.

2. Idle the engine.

3. Monitor the (IC) Ignition Control status for the cylinder

with the ignition control OTC using the scc:i.n tool in

the Misfire Data List.
Does the scan tool indicate Fault?
1. Turn ON the ignition leaving the engine OFF.
2. Review the Freeze Frame and/or Failure Records
data for this OTC and observe the parameters.

3. Turn OFF the ignitionfor 15 seconds .

""<

4. Start the engine.

5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.
6. Select the Diagnostic Trouble Code (OTC} option, the
Specific, OTC option, then enter the OTC numper
. using the :Scan tool.

Does the scan tool indicate that this diagnostic failed this
ignition?

1. Turn OFF the engine.

2. biscon'nect the ignition coil electrical harness.

3. Idle the engine.

4

4. Measure the frequency at the ignition control signal

circuit using the DMM J 39200 on the DC Hertz
setting.
Is the frequency within the specified range?
Measure the voltage at the ignition control signal circuit
using the DMM J 39200.

3.0-20 Hz

1.0 volts

Is the voltage greater than the specified value?

1. Turn OFF the ignition.

2. Disconnect the PCM connector C1 located on the

opposite side of the manufacturer's logo. Refer to

PCM Replacement/Programming.
3. Test the continuity from the IC circuit (at the ignition
coil harness connector) to the PCM connector using
the DMM J 39200.
Does the DMM indicate continuity?
Test the resistance from the IC circuit (at the ignition coil
harness connector) to ground using the DMM J 39200.
Does the DMM indicate OL?
Replace the ignition coil. Refer to Ignition Coil
Replacement in Engine Electrical.
Is the action complete?

Go to Step 13

6-1516

Engine Controls - 5.7L

Engine

DTC P0352 Ignition Coil 2 Control Circuit (cont'd)

Step

10

Action

Value(s)

Repair the Ignition Control circuit for a short to voltage.

Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Repair the Ignition Control circuit for an open or grounded

circuit. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Yes

No

Go to Step 13
-

Go to Step 13

1. Inspect for a poor connection at the PCM. Refer to

11

12

lntermittents and Poor Connections Diagnosis in

Wiring Systems.
2. If you find a poor connection repair the condition as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and correct the condition?
Important: Program the replacement PCM. Refer to PCM
Replacement/Programming.
Replace the PCM.
Is the action complete?

Go to Step 13

Go to Step 12

Go to Step 13

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.

2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (OTC} option and
13

the Specific OTC option, then enter the OTC number

using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.

Does the scan tool indicate that this test ran and passed?

14

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 14

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine Controls - 5. 7L

Engine

6-1517

DTC P0353 Ignition Coil 3 Control Circuit

,!Hot In RUN And START I

)

r - - - I Power
Distribution

I cen 10

~ _ _ _ _ _

,Underhood
1

1Electrical
MiniFuse
Center 2

JS

- INJ 1

15A

_ ___

PNK/WHT 639

~ - - - - - - - - - - - - - - P~M- - ., Powertrain
I

c1 - RED

C2=BLU

I
I

Ignition
Control

Reference

LJiJ

Control
Module
I (PCM)
:
I

.....,....__,,.,......,......,-PNK/WHT 639
Fuse Block
Details

+ - -

Cell 11

PNK/WHT 639

LT BLU 2123

-------------Ignition Coil/ - Modules # 1, 5 and 7

-:--

------,
D

Ignition

Ignition

Reference

Feed

Control
Signal

Low

rnr ~ru:k

......___Ground
_

....

Ignition

Ignition Coil/
Modules #1, 5 and 7

Coil/
Module
____.

#3

I_-----

At,____________

BLK 550

BLK

Ground

Distribution

550

Ce1114

BLK 550
BLK
450

218522

Circuit Description
The ignition system on this engine uses an individual
ignition coil/module for each cylinder. The PCM
controls the ignition system operation. The PCM
controls each coil using one of eight Ignition Control
(IC) circuits. The PCM commands the IC circuit
low when a spark event is requested. This causes the
IC module to energize the ignition coil to create a
spark at the spark plug. Each ignition coil/module has
the following circuits:
A power feed
A ground circuit
\

An ignition control (IC) circuit

A reference low circuit
Sequencing and timing are PCM controlled. This OTC
sets when the IC circuit is out of range.

Conditions for Running the OTC

The ignition voltage is between 9.0 volts and
17.0 volts.
The engine is operating.

Conditions for Setting the OTC

The PCM detects the ignition control circuit is
grounded, open or shorted to a voltage.
All conditions met for less than 1 second.

6-1518

Engine Controls - 5.7L

Ehgine

Action Taken When the DTC Sets

The following may cause an intermittent '

- Poor cor:mections. T~.stfor adequate terminal
tension. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems for
proper
procedure.
,,
"
!;
- Corrosion
- Mi.s-routed harness.
- Rubbed through wire insulation
- Broken wire inside the insulation
Using Freeze Frame and/or Failure Records data
may aid in locating an intermittent condition. If
you cannot duplicate the DTC, ,he information
included in the Freeze Frame and/or F;3ilure
flecords data can aid in determining how many
miles since the DTC set. The Fail Counter
and Pass Counter can also aid determining how
many ignition cycles the diagnostic reported a
pass and/or a fail. Operate the vehicle within the
same freeze frame conditions (RPM; load,
vehicle speed, temperature etc.) that you
observed. This will isolate when the DTC failed.
For an intermittent condition, refer to Symptoms.

The PCM illuminates the Malfunction Indicator

Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
' time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIL/DTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM..
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit.
prevents damage to the harness connector
terminals.

Test Description
The numbers below refer to the step numbers on the
dic1.g11ostic table. .
2, 'This step verifies that the fault is present.
4. This step tests the integrity of the IC circuit and
the PCM output.
.
5. This step tests for a short to ground on the IC
control circuit.

Engine Controls - 5.7L

Engine

6-1519

OTC P0353 Ignition Coil 3 Control Circuit

Step

..

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 4

Go to Step 3

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Important: If all the Ignition Control (IC) DTCs.are set at

the same time, inspect the IC ground circuits for an open,
1. Install a scan tool.

2. Idle the engine.

3. Monitor the (IC) Ignition Control status for the cylinder

2
';

with the ignition control OTC using the scan tool in

the Misfire Data List.
Does the scan tool indicate
.. Fault?,..

'

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records

'

data for this OTC and observe the parameters.

3. Turn OFF the ignition for 15 ,Seconds.

4. Start the engine.
5. Operate the vehicle within the conditions required for

'

this diagnostic to run, and as close to the conditions

recorded in Freeze Frame/Failure Records as
'!
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.

6. Select the Diagnostic Trouble Code (OTC) option, the

Specific OTC option, then enter the OTC numb~H
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

1.
2.
3.
4.

Go to
Diagnostic Aids

Go to Step B

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 7

Go to Step 10

Go to Step 11

Go to Step 10

Turn OFF the engine.

Disconnect the ignition coil electrical harness.
Idle the engine.
Measure the frequency at the ignition control signal
circuit using the DMM J 39200 on the DC Hertz
setting.

3.0-20 Hz

Is the frequency within the specified range?

Go to Step 4

Measure the voltage at the ignition control signal circuit

using the DMM J 39200.

1.0 volts

Is the voltage greater than the specified value?

1. Turn OFF the ignition.

2. Disconnect the PCM connector C1 located on the
6

opposite side of the manufacturer's logo. Refer to

PCM Replacement/Programming.

3. Test the continuity from the IC circuit (at the ignition

coil harness connector) to the PCM connector using

the DMM J 39200.
Does the DMM indicate continuity?

Test the resistance from the IC circuit (at the ignition coil
harness connector) to ground using the DMM J 39200.

Does the DMM indicate OL?

Replace the ignition coil. Refer to Ignition Coil

Replacement in Engine Electrical.
Is the action complete?

Go to Step 13

6-1520

Engine Controls - 5.7L

Engine

OTC P0353 Ignition Coil 3 Control Circuit (cont'd)

Step

Action

Repair the Ignition Control circuit for a short to voltage.

Refer to Wiring Repairs in Wiring Systems.

Value(s)

Is the action complete?

10

Repair the Ignition Control circuit for an open or grounded

circuit. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Yes

No

Go to Step 13

Go to Step 13

1. Inspect for a poor connection at the PCM. Refer to

11

lntermittents and Poor Connections Diagnosis in

Wiring Systems.
2. If you find a poor connection repair the condition as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.

Did you find and correct the condition?

12

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

Go to Step 13

Go to Step 12

Go to Step 13

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear DTC Information option using the scan tooL

2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (DTC) option and
13

the Specific DTC option, then enter the DTC number

using the scan tool.

4. Operate the vehicle within the Conditions for Running

the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

14

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 14

Go to Step 2

Go to the
applicable
DTC table

System OK

(
\

Engine Controls,- 5.7L

Engine

6-1521

DTC P0354 Ignition Coil 4 Control Circuit

[M;"l

L:tiJ

Ignition Coil/ - Modules # 2, 6 and a

------,
D
Ignition
Feed

r
m~iu~k

c
Ignition
Control
Signal

Reference
Low

Ignition
Coil/
Module

Ignition Coil/
Modules #2, 6 and 8

L---------r------

Ground
L...-~..;........~---J

#4

Af

BLK 550

BLK
550

Ground
Distribution
Cell14

BLK 550
BLK

450

218524

Circuit Description
The ignition system on this engine uses an individual
ignition coil/module for each cylinder. The PCM
controls the ignition system operation. The PCM
controls each coil using one of eight Ignition Control
(IC) circuits. The PCM commands the IC circuit
low when a spark event is requested. This causes the
IC module to energize the ignition coil to create a
spark at the spark plug. Each ignition coil/module has
the following circuits:
A power feed
A ground circuit
An ignition control (IC) circuit
A reference low circuit
Sequencing and timing are PCM controlled. This DTC
sets when the IC circuit is out of range.

Conditions for Running the OTC

The ignition voltage is between 9.0 volts and
17.0 volts.
The engine is operating.

Conditions for Setting the OTC

The PCM detects the ignition control circuit is
grounded, open or shorted to a voltage.
All conditions met for less than 1 second.

5.,1522

Engine Controls - 5.7L

Engine

Action Taken When the DTC Sets

The following may cause an intermittent

- Poor connections. Test for adequate terminal
tension. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems for
proper procedure.
- Corrosion
- Mis-routed harness
- Rubbed through wire insulation
- Broken wire inside the insulation
Using Freeze Frame and/or Failure Records data
may aid in locating an intermittent condition. If
you cannot duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data can aid in determining how many
miles since the OTC set. The Fail Counter
and Pass Counter can also aid determining how
many ignition cycles the diagnostic reported a
pass and/or a fail. Operate the vehicle within the
same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you
observed. This will isolate when the OTC failed.
For an intermittent condition, refer to Symptoms.

The PCM illuminates the Malfunction Indicator

Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC} clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step verifies that the fault is present.
4. This step tests the integrity of the IC circuit and
the PCM output.
5. This step tests for a short to ground on the IC
control circuit.

Engine Controls - 5.7U 6-1523

Engine

OTC P0~54 ~ntti~h '(?oil 4 Control Circuit .

.
.~Jep.

Action

.....

.,

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Bo.ard Diagnostic
(;OBD) System
Ctieck

Go.to $tep 4

Go to Step 3

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Important: If all the Ignition Control (IC) DTCs are set at

the same. time, inspect the IC ground circuits for an open.
1. Install a scan tool.
,
2

2. Idle the engine.

3. Monitor the (IC) lgnition:control status for the cylinder
with the ignition control OTC using the scan tool in
'
the Misfire Data List.
Does the scan

tool indicate fault?

'

...

1. Turn ON the ignition leaving the engine OFF.

.!

2. Review the Freeze Frame and/or Failure Records

data for ,this OTC an,d observe the parameters.
3. Turn OFF the ignition f-0r 15seconds,.

4. Start the engine.

5. Operate the vehicle witnin the conditions required 'fo~
this diagnostic to run, and as close to the 9onditions
recorded in Freeze Frame/Failure Records a$ b
possible. Special operating conditions that Y meed '
to meet before the PCM. will run this diagnostic,
where applicable, are listed in Conditions fpr Runnirig
the OTC.
.
.

6. Select the Diagnostic Trouble Code (OTC) option, the

Specific DTG ,opti<:,O, then enter the OTC rtumber
using the scan tool.
.
: '.

,.,,"'

Go to Step 4

Go to
Diagrrosfic Aids

Go to Step B

Go to Step 5

Go to Step 9

Go to Step 6

1. Turn OFF the ignition.

2. Disconnect the PCM connector C1 located on the
opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.
3. Test the continuity from the IC circuit (at the ignition
coil harness connector) to the PCM connector using
the DMM J 39200.
Does the DMM indicate continuity?

Go to Step 7

Go to Step 10

Test the resistance from the IC circuit (at the ignition coil
harness connector) to ground using the DMM J 39200.
Does the DMM indicate OL?

Go to Step 11

Go to Step 10

Does the scan tool indicate that this diagnostic Jailed ttiis

ignition?

........

,.t;

Turn 9FFithe engine.

2. Disconnect the ignition coil electrical harness.

3. Idle the engine.

4. Measure the frequency at the ignition control signal

circuit using the DMM J 39200 on the DC Hertz
setting.

3.0-20 Hz

Is the frequency within the specified range?

Measure the voltage at the ignition control signal circuit

using the DMM J 39200.
Is the voltage greater than the specified value?

1.0 volts

Replace the ignition coil. Refer to Ignition Coil

Replacement in Engine Electrical.
Is the action complete?

Go to Step 13

6-1524

Engine Controls - 5. 7L

Engine

DTC.P0354 Ignition Coil 4 C.ontrol Circuit (cont'd)

Step
9

Action
Repair the Ignition Control circuitfcir a short to voltage.
Refer to Wiring Repairs in Wiring Systems.

Value(s)

Is the action complete?

10

Repair the Ignition Control circuit for an open or grounded

circuit. Refer to Wiring Repairs in. Wiring Systems.

Yes

No

Go to Step 13

Is the action complete?

Go to Step 13

1. Inspect for a poor connection at the PCM. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.

11

2. ff you find a poor connection repair the condition ~s

necessary. Refer to Repairing Connector f erminals in

Wiring Systems.

Did you find and correct the condition?

12

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

Go to Step 13

Go to Step 12

Go to. Step 13

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear DTC Information option using the scan tool.

2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Tr.ouble Code (DTC) option and
13

the Specific DTC option, then enter the DTC number

using the scan tool.

4. Operate the vehicle within the Conditions for Running

the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

14

Select the Capture Info option and the Review Info optiqn .
u,sing the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 14

Go to Step 2

(
\

Go to the
applicable
DTC table

System OK

Engine

Engine Controls - 5.7L

6-1525

DTC P0355 Ignition Coil 5 Control Circuit

!Hot In RUN And START l

P-;;~ - ;.--=---=i -

- - -

~ Unde~hood
1 Electrical
Min,Fuse
Center 2
15

Distribution
I
Cell 10

J9 " l~J .1

Ja

:
-

..

PNK/WHT 639

'" -

I
I

Ignition
Control

P:K~~T 639

PNK/WHT 639

- PCM

Powertrain
I Control
I M d I

.,

Cl= RED
C2=BLU

O U0

I (PCM)

fl- ~ ~ ~ ~';~:r:~g-----~
Reference

DK GRN 2125

-------------Ignition Coil/ - Modules # 1, 3 and 7

------,
D
Ignition
Feed

r
m~iu~k

c
Ignition
Control
Signal

Reference
Low

Ignition
Coil/
Module
#S

Ignition Coil/
Modules #1, 3 and 7

,.

'----------r----,- --

Ground

i....---------'

...

Af

.J

BLK 550

BLK
550

Ground
Distribution
Ce1114

BLK 550
BLK
450

218526

Circuit Description
The ignition system on this engine uses an individual
ignition coil/module for each cylinder. The PCM
controls the ignition system operation. The PCM
controls each coil using one of eight Ignition Control
(IC) circuits. The PCM commands the IC circuit
low when a spark event is requested. This causes the
IC module to energize the ignition coil to create a
spark at the spark plug. Each ignition coil/module has
the following circuits:
A power feed
A ground circuit
An ignition control (IC) circuit
A reference low circuit
Sequencing and timing are PCM controlled. This DTC
sets when the IC circuit is out of range.

Conditions for Running the DTC

The ignition voltage is between 9.0 volts and
17.0 volts.
The engine is operating.

Conditions for Setting the DTC

The PCM detects the ignition control circuit is
grounded, open or shorted to a voltage.
All conditions met for less than 1 second.

5.:.1525

Engine Controls $.7L

Engine

Action Taken When the DTC Sets

The following may cause an intermittent:

- Poor connections. Test for adequate terminal.
tension. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems for
proper procedure.
- Corrosion
- Mis-routed harness
- Rubbed through wire insulation
- Broken wire inside the insulation
Using Freeze Frame and/or Failure Records data
may aid in locating an intermittent condition. If
you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can aid in determining how many
miles since the DTC set. The Fail Counter
and Pass Counter can also aid determining how
many ignition cycles the diagnostic reported a
pass and/or a fail. Operate the vehicle within the
same freeze frame conditions (RPM, load,,
vehicle speed, temperature etc.) that you
observed. This will isolate when the DTC failed.
For an intermittent condition, refer to Symptoms.

The PCM illuminates the Malfunction Indicator

Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
. 2. This step verifies that the fault is present.
4. This step tests the integrity of the IC circuit and
the PCM output.
5. This step tests for a short to ground on the IC
control circuit.

Engine Controls - 5.7L

Engine

6-1527

OTC P0355 Ignition Coil 5 ControkCircuit

Step

Value(s).

Action

Did you perform the Powertr,ain On-Board Diagnostic

(OBD) System Check?

Yes
',

Gqto Step 2

No

Important: If all the Ignition Control (IC) DTCs are set at

the same time, inspect the IC ground circuits for an open.
1. Install a scan tool.
2. Idle the engine.
3. Monitor the (IC) Ignition Control status for the cylinder
with the ignition control OTC using the scan tool in
the Misfire Data List.
Does the scan tool indicate Fault?
,i

!
Go to A
Powertrain On
Board Diagnostic:
(01;30) System ,
Check

'

Go to Step 4

Go to Step 3
i

1. Turn ON the ignition leaving the engine OFF

2. Review the Freeze Frame and/or Failure Records
data for this OTC and observe the parameters.

3. Turn OFF the ignition for 15 seconds.

i'
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the.conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCtl{l will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.
.

'"'

..

.
'
<

6. Sel$ct the Diagnostic Trouble Code (OTC) option, the

Specific OTC option, then enter the OTC nurn.ber
using .the scan tooL .. ' '
Does the scan tool indicate 1hat this diagnostic! failed this
ignition?
'

1. Turn OFF the engine.

2. Disconnect the ignition coil electrical harness.
3. Idle the engine.
4. Measure the frequency at the ignition control signal
circuit using the DMM J 39200 on the DC Hertz
setting.
Is the frequency within the specified range?
Measure the voltage at the ignition control signal circuit
using the DMM J 39200.

':

'

Go to Step 4

3.0-20 Hz

Test the resistance from the IC circuit (at the ignition coil
harness connector) to ground using the DMM J 39200.
Does the DMM indicate OL?

Is the action complete?

Go to Step B

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 7

Go to Step 10

Go to Step 11

Go to Step 10

1.0 volts

1. Turn OFF the ignition.

2. Disconnect the PCM connector C1 located on the
opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.
3. Test the continuity from the IC circuit (at the ignition
coil harness connector) to the PCM connector using
the DMM J 39200.
Does the DMM indicate continuity?

Replace the ignition coil. Refer to Ignition Coil

Replacement in Engine Electrical.

Is the voltage greater than the specified value?

Gd to
Diagnostic.Aids '.

Go to Step 13

6-1528

Engine Controls - 5;7L

Engine

OTC P0355 Ignition Coil 5 Control Circuit (cont'd)

Step
9

Action
Repair the Ignition Control circuit for a short to voltage.
Refer to Wiring Repairs in Wiring Systems.

Value(s)

11

Repair the Ignition Control circuit for an open or grounded

circuit. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?
1. Inspect for a poor connection at the PCM. Refer to
lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection repair the condition as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.

Go to Step 13

12

Go to Step 13

Go to Step 13

Did you find and correct the condition?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

No

Is the action complete?

10

Yes

Go to Step 12

Go to Step 13

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
13

3. Select the Diagnostic Trouble Code (OTC) option and

the Specific OTC option, then enter the OTC number
using the scan tool.

4. Operate the vehicle within the Conditions for Running

the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

14

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 14

Go to Step2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5.7L

6-1529

DTC P0356 Ignition Coil 6 Control Circuit

rel
L.::'...1

lS]
I

'------

____ _ . I

PNK 839

I
I

PNK 839

IC

PCM

1 ontrol
I Module

C1=REb
C2=BLU

Fuse Block
Details
Cell11

':' - - - - - - - - - - - - - - - - - , Powertrain

Ignition
:Control

1 (PCM)

Reference

J;

+-PN.K 839

BRN/WHT 2130

-------------Ignition Coil/ - Modules #2, 4 and B

.....---------- - - - - - D
Ignition
Feed

r ~ru:k
m

...

Ignition
Control
Signal

Ground
......____

Reference

Ignition

Low

Coil/

Ignition Coil/
Modules #2, 4 and 8

.,

Module
____. #G

~-________...,...I _ - - - - -

Af

BLK 550

BLK
550

BLK 550
BLK

450

218527

Circuit Description
The ignition system on this engine uses an individual
ignition coil/module for each cylinder. The PCM
controls the ignition system operation. The PCM
controls each coil using one of eight Ignition Control
(IC) circuits. The PCM commands the IC circuit
low when a spark event is requested. This causes the
IC module to energize the ignition coil to create a
spark at the spark plug. Each ignition coil/module has
the following circuits:
A power feed
A ground circuit
An ignition control (IC) circuit
A reference low circuit
Sequencing and timing are PCM controlled. This DTC
sets when the IC circuit is out of range.

Conditions for Running the DTC

The ignition voltage is between 9.0 volts and
17.0 volts.
The engine is operating.

Conditions for Setting the DTC

The PCM detects the ignition control circuit is
grounded, open or shorted to a voltage.
All conditions met for less than 1 second.

6-1530

Engine Controls .. 5.7L

Engine

Action Taken When the DTC Sets

. The following may cause an intermittent:

- Poor connections. Test for adequate terminal
tension. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems for
proper procedure.
- corrosion
- Mis-routed harness
- Rubbed through wire insulation
- Broken wire inside the insulation
Using Freeze Frame and/or Failure Records data
may aid in locating an intermittent condition. If
you cannot duplicate Jhe OTC, the information
incluQed .in the Freeze Frame and/or Failure
Records data can aid in determining how many
miles since the OTC set. The Fail Counter
and Pass Counter can also aid determining how
many ignition cycles the diagnostic reported a
pass and/or a fail. Operate the vehicle within the
same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you
observed. This will isolate when the OTC failed.
For an intermittent condition, refer to Symptoms.

The PCM illuminates the Malfunction Indicator

Lamp on the second consecutive ignition cycle
.that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stor:es th.is information in
.tt:Je Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze. Frame and updates the
Failure records.

,Conditions for Clearing the MIL/DTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

'Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
. For any test that requires probing the PCM pr a
'
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the hamess connector
terminals.

Test Description
The numbers .below refer to the step numbers on the
diagnostic table.
2. This step verifies that the fault is present.
4. This step tests the integrity of the IC circuit and
the PCM output.
5. This step tests for a short to ground on the IC
control circuit.

Engine Controls- 5.7L

Engine

6-1531

. DTC P0356 Ignition Coil 6 Control Circuit

-

Action

Step

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

)
1

liriportant: ltall Jhe Ignition Control (IC) DTCs .are set at

the same time, inspect the IC ground circuits for an open.
1. Install a scan tool.
2. Idle the engine.
3. Monitor the (IC) Ignition Control status for the cylinder
with the ignition control DTC using the scan tool in
the Misfire Data List.
Does the. scan tool indicate Fault?

. Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step B

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 7

Go to Step 10

Go to Step 11

Go to Step 10

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records

data for this DTC and observe the parameters.

3. Turn OFF the ignition for 15 seconds.
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
.
.
the DTC.

6. Select the Diagnostic Trouble Code (DTC) option, the

Specific DTC option, then enter the DTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?
1. Turn OFF the engine.
2. Disconnect the ignition coil electrical harness.
3. Idle the engine.

4. Measure the frequency at the ignition control signal

circuit using the DMM J 39200 on the DC Hertz
setting.
Is the frequency within the specified range?
Measure the voltage at the ignition control signal circuit
using the DMM J 39200.

3.0-20 Hz

1.0 volts

Is the voltage greater than the specified value?

1. Turn OFF the ignition.

2. Disconnect the PCM connector C1 located on the

6

opposite side of the manufacturer's logo. Refer to

PCM Replacement/Programming.
3. Test the continuity from the IC circuit (at the ignition
coil harness connector) to the PCM connector using
the DMM J 39200.
Does the DMM indicate continuity?
Test the resistance from the IC circuit (at the ignition coil
harness connector) to ground using the DMM J 39200.

Does the DMM indicate OL?

Replace the ignition coil. Refer to Ignition Coil

Replacement in Engine Electrical.
Is the action complete?

Go to Step 13

6-1532

Engine Controls - 5.7L

Engine

OTC P0356 Ignition Coil 6' Contr.ol Circuit (cont'd)

Step
9

10

11

12

Action

Value(s)

Repair the Ignition Control circuit for a short to voltage.

Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Repair the Ignition Control circuit for an open or grounded

circuit. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

1. Inspect for a poor connection at the PCM. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection repair the condition as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and,correct the condition?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.

Replace the PCM.

Is the action complete?

Yes

No

Go to Step 13

Go to Step 13

Go to Step 13

Go to Step 12

Go to Step 13

13

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

14

Select the Capture Info option and the Review Info option
using the scan .tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 14

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls 5.7L

6-1533

DTC P0357 Ignition Coil 7 Control Circuit

\
)

!Hot In RUN And START!

... - - - - I Power

Distribution
I Cell 10
I

- - - - , Underhood
1
INJ 1
1 Electrical
MiniFuse
Center 2
J8

15A

___ __ ____ ~

~
I
I

PNK/WHT 639

I
I

- - - - - - - - - - - - - - ;;;M- - j Powertrain
c1= RED

Control
Module
1 (PCM)
I
I

C2=BLU
Ignition
Control

Reference

_ .

>

.....,...__,,,,......,.......,PNK/WHT 639
Fu~ Block
Details
Cell11

+ - PNK/WHT 639

RED 2127

-------------Ignition Coil/ - Modules # 1, 3 and 5

'-

------,
D
Ignition
Feed

r ~ru:k

C
Ignition
Control
Signal

Reference

Low

....
Ignition
Coil/
Module

Ignition Coil/
Modules #1, 3 and 5

'

'----------r------

Ground

L..-~~~---1

[I]

.B

#7

At

BLK 550

BLK
550

_Ground ,
Distribution
Cell14

BLK 550
BLK
450

218530

Circuit Description
The ignition system on this engine uses an individual
ignition coil/module for each cylinder. The PCM
controls the ignition system operation. The PCM
controls each coil using one of eight Ignition Control
(IC) circuits. The PCM commands the IC circuit
low when a spark event is requested. This causes the
IC module to energize the ignition coil to create a
spark at the spark plug. Each ignition coil/module has
the following circuits:
A power feed
A ground circuit
An ignition control (IC) circuit
A reference low circuit
Sequencing and timing are PCM controlled. This OTC
sets when the IC circuit is out of range.

Conditions for Running the DTC

The ignition voltage is between 9.0 volts and
17.0 volts.
The engine is operating.

Conditions for Setting the DTC

The PCM detects the ignition control circuit is
grounded, open or shorted to a voltage.
All conditions met for less than 1 second.

Engine Controls - 5. 7L

Engine

Action Taken When the DTC Sets

.The following may cause an .intermittent:

- Poor connections. Test for adequate terminal
tension. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems for
proper procedare.
- Cofrosion
- Mis-routed harness
- Rubbed through wire insulation
- Broken wire inside the insulation
Using Freeze Frame and/or Failure Records data
may aid in locating an intermittent cqndition. If
you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can aid in determining how many
miles since the OTC set. The Fail Counter
and Pass Counter can also aid determining how
many ignition cycles the diagnostic reported a
pass and/or a fail. Operate the vehicle within the
same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you
observed. This will isolate when the DTC failed.
For an intermittent condition, refer to Symptoms.

6-1534

The PCM illuminates the Malfunction Indicator

Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this ki.t
prevents damage to the harness connector
terminals.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step verifies that the fault is present.
4. This step tests the integrity of the IC circuit and
the PCM output. .
.
5. This step tests tor a short to ground on the IC
control circuit.

Engine

Engine Controls - 5.7L

6-1535

OTC P0357 Ignition Coil 7 Control Ci'rcuit

Step
\

Value(s)

Action

Yes

No

Go to Step2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

'

11

Important: If all the Ignition Control (IC) DTCs are set at

the same time, inspect the IC ground circuits for: an open.
1. Install a scan tool.
2. Idle the engine.
3. Monitor the (IC) Ignition Control status for the cylinder
with the ignition control C!>TC using the scan tool in
the Misfire Data List.
Does the scan tool inc:!icate Fault?

I
1,

,Go to Step 4

Go to Qtep 3

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure R~cords
data for this DTC and observe the parameters.
3. Turn OFF the ignition to( 15 seconds.

4. Start the engine.

'

5. Operate the vehicle within the conditions required for

this diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.

?,

,,

6. Select the Diagnostic Trouble Code (OTC) 'Option, the

Specific OTC option, then enter the OTC number
using the scan tool.
Does the scan tool indicate that this diagnostic f~iled this
ignition?

1. Turn OFF the engine.

2. Disconnect the ignition coil electrical harness.
3. Idle the engine.
4. Measure the frequency at the ignition control signal
circuit using the DMM J 39200 on the DC Hertz
setting.
Is the frequency within the specified range?

3.0-20 Hz

Measure the voltage at the ignition control signal circuit

using the DMM J 39200.
Is the voltage greater than the specified value?

1.0 volts

1. Turn OFF the ignition.

2. Disconnect the PCM connector C1 located on the
opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.
3. Test the continuity from the IC circuit (at the ignition
coil harness connector) to the PCM connector using
the DMM J 39200.
Does the DMM indicate continuity?

Test the resistance from the IC circuit (at the ignition coil
harness connector) to ground using the DMM J 39200.
Does the DMM indicate OL?

Replace the ignition coil. Refer to Ignition Coil

Replacement in Engine Electrical.
Is the action complete?

Go to Step 4

Go to
Diagnostic Aids

Go to Step 8

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 7

Go to Step 10

Go to Step 11

Go to Step 10

Go to Step 13

6-1536

Engine

Engine Controls - 5. 7L
DTC P0357 Ignition Coil 7 Control Cir.cuit (cont'd)

Step
9

10

Action

Value(s)

Repair the Ignition Control circuit for a short to voltage.

Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Repair the Ignition Control circuit for an open or grounded

circuit. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Yes

No

Go to Step 13
-

Go to Step 13

1. Inspect for a poor connection at the PCM. Refer to

11

12

lntermittents and Poor Connections Diagnosis in

Wiring Systems.
2. If you find a poor connection repair the condition as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and correct the condition?
Important: Program the replacement PCM. Refer to PCM
Replacement/Programming.
Replace the PCM.
Is the action complete?

Go.to Step 13

Go to Step 12

Go to Step 13

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear DTC Information option using the scan tool.

2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (OTC) option and
13

14

the Specific OTC option, then enter the OTC number

using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.

Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 14

Go to Step2

Go to the
applicable
OTC table

System OK

Engine Controls - 5.7L

Engine

6-1537

OTC P0358 Ignition Coil 8 Control Circuit

._

_____ - - - - ..
PNK

839

I
I

PNK 839
Fuse Block
Details
Cell11

- - - - - - - - - - - - - - ;M- -

1
I

01 RED
C2=BLU
=

Ignition
Control

I
I

Powertrain
Control
Module

L.2w

I (PCM)
=

Reference

+-"BRN/WHT 30

PNK 839

Ignition Coil/ - Modules # 2, 4 and 6

------,
I

D
Ignition
Feed

r
m~ru:k

Ignition
Control
Signal

Reference
Low

Ignition Coil/
Modules #2, 4 and 6

Coil/
Module

'-----------r------

Ground
i...------~~__...J

Ignition

#B

At

BLK 550

BLK

550

Ground
Distribution
Cell14

BLK 550
BLK
450

218533

Circuit Description
The ignition system on this engine uses an individual
ignition coil/module for each cylinder. The PCM
controls the ignition system operation. The PCM
controls each coil using one of eight Ignition Control
(IC) circuits. The PCM commands the IC circuit
low when a spark event is requested. This causes the
IC module to energize the ignition coil to create a
spark at the spark plug. Each ignition coil/module has
the following circuits:
A power feed
A ground circuit
An ignition control (IC) circuit
A reference low circuit
Sequencing and timing are PCM controlled. This OTC
sets when the IC circuit is out of range.

Conditions for Running the OTC

The ignition voltage is between 9.0 volts and
17.0 volts.
The engine is operating.

Conditions for Setting the OTC

The PCM detects the ignition control circuit is
grounded, open or shorted to a voltage.
All conditions met for less than 1 second.

6-1538

Engine Controls - 5.7L

Engine

Action Taken When the DTC Sets

The following.may cause an intermittent:

- Poor connections. Test for adequate terminal
tension. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems for
proper. procedure.
- Corrosion
- Mis-routed harness
- Rubbed through Wire insulation
- Broken wire inside the insulation
Using Freeze Frame an9/Qr Failure Records data
may aid in locating an intermitterit co,ndition. If
you cannot duplicate tbe DTC,, the inf,ormation
included in the Freeze Frame and/or FaillJre
Records data can ,aid in determining how many
miles since the DTC set. The Fail Counter
and Pass Counter can also aid determining how
many ignition cycles the diagnostic reported a
pass and/or a fail. Operate the vehicle within the
same freeze frame co~ditions (RPM; load,
vehicle speed, temperature etc.) that you
observed. This will isolate when the DTC failed.
For an intermit.tent condition, refer to Symptoms.

The PCM illuminates the Malfunction Indicator

Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
' The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures .
., Use a scan tool in order to clear the MIUDTC.

l!)iagnostic Aids
Important:
Remove any debris from the PCM connector
surfaces before servicing the PCM. Inspect
the PCM connector gaskets when
.
diagnosing/replacing the PCM .. Ensure that the
gaskets are installed correctly. The gaskets
prevent contaminate intrusion into the PCM.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.

Test Description
The numbexs beloidefer to the step numbers on the
diagnostic table.
2. This step verifies that the fault is present.
4. This step tests the integrity of the IC circuit and
the PCM output

5. Th'is step tests for a shortto ground on the IC
control circuit.

Engine

Engine Controls .. 5.7L

DTC P0358 Ignition Coil 8 Control.. Circuit

..

Action

Step . .
\

Value(s)

Yes

No

Go to Step2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Steg 4

Go.to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 8

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 7

Go to Step 10

Go to Step 11

Go to Step 10

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Important: If all the Ignition Control (IC) DTCs are set at

the same time, inspect the IC ground circuits for an open.
1. Install a scan tool.
2. Idle the engine.

3. Monitor the (IC) Ignition Control status for the cylinder

with the ignition control OTC using the scan tool in
the Misfire Data List.
. Does the scan too.I indicate Fault?

'

6-1539

1. Turn ON the ignition leaving the engine OfF.

2. Review the Freeze Frame and/or Failure Records
data for this OTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Runni11g
the OTC.

..

6. Select the Diagnostic Trouble Code (DTC) option, the

Specific .DTC. option, then enter the DTC number
using the scan fool.
Does the :scan tool indicate that this diagnostic failed this
ignition?
'

1. Tum OFF the engine.

2. Disconnect the ignition coil electrical harness.
3. Idle the engine.
4. Measure the frequency at the ignition control signal
circuit using the DMM J 39200 on the DC Hertz
setting.

3.0-20 Hz

Is the frequency within the specified range?

Measure the voltage at the ignition control signal circuit

using the DMM J 39200.
Is the voltage greater than the specified value?

1.0 volts

1. Turn OFF the ignition.

2. Disconnect the PCM connector C1 located on the
opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.
3. Test the continuity from the IC circuit (at the ignition
coil harness connector) to the PCM connector using
the DMM J 39200.
Does the DMM indicate continuity?

Test the resistance from the IC circuit (at the ignition coil
harness connector) to ground using the DMM J 39200.
Does the DMM indicate OL?

Replace the ignition coil. Refer to Ignition Coil

Replacement in Engine Electrical.
Is the action complete?

Go to Step 13

6-1540

Engine Controls - 5.7L

Engine

DTC P0358 Ignition Coil 8 Control Circuit (cont'd)

Step

10

Action

Value{s)

Repair the Ignition Control circuit for a short to voltage.

Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Repair the Ignition Control circuit for an open or grounded

circuit. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Yes

No

Go to Step 13

Go to Step 13

1. Inspect for a poor connection at the PCM. Refer to

11

12

lntermittents and Poor Connections Diagnosis in

Wiring Systems.
2. If you find a poor connection repair the condition as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and. correct the condition?
Important: Program the replacement PCM. Refer to PCM
Replacement/Programming.
Replace the PCM.
Is the action complete?

Go to Step 13

Go to Step 12

Go.to Step 13

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear DTC Information option using the scan tool.

2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (DTC) option and
13

14

the Specific DTC option, then enter the DTC number

using the scan tool.
4. Operate the vehicle within the Conditions for Running
the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.

Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 14

Go to Step2

Go to the
applicable
DTC table

System OK

Engine

Engine Controls - 5.7L

6-t541

DTC P0401 Exhaust Gas Recirculation (EGR) Flow Insufficient

Circuit Description
)

The PCM tests the EGR system during deceleration

by momentarily commanding the EGR valve open. The
pressure in the intake manifold increases when the
EGR valve is open. The PCM monitors the Manifold
Absolute Pressure (MAP) sensor signal during
the EGR system diagnostic in order to determine the
amount of EGR flow. The PCM calculates an error
based on the difference between the actual MAP
increase and a predetermined value. The PCM records
the error and adjusts an internal fail counter towards
the fail threshold if the error is too great. The PCM sets
a OTC P0401 when the fail counter exceeds the fail
threshold. The number of test samples required
to exceed the fail threshold varies according to the
magnitude of the detected flow errors.
The PCM allows only one EGR flow test sample to be
taken during an ignition cycle. Following a scan tool
Clear Info or a battery disconnect the PCM allows
twelve test samples during the first ignition cycle in
order to aid in verifying a repair.

Conditions for Running the DTC

DTCs P0101, P0102, P0103, P0107, P0108,
P0112, P0113, P0117, P0118, P0121, P0122,
P0123, P0125, P0404, POSOO, P0502, P0503,
P0560, P0562, P0563 are not set.
The ignition voltage is between 11. 7 and 16 volts.
The BARO is greater than 70 kPa.
The ECT is between 60C (140F)
and 117C (243F).
The IAT is less than 65C (140F).
The engine speed is between 800 RPM
and 2,000 RPM.
The engine vacuum (BARO minus MAP) is
between 60 kPa (9 psi) and 83 kPa (12 psi).
The IAC position is steady.
The vehicle speed is between 44 km/h (27 MPH)
and 113 km/h (70 MPH).
The change in VSS is less 6 km/h (4 MPH).
The change in MAP is less than 0.5 kPa.
The A/C clutch status is steady.

Conditions for Setting the DTC

The change in the MAP is less than a
predetermined value during the EGR flow test.
All conditions present for 2.0 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL) when the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Freeze Frame and/or the Failure
Records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
Use a scan tool in order to clear info. Run the EGR
flow test in order to verify a repair. Keep the following
items in mind when running the EGR flow test:
The PCM runs the EGR flow test during a gradual
deceleration.
The PCM runs the EGR flow test during a closed
throttle condition.

The PCM runs the EGR flow test at vehicle

speeds between 44 km/h (27 MPH) and
113 km/h (70 MPH).
Several deceleration cycles will be necessary to
run a sufficient number of EGR flow test
samples (9-12).
Inspect tor the following conditions:
Vacuum restriction to the MAP sensor.
A restriction to the MAP sensor can cause the
EGR flow test to fail due to insufficient MAP
changes being monitored during the test. Inspect
for objects blocking the vacuum to the MAP
sensor.
An engine that is running poorly may cause this
OTC to set.
Poor connection or damaged harness.
Inspect the wiring harness tor damage.
If the harness appears to be OK, observe the
Actual EGR Position display on the scan tool while
moving connectors and wiring harnesses related
to the EGR valve. A change in the display
indicates the location of the malfunction.
Reviewing the Fail Records vehicle mileage since the
diagnostic test last failed helps determine when the
condition that caused the DTC to be set occurred. This
may assist in diagnosing the condition.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This OTC is set when the PCM does not detect a
predetermined change in MAP when the EGR
valve is commanded. This step inspects tor any
MAP or MAF sensor OTCs. A malfunctioning MAP
or MAF sensor may cause this OTC to set.

6-1542

Engine

Engine Controls - 5.7L

OTC P0401 Exhaust Gas Recirculation (EGR) Flow Insufficient

Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBQ) System Check?

Value(s)

Is there any MAP or MAF DTC's set?

No

Go.to Step 2

Go to the A
Powertrain On
Board Diagnosti~
(080) System
Check

Go to the
applicable DTC

Go to Step 3

Go,to.Step 7

Go to Step 4

Go to Step 7

Go to Step 5

Go to Step 7

Go to Step 6

Go to Step 7

Go to
Diagnostic Aids

'
2

Yes

1. Inspect the exhaust system for modification of original

3

installed parts or leaks. Refer to Exhaust Leakage in

Engine Exhaust.
2. Repair the exhaust system as necessary if you locate
a condition.
Did you find and correct the condition?

Inspect the EGR valve gasket and pipes for leaks. Clean
or replace the EGR system components as necessary if
you locate a condition.
Did you find and correct the condition?

1. Remove the EGR valve. Refer to EGR Valve

Replacement.
2. Visually and physically inspect the following items for
a leak and/or a restriction:
The EGR pintle
The EGR valve passages
Did you find and correct the condition?

1. Remove the EGR inlet and outlet pipes from the

exhaust manifold and the intake manifold. Refer to

EGR System Cleaning.
2. Inspect the manifold EGR ports and the EGR inlet
and outlet pipes for a blockage caused by excessive
deposits or other damage.
3. Correct the condition as necessary.
Did you find and correct the condition?

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear DTC option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (DTC) option and
the Specific DTC option, then enter the OTC number
using the scan tool.
4. Operate vehicle within the Conditions for Running this
DTC as specified in the supporting text, if applicable.
Does the scan tool indicate that this test failed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

'.

Go to Step 8

Go to Step 2

Go to
applicable DTC

System OK

Engine

Engine Controls - 5. 7L

6-1543

OTC P0404 Exhaust Gas Recirculation (EGR) Open Position Performance

',

-.
o,,
i l
A

,~

1Exhaust
Gas
Recirculation

(EGR)
.__~
_______._____~__, Valve
I

BLK 552

-1-u-

.. - Sensor
EGR

I
I

Ground

C1 65

5
V

LT BLU 697

-u--------- -1- -,
9

sv

38

34

EGR
~alve

ontro

EGR
Valve

Ground

I
I

GRY 435

BRN 1456

GRY 705

62

5V
Reference

EGR
Pintle
Position

C1=RED
C2 = BLU

C2

Powertrain

Control

Module
I (PCM)
I

I~

L--------------------------J
218695

Circuit Description
The ability of the PCM to control the EGR valve is
verified with this test. The PCM calculates an
error based on the difference between the actual EGR
position and the desired EGR position. The PCM
sets this OTC if the error is too great.

Conditions for Running the DTC

The ignition voltage is greater than 11.7 volts.
The desired EGR position is greater than 0%.

Conditions for Setting the DTC

The difference between the desired EGR position
and the actual EGR position is greater than 20%.
The failure counter is greater than a
predetermined value.

Action Taken When the DTC Sets

The PCM disables the EGR for the ignition cycle.
The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

6-1544

Engine Controls - 5.7L

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Engine
Test Description
The numbers below refer to the step numbers on the
Diagnostic Table.
2. This step determines if the EGA valve can be
commanded open.
3. Excessive resistance in the EGA control circuit or
the EGA ground circuit will result in the EGA not
responding correctly to the commanded EGA
position.
4. Inspect the PCM connector for poor connections.
5. Inspect the PCM connector for poor connections.
6. Excessive resistance in the control circuit or the
ground circuit will cause this DTC to set. With
the EGA commanded to 100% the test lamp
should light with full intensity. Connect the test
lamp across the battery terminals and compare the
test lamp intensity to the EGA control circuit
intensity.

Engine

Engine Controls - 5.7L

6-1545

OTC P0404 Exhaust Gas Recirculation (EGR) Open Position Performance

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go tb Step 6

Go to
Diagnostic Aids

Go to Step 4

Go to Step 5

Go to Step 14

Go to Step 16

Go to Step 15

Go to Step 7

Go to Step B

Go to Step 16

Go to Step 11

Go to Step 9

Go to Step 12

Go to Step 12

Go to Step 10

Go to Step 12

Go to Step 18

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

1. Idle the engine.

2. Command the EGR valve to 50% using the scan tool.

Does the engine run rough or stall?

1. Idle the engine.

2. Command the EGR valve to 50% using the scan tool.

3. Monitor the Actual EGR position on the scan tool.

48-52%

Is the Actual EGR Position within the specified range?

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2. Refer to PCM
Replacement/Programming.
4

3. Disconnect the EGR valve electrical connector.

o-2n

4. Test the continuity of the EGR valve control circuit

using the DMM J 39200. Refer to Testing for
Continuity in Wiring Systems.
Is the resistance within the specified range?

Test the continuity of the EGR valve ground circuit using

the DMM J 39200. Refer to Testing for Continuity in Wiring
Systems.

o-2n

Is the resistance within the specified range?

1. Turn OFF the ignition.
2. Disconnect the EGR valve electrical connector.

3. Probe the EGR control circuit using the test lamp

J 34142-8 connected to ground. Refer to Probing
6

Electrical Connectors in Wiring Systems.

4. Turn ON the ignition.
5. Command the EGR to the specified value using the
scan tool.
Is the test lamp illuminated?
Probe the EGR ground circuit using the test lamp
J 34142-8 connected to B+. Refer to Probing Electrical
Connectors in Wiring Systems.

100%

Is the test lamp illuminated?

1. Turn OFF the ignition.
2. Disconnect the PCM connector C2. Refer to PCM
Replacement/Programming.
8

3. Test the continuity of the EGR valve control circuit

using the DMM J 39200. Refer to Testing for

Continuity in Wiring Systems.

Does the DMM display continuity?

Test the continuity of the EGR valve control circuit using

the DMM J 39200 connected to ground. Refer to Testing
for Continuity in Wiring Systems.

Does the DMM display continuity?

10

Test for continuity from the EGR control circuit to all other
circuits in the PCM harness connector. Refer to Testing for
Continuity in Wiring Systems.
Does the DMM display continuity to any other circuit in the
PCM harness connector?

6-1546

Engine Controls - 5.7L

Engine

ore P0404 Exhaust Gas Recirculation (EGR) Open Position Performance

Step

Action

Value(s)

11

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2. Refer to PCM
Replacement/Programming.
3. Test the continuity of the EGR valve ground circuit
using the DMM J 39200. Refer to Testing for
Continuity in Wiring Systems.
Does the DMM display continuity?

12

Repair the open or short to ground in the EGR valve

control circuit. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

13

Repair the open in the EGR valve ground circuit. Refer to

Wiring Repairs in Wiring Systems.

15

16

17

18

19

20

21

Repair the high resistance in the EGR valve ground circuit.

Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

1. Inspect for poor connections at the EGR valve

electrical connector. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
2. If you find a poor connection repair the terminal as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and correct the condition?

Replace the EGR valve. Refer to EGR Valve

Replacement.
Is the replacement complete?

1. Inspect for a poor connection at the PCM. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection repair the terminal as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did find and correct the condition?

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate vehicle within the Conditions for Running this
OTC as specified in the supporting text, if applicable.
Does the scan tool indicate that this test passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 13

Go to Step20

Replace the PCM.

Is the action complete?

Go to Step 18

Repair the high resistance in the EGR valve control circuit.

Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.

No

Go to Step 20

Is the action complete?

14

(cont'd)

Yes

Go to Step 20

Go to Step20

Go to Step20

Go to Step 17

Go to Step 20

Go to Step20

Go to Step 19

Go to Step 20

Go to Step 21

Go to Step 2

Go to
applicable OTC

System OK

Engine

Engine Controls - 5.7L

6-1547

DTC P0405 Exhaust Gas Recirculation (EGR) Position Sensor Circuit Low Voltage
B

BLK 552

LT BLU 697

-::~r 1- -u; -u~ ---~G;- - - - ~~~e -i- - ~6~~:~rain

62.

I
I

Ground

C1. 65

38

34

Ground

~alv~
1
on ro

I
I
I

GRY 435

BAN 1456

GRY 705 ,

PCM

5V
Reference

EGA
Pintle
Position

C1=RED
C2 = BLU

C2

I
I

Module
(PCM)
~

II~

L--------------------------~
218695

Circuit Description

An Exhaust Gas Recirculation (EGR) system is used

in order to lower Oxides of Nitrogen (NOx) emission
levels. the. EGR system accomplishes this by feeding
.small amounts of exhaust gas back into the
combustion chamber. High combustion temperatures
cause NOx~ .Combustion temperatures are reduced
when the air/fuel mixture is diluted with the
exhau$t gases.
The EGR valve is designed to accurately supply
exhaust gases to the engine without the use of intake
manifold vacuum. The EGR valve controls the
exhaust flow into the intake manifold from the exhaust
'manifold through an orifice with a PCM controlled
pintle. The PCM controls the pintle position using
inputs from the Throttle Position (TP) sensor,
the Manifold Absolute Pressure (MAP) sensor and, the
Engine Coolant Temperature sensor. The PCM
commands the EGR valve in order to supply the
correct amount of exhaust gas recirculation for
the current engine operating conditions. This can be
monitored on a scan tool as the Desired EGR Position.
The PCM monitors the position of the EGR valve
through a feedback signal. The PCM supplies
a 5.0 volt reference and a ground to the EGR valve. A
voltage signal representing the EGR valve pintle

position is sent to the PCM from the EGR valve. This

feedback signal can also be monitored on a scan
tool and is the actual position of the EGR pintle. The
Actual EGR Position should always be near the
commanded or Desired EGR Position .

Conditions for Running the OTC

The ignition voltage is greater than 11.7 V.

Conditions for Setting the OTC

The EGR feedback signal voltage is less
than 0.14 volts.
All conditions present for 10 seconds.

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

6-1548

Engine Controls - 5.7L

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Due to the moisture associated with exhaust systems,
the EGR valve may freeze and stick in colder
weather at times. After the vehicle is brought into a
warm shop for repairs, the valve warms and the
condition disappears. By monitoring the Actual EGR
and the Desired EGR Positions on a cold engine with a
scan tool, the fault can be verified easily. Review
the freeze frame data to determine if the DTC
set when the vehicle was cold by viewing the Engine
Coolant Temperature (ECT).

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. If DTC P1635 sets at the same time, this indicates
that the 5.0 voltage reference circuit is either
shorted to a ground or shorted to a voltage. The
5.0 volt reference circuit is internally connected
within the PCM. The A/C Refrigerant Pressure
sensor or the MAP sensor circuits may be causing
this DTC to set. Refer to DTC P1635 for further
diagnosis.

Engine
3. This step determines if the malfunction is present.
4. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the DTC failed.
5. If the scan tool displays 5.0 volts, the EGR pintle
position signal, 5.0 volt reference circuit, and the
PCM are OK. For any test that requires probing
the PCM or component harness connectors,
use the Connector Test Adapter Kit J 35616-A.
Using this kit will prevent any damage to the
harness connector terminals.
6. If the scan tool displays 5.0 volts, the EGR pintle
position signal circuit and the PCM are OK. For
any test that requires probing the PCM or
component harness connectors, use the
Connector Test Adapter Kit J 35616-A. Using this
kit will prevent any damage to the harness
connector terminals.
7. Disconnecting the PCM allows using the DMM
J 39200 in order to test the continuity of the
circuits. This aids in locating an open or a shorted
circuit.

DTC P0405 Exhaust Gas Recirculation (EGR) Position Sensor Circuit Low Voltage
Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to
DTCP1635
5 Volt
Reference 1
Circuit

Go to Step 3

Go to Step 5

Go to Step 4

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

1. Install a scan tool.

2. Idle the engine.
3. Monitor the Diagnostic Trouble Code (OTC)
Information using the scan tool.
Did OTC P1635 fail this ignition cycle?
Monitor.the EGR pintle position voltage on Engine 1 Data
List on the scan tool.
Is the EGR pintle position voltage below the
specified value?

0.14V

Engine

Engine Controls - 5.7L

6-1549

DTC P0405 Exhaust Gas Recirculation {EGR) Position Sensor Circuit Low Voltage {cont'd)
Step

Action

Value(s)

Yes

No

Go to Step 5

Go to
Diagnostic Aids

Go to Step 11

Go to Step 6

Go to Step 7

Go to Step 9

Go to Step 14

Go to Step B

Go to Step 14

Go to Step 13

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this DTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.

4. Start the engine.

5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in the Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the DTC.
6. Select the Diagnostic Trouble Code (DTC) option, the
Specific DTC option, then enter the DTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

1. Disconnect the EGR valve electrical connector.

2. Jumper the 5.0 volt reference circuit and the EGR
pintle signal circuit together at the EGR valve harnEiss
connector.
3. Observe the EGR pintle position voltage display on
the scan tool.
Is the EGR pintle position voltage near the
specified value?

5.0V

1. Connect the test lamp J 34142-8 between B+ and the

EGR pintle position signal circuit at the EGR valve
harness connector.
2. Observe the EGR pintle position voltage display on
the scan tool.
Is the voltage near the specified value?

5.0V

1. Turn OFF the ignition.

2. Disconnect the PCM C2 connector located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the 5.0 volt reference circuit for the following:

an open
a short to a ground
a short to a voltage
4. If you find the 5.0 volt reference circuit is open or
shorted, repair the circuit as necessary. Refer to
Wiring Repairs in Wiring Systems.
Did you find the 5.0 volt reference circuit open or shorted?
1. Test the 5.0 volt reference circuit for a poor
connection at the PCM. Refer to lntermittents and
Poor Connections Diagnosis in Wiring Systems.
2. If you find a poor connection, repair the terminal as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and correct the condition?

6-1550

Engine Controls - 5.7L

Engine

DTC P0405 Exhaust Gas Recirculation (EGR) Position Sensor Circuit Low Voltage (cont'd)
Step

Action

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the EGR pintle position signal circuit for the
following:
Open circuit
Short to a ground
Short to sensor ground circuit
4. If you find the EGR pintle position signal circuit is
open or shorted to a ground, repair the circuit as
necessary. Refer to Wiring Repairs in Wiring
Systems.
Did you find the EGR pintle position signal circuit open or
shorted to a ground?

Value(s)

Yes

No

(
'

Go to Step 14

Go to Step 10

Go t9 Step 14,

Go to Step 13

Go to Step 14

Go to Step 12

1. Test the EGR pintle position signal circuit for a poor

connection at the PCM. Refer to lntermittents and
Poor Connections Diagnosis in Wiring Systems.
10

11

12

13

14

15

2. If you find a poor connection, repair the terminal as

necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and correct the condition?

'

1. Test the connections at the EGR valve. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection, repair the terminal as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and correct the condition?

Replace the EGR valve. Refer to EGR Valve

Replacement.
Is the action complete?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.

Replace the PCM.

Is the action complete?

Go to Step 14
;

Go to Step 14

1. Select the Diagnostic Trouble Code (OTC} option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC numl;>er
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 15

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5.7L

6-1551

DTC P0410 Secondary Air Injection (AIR) System

lHot At All Timesl
r - - -

I Power

- -

- - - ., Underhood

AIR PUMP
Electrical
MlnlFuse I Center 1
25A
I

I Distribution
een 10

L-----

----..1

ORN 1440
ORN 1440

ORN 1440
ORN 1440

r -

E-;;
85

- - -

-F9- -

'.

Es - - - - FB

Underhood

\
D
f.;-_~.' -------~;:f..; -'.:' ----"
AIR
Sol
Relay

30

______

86

ORN 1440

85

30

AIR
I
I
Pump
Relay :

__ _ _ __

871-

871---

86

Electrical
Center 2

~~

RED 78

PNK/BLK 429
PNK/BLK 429

PNK/BLK 429

Air
Injection
Pump

BLK 150

:39

.A

C2

Air- - - - Solenoid
Relay
Control

J
---T
!

ATr - - - - - - , Powertrai n
I Control
Relay
I Module
Control
: (PCM)
Pump

PCM
C1~RED
C2=BLU

I~

L---------------~

.....
'l
L. -

BLK 150

(AIR)

.....

J
---r

r -

Secondary

Air Injection (AIR)

Bleed Valve
Solenoid

BRN 436

3~ ______

~Secondary

'I

PPL 421

__..,.

Ground
Distribution
Cell14

218550

Circuit Description
An AIR pump is used on this vehicle to lower tail pipe
emissions on start-up. The PCM supplies a ground
to the AIR pump relay, which energizes the AIR pump.
The PCM monitors the H02S voltages to diagnose
the AIR system.
During the AIR test the PCM activates the AIR pump
during closed loop operation. When the AIR is
activated, the PCM monitors the H02S voltages and
short term fuel trim values for both banks of the
engine. If the AIR system is operating properly, the
H02S voltages should go low and the short term fuel
trim should go high.
If the PCM determines that the H02S voltages for
both banks did not respond as expected during
the tests, OTC P041 O sets. If only one sensor

responded, the PCM sets either a OTC P1415 or

P1416 to indicate on which bank the AIR system is
inoperative.

Conditions for Running the OTC

DTCs P0101, P0102, P0103, P0107; P0108,
P0112, P0113, P0117, P0118, P0300, P0325,
P0327, P0335, P0441, P0502, P0503, and H02S
DTCs not set.
The engine operating.
The engine operates for greater than 15 seconds
in short term fuel trim cells 2, 5, and 20.
Engine speed is greater than 550 RPM.
Maximum air flow is 22 g/s.
ECT is greater than 50C (122F).
IAT is greater than 10C (50F).
Ignition voltage is greater than 11 .6 volts.
Engine load is less than 30%.

6-1552

Engine Controls - 5.7L

Conditions for Setting the DTC

H02S voltage does not go below 222 mV for
0.9. seconds when the AIR pump turns ON during
closed loop operation.
Short term fuel trim does not go above a
predetermined amount when the AIR pump turns
ON during closed loop operation.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIL/DTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Engine
Diagnostic Aids
Using Freeze Frame and/or Failure Records data
may aid in locating an intermittent condition. If
you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can aid in determining how many
miles since the DTC set. The Fail Counter
and Pass Counter can also aid determining how
many ignition cycles the diagnostic reported a
pass and/or a fail. Operate the vehicle within the
same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you
observed. This isolates when the DTC failed.
For an intermittent, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. If DTCs P0412 and P0418 are also set at the
same time, this indicates the AIR pump
fuse is open.
4. Excessive resistance in either the control circuit or
the B+ circuit will cause an inoperative relay.
Command each relay ON and OFF as necessary
to verify operation. This step verifies the AIR
pump operation.
9. This step isolates if the condition is the AIR
integral stop valve or the AIR Bleed Valve
solenoid. If no air is present at the outlet of the
pump, this indicates a condition with the integral
stop valve or circuit.
20. When an engine is started, a vacuum is created in
the AIR system. This vacuum causes the integral
stop valve from not opening which causes
DTC P041 O to set. When the engine is started the
PCM commands the AIR Bleed Valve solenoid
to open and relieve the vacuum in the AIR system.
This step verifies the solenoid is capable of
relieving the vacuum.

DTC P0410 Secondary Air Injection (AIR) System

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 13

Go to Step 3

Go to Applicable
OTC table

Go to Step 4

Go to Step B

Go to Step 5

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Are both DTCs P0412 AND P0418 also set?

Is OTC P0412 or P0418 set?

Important: Listen for an audible click as the relays

operate. If no audible click can be heard, inspect the
related circuits for excessive resistance.
1. Turn ON the ignition leaving the engine OFF.

2. Enable the AIR System using a scan tool.

Does the AIR pump turn ON?

Engine Controls - 5.7L 6-1553

Engine

DTC P0410 Secondary Air Injection (AIR) System (cont'd)

Action

Step

Important: Refer to Electrical Center Identification for

relay terminal identification.
1. Turn OFF the ignition.
2. Disconnect the AIR pump relay.
3. Turn ON the ignition leaving the engine OFF.
4. Probe the AIR pump relay B+ supply circuit terminal
at the underhood electrical center 1 using the test
lamp J 34142-8 connected to battery ground. Refer to
Probing Electrical Connectors in Wiring Systems.

Value(s)

No

Is the test lamp illuminated?

1.
2.
3.
4.

Yes

Go to Step 6,

Go to Step 21

Go to Step 7

Go to Step 22

Go to Step 32

Go to Step 23

Turn OFF the ignition.

Reconnect the AIR pump relay.
Turn ON the ignition leaving the engine OFF.
Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.

5. Disconnect the electrical connector from the

AIR pump.
6. Probe terminal A of the AIR pump electrical
connector to battery ground using the test lamp
J 34142-8. Refer to Probing Electrical Connectors
and Troubleshooting with a Test Lamp in Wiring
Systems.
7. Enable the AIR System using a scan tool.
Is the test lamp illuminated?

1. Probe terminal A of AIR pump electrical connector td

terminal C of the AIR pump electrical connector using
the test lamp J 34142-8. Refer to Probing Electrical
Connectors in Wiring Systems.
2. Enable the AIR System using a scan tool.
Is the test !amp illuminated?

Important: Refer to Electrical Center Identification for

relay terminal identification.
1. Turn OFF the ignition.
2. Disconnect the AIR Sol~noid relay.
3. Turn ON the ignition leaving the engine OFF.
4. Probe the AIR solenoid relay B+ supply circuit
terminal (switch side of relay) at the underhood
electrical center 1 using the test lamp J 34142-8
connected to battery ground. Refer to Probing
Electrical Connectors in Wiring Systems.
Is the test lamp illuminated?

Go to Step 9 .

Go to Step 21

'

1.
2.
3.
4.

Turn OFF the ignition.

Reconnect the AIR solenoid relay.
Turn ON the ignition.
Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
5. Disconnect the AIR pump outlet hose.

6. Enable the AIR System using a scan tool.

Is air present at the AIR pump outlet?

Go to Step 12

Go to Step 10

61'554

Engine Controls - 5.7L

Engine

OTC P0410 Secondary Air.Injection (AIR) System (cont'd)

Aqtion .

Step

10

1. Disconnect the electrical connector from the

AIR pump.
2. Probe terminal B of the AIR pump electrical
connector to battery ground using the test lamp
J 34142-8. Refer to Probing Electrical Connectors in
Wiring Systems.
3. Enable the AIR System using a scan tool.
Is the test lamp illuminated?

Value(s)

Yes

No.

Goto Step 32

Go to Step 11

Go to Step 37

Go to Step 31

Go to Step 37

Go to Step 18

'

11

12

13

14

15

1. Test the continuity between the AIR pump and the

AIR solenoid relay using the DMM J 39200. Refer to
Testfng for Continuity in Wlring Systems.
2. Repair the circuit as necessary. Refer to Wiring
Repairs.
Did you find and correct the condition?

1. Inspect for a restriction/blockage or a disconnect in

the AIR hoses/pipes between the AIR pump and the
poirit where the system branches to both sides of the
engine.
2. If you find a condition repair as necessary.
Did you find and correct the condition?

1. Turn OFF the ignition.

2. Disconnect the AIR pump relay and AIR
solenoid relay.
3. Probe one of the B+ supply circuits for the AIR Pump
relay at the underhood electrical center 1 with the test
lamp J 34142-8 connected to B+. Refer to Probing
Electrical Connectors and Testing for Short to Ground
in Wiring Systems.
Does the test lamp illuminate?
1. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
2. Disconnect the AIR Pump electrical connector.
3. Probe terminal A of the AIR Pump harness connector
with the test lamp J 34142-8 connected to B+. Refer
to Probing Electrical Connectors and Testing for
Short to Ground in Wiring Systems.
Does the test lamp illuminate?
1. Disconnect the AIR Bleed Valve solenoid :electrical
connector.
2. Probe terminal A of the AIR Bleed Valve solenoid
harness connector with.the test lamp J 34142-8
connected to B+. Refer to Probing Electrical
Connectors and Testing for Short to Ground in Wiring
Systems.

'

..

..
'
Go to Step 25 , . Go to Step
14

17

Measure the resistance of th,e AIR Bleed Valve solenoid.

Refer to Testing for Continuity in Wiring Systems.
Is the resistance less than the specified value?

1.. Install all the disconnected components.

2. Install a new fuse.
3. Turn ON the ignition leaving the engine OFF.
4. Enable the AIR System using a scan tool.
Does the fuse open?

'

'

Go to Step 26 9,

Go to Step 15

Does the test lamp illuminate?

16

Go to Step 27

Go to Step 16

Go to Step 29

Go to Step 17

Go to Step 33

Go to
Diagnostic Aids

15Q

Engine

Engine Controls - 5.7L

6-1555

OTC P0410 Secondary Air Injection (AIR) System (cont'd)

Action

Step

Value(s)

Yes

No

Go to Step 19

Go to Step 24

Go to Step 20

Go to Step 35

Go to Step 36

Go to Step 28

1. Disconnect the AIR Bleed Valve Solenoid.

2. Probe the AIR Bleed Valve Solenoid B+ supply circuit
18

19

terminal at the solenoid harness connector using the

test lamp J 34142-8 connected to ground. Refer to
ProtJing Electrical Connectors in Wiring Systems.
3. Enable the AIR Solenoid relay using a scan tool.
Is the test lamp illuminated?

1. Connect the test lamp J 34142-8 across the AIR

Bleed Valve solenoid harness connector. Refer to
Probing Electrical Connectors in Wiring Systems.
2. Enable the AIR Solenoid relay using a scan tool.
Does the test lamp illuminate?

1. Disconnect the vacuum "line at AIR Bleed Valve

solenoid.

2. Connect the ha.nd vacuum pump J 23738-A to the

20

AIR Bleed Valve solenoid.

3. Apply the specified amount of vacuum to the
solenoid.
4. Enable the AIR Solenoid relay using a scan tool.

10 in.

Does the vacuum hold before the solenoid was enabled

and release when the solenoid is enabled?

21

Go to Step 37

1. Test the continuity between the AIR pump and t.he

AIR pump relay using the DMM J 39200. Refer tb

Repair the open circuit between the fuse and the relay.
Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

22

Testing for Continuity in Wiring Systems.

2. Repair the circuit as necessary. Refer to Wiring

Repairs.
Did ypu find and correct the condJtjon?

23

Repair the faulty ground connection or open AIR pump

ground circuit. Refer to Wiring Repairs in Wiring Systems.

Go to Step 37

24

25

26

Go to Step 37

Test the continuity between the AIR Solenoid relay and the
AIR Bleed Valve Solenoid using the DMM J 39200. Refer
to Testing for Continuity in \/\'.iring Systems.
Does the.DMM display OL?

Repair the short to ground in the ignition feed circuit

between the fuse and the relays. Refer to Wiring Repairs.
Is the action complete?

Repair the short to ground in the circuit between the AIR

Pump relay and the AIR purnp. Refer to Wiring Repairs in
Wiring Systems.

Go to Step 34

27

Go to Step 31

Go to Step 37

Is the action complete?

Repair the short to ground in the circuit between the AIR
Solenoid relay and the AIR Bleed Valve Solenoid/AIR
pump. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Is the action complete?

Go to Step 30

Go to Step 37

Go to Step 37

1. Inspect for a poor connection at the AIR Bleed Valve

28

solenoid. Refer to lntermittents and Poor Connections

Diagnosis in Wiring Systems.
2. If you find a poor connection repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and repair the condition?

Go to Step 37

Go to Step 29

6-1556

Engine Controls - 5~7L

Engine

DTC P0410 Secondary Air Injection (AIR) System (cont'd)

Step
29

Action
Replace the AIR Bleed Valve Solenoid. Refer to
Secondary Air lnj Bleed Valve Sol Replacement.

Value(s)

Is the action complete?

30

Replace the AIR pump relay. Refer to Secondary Air

Injection Pump Relay Replacement.
Replace the AIR solenoid relay. Refer to Secondary Air
Injection Solenoid Relay Replacement.

No
-

Go to Step 37

Go to Step 37

Is the action complete?

31

Yes

Go to Step 37

Is the action comp'ete?

1. Inspect for a poor connection at the AIR pump. Refer
to lntermittents and Poor Connections Diagnosis in
Wiring Systems.
32

2. If you find a poor connection repair as necessary.

Refer to Repairing Connector Terminals in Wiring
Systems.

Did you find and repair the condition?

33

Replace the AIR pump. Refer to Secondary AIR Injection

Pump Replacement.

Go to Step 37

Is the action complete?

34

Repair the open B+ supply circuit to the AIR Bleed Valve

solenoid. Refer to Wiring Repairs in Wiring Systems.
Repair the open ground circuit to the AIR Bleed Valve
solenoid. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Go to Step 37

Is the action complete?

35

Go to Step 33

Go to Step 37

Go to Step 37

Repair the vacuum line to the AIR Bleed Valve solenoid

for the following:
36

Restrictions

Kinked vacuum line

Go to Step 37

Is the action complete?

1. Select the Diagnostic Trouble Codes (DTC) option
and the Clear DTC Information option using the
scan tool.
2. Idle the engine at the normal operating temperature.
37

3. Select the Specific DTC option under the Diagnostic

Trouble Code (DTC) option using a scan tool.

4: Operate vehicle within the Conditions for Running the

DTC as specified in the supporting text, if applicable.
Does the scan tool indicate that this test passed?
38

Select the Capture Info option and the Review Info option
using the scan tool.
Are any DTCs displayed that you have not diagnosed?

Go to Step 38

Go to Step 2

Go to the
applicable
DTC table

System OK

Engine

Engine Controls - 5.7L

6-1557

DTC P0412 Secondary Air Injection (AIR) Solenoid Relay control Circuit

Lfil
ORN 1440

.. - E9

ORN 1440
ORN .1440

-F9- -

ORN 1440

85

E6
85

\
P
-

- Fs

30

------

..... .,

AIR

Pump
Relay

Ele. ctrical
Center 2

I
I

-------~q:; 86

86

Underhood

871---

:8 - - - - ;

RED 78

PNK/BLK 429
PNK/BLK 429

PPL 421

PNK/BLK 429

31
30 C2
/'.----------"'

Secondary
Air Injection (AIR)
Bleed Valve
Solenoid

'" -

Secondary
Air
Injection
(AIR)

.__~~~_;:il',_~Pump

BLK 150

'

BRN 436

I
I

...,. Air- -

solenoid
: __ ...,. Relay
.. Control

J
----T
-

~ -

Pump
Relay
. . Control

Powertrain
I Control
I Module
I (PCM)
I ~

.,

PCM
C1~RED
C2=BLU

~ ..~ .

~---------------J
'

BLK 150

L--oilll

Ground
Distribution
Cell14

218550

Circuit Description
The PCM controls the relay by grounding the control
circuit via an internal switch called a driver. The
primary function of the driver is to supply the ground
for the component being controlled. Each driver
has a fault line which the PCM monitors. When the
PCM commands a component ON, the voltage of the
control circuit should be low (near O volts). When
the PCM commands the control circuit to a component
OFF, the voltage potential of the circuit should be
high (near the battery voltage). If the fault detection
circuit senses a voltage other than what is expected,
the fault line status changes causing the DTC
to set.
The relay controls the high current flow to the AIR
injection pump integral bypass valve. This allows the
PCM driver to only have to control the relatively
low current used by the relay.

Conditions for Running the DTC

The engine speed is greater than 600 RPM.
The ignition voltage is between 6.0 volts and
16 volts.

Conditions for Setting the DTC

The PCM detects that the commanded state of
the driver and the actual state of the control
circuit do not match.
All the above conditions are present for a minimum
of 1O seconds.

6-1558

Engine Controls - 5.7L

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
.the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Using Freeze Frame and/or Failure Records data may
aid in locating an intermittent condition. If you
cannot duplicate the DTC, the information included in
the Freeze Frame and/or Failure Records data can
aid in determining how many mil.es since the DTC set.
The Fail Counter and Pass Counter can also aid
determining how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate the vehicle
within the same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you observed.
This will isolate when the DTC failed.
For an intermittent, refer to Symptoms.

Engine
Test Description
The numbers below refer to the step numbers on the
diagnostic table:
2. Listen for an audible click when the relay operates.
Be sure that both the ON and the OFF states are
commanded. Repeat the commands as
necessary .

3. This test can detect a partially shorted coil which

would cause excessive current flow. Leaving the
circuit energized for 2 minutes allows the coil
to warm up. When warm the coil may open (Amps
drop to 0), or short (goes above 0.75 Amp).
5. Identify and test the correct relay terminals to
avoid misdiagnosis.
7. Listen for an audible click as the relay operates.
Repeat the procedure as necessary.
13. If no trouble is found in the control circuit or the
connection at the PCM, the PCM may be
faulty, however, this is an extremely unlikely
failure.
14. The repair is not complete if the scan tool
indicates that the diagnostic ran and failed.

Engine

Engine Controls - 5.7L

6-1559

DTC P0412 Secondary Air Injection (AIR) Solenoid Relay Control Circuit
Step

Action

Value{s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to Step 5

Go to
Diagnostic Aids

Go to Step 4

Go to Step 12

Go to Step 10

Go to Step B

Go to Step 6

Go to Step 7

Go to Step 11

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

1. Turn ON the ignition leaving the engine OFF.

2. Command the AIR solenoid relay ON and OFF using
the scan tool.
Does the relay turn ON and OFF when commanded?

1. Turn OFF the ignition.

2,. Disconnect the PCM connector C2 located on the

same side as the manufacturers logo. Refer to PCM
Replacement/Programming.
3. Ignition ON.
Important: If the DMM goes to O Amps during the current
draw test, replace the relay.
4. Measure the current from the relay control circuit in
the PCM harness connector to ground for 2 minutes
using the DMM ;J 39200 on the 40Amp scale.
Does the current draw measure less than the specified
value shown but not O?

0.75A

Important: For underhood electrical center relay terminal

identification, refer to Electrical Center Identification in
Wiring Systems.
1. Turn OFF the ignition.
2. Disconnect the relay.
3. Measure the resistance from the relay control circuit
in the PCM harness connector to ground using the
DMM J39200.
Does the DMM display infinite resistance?

. Important: For underhodd electrical center relay terminal

identification, refer to Electrical Center Identification in
Wiring Systems.

1. Tum OFF the ignition.

2. Disconnect the relay.
3. Connect the test lamp J 34142-8 between the AIR
solenoid relay control circuit and the AIR solenoid
relay battery feed circuit at the underhood electrical
center 2.

4. Turn ON the ignition.

5. Command the relay ON and OFF using the scan tool.

Does the test lamp turn ON and OFF when commanded?

Probe the battery feed circuit at the underhood electrical

center 2 with the test lamp J 34142-8 connected to
ground.
Is the test lamp illuminated?

...

6.,1560

Engine Controls - 5.7L

Engine

DTC P0412 Secondary Air Injection (AIR) Solenoid Relay Control Circuit (cont'd)
Step

Action

Value(s)

Yes

No

Go to Step 9

Go to Step 10

Go to Step 14

Go to Step 12

Go to Step 14

Go to Step 13

1. Turn OFF the ignition.

2. Reconnect the relay.

3. Disconnect the PCM connector C2 located on the

same side as the manufacturers logo. Refer to PCM
Replacement/Programming.

4. Turn ON the ignition.

5. With a fused jumper wire connected to ground,

momentarily probe the relay control circuit in the PCM
harness connector. Refer to Using Fused Jumper
Wires in Wiring Systems.
Does the relay turn ON when the circuit is grounded and
OFF when the circuit is opened?

1. Inspect for a poor connection at the relay. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.
8

2. If you find a poor connection, repair the condition as

necessary. Refer to Repairing Connector Terminals in
Wiring Systems.

Did you find and correct the condition?

1. Inspect for a poor connection at the PCM. Refer to

lntermi.ttents and Poor Connections Diagnosis in
Wiring Systems.
,

2. If you find a poor connection, repair the condition as

necessary. Refer to Repairing Connector Terminals in

Wiring Systems.
Did you find and correct the condition?

10

Repair the faulty relay control circuit. Refer to Wiring

Repairs in Wiring Systems.

11

Repair the faulty relay battery feed circuit. Refer to Wiring

Repairs in Wiring Systems.

Go to Step 14

13

Go to Step 14

Is the action complete?

12

Is the action complete?

Replace the relay. Refer to Secondary Air Injection

Solenoid Relay Replacement.
Is the action complete?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

Go to Step 14

Go to Step 14

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (OTC) option and

14

the Specific OTC option, then enter the DTC number

using the scan tool.

4. Operate the vehicle within the Conditions for Running

the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test passed?

15

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 15

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5.7L 6;:.1561

DTC P0418 Secondary Air Injection (AIR) Pump Relay Control Circuit

IHot At All Times!

'" - - - - -

- - - - ., Underhood
I
AIR PUMP.
Electrical
MiniFuse I Center 1

I Power ,
Distribution
I ce1110

25A

L-----

L.2tJ

. I

----.J

ORN 1440

,,~

ORN 1440

'" - E;
as

fJ

ORN 1440

ORN 1440

- - - -Fe- - - - - - - - AIR
Sol
Relay

30 \

------

E6
as

- - - - Fe
30

[I]

PPL 421

Secondary
Air Injection (AIR)
Bleed Valve
Solenoid

'" -

Secondary
Air
Injection
(AIR)

II

Pump

BRN 436

31,, ______ ~Q ""C2

I
I

Electrical
Center 2

PNK/BLK 429

I
I

----;

RED 78

PNK/BLK 429

AIR
Pump
Relay

871

86

'. ;~[.;, -_~.: -------~;:f:a; -~

PNK/BLK 429

- - - ., Underhood

------

871

86

p\

ORN 1440

J
-

I
I .... f
I

I
I

Air- Solenoid
Relay
Control

z; - - - - - - .,
J
-T
-

Powertrain'
I Control
I Module
I (PCM)
I

Pump
Relay
Control

PCM

C1=RED
C2=BLU

BLK 150

' '

~---------------J

'

BLK 150

,!~

-<ii

Ground
Distribution
Cell14

218550

Circuit Description
The PCM controls the relay by grounding the control
circuit via an internal switch called a driver. The
primary function of the driver is to supply the ground
tor the controlled component. Each driver has a
fault line which the PCM monitors. When the PCM
commands a component ON, the voltage of the control
circuit should be low (near O volts). When the PCM
commands the control circuit to a component OFF, the
voltage potential of the circuit should be high (near
the battery voltage). If the fault detection circuit senses
a voltage other than what the PCM is expects, the
fault line status changes causing the OTC to set.
The relay controls the high current flow to the
AIR injection pump integral bypass valve. This allows
the PCM driver to only have to control the relatively
low current used by the relay.

Conditions for Running the DTC

The engine speed is greater than 600 RPM.
The ignition voltage is between 6.0 volts and
16 volts

Conditions for Setting the OTC

The PCM detects that the commanded state of
the driver and the actual state of the control
circuit do not match.
All the above conditions are present tor a minimum
of 1O seconds.

6-1562

Engine

Engine Controls -5.7L

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions.
at the time of the failure. The PCM writes the
conditions to the Freeze Frame andupdates the
Failure records.

Conditions for Clearing the MIL/DTC

A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
Using Freeze Frame and/or Failure Records data may
aid in locating an intermittent condition. If you

cannot duplicate the OTC, the information included in

the Freeze Frame and/or Failure Records data can
aid i\1 determining how many miles since the OTC set.
The Fail Counter and Pass Counter can also aid
determining how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate the vehicle
within the same freeze frame conditions (RPM, load,
vehicle. speed, temperature etc.) that you observed.
This will isolate when the OTC failed.
For an intermittent, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Listen for an audible click when the relay operates.
Command both the ON and the OFF states.
Repeat the commands as necessary.

3. This test can detect a partially shorted coil which

would cause an excessive current flow. Leaving
the circuit energized for 2 minutes allows the
coil to warm up. When warm the coil may open
(current drops to 0), or short (current goes above
0.75 Amp).
5. Identify and test the correct relay terminals to
avoid misdiagnosis.
7. Listen for an audible click as the relay operates.
Repeat the procedure as necessary.
13. If no trouble is found in the control circuit or the
connection at the PCM, the PCM may be
faulty. However, this is an extremely unlikely
failure.
14. The repair is not complete if the scan tool
indicates that the diagnostic ran and failed.

Engine Controls - 5.7L

Engine

6-1563

OTC P0418 Secondary Air Injection (AIR) Pump Relay Control Circuit
Action

Step

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

)
1

1. Turn O.N the ignition leaving the engine OFF.

2. Command the relay ON and OFF using a scan tool.
Does the relay turn ON and OFF when commanded?
1. Turn OFF the ignition.
2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo.
3. Turn ON the ignition.
Important: If the DMM goes to O Amps during the current
draw test, replace the relay.
4. Measure the current from the relay control circuit in
the PCM harness connector to ground for 2 minutes
using DMM J 39200 on 10 Amp scale.
Does the current draw measure less than the specified
value shown (but not O)?

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Step 5

Go to
Diagnostic Aids

Go to Step 4

Go to Step 12

Go to Step 10

Go to Step 8

Go to Step 6

Go to Step 7

Go to Step 11

Go to Step 9

Go to Step 10

Q;75A

..

1. Turn OFF the ignition.

2. Disconnect the relay.
3. Measure resistance from the relay control circuit in
the PCM harness connector to ground using the
DMM J39200.
Does the DMM display infinite resistance?
1. Turn OFF the ignition.
2. Disconnect the relay.
3. Connect the test lamp J 34142-8 between the AIR
pump relay control circuit and the AIR pump relay
battery feed circuit at the underhood electrical
center 2.
4. Turn ON the ignition.
5. Command the relay ON and OFF using a scan tool.

Does the test lamp turn ON and OFF when commanded?

Probe the battery feed circuit at the underhood electrical

center 2;with the test lamp ..134142-8 connected to
ground.
Is the test lamp illuminated?

1. Turn OFF the ignition.

2. Reconnect the relay.
3. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo.
4. Turn ON the ignition.
5. Probe the relay control circuit in the PCM harness
connector with a fused jumper wire connected to
ground. Refer to Using Fused Jumper Wires in Wiring
Systems.
Does the relay turn ON when the circuit is grounded and
OFF when the circuit is opened?

6-1564

Engine

Engine Controls - 5.7L

DTC P0418 Secondary Air Injection (AIR) Pump Relay Control Circuit (cont'd)

Step

Action

Value(s)

Yes

No

Go to Step 14

_Go to Step 12

Go to Step 14

Go to Step 13

1. Inspect for a poor connection at the relay. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.
8

2. If you find a poor connection repair the condition as

necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and correct the condition?
1. Inspect for a poor connection at the PCM. Refer to
lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection repair the condition as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.

Did you find and correct the condition?

10

11

Repair the faulty relay control circuit. Refer to Wiring

Repairs in Wiring Systems.
Is the action complete?
Repair the faulty relay battery feed circuit. Refer to Wiring
Repairs in Wiring Systems.

Replace the relay. Refer to Secondary Air Injection Pump

Relay Replacement.

Go to Step 14

13

14

15

Replace the PCM.

Is the action complete?
1. Select the Diagnostic Trouble Code (OTC) option and
the Clear OTC option using the scan tool.
2. Start engine and idle at normal operating
temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate vehicle within the Conditions for Running the
OTC as specified in the supporting text, if applicable.
Does the scan tool indicate that this test passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Is the action complete?

Important: Program the replacement PCM. Refer to PCM
Replacement/Programming.

Is the action complete?

12

Go to Step 14

Goto Step 14

Go to Step 14

Go to Step 15

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine Controls - 5.7L

Engine

6-1565

DTC P0420 Catalyst System Low Efficiency Bank 1

Circuit Description

Conditions for Setting the DTC

In order to maintain a reasonably low emissions of

Hydrocarbons (HC), Carbon Monoxide (CO), and
Oxid!3S of Nitrogen (NOx), the engine controls system
uses a three-way catalytic converter. The catalyst
within the converter promotes a chemical reaction
which oxidizes the HC and CO present in the exhaust
gas. This reaction converts them into harmless
water vapor and Carbon Dioxide. The catalyst also
reduces NOx, converting it to Nitrogen. The PCM
monitors this process using Bank 1 H02S #2. Bank 1
H02S #2, located in the exhaust stream past the
three-way catalytic converter, produces an output
signal which indicates the oxygen storage capacity of
the catalyst. This determines the catalysts ability to
convert exhaust emissions effectively. If the catalyst is
functioning correctly, the Bank 1 H02S #2 signal
will be tar less active than that produced by Bank 1
H02S #1. If a condition exists which causes the PCM
to detect excessive Bank 1 H02S #2 activity outside
of an acceptable range tor an extended period of time,
the PCM will set DTC P0420. This indicates that the
three-way catalytic converters oxygen storage capacity
is.below a threshold considered acceptable.

The PCM determines the oxygen storage capability of

the catalytic converter has degraded below a
calibrated threshold.

Conditions for Running the DTC

Test Description

No AIR, CKP, CMP, IAT, IC, MAF, MAP, ECT,

TP, EVAP, Left Bank H02S, Misfire, Left Bank
Fuel Trim, Injector, VSS, Engine Protection,
or Transmission DTCs are set.
The ECT is greater than 65C (149F).
The vehicle speed is between 32 km/h (20 mph)
and 136 km/h (85 mph).
The IAT is greater than -30C (-22F).
The TP sensor angle is greater than 2%.
The engine speed is between 800 RPM and
3000 RPM.
The MAP is between 25 kPa and 80 kPa.
The engine air flow is between 14 g/s and 40 g/s.
The fuel system is operating in closed loop
fuel control.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL) when the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Freeze Frame and/or the Failure
Records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.
The numbers below refer to the step numbers on the
diagnostic table.
4. Before replacing the Three Way Catalytic
Converter, correct any conditions which may have
damaged the catalyst.

6-1566

Engine

Engine Controls - 5.7L

OTC P0420 Catalyst System Low Efficiency Bank 1

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain Oh
Board Diagnostic
(OBD) System
Check

Go to the
applicable
DTC table

Go to Step 3

Go to Step 5

Go to Step4

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Are any other DTCs set?

2

Inspect for the following conditions:

Verify that the three-way catalytic converter is an
original equipment part.
Inspect the three-way catalytic converter for damage
(dents, severe discoloration caused by excessive
temperature, holes, etc.).
Ensure that the internal three-way catalytic converter
rattle caused by damaged catalyst is not present.
Inspect the exhaust system for leaks, damage, or
loose or missing hardware (area from converter to
H02S #2 primarily).

'..

Ensure that the H02S #1 and the H02S #2 are

secure and that the pigtails and wiring are not
damaged or contacting the exhaust.
Did you find and correct the condition?

Replace the catalytic converter. Refer to Oxidation

Catalytic Converter Replacement (Left) in Engine
Exhaust.
Is the action complete?

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific DTC option, then enter the DTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the DTC as specified in the supporting text, if
applicable.

Go to Step 5

Does the scan tool indicate that this test ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 6

Go to Step 2

Go to the
applicable
DTC table

System OK

Engine

Engine Controls - 5.7L

6-1567

DTC P0430 Catalyst System Low Efficiency Bank 2

Circuit Description

Conditions for Setting the OTC

In order to maintain a reasonably low emissions of

Hydrocarbons (HC), Carbon Monoxide (CO), and
Oxides of Nitrogen (NOx), the engine controls system
uses a three-way catalytic converter. The catalyst
within the converter promotes a chemical reaction
which oxidizes the HC and CO present in the exhaust
gas. This reaction converts them into harmless
water vapor and Carbon Dioxide. The catalyst also
reduces NOx, converting it to Nitrogen. The PCM
monitors this process using Bank 2 H02S #2. Bank 2
H02S #2, located in the exhaust stream past the
three-way catalytic converter, produces an output
signal which indicates the oxygen storage capacity of
the catalyst. This determines the catalysts ability to
convert exhaust emissions effectively. If the catalyst is
functioning correctly, the Bank 2 H02S #2 signal
will be far less active than that produced by Bank 2
H02S #1. If a condition exists which causes the PCM
to detect excessive Bank 2 H02S #2 activity outside
of an acceptable range for an extended period of time,
the PCM will set DTC P0420. This indicates that the
three-way catalytic converters oxygen storage capacity
is below a threshold considered acceptable.

The PCM determines the oxygen storage capability of

the catalytic converter has degraded below a
calibrated threshold.

Conditions for Running the OTC

Test Description

No AIR, CKP, CMP, IAT, IC, MAF, MAP, ECT,

TP, EVAP, Left Bank H02S, Misfire, Left Bank
Fuel Trim, Injector, VSS, Engine Protection,
or Transmission DTCs are set.
The ECT is greater than 65C (149F).
The vehicle speed is between 32 km/h (20 mph)
and 136 km/h (85 mph).
The IAT is greater than -30C (-22F).
The TP sensor angle is greater than 2%.
The engine speed is between 800 RPM and
3000 RPM.
The MAP is between 25 kPa and 80 kPa.
The engine air flow is between 14 g/s and 40 g/s.
The fuel system is operating in closed loop
fuel control.

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL) when the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Freeze Frame and/or the Failure
Records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.
The numbers below refer to the step numbers on the
diagnostic table.
4. Before replacing the three way catalytic converter,
make sure that any conditions which may have
caused the catalyst to be damaged have
been corrected.

6;.1568

Engine

Engine Controls - 5.7L

OTC P0430 Catalyst System Low Efficiency Bank 2

Step

Action

Value(s)

Did you perform the Powertrain On-Board Di.agnostic

(OBD) System Check?

Are any other DTCs set?

Replace converter. Refer to Oxidation Catalytic Converter

Replacement (Right) in Engine Exhaust
Is the action complete?
1. Select the Diagnostic Trouble Code (OTC) option and
the Clear OTC Information option Using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (DTq option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

No.

Go to Step 2

Go to A
Powertrain On
Board .Diagnostic
(OBD) System
Check

Go to the
applicable
OTC table

Go to Step 3

Inspect for the following conditions:

Verify that the three-way catalytic converter is an
original equipment part.
Inspect the three-way catalytic converter for damage
such as dents, severe discoloration caused by
excessive temperature, holes, etc.
Ensure that internal three-way catalytic converter rattle
caused by damaged catalyst is not present.
Inspect exhaust system for leaks, damage, or loose or
missing hardware in the area from the converter to the
H02S #2 primarily.
Ensure that the H02S #1 and the H02S #2 are
secure and that their pigtails and wiring. are not
damaged or contacting the exhaust.
Did you find. and correct the condition?

Yes

.,

1,

Go to Step 5
-

Go to Step 4
-

Go to Step 5

(
-

Goto Step 6

.-

Go to the
applicable
. OTC .table

Go to Step2

System OK

Engine Controls - 5.7L

Engine

6-1569

OTC P0440 Evaporative Emission (EVAP) System

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A
Evaporative
Emission
(EVAP)
Canister
Purge
Valve

239

Evaporative
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Canister

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Circuit Description
The PCM tests the EV AP system for the following
conditions:
Large and small leaks
Excess vacuum
Purge flow during non-commanded conditions
Fuel Level and Fuel Pressure sensor faults
EVAP Purge and Vent Valve faults
The PCM monitors the Fuel Tank Pressure sensor in
order to determine the level of vacuum/pressure in
the EVAP system. The PCM commands both the

EVAP Purge Solenoid and the EVAP Vent Valve ON

when the Conditions for Running the DTC are met
in order to apply an engine vacuum to the EVAP
system. The PCM commands the EVAP Purge
Solenoid OFF once the system has reached a
predetermined level of vacuum. This test verifies if a
vacuum can be achieved in the EVAP system.
Failure to develop a vacuum may be caused by a
large leak or a restriction. This DTC sets after twice
failing the above test.

5..1510

Engine

Engine Controls .. 5.7L

Conditions for Running the DTC

DTGs P0107, P0108, P0112, P0113, P0121,
P0122, P0123, P0420, P0430, P0500, P0502,
P0503, P1111, P1112, P1114, P1115, and H02S
DTGs are not set.
The ignition voltage is between 10 volts and
17 volts.
The barometric pressure is greater than 75 kPa.
The fuel level is between 15% and 85% of
full capacity.
The engine coolant temperature is between 4G
(39F) and 30G (86F).
The intake air temperature is between 4G (39F)
and 30G (86F).
The start up engine coolant and intake air
temperatures are within 9G (16F) of each other.

Conditions for Setting the DTC

The EVAP system cannot develop a vacuum greater
than a predetermined value.

Action Taken When the DTC Sets

The PGM illuminates the Malfunction Indicator
Lamp (MIL) when the diagnostic runs and fails.
The PGM records the operating conditions at the
time the diagnostic fails. The PGM stores this
information in the Freeze Frame and/or the Failure
Records.

Conditions for Clearing the MIUDTC

The PGM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTG) clears when the
diagnostic runs and does not fail.
A History DTG clears after forty consecutive
warm-up cycles, if this or, a;ny other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTG.

Diagnostic Aids
Important: An accurate indication of fuel level is
required for the PGM to properly Pas.s or Fail this DTC.
Always diagnose fuel level sensor DTG's before
performing this DTG's diagnostic table. Always inspect
for fuel level sensor DTC's stored as History.
Important: The Service Bay Test may have to be
performed in cold ambient air temperatures when the
vehicle is running a winter grade fuel. .The scan
tool displays a message when the service bay test
does not run.
Conditions for Running the Service Bay Test
The battery voltage is between 10.5 and
17.5 volts.
The fuel level is between 15% and 85% of the full
capacity.
The engine temperature is between 3.5G (38F)
and 35G (95F).
The scan tool displays Test Aborted if any of the
above conditions are not met.

Perform a physical inspection of the EVAP system}'

Inspect for the following conditions:
A loose, missing, defective, or incorrect fuel
.tank cap
Incorrectly routed or defective EV AP system
vacuum and vapor lines
A malfunctioning or damaged vapor canister
Inspect for charcoal release from the vapor canister.
Refer to the EVAP System Cleaning procedure.
The vacuum and pressure in the EVAP system is
measured in inches of H20 (water). Most gauges
measure vacuum in inches of Hg (mercury) and
pressure in psi (pounds per sq1Jare inch). The following
table illustrates how the values compare:
in. H20
1 in. H20
5 in. H20
10in. H20
15 in. H20

in. Hg.
0.07 in. Hg
0.36 in. Hg
0.73 in. Hg
1.10 in. Hg

psi
0.0361 psi.
0.180 psi.
0.361 psi.
0.541 psi.

Test Description
The numbers below refer to the step numbers on the
Diagnostic Table.
3. It may be 1;1ecessary to partially lower the fuel tank
to inspect the upper portion of the tank and the
EVAP line connections.
4. An intermittent leak or restriction is indicated if the
vehicle passes the Service Bay Test. A fuel tank
cap that is loose or oft causes this DTC to set.
If the Service Bay Test can not be run, proceed to
step 5. If a fault is not currently present the
diagnostic table steps will return you to step 3.
12. This step tests for. a leak at the top of the fuel
tank, at the fuel fille~ hose, and the fuel cap. Place
the ultrasonic leak detector in these areas.
Refer to the inforrnation supplied with the EVAP
pressure/purge diagnostic cart on proper setup
and adjustment procedures.
13. With pressure applied it may be necessary to
disconnect the EVAP lines at the components.
to verify that a line or compopent is not res.tricted.
A restriction would prevent avacuum (or the
Step 10 test pressure) from forming in
the fuel tank.
19. A Fuel Tank Pressure sensor that does not
correctly respond to pressure (orvacuutn) causes
this DTG to set.
The Fuel Tank Pressure sensor range is from
7.5 in. H20 of pressure to -175in. H20 of
pre~sure (vacuum).
In order to test the Fuel Tank Pressure sensbr for
vacuum response, command the EV AP Purge
Solenoid Valve ON with the engine running
and quickly SEAL the system. Leaving the EVAP
Purge Solenoid Valve ON for a longer period
of time allows a greater level of vacuum to
develop.

Engi_ne

Engine Controls - 5.7L

6-1571

DTC P0440 Evaporative. Emission (EVAP) System

Step

Action

Value{s)

Yes

No

Go to Step 2

Go to A
Powertrain On
B~ard Diagnostic
(080) System
Check

Go to
applicable OTC

Go to Step 3

Go to Step 21

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 6

Go to Step 15

Go to Step 8

Go to Step 7

GoJo Step 15

Go to Step 14

Did you perform the Powertrain On-Board Diagnostic

(080) System Check?

Are any other EVAP system DTC's stored in history?

Inspect the EVAP system for the following conditions:

A loose, incorrect, defective or missing fuel tank cap.
Disconnected, improperly routed, kinked or damaged
EVAP system purge lines.
A damaged EVAP system component.
A loose, missing, or damaged service port dust cap
and/or schrader valve. Refer to the test description for
additional information.
Repair the EVAP system if needed.
Did you find and repair the condition?

Important: Ensure that The Conditions for Running the

Service Bay test are met before proceeding with this
diagnostic. Refer to Diagnostic Aids.
Perform the EVAP system Service Bay Test using a
scan tool.
Does the EVAP diagnostic pass the Service Bay Test?

Important: The DTCs must be cleared from the PCM in

order to use the output control function on the scan tool.
1. Clear the DTCs using a scan tool.
2. Turn OFF the ignition.
3. Remove the EVAP Purge line from the EVAP Purge
Solenoid Valve.
4. Connect the hand held vacuum pump J 23738-A to
the vacuum port of the EVAP Purge Solenoid Valve.
5. Attempt to apply a vacuum up to the specified value
using the hand vacuum pump.
Can the value specified be obtained and held?

10 in Hg

Important: If an audible solenoid click cannot be heard

and OTC P0443 is not set, inspect the EVAP canister
purge solenoid circuits for high resistance..
1. Connect a vacuum gauge to the EVAP Purge
solenoid valve.
2. Idle the engine.
3. Command the EVAP Purge Solenoid Valve to 50%
using a scan tool.
Is the vacuum measured on the gauge the same or more
than the specified value?

12 in Hg

1. Turn OFF the ignition.

2. Remove the vacuum source from the EVAP Purge
Solenoid.
3. Connect a vacuum gauge to the vacuum source.
4. Idle the engine.
Is the vacuum measured on the gauge the same or more
than the specified value?

12 in Hg

6-1572

Engine Controls - 5.7L

Engine

OTC P0440 Evaporative Emission (EVAP) System (cont'd)

Step

Action

Value(s)

Yes

No

Go to Step 9

Go to Step 18

Go to Step 12

Go to Step 10

1. Turn OFF the ignition.

2. Reconnect the EVAP purge line to the EVAP purge
solenoid.

3. Disconnect the EVAP purge line from the EVAP

Canister (line from the EVAP purge solenoid valve).
Refer to EVAPCanister Replacement.

5 in Hg

4. Connect the Vacuum Pump J 23738-A to the EVAP

Purge line from the EVAP purge solenoid valve.
5. Using the Vacuum Pump J 23738-A attempt to apply
a vacuum up to the specified value.
Can the specified value of vacuum be obtained and held?
1. Turn OFF the ignition.
2. Disconnect the fuel tank vapor line from the EVAP
Canister.
3. Plug the EVAP canister port for the fuel tank
vapor line.

4. Connect the Vacuum Pump J23738-A to the EVAe

9
5.
6.

7.
Can

10

Purge port on the EVAP canister.

Turn ON the ignition.
Command the EVAP Vent Valve ON (closed) using a
scan tool.
Using the Vacuum Pump J 23738-A attempt to apply
a vacuum up to the specified value.
the specified value of vacuum be obtained and hel9?

1. Leave the system connected as in Step 9.

2. Disconnect the vent line at the EVAP Vent Valve.
3. Plug the vent line.
4. Attempt to apply a vacuum up to the specified va:lue
using the Vacuum Pump J 23738-A.

5 in Hg

Can the specified value of vacuum be obtained and held?

11

1. Inspect the EVAP Vent line from the canister to the

EVAP Vent Valve for leaks or missing/damaged
0-ring seals.
2. If you find a condition repair the EVAP system as
necessary.

5 in. Hg.

Go to Step 16

Go to Step 11

Go to Step 21

Go to Step 17

Go to Step 21

Go to Step 13

Did you find and correct the condition?

Important: The following steps require the EVAP
Pressure/Purge Diagnostic Station J 41413 and the
Ultrasonic Leak Detector J 41416.

12

Always zero the EVAP Pressure and Vacuum (in. H20)

gauges on the EVAP Pressure/Purge Diagnostic Station
J 41413 before proceeding with diagnosis.
1. Turn OFF the ignition.
2. Remove the plug and the hand vacuum pump.
3. Reconnect all the EVAP components.
4. Connect the EVAP Pressure/Purge Diagnostic Station
J 41413 to the EVAP system service port..
5. Command the EVAP Vent Valve ON (closed) using a
scan tool.
6. Continuously attempt to pressurize the EVAP system
by leaving the EVAP pressure/purge diagnostic
station control knob in the pressurize position.
7. Using the Ultrasonic Leak Detector J 41416 locate
and repair EVAP system leak.
Did you find and repair the condition?

Engine Controls - 5.7L

Engine

6-1573

DTC. P0440 Evaporative Emission (EVAP) System (cont'd)

Action

Step

)
13

1. Inspect the EVAP system for restrictions. Refer to

Test Descriptions.
2. Repair as needed.

Value(s)

Repair the vacuum source to the EVAP Purge

Solenoid Valve.

16

17

18

19

20

21

22

Go to Step 21

Go to Step 19

Go to Step 21

Is the action complete?

15

No

Did you find and correct the condition?

14

Yes

Important: Inspect the EVAP Purge Solenoid Valve and

the purge line for carbon contamination. Refer to
Diagnostic Aids.
Replace the EVAP Purge Solenoid Valve. Refer to EVAP
Canister Purge Solenoid Valve Replacement.
Is the action complete?

Replace the EVAP Vent Valve. Refer to EVAP Vent Valve

Replacement.
Is the action complete?

Replace the EVAP Vapor Canister. Refer to EVAP

Canister Replacement.
Is the action complete?

Replace the EVAP line from the EVAP Purge solenoid

valve to the EVAP canister. Refer to Fuel Hose/Pipes
Replacement (Chassis).
Is the action complete?

1. With the EV AP system pressurized, compare the

EVAP pressure/purge diagnostic station pressure
gauge (in. H20) reading to the Fuel Tank Pressure
sensor reading on the scan tool.
2. Compare the readings with the system depressurized.
Refer to the Test Description.
Does the Fuel Tank Pressure sensor indicate the actual
amount of pressure in the EVAP system?

Replace the Fuel Tank Pressure sensor. Refer to Fuel

Tank Pressure Sensor Replacement.
Is the action complete?

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 21

Go to Step 21
-

Go to Step 21

Go to Step 21

Go to Step 3

Go to Step 20
-

Go to Step 21

Go to Step 22

Go to Step 2

Go to
Applicable OTC

System OK

Engine

---~,,.~

! Hot With lgn Relay Energi2ed !

r -

I Power
I Distribution
Cell 10

Underhood

.,

I Electrical
MiniFuse
Center 2
1
ENG CTRL

I
I

15 A

L-----

----..1

PNK 239
PNK 239

PNK
239

PNi
PN:I

PNK 239
Fuse Block

PNK
239

Details
Cell11

PNK 239
A

Evaporative
Emission
[ ] (EVAP)
Canister
B
Purge
Valve

239

239

Evaporative
Emission
[ ] (EVAP)
Canister

BI ~=~~

WHT 1310

DK GRN,WHT 428

WHT 1310

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Purge
Valve

Control
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PCM
C1=RED
C2=BLU

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Control
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218692

Circuit Description
The PCM tests the EVAP system for the following
conditions:
Large and small leaks
Excess vacuum
Purge flow during non-commanded conditions
Fuel Level and Fuel Pressure sensor faults
EVAP Purge and VentValve faults
The PCM monitors the Fuel Tank Pressure sensor in
order to determine the level of vacuum/pressure in
the EVAP system. The PCM commands both the
EVAP Purge Solenoid and the EVAP Vent Valve ON
when the Conditions for Running the DTC are met
in order to apply an engine vacuum to the EV AP
system. The PCM commands the EVAP Purge
Solenoid OFF once the system has reached a

predetermined level of vacuun;i. The EVAP system

should HOLD .the vacuum in the sealed system. The
PCM sets this DTC in order to indicate a small
leak if 'the EVAP system fails to hold a predetermined
level of vacuum for a predetermined length of time.
This DTC sets after failing the above test twice,
Conditions for Running the OTC
DTCs P0107, P0108, P0112, P0113, P0117,
P0118, P0121, P0122,P0123, P0420, P0430,
P0500, P0502, P0503, P1111, P1112, P1114,
P1115 and H02S DTCs are not set.
The barometric pressure is greater than 75 kPa.
The fuel level is between 15% and 85% of
full capacity.
The engine coolant temperature is between 4 C
(39F) and 30C (86F).

Engine
The intake air temperature is between 4C (39F)
and. 30C (86F).
The start up engine coolant temperature and
intake air temperature are within 9C (16F) of
each other.

Conditions for Setting the OTC

The vacuum in the EVAP system decays (leaks) at
too fast a rate.

Important: This OTC does NOT report a first failed

test. A first fail of this OTC will have a scan tool status
as Not Run. Use the scan tool data display parameter
of EVAP Test Result to determine if this OTC has
failed or passed for this ignition cycle.

Engine Controls - 5.7L 6-1575

Perform a physical inspection of the EVAP system.
Inspect for the following conditions:
A loose, missing, defective, or incorrect fuel
.tank cap
..
Incorrectly routed or defective EVAP system
"\
vacuum and vapor lines
,
malfunctioning or damaged vapor caniste!:,_.. / /
lnspecfforcharcoalreleasefromttl~rvapor'canister.
Refer to the EVAP System Cleaning procedure.
The vacuum and pressure in the EVAP system is
measured in inches of H20 (water). Most gauges
measure vacuum in inches of Hg (mercury) and
pressure in psi (pounds per square inch). The following
shows how the values compare:

----==::::~~,,

!_P..

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in ordet to clear the MIUDTC.

Diagnostic Aids
Important: An accurate indication of fuel level is
required for the PCM to properly Pass or Fail this OTC.
Always diagnose fuel level sensor DTC's b~fore
performing this DTC's diagnostic table. Always inspect
for fuel level sensor DTC's stored as History.
Important: The Service Bay Test may have to be
performed in cold ambient air temperatures when the
vehicle is running a winter grade fueL The scan
tool displays a message when the service bay test
does not run.

Conditions for Running the Service Bay Test

The battery voltage is between 10.5 and
17.5 volts.
The fuel level is between 15% and 85% of the full
capacity.
The engine temperature is between 3.5C (38F)
and 35C (95F).
The scan tool displays Test Aborted if any of the
above conditions are not met.

in. H20
1 in. H20
5 in. H20
10 in. H20
15 in. H20

in.. Hg.
0.07 in. Hg
0.36 in. Hg
0.73 in. Hg
1.10 in. Hg

psi
0.0361 psi.
0.180 psi.
. 0.361 psi.
0.541 psi.

Test Description
The numbers below refer to the step numbers on the

Diagnostic Table.
3. It may be necessary to partially lower the fuel tank
to inspect the upper portion of the tank and the
EVAP line connections.
4. An intermittent leak or restriction is indicated if the
vehicle passes the Service Bay Test. A fuel tank
cap that is loose or off causes this OTC to set.
If the Service Bay Test can not be run, proceed to
step 5. If a fault is not currently present the
diagnostic table steps will return you to step 3.
12. This step tests for a leak at the top of the fuel
tank, at the fuel filler hose, and the fuel cap. Place
the ultrasonic leak detector in these areas.
Refer to the information supplied with the EV AP
pressure/purge diagnostic cart on proper setup
and adjustment procedures.
13. With pressure applied it may be necessary to
disconnect the EVAP lines at the components
to verify that a line or component is not restricted.
A restriction would prevent a vacuum (or the
Step 10 test pressure) from forming .in
the fuel tank.
'""
19. A Fuel Tank Pressure sensor that does not
\
correctly respond to pressure (or vacuum)causes
i
this OTC to set.
./
The Fuel Tank Pressure sensor range is from
7.5 in. H20 of pressure to -17.5 in. H20 of
pressure (vacuum).
In order to test the Fuel Tank Pressure sensor for
vacuum response, command the EVAP Purge
Solenoid Valve ON with the engine running
and quickly SEAL the system. Leaving the EVAP
Purge Solenoid Valve ON for a longer period
of time allows a greater level of vacuum to
develop.

6-1576

Engine Controls - 5.7L

Engine

DTC P0442 Evaporative Emission {EVAP) Control System Small Leak Detected
Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to
applicable OTC

Go to Step 3

Go to Step 21

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

Are any other EVAP system DTC's stored in history?

Inspect the EVAP system for the following conditions:

A loose, incorrect, defective or missing fuel tank cap.
Disconnected, improperly routed, kinked or damaged
EVAP system purge lines.
A damaged EVAP system component.

,,-

-->
4

A loose, missing, or damaged service port dust cap

and/or schrader valve. Refer to the test description for
additional information.
Repair the EVAP system if needed.
Did you find and repair the condition?
Important: Ensure that The Conditions for Running the
Service Bay test are met before proceeding with this
diagnostic. Refer to Diagnostic Aids.
Perform the EVAP system Service Bay Test using a
scan tool.
Does the EVAP diagnostic pass the Service Bay Test?

(' e:/'f f

Important: The DTCs must be cleared from the PCM in

order to use the output control function on the scan tool.
1. Clear the DTCs using a scan tool.
2. Turn OFF the ignition.
3. Remove the EVAP Purge line from the EVAP Purge
Solenoid Valve.

(,.)Jo

\{"'

10 in Hg

4. Con~~c~ the hand held vacuum pump ~ ?]Z.,{~~

th~ vacuum port of tl'le EVAP--Parge-s-0Teno1d Valv~,-/
"---~-~-,,.,.,----- __ , -""'""
5. Attempt to apply avacuum-up,cnfie specified value
using the hand vacuum pump.
Can the value specified be obtained and held?

Important: If an audible solenoid click cannot be heard

and OTC P0443 is not set, inspect the EVAP canister
purge solenoid circuits for high resistance.
1. Connect a vacuum gauge to the EVAP Purge
solenoid valve.
2. Idle tha engine.
3. Command the EVAP Purge Solenoid Valve to 50%
using a scan tool.
Is the vacuum measured on the gauge the same or more
than the specified value?

1. Turn OFF the ignition.

2. Remove the vacuum source from the EVAP Purge
Solenoid.
3. Connect a vacuum gauge to the vacuum source.
4. Idle the engine.
Is the vacuum measured on the gauge the same or more
than the specified value?

Go to Step 6

Go to Step 15

Go to Step B

Go to Step 7

Go to Step 15

Go to Step 14

'
(\;.('\,Ce
\;;.;.

'-.,) (\ 1,,,,J ~
12 in Hg

12 in Hg

Engine Controls - 5.7L 6-1577

Engine

OTC P0442 Evaporative Emission (EVAP) Ccmtrol System Small Leak Detected, (cont'd)

Value(s)

Action

Step

1. Turn OFF the ignition.

2. Reconnect the EVAP purge line to the EVAP purge
solenoid.
3. Disconnect the EVAP purge line from the EVAP
Canister (line from the EVAP purge solenoid valve).
Refer to EVAP Canister Replac(:]ment.
4. Connect the Vacuum Pump J 23738-A to the EVAP
Purge line from the EVAP purge solenoid valve.
5. Using the Vacuum Pump J 23738-A attempt to apply
a vacuum up to the specified value.
Can the specified value of vacuum be obtained and hE1ld?
1. Turn OFF the ignition.
2. Disconnect the fuel tank vapor line from the EVAP.
Canister.
3. Plug the EVAP canister port for the fuel tank
vapor line.
4. Connect the Vacuum Pump J 23738-A to the EVAP
Purge port on the EVAP canister.
5. Turn ON the ignition.
6. Command the EVAP Vent Valve ON (closed} using a
scan tool.
7. Using the Vacuum Pump J 23738-A attempt to apply
a vacuum up to the specified value.
Can the specified value of vacuum be obtained .and held?

1. Leave the system connected as in Step 9.

2. Disconnect the vent line at the EVAP Vent Valve.

10

3. Plug the vent line.

4. Attempt to apply a vacuum up to the specified value
using the Vacuum Pump J 23738-A.

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P1 r[

5 in Hg

.,

11

EVAP Vent Valve for leaks or missing/damaged

0-ring seals.
2. If you find a condition repair the EVAP system as
necessary.
Did you find and correct the condition?

IL<-1)
0

L(\

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c:'.'t:'

p-J cZ

Gci to Step 18

Go to Step 9

~~'5v

(:,r. ~ ' ') ,r <$!\.-

v>)o

"fl-I<

..[ ,t)''"
J 1e.
'-((\"-

.,

5 in Hg

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Go to Step 12 .

Go to Step 10

\) ~N'f

')' f'~ \ -,J t.!

5in. Hg.

R.
~

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,.)()\l'l~
,.J !', l.

"Ct-J'I

VI:.

Go to Step 16

1. Inspect the EVAP Vent line from the canister to the

No

'-' t-l !.

Can the specified value of vacuum be obtained and held?

Yes

Goto Step 11

/rJ$G>~'C'\

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~ /\, ',!f d'\_

Go to Step 21

Go to Step 17

Go to Step 21

Go to Step 13

Important: The following steps require the EVAP

Pressure/Purge Diagnostic Station J 41413 and the
Ultrasonic Leak Detector J 41416.

Always zero the EVAP Pressure and Vacuum (in: H20)

gauges on the EVAP Pressure/Purge Diagnostic Station
J 41413 before proceeding with diagnosis.
1. Turn OFF the ignition.
2. Remove the plug and the hand vacuum pump.

12

3. Reconnect all the EVAP components.

4. Connect the EVAP Pressure/Purge Diagnostic Station
J 41413 to the EVAP system service port.
5. Command the EVAP Vent Valve ON (closed) using a

scan tool.

6. Continuously attempt to pressurize the EVAP system

\

by leaving the EVAP pressure/purge diagnostic

station control knob in the pressurize position.
7. Using the Ultrasonic Leak Detector J 41416 locate
and repair EVAP system leak.
Did you find and repair the condition?

6-1578

Enginecontrols - 5.7L

Engine

OTC P0442 Evaporative Emission (EVAP) Control System Small Leak Detected (cont'd)
Step

Action

Value(s)

1. Inspect the EVAP system for restrictions. Refer to

Test Descriptions.
2. Repair as needed.

13

No

Go to Step 21

Go to Step 19

Did you find and correct the condition?

Repair the vacuum source to the EVAP Purge
Solenoid Valve.

14

Yes

Is the action complete?

Go to Step 21
'

15

Important: Inspect the EVAP Purge Solenoid Valve and

the purge line for carbon contamination. Refer to
Diagnostic Aids.
Replace the EVAP Purge Solenoid Valve. Refer to EVAP
Canister Purge Solenoid Valve Replacement.
Is the action complete?

16

Replace the EVAP Vent Valve. Refer to EVAP Vent Valve

Replacement.
Is the action complete?

Replace the EVAP Vapor Canister. Refer to EVAP

Canister Replacement.
Is the action complete?

Replace the EVAP line from the EVAP Purge solenoid

valve to the EVAP canister. Refer to Fuel Hose/Pipes
Replacement (Chassis).
Is the action complete?

17

18

1. With the EVAP system pressurized, compare the.

EVAP pressure/purge diagnostic station pressure
gauge (in. H20) reading to the Fuel Tank Pressure
sensor reading on the scan tool.

19

2. Compare the readings with the system depressurized.

Refer to the Test Description.
Does the Fuel Tank Pressure sensor indicate the actual
amount of pressure in the EVAP system?

20

21

22

Go to Step 21

Go to Step21

Go to .Step 21

Go to Step 21

Go to Step 3

Replace the Fuel Tank Pressure sensor. Refer to Fuel

Tank Pressure Sensor Replacement.
Is the action complete?

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operatin_g temperature.
3. Select the Diagnostic Trouble Code (DTC) option and
the Specific DTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have. not
diagnosed?
'

Go to Step 20

Go to Step 21

Go to Step 22

Go to Step 2

Go to
Applicable OTC

System OK

Engine

Engine Controls - 5.7L

6~1579

DTC P0443 Evaporative Emission (EVAP) Purge Solenoid Control Circuit

! Hot With :lgn Relay Energized !

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PNKI 239

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.Evaporative
Emission
[ ] (EVAP)
Canister
Purge
Valve

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er

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Vent
Valve

IWHT 1310
DK GRN/WKT 428

---- -

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Purge
Valve
Control

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PCM

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C1=RED
C2=BLU

Canister
vent
Valve
Control

~ CPowertrain

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Module
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~----------------------J

218692

Circuit Description

An ignition voltage is supplied directly to the EVAP

solenoid relay coil. The PCM controls the solenoid by
grounding the control circuit via an internal switch
called a driver. The primary function of the driver is to
supply the ground for the controlled component.
Each driver has a fault line which the PCM monitors.
The voltage of the control circuit should be low
(near O volts) when the PCM commands a component
ON. The voltage potential of the circuit should be
high (near the battery voltage) when the PCM
commands the control circuit to a component OFF. If
the fault detection circuit senses a voltage other
than what the PCM is expects, the fault line status
changes causing the OTC to set.

Conditions for Running the DTC

The engine speed is greater than 600 RPM.
The ignition voltage is between 6.0 volts and
16.0 volts.

Conditions for Setting the DTC

The PCM detects that the commanded state of
the driver and the actual state of the control
circuit do not match.
The conditions are present for a minimum of
10.0 seconds.

6-1580

Engine

Engine Controls - 5.7L

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC} clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
Using Freeze Frame and/or Failure Records data may
aid in locating an intermittent condition. If you
cannot duplicate the OTC, the information included in
the Freeze Frame and/or Failure Records data can
aiq in determining how many miles since the OTC set.
The Fail Counter and Pass Counter can also aid
determining how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate the vehicle
within the same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you observed.
This will isolate when the OTC failed.
For an intermittent, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
Important: The ignition must be in the on position in
order to command the EVAP Purge Solenoid
Valve to a desired percentage.
2. Listen for audible clicks when the solenoid
operates. Repeat the command as necessary.
3. This test can detect a partially shorted coil which
would cause excessive current flow. Leaving the
circuit energized for 2 minutes allows the coil
to warm up. When warm the coil may open (Amps
drop to O), or short (goes above 0.75 Amp).
7. Listen for an audible click as the solenoid
operates. Repeat the procedure as necessary.
13. If no trouble is found in the control circuit or the
connection at the PCM, the PCM may be
faulty, however, this is an extremely unlikely
failure.

Engine

Engine Controls ... 5.7L

6-1581

DTC P0443 Evaporative Emission (EVAP) Purge Solenoid Control Circuit

Step

Value(s)

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

)
I

1. Idle the engine at the normal operating temperature.

2. Command the solenoid to 50 percent using the
scan tool.
Does the solenoid operate when commanded?
1. Turn OFF the ignition.
2. Disconnect the PCM connector C1 located on the
opposite side of the manufacturers logo. Refer to
PCM Replacement/Programming.
3. Turn ON the ignition leaving the engine OFF.
Important: If the DMM goes to O Amps replace the
solenoid.
4. Measure the current from the solenoid control circuit
in the PCM harness connector to ground for
2 minutes using the DMM J 39200 on the
40 Amp scale.
Does the current draw measure less than the specified
value shown but not O?
1. Turn OFF the ignition.
2. Disconnect the solenoid.
3. Measure the resistance from the solenoid control
circuit in the PCM harness connector to ground using
the DMM J 39200.
Does the DMM display infinite resistance?

No

Go to Step 2

Goto A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to Step 5

Go to
Diagnostic Aids

Go to Step 4

Go to Step 12

Go to Step 10

Go to Step 8

Go to Step 6

Go to Step 7

Go to Step 11

Go to Step 9

Go to Step 10

Yes

0.75A

"

1. Turn OFF the ignition.

2. Disconnect the solenoid.

3. Connect the test lamp J 34142-8 between the
terminals in the solenoid harness connector.
4. Idle the engine at the normal operating temperature.
5. Command the solenoid to 1O percent using the
scan tool.

Does the test lamp flash ON and OFF?

With the test lamp connected to ground, probe the ignition

feed circuit in the solenoid harness connector.
Is the test lamp illuminated?
1. Turn OFF the ignition.
2. Reconnect the solenoid.
3. Disconnect the PCM connector C1 located on the
opposite side of the manufacturers logo. Refer to
PCM Replacement/Programming.
4. Turn ON the ignition leaving the engine OFF.

5. With a fused jumper wire connected to ground, probe

the solenoid control circuit in the PCM harness
connector. Refer to Using Fused Jumper Wires in
Wiring Systems.
Does the solenoid turn ON when the circuit is grounded
and OFF when the circuit is opened?

6-1582

Engine

Engine Controls- 5.7L

DTC P0443 EvaporativeEmission (EVAP) Purge Solenoid Control Circuit (cont'd)

Step,,

ActiOl'l

Value(s)

Yes

No

Go. to Step 14

Go to Step 12

Go to Step 14

Go to Step 13

1. Inspect for a poor connection at the solel')oid. Refer

to lntermittents and Poor Connections Diagnosis in
Wiring Systems.

2. If you find a poor connection, repair as necessary.

.Refer to Repairing Conryector Terminals i.n Wiring

Systems.
Did you find and correct the,condition?
1. Inspect for a poor connection at the PCM. Refer to
lntermittents and Ppor Connections Diagnosis in
Wiring Systems.
9

2. If you find a poor connection, repair as necessary.

Ref.er to Repairing Connector Terminals in Wiring

Systems.
Did you find and correct the condition?

10

Repair the faulty solenoid control circuit. Refer to Wiring

Repairs in Wiring Systems.

Is the action complete?

11

12

13

Repair the faulty solenoid ignition feed circuit. Refer to

Wiring Repairs in Wiring Systems.
Is the action complete?

Replace the solenoid. Refer to EVAP Canister Purge.

Solenoid Valve Replacement.
Is the action complete?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
'

Replace the PCM.

Is the action complete?

Go to Step 14

Go to Step 14
-

Go to Step 14

Go .to Step 14,

1. Select the Diagnostic Trouble Code (DTC) op!ion and

the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (DTC) option and

14

the. Specific DTC option, then enter the DTC number

using the scan tool.

4. Operate the vehicle within the Conditions for Running

the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
15

Select the Capture Info option and the Review Info Qption
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 15

Go to Step 2

Go to the
applicable
DTC table

System OK

Engine

Engine Controls - 5.7L

6-1583

DTC P0446 Evaporative Emission (EVAP) Vent System Performance

! Hot With lgn Relay Energi2ed !

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Distribution
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Electrical
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Evaporative
Emission

Evaporative
Emission

[ ] (EVAP)
Canister
B
Purge
Valve

(EVAP)
Canister

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WHT 1310

DK GRN/WHT 428

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Valve
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PCM

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Cl=RED
C2=BLU

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~----------------------J
218692

Circuit Description
The PCM monitors the performance of the EVAP
system by applying a predetermined level of vacuum
to the EVAP system then monitors the vacuum
decay rate. The PCM sets this DTC if the vacuum
decay rate is greater than a predetermined value.
Conditions for Running the OTC
DTCs P0107, P0108, P0112, P0113, P0117,
P0118, P0121, P0122, P0123,P0125, P0420,
P0430, P0452, P0453, P0500, P0502, P0503,
P1111, P1112, P1114, P1115 or H02S DTCs are
not set.
The ignition voltage is between 10 and 17 volts.
The barometric pressure is more than 75 kPa.
The fuel level is between 15% and 85% of
full capacity.
The engine coolant temperature is between 4C
(39F) and 30C (86F).

The intake air temperature is between 4C (39F)

and 30C (86F).
The start up engine coolant temperature and the
intake air temperature are within 9C (16F) of
each other.
Conditions for Setting the OTC
The EV AP vacuum decay rate is greater than a
predetermined value..
The conditions are present for greater than
2 seconds.

OR
The vacuum present in the EV AP system is
greater than a predetermined value.
The conditions are present for greater than
4 seconds.
Important: This DTC does not report a first failed test.
A first fail of this DTC will have a scan tool status
as Not Run.

5..1554 Engin,e Con,trols .. 5.7L

Engine

Action Taken When the DTC Sets

Inspect for charcoal releaseJrom the vapor canister..

Refer to the EVAP System Cleaning procedure.
The vacuum and pressure in the EVAP system is
measured in inches of H20 (water). Most gauges
measure vacuum in inches of Hg (mercury) and
pressure in psi (pounds per square inch). The following
shows how the values compare:

The PCM will illuminate the Malfunction Indicator

Lamp (MIL) after two consecutive drive trips that
the diagnostic runs and fails.
The PCM will record operating conditions at the
time the OTC sets. This information will be
stored in the Freeze Frame and Failure Records.
Afirst failure of this OTC will NOT store in
Last Test Failed or History.

Conditions for Clearing the MIL/DTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
' A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
Important: An accurate indication of fuel level is
.required for the PCM to properly Pass or Fail this OTC.
Always diagnose the fuel level sensor OTC's before
performing this OTC's diagnostic table. Always inspect
for fuel level sensor OTC's stored as History.
Important: The Service Bay Test may have to be
performed in cold ambient air temperatures .when the
vehicle is running a winter grade fuel. The scan
tool displays a message when the service bay test
does not run.
Conditions for Running the Service Bay Test
The battery voltage is between 10.5 and
17.5 volts.
The fuel level is between 1;5% and 85% of the full
capacity.
The engine temperature is between 3.5C (38F)
and 35C (95F).
Perform a physical inspection of the EVAP system.
lnspe9t for the following conditions:
A loose, missing, defective, or incorrect fuel
tank cap
Incorrectly routed or defective EVAP system

vacuum and vapor lines

A stuck closed EVAP Vent Valve
A restricted or blocked EV AP system hose
A restricted or stuck closed fuel tank rollover
valves
A malfunctioning or damaged vapor canister

in. H20
1 in. H20
5 in. H20
10 in. H20
15 in. H20

in. Hg.
0.07 in. Hg
0.36 in. Hg
0.73 in. Hg
1.10 in. Hg

psi
0.0361 psi.
0.180 psi.
0.361 psi.
0.541 psi.

Test Description
The numbers below refer to the step numbers on the
Diagnostic Table.
3. An intermittent leak or restriction is indicated if the
vehicle passes the Service Bay Test. A fuel tank
cap that is loose or off causes this OTC to set.
If the Service Bay Test can not be run, proceed to
Step 5. If a fault is not currently present the
diagnostic table steps will return you to Step 3.
4. Testing the vapor canister and the EVAP Vent
Valve for restriction.
8. A Fuel Tank Pressure sensor that does not
correctly respond to pressure (or vacuum) causes
this OTC to set.
An open fuel tank pressure sensor ground circuit
causes this OTC to set. If the fuel tank pressure
sensor does not respond to pressure (or vacuum),
inspect the ground circuit for an open.
The Fuel Tank Pressure sensor monitors a range
from 7.5 in. H20 of pressure to -17.5 in. H20
of pressure (vacuum).
In order to test the Fuel Tank Pressure sensor for
vacuum response, command the EVAP Purge
Solenoid Valve to 100 percent with the engine
running and quickly SEAL the system. Leaving the
EVAP Purge Solenoid Valve activated for a
longer period of time allows a greater level. of
vacuum to develop.

Engine

Engine Controls - 5.7L

6-1585

DTC P0446 Evaporative Emission (EVAP) Vent System Performance

Step

Action

Value(s}

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 12

Go to Step 3

Go to
Diagnostic Aids

Go to Step 4

Go to Step 7

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 13

Go to Step 10

Go to Step 13

Go to Step 8

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Inspect the EVAP system for the following conditions:

1. Improperly routed, kinked or damaged EVAP purge
and tank vent lines.
2. A damaged EVAP system component.
Repair the EVAP system as necessary if you find a
condition.
Did you find and correct the condition?
Important: Ensure that The Conditions for Running the
Service Bay are met before proceeding with this
diagnostic. Refer to Diagnostic Aids.

Perform the EVAP system Service Bay Test.

Does the vehicle pass the Service Bay Test?

1. Turn OFF the ignition.

2. Disconnect the fuel tank vapor and the EVAP purge
lines from the EVAP vapor canister. Refer to EVAP
Canister Replacement.
3. Plug the CANISTER fitting for the fuel tank vapor line.
4. Connect the hand held vacuum pump J 23738-A to
the EVAP purge line canister fitting.
5. Turn ON the ignition leaving the engine OFF.

5 in. Hg.

6. Command the EVAP Vent Valve ON (closed) using

the scan tooL
7. Attempt to apply and hold the specified amount of
vacuum using the hand held vacuum pump.
8. Command the EVAP Vent Valve OFF (open) while
monitoring the hand held vacuum pump gauge.
Does the vacuum drop from the specified value when the
EVAP Vent Valve is opened?

1. Leave the system as connected in Step 4.

2. Disconnect the vent line at the EVAP Vent Valve.
3. Plug the vent line.
4. Attempt to apply and hold the specified amount
of vacuum using the hand held vacuum
pump J 23738-A.
5. Remove the plug from the vent line while monitoring
the hand held vacuum pump gauge.
Does the vacuum drop from the specified value when the
vent line is unplugged?
1. Inspect the EVAP Vent line from the canister to the
EVAP Vent Valve for restrictions.
2. Repair as necessary if you find a condition.

5 in. Hg.

Did you find and correct the condition?

1. Inspect the fuel tank vapor line for a restriction.

2. Repair as necessary if you find a condition.
Did you find and correct the condition?

6-1586

Engine Controls. 5.7L

Engine

DTC P0446 Evaporative Emission (EVAP) Vent System Performance (cont'd)

Step

Action

Value(sf

Yes

No

Important: The following steps require the EVAP

pressure/purge diagnostic station J 41413.
Always zero the EVAP Pressure and Vacuum (in. H20)
gauges on the EVAP pressure/purge diagnostic station
before proceeding with diagnosis.
1. Turn OFF the ignition.
2. Remove the plug and the hand held vacuum pump.

3. Reconnect the EVAP vapor canister purge and

vent lines.

4. Connect the EVAP pressure/purge diagnostic station

8

to the EVAP system service port.

5. Operate the vehicle until the EVAP Purge Solenoid

Valve can be commanded to a percentage with a

scan tool.

6. Command the EVAP Purge Solenoid Valve to 100

percent with the engine running and quickly SEAL the
system with the scan tool.
7. Compare the EVAP pressure/purge diagnostic
station's vacuum gauge (in. H20) to the vacuum
shown on the scan tool from the Fuel Tank Pressure
sensor while the system is sealed.
Does the Fuel Tank Pressure sensor indicate the actual
amount of vacuum in the EVAP system?

10

11

12

Go to Step 3

Replace the EVAP Vent Valve. Refer to EVAP Vent Valve

Replacement.
Is the action complete?

Replace the EVAP Vapor Canister. Refer to EVAP

Canister Replacement.
Is the action complete?

Replace the Fuel Tank Pressure sensor. Refer to Fuel

Tank Pressure Sensor Replacement.
Is the action complete?

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (DTC) option and
the Specific DTC option, then enter the DTC number
using the scan tool.

Go to Step 11

Go to Step 13

Go to Step 13

Go to Step 13

4. Operate the vehicle within the Conditions for Running

the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
13

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 13

Go to Step 2

Go to the
applicable DTC

System OK

Engine

Engine Controls - 5.7L

6-1587

OTC P0449 Evaporative Emission (EVAP) Vent Solenoid Control Circuit

! Hot With lgn Relay Energi2ed !

Distribution
I
Cell 10

Underhood
Electrical
MiniFuse I Center 2

15 A

r -

Power

.,

ENG CTRL

U:iJ

L-----

...;.---,:.I

PNK 239
PNK 239

Fuse Block
Details

PNK
239

PNK 239

PN1239

PNK 239

PN:I 239

PNK
239

Cell11

Evaporative
Emission
(EVAP)
Canister
Purge
Valve

Ev.aporative
Emission
(EVAP)

Canister

BI ~:~~
WHT 1310

I1310

DK GRN/WHT 428

45
r -

Valve

-~:l:10

-;v; - ;-- - - - - - - E~A; -; - Canister

Purge

I
I
I
I

. WHT

Control

--T

PCM
C1=RED
C2=BLU

Canister
vent
Valve

Control

--T

Powertrain
Control
1 Module
I (PCM)

.A

I ~
I~
I

L----------------------.1
218692

Circuit Description

An ignition voltage is supplied directly to the EVAP

Vent valve relay coil. The PCM controls the solenoid
by grounding the control circuit via an internal
switch called a driver. The primary function of the
driver is to supply the ground for the controlled
component. Each driver has a fault line which the
PCM monitors. The voltage of the control circuit should
be low (near O volts) when the PCM commands a
component ON. The voltage potential of the circuit
should be high (near the battery voltage) when
the PCM commands the control circuit to a component
OFF. If the fault detection circuit senses a voltage
other than what the PCM is expects, the fault
line status changes causing the OTC to set.

Conditions for Running the DTC

The engine speed is greater than 600 RPM.
The ignition voltage is between 6.0 volts and
16.0 volts.

Conditions for Setting the DTC

The PCM detects that the commanded state of
the driver and the actual state of the control
circuit do not match.
The conditions are present for a minimum of
10.0 seconds.

6-1588

Engine Controls - 5.7L

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

Engine
Diagnostic Aids
Using Freeze Frame and/or Failure Records data may
aid in locating an intermittent condition. If you
cannot duplicate the OTC, the information included in
the Freeze Frame and/or Failure Records data can
aid in determining how many miles since the OTC set.
The Fail Counter and Pass Counter can also aid
determining how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate the vehicle
within the same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you observed.
This will isolate when the OTC failed.
For an intermittent, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Listen for an audible click when the solenoid
operates. Be sure that both the ON and the OFF
states are commanded. Repeat the commands
as necessary.
3. This test can detect a partially shorted coil which
would cause excessive current flow. Leaving the
circuit energized for 2 minutes allows the coil
to warm up. When warm the coil may open (amps
drop to 0), or short (goes above 0.75 amp).
13. If no trouble is found in the control circuit or the
connection at the PCM, the PCM may be
faulty, however, this is an extremely unlikely
failure.

Engine

Engine Controls - 5.7L

5,;,1599

OTC P0449 Evaporative Emission (EVAP) Vent Solenoid Control Circuit

Step

Action
Did you perform the Powertrain On-Board Diagnostic
(OBD) System Check?

1. Idle the engine at the normal operating temperature.

2. Command the solenoid ON and OFF using,the
scan tool.
Does the solenoid turn ON and OFF when commanded?
1. Turn OFF the ignition.
2. Disconnect the PCM connector C1 located on the
opposite side of the manufacturers logo. Refer to
PCM Replacement/Programming.
3. Tu'rn ON the ignition leaving the engine OFF.
Important: If the DMM goes to O, replace the relay.
4. Measure the current from the solenoid control circuit
in the PCM harness connector to ground for
2 minutes using the DMM J 39200 on the
40 amp scale.
Does the current draw measure less than the ~pecified
value shown?

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Step 5

Go to
Diagnostic Aids

Go to Step 4

Go to Step 12

Go to Step 10

Go to Step B

Go to Step 6

Go to Step 7

Go to Step 11

Go to Step 9

Go to Step 10

0.75A

1. Turn OFF the ignition.

2. Disconnect the solenoid.
3. Measure the resistance from the solenoid control
circuit in the PCM harness connector to ground using
the DMM J 39200.
Does the DMM display infinite resistance?

1. Turn OFF the ignition.

2. Disconnect the solenoid.
3. Connect the test lamp J 34142-8 between the
terminals in the solenoid harness connector.
4. Idle the engine at the normal operating temperature.
5. Command the solenoid ON and OFF using the
scan tool.
Does the test lamp turn ON and OFF when commanded?

With the test lamp connected to ground, probe the ignition

feed circuit in the solenoid harness connector. Refer to
Probing Electrical Connectors in Wiring Systems.
Is the test lamp illuminated?

1. Turn OFF the ignition.

2. Reconnect the solenoid.
3. Disconnect the PCM connector C1 located on the
opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.
7

4. Turn ON the ignition leaving the engine OFF.

5. With a fused jumper wire connected to ground,
momentarily probe the solenoid control circuit in the
PCM harness connector.
Does the solenoid turn ON when the circuit is grounded
and OFF when the circuit is opened?

Engine Controls. - ~.7L

6-1590

Engine

DTC P0449 Evapotative Emission (EVAP) Vent Solenoid Control Circuit (cont'd)
..

Step

Action

10

11

12

..

'

"

1. Inspect for poor connections at the solenoid. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?
'
.
1. Inspect for poor connections at the PCM. Refer to
lntermittents and Poor Connections Diagnosis in
.,,,,
Wiring Systems.
2. If you find a poor connection, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

Value(s)

Repair the faulty solenoid ignition feed circuit. Refer to

Wiring Repairs in Wiring Systems.
Is the action complete?

14

15

1. Select the Diagnostic Trouble Code (D'fC) option and

the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 12

Go to Step 14

Go to Step 13

Go to Step 14

Go to Step 14

Is the action complete?

13

Go to Step 14

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

No,

Repair the faulty solenoid control circuit. Refer to Wiring

Repairs in Wiring Systems.
Is the action complete?

Replace the solenoid. Refer to EVAP Vent Valve

Replacement.

Yes

Go to Step 14

'

Go to Step 14

Go to Step 15

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine Controls - s~7L

Engine

6.;.1591

DTC P0452 Fuel Tank Pressure Sensor Circuit Low Voltage

GRY 720

'Loe I

GAY 720

(5:1

i-----------

BLK/
WHT 651

ORN/ 469
BLK

D
r--

[EJ

- - - - - -

Fuel
Level
Sensor

- - - - - ., Fuel

......._.....,.....-

Fuel Tank
Pressure
Sensor

Tank
: Unit
I

I
I

- - - - - -C B- - - .- ..

GRY 720
r -

- ,

Instrument

I. Fuel I Cluster
I Gauge I ~

DKGRN 890

~-, .. ~

GRY 416

DK BLU 1936

PPL 30
DKGRN 890

DK BLU 1936

GRY 720

GRY 598

tJ

67

10

~ - -;
I Fuel

I Level
Input

- - - - - -u5V
- -5V
Feed

52

-Fu:I

C2

-1----------

Tank
Pressure

-1-------1~~9: - -P~M- 6~;:~rain

75

36

--------------

Fuel
Ground

C1

Output
Control

I
C1 = RED I
C2 = BLU

Module

(PCM)
~

L-------------------------------------------.1~
218697

Circuit Description
The Fuel Tank Pressure sensor changes resistance
based on the fuel tank pressure (or vacuum). A
vacuum is considered negative pressure.
The PCM provides a 5.0 volt reference and a ground.
The Fuel Tank Pressure sensor signal varies
between ground and 5.0 volts as fuel tank pressure
varies. The Fuel Tank Pressure sensor voltage
increases as the fuel tank pressure decreases
(negative pressure, or vacuum). The Fuel Tank
Pressure sensor voltage decreases (positive pressure,
low voltage) as the fuel tank pressure increases.
The PCM uses the Fuel Tank Pressure sensor voltage
for EVAP system leak detection. This DTC sets
when the Fuel Tank Pressure sensor signal goes
below a predetermined value.

Conditions for Running the OTC

The ignition switch is in the RUN position.

Conditions for Setting the OTC

The Fuel Tank Pressure sensor voltage is less
0.1 volts.
All conditions present for greater than 5.0 seconds.

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

5.;;1592

Engine

Engine Controls - 5.7L

Conditions for Clearing the MIL/DTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not tail.
A last test tailed (current DTC) clears when the
diagnostic runs and does not tail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

The numbers below refer to the step numbers on the

diagnostic table.
2. If DTC P1639 sets at the same time, this indicates
that the 5.0 volt reference circuit is either shorted
to ground or shorted to a voltage. The 5.0 volt
reference circuit is internally connected within the
PCM. The A/C Refrigerant Pressure sensor
may be causing this DTC to set.

3. This step determines if the malfunction is present.

4. Using the Freeze Frame and/or Failure Records

Diagnostic Aids
The EVAP Pressure Sensor monitors a range from
7.5 in. H20 of pressure to -17.5 in. H20 of pressure
(vacuum).
The vacuum and pressure in the EV AP system is
measured in inches of H20 (water). Most gauges
measure vacuum in inches ofHg (mercury) and
pressure in psi (pounds per square inch). The following
shows how the values compare:
in. H20
1 in. H20
5 in. H20
10 in. H20
15 in. H20

Test Description

in. Hg.
0.07 in. Hg
0.36 in. Hg
0.73 in. Hg
1.10in.Hg

psi
0.0361 psi.
0.180 psi.
0.361 psi.
0.541 psi.

data may aid in locating an intermittent condition.

If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the DTC failed.
5. If the scan tool displays 5.0 volts, the Fuel Tank
Pressure sensor signal, 5.0 volt reference
circuit, and the PCM are OK.
6. If the scan tool displays 5.0 volts, the Fuel Tank
Pressure sensor signal circuit and the PCM
are OK.
7. Disconnecting the PCM allows using the DMM in
order to test the continuity of the circuits. This
aids in locating an open or a shorted circuit.

Engine

Engine Controls - 5.7L

6-1593

DTC P0452 Fuel Tank Pressure Sensor Circuit Low Voltage

Step

Action

Value(s).

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
. (OBD) System
Check

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

.
1. Install a scan tool.

Go to

2. Idle the engine.

2

3. Monitor the Diagnostic trouble Code (DTC)

Information using the scan tool.

Did DTC P1639 fail this ignition cycle?

Monitor the Fuel Tank Pressure sensor voltage using the

scan tool.
Is the Fuel Tank Pressure sensor voltage below the
specified value?

DTCP1639
5 Volt
Reference 2
Circuit

. Go to Step 3

Go to Step 5

Go to Step 4

0.10V

1. Turn ON the ignition leaving the engine OFF.

'

2. Review the Freeze Frame and/or Failure Records

data for this DTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Idle.the engine.

5. Operate the vehicle witt!lin the conditions required for

this diagnostic to run, and as close to the conditions
recorded in the Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the DTC.
6. Select the Diagnostic Trouble Code (DTC) option, the
Specific DTC option, then enter the DTC number
using the scan tool.

Does the scan tool indicate that this diagnostic failed this
ignition?

Go to Step 5

Go to
Diagnostic Aids

Go to Step 11

Go to Step 6

Go to Step 7

Go to Step 9

1. Disconnect the Fuel Tank Pressure sensor jumper

harness at the body pass through connector. Refer to

Outside Left of Rear Floor Pan, Fwd Rear of Axle 98

in Wiring Systems.

2. Jumper the 5.0 volt reference circuit and the Fuel

Tank Pressure sensor signal circuit together at the

body pass through connector (PCM side of harness).

5.0V

3. Observe the Fuel Tank Pressure sensor voltage

display on the scan tool.
Is the Fuel Tank Pressure sensor voltage near the
specified value?
1. Connect the test lamp J 34142-B between B+ and the
Fue) Tank Pressure sensor signal circuit at the body
pass through connector.

2. Observe the Fuel Tank Pressure sensor voltage

5.0V

display on the scan tool.

Is the Fuel Tank Pressure sensor voltage near the
specified value?

6-1.594

Engine Controls - 5.7L

Engine

DTC P0452 Fuel Tank Pressure Sensor Cirouit Low Voltage (cont'd)
Step.

Value(s)

Action

Yes

No

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacemept!Programming.
3. Test the 5.0 volt reference circuit for an open or short
to ground.

'.

4. If you find the 5.0 volt reference circuit is open or

shorted to ground, repair the circuit as necessary.
Refer to Wiring Repairs in Wiring Systems.
Did you find ancl repair the condition?

Go.to Step 19

Go to Step 8

Go to Step 19

Go to Step 18

,.

1. Inspect the 5.0 volt reference circuit for a poor

connection at the PCM. Refer to lntermittents and
Poor Connections Diagnosis in Wiring Systems.
2. Repair the :terminal as necessary. Refer to Repairing
Connector Terminals in Wiring Systems.
Did you find and repair the condition?

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the Fuel Tank Pressure sensor signal circuit for
the following:
.,

10

11

'.

.
l

Open circuit
Short to ground
Short to sensor ground circuit
Short to another C1 circuit.
4. If you find the Fuel Tank Pressure sensor signal
circuit is open or shorted to ground, repair the circuit
as necessary. Refer to Wiring Repairs in Wiring
Systems.
Did you find and repair the condition?

.,

'

1. Inspect the Fuel Tank Pressure sensor signal circuit

for a poor connection at the PCM. Refer to
lntermittents and Poor Connections Diagnosis.
2. If you find a poor connection repair the terminal as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and repair the cpndition?
1. Inspect for a poor connection at the body pass
through connector. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
2. If you find a poor connection repair the terminal as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and repair the condition?

Go to Step 19

Go to Step 10

Go to Step 19

Go to Step 18

-
,.

'j

'

Go to Step 19

Go to Step 12

Engine

Engine Controts - 5.7L

6-1595

OTC P0452 Fuel Tank Pressure Sensor Circuit Low Voltage (cont'd)
Step

Action

Value(s)

12

1. Turn OFF the ignition.

2. Re-connect the Fuel Tank Pressure sensor jumper
harness to the body pass through connector.
3. Lower the fuel tank to gain access to the Fuel Tank
Pressure sensor. Refer to Fuel Tank Replacement.
4. Disconnect the Fuel Tank Pressure Sensor.
5. Turn ON the ignition leaving the engine OFF.
6. Jumper the Fuel Tank Pressure sensor 5 volt
reference and signal circuit together at the Fuel Tank
Pressure sensor connector.
7. Observe the Fuel Tank Pressure sensor voltage
using a scan tool.
Is the Fuel Tank Pressure sensor voltage near the
specified value?

5.0V

13

Measure the Fuel Tank Pressure sensor 5.0 volt reference

circuit at the Fuel Tank Pressure sensor connector using
the DMM J 39200.
Does the DMM display a voltage near the specified
voltage?

5.0V

14

Repair the open or grounded Fuel Tank Pressure sensor

signal circuit. Refer to Wiring Repairs in Wiring Systems.

15

16

1. Inspect for a poor connection at the Fuel Tank

Pressure sensor harness connector.
2. If you find a poor connection repair the terminal as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.

17

18

19

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?
1. Select the Diagnostic Trouble Code (OTC) option and
the Clear DTC lnforma.tion option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the DTC . number
using the scan tool.

Go to Step 16

Go to Step 13

Go to Step 14

Go to Step 15

Go to Step 19

Go to Step 19

Go to Step 19

Did you find and repair the condition?

Replace the Fuel Tank Pressure sensor. Refer to Fuel
Tank Pressure Sensor Replacement.
Is the action complete?

No

Is the action complete?

Repair the open or grounded Fuel Tank Pressure sensor
5.0 volt reference circuit. Refer to Wiring Repairs in Wiring
Systems.
Is the action complete?

Yes

Go to Step 17

Go to Step 19

Go to Step 19

4. Operate the vehicle within the Conditions for Running

the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

20

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 20

Go to Step'2

Go to the
applicable OTC

System OK

6-1596

Engine Controls .. 5.7L

Engine

OTC P0453 Fuel Tank Pressure Sensor Circuit High Voltage

I I
E:l
A
L0 c

GRY 720

GRY 720

r---------

BU</

WHT 651

.--

[ti]

- - - - - -;:

......-!--, Fuel
Level
Sensor

-----C

L--

ORN/ 469
BLK

- - - - - ., Fuel
Fuel Tank
Pressure
Sensor

_____

I
:

Tank
Unit

I
I

_.I

GRY 720

'" - - ., Instrument
I Fuel I Cluster

pp}

DKGRN 890

Gauge

L--J~
k2.

GRY 416

DK BLU 1936

130 -- 1598

PPL

~RY

1890

DK GAN

------ T -

PPL 30
DKGRN1890

DK BLU 1936

GAY 720

GRY 598

~
I
I

---------~? --------~?
?~
--t]~-----u;V
- - - -F:I - - - - - - - - - - - -1-------1~~g: - -P:M10

Fuel
Level
Input

C2

sv

Feed

Tank
Pressure

75

____________

Fuel
Ground

C1

Output
Control

Cl = RED
C2 = BLU

6~~~~rain

I Module
I

(PCM)

L-------------------------------------------J~
218697

Circuit Description
The Fuel Tank Pressure sensor changes resistance
based on the fuel tank pressure (or vacuum). A
vacuum is considered negative pressure.
The PCM provides a 5.0 volt reference and a ground.
The Fuel Tank Pressure sensor signal varies
between ground and 5.0 volts as fuel tank pressure
varies. The Fuel Tank Pressure sensor voltage
increases as the fuel tank pressure decreases
(negative pressure, or vacuum). The Fuel Tank
Pressure sensor voltage decreases (positive pressure,
low voltage) as the fuel tank pressure increases.
The PCM uses the Fuel Tank Pressure sensor voltage
for EVAP system leak detection. This DTC sets
when the Fuel Tank Pressure sensor signal goes
above a predetermined value.

Conditions for Setting the DTC

The ignition switch is in the RUN position.

Conditions for Setting the DTC

The Fuel Tank Pressure sensor voltage is greater
than 4.90 volts.
All conditions present for greater than 5.0 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Engine

Engine Controls - 5.7L

Conditions for Clearing the MIL/DTC

The PCM turns the MIL OFF after three

consecutive ignition cycles that the diagnostic
runs and does not tail.
A last test tailed (current OTC) clears when the
diagnostic runs and does not tail.
A History OTC clears after forty consecutive
warm-up cycles, it this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
The EVAP Pressure Sensor monitors a range from
7.5 in. H20 of pressure to -17.5 in. H20 of pressure
(vacuum).
The vacuum and pressure in the EV AP system is
measured in inches of H20 (water). Most gauges
measure vacuum in inches of Hg (mercury) and
pressure in psi (pounds per square inch). The following
shows how the values compare:
in. H20
1 in. H20
5 in. H20
10 in. H20
15 in. H20

in. Hg.
0.07 in. Hg
0.36 in. Hg
0.73 in. Hg
1.10 in. Hg

psi
0.0361 psi.
0.180 psi.
0.361 psi.
0.541 psi.

6-1597

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step determines if the malfunction is present.
If OTC P1635 sets at the same time, this indicates
that the 5.0 volt reference circuit is either
shorted to ground or shorted to a voltage. The
5 volt reference circuit is internally connected
within the PCM. The A/C Refrigerant Pressure
sensor may be causing this OTC to set. Refer to
OTC P1635 for further diagnosis.
3. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the OTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the OTC failed.
4. This step tests whether the signal circuit is
shorted to a voltage.
5. This step tests whether a ground circuit is
available for the Fuel Tank Pressure sensor at the
body pass through connector.
9. This step tests whether a ground circuit is
available for the Fuel Tank Pressure sensor.

DTC P0453 Fuel Tank Pressure Sensor Circuit High Voltage

Step

Action

Value(s)

Yes

No

Go to Step 2

Goto A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

1. Turn ON the ignition leaving the engine OFF.

2. Monitor the Fuel Tank Pressure sensor voltage using

the scan tool.

4.3V

Is the Fuel Tank Pressure sensor voltage above the

specified value?
1. Turn ON the ignition leaving the engine OFF.
2. Review the Freeze Frame and/or Failure Records
data for this OTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Idle the engine.

5. Operate the vehicle within the conditions required for

this diagnostic to run, and as close to the conditions
recorded in the Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.

6. Select the Diagnostic Trouble Code (OTC) option, the

Specific OTC option, then enter the OTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

6-1598

Engine

Engine Controls - 5.7L

OTC P0453 Fuel Tank Pressure Sensor Circuit High Voltage (cont'd)

Step

Action

1. Disconnect the Fuel Tank Pressure sensor jumper

harness at the body pass through connector. Refer to
Outside Left of Rear Floor Pan, Fwd Rear of Axle 98
in Wiring Systems.
2. Observe the Fuel Tank Pressure sensor voltage
displayed on the scan tool.

Value(s)

Measure the voltage at the 5.0 volt reference circuit at the

body pass through connector to the battery ground using
the DMM J 39200.
Is the voltage near the specified value?
'
1. Inspect for a poor connections at the body pass
through connector. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
2. If you. find a poor connection, repair the terminal as
necessary. Refer to Connector Repairs in Wiring
Systems.
Did you find and repair the condition?

No

(
1.0V

Is the Fuel Tank Pressure sensor voltage below the

specified value?
Probe the sensor ground circuit at the body pass through
connector (PCM side) with the test lamp J 34142-8
connected to B+.
Is the test lamp illuminated?

Yes

Go to Step 5

Go to Step 11

Go to Step 6

Go to Step 12

Go to Step 7

Go to Step 19

Go to Step 20

Go to Step 8

Go to Step 9

Go to Step 14

Go to Step 10

Go to Step 15

Go to Step 17

Go to Step 16

Go to Step 20

Go to Step 13

5.0V

1. Turn OFF the ignition.

2. Re-connect the Fuel Tank Pressure sensor jumper

harness to the body pass through connector.

3. Lower the fuel tank to gain access to the Fuel Tank

Pressure sensor. Refer to Fuel Tank Replacement.

4. Disconnect the Fuel Tank Pressure Sensor electrical

connector.

1.0V

5. Turn ON the ignition leaving the engine OFF.

6. Observe the Fuel Tank Pressure sensor voltage

using a scan tool.
Is the Fuel Tank Pressure sensor voltage below the
specified value?

10

11

Probe the Fuel Tank Pressure sensor ground circuitwith

the test lamp J 34142-8 connected to B+ at the Fuel Tank
Pressure sensor jumper harness (PCM side).
Is the test lamp illuminated?
Measure the voltage at the Fuel Tank Pressure sensor
5.0 volt reference circuit to the battery ground using the
DMM J 39200. Refer to Measuring Voltage in Wiring
Systems.
Is the voltage near the specified value?
1. Test the Fuel Tank Pressure sensor signal circuit for
a short to voltage or a short to the 5 volt reference
circuit between the body pass through connector and
the PCM. Refer to Measuring Voltage in Wiring
Systems.
2. Repair the Fuel Tank Pressure sensor signal circuit if
the circuit is shorted. Refer to Wiring Repairs in
Wiring Systems.
Did you find and correct the condition?

5.0V

Engine

Engine Controls - 5.7L

6-1599

OTC P0453 Fuel Tank Pressure Sensor Circuit High Voltage (cont'd)
Step

Action

Vatue(s)

12

1. Test for continuity of the Fuel Tank Pressure sensor

ground circuit between the body pass through
connector and the PCM. Refer to Testing tor
Continuity in Wiring Systems.
2. Repair the open or the poor connection if the Fuel
Tank Pressure sensor ground circuit measures over
the specified value. Refer to Wiring Repairs in Wiring
Systems.
Did you find and correct the condition?

20

13

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.

Replace the PCM.

Is the action complete?

15

Repair the poor connection or open ground circuit in the

Fuel Tank Pressure sensor jumper harness, Refer to
Wiring Repairs in Wiring Sys\ems.
Is the action complete?

16

Repair the 5 volt reference circuit in the Fuel Tank

Pressure jumper harness for a short to voltage. Refer to
Wiring Repairs in Wiring Systems.
Is the action complete?

1. Inspect for a poor sensor ground terminal connection

at the Fuel Tank Presst,Jre sensor jumper harness
connector. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
2. If you find a poor connection repair the terminal as
necessary. Refer fo Repairing Connector T_erminals in
Wiring Systems.
Did you'find and correct the condition?

18

2Q

21

Go to Step 13

Go to Step 20

Go to Step 20

Go to Step 20

Go to Step 20

Go to Step 18

Is the action complete?

19

Go to Step 20

'Go to Step 20

14

Replace the Fuel Tank Pressure sensor. Refer to Fuel

Tank Pressure Sensor Replacement.

No

Repair the poor connectiqn or the signal circuit for a short

to voltage in the Fuel Tank Pressure sensor jumper
harness. Refer to' Wiring Repairs in Wiring Systems.
Is the action complete?

17

Yes

Go to Step 20

Repair the 5 volt reference circuit for a short to voltage

between the PCM and the jumper harness. Refer to Wiring
Repairs in Wiring Systems.
Is the.action complete?

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific DTC option, then enter the DTC number,
using the scan tool.
4. Operate the vehicle within the Conditi9ns for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this t.est ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 20,

'

Go to Step 21

Go tocStep 2

Go to tr\e
. applicable OTC

System OK

6-1600

Engine Controls - 5.7L

Engine

OTC P0461 Fuel Level Sensor Performance

I I
L 0c

GRY 720

BLK/

GAY 720

....

--

ORN/ 469
BLK

[i]

- - - - - -;;:

.--1--

Fuel

Level
Sensor

-----C

L--

r---------

WHT 651
D

- - - - - ., Fuel
Fuel Tank

Pressure
Sensor

Tank

Unit

I
I

_____ _.

GAY 720
r - - , Instrument
I Fuel I Cluster
I Gauge I /j

DKGRN 890
GRY 416

L--..1~

A2
DK BLU 1936

PPL 30

DKGRN 890

DK 13LU 1936

GRY 720

GAY 598
10

67

52

75

C2

36

C1

218697

Circuit Description
The Fuel Level Sensor changes resistance based on
fuel level. The Fuel Level Sensor has a signal
circuit and a ground circuit. The PCM applies a voltage
(about 5.0 volts) on the signal circuit to the sensor.
The PCM monitors the changes in this voltage caused
by changes in the resistance of the sensor in order
to determine fuel level.
When the fuel tank is full, the sensor resistance is
high, and the PCM's signal voltage is only pulled down
a small arnount through the sensor to ground.
Therefore, the PCM will sense a high signal voltage
(fuel tank full). When the fuel tank is empty, the sensor
resistance is low, and the. signal voltage is pulled
down a greater amount. This causes the PCM to sense
a low signal voltage (fuel tank empty).

The PCM uses inputs from the Fuel Level Sensor in

order to calculate the total fuel remaining in the
fuel tank. This information is then sent to the
fuel gauge.
This diagnostic tests for a stuck fuel level sensor
signal. The PCM sets this DTC if the fuel level signal
appears to be stuck based on a lack of signal
variation expected during normal operation.

Conditions for Running the DTC

The fuel level sender indicates a fuel level greater
than 58.7 liters.
More than 150 miles have been accumulated.
OR
The fuel level sender indicates a fuel level less
than 58. 7 liters.
More than 125 miles have been accumulated.

Engine

Engine Controls - 5.7L

6-1601

Conditions for Setting the DTC

Diagnostic Aids

The fuel level in the fuel tank does not decrease by at

least 3.0 liters.

The vehicle fuel gauge displays empty with this

DTC set:

Action Taken When the DTC Sets

Using Freeze Frame and/or Failure Records data may

aid in locating an intermittent condition. If you
cannot duplicate the DTC, the information included in
the Freeze Frame and/or Failure Records data can
aid in determining how many miles since the DTC set.
The Fail Counter and Pass Counter can also aid
determining how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate the vehicle
within the same freeze frame conditions (RPM, load,
.vehicle speed, temperature etc.) that you observed.
This will isolate when the OTC failed.

The PCM stores the DTC information into memory

when the diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL) will not
illuminate.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Failure Records.

Conditions for Clearing the MIUDTC

A History DTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other non-emission related diagnostic.
A last test failed (Current DTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUDTC.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step d~termines if the fault is present.

DTC P0461 Fuel Level Sensor Performance

Step

Action
Did you perform the Powertrain On-Board Diagnostic
(080) System Check?

Value(s)

Yes

Go to Step 2

No
Go to A
Powertrain On
Board Diagnostic
(080) System
Check

1. Disconnect the Fue.1 Level sensor at the body pass

through connector. Refer to Outside Left of Rear
Floor Pan, Fwd Rear of Axle 98 in Wiring Systems.

2. Jumper the Fuel Level sensor signal circuit (PCM

side) to a known good ground.

o.ov

3.. Monitor the Fuel Level sensor parameter using the

scan tool.
Is the Fuel Level sensor at the specified value?

Go to Step 3

Go to Step 5

Go to Step 4

Go to Step 6

Go to Step 10

Go to Step 7

1. Jumper the Fuel Level ~ensor signal circuit and the

ground circuit together (PCM side).

2. Monitor the Fuel Level sensor parameter using the

scan tool.

o.ov

Is the Fuel Level sensor at the specified value?

1. Remove the fuel tank level sensor. Refer to Fuel

Sender Assembly Replacement.
2. Inspect for the following:

Damage to the Fuel Level sensor jumper harness.

Poor connections at the Fuel Level sensor. Refer
to lntermittents and .Poor Connections piagnosis in
Wiring Systems.
A stuck Fuel Level sensor (i.e. the fuel strainer
interfering with the sender float arm.)

Foreign material in the fuel tank (ice).

A deformed fuel tank.
3. If you find a condition, repair the condition as
necessary.

Did you find and correct the condition?

6-1602

Engine Controls - 5.7L

Engine

OTC P0461 Fuel Level Sensor Performance (cont'd)

Step

Action

Value(s)

Yes

No

1. Disconnect the PCM connector C2 located on the

.~ame !:iide as the manufacturer's logo. Refer to PCM
Replacement/Programming.

2. Test the Fuel Level signal circu.itfor excess.ive

resistance.

3. If you find a circuit condition, repair the circuit as

necessary. Refer to Wiring Repairs in Wiring
Systems.
Did you find and correct the condition?

Go toStep 10

Go to Step 8

Go to Step 10

Go to Step 8

1. Disconnect the PCM connectors C1 located on the

opposite side of the manufacturer's logo. Refer to

PCM Replacement/Programming.
2. Test the Fuel Level sensor ground circuit for
excesses resistance.
3. If you find a circuit condition, repair the circuit as
necessary. Refer to Wiring Repairs in Wiring.
Systems.

"

Did you find and correct the condition?

10

Replace the Fuel Level sensor . .Refer to Fuel Sender

Assembly Service.
Is the action complete?

1. Test the terminal tension at the PCM. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If a condition is found, repair as necessary. Refer to
Repairing Connector Terminals in Wiring Systems.
Did you find and correct the condition?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (DTC} option and
the Specific DTC option, then enter the DTC number
using the scan tool.

.Go to Step 10

Go to Step 1'0

Go to Step 9

(
-

Go to Step 10

4. Operate the vehicle within the Conditions for Running

the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
11

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 11

Go to Step 2

Go to
Applicable OTC

System OK

Engine Controls - 5.7L

Engine

6-1603

DTC P0462 Fuel Level Sensor Circuit Low Voltage

L0 c

GRY 720

GRY 720

r---------

BLK/
WHT 651
D

ORN/ 469
BLK

[5]

- - - - - ,;:
_....__ Fuel

Level
Sensor

....

'

- - - - Fu~ Tank

BJ
A

Fu~I
Ta~k

Unit

P_ressure
Sensor I

I
I

_- ------ _____ ...

C

.. I

'

GAY 720
.- - - , Instrument
I Fuel I Cluster

' ,'

DKGRN 890

GRY 416

Gauge

L.- -

A2.

I
.J

>,

~,,~

..-.-;;'.' '

DK BLU 1936

PPL 30

DKGRN 890

DK BLU 1936

GAY 720

GRY 598

-t]~-..::.-.;;.-.;.--=n~~:.-.:--=:.-.;;.-.;:1-;..- - - - - ---.- - -.I;;..--..

67

10

r-

I
I

Fuel
Level
I Input

5V
Feed

52

C2

Fuel
Tank
Pressure

75

Fuel
Ground
~

36

C1

-.,;;.--=-;.;-:.:::--~u;;i -. - - - - .,' _Pow.ertrain

Gauge
Output
Control

PCM

I Control
I

C1 = RED
C2 = BLU I

L---------------------. ------------.- --- . -----1

Module
(PCM)
..t..

~
218697

,Circuit Description
The Fuel Level Sensor changes resistance based o,n
fuel level. The Fuel Level Sensor has a signal
circuit and a ground circuit. The PCM applies a voltage
(about 5.0 volts) on the signal circuit to the sensor.
The PCM monitors changes in this voltage caused by
changes in the resistance of the sensor to determine .
fuel level.

,When the fuel tank is full, the sensor resistance is

high, and the PCM's signal voltage is only pulled down
a small amount through the sensor to ground.
:Therefore, the PCM will sense a hi~h signal voltage
(fuel tank full}. Wl;len the fuel_ tank is empty, the ~ensor
resistance is low, and the signal voltage is pulled
down a greater amount. This causes the PCM to sense
a low signal voltage (fuel tank empty).

The PCM uses inputs from the Fuel Level Sensor to

calculate the total fuel remaining in the fuel. tank.
This information is then sent to the fuel gauge.
.This OTC sets when the PCM senses a signal voltage
lower than t~e nor_mal operating range of the sensor.

Condi_tions for Running the OTC

. The ignition switch is in the RUN position.

Conditions for Setting the OTC

The Fuel Level Sensor voltage is below 0.39 volts.
All conditions present for 6.0 minutes.

6-1604

Engine Controls - 5.7L

Action Taken When the OTC Sets

The PCM stores the OTC information into memory
when the diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL) will not
illuminate.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Failure Records.

Conditions for Clearing the MIUDTC

A History OTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other non-emission related diagnostic.
A last test failed (Current OTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUOTC.

Engine
Diagnostic Aids
The vehicle fuel gauge displays empty with this
OTC set:
Using Freeze Frame and/or Failure Records data may
aid in locating an intermittetit condition. If you
cannot duplicate the OTC, the information included in
the Freeze Frame and/or Failure Records data can
aid in determining how many miles since the OTC set.
The Fail Counter and pass Counter can also aid
determining how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate the vehicle
within the same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you observed.
This will isolate when the OTC failed.

Test Description
The numbers below refer to the step numbers on the
Diagnostic Table.
2. This step determines if the fault is present.

OTC P0462 Fuel level Sensor Circuit Low Voltage.

Step

Action

Value(s)

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

1. Install the scan tool.

2. Turn ON the ignition leaving the engine OFF.
3. Monitor the Fuel Level sensor display on the
scan tool.
Is the Fuel Level sensor above the specified value?

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Step 4

Go to Step 4

Go to
Diagnostic Aids

Go tq Step 6

Go to Step 5

0.39V

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this OTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame anc;l/or Fliilure. Record:; as . .
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.
6. Select the Diagnostic Trouble Code (OTC) option and ..
the Specific OTC option, then enter the DTC number

.
using the scan tool.
Does the scan tool indicate that this diagnostic failed this

ignition?.

No

Yes

,,

1. Disconnect the Fuel Level sensor electrical connector '

at the body pass through connector. Re.fer to Outside
Left of Rear Floor Pan, Fwd Rear ofAxle 98 in Wiring
Systems.
2. Ob:;erve the Fuel Level sensor display on the
scan tool.
Is the Fuel Level sensor above the specified value?

. j-;

.,

.Q,39V

Engine Controls - 5.7L

Engine

6-1605

DTC P0462 Fuel Level Sensor Circuit Low Voltage {cont'd)

Step

Action

Value(s)

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturers logo. Refer to PCM
Replacement/Programming.
3. Test the Fuel Level sensor signal circuit for a
grounded circuit.
4. If you find the Fuel Level sensor signal circuit is
grounded, repair the circuit as necessary. Refer to
Wiring Repairs in Wiring Systems.
Did you find and correct the condition?

1. Lower the Fuel Tank, if necessary. Refer to Fuel

Tank Replacement.
2. Inspect the Fuel Level jumper harness for the
following:
Damage to the harness.
Broken or rubbed through wires.
If you find a condition repair the circuit as
necessary. Refer to Wiring Repairs in Wiring
Systems.
Did you find and correct the condition?

Replace the Fuel Level sensor. Refer to Fuel Sender

Assembly Service.
Is the action complete?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

Yes

No

Go to Step 9

Go to Step 8

Go to Step 9

Go to Step 7

Go to Step 9

Go to Step 10

Go to Step 9

Go to Step 10

Go to Step 2

Go to the
applicable OTC

System OK

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.

10

3. Select the Diagnostic Trouble Code (DTC) option and

the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

64606

Erigine Controls - 5.7L

Engine

OTC P0463 Fuel Level Sensor Circuit High Voltage

!Loe
GAY 720

BLK/

GAY 720

.--

[i]

- - - - - -;

......-1--, Fuel
Level
Sensor

I
I
I

ORN/ 469
BLK

[SJ

r---------

WHT 651

- - - - - ., Fuel
I

Fuel Tank
Pressure
Sensor

Tank

Unit

I
I

------C B_____ ...I

L--

GAY 720

'" - - ., Instrument
I Fuel I Cluster
I Gauge I ~

DKGRN 890

L--..IM6

GAY 416

A2.
DK BLU 1936

PPL 30

DK BLU 1936

DKGRN 890

GAY 720

GAY 598

--tJ~-....;-;;.-~-..;;-..;-D~~=--..;;-..;-;;.~~1--=1-=-- - - - - - - - . . ~I;;.-~-..;;-~-=----~-i~~g;- - - 67

10

~
I
I

Fuel
Level
Input

52

5V
Feed

75

Tank
Pressure

~
-

C1

36

Fuel
Ground

I
L

C2

Output

.PCM

Control

C1 = RE.D
C2=BW

.
-

I Module
I

I
-

-.- -

6~~i~~ain
(PCM)
~

..I.~

218697

Circuit Description
iThe Fuel Level Sensor changes resistance based on
fuel level. The Fuel Level Sensor has a signal
circuit and a ground circuit. The PCM applies a voltage
(about 5.0 volts) on the signal circuit to the sensor.
The PCM monitors changes in this voltage caused by
changes in the resistance of the sensor to determine
fuel level.
When the fuel tank is full, the sensor resistance is
high, and the PCM's signal voltage is only pulled down
a small amount through the sensor to ground.
Therefore, the PCM will sense a high signal voltage
(fuel tank full). When the fuel tank is empty, the sensor
resistance is low, and the signal voltage is pulled
down a greater amount. This causes the PCM to sense
a low signal voltage (fuel tank empty).

The PCM uses inputs from the Fuel Level Sensor to

calculate the total fuel remaining in the fuel tank.
This information Is then sent to the fuel gauge.
This OTC sets when the PCM senses a signal voltage
higher than the normal operating range of the
sensor.

Conditions for Running the OTC

The ignition switch is in the RUN position.

Conditions for Setting the OTC

The Fuel Level Sensor voltage is above 2.9 volts.
The condition present for 6.0 minutes.

Engine

Engine Controls - 5. 7L

Action Taken When the DTC Sets

The PCM stores the DTC information into memory
when the diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL) will not
illuminate.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Failure Records.

Conditions for Clearing the MIUDTC

The Fail Counter and Pass Counter can also aid

determining how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate the vehicle
within the same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) thatyou observed.
This will isolate when the DTC failed.

Test Description
The numbers below refer to the step numbers on the
Diagnostic Table.

A History DTC will clear after forty consecutive

warm-up cycles, if no failures are reported by
this or any other non-emission related diagnostic.
A last test failed (Current DTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUDTC.

3. This step determines if the fault is present.

4. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the DTC failed. For an
intermittent condition, refer to Symptoms.

Diagnostic Aids

Important: The PCM terminals C1-24 and C2-24 are

the Sensor Ground Jumper terminals. This DTC
sets if the jumper is open or the connection between
the jumper and the PCM is faulty. Inspect for
proper terminal tension/connections at the PCM
harness connector before replacing the PCM.
The vehicle fuel gauge displays empty with this
DTC set.
Using Freeze Frame and/or Failure Records data may
aid in locating an intermittent condition. If you
cannot duplicate the DTC, the information included in
the Freeze Frame and/or Failure Records data can
aid in determining how many miles since the DTC set.

6-1607

16. The PCM terminals C1-24 and C2-24 are the

Sensor Ground Jumper terminals. This DTC sets if
the jumper is open or the connection between
the jumper and the PCM is faulty. Inspect
for proper terminal tension/connections at the
PCM harness connector before replacing
the PCM.

DTC P0463 Fuel Level Sensor Circuit High Voltage

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to
OTC P16395
Volt Reference 2
Circuit

Go to Step 3

Go to Step 5

Go to Step 4

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

1. Install the scan tool.

2. Idle the engine at the normal operating temperature.
3. Monitor the Diagnostic Trouble Code (DTC)
information using the scan tool
Did DTC P1639 Fail This Ignition cycle?
1. Install the scan tool.
2. Turn ON the ignition leaving the engine OFF.
3. Monitor the Fuel Level sensor display on the
scan tool.
Is the Fuel Level Sensor voltage above the
specified value?

2.9 V

6-1608

Engine

Engine Controls - 5.7L

DTC P0463 Fuel Level Sensor Circuit High Voltage (cont'd)

Step

Action

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this OTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame and/or Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the DTC.
6. Select the Diagnostic Trouble Code {OTC) option and
the Specific DTC option, then enter the OTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

1. Turn OFF the ignition.

2. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
3. Disconnect the Fuel tank jumper harness at the body
pass through connector. Refer to Outside Left of Rear
Floor Pan, Fwd Rear of Axle 98 in Wiring Systems.
4. Turn ON the ignition leaving the engine OFF.
5. Measure the voltage from the Fuel level signal circuit
using the DMM J 39200.
Is the Fuel Level sensor voltage above the
specified value?

5V

Jumper the Fuel Level sensor terminals together at the

body pass through connector (PCM side).
Is the Fuel Level sensor voltage near the specified value?

OV

Jumper the Fuel Level sensor signal circuit (PCM side) to

a known good ground.
Is the Fuel Level sensor voltage near the specified value?

OV

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturers logo. Refer to PCM
Replacement/Programming.
3. Test the Fuel Level sensor signal circuit for an open.
Is the Fuel Level sensor signal circuit open?

Repair the Fuel Level sensor signal circuit. Refer to Wiring

Repairs in Wiring Systems.
Is the action complete?

1. Turn OFF the ignition.

2. Disconnect the PCM connector C1 located on the
opposite side of the manufacturers logo. Refer to
PCM Replacement/Programming.
3. Test the Fuel Level sensor ground circuit for an open.
Is the Fuel Level sensor ground circuit open?

1. Inspect the fuel tank jumper harness for poor

connections at the body pass through connector.
Refer to lntermittents and Poor Connections
Diagnosis in Wiring Systems.
2. If you find a poor connection, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

10

11

Value(s)

Yes

No

Go to Step 5

Go to
Diagnostic Aids

Go to Step 14

Go to Step 6

Go to Step 11

Go to Step 7

Go to Step 10

Go to Step 8

Go to Step 9

Go to Step 16
-

Go to Step 19

Go to Step 15

Go to Step 16

Go to Step 19

Go to Step 12

Engine

Engine Controls - s~1L

6-1609

DTC P0463 Fuel Level Sensor Circuit High Voltage (cont'd)

Step

12

13

14

15

Action

1. Lower the fuel tank. Refer to Fuel Tank

Replacement.
2. Inspect the fuel tank jumper harness for the following
conditions:
Damage to the fuel tank jumper harness.
Poor connections at the fuel level sender
assembly. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
Broken or rubbed through wires.
3. If you find a condition, repair as necessary. Refer to
lntermittents and Poor Connections Diagnosis or
Wiring Repairs in Wiring Systems.
Did you find and correct the condition?
Replace the Fuel Level sensor. Refer to Fuel Sender
Assembly Service.
Is the action complete?
Repair the Fuel Level sensor signal circuit for a short to
voltage. Refer to Wiring Repairs in Wiring Systems.
Did you find and correct the condition?
Repair the Fuel Level sensor ground circuit. Refer to
Wiring Repairs in Wiring Systems.
Is the action complete?

Value(s)

Go to Step 19

Go to Step 19

Go to Step 18

Go to Step 19

1. Inspect for poor connections at the PCM. Refer to

/ntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

19

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

20

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

18

Go to Step 13

Go to Step 19

17

No
'

1. Disconnect the PCM. Refer to PCM

Replacement/Programming.
2. Test for continuity from the PCM harness
connector C1-24 to PCM harness connector C2-24.
Refer to Testing for Continuity in Wiring Systems.
3. If you find an open circuit, repair as necessary. Refer
to Wiring Repairs in Wiring Systems.
Did you find and correct the condition?

16

Yes

Go to Step 19

Go to Step 17

Go to Step 19

Go to Step 18

Go to Step 19

Go to Step 20

Go to Step 2

Go to the
applicable OTC

System OK

6;;.1610

Engine Controls .. 5.7L

Engine

DTC P0480 Cooling Fan R~l~y 1 Control Circuit

For schematic details refer to Engine Cooling Fan
Circuit.

Circuit Description
The cooling fan system in this vehicle provides for two
separate modes of operation. These are the low
speed fan and the high speed fan operating modes.
The low speed mode operates both fans at half speed
by using a series circuit configuration. The high
speed mode operates both fans at full speed by using
a parallel circuit configuration. These two operating
modes are accomplished using 3 fan control relays.
This system which uses three relays to control two fan
motors appears complicated. To aid in better
understanding this system it is suggested to follow the
circuits in the schematic as you read the description.
This will aid in understanding the two distinct modes of
operating the relays and coolant fans.
Low speed fan operation is established when the PCM
commands Fan Relay #1 ON by grounding circuit
335 with an internal driver (relays #2 and #3 are left
OFF). This closes the relay switch and allows
current to flow from the battery, through the switch
contacts on circuit 409 to the Left Hand cooling
fan. Current flow continues out of the fan motor on
circuit 532 to relay #3. The unenergized relay #3
switch contacts allow current to flow to circuit 504. This
provides power to the Right Hand cooling fan motor.
The low side of the RH cooling fan ,completes the
circuit to ground on circuit 150. This circuit is a series
circuit which allows half speed operation for each
fan since each fan motor will use half of the supplied
battery power.
High speed operation is established when all three
relays are energized. Relays #2 and #3 share
the same control circuit to the PCM. This is circuit
473. As in the low speed mode, Relay #1 supplies
current flow to the LH cooling fan on circuit 409.
Current flow continues through the motor on circuit
532 to relay #3 which is now energized. The
switch has now provided a path for current to flow
through circuit 150 directly to ground. This circuit now
only has the LH fan motor to power and allows it to
run at full speed. Relay #2 is also energized and
provides current flow on circuit 504 to the RH cooling
fan. This fan now has its own dedicated circuit and
will operate at full speed. This mode is operating as a
parallel circuit.

Conditions for Running the DTC

The engine speed is greater than 600 RPM.
The ignition voltage is between 6.0 volts and
1.6.0 volts.

Conditions for Setting the DTC

The PCM detects that the commanded state of
the driver and the actual state of the control
circuit do not match.
The conditions must be present for a minimum of
10 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle

that the diagnostic runs and fails.

The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIL/DTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not. fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears. after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use scan tool in order to clear the MIUOTC.

Diagnostic Aids
Using. Freeze Frame and/or Failure Records data may
aid in locating an intermittent condition. It you
cannot duplicate the OTC, the information included in
the Freeze Frame and/or Failure Records data can
aid in determining how many miles since the OTC set.
The Fai! Counter and Pass Counter can also aid
determining how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate the vehicle
within the same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you observed.
This will isolate when the OTC failed.
For an intermittent, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Listen for an audible click when the relay operates.
Command both the ON and the OFF states.
Repeat the commands as necessary.
3. This test can detect a partially shorted coil which
would cause excessive current flow. Leaving the
circuit energized for 2 minutes allows the coil
to warm up. When warm the coil may open (Amps
drop to 0), or short (goes above 0.75 Amp).
5. Identify and test the relay coil terminals in order to
avoid improper diagnosis.
13. If you do not find any trouble in the control circuit
or the connection at the PCM, the PCM may be
faulty. However, this is an extremely unlikely
failure.
14. The repair is not complete if the scan tool
indicates that the diagnostic ran and failed.

Engine Controls - 5.7L

Engine

6-1611

OTC P0480 Cooling Fan Relay 1 Control Circuit

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to Step 5

Go to
Diagnostic Aids

Go to Step 4

Go to Step 12

Go to Step 10

Go to Step 8

Go to Step 6

Go to Step 7

Go to Step 11

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

1. Turn ON the ignition leaving the engine OFF.

2. Command the relay ON and OFF using a scan tool.

Does the relay turn ON and OFF when commanded?

1. Turn OFF the ignition.

2. Disconnect the PCM connector C1 located on the
opposite side of the manufacturer's logo.
3. Turn ON the ignition.
Important: If the DMM goes to O Amps during the current
draw test, replace the relay.
4. Measure current from the relay control circuit in the
PCM harness connector to ground for 2 minutes
using DMM J 39200 on 40 Amp scale.
Does the current draw measure less than the specified
value shown (but not O)?
Important: For underhood electrical center relay terminal
identification, refer to Electrical Center Identification in
Wiring Systems.
1. Turn OFF the ignition.
2. Disconnect the relay.
3. Measure the resistance from the relay control circuit
in the PCM harness connector to ground using the
DMM J39200.
Does the DMM display infinite resistance?

0.75A

Important: For underhood electrical center relay terminal

identification, refer to Electrical Center Identification in
Wiring Systems.
1. Turn OFF the ignition.
2. Disconnect the relay.

3. Connect the test lamp J 34142-8 between the FC

relay 1 control circuit and the FC relay 1 B+ supply
circuit at the underhood electrical center. Refer to the
thumbnail wiring schematic for terminal identification.
4. Turn ON the ignition.
5. Command the relay ON and OFF using a scan tool.
Does the test lamp turn ON and OFF with each
command?
Probe the FC relay 1 B+ supply circuits at the underhood
electrical center with the test lamp J 34142-8 connected to
ground.
I
Is the test lamp illuminated?

6-1612

Engine

Engine Controls - 5.7L

DTC P0480 Cooling Fan Relay 1 Control Circuit (cont'd)

Step

Action

Value(s)

Yes

No

Go to Step 9

Go to Step 10

Go to Step 14

Go to Step 12

Go to Step 14

Go to Step 13

1. Turn OFF the ignition.

.

2. Reconnect the relay.

3. Disconnect the PCM connector C1 located on the
opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.
4. Turn ON the ignition.
5. Momentarily probe the relay control circuit in the PCM
harness connector with a fuse, jumper wire
connected to ground. Refer to ~ing Fused Jumper
Wires in Wiring Systems.
Does the relay turn ON when the circuit is grounded and
OFF when the circuit is opened?
1. Inspect for poor connections at the relay. Refer to
lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

1. Inspect for poor connections at the PCM. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.
9

2. If you find a poor connection, repair as necessary.

Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

10

Repair the relay control circuit. Refer to Wiring Repairs in

Wiring Systems.
Is the action complete?

11

Repair the relay B+ supply circuit. Refer to Wiring Repairs

in Wiring Systems.
Is the action complete?

Replace the relay. Refer to Cooling Fan Relay

Replacement in Engine Cooling.
Is the replacement complete?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

12

13

14

1. Select the Diagnostic Trouble Code {OTC) option and

the Clear OTC. option using the scan tool.
2. Start engine and idle at normal operating
temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.

Go to Step 14

Go to Step 14

Go to Step 14

Go to Step 14

4. Operate vehicle within the Conditions for Running the

OTC as specified in the supporting text, if applicable.
Does the scan tool indicate that this test passed?

15

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 15

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5.7L

6-1613

OTC P0481 Cooling Fan Relay 2 and 3 Control Circuit

For schematic details refer to Engine Cooling Fan
Circuit.

Circllit Description
The cooling fan system in this vehicle provides for two
separate modes of operation. These are the low
speed fan and the high speed fan operating modes.
The low speed mode operates both fans at half speed
by using a series circuit configuration. The high
speed mode operates both fans at full speed by using
a parallel circuit configuration. These two operating
modes are accomplished using 3 fan control relays.
This system which uses three relays to control two fan
motors appears complicated. To aid in better
understanding this system it is suggested to follow the
circuits in the schematic as you read the description.
This will aid in understanding the two distinct modes of
operating the relays and coolant fans.
Low speed fan operation is established when the PCM
commands Fan Relay #1 ON by grounding
circuit 335 with an internal driver (relays #2 and #3
are left OFF). This closes the relay switch and allows
current to flow from the battery, through the switch
contacts on circuit 409 to the Left Hand cooling
fan. Current flow continues out of the fan motor on
circuit 532 to relay #3. The unenergized relay #3
switch contacts allow current to flow to circuit 504. This
provides power to the Right Hand cooling fan motor.
The low side of the RH cooling fan completes the
circuit to ground on circuit 150. This circuit is a series
circuit which allows half speed operation for each
fan since each fan motor will use half of the supplied
battery power.
High speed operation is established when all three
relays are energized. Relays #2 and #3 share
the same control circuit to the PCM. This is
circuit 473. As in the low speed mode, Relay #1
supplies current flow to the LH cooling fan on
circuit 409. Current flow continues through the
motor on circuit 532 to relay #3 which is now
energized. The switch has now provided a path for
current to flow through circuit 150 directly to ground.
This circuit now only has the LH fan motor to
power and allows it to run at full speed. Relay #2 is
also energized and provides current flow on circuit 504
to the RH cooling fan. This fan now has its own
dedicated circuit and will operate at full speed. This
mode is operating as a parallel circuit.

Conditions for Running the DTC

The engine speed is greater than 600 RPM.
The ignition voltage is between 6.0 volts and
16.0 volts.

Conditions for Setting the DTC

The PCM detects that the commanded state of
the driver and the actual state of the control
circuit do not match.
Condition must exist for a minimum of 1O seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignitior cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIL/DTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Using Freeze Frame and/or Failure Records data may
aid in locating an intermittent condition. If you
cannot duplicate the DTC, the information included in
the Freeze Frame and/or Failure Records data can
aid in determining how many miles since the DTC set.
The Fail Counter and Pass Counter can also aid
determining how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate the vehicle
within the same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you observed.
This will isolate when the DTC failed.
For an intermittent, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
4. This tests for a control circuit that may be shorted
to ground.
5. This tests for an open control circuit.
11. The repair is not complete if the scan tool
indicates that the diagnostic ran and failed.

6-1614

Engine Controls - 5.7L

Engine

OTC P0481 Cooling Fan Relay 2 and 3 Control Circuit

Step

Action

Value(s)

Yes

No

.Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check .

Go to Step 3

.Go to Step 4

Go to Step 7

Go to Step 10

Go to Step B

Go to Step 5

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Turn OFF the ignition.

Is the right hand fan ON at all times?

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Turn ON the ignition.
Are the fans ON?

1. Disconnect engine cooling fan relays #2 and #3.

2. Probe the control side of the relay #2 at the
underhood electrical center using the test lamp
J 34142-B connected to ground. Refer to Probing
Electrical Connectors in Wiring Systems.
Is the test lamp illuminated?

1. Turn OFF the ignition.

2. Reconnect both relays.
3. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming.
4. Probe the engine cooling fan relay #2 and #3 control
circuit at the PCM harness using test lamp J 34142-B
connected to ground.
5. Turn ON the ignition.
Is the test lamp illuminated?

Repair the open circuit between .the PCM harness

connector and the splice. Refer to Wiring Repairs in Wiring
Systems.
Is the action complete?

Repair the short to ground in the engine cooling fan

relay #2 and #3 control circuit. Refer to Wiring Repairs in
Wiring Systems.
Is the action complete?

Repair the short to B+ in the engine cooling fan relay #2

and #3 control circuit. Refer to Wiring Repairs in Wiring
Systems.
Is the action complete?

1. Inspect the PCM harness connector for poor

connections. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
2. If you find a poor connection, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

10

(
Go to Step 9

Go to Step 6

Go to Step 11

Go to Step 11

Go to Step 11

Go to Step 11

Go to Step 10

Go to Step 11

Engine Controls -.5.7L

Engine

6-1615

DTC P0481 Cooling Fan Relay 2 and 3 Control Circl,lit (cc>nfd)

Step

Action

Value(s)

Yes

No

Go to Step 12

Go to Step 2

Go to the
applicable
OTC table

System OK

1. Select the Diagnostic Trouble Code (OTC) option and

)
1.1

the Clear OTC option using the scan tool.

2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate vehicle within the Conditions for Running the
OTC as specified in the supporting text, if applicable.

Does the scan tool indicate that this test passed?

12

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

6-1616

Engine

Engine Controls;.; 5.7L

DTC POSOO Vehicle Speed Sensor {VSS) Circuit

.1 Vehicle Sp.eed

=.

~ Sensor (VSS)

YEL 400
PPL 401
7
r -

71

C1

vst~-""" ;;_-~-vsi - - - - , Powertrain

High

Low

PCM 1

lc1=REDI
c2 = BLU

I Control

I Module ~
I (PCM)

L--------------.1
218719

Circuit Description
A toothed wheel mounted on the output shaft of the
transmission generates an AC voltage pulse as it
moves past the Vehicle Speed Sensor (VSS).
The VSS contains a permanent magnet surrounded by
a coil of wire, which produces a magnetic field. The
toothed wheel interrupts the magnetic field this
generates an AC voltage pulse. As the vehicle speed
increases the AC voltage pulse rate also increases.

Conditions for Running the DTC

DTCs P0107, P0108, P0117, P0118, P0121,
P0122, P0123, P0125, P0506, P0507 are not set.
The engine coolant temperature is greater
than 35C (95F).
The engine speed is greater than 1000 RPM.
The TP sensor angle is between 5.0% and 100%.
The MAP is between 40 kPa and 100 kPa
when the A/C is OFF.
The MAP is between 45 kPa and 100 kPa when
the A/C is ON.
All conditions met for 2 seconds.

Conditions for Setting the DTC

The PCM detects vehicle speed at O km/h (0 mph) for
100 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Inspect all of the circuits to the PCM and the VSS.
Inspect the terminal connections at the VSS harness
connector and at the PCM harness connector. If
all of the circuits and connections are OK, replace
the PCM.
For an intermittent, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. The ASR/TCS must be disabled when performing
this step. Whenever the ignition key is cycled to
the OFF position and then cycled back ON,
the ASR/TCS system will default ON.

Engine Controls - 5.. 7L

Engine

6-1617

. OTC P0500 Vehicle Speed Sensor (VSS) Circuit

Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

1. Turn OFF the ignition.

2. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle.
3. Idle the engine.
4. Disable the ASR/TCS systems, if so equipped.
5. Place the transmission in 2nd gear and release the
clutch pedal.
6. Slowly bring the engine speed to 1,500 RPM
and hold.
Does the scan tool indicate a vehicle speed above the
specified value?
1. Turn OFF the ignition.
2. Disconnect the VSS electrical connector.
3. Install the appropriate jumpers from the connector kit
J 33431-B to the VSS (sensor side).
4. Connect the black lead from the DMM J 39200 to pin
A of the VSS and the red lead to pin B of the VSS.
5. Set the DMM to the AC volt scale.

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to
Diagnostic Aids

Go to Step 3

Go to Step 4

Go to Step 9

Go to Step 5

Go to Step 10

Go to Step 7

Go to Step 6

Go to Step 8

Go to Step 11

15 mph
(24 kph)

1.20 V

6. Idle the engine.

7. Place the transmission in 2nd gear and release the
clutch pedal.
Slowly bring the engine speed to 1,500 RPM and hold.
Does the DMM indicate a voltage above the
specified value?

1. Turn OFF the ignition.

2. Probe the VSS low circuit (terminal A) using the test
lamp J 39200 connected to B+.
Is the test lamp illuminated?
1. Turn OFF the ignition.
2. Disconnect the PCM connector C1 located on the
opposite side of the manufactures logo. Refer to PCM
Replacement/Programming.
3. Turn ON the ignition.
4. Measure the voltage from the VSS high circuit to a
known good ground using the DMM J 39200 set to
the DC volt scale.
Is the voltage above the specified value?

0.2 V

Test the VSS high circuit for an open or short to ground.

Refer to Testing for Continuity or Testing for Short to
Ground in Wiring Systems.
Did you find and correct the condition?

Repair the short to voltage on the VSS high circuit. Refer

to Wiring Repairs in Wiring Systems.
Is the action complete?

Repair the open/high resistance in the VSS high circuit.

Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Go to Step 12
-

Go to Step 12

6-1618

Engine

Engine Controls - 5.7L

DTC POSOO Vehicle Speed Sensor (VSS) Circuit (cont'd)

Step

10

Action
Important: Inspect the reluctor wheel on the transmission
output shaft for damage.
Replace the VSS. Refer to Vehicle Speed Sensor in
Manual Transmission MM6.
Is the action complete?

Repair the open in the VSS low circuit. Refer to Wiring

Repairs in Wiring Systems.

Value(s)

11

12

13

Replace the PCM.

Is the action complete?

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the conditions for running
this OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

No

Go to Step 12

Go to Step 12

Is the action complete?

Important: Program the replacement PCM. Refer to PCM
Replacement/Programming.

Yes

Go to Step 12

Go to Step 13

Go to Step 2

Go to the
applicable
OTC table

System OK

Eng,ine

Engine Controls .. 5.7L

s~.1619

Idle Air
Control
(IAC)
Valve

(M;'"l

OTC P0506 Idle Speed Low

Stepper
Motor

Coil
A

lj
I
I

Coil

L2i1

A'

LT
BLU/BLK 1748

57
______ 55, '-- - - -- _:1-, --------

'" - 1AC - - - -

IAC -

Coll A
Low

LT
GRN/WHT 1749

LT
GRN/BLK 444

LT
BLU/WH T 1747

56

Coil A
High

IAC - - - Coil B
Low

c2

IAC - Coil B.
High

.,

Powertrain

I Control

I Module
I~~

'>

.--P-C!-A-:~
C1=RED
C2=BLU

L---------------------~

218553

Circuit Description

The barometric pressure is greater than 65 kPa.

The Idle Air Control valve is a PCM controlled stepper

motor located on the throttle body. The stepper
motor drives a valve pintfe which protrudes into a
passage that bypasses the throttle plates. The PCM
commands the IAC valve pintle to extend to decrease
the idle speed. The bypass air flow is reduced and
the idle speed decreases as the pintle approaches its
seat. The PCM retracts the IAC valve pintle away
from its seat to increase the idle speed. The retracting
of the IAC valve pintle allows more air to bypass
the throttle plates. One of the PCMs uses for the IAC
system is to maintain a desired idle speed. This
DTC sets when the PCM detects an engine speed
outside of the IAC's range of control.

The ignition voltage is between 9.0 and 17.0 volts.

Conditions for Running the DTC

DTCs P0101, P0102, P0103, P0107, P0108,
P0112, P0113, P0117, P0118, P0125, P0171,
P0172, P0174, P0175, P0300, P0401, P0404,
P0405, P0443, P0500-P0503, P1441 are not set.
The engine run time is greater than 60 seconds.
The engine coolant temperature is greater
than 60C (140F).
The intake air temperature is greater
than -10C (14F).

The vehicle speed is no more than

1 mph (1.6 km/h).

Conditions for Setting the DTC

The actual idle speed is 100 RPM less than the
desired idle speed.
All of the above conditions are present for
5.0 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition.
cycle, the PCM records the operating conditions
at the time of the fai.lure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

6-1620

Engine Controls - 5.7L

Engine

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Using Freeze Frame and/or Failure Records data may
aid in locating an intermittent condition. If you
cannot duplicate the DTC, the information included in
the Freeze Frame and/or Failure Records data can
aid in determining how many miles since the DTC set.
The Fail Counter and Pass Counter can also aid
determining how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate the vehicle
within the same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you observed.
This will isolate when the DTC failed. For an
intermittent, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This test determines whether or not the engine
can achieve the commanded RPM, and if not,
whether the RPM is too high or too low.

OTC P0506 Idle Speed Low

Step

Action
Did you perform the Powertrain On-Board Diagnostic
~BD) System Check?

Value{s)

Yes

No

Go to Step2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Important: If there are any MAF/MAP DTCs set, go to the

appropriate diagnostic table.
1. Idle the engine.
2. Command the engine speed up to 1500 RPM, down
to 500 RPM, up to 1500 RPM, and then EXIT using
the scan tool.
Does the engine speed correspond, within 100 RPM, with
each command?

Is the engine RPM greater than 100 RPM above

Desired RPM?

(
Go to
Diagnostic Aids

Go to Step 3

Go tostep 4

Go to Step 5

Go to Step 11

Go to Step 6

Go to Step 11

Go to Step 6

1. Inspect for the following conditions:

4

Vacuum leaks.
Throttle plates not closing properly.
A faulty PCV valve.
2. If you find a condition, repair as necessary.
Did you find and correct the condition?

1. Inspect for the following conditions:

5

Excessive deposits in the throttle body.

Parasitic load on the engine (i.e.: transmission
condition etc.).
2. If you find a condition, repair as necessary.
Did you find and correct the condition?

1. Start and idle the engine

2. Disconnect the IAC harness connector and install the
appropriate IAC node light from kit J 37027-A.
3. Command the RPM up to 1500, down to 500 and up
to 1,500 using the scan tool while observing the
node light.
Does both of the LEDs on the node light cycle red and
green, but never OFF?

(
Go to Step 7

Go to Step 8

Engine

Engine Controls - 5.7L

6-1621

DTC P0506 Idle Speed Low (cont'd)

Step

Action

Important: During the following test it is possible to

overextend the IAC valve pintle until it falls out of the
worm drive. If this occurs, manually screw the pintle shaft
into the worm drive about 2 turns to get it started, align the
keyways on the shaft with the keys in the housing and
gradually retract the pintle using the IAC driver tool.
1. Turn OFF the ignition.
2. Remove the IAC valve.
3. Connect the IAC valve to the IAC Driver tool from
kit J 37027-A.
4. Hold the IAC valve with a finger over the pintle in
case it is over extended. Using the driver tool retract
and extend the pintle.
Does the pintle move steadily with each flash of the IAC
driver light?

Value(s)

Yes

No

Go to Step 9

Go to Step 10

Go to Step 13

Go to Step 11

1. Inspect for the following conditions:

Faulty connections. Refer to lntermittents and
Poor Connections Diagnosis in Wiring Systems.

Open circuit. Refer to Testing for Continuity in

Wiring Systems.
Short to ground. Refer to Testing for Short to
Ground in Wiring Systems.

Short to B+.
2. If you find a condition, repair as necessary. Refer to
Wiring Repairs in Wiring Systems,
Did you find and correct the condition?

Inspect the IAC passages.

Is the action complete?

10

Replace the IAC valve. Refer to /AC Valve Replacement

Is the action complete?

Go to Step 13
Go to Step 13

1. Inspect for poor connecti.ons at the PCM. Refer to

11

12

lntermittents and Poor Connections Diagnosis in

Wiring Systems.
2. If you find a poor connection, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?
Important: Program the replacement PCM. Refer to PCM
Replacement/Programming.

Replace the PCM.

Is the action complete?

Go to Step 13

Go to Step 12

Go to Step 13

1. Select the Diagnostic Trouble Code (OTC) option and

13

I
J

14

the Clear OTC Information option using the scan tool.

2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select tne Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 14

Go to Step 2

Go to the
applicable
OTC table

System OK

6-t.622

Engine

Engine Controls - 5.7L.

DTC P0507 ,Idle Speed High

I
Coil
A

D;

Idle Air
Control
(IAC)
Valve

Stepper
Mo.tor

c'

B~U/WHJ 17:47

I
I

Coil
B.

[SJ
N

A
B'

LT
BLU/BLK 1746

LT

lj

[SJc

LT
GRN/WHT 1749

LT
GRN/BLK 444

57 c2
56, ' - - - - - - - -55
- - ' '-------~ '- - - - -- - - - ..,
tAc - - - - 1Ac - - - - ""iAc' - - - - IAc - - ., Powertrain
I
Coil A
Coil A
Coil B
Coil B
I Control
I
High
Low
Low
High
I Module
r -

~~

I}.

.--P-CI-A..., : ~
C1o;,l;IED
C2=BLU

L---------------------~

218553

'circuit Description
The Idle Air Control valve is a PCM controlled stepper
motor located on the throttle body. The stepper
motor drives a valve pintle which protrudes into a
passage that bypasses the throttle plates. The PCM
commands the IAC valve pintle to extend to decrease
th.e idle speed. Tt,e bypass air flow is reduced and
.the idle speed decreases as the pintle approaches its
seat. The PCM retracts the IAC valve pintle away
from its seat to increase the idle speed. The retracting
of the IAC valve pintle allows more air to bypass
the throttle plates. One of the PCMs uses for the IAC
,system is to maintain a desired idle speed; This
DTC sets when the PCM detects an engine speed
outside of the IAC's range of control.

Conditions for Running the OTC

DTCs P0101, P0102, P0103, P0107, P0108,
P0112, P0113, P0117, P0118,'P0125, P0171,
P0172, P0174, P0175, P0300, P0401, P0404,
P0405, P0443, P0500-P0503, P1441 are not set.
The engine run time is greater than 60 seconds.
The engine coolant temperature is greater
than 60C (140F).
The intake air temperature is greater
than -10C (14Ff'
.

The barometric pressure is greater than 65 kPa.

The ignitionv~hagers between 9.0 and 17.0 volts
The vehicle speed is no more than
1 mph (1.6 km/h).

Conditions for Setting the OTC

The actuaf idle spe~d is 200 RPM greater than
the desired idle speed.
All of the above conditions are present for
5 seconds.

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the. diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the .failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Engine Controls - 5.7L

Engine
Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three

consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

6-1623

Diagnostic Aids
Using Freeze Frame and/or Failure Records data may
aid in locating an intermittent condition. If you
cannot duplicate the DTC, the information included in
the Freeze Frame and/or Failure Records data can
aid in determining how many miles since the DTC set.
The Fail Counter and Pass Counter can also aid
determining how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate the vehicle
within the same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you observed.
This will isolate when the DTC failed. For an
intermittent, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This test determines whether or not the engine
can achieve the commanded RPM, and if not,
whether the RPM is too high or too low.

OTC P0507 Idle Speed High

Step

Action
Did you perform the Powertrain On-Board Diagnostic
(OBD) System Check?

Value(s)

Is the engine RPM greater than 100 RPM above

Desired RPM?

A faulty PCV valve.

2. If you find a condition, repair as necessary.
Did you find and correct the condition?

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to
Diagnostic Aids

Go to Step 3

Go to Step 4

Go to Step 5

Go to Step 11

Go to Step 6

Go to Step 11

Go to Step 6

Go to Step 7

Go to Step 8

Important: If there are any MAF/MAP DTCs set, go to the

appropriate diagnostic table.
1. Idle the engine.
2. Command the engine speed up to 1500 RPM, down
to 500 RPM, up to 1500 RPM, and then EXIT using
the scan tool.
Does the engine speed correspond, within 100 RPM, with
each command?

1. Inspect for the following conditions:

Vacuum leaks.
Throttle plates not closing properly.

Yes

1. Inspect for the following conditions:

Excessive deposits in the throttle body.
Parasitic load on the engine (i.e.: transmission
condition etc.).
2. If you find a condition, repair as necessary.
Did you find and correct the condition?

1. Start and idle the engine

2. Disconnect the !AC harness connector and install the
appropriate !AC node light from kit J 37027-A.
3. Command the RPM up to 1500, down to 500 and up
to 1,500 using the scan tool while observing the
node light.
Does both of the LEDs on the node light cycle red and
green, but never OFF?

6-1624

Engine

Engine Controls - 5.7L

DTC P0507 Idle Speed High (cont'd)

Step

Y~s

Val.ue(s)

Action

No

Important: During the following t!=)St it is possible to

overextend the IAC valye pintle i.,mtil it falls out of the
worm drive. If this occurs, ma,nual!Y screw the pintle shaft
into the worm drive about 2 turns to get it started, align the
keyways on the shaft with the keys in the housing and
gradually retract the pintle using the IAC driver tdol.

1. Inspect for the followinfJ .conditions:

Faulty connections. Refer to lntermittents and
Poor Connections Diagnosis in Wiring. $yste['1s. ,

,,

~. Turn OFF the ignition.

2. Remove the IAC valve.
3. Connect the IAC valve. to the IAC Driver toQI from kit
J 37027-A.
4. Hold the IAC valve with a finger over,the pintle in
case it is over extended. Using the di'ivertool retract
and extend the pintle.
Does the pintle move steadily with each flash of the IAC
driver light?

Open circuit. Refer to Testing for Continuity in

Wiring Systems.
Short to ground. Refer to Testing for Short to
Ground in Wiring Systems.

Go to Step 9

'
,'s-

Inspect the IAC passages.

Is the action complete?

10

Replace the IAC valve. Refer to /AC Valve Replacement

Is the action complete?

11

1. Inspect for poor connections at the PCM. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

12

Go to Step 13

Go to Step 11

Go to Step 13

'
Go to Step 12
'

Go to Step 13

,,

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
13

14

3. Select the Diagnostic Trouble Code (OTC) option and

the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 13

Go to Step 13

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.

Replace the PCM.

Is the action complete?

Go to Step 10

,,

Short to B+.
2. If you find a condition, repair as necessary. Refer to
Wiring Repairs in Wiring Systems.
Did you find and correct the condition?
9

'

'

,,

Go to Step 14

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls 5;7L

61625

OTC P0530 Air Conditioning (A/C) Refrigerant Pressure Sensor Circuit

!Hot In RUN Or START !

.- - G7

- - - A/C

G6
L--

Fuse Block
Details
Cell11

P-:;-w; - , Underhood
Distribution :

CRUISE
Cell 10
MiniFuse
15A

I
I

Electrical

Center 2

L..1!I

-------J

PNK 139

+- - - ---------,
PNK 139

PNK 139

A/C
Diode

218753

Circuit Description

The A/C system uses an A/C refrigerant pressure

sensor mounted in the high side of the A/C system to
; monitor A/C refrigerant pressure. The PCM utilizes
.this information in order to turn ON the engine coolant
fans when the A/C refrigerant pressure is high.
The A/C refrigerant pressure sensor operates much
like other 3-wire sensors. The PCM supplies a 5.0 volt
reference to the sensor. The sensor supplies a
signal circuit to the PCM. As the A/C pressure
increases or decreases, the resistance of the sensor
changes and varies the amount of signal returning to
the PCM.
The PCM monitors the A/C refrigerant pressure
sensor signal circuit and can determine when the A/C
pressure is too high or too low. The PCM disables

the A/C compressor clutch and sets a DTC P0530

when the pressures are out of range (high or low) for
a predetermined time. The PCM disables the A/C
compressor in order to prevent A/C compressor
damage .

Conditions for Running the DTC

The PCM detects an A/C request.

Conditions for Setting the DTC

A/C refrigerant pressure sensor indicate.s A/C
refrigerant pressure is below 3.0 psi for 5.0 seconds.

OR
A/C refrigerant pressure sensor indicates A/C
refrigerant pressure is above 445 psi for 5.0 seconds.

6-1626

Engine

Engine Controls - 5.7L

Action Taken When the OTC Sets

The PCM stores the OTC information into memory
when the diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL) will not
illuminate.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Failure Records.

Conditions for Clearing the MIUDTC

A History OTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other non-emission related diagnostic.
A last test failed (Current OTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
If the test did not fail this ignition cycle, move the
related electrical harnesses and the connectors while
monitoring a scan tool.
For an intermittent, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. The normal A/C voltage is between 1.0 and
1.8 volts. If the A/C voltage is within the range,
review the freeze frame data in order to determine
when the OTC P0530 set.
5. If the A/C pressure/voltage stays high after
disconnecting the A/C refrigerant pressure sensor
electrical connector, this indicates the signal
circuit is shorted to a voltage.
7. This step tests for a good ground circuit.
8. This step tests the integrity of the A/C refrigerant
pressure sensor signal circuit.
11. If you have thoroughly tested the 5.0 volt reference
circuit (for opens, shorts to ground, PCM
connections etc.) and the circuit tests OK, then
replace the PCM.
12. If you have thoroughly tested the ground circuit for
opens and the PCM connections are OK, then
replace the PCM.

OTC P0530 Air Conditioning (A/C) Refrigerant Pressure Sensor Circuit

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to
OTC P1635 5
Volt Reference 1
Circuit

Go to Step 3

Go to Step 4

Go to Step 5

Go to Step 5

Go to
Diagnostic Aids

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

1. Install the scan tool.

2. Idle the engine.
3. Monitor the Diagnostic Trouble Code (OTC)
information option using the scan tool.
Did OTC P1635 Fail This Ignition cycle?
1. Turn ON the ignition leaving the engine OFF.
2. Monitor the A/C High Side using the scan tool.
Does the scan tool indicate the A/C High Side between the
specified range?
1. Turn ON the ignition leaving the engine OFF.
2. Review the Freeze Frame and/or Failure Records
data for this OTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame and/or Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.
6. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

0.1-1.BV

Engine Controls - !:;.7L

Engine

5:..1527

DTC P0530 Air Conditioning (A/C) Refrigerant Pressure Sensor Circuit (cont'd)
Action

Step

Disconnect the A/C refrigerant pressure sensor electrical

connector.
'
Does the scan tool indicate the A/C High Side less than
the specified value?
Measure the voltage from the A/C refrigerant pressure
sensor 5.0 volt reference circuit to the battery ground using
the DMM J 39?00.
Is the voltage near the specified value?
Measure the voltage from the A/C refrigerant pressure
sensor 5.0 volt reference circuit to the sensor ground
circuit using the DMM J 39200.

.. Valu~(s)

10

'

11

Repair the ground circuit to the A/C refrigerant pressure

sensor. Refer to Wiring Repairs in Wiring Systems.
Repair the signal circuit to the A/C refrigerant pressure
sensor. Refer to Wiring Repairs in Wiring Systems.

Go to StepB .

Go to Step 12

Go to Step 9

Go to Step 13

Go to Step 14

Go to Step 14

Go to Step 14

Go to Step 14

Is the action complete?

13

Go to Step 11

5.0V

Is the action complete?

12

Go to Step 7

5.0V

Is the action complete?

Repair the 5.0 volt reference circuit to the A/C refrigerant
pressure sensor. Refer to Wiring Repairs in Wiring
Systems.

Go to Step 10

'

Is the action complete?

Repair the short to voltage in the A/C refrigerant pressure
sensor signal circuit. Refer to Wiring Repairs in Wiring
Systems.

Go to Step 6

5.0V

Does' the scan tool indicate the A/C High Side voltage at
the specified value?
Repair the faulty A/C refrigerant pressure sensor
connection or faulty sensor. Refer to A/C Refrigerant
Pressure Sensor Replacement in HVAC Manual.

No

1.0V

Is the voltage at the specified value?

Jumper the 5.0 volt reference circuit to the A/C refrigerant
pressure sensor signal circuit using a fused jumper wire.
Refer to Using Fused Jumper Wires in Wiring Systems.

Yes

Go to Step 14

Is the action complete?

1. Select the Diagnostic'Trouble Code (DTC) option and
the Clear DTC Information option using the scan tool.
2. Idle the engine afthe nOrmal operating temperature.

3. Select the Diagnostic Trouble Code (DTC) option and

14

the Specific DTC,optior:i, then epter .the DTC, number

using the scan tool. .
.
. '

4. Op'erate the vehicle within the Conditions for Running

the DTC as specified in the supporting text, if
applicable.
Does the scanJool indicate that this test ran and passed?

15

Select the Capture Info option and the Review Info option
using the scan tool.

Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 15

Go to Step 2

Go to the
applicable
DTC table

System OK

6-1628

Engine

Engine Controls - 5.7L

DTC P0562 System Voltage Low

! Hot In RUN. BULB TESTAnd START!

!Hot At All Times!

" - - - I Power
H11

- - - - , U nderhood
PCM BAT
I Electrical
MiniFuse I Center 1
I
10 A

I Distribution
I Cell 10

...

H10

- - - - - - - - , Underhood
PCM IGN
6~:rf~ution I Electrical
MiniFuse
15 A

I Center 2

Cell 10

ORN

::: =------

I H6

...

...
I

_ --------.J
PNKJBLK 439

_-- - ----.J
340
61

" I H7

--------.,
Malfunction

Indicator
Lamp (MIL)
(SERVICE

I.

\J)

A4

-~RN-~~-~~~1439

Instrument
Cluster

~~
~

-------------- ------

C2

37

Powertrain

>

BRN/WHTI419

19

~_I _E~G~~~o~ ~
BRN/WHT 419

20

MJ6

C1

Control
Module
(PCM)

r - - -Battery
- - - - - - - - -Battery
- - - - -Ignition
- - - - - - - - - - - - - - - - - -MIL
- - - - - - - - - - ,I

I
I
I

Positive
Voltage

Positive
Voltage

Positive
Vottage

lV

Serial Data
-

r -

D3

Distribution

I
I

1- _ _ _

Fuse Block

C3

Details

Cell 11_ _ _ _

ORN
Fuse Block
Details
Cell11

_ lH~'::_AIITi'.'.'.e~ -

I Power

I Cell 10

.........

(Class II}

,IP

58 1-8-07- - - - - - - -T-A~UN3AA1n8C02a

540

451

Ground

ORN

BLK 451

BLK 451

BLK 451

.JI

TAN 800

Ground
Distribution
Cell14

TAN 800
An1ilock
Brakes
Cell 44

540

TAN 800

---

Distribution
Cell14

I
I

7;rou~d-B7L~Krou~1 ;;oun_d- 6~oun~i

PPL

CIGAR ACCY Fuse

1 Block
Fuse 11
25 A
I
___

PCM

C1=F\ED
C2=BW

Serial Data

c4_

Control

BLK 451

TAN 800

PPL 1807

TAN 800 TAN 800

Supplemental
Inflatable

BLK/WHT 451

F\estralnts

(SIF\)
Cell47

BLK 650
4

16

_________________ ? ____________ ~

Data Link Connector (DLC)

216506

Circuit Description
The PCM continuously monitors the system voltage.
The system voltage information is taken from the
PCM's ignition feed circuits. Voltages below 8.0 volts
or above 17 .1 volts causes improper system
operation and/or component damage. The PCM
operates in a default mode if a PCM voltage DTC sets.
If the system voltage is low the PCM raises the idle
speed in order to increase the generator output.
The PCM disables most outputs to protect the
hardware if the system voltage is high. A scan tool
may not display data if system voltage is outside this
range. Use a DMM in order to monitor the system
voltage in order to verify if the fault is currently present.

Conditions for Running the OTC

The engine run time is long~r than 10 seconds.
The engine speed is greater than 1000 RPM.
The vehicle speed is greater than 8 km/h (5 mph).

Conditions for Setting the OTC

The PCM senses system voltage below 8.0 volts.
All the above conditions are present for
5 seconds.

Engine
Action Taken When the OTC Sets

The PCM stores OTC P0562 in memory when the

diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL) will not
illuminate.
The PCM will record the opera~ing conditions at
the time the diagnostic fails. The PCM stores
this information in Failure Records.
The PCM will command a high idle speed.
The transmission defaults to third gear.
The TCC operation is inhibited.

Conditions for Clearing the MIL/OTC

A History OTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other non-emission related diagnostic.
A last test failed (Current OTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUOTC.

Engine Controls - 5.7L

Diagnostic Aids

An extremely low voltage (below 7.5 volts) may

cause the loss of serial data and the MIL may
not function. An open ignition feed circuit causes
a no start and the MIL will not illuminate. A
low system voltage may cause other OTCs to set.
Using Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data can aid in determining how many
miles since the OTC set. The Fail Counter
and Pass Counter can also aid determining how
many ignition cycles the diagnostic reported a
pass and/or a fail. Operate the vehicle within the
same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you
observed. This will isolate when the OTC failed.
For an intermittent, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step verifies the fault is present.

6-1629

6-1630

Engine Controls ... 5.7L

Engine

OTC .P0562 System Voltage Low

Step

.Action

Value(s),

Did y6u perform the Powertrain On-Board Diagnostic

(OBD) System Check?

:<

Important: Ensure the battery is fully charged before

proceeding with this diagnostic.
Mbnitor the Ignition 1 voltage using the scan tool.
Does the scan tool display the specified value?

B+

Inspect the PCM IGN fuse.

IS the fuse open?

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
ReplacementiProgramming.
3. Turn ON the ignition leaving the engine OFF.
4. Measure the voltage at terminal (C2-19) for the
ignition feed circuit using the DMM J 39200.
IS the voltage at the specified value?

13+

Test th!:l continuity of the ignition fee<:! circ.uit using the

DMM'J 39200. Refer to Testing for Continuity in Wiring
Systems.
Does the DMM display continuity below the
specified value?

SQ

1. Repair the ignition feed circuit to the PCM for an

open or a short to ground. Refer to Wiring Repairs in
Wiring Systems.
2. Replace the fuse if necessary.
Is the action complete?

1. Inspect for poor connections at the PCM. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.

10

,Go to Step2

Go to A
Powf;lrtrain On
Board Diagnostic
(080) System
Check

Go to Charging
System Check in
Engine .Electrtcal

Go toStf;lp3

Go to Step 6

Go to Step 4

Go to.Step 7

Go to Step 5

Go to Step 7

Go to Step 6

Go to Step 9

Did you find and correct the condition?

No

Yes

Go to Step 9

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (DTC) option and
the Specific DTC option, then enter the DTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step B

Go to Step 9

Go to Step 10

Go to Step 2

Go to the
applicable
DTC table

System OK

Engine Controls - 5.7L

Engine

6-1631

OTC P0563 System Voltage High

!Hot In RUN, BULB TEST And START!

'

r -

._

I
I

___ - - - - -.J

H7
HS

ower
Distribution
Cell 10

PCM IGN
MiniFuse
15 A

439--------.J
::: ::-------~~~ -~~ -p~~1439
61

20

19

Positive

Positive
Voltage

. Voltage

C2

Posttive
Voltage

- - - -

!HotAtAIITi~e~ -

I Power
I Distribution
I Cell 10
Fuse Block
L

D3
C3

.9_e!!_]1 _ -

,Ip

CIGAR ACCY I Fuse

Fuse 11
1 Block
25 A
I

Details

....... -

Ground
Distribution
Cell14

37
-

_ _

LJil

Instrument
Cluster

~
~

Powertrain

>

Control
Module
~ (PCM)

C1

-Mil - - - - - - - - - .,
I

Control
PCM
C1=RED
C2-BLU

Serial Data
(UART) _ _ _ Ground

Ground

Ground

Ground

72
-~:: ~;/
BLK 451

-~:~

I
I
I

~~

BLK 451

TAN 800

I
-

TAN 800

- -

ORN 540

Ground
Distribution
Cell14

TAN 800
Antilock
Brakes
Cell44

BLK 451
TAN 800

PPL 1807
TAN 800 TAN 800
Supplemental
Inflatable
Restraints
(SIR)
Cell47

BLK 650

- -

_I _E~G~:_s~o~ ~

BRN/WHTI419

p:~ 1

BLK/WHT 451

Malfunction
Indicator
Lamp (lvllL)
(SERVICE

BRN/WHT 419

?V

ORN 540
Fuse Block
Details
Cell11

\1)

A4

J
~~~-- - - ~~~1::

- -

Serial Data
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ {Class 11) _

r _ -

L-

r - - - Bafte-;y-------------- - - - - - -Biiiteiy------ - -lgniti00

T
ffi

PNK/BLK

ORN 340

I
I
I

r--------.,

Underhood
.
Electrical
I Center 2
I
I

16

____________ ~

Data Link Connector (DLC)

218506

Circuit Description

Conditions for Running the DTC

The PCM continuously monitors the system voltage.

The system voltage information is taken from the
PCMs ignition feed circuits. Since voltages below
8.0 volts or above 17.1 volts, could cause improper
system operation and/or component damage, the PCM
operates in a default mode if a PCM voltage DTC
sets. If the system voltage is low the PCM raises the
idle speed in order to increase the generator
output. If the system voltage is high, the PCM disables
most outputs to protect the hardware. A scan tool
may not display data if system voltage is outside this
range. Because of this, use a DMM in order to
monitor system voltage to verify if the fault is currently
present.

The engine run time is greater than 1O seconds.

Conditions for Setting the DTC

The PCM senses the system voltage is above
17.1 volts.
All the conditions are present for 5 seconds.

6-1632

Engine Controls - 5.7L

Action Taken When the DTC Sets

The PCM stores DTC P0563 in the PCM memory
when the diagnostic runs and fails.
.The Malfunction Indicator Lamp (MIL) will not
illuminate.
The PCM will record the operating conditions at
the time the diagnostic fails. The PCM stores
this information in Failure Records.
The PCM disables most outputs.
The transmission defaults to third gear.
The TCC operation is inhibited.
The PCM will cycle the cooling fans ON and OFF
every few seconds during the time the condition
is present.

Conditions for Clearing the MIUDTC

A History DTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other non-emission related diagnostic.
A last test failed (Current DTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUDTC.

Engine
Diagnostic Aids
Test the generator voltage sense circuit for high
resistance or loose connections. These could
cause an intermittent overcharging condition.
Refer to Starting and Charging Schematics
in Engine Electrical for circuit details.
Using Freeze Frame and/or Failure Records data
may aid in locating an intermittent condition. If
you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can aid in determining how many
miles since the DTC set. The Fail Counter
and Pass Counter can also aid determining how
many ignition cycles the diagnostic reported a
pass and/or a fail. Operate the vehicle within the
same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you
observed. This will isolate when the DTC failed.
For an intermittent, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step tests for excessive generator output
The voltage should remain below 17.1 volts.

DTC P0563 System Voltage High

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to
Diagnostic Aids

Go to Step 3

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Important: If OTC P1635 and/or P1639 are set, refer to

those DTCs for further diagnosis.
1. Turn OFF all the accessories.
2. Measure the battery voltage at the battery using the
DMM J39200.
3. Operate the engine speed above 2000 RPM.
Is the battery voltage less than the specified value?
Repair the Charging system. Refer to Charging System
Check in Engine Electrical.
Is the repair completed?

17.1V

Go to Step 4

'

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 5

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls~ 5.7L

6-1633

DTC P0601 Control Module Read Only Memory (ROM)

Circuit Description

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL) when the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Freeze Frame and/or the Failure
Records.

The PCM EEPROM contains data which is essential

to running the engine and transmission. The PCM
continuously te~ts the integrity.of this data.

Conditions for Running the DTC

The ignition switch is in the crank position or the run
position.

Conditions for Clearing the MIL/OTC

Conditions for Setting the DTC

Diagnostic Aids

Th.e PCM is unable to cqrrectly re~d data from the

flash memory.

Replace the PCM everl if this DTC exists only in

history.
For an intermittent, refer to Symptoms.

Replace the PCM.

Test Descri.ption
The numbers below refer to the step numbers on the
diaijnostic table.
.
.
2. This DTC .indicates an internal PCM condition.

OTC P0601 Control Module Read Only Memory (ROM)

Step
.

Action

Value{s)

Important: Program the replacement PCM. Refer to PCM

.Repl;:1pement!P'rogramming. .

Replace the PCM.

Is the action complete?
1. Select the Diagnostic Trouble Code (OTC) option and
the Clear OTC option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?
'p

\j

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

4. Operate vehicle within the Conditions for Running the

OTC as specified in the supporting text, if applicable.
Does the .scan tool indicate that this test ran and passed?

No

'

. Did you perform the PoWEtr:traJn bn-Board Diagnostic

(OBD) System Check?

Yes

Go to Step 4

Go to

Step 2

Go to applicable
OTC table

System OK

6-1634

Engine

Engine Controls - 5.7L

DTC P0602 Control Module Not Programmed

Circuit Description

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

This DTC indicates that the PCMs internal EEPROM

is not flashed with any vehicle software. If you
install a service PCM and do not flash the EEPROM,
the engine will not run. This DTC indicates that an
un-flashed PCM causes the engine cranks but will not
run situation.

Conditions for Running the DTC

The ignition switch is in the run position.

Conditions for Setting the DTC

Test Description

No software data is present in the PCM.

The numbers below refer to the step numbers on the

diagnostic table.
3. If the flashing routine fails, verify that the
equipment used is functioning properly and that all
cable connections are clean and tight. Also,
make sure that the software you download is
correct for the PCM being flashed. If everything
tests out OK, and a ~ec:::ond attempt fails, the PCM
is faulty.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp {MIL) when the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Freeze Frame and/or the Failure
Records.

DTC P0602 Control Module Not Programmed

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to Steps

Go to Step 4

Go to Step 5

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Flash the PCM with the correct software. Refer to PCM

Replacement/Programming.
Does DTC P0602 reset?

1. Verify that the equipment being used is functioning

properly and that all the cable connections are clean
and tight.
2. Attempt to flash the PCM again.
Does DTC P0602 reset?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (DTC) option and
the Specific DTC option, then enter the DTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

'

Go to Step 5

Go to Step 6

Go to Step2

Go to the
applicable
DTC table

System OK

Engine

Engine Controls - 5.7L 6-1635

DTC P0604 Control Module Random Access Memory (RAM)

Circuit Description

Action Taken When the [)TC Sets

The PCM illuminates the Malfunction Indicator
Lamp {MIL) when the diagnos~ic runs and fails.
The PCM records the operating conditions at the
time the diagnostic tails. The PCM stores this
information in the Freeze Frame and/or the Failure.
Records.

The PCM performs an internal self-test on it's Random

Access Memory (RAM) or read/write memory. If this

self.-test fails, this DTC sets.

Conditions for Running the OTC

The ignition voltage is greater than 1O volts.

Conditions for Clearing the MIUDTC

The ignition is ON for 5 seconds.

Replace the PCM.

Test Description

Conditions for Setting the OTC

The numbers below refer to the step numbers on the

diagnostic table.
2. This DTC indicates an internal PCM condition.

The internal RAM test fails.

DTC P0604 Control Module Random Access Memory (RAM)

Step

Action

Value(s)

Yes

Did you perform the Powertrain On-Board Diagnostic

(080) System Check?

Go to Step 2

No
Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?\

Go to Step 3

1. Select the Diagn~stic Trouble Code (OTC) option and

the Clear OTC option using the st:an tool.

2. Idle the engine.at the normal operating temperature.

3. Select the Diagnostic Trouble Code (OTC) option and
3

the Spe~ific OTC option, then enter the .DTC number

using the scan tool: , ..

4. Operate vehicle within .the Conditions for Running the

OTC as specified in the supporting te~t. if applicable.
Does the scan tool indicate that this test ran and passed?

.Goto Step 4

Go to.Step 2

Select the Cll(pture Info option ar:idthe Review Info option

using the scan tool.
Does the scan tool display any DTCs that yg have not

diagnosed?
.

Go to applicable
OTC table

System OK

6-1636

Engine

Engine Controls - 5.7L

DTC P0608 Vehicle Speed Output Circuit

CHEVROLET

,cruise
I vss 1Control
I Input I Module

r -

r -

IL 0 c

, Radio

'" - , Instrument
I vss I Cluster

K-I~ ~

Input

J.

B1L2- ~ ~

L2!il

DK GRN/WHT 817

-~
DK GRN/WHT 817

DK GRN/WHT 817

DKGRN/WHT 817

DK GRN/WHT 817

DK GRN/WHTI817

55 C1
r - - -

vss - - - - - - - - , Powertrain
Output

I
I

I PCM I

1c1 '.:. RED I

C2-l'!LUI

I Control

I Modul.e J.
I (P,CM) ~

L-------------.1

218715

Circuit Description
Various components apply a voltage to the Vehicle
Speed Output circuit. The PCM creates the Vehicle
Speed Output signal by rapidly grounding this
circuit via an internal switch called a driver. The driver
operates at the same rate as the VSS signal input.
The various components recognize the voltage being
pulled to ground as an indication of vehicle speed.
The driver supplies the ground for the component
being controlled. Each driver has a fault line which the
PCM monitors. When the PCM commands a
component ON, the voltage of the control circuit
should be low (near O volts). When the PCM
commands the control circuit to a component OFF, the
voltage potential of the circuit should be high (near
battery voltage). If the fault detection circuit senses a
voltage other than what is expected, the fault line
status changes causing the OTC to set.

Conditions for Running the DTC

The engine speed is greater than 600 RPM.
The ignition voltage is between 6.0 volts and
16.0 volts.

Conditions for Setting the DTC

The PCM detects that the commanded state of
the driver and the actual state of the control
circuit do not match.
The .condition must be present for a minimum of
10 seconds.

Action Taken When the DTC Sets

The PCM stores the OTC information into memory
when the diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL) will not
illuminate.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Failure Records.

Conditions for Clearing the MIUDTC

A History OTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other non-emission related diagnostic.
A last test failed (Current OTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUOTC.

Engine Controls - 5.7L

Engine

6-1637

Diagnostic Aids

Test Description

Using Freeze Frame and/or Failure Records data may

aid in locating an intermittent condition. If you
cannot duplicate the DTC, the information included in
the Freeze Frame and/or Failure Records data can
aid in determining how many miles since the DTC set.
The Fail Counter and Pass Counter can also aid
determining how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate the vehicle
within the same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you observed.
This will isolate when the DTC failed.
For an intermittent, refer to Symptoms.

The numbers below refer to the step numbers on the

diagnostic table.
3. Further circuit diagnosis may require 1/P removal.
The circuit from the PCM to the speedometer
must be tested for being open, shorted to ground
or, voltage. If you do not find any trouble,
follow the appropriate 1/P diagnostic procedure.
9. The repair is not complete if the scan tool
indicates that the diagnostic ran and failed.

OTC P0608 Vehicle Speed Output Circuit

Step

Action

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to
Diagnostic Aids

Go to Step 3

Value{s)

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Important: If the 1/P is completely inoperative, refer to

Instrument Cluster System Check in Instrument Panel,
Gauges and Console for further diagnosis.
1. Turn OFF the ignition.
2

2. Raise the drive wheels.

3. Start the engine.

4. Disable the ASR/TCS systems (if so equipped).
5. Allow the engine to idle in gear.
Does the vehicles speedometer indicate vehicle speed?
1. Turn OFF the ignition.

2. Disconnect the PCM connector C1 located on the

opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.
3. Turn ON the ignition.

9.6V

4. Measure the voltage from the vehicle speed circuit

using the DMM J 39200.
Does the DMM display above the specified value?

Go to Step 7

Go to Step 4

Go to Step 5

Go to Step 6

Go to Step 9

Go to Instrument
Cluster System
Check in
Instrument
Panel, Gauges
and Console.

1. Remove the Instrument Panel Cluster (IPC). Refer to

IP Cluster Replacement in Instrument Panel, Gauges
and Console.
4

2. Test the continuity of the vehicle speed circuit using

the DMM J 39200. Refer to Testing for Continuity in
Wiring Systems.

Does the DMM display continuity?

1. Inspect for poor connections at the IPC. Refer to
lntermittents and Poor Connections Diagnosis in
Wiring Systems.

2. If you find a poor connection, repair as necessary.

Refer to Repairing Connector Terminals in Wiring
Systems.

Did you find and correct the condition?

Repair the open vehicle speed output circuit. Refer to

Wiring Repairs in Wiring Systems.
Is the action complete?

Go to Step 9

6-1638' . Engine Controls - 5.7l

Engine

OTC P0608 Vehicle Speed Output Circuit (cont'd)

Step ..

Value(s)

Action
1. Inspect for poor connections at the PCM. Refer to
lntermittents and Poor Connections Diagnosis in
Wiring Systems.

Replace the PCM.

Is the action complete?

No

Go to $tep.9

Go to Step .B

2. If you,find a poor connection, repair as necessary.

~efer to Repairing Connector Terminals in Wiring
System&Did you find and correct the condition?

lr:1;1portant: Program the repl1;1cementPCM. Refer to PCM

Replacement/Programming.

Yes

'

.'

'.

,:

Go to Step 9
. ,,;

,..

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear. OTC option using the scan tool.
2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (OTC) option and

. the Specific OTC option, then enter the OTC number
using the scan tool.

4. Operate vehicle within the Conditions for Running the

OTC as specified in the supporting text, if applicable ..
Does the scan tool indicate that this test passed?

10

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 10

Go to Step 2

Go to the
applicable
OTC table

System OK

..

Engine

Engine Controls - 5. 7L

6-1639'

OTC P0650 Malfunction Indicator Lamp (MIL) Control Circuit

f Hot In RUN, BULB TEST And START!

!Hot At All Times!

- - - - ., Underhood
PCM BAT
I Electrical
MiniFuse I Center 1
10A
I

L -

r -

H7

- - - -.J

H6

L-

PNK/BLK

ORN 340

Power
Distribution
Cell 10

PCM IGN
MiniFuse
15 A

Underhood
I El t . I
eC nca
I Center

r---------,
1

--,)..

\].)

--------.J

439

Malfunction
Indicator
Lamp (MIL)
(SERVICE

BRN/WHT 419
: : : :::------- -~~~-~-:~K1439

Instrument
Cluster

~~
~

Powertrain

>

BRN/WHTI419
61

20
19
-------------------

C2

37

I
I
I

Positive
Voltage

Positive
Voltage

Positive
Voltage

---- -- -- -

r -

lHotAtAIITimesl
-

.,

IP

..,,._

BLK 451

60

C2

BLK 451

BLK 451

Ground
Distribution
Cell14

TAN 800
Antilock
Brakes
Cell 44

BLK 451
TAN 800

PPL 1807
TAN 800 TAN 800
Supplemental
Inflatable
Restraints
(SIR)
Cell47

BLK 650

I
I

Groun_d __~round~

C1 21

TAN 800

BLK;WHT 451

76

BLK 451

c4- - - - J

ORN 540

72

I
I

TAN 800

_- -

Ground
Distribution
Cell14

TAN 800

I
I

ORN 540

Fuse Block
Details
Cell11

- - - - - - - - - - - - 3 C2

PPL 1807

PCM
Cl=RED
C2=BLU

Serial Data
(UART) _ _ _ (;lrou~d- _~round

_ _ _ _ _ _

IF
CIGAR ACCY
use
1 Block
11
Fuse

25 A

-----.,

Control

Serial Data

58

Control

Module

~ (PCM)

C1

- - -MIL
---- -

lV

~ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ (Class II) _

I Power
Distribution
03
I Cell 10
I
Fuse Block
C3
I
Details
... _________
Cell11

LJiJ

_I _E~G~:_s~~ ~

A4

r - - -Battery
- - - - - - - - -Battery
- - - - -Ignition
---- -

16

__ __ _ __ __ _ _ 9

Data Link Connector (DLC)

218506

Circuit Description

A voltage is supplied directly to the Malfunction

Indicator Lamp (MIL). The PCM controls the lamp by
grounding the control circuit via an internal switch
called a driver. The primary function of the driver is to
supply the ground for the component being controlled.
Each driver has a fault line which is monitored by
the PCM. When the PCM is commanding a component
ON, the voltage of the control circuit should be low
(near O volts). When the PCM is commanding
the control circuit to a component OFF, the voltage
potential of the circuit should be high (near battery
voltage). If the fault detection circuit senses a voltage
other than what is expected, the fault line status
will change causing the DTC to set.

Conditions for Running the DTC

Engine speed is greater than 600 RPM.
The ignition voltage is between 6.0 volts and
16.0 volts.

Conditions for Setting the DTC

The PCM detects that the commanded state of
the driver and the actual state of the control
circuit do not match.
The conditions are present for a minimum of
10 seconds.

Action Taken When the DTC Sets

The PCM will not command the MIL ON. The
PCM stores DTC P0650 in memory when the
diagnostic runs and fails.
The PCM records the conditions present at the
time the diagnostic fails to the Freeze Frame.

6-1640

Engine

Engine Controls - 5~7L

Conditions for Clearing the MIL/DTC

A History OTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other non-emission related diagn_ostic.
A last test failed (Current OTC} will clear when the
diagnostic runs and does not fail.
Use a scantool in order to clear the MIUOTC.

Diagnostic Aids
If the ignition feed circuit is suspected of being
open, check if other bulbs on that circuit
illuminate.
Using Freeze Frame and/or Failure Records data
may aid in locating an intermittent condition. If
the OTC cannot be duplicated, the information
included in the Freeze Frame and/or Failure
Records data can be useful in determining how
many miles since the OTC set. The Fail Counter
and Pass Counter can also be used to determine
how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate vehicle
within the same freeze frame conditions (RPM,
load, vehicle speed, temperature etc.) that
were noted. This will isolate when the OTC failed.

Test Description,
The numbers below refer to the step numbers on the
diagnostic table.
2. Command both the ON and the OFF states.
Repeat the commands as necessary.
8. If you do not find trouble in the control circuit or
the connection at the PCM, the PCM may be
faulty. However, this is an extremely uriiikely
failure.

Engine Controls - 5.7L 6-1641

Engine

OTC P0650 Malfunction Indicator Lamp (MIL) Control Circuit

Step

Action
Did you perform the Powertrain On-Board Diagnostic
(OBD) System Check?

.,

Important: If the 1/P is completely inoperative, refer to

Instrument Cluster System Check in Instrument Panel,
Gauges and Console for further diagnosis.
1. Turn ON the ignition leaving the engine OFF.
2. Command the lamp ON and OFF using the
Scan tool.
Does the lamp turn ON and OFF with each command?

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to
Diagnostic Aids

Go to Step 3

1. Turn OFF the ignition.

2. Disconnect the PCM connector C1 located on the
opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.
3. Turn ON the ignition.
Is the lamp OFF?
Probe the lamp control circuit in the PCM harness
connector with a fused jumper wire connected to ground.
Refer to Using Fused Jumper Wires in Wiring Systems.
Is the lamp ON? ,

Go to Step 4

Go to Step 5

Go to Step6

Go to Step 7

Repair the short to ground in the lamp control circuit. Refer

to. Wiring Repairs.in Wiring Systems.
Is the repair complete?
1. Inspect for poor connections at the PCM. Refer to
lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?
Inspect for the following conditions:
Faulty indicator
,
Open ignition feed to the indicator
Control circuit open or shorted to B+
If you find a condition, repair as necessary. Refer to
Wiring Repairs in Wirin!;J Systems.
Is the repair complete?

Go to Step 9

. Go to Step 9

Go to Step 8

'

Go to Step 9

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.

Replace the PCM.

Is the action complete?

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the DTC number
using the scan tool.
4. Operate vehicle within the Conditions for Running the
OTC as specified in the supporting text, if applicable.
Does the scan tool indicate that this test passed?

10

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Yes

Value(s)

Go to Step 9

Go to Step 10

Go to Step 2

Go to the
applicable
OTC table

System OK

6-1642

Engine

Engine Controls - 5.7L

DTC P0654 Engine Speed Output Circuit

'" - - - ., Instrument
I Tachometerl Cluster
I input

rel

Li.I

Jt,

813--.1~
WHTI121
With
Traction

WHT 121

Control
Antilock
Brakes
Cell44

WHT
121
WHT 121

35

C2

'" - - :- - - - - - - - - - ., Powertrain
I
Engine Speed
I PCM
I
I C t I
Output
On ro
I
Control
IC1=RED
I Module JI!.
I
C2=BLU
I (PCM) ~

.... _ _ _ _ _ _ _ _ _ _ _ _ J

218512

Circuit Description
The Instrument Panel Cluster (IPC) supplies a voltage
to the Engine Speed Output circuit. The PCM
creates the Engine Speed Output signal by rapidly
grounding this circuit via an internal switch called
a driver. The other components on this circuit
recognize the voltage being pulled to ground as an
indication of engine speed.
The driver supplies the ground for the component
being controlled. Each driver has a fault line which the
PCM monitors. When the PCM commands a
component ON, the voltage of the control circuit
should be low (near O volts). When the PCM
commands the control circuit to a component OFF, the
voltage potential of the circuit should be high (near
battery voltage). If the fault detection circuit senses a
voltage other than what is expected, the fault line
status changes causing the DTC to set.

Conditions for Running the DTC

The engine speed is greater than 600 RPM.
The ignition voltage is between 6.0 volts
and 16.0 volts.

Conditions for Setting the DTC

The PCM detects that the commanded state of
the driver and the actual state of the control
circuit do not match.
All conditions present for a minimum of
10.0 seconds.

Action Taken When the DTC Sets

The PCM stores the DTC information into memory
when the diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL) will not
illuminate.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Failure Records.

Conditions for Clearing the MIUDTC

A History DTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other non-emission related diagnostic.
A last test failed (Current DTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Using Freeze Frame and/or Failure Records data may
aid in locating an intermittent condition. If you
cannot duplicate the DTC, the information included in
the Freeze Frame and/or Failure Records data can
aid in determining how many miles since the DTC set.
The Fail Counter and Pass Counter can also aid
determining how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate the vehicle
within the same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you observed.
This will isolate when the DTC failed. If the 1/P is
completely inoperative, refer to Instrument Cluster
System Check in Instrument Panel, Gauges and
Console for further diagnosis. For an intermittent, refer
to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step is testing for voltage on the engine
output circuit.

11. The repair is not complete if the scan tool

indicates that the diagnostic ran and failed.

Engine Controls - 5.7L 6-t6~3

Engine

OTC P0654 Engine Spee.'d Output Clrcuit

Did you perform the Powertrain On-Board Diagnostic
(OBD) System Check?

)
1

Value(s}

Ac,ion

Step

Important: If the 1/P is completely inoperative, refer to

Instrument Cluster System Check in Instrument 'Panel,
Gauges and Console.
With the engine .running, does the vehicles tachbmeter
indicate engine RPM?
. ...

..

3. Turn ON the ignition leaving the engine OFF.

No
.,

Go tq Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to
Diagnostic Aids

. Go to Step 3

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located, on the
same side as the manufacturer's logo. Refer.to PCM ..
Replacement/Programming.

Yes

9.5V

4. Measure the voltage from the engine speed output

circuit using the DMM J 39200.
Is the voltage above the specified value?

Go to Step 9

Go to Step 4

Go to Step 5

Go to Step 7

Go to Step B

Go to Step 6

Go to Step 11

Go to Instrument
Cluster System
Check in
Instrument
Panel, Gauges
and Console.

1. Remove the Instrument Panel Cluster {IPC). Refer to

IP Cluster Replacement in Instrument Panel, Gauges
and Console.

2. Test the continuity of the engine speed output circuit

using the DMM J 39200. Refer to Testing for
Continuity in Wiring Systems.

Does the DMM display continuity?

Test for continuity of the engine speed output circuit using

the DMM J 39200 connected to ground. Refer to Testing
for Continuity in Wiring Systems.

Does the DMM display continuity?

1. Inspect for poor connections at the IPC. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.

2. If you find a poor connection, repair as necessary.

Refer to Repairing Connector Terminals in Wiring
Systems.

Did you find and correct the condition?

Repair the open engine speed output circuit. Refer to

Wiring Repairs in Wiring Systems.

Repair the grounded engine speed output circuit. Refer to

Wiring Repairs in Wiring Systems.

Go to Step 11

Is the action complete?

Go to Step 11

Is the action complete?

1. Inspect for poor connections at the PCM. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.

2. If you find a poor connection, repair as necessary.

Refer to Repairing Connector Terminals in Wiring
Systems.

Go to Step 11

Did you find and correct the condition?

10

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the replacement complete?

Go to Step 10

Go to Step 11

6-1644

Engine Controls - 5.7L

Engine

DTC P0654 Engine Speed Output Circuit (cont'd)

Step

Action

Value(s)

Yes

No

Go to Step 12

Go to Step2

Go to the
applicable
OTC table

System OK

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC option using the scan tool.
2. Idle the engine at the normal operating temperature.

11

12

3. Select the Diagnostic Trouble Code (OTC) option and

the Specffic OTC option, then enter the OTC number
using the scan tool.
4. Operate vehicle within the Conditions for Running the
OTC as specified in the supporting text, if applicable.
Does the scan tool indicate that this test passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Engine

Engine Controls - 5.7L

6-1645

OTC P0656 Fuel Level Output Circuit

r - - , Instrument
I Fuel I Cluster
I Gauge1

>

1.--J~

DKB:r~
DK

BLlJI 1936
36

'" -

C1

-F~ -

Gauge

I PCM

Control

IC1=REDI
lc2=BLU

Powertrain

I Control

>

I Module
I (PCM) ~

L-------------.1
219469

Circuit Description

Conditions for Clearing the MIL/DTC

The PCM controls the fuel gauge through the fuel

gauge control circuit. The PCM supplies a pulse width
modulated (PWM) duty cycle signal to control the
fuel gauge. The PCM receives the fuel level
information from the fuel level sensor.

The PCM controls the gauge by grounding the control

circuit via an internal switch called a driver. The
primary function of the driver is to supply the ground
for the controlled component. Each driver has a
fault line which the PCM monitors. If the fault detection
circuit senses a voltage other than what the PCM
expects, the fault line status changes causing the OTC
to set.

Conditions for Running the DTC

The engine speed is greater than 600 RPM.
The ignition voltage is between 6.0 volts
and 16.0 volts.

Conditions for Setting the DTC

The PCM detects that the commanded state of
the driver and the actual state of the control
circuit do not match.
All the above conditions present for a minimum of
10 seconds.

Action Taken When the OTC Sets

The PCM stores the OTC information into memory
when the diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL) will not
illuminate.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Failure Records.

A History OTC will clear after forty consecutive

warm-up cycles, if no failures are reported by
this or any other non-emission related diagnostic.
A last test failed (Current OTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
An open GAGE fuse causes OTC P0656 to set.
The instrument cluster is inoperative with an
open GAGE fuse.
The C210 connector half with the female terminals
is the gauge side of the circuit. The connector half
with the male terminals is the PCM side of the
harness.
The following may cause an intermittent:
- Poor connections: Test for adequate terminal
tension. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
- Corrosion
- Mis-routed harness
- Rubbed through wire insulation
- Broken wire inside the insulation
Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the OTC, the inform~tion
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the OTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the OTC failed. For an
intermittent condition, refer to Symptoms.

6..1646

Ehgimf Controls - 5i7L

Engine

a ..

If the gauge displays empfy,.this .indiaates the;, ,

circuit between the C210 connector.andthe gauge
is shorted to ground or the gauge is
malfunctioning.
... 7. This step determines if the circuit between the
gauge and the C210 connector is open. If the
gauge goes to empty, this indicates the circuit and
the gauge are OK.

The numbers below refer to the step numbers on the

diagnostic table.

to

2. Fu~l level DTCs set causes the fuel gauge

display empty. Do not perform this DTC table
if DTCs P0461, P0462, or P0463 are set. Only
perform this table if a DTC P0656 is set.
5. The C210 connector is located behind the right
side (passenger side) kick panel. Connector
C210 contain circuits for the fuel tank pressure
sensor and the fuel level sensor. Disconnecting
this connector causes additional DTCs to set.

8. This step determines if the PCM is capable of

controlling the gauge. If the test lamp changes
brightness, the PCM and circuit are OK.

DTC P0656 Fuel Level Output Circuit

Step

Action

Value(s)

Did you perform the Powertrain On-Board Diagnostic

(080) System Check?
' '>~
1

Yes

No

Go to Step 2

!
Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

1. Install a scan tool.

2

2. Turn ON the ignition leaving the engine OFF.

Go to
Applicable OTC

Is OTC P0461, P0462, or P0463 also set.?

lsthe Gages fuse open?'
..

..

..
'"

.,,

,.

, ..

;:.,

\:.,'.

1. Select the Output Gbr'ltrols using tl'le scan tool.

2. Control the fuel gauge fr6m empty to full dsing a scan
tool in the Output Controls,.,
Does the fuel gauge respond?

Important: AdditionalDTCs set wh.en connector C210 is. .,,.

,.,
disconnected.

Go to lnstrumeh(
Cluster System
Check tnstrument
Panel, Gauges .
.. and ,Gbnsbje,

..

,.

.Go to ~iep 4 .
.

,.

1-.,.

...

.Jr'

'

'

';

\,

Go to
1Diagnostic Aids,

.
'.L"

..,

.'

Go to'step 5, i

,.

"

'

; '\

Disconnl:)ct the 8-way C210 connector located pehind the ,

. passeng~r side kick panel. Refer to Lower Right Side of IP
in Wiring Systems.
'',
Does the fuel gauge display empty? ..

.. ;.!

.,

Go to step 3
1

..,

,..,........
;

,,

.,

. Go to. sfep

Go to step?

1. Inspect the fuel gauge control circuit between the

C210 connector and the instrument cluster for a
grounded circuit.
'
6

2. If you find the circu.it grounded, repair the fuel gauge

control circuit. Refer to Wiring Repairs in Wiring
Systems.
Did you find and correct the condition?

Does the. fuei gauge display empty?

'
1,, Go to Step 21

;,.:

Jumper .~be fuel gauge control cir.cuit. (gauge side of

C210 connector) to ground.

Go to Instrument
Cluster System
Check
. . lnstrurn~nt.
.' Pan'ei, 'Ga\.lg~s ,'
and Console

.,

' ' ' 'j'

;\

,.

Go to step 12

.Goto step B

....

:-

,
8

. 1.: :Probe the fuel gauge control circuit ( PCM side of

C2.10 connector) with the test lamp .J34142-B
- connected to B+.
2. CorJtroJ the tu.el gauge from empty.to full using a scan
toql i,n Output Contr.ols.

Does the test lamp brightness change with ea.ch

command?
;('

\:

'

"
' ,~

xt

\',

Go to step 13

'

'.

'

Go to,qtep 9

Engine

Engine Controls - 5.7L

6-1647

DTC P0656 Fuel Level Output Circuit (cont'd)

Action

Step

)
9

10

11

12

13

14

15

Value(s)

1. Turn OFF the ignition.

2. Disconnect the PCM connector C1 located on the
opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.
3. Test the continuity of the fuel gauge control circuit
from connector C210 and the PCM using the DMM
J 39200. Refer to Testing for Continuity in Wiring
Systems.
Is continuity indicated?

1. Connect the test lamp J 34142-8 to B+.

2. Probe the fuel gauge control circuit (PCM side of
harness) with the test lamp J 34142-8.
Does the test lamp illuminate?

1. Connect the test lamp J 34142-8 to ground.

2. Probe the fuel gauge control circuit (PCM side of
harness) with the test lamp J 34142-8.
Does the test lamp illuminate?

1. Turn OFF the ignition.

2. Disconnect the .cluster from the instrument panel.
Refer to IP Cluster Replacement in Instrument Panel,
Gauges and Console.
3. Test the continuity of the fuel gauge control circuit
from connector C21 O and the instrument cluster using
the DMM J 39200. Refer to Testing for Continuity in
Wiring Systems.
Is continuity indicated?

1. Inspect for a poor connection at connector C210.

Refer to lntermittents and Poor Connections
Diagnosis in Wiring Systems.
2. If you find a poor connection, repair the connection
as necessary. Refer to Repairing Connector
Terminals in Wiring Systems.
Did you find and correct the condition?

Repair the open fuel gauge control circuit between the

PCM and the C210 connector. Refer to Wiring Repairs in
Wiring Systems.
Is the action complete?

Repair the grounded fuel gauge control circuit between the

PCM and the C21 O connector. Refer to Wiring Repairs in
Wiring Systems.

16

18

Go to step 10

Go to step 14

Go to step 15

Go to step 11

Go to step 16

Go to step 19

Go to step 18

Go to step 17

Go to Step 21

Go to
Diagnostic Aids

Go to Step 21

Go to Step 21

Is the action complete?

17

No

Go to Step 21

Is the action complete?

Repair the fuel gauge control circuit for a short to voltage
between the PCM and the C210 connector. Refer to
Wiring Repairs in Wiring Systems.

Yes

Repair the open fuel gauge control circuit between the

cluster and the C210 connector. Refer to Wiring Repairs in
Wiring Systems.
Is the action complete?

Repair the fuel gauge control circuit for a short to voltage

between the cluster and the C21 O connector. Refer to
Wiring Repairs in Wiring Systems.
Is the action complete?

Go to Step 21

Go to Step 21

6-1648

Engine Controls - 5.7L

Engine

OTC P0656 Fuel Level Output Circuit (cont'd)

Step

19

20

Action

"

1. Inspect the PCM harness for poor a connection.

Refer to lntermittents and Poor Connections
Diagnosis in Wiring Systems.
2. If you find a poor connection, repair the connection
as necessary. Refer to Repairing Connector
Terminals in Wiring Systems.
Did you find and correct the condition?
Important: Program the replacement PCM. Refer to PCM
Replacement/Programming. .

Replace the PCM.

Is the action complete?

Value(s)

Yes

No

(
-

Go to Step 21

Go to Step 20

Go to Step 21

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
21

3. Select the Diagnostic Trouble Code (OTC) option and

the Specific OTC optiori, then enter the OTC number
using the scan tool.

4. Operate the vehicle within the Conditions for Running

the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?
22

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have. not
diagnosed?

Go to Step 22

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls .. 5.7L

61649

DTC P0801 Reverse Inhibit Solenoid Control Circuit

!Hot With Ignition Relay Energized !

~v:r - - - - - - - .,Underhood

I
L

ENG SEN I Electrical

MiniFuse
I Center 2
20A
I

I Distribution
Ce1110
I

LJil

I
-

,_ -

PNK 539
.. - ..,. I
I ~Skip
I \!) ~hift

T.

, Instrument
I Cluster
I }.
I~

PNK 539

~J __ ~

B4
Fuse Block
Details
Cell11

+- - - - - - - - - - - - - ~
PNK 539

PNK 539
WHT 375

:[m
'"

II

Reverse
Inhibit.
Solenoid

II

L-------------

WHT 375

LT GRN 1652

~ .. Skip
.
Shift
Solenoid

I
I

.,Manual

Transmission
I
:

I
I

----J

GRY 587

218747

Circuit Description
An ignition voltage is supplied to the Reverse Inhibit
solenoid. The PCM controls the solenoid by grounding
the control circuit via an internal switch called a
driver. The driver supplies the ground for the
component being controlled. Each driver has a fault
line which the PCM monitors. When the PCM
commands a component ON, the voltage of the control
circuit should be low (near O volts). When the PCM
commands the control circuit to a component OFF, the
voltage potential of the circuit should be high (near
battery voltage). If the fault detection circuit senses a
voltage other than what is expected, the fault line
status changes causing the OTC to set.
\

When the Reverse Inhibit solenoid energizes, the

operator can shift the transmission into reverse. The
PCM enables the Reverse Inhibit solenoid whenever
vehicle speed is below 5 mph. When the vehicle speed
is above 5 mph, the PCM de-energizes the solenoid,
which prevents the operator from shifting the
transmission into reverse.

Conditions for Setting the DTC

Engine speed is greater than 600 RPM.
The PCM detects that the commanded state of
the driver and the actual state of the control
circuit do not match.
Condition must exist for a minimum of
10.0 seconds.

6-1650

Engine,Controls - 5.7L

Action Taken When the DTC Sets

The PCM stores the DTC information into memory
when the diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL) will not
illuminate.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Failure Records.

Conditions for Clearing the MIL/DTC

A History DTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other non-emission related diagnostic.
A last test failed (Current DTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Using Freeze Frame and/or Failure Records data
may aid in locating an intermittent condition. If
you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can aid in determining how many
miles since the DTC set. The Fail Counter
and Pass Counter can also aid determining how
many ignition cycles the diagnostic reported a
pass and/or a fail. Operate the vehicle within the
same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you
observed. This will isolate when the DTC failed.
Low system voltage can cause this DTC to set.
When reviewing captured data, verify if a low
system voltage condition was present at the time
the DTC was stored in memory.

Engine
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Listen for an audible click when the solenoid
operates. Command both the ON and the
OFF states. Repeat the commands as necessary.
3. This test pan detect a partially shorted coil which
would cause excessive current flow. Leaving the
circuit energized for 2 minutes allows the coil
to warm up. When warm the coil may open (Amps
drop to 0), or short (goes above 1.5 Amp).
7. Listen for an audible click as the solenoid
operates. Repeat the procedure as necessary.
13. If you find no trouble in the control circuit or the
connection at the PCM, the PCM may be
faulty. However, this is an extremely unlikely
failure.
14. The repair is not complete if the scan tool
indicates that the diagnostic ran and failed.

Engine Controls - 5.7l

Engine

6~1651

DTC P0801: Reverse Inhibit Solenoid Cont,rol Circuit

Step

Action
Did you perform the Powertrain On-Board Diagnostic
(OBD) System Check?

Value(s)

Yes

No:

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Chl?Ck

Go to Step 3

Go to Step 5

1. Turn ON the ignition leaving the engine OFF.

2

2. Command the solenoid ON and OFF using a

scan tool.
Does the solenoid turn ON and OFF when commanded?
1. Turn OFF the Ignition:
2. Disconnect the PCM connector C1 located on the
opposite side of the manufacturer's logo.
3. Turn ON the ignition.
Important: If the DMM goes to O replace the relay.
4. Measure the current from the solenoid control circuit
in the PCM harness connector to ground for
2 minutes using the DMM J 39200 on 40 Amp scale.
Does the Current draw measure less than the value shown
(but not O)?

1.5A
...

Go to
Diagnostic Aids

,Go to Step 4

Go to Step 12

Go to Step 10

1. Turn OFF the Ignition.

2. Disconnect the solenoid.
4

3. Measure the resistance from the solenoid control

circuit in the PCM harness connector to ground using
the DMM J 39200.
Does the DMM display infinite resistance?

'
1. Turn OFF the Ignition.
2. Disconnect the solenoid.
3. Connect the test lamp J 34142-B between the
terminals in the solenoid harness connector.
4. Turn ON the ignition leaving the engine OFF.
5. Command the solenoid ON and OFF using a
scan tool.

Does the test lamp turn ON and OFF when commanded?

Probe the ignition feed circuit in the solenoid harness

connector with the test lamp connected to ground.

Go to Step 6

Go to Step 7

Go to Step 11

Go to Step 9

Go to Step 10

Go to Step 14

Go to Step 12

5. Using a fused jumper wire connected to ground,

momentarily probe the solenoid control circuit in the
PCM harness connector. Refer to Using Fused
Jumper Wires in Wiring Systems.
Does the solenoid turn ON when the circuit is grounded
and OFF when the circuit is opened?
1. Inspect for poor connections at the solenoid. Refer to
lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

Go to Step B

Is the test lamp illuminated?

1. Turn OFF the Ignition.
2. Reconnect the solenoid.
3. Disconnect the PCM connector C1 located on the
opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.
4. Turn ON the ignition.

.,

6-1652

Engine

Engine Controls - 5.7L

DTC P0801 Reverse Inhibit Solenoid Control Circuit (cont'd)
Action

Step

10

11

12

13

14

15

Value(s)

1. Inspect for poor connections at the PCM. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

Repair the faulty solenoid control circuit. Refer to Wiring

Repairs in Wiring Systems.
Is the repair complete?

Repair the faulty solenoid ignition feed circuit. Refer to

Wiring Repairs in Wiring Systems.
Is the repair complete?

Replace the solenoid. Refer to Reverse Lockout Solenoid

in Manual Transmission MM6.
Is the replacement complete?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.

Replace the PCM.

Is the action complete?

Yes

No

Go to Step 14

Go to Step 13

Go to Step 14

Go to Step 14

Go to Step 14

Go to Step 14

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific DTC option, then enter the DTC number
using the scan tool.
4. Operate vehicle within the Conditions for Running the
DTC as specified in the supporting text, if applicable.
Does the scan tool indicate that this test passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

(
Go to Step 15

Go to Step 2

Go to the
applicable
DTC table

System OK

Engine

Engine Controls - 5.7L

6-1653

DTC P0803 Skip Shift Solenoid Control Circuit

!Hot.With Ignition Relay Energized!

)

r - - - I Power
I Distribution
Cell 10
I

- - - ., Underhood
I
ENG SEN I Electrical
MiniFuse
Center 2
20A
I

LJil

L.-----

----J

PNK 539
.- - - - , Instrument

I
I Cluster
1
~Skip .I J.
I l;r)Shift I ~

PNK 539

~l--~

84

Fuse Block
Details
Cell11

,.__ -

-a-----------,

PNK 539
WHT 375

PNK 539

[ij

6 - - - - - - - - - - 8 - - - - .,I Manual
~ Reverse
Skip
Transmission

r -

1
:I

I
I

'' Solenoid
Inhibit

Solenoid
Shift

L-------------

WHT 375

40

LT GRN 1652

I:
I
I

----J

GRY 587

34

42

C1

r-,------------------------;---------,p
.
owetram
1
---1
---1
---1
Module

I
1
I
I

Skip Shift
Lamp Control

Reverse Inhibit
Solenoid Control

Skip Shift
Solenoid Control

L----------. --------. -----.

I Control

PCM
C1=RED

I
I

C2=BLU

(PCM)

J.

---------J~
218747

Circuit Description
An ignition voltage is supplied to the Skip Shift
solenoid coil. The PCM controls the solenoid by
grounding the control circuit via an internal switch
called a driver. The driver supplies the ground for the
component being controlled. Each driver has a
fault line which the PCM monitors. When the PCM
commands a component ON, the voltage of the control
circuit should be low (near O volts). When the PCM
commands the control circuit to a component OFF, the
voltage potential of the circuit should be high (near
battery voltage). If the fault detection circuit senses a
voltage other than what is expected, the fault line
status changes causing the DTC to set.

Conditions for Running the OTC

The engine speed is greater than 600 RPM.
Ignition voltage greater than 6.0 volts but less
than 16 volts.

Conditions for Setting the OTC

The PCM detects that the commanded state of
the driver and the actual state of the control
circuit do not match.
All conditions exist for a minimum of 1O seconds.

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure. records.

6-1654

Engine Controls - 5.7L

Conditions for Clearing the MIUDTC

A History OTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other non-emission related diagnostic.
A last test failed (Current OTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUOTC.

Engine
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Listen for an audible click when the solenoid
operates. Command both the ON and the
OFF states. Repeat the commands as necessary.
3. This test detects a partially shorted coil which
would cause excessive current flow. Leaving
the circuit energized for 2 minutes allows the coil
to warm up. When warm the coil may open
(Amps drop to 0), or short (goes above 0.75 Amp).

Diagnostic Aids
Using Freeze Frame and/or Failure Records data
may aid in locating an intermittent condition. If
you cannot duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data can aid in determining how many
miles since the OTC set. The Fail Counter
and Pass Counter can also aid determining how
many ignition cycles the diagnostic reported a
pass and/or a fail. Operate the vehicle within the
same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you
observed. This will isolate when the OTC failed.
For an intermittent, refer to Symptoms.

5. Identify and test the solenoid coil terminals in

order to avoid improper diagnosis.
13. If you do not find any trouble in the control circuit
or the connection at the PCM, the PCM may be
faulty. However, this is an extremely unlikely
failure.

OTC P0803 Skip Shift Solenoid Control Circuit

Step

Action
Did you perform the Powertrain On-Board Diagnostic
(OBD) System Check?

Value{s)

Yes

Go to Step 2

1. Turn ON the ignition leaving the engine OFF.

2. Command the solenoid ON and OFF using a
scan tool.
Does the solenoid turn ON and OFF when commanded?
1. Turn OFF the ignition.
2. Disconnect the PCM connector located on the
opposite side of the manufacturer's logo.
3. Turn ON the ignition.
Important: If the DMM goes to 0, replace the relay.
4. Measure the current from the solenoid control circuit
in the PCM harness connector to ground for
2 minutes Using DMM J 39200 on 40 Amp scale.
Does the current draw measure less than the specified
value shown?

No
Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Step 5

Go to
Diagnostic Aids

Go to Step 4

Go to Step 12

Go to Step 10

Go to Step B

Go to Step 6

0.75A

1. Turn OFF the ignition.

2. Disconnect the solenoid.
3. Measure the resistance from the solenoid control
circuit in the PCM harness connector to a ground
using DMM J 39200. Refer to Testing for Continuity in
Wiring Systems.
Does the DMM display infinite resistance?

1. Turn OFF the ignition.

2. Disconnect the solenoid.
3. Connect the test lamp J 34142-8 between the
solenoid harness connector. Refer to Probing
Electrical Connectors in Wiring Systems.
4. Turn ON the ignition leaving the engine OFF.
5. Command the solenoid ON and OFF using the
scan tool.
Does the test lamp turn ON and OFF with each
command?

Engine Controls - 5.7L

Engine

6-1655

OTC P0803 Skip Shift Solenoid Control Circuit (cont'd)

Step
6

Action
Probe the ignition feed circuit in the solenoid harness
connector with the test lamp J 34142-8 connected to a
ground.
Is the test lamp illuminated?

Value(s)

Yes

No

Go to Step 7

Go to Step 11

Go to Step 9

Go to Step 10

Go to Step 14

Go to Step 12

Go to Step 14

Go to Step 13

1. Turn OFF the ignition.

2. Reconnect the solenoid.

3. Disconnect the PCM connector C1 located on the
7

opposite side of the manufacturer's logo. Refer to

PCM Replacement/Programming.
4. Turn ON the ignition leaving the engine OFF.
5. With a fused jumper wire connected to ground,
momentarily probe the solenoid control circuit in the
PCM harness connector.
Does the solenoid turn ON when the circuit is grounded
and OFF when the circuit is opened?

1. Inspect for poor connections at the solenoid. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

1. Inspect for poor connections at the PCM. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

10

Repair the faulty solenoid control circuit. Refer to Wiring

Repairs in Wiring Systems.
Is the repair complete?

Repair the faulty solenoid ignition feed circuit. Refer to

Wiring Repairs in Wiring Systems.
Is the repair complete?

Replace the faulty solenoid. Refer to Gear Select/Skip

Shift Solenoid Replacement in Manual Transmission MM6.
Is the action complete?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

11

12

13

Go to Step 14

Go to Step 14

Go to Step 14

Go to Step 14

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear DTC option using the scan tool.

14

15

2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic.Trouble Code (DTC) option and
the Specific DTC option, then enter the DTC number
using the scan tool.
4. Operate vehicle within the conditions for setting this
DTC as specified in the supporting text, if applicable.
Does the scan tool indicate that this test failed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 2

Go to Step 15

Go.to the
applicable
DTC table

System OK

6-1656

Engine Controls - s~7L

Engine

OTC P0804 Skip Shift Lamp Control Circuit,

IHot With Ignition Rel~y E~ergizeQ, l

'" - - - - -

I Power
Distribution
I Cell 10

- - - - ., Undethood
I
ENG SEN Electrical
MiniFuse
I Center 2

~-----

____ ..

I
I

I ,
I

20A

..

PNK 539

'"T-- "'Instrument
I
I Cluster
I
I >
I
I~

PNK 539

~Skip
\l)Shift

~1--~

84

Fuse Block
Details
Cell11

..- -

--------,----,,-..,.....

PNK 539
WHT 375

PNK 539

.. - - - - - - - - - - - - -

~ B Reverse..
l11hibit

II

~ Skip
Shift

Solenoid

..

L-------------A
I

WHT 375

40

LT GRN 1652

42

I
I
I

--1 ~

L--------:

J1

: .

----.!

34 C1
~-=-~-= :. ~=---=,
; ;. ..;.; '- - - - . : . - ., Powetrain
Control
' --1
Module
Q1
(P,CM)
>
~

Solenoid Control

Solenoid

.'Transmission

. GRY 587

'" -, =--=---=-:..=
;;.;-.=.. --=-:..= ;;.;-.=.. --=--=:.. -,=---= ~
I
Skip Shift
Reverse 1nh1bit .
Lamp Control

- .,,. - - "'r<Aanual

.- .
. .

Skip'Shifl
.
SOienoid Control

.= . ,

PCM
I
= RED
I
, C2=BLU . I

--------------------------.!~

218747

Circuit Description
An ignition voltage is supplied to the Skip Shift Lamp.
The PCM controls the lamp by grounding the
control circuit via an internal switch called a driver.
The driver supplies the ground for the component
being controlled. Each driver has a fault line which the
PCM monitors. When the PCM commands a
component ON, the voltage of the control circuit
should be low (near O volts). When the PCM
commands the control circuit to a component OFF, the
voltage- potential of the circuit should be high (near
battery voltage). If the fault detection circuit senses a
voltage other than what ,is expected, the fault line
status changes causing the OTC to set.

Conditions for Running the DTq

?oo

The engine speed is greater than

RPM.
Ignition voltage-greater than 6.0 volts but less
than 16 volts.

Condifiohs for Setting the OTC

The PCM detects that the commanded state of
the driver and the actual state of the control
circuit do not match.
All conditions exist for a minimum of 1O seconds.

Engine
Action Taken When the DTC Sets

The PCM. stores the OTC information into memory

when the diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL) will not
illuminate.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Failure Records.

Conditions for Clearing the MIUDTC

A History OTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other non-emission related diagnostic.
A last test failed (Current OTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUOTC.

Engine Controls - 5.7L 6-1657

Diagnostic Aids
Using the Freeze Frame and/or Failure Records data
may aid in locating an intermittent condition. If you
cannot duplicate the OTC, the information included in
the Freeze Frame and/or Failure Records data
determines how many miles since the OTC set. The
Fail Counter and Pass Counter can also aid
determining how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate the vehicle
within the same freeze frame conditions (RPM, load,
vehicle speed, te.mperature etc.) that you observed.
This will isolate when the OTC failed.
If the 1/P is completely inoperative, refer to Instrument
Cluster System Check in Instrument Panel, Gauges
and Console for further diagnosis.
For an intermittent, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Listen for an audible click when the solenoid
operates. Command both the ON and the
OFF states. Repeat the commands as necessary.
8. If you do not find any trouble in the control circuit
or the connection at the PCM, the PCM may be
faulty. However, this is an extremely unlikely
failure.
9. The repair is not complete if the scan tool
indicate.s that the diagnostic ran and failed.

6-1658

Engine

Engine Controls - 5.7L

OTC P0804 Skip Shift Lamp Control Circuit

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Oiagnostic
(080) System
Check

Go to
Diagnostic Aids

Go to Step 3

Go to Step 4

Go to Step 5

Go to Step 6

Go to Step 7

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Important: If the 1/P is completely inoperative, refer to

Instrument Cluster System Check in Instrument Panel,
Gauges and Console for further diagnosis.
1. Turn ON the ignition leaving the engine OFF.

2. Command the shift lamp ON and OFF using the

scan tool.
Does the shift lamp turn ON and OFF when commanded?

1. Turn OFF the ignition.

3

2. Disconnect the PCM connector C2 located on the

opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.

3. Turn ON the ignition leaving the engine OFF.

Is the shift lamp OFF?

Probe the shift lamp control circuit in the PCM harness

connector with a fused jumper wire connected to ground.
Refer to Probing Electrical Connectors in Wiring Systems.

Is the shift lamp ON?

Repair the short to ground in the shift lamp control circuit.

Refer to Wiring Repairs in Wiring Systems.

Go to Step 9

Is the repair complete?

1. Inspect for poor connections at the PCM. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.

2. If you find a poor connection repair as necessary.

Reefer to Repairing Connector Terminals in Wiring
Systems.

(
Go to Step 9

Did you find and correct the condition?

Go to Step 8

Test for the following conditions:

Faulty shift lamp indicator

Open ignition feed to the shift lamp indicator

Control circuit open or shorted to B+

Refer to Wiring Repairs in Wiring Systems.

Is the repair complete?

10

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate vehicle within the Conditions for Running the
OTC as specified in the supporting text, if applicable.
Does the scan tool indicate that this test passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 9

Go to Step 9

Go to Step 10

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5.7L

6-1659

DTC P1111 Intake Air Temperature (IAT) Sensor Circuit Intermittent High Voltage

,. - - - - - - - - , Powertrain
I
sv
I Control
I IAT
I Module
I
Sensor ~ : (PCM)

8IC2

J.

~ ~ig!_al_ _ _ _ _ _ ...

L.1il

TA: 472

rn
A

Intake
Air
Temperature
(IAT)
Sensor

PPL 719

21 C1
'" - - - - - - - - - - - - - - - , Powertrain
I Control
I
PCM
I
IAT
I Module
I
Sensor
I (PCM)

Ground

g~:~i~

~---------------~

'~
218499

Circuit Description

The Intake Air Temperature (IAT) sensor contains a

semiconductor device which changes resistance based
on temperature (a thermistor). The IAT sensor
mounts in the air intake passage of the engine air
induction system. The IAT sensor has a signal circuit
' and a ground circuit. The PCM applies a voltage
(about 5.0 volts) on the signal circuit to the sensor.
The PCM monitors changes in this voltage caused by
changes in the resistance of the sensor in order to
determine the intake air temperature.
When the intake air is cold, the sensor (thermistor)
resistance is high, and the PCMs signal voltage is only
pulled down a small amount through the sensor to
ground. The PCM senses a high signal voltage
(low temperature). When the intake air is warm, the
sensor resistance is low, and the signal voltage
is pulled down a greater amount. This causes the PCM
to sense a low signal voltage (high temperature).
this DTC sets when the PCM senses a signal voltage
higher than the normal operating range of the
sensor.

Conditions for Running the OTC

DTC(s) P0102, P0103, P0117, P0118, P0500,
P0502, P0503 are not set.
The engine run time is greater than 100 seconds.
The engine coolant temperature is greater
than 0C (32F).
The vehicle speed is less than 11 km/h (7 mph).
The mass air flow is less than 15 g/s.

Conditions for Setting the DTC

The intake air temperature is less than
-35C (-31 F).
All conditions are present for 0.3 seconds.

Action Taken When the OTC Sets

The PCM stores the OTC information into memory
when the diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL) will not
illuminate.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Failure Records.

Conditions for Clearing the MIL/OTC

A History OTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other non-emission related diagnostic.
A last test failed (Current OTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
If the engine has sat overnight, the engine coolant
temperature and intake air temperature values should
display within a few degrees of each other. If the
temperatures are not within 3C (5F), refer to
Temperature vs Resistance.
For an intermittent, refer to Symptoms.

6-1660

Engine

Engine Controls - 5.7L

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. If DTC P0113 failed this ignition, this indicates a
hard failure is present. When a hard failure is
present, both the hard and intermittent DTCs set.
3. When moving related connectors,
visually/physically inspect connectors for the
following:
Poor mating of the connector halves or a
terminal not fully seated in the connector body
(backed out).
Improperly formed or damaged terminals.
Carefully reform or replace all connector
terminals in the related circuits in order to
insure proper terminal contact tension.
Poor terminal to wire connection. Inspect for
poor crimps, crimping over wire insulation
rather than the wire.
Dirt or corrosion on the terminals. Inspect for
missing connector seals and for damage to
the connector seals.

4. When moving the related wiring harnesses,

visually/physically inspect the wiring for the
following:
Wire insulation that is rubbed through, causing
an intermittent short.
Wiring broken inside the insulation.
5. Using theFreeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many
.ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the OTC failed. For any test
that requires probing the PCM or component
harness connectors, use the Connector Test
Adapter Kit J 35616-A. Using this kit prevents any
damage to the harness connector terminals.

DTC P1111 Intake Air Temperature (IAT) Sensor Circuit Intermittent High Voltage
Action

Step

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to
DTC P0113
Intake Air
Temperature
(/AT) Sensor
Circuit High
Voltage

Go to Step 3

Go to Step 6

Go to Step 4

Go to Step 7

Go to Step 5

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Did OTC P0113 also set?

1. Turn ON the ignition leaving the engine OFF.

2. Observe the affected sensor value on a scan tool
while moving the related harness connectors (at the
component and the PCM).
Does the sensor value change abruptly while a related
connector is being moved?
Observe the affected sensor value on a scan tool. while
moving the related wiring harnesses.
Does the sensor value change abruptly while moving the
related electrical harnesses?

Engine

Engine Controls - 5.7L

6-1661

OTC P1111 Intake Air Temperature (IAT) Sensor Circuit Intermittent High Voltage (cont'd)
Action

Step

Value(s)

Yes

No

Go to Step 8

Go to
Diagnostic Aids.

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records

data for this OTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.

4. Start the engine.

5. Operate the vehicle within the conditions required for

this diagnostic to run, and as close to the conditions
recorded in the Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.

6. Select the Diagnostic Trouble Code (OTC) option, the

Specific OTC option, then enter the OTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?
'

Repair the damage connectors/terminals following the

Repair Procedures in Connector Repairs in Wiring
Systems.

Go to Step 9

Is the action complete?

Repair the faulty wiring. Refer to Wiring Repairs in Wiring

Systems.

Go to Step 9

Is the action complete?

1. Re-inspect all the related circuits and the connectors.

8
\

2. Replace the sensor/component if all the circuits have

been tested thoroughly and no faults can be found.

Go to Step 9

Is the action complete?

1. Select the Diagnostic Trouble Code (OTC) option and
the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
9

3. Select the Diagnostic Trouble Code (OTC) option and

the Specific OTC option, then enter the OTC number
using the scan_ tool.

4. Operate the vehicle within the Conclitions for Running

the OTC as specified in the supporting text, if
applicable.
Does the scan toot indicate that this test ran. and passed?

10

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 10

Go to Step 2

Go to the
applicable
OTC table

System OK

6-1662

Engine Controls - 5.7L

Engine

DTC P1112 Intake Air Temperature (IAT) Sensor Circuit Intermittent Low Voltage
.. - - - - - - - - , Powertrain

r
sv

I
I
I

IAT

I Control
I

Sensor ~ :
~ig_'.!al _ _ _ _ _ _ .,

Module
(PCM)

>

8IC2
TA: 472

rn
A

Intake

Air
Temperature
(IAT)

Sensor

PPL 719

21 C1
.. - - - - - - - - - - - - - - - , Powertrain
I Control
I
PCM
I M dule
I
IAT
c1 =RED
C2=BLU
I
O
I
Sensor
{PCM)

Ground

>

L---------------.1 ~
218499

Circuit Description
The Intake Air Temperature (IAT) sensor contains a
semiconductor device which changes resistance based
on temperature (a thermistor). The IAT sensor
mounts in the air intake passage of the engine air
induction system. The IAT sensor has a signal circuit
and a ground circuit. The PCM applies a voltage
(about 5.0 volts) on the signal circuit to the sensor.
The PCM monitors changes in this voltage caused by
changes in the resistance of the sensor in order to
determine the intake air temperature.
When the intake air is cold, the sensor (thermistor)
resistance is high, and the PCMs signal voltage is only
pulled down a small amount through the sensor to
ground. The PCM senses a high signal voltage
(low temperature). When the intake air is warm, the
sensor resistance is low, and the signal voltage
is pulled down a greater amount. This causes the PCM
to sense a low signal voltage (high temperature).
When the PCM senses a signal voltage lower than the
normal operating range of the sensor, this DTC sets.

Conditions for Running the DTC

DTCs P0102, P0103, P0117, P0118, P0500,
P0502, P0503 are not set.
The engine run is greater than 30 seconds.
The vehicle speed is greater than
40 km/h (25 mph).

Conditions for Setting the DTC

The intake air temperature is greater
than 139C (282F).
All conditions exist for 0.3 second.

Action Taken When the DTC Sets

The PCM stores the DTC information into memory
when the diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL) will not
illuminate.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Failure Records.

Conditions for Clearing the MIUDTC

A History DTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other non-emission related diagnostic.
A last test failed (Current DTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
If the engine sat overnight, the engine coolant
temperature and intake air temperature values should
display within a few degrees of each other. If the
temperatures are not within 3C (5F), refer to
Temperature vs Resistance.
For an intermittent, refer to Symptoms.

(
\

Engine Controls - 5.7L 6-1663

Engine
Test Description

The numbers below refer to the step numbers on the

diagnostic table.

4. When moving the related wiring harnesses,

visually/physically inspect the wiring for the
following:

2. If DTC P0112 failed this ignition, this indicates a

hard failure is present. When a hard failure is
present, both the hard and intermittent DTCs set.

Wire insulation that is rubbed through, causing

an intermittent short.

3. When moving related connectors,

visually/physically inspect connectors for the
following:
Poor mating of the connector halves or a
terminal not fully seated in the connector body
(backed out).
Improperly formed or damaged terminals.
Carefully reform or replace all connector
terminals in the related circuits in order to
insure proper terminal contact tension.
Poor terminal to wire connection. Inspect for
poor crimps, crimping over yvire insulation
rather thah the wire.
Dirt or corrosion on the terminals. Inspect for
missing connector seals and for damage to
the connector seals.

5. Using the Freeze Frame and/or Failure Records

data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the DTC failed. For any test
that requires probing the PCM or component
harness connectors, use the Connector Test
Adapter Kit J 35616-A. Using this kit prevents any
damage to the harness connector terminals.

Wiring broken inside the insulation.

DTC P1112 Intake Air Temperature (IAT) Sensor Circuit Intermittent Low Voltage
Value(s)

Action

Step

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to
OTC P0112
Intake Air
Temperature
(IA T) Sensor
Circuit Low
Voltage

Go to Step 3

Go to Step 6

Go to Step 4

Go to Step 7

Go to Step 5

Did OTC P0112 also set?

Yes

1. Turn ON the ignition leaving the engine OFF.

.3

2. Observe the affected sensor value on a scan tool

while moving related harness connectors (at the
component and the PCM).

Does the sensor value change abruptly while a related

connector is being mo:ved?

Observe the affected sensor value qn a scan too.I while

moving the related wiring harnesses.
Does the sensor value change abruptly while moving the
related electrical harnesses?

6-1664

Engine

Engine Controls - 5.7L

OTC P1112 Intake Air Temperature (IAT) Sensor Circuit Intermittent Low Voltage (cont'd)
Step

Action

Value(s)

Yes

No

Go to Step 8

Go to
Diagnostic Aids

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this OTC and observe the parameters.

'

3. Turn OFF the ignition for 15 seconds.

4. Start the engine.

5. Operate the vehicle within the conditions required for

this diagnostic to run, and as close to the conditions
recorded in the Freeze Frame/Failure. Records as
possible. Special operating conditions that you need
to meet before the PCM will .run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.

'

6. Select the Diagnostic Trouble Code (OTC) option, the

Specific OTC option, then enter the OTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

Repair the damage connectors/terminals following the

Repair Procedures in Connector Repairs ih Wiring
Systems
Is the actioncomplete?

Go to Step 9

Repair the faulty wiring. Refer to Wiring Repairs in Wiring ,

Systems.

Go to Step 9

Is the action complete?

1. Re-inspect all the related circuits and the connectors.

2. Replace the sensor/component if all the circuits have

been tested thoroughly and no faults can be found.

Is the action complete?

Go to Step 9

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (OTC) option and

9

the Specific OTC option, then enter the OTC number

using the scan tool.

4. Operate the vehicle within the Conditions for Running

the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

10

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

'

Go to Step 10

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5.7L

6-1665

DTC P1114 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent Low Voltage

J
--J;r;,s~r - ------ i

'" - - - - - - - - - - - - - , Powertrain
I Control
sv
,
lad
I
.&
ECT
1v10 Ue
~

I
I

'

(PCM)

'

UiJ

49 C2

... - ., Instrument
I
I
YEL 410

A1L7-I

I Cluster
I~
..1

DKGRN 135

C rGRN J135

I-

[ ]

, A.

2;~~il~~.

Temperature
(ECT)
Sensor

BAN 718

25.

C2

... - - - ..;f - - - - - - - , Powertrain

. 1
,.1
I

.t.

ECT

Sensor

Ground

PCM

C1=RED

C2=BLU

I Control
IM
I

d I
ue

(PCM)

.&

L------------.1
218500

Circuit Description
The Engine Coolant Temperature (ECT) sensor
contains a semiconductor device which changes
resistance based on ternpetature (a thermistor). The
ECT sensor mounts in the left bank cylinder head near
the front of the engine. The ECT sensor has a
signal circuit and a ground circuit. The PCM applies a
voltage (about 5.0 volts) on the signal circuit to the
sensor. The PCM monitors changes in this voltage
caused by changes in the resistance of the sensor in
order to determine the.engine coolant temperature.
When the engine coolant is cold, the sensor
(thermistor) resistance is high, and the PCMs signal
voltage is only pulled down a small amount through the
sensor to ground. The PC~ ~enses a high signal
voltage (low temperature). When the engine coolant is
warm, the sensor resistance is low, and the signal
voltage is pulled down a greater amount. This causes
the PCM to sense a low signal voltage (high
temperature).
This DTC sets when the PCM senses a signal voltage
lower than the normal operating range of the sensor.

Conditions for Running the DTC

The engine run time is greater than 1O seconds.

Conditions for Setting the DTC

The Engine Coolant Temperature is greater
than 139C (282F) for less than a second.

Action Taken When the DTC Sets

The PCM stores the DTC information into memory
when the diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL) will not
illuminate;
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Failure Records.

Conditions for Clearing the MIUDTC

A History DTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other .non-emission related diagnostic.
A last test failed (Current DTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Electromagnetic interference (EMI) can cause an
intermittent DTC. Inspect the related circuits for
being too close to secondary ignition wires and the
generator.
If the engine sat overnight, the engine coolant
temperature and intake air temperature values
should display within a few degrees of each other.
If the temperatures are not within 3C (5F),
refer to Temperature vs Resistance.
For an intermittent, refer to Symptoms.

61666

Engine Controls .. 5. 7L

Test Description
The numbers below refer to the step numbers on the
diagnostic table.

Engine
4. When moving the related wiring harnesses,
visually/physically inspect the wiringJor the
following:

2. If OTC P0117 failed this ignition, this indicates a

hard failure is present. When a hard failure is
present, both the hard and intermittent DTCs set.
3. When moving related connectors,
visually/physically inspect connectors for the
following:
Poor mating of the connector halves or a
terminal not fully seated in the connector body
(backed out).
Improperly formed or damaged terminals.
Carefully reformed or replaced all connector
terminals in the related circuits in order to
insure proper terminal contact tension.
Poor terminal to wire connection. Inspect for
poor crimps, crimping over wire insulation
rather than the wire.
Dirt or corrosion on the terminals. Inspect the
connector seals for being there and for being
damaged.

Wire insulation that is rubbed through, causing

an intermittent short.

Wiring broken inside the insulation.

5. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the OTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the OTC failed. For any test
that requires probing the PCM or component
harness connectors, use the Connector Test
Adapter Kit J 35616-A. Using this kit prevents any
damage to the harness connector terminals.

DTC P1114 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent Low Voltage
Step

Action

Value(s)

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to
OTC P0117
Engine Coolant
Tempf:Jrature
(ECT) Sensor
Circuit LQW
Voltage

Go to Step 3

Go to Step 6

Go to Step 4

Go to Step 7

Go to Step 5

1. Install a scan tool.

2. Idle the engine,
2

Yes

3. Monitor the Diagnostic Trouble Code Information

(OTC) information using the scan tool.
Did OTC P0117 fail this ignition cycle?
1. Turn ON. the ignition leaving the engine OFF.

2. Observe the affected sensor value on the scan tool

3

while moving the related harness connectors (at the

component and the PCM).
Does the sensor value change abruptly while a related
connector is being moved?
Observe the affected sensor value on the scan tool while
moving the related wiring harnesses.
Does the sensor value change abruptly while moving the
related electrical harnesses?

Engine Controls - 5.7L

Engine

6-1667

OTC P1114 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent Low Voltage (cont'd)
Action

Step

Value(s)

Yes

No

Go to Step 8

Go to
Diagnostic Aids

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this DTC and observe the parameters.

3. Turn OFF the ignition for 15 seconds.

4. Start the engine.

5. Operate the vehicle within the conditions required for

this diagnostic to run, and as close to the conditions
recorded in the Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the DTC.

6. Select the Diagnostic Trouble Code {DTC) option, the

Specific DTC option, then enter the DTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

Repair the damage connectors/terminals. Refer to

Repairing Connector Terminals in Wiring Systems.

Repair the faulty wiring. Refer to Wiring Repairs in Wiring

Systems.

Go to Step 9

Is the action complete?

Go to Step 9

Is the action complete?

1. Re-inspect all the related circuits and the connectors.

2. Replace the sensor/component if all the circuits have

been tested thoroughly and no faults can be found.

Go to Step 9

Is the action complete?

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code {DTC) option and

9

the Specific DTC option, then enter the DTC number

using the scan tool.

4. Operate the vehicle within the Conditions for Running

the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

10

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 10

Go to Step 2

Go to the
applicable
DTC table

System OK

6-1668

Engine Controls - 5.7L

Engine

OTC Pt115 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent High Voltage

J
- - -;r;,s~r - - - - - - -

.. - - - - - - - - - - - - - , Powertrain
I
sv
I Control
I
ECT
I Module >,

~ (PCM) ~

49 C2

.. - ., Instrument
I
I

I Cluster
I >,

A1L7-I ~

YEL 410

.J

DKGRN 135

C rGRNJ135

[I]
I
A

-=-

~~~l~~t

Temperature
(ECT)

Sensor

BRN 718

25

C2

.. - - - - f' - - - - - - - , Powertrain
I

I
I

jt
.,,.

ECT
Sensor

Gmu~

PCM

c1 = RED

C2=BLU

I Control

Module

I (PCM)
I

>,

i,,~

L------------..1
218500

Circuit Description
The Engine Coolant Temperature (ECT) sensor
contains a semiconductor device which changes
resistance based on temperature (a thermistor). The
ECT sensor mounts in the left bank cylinder head near
the front of the engine. The ECT sensor has a
signal circuit and a ground circuit. The PCM applies a
voltage (about 5.0 volts) on the signal circuit to the
sensor. The PCM monitors changes in this voltage
caused by changes in the resistance of the sensor in
order to determine the engine coolant temperature.
When the engine coolant is cold, the sensor
(thermistor) resistance is high, and the PCMs signal
voltage is only pulled down a small amount through the
sensor to ground. The PCM senses a high signal
voltage (low temperature). When the engine coolant is
warm, the sensor resistance is low, and the signal
voltage is pulled down a greater amount. This causes
the PCM to sense a low signal voltage (high
temperature).
When the PCM senses a signal voltage higher than
the normal operating range of the sensor, this
OTC sets.

Conditions for Setting the OTC

Engine operates longer than 60 seconds.

Conditions for Setting the OTC

The engine coolant temperature is less than
-35C (-31 F) for less than a second.

Action Taken When the OTC Sets

The PCM stores the OTC information into memory
when the diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL) will not
illuminate.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Failure Records.

Conditions for Clearing the MIUDTC

A History OTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other non-emission related diagnostic.
A last test failed (Current OTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
Electromagnetic interference (EMI) can cause an
intermittent OTC. Inspect the related circuits for
being too close to secondary ignition wires and the
generator.
If the engine sat overnight, the engine coolant
temperature and intake air temperature values
should display within a few degrees of each other.
If the temperatures are not within 3C (5F),
refer to Temperature vs Resistance.
For an intermittent, refer to Symptoms.

Engine Controls - 5.7L 6-1669

Engine
Test Description

The numbers below refer to the step numbers on the

diagnostic table.
2. If OTC P0118 failed this ignition, this indicates a
hard failure is present. When a hard failure is
present, both the hard and intermittent OTCs set.
3. When moving related connectors,
visually/physically inspect connectors for the
following:
Poor mating of the connector halves or a
terminal not fully seated in the connector body
(backed out).
Improperly formed or damaged terminals.
Carefully reformed or replaced all connector
terminals in the related circuits in order to
insure proper terminal contact tension.
Poor terminal to wire connection. Inspect for
poor crimps, crimping over wire insulation
rather than the wire.
Dirt or corrosion on the terminals. Inspect the
connector seals for being there and for being
damaged. .

4. When moving the related wiring harnesses;i

visually/physically inspect the wiring for the
following:
Wire insulation that is rubbed through, causing
an intermittent short.
Wiring broken inside the insulation.
5. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the OTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the DTC failed; For any test
that requires probing the PCM or component
harness connectors, use theConnector Test
Adapter Kit J 35616-A. Using this kit prevents any
damage to the harness connector terminals.

DTC P1115 Engine Coolant Temperature (ECT) Sensor Circyit Intermittent High Voltage
Step

Action
Did you perform the Powertrain On-Board Diagnostic
(OBD) System Check?

Value(s)

Yes

No

Go to Step 2

Go to'A
Powertrain On
Board Diagnostic
(OBD) System
Check

1. Install a scan tool.

2. Idle the engine.
3. Monitor the Diagnostic Trouble Code (OTC)
Information using the scan tool.
Did OTC P0118 Fail This Ignition cycle?

1. Turn ON the ignition leaving the engine OFF.

2. Observe the affected sensor value on the scan tool
while moving the related harness connectors (at the
component and the PCM).
Does the sensor value change abruptly while a related
connector is being moved?

Observe the affected sensor value on the scan tool while

moving the related wiring harnesses.
Does the sensor value change abruptly while moving the
related electrical harnesses?

Go to
OTC P0118
Engine Coolant
Temperature
(ECT) Sensor
Circuit High
Voltage

Go to Step 3

Go to Step 6

Go to Step 4

Go to Step 7

Go to Step 5

,.

5.. 1570

Engine Controls .. 5.7L

Engine

DTC P1115 Engine Coolant Temperature (ECT) Sensor Circuit Intermittent High Voltage
(cont'd)
Step

Action

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this DTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Start the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in the Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the DTC.
6. Select the Diagnostic Trouble Code (DTC) option, the
Specific DTC option, then enter the DTC number
using the scan tool.

Value(s)

No

Does the scan tool indicate that this diagnostic failed this
ignition?
6

Yes

Go to Step 8

Repair the damage connectors/terminals. Refer to

Repairing Connector Terminals in Wiring Systems.
Is the action complete?

Repair the faulty wiring. Refer to Wiring Repairs in Wiring

Systems.
Is the action complete?

1. Re-inspect all the related circuits and the connectors.

2. Replace the sensor/component if all the circuits have
been tested thoroughly and no faults can be found.
Is the action complete?

Go to
Diagnostic Aids

Go to Step 9
-

Go to Step 9

Go to Step 9

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (DTC) option and

9

the Specific DTC option, then enter the DTC number

using the scan tool.
4. Operate the vehicle within the Conditions for Running
the DTC as specified in the supporting text, if
applicable.

Does the scan tool indicate that this test ran and passed?
10

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 10

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5.7L

6-1671

DTC P1121 Throttle Position (TP) Sensor Circuit Intermittent High Voltage
.. - - - - - - - - - - - - - - - - - - - - - - - - - - - - ., Powertrain
I Control
sv
I
I
TP Sensor
Fuel Tank
Module
1
SV
Pressure Sensor
(PCM)

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 5.;:'._ R,::e'::,n<:'.; _

._ _ ~fe_'.:n,:e

43 r

- - - - -

GRY 596
Antilock
Brakes
Cell44

-67

.J

C2

GRY 598

GRY

596
GRY 596

l
c

fI

Throttle (Tl')
Pos~an
Sensor

DKBLU 417

BLK 452
DKBLU
417

DK BLU 417

I
:

Antilack

B.LK
452

Brakes
Cell44

DKGRN 890

Ground
_ _ _.,. Distribution
Cell14

ORN/BLK 469

23

,- -

Sensor
Signal

ORN/BLK 469

BLK 452

12
~ TP

52 C2

l_ - - - - - - - - - - Fuel Tank -

Sensor
Ground

Pressure
Sensor
Signal

75 C1
-

-1 - ~

Sensor
Ground

PCM -

~ Powertrain

C1= RED
2 =BLU

Control

I Module
:

(PCM)

1---------------------------------------.J~
218503

Circuit Description

Conditions for Running the DTC

The Throttle Position (TP) sensor is a potentiometer.

The TP sensor is mounted to the left side of the
throttle body. The TP sensor provides a voltage signal
that changes relative to throttle blade angle. This
signal voltage is one of the most important inputs used
by the PCM. The TP sensor has a 5.0 volt reference,
a ground and a signal circuit.
TP sensor Signal voltage should be about 0.6 volt at
idle. The TP sensor voltage should increase to
above 4.0 volts at wide open throttle (WOT).
When the PCM senses a signal voltage higher than
the normal operating range of the sensor, this
DTC will set.

The ignition switch is in the Run position.

Conditions for Setting the DTC

The TP sensor voltage is greater than 4.8 volts.
All the conditions present for 3.5 minutes.

Action Taken When the DTC Sets

The PCM stores the DTC information into memory
when the diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL} will not
illuminate.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Failure Records.

6-1672

Engine Controls - 5.7L

Conditions for Clearing the MIUDTC

A History OTC will clear after forty consecative
warm-up cycles, if no failures are reported by
this or any other non-emission related diagnostic.
A last test failed (Current OTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
An intermittent OTC can be caused by electromagnetic
interference (EMI). Inspect related circuits for being
too close to secondary ignition wires. and the
alternator.
For an intermittent, refer to Symptoms.

Test Description
Number(s) below refer to step numbers on the
diagnostic table.
2. If OTC P0123 failed this ignition, indicates a hard
failure is present. When a hard failure is present,
both the hard and intermittent OTCs will set.
3. When moving related connectors,
visually/physically inspect connectors for the
following:
Poor mating of the connector halves or a
terminal not fully seated in the connector body
(backed out).
Improperly formed or damaged terminals. All
connector terminals in the related circuits
should be carefully reformed or replaced to
insure proper contact tension.

Engtne
Poor terminal to wire connection. Inspect for
poor crimps, crimping over wire insulation
rather than the wire:
Dirt or corrosion on terminals. Inspect
connector seals for being there and for being
damaged.
4. When moving related wiring harnesses,
visually/physically inspect wiring for the following:
Wire insulation that is rubbed through,
causing an intermittent short.
Wiring broken inside the insulation.
5. Using Freeze Frame and/or Failure Records data
may aid in locatin,gan intermittent condition. If
the OTC cannot be duplicated, the.. information
included in the Freeze Frame and/or Failure
Records data can be useful in determining how
many miles since the OTC set. The Fail Counter
and Pass Counter can also be used to determine
how many ignition cycles the. diagnostic
reported a pass and/or a fail. Operate vehicle
within the same freeze frame conditions (RPM,
load; vehicle speed, temperature etc.) that
were noted. This will isolate when the OTC failed.
If this OTC runs and passes the diagnostic, the
scan tool will not indicate any information
under DTC Status.

DTC P1121 Throttle Position (TP} Sensor Circuit Intermittent High Voltage
Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Goto
DTCP0123
Throttle Position
(TP) Sensor
Circuit High
Voltage

Go to Step 3.

Go to Step 6

Go to Step 4.

Go to Step 7

Go to Step 5

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

1. Install the scan tool.

2. Start and idle the engine.
3. Monitor the Diagnostic Trouble Code (OTC)
information using the scan tool.
Did OTC P0123 fail this ignition cycle?

1. Turn the ignition ON, leaving the engine OFF.

2. Using a scan tool, observe affected sensor value
while moving related harness connectors (at
component and PCM).
Does sensor value change abruptly while a related

connector is being moved?

Using a scan tool, observe affected sensor value while

moving related wiring harnesses.
Does sensor value change abruptly while moving related

electrical harnesses?

Engine

Engine Controls - 5.7L

6-1673

DTC P1121 Throttle

Position (TP) Sensor Circuit Intermittent High Voltage (cont'd)
'
Step

Action

1. Turn the ignition ON, engine OFF, review Freeze

Frame and/or Failure Records data for this OTC and
note parameters.
2. Turn the ignition OFF for 15 seconds.
3. Start the engine and operate the vehicle within the
conditions required for this diagnostic to run, and as
close to the conditions recorded in Freeze
Frame/Failure Record$ as possible. Special operating
conditions that need to be met before the PCM will
run this diagnostic, where applicable, are listed in
Conditions for Running ttie OTC.
4. Using the scan tool, select OTC, Specific, then enter
the OTC number which was set.
Does the scan tool indicate that this diagnostic failed this
ignition?

Repair the damage connectors/terminals. Refer to

Repairing Connector Terminals in Wiring Systems.
Is the action complete?

Repair the faulty wiring. Refer to Wiring Repairs in Wiring

Systems.

Value(s)

)
9

10

No

Go to Step B

Go to
Diagnostic Aids

Go to Step 9

Go to Step 9

Is the action complete?

Yes

1. Re-inspect all related circuits and connectors.

2. If all the circuits have been tested thoroughly and no
faults can be found, replace the sensor/component.
Is the action complete?

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate theveh.icle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the $Can tool display any DTCs that you have not
diagnosed?

Go to Step 9

Go to Step 10

Go to Step 2

Go to the
applicable
OTC table

System OK

'"'

6-1674

Engine

Engine Controls - 5.7L

OTC P1122 Throttle Position (TP} Sensor Circuit Intermittent Low Voltage
r - -

5V

TP Sensor

~ -

43 '

Powertrain
I Control

.,

Module
1 (PCM)
~

>

LJJ

JJ4.

67 C2

GAY 596
~

Fuel Tank
Pressure Sensor
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~R:;e~n<;: _

I
5V
~ _ ~e~n.:_e

Antilock
Brakes
Cell 44

GRY 598

GRY
596
GRY 596
A

l
c"
DKBLU 417

irrome

: Posttion (TP)
Sensor

B,
BLK 452

DKBLU
417

DKBLU 417

I
:

BLK
452

ORN/BLK 469

--

..

Antilock
Brakes
Cell44

DKGRN 890

Sensor
Signal

23

~~---------

52
~------------------------Fuel Tank -

Sensor
Ground

Ground
- - -... Distribution
Cell14

ORN/BLK 469

BLK 452

1----------------!
1

12
~ TP

Pressure
Sensor
Signal

75 C1

C2

Sensor
Ground

PCM -

~ Powertra1n

C1= RED
c 2 =BLU

I
:

Control
Module
(PCM)

I>

~--------------------------------------J~
218503

Circuit Description

Conditions for Setting the DTC

The Throttle Position (TP) sensor is a potentiometer.

The TP sensor is mounted to the left side of the
throttle body. The TP sensor provides a voltage signal
that changes relative to throttle blade angle. This
signal voltage is one of the most important inputs used
by the PCM. The TP sensor has a 5.0 volt reference,
a ground and a signal circuit.
TP sensor Signal voltage should be about 0.6 volt at
idle. The. TP sensor voltage should increase to
above 4.0 volts at wide open throttle (WOT).
When the PCM senses a signal voltage lower than the
normal operating range of the sensor, this OTC
will set.

TP sensor voltage is less than 0.2 volts for 0.3 second.

Conditions for Setting the DTC

TP sensor voltage is less than 0.2 volts.
All above conditions are present for greater
than 3.5 minutes.

Action Taken When the DTC Sets

The PCM stores the OTC information into memory
when the diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL) will not
illuminate.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Failure Records.

Engine

Engine Controls - 5.7L

Conditions for Clearing the MIL/DTC

)
I

A History DTC will clear after forty consecutive

warm-up cycles, if no failures are reported by
this or any other non-emission related diagnostic.
A last test failed (Current DTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
An intermittent DTC can be caused by electromagnetic
interference (EMI). Inspect related circuits for being
too close to secondary ignition wires and the
alternator.
For an intermittent, refer to Symptoms.

Test Description
Number(s) below refer to step numbers on the
diagnostic table.
2. If DTC P0122 failed this ignition, indicates a hard
failure is present. When a hard failure is present,
both the hard and intermittent DTCs will set.
The engine must be operating longer than 30
seconds before the DTC sets.
3. When moving related connectors,
visually/physically inspect connectors for the
following:
Poor mating of the connector halves or a
terminal not fully seated in the connector body
(backed out).
Improperly formed or damaged terminals. All
connector terminals in the related circuits
should be carefully reformed or replaced to
insure proper contact tension.

6-1675

Poor terminal to wire connection. Inspect for

poor crimps, crimping over wire insulation
rather than the wire.
Dirt or corrosion on terminals. Inspect
connector seals for being there and for being
damaged.
4. When moving related wiring harnesses,
visually/physically inspect wiring for the following:
Wire insulation that is rubbed through,
causing an intermittent short.
Wiring broken inside the insulation.
5. Using Freeze Frame and/or Failure Records data
may aid in locating an intermittent condition. If
the DTC cannot be duplicated, the information
included in the Freeze Frame and/or Failure
Records data can be useful in determining how
many miles since the DTC set. The Fail Counter
and Pass Counter can also be used to determine
how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate vehicle
within the same freeze frame conditions (RPM,
load, vehicle speed, temperature etc.) that
were noted. This will isolate when the DTC failed.

OTC P1122 Throttle Position (TP) Sensor Circuit Intermittent Low Voltage
Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to
DTCP0122
Throttle Position
(TP) Sensor
Circuit Low
Voltage

Go to Step 3

Go to Step 6

Go to Step 4

Go to Step 7

Go to Step 5

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

1. Install the scan tool.

2. Start and idle the engine.

3. Monitor the Diagnostic Trouble Code (DTC)

information using the scan tool.

Did DTC P0123 fail this ignition cycle?

1. Turn the ignition ON, leaving the engine OFF.

2. Using a scan tool, observe affected sensor value

while moving related harness connectors (at
component and PCM).

Does sensor value change abruptly while a related

connector is being moved?

Using a scan tool, observe affected sensor value while

moving related wiring harnesses.
Does sensor value change abruptly while moving related
electrical harnesses?

6-1676

Engine

Engine Controls - 5.7L

DTC P1122 Throttle Position {TP) Sensor Circuit Intermittent Low Voltage (cont'd)
Value(s)

Step

Action

1. Turn the ignition ON, engine OFF, review Freeze

Frame and/or Failure Records data for this OTC and
note parameters.
2. Ignition OFF for 15 seconds.
3. Start the engine and operate the vehicle within the
conditions required for this diagnostic to run, and as
close to the conditions recorded in Freeze
Frame/Failure Records as possible. Special operating
conditions that need to be met before the PCM will
run this diagnostic, where applicable, are listed in
Conditions for Running the OTC.
4. Using the scan tool, select OTC, Specific, then enter
the OTC number which was set.
Does the scan tool indicate that this diagnostic failed this
ignition?

Repair the damaged connectors/terminals. Refer to

Repairing Connector Terminals in Wiring Systems.
Is the action complete?

Repair the faulty wiring. Refer to Wiring Repairs in Wiring

Systems.
Is the action complete?

1. Re-inspect all the related circuits and connectors.

2. If all the circuits have been tested thoroughly and no
faults can be found, replace the sensor/component.
Is the action complete?

10

Yes

No

Go to Step 8

Goto
Diagnostic Aids

Go to Step 9

Go to Step 9

Go to Step 9

1. Select the Diagnostic Trouble Code (DTC) option and

the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (DTC) option and
the Specific DTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 10

Go to Step2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5. 7L 6-1677

DTC P1133 H02S Insufficient Switching Bank 1 Sensor 1

!Hot \JI/Ith lgn 1 Energized' f

P:;-w;

I"' -

- - , Underhood

Distribution
ee1110

J7
J6

I. -

I Electrical
1Center 2
1

ENG SEN
Fuse 10
20 A
-

_, .I

PNK 539
Fuse Block
Details
Cell11

+--- .....

PNK 539
.....

~------------------------ -

- - - - - -,
I

'" -

PNK 539

High

PPWW:~
D

-;,

-;;-k :;;- - - - - - - - - - - - - -

I
Left Front
I
I H02S
H02S
Low

PCM

;n;;-#~ - - ., Powertrain
Left Rear

C1:RED
C2=BLU

H02S
High

H02S

Low

I Control
I Module
I (PCM)

,:~~H~ ,~- ~~~~~::F:Nm~:1:~ A

Bank #2
Right Front H02S #1
Right Rear H02S #2

c
BLK 450

Bank #1
Left Front
Heated Oxygen
Sensor (H02S) # 1

BLK 450

Bank #1
Left Rear
Heated Oxygen
Sensor (H02S) # 2

I
'-------------------------.. -

_J

---------~
218508

Circuit Description

The engine run time is greater than 2.0 seconds.

The PCM monitors the Heated Oxygen Sensor

(H02S) activity for 100 seconds. During this monitor
period the PCM counts the number of times that
the H02S switches from rich to lean and lean to rich.
A DTC P1133 sets when the PCM determines that
the H02S did not switch enough times.
A lean to rich switch is determined when the H02S
voltage changes from less than 300 mV to greater
than 600 mV. A rich to lean switch is determined when
the H02S voltage changes from more than 600 mV
to less than 300 mV.

The engine speed is greater than 1000 RPM

but less than 2300 RPM.

Conditions for Running the OTC

DTCs P0102, P0103, P0112, P0113, P0117,

P0118, P0125, P0335, P0336, P0351P0358, P1258 not set.
The fuel system is operating in Closed Loop.

The ignition voltage is greater than 9.0 volts.

The engine coolant temperature is greater
than 65C (149F).
The MAF is between 15 g/s and 35 g/s.
The EVAP purge duty cycle is greater than 0%.

Conditions for Setting the OTC

The PCM determines that within 100 seconds the
H02S lean to rich switches are less than 30 and rich
to lean switches are less then 30.

6-1678

Engine Controls - 5.7L

Action Taken When the DTC Sets

The PCM illuminates the Matfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
th~ Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A, last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Inspect the H02S signal circuit for being shorted
to a PCM ground. The H02S signal circuit
shorted to a PCM ground will not cause a H02S
low DTC to set, but will set a switching DTC.
A malfunction in the H02S heater circuits will
cause a DTC P1133 to set. Test the H02S heater
circuits for intermittent opens/connections.
An oxygen supply inside the H02S is necessary
for proper operation. This supply of oxygen is
provided through the H02S wires. All H02S wires
and connections should be inspected for breaks
or contamination. Refer to H02S Wiring Repairs In
Wiring Systems.

Engine
Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If the DTC cannot be duplicated, the information
included in the Freeze Frame and/or Failure
Records data can be useful in determining how
many miles since the DTC set. The Fail Counter
and Pass Counter can also be used to determine
how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate vehicle
within the same freeze frame conditions (RPM,
load, vehicle speed, temperature etc.) that
you observed. This will isolate when the DTC
failed.
For an intermittent, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step determines if the fault is present. This
test may take 5 minutes for the diagnostic
to run.
3. DTCs P1133 and P1153 setting at the same time
.is a good indication that a fuel contamination
condition is present.
4. An exhaust leak 6 to 12 inches away from the
H02S can cause a DTC to set.
6. This step tests whether a good ground circuit is
available.
7. This step tests the integrity of the signal circuit to
the PCM.
8. Certain RTV silicone gasket materials give off
vapors that can contaminate the H02S. There
is also a possibility of silicone contamination
caused by silicone in the fuel. If the sensors
appear contaminated by silicone and all the
silicone sealant is a non-silicone base, advise the
customer to try a different fuel company. A
missing fuel filler restrictor, indicates the customer
may have used leaded fuel.

Engine Controls - 5.7L

Engine

6-1679

DTC P1133 H02S Insufficient Switching Bank 1 Sensor 1

Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

Did the scan tool also indicate P1153 test failed?

1. Inspect the exhaust system for leaks. Refer to

Exhaust Leakage in Engine Exhaust.
2. If you find an exhaust leak, repair the exhaust as
necessary.
Did you isolate an exhaust leak?

Visually/physically inspect the following items:

Ensure that the H02S is securely installed.
Inspect for corrosion on the terminals.
Test the terminal tension at the H02S and at the
PCM. Refer to lntermittents and Poor Connections
Diagnosis in Wiring Systems.
Inspect for damaged wiring. Refer to Wiring Repairs in
Wiring Systems.
Did you find a condition in any of the above areas?

1. Disconnect the Bank 1 H02S 1.

2. Jumper the H02S low (PCM side) signal circuit to a
ground.
3. Monitor the Bank 1 H02S 1 voltage using the
scan tool.
Is the H02S voltage within the specified range?
1. Jumper the Bank 1 H02S 1 high and low (PCM side)
signal circuits to a ground.
2. Monitor the Bank 1 H02S 1 voltage using the
scan tool.
Is the H02S voltage below the specified value?

Yes

No

Go to Step 2

Goto A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to
Diagnostic Aids

Go to Step B

Go to Step 4

Go to Step 13

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 7

Go to Step 10

Go to Step 12

Go to Step 11

Important: If any DTCs are set (Except P1153), refer to

those DTCs before proceeding with this diagnostic table.
1. Install a scan tool.
2. Idle the engine at the normal operating temperature.
3. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
4. Monitor the Diagnostic Trouble Code (DTG)
Information using the scan tool.
Does the scan tool indicate DTC P1133 test failed?

Value(s)

350-550 mV

200mV

Important: Before replacing a sensor, determine and

correct the cause of the contamination. Inspect for the
following conditions:
Fuel contamination. Refer to
Alcohol/Contaminants-in-Fuel Diagnosis.
Use of improper RTV sealant.
Engine oil/coolant consumption.
Replace the affected Heated Oxygen sensor. Refer to
H02S Replacement - Bank 1 or H02S Replacement Bank 2.
Is the action complete?

Repair the condition as necessary.

Is the action complete?

Go to Step 13
Go to Step 13

6-'1680

Engine Controls,..; 5;7l

Engine

DTC P1133 H02S Insufficient Switching Bank 1 Sensor 1 . {cont'd)

Step

10

11

Action

Repair the open Bank 1 H02S 1 low signal circuit or

grounded Bank 1 H02S 1 high signal circuit. Refer to
Wiring .Repairs in Wiring Systems.
Is the action complete?
Repair the open Bank 1 H02S 1 high signal circuit or
faulty PCM connections. Refer to Wiring RepaiFS or
lntermittents and Poor Connections Diagnosis ih Wirini;J'
Systems.

Value(s)

Yes

12

13

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine aUhe normal operating temperature.
3. Seiect the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
,.
applicable.

14

Go to Step 13

Go to Step 13

..

Go to Step 13

Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

.:

Is the action complete?

Replace the Bank 1 H02S 1. Refer to H02S Replacement
'
- Bank 1.
Is the action complete?

No

Go to Step 14

Go to Step 2

Go to the
applicable
OTC table

System OK

'

Engine

Engine Controls - 5.7L

6-1681

DTC P1134 H02S Transition Time Ratio Bank 1 Sensor 1

!Hot With lgn 1 Energized !

'"-p:;-,,,;- - - - - - - - -

'

I..

Distribution
Cell 10

J7

ENG SEN
Fuse 10
20 A

,Underhood
I Electrical
I Center 2

____________ ..I
J6

L'..tiJ

PNK 539
Fuse Bibel<
Details
Cell11

,...- - -~

'

PNK 539

--------,
I

.
Bank #2
Right Front H02S #1
Right Rear H02S #2

c
BLK 450

Bank #1.
Left .Front
Heated Oxygen
Sensor (H02S) #1

c
BLK 450

Bank #1
Left Rear
Heated Oxygen
Sensor (H02S) # 2

' - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .J

'
-----------....

BLK 450' "-- - - - - - - _...,.

Ground
Distribution
Celf 14

218508

Circuit Description

The engine run time is greater than 2.0 seconds.

The engine speed is greater than 1000 RPM
but less than 2300 RPM.
The ignition voltage is greater than 9.0 volts.
The engine coolant temperature is greater
than 65C (149F).
The MAF is between 15 g/s and 35 g/s.
The EVAP purge duty cycle is greater than 0%.

The PCM monitors the Heated Oxygen Sensor

(H02S) activity. During the monitor period the PCM
counts the number of times that the H02S responds
from rich to lean and from lean to rich and adds
the amount of time it took to complete all transitions.
With this information, an average time for all transitions
can be determined. The PCM then divides the rich
to lean average by the lean to rich average to obtain a
ratio. A DTC P1134 sets if the H02S ratio is not
within range.

Conditions for Setting the DTC

Conditions for Setting the DTC

The PCM determines that the H02S transition time

ratio is not at the expected value.

DTCs P0102, P0103, P0112, P0113, P0117,

P0118, P0125, P0335, P0336, P0351P0358, P1120, P1220, P1221, P1258 not set.
The fuel system is operating in Closed Loop.

Engine Controls - 5.7L

Engine

Action Taken When the DTC Sets

An oxygen supply inside the H02S is necessary

for proper operation. This supply of oxygen is
provided through the H02S wires. All H02S wires
and connections should be inspected for breaks
or contamination. Refer to H02S Wiring Repairs In
Wiring Systems.
For an intermittent, refer to Symptoms.

6-1682

The PCM illuminates the Malfunction Indicator

Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIL/DTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If the DTC cannot be duplicated, the information
included in the Freeze Frame and/or Failure
Records data can be useful in determining how
many miles since the DTC set. The Fail Counter
and Pass Counter can also be used to determine
how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate vehicle
within the same freeze frame conditions (RPM,
load, vehicle speed, temperature etc.) that
you observed. This will isolate when the DTC
failed.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step determines if the fault is present. This
test may take 5 minutes for the diagnostic
to run.
3. When DTCs P1134 and P1154 are set at the
same time, is good indication that a fuel
contamination condition is present.
4. An exhaust leak 6 to 12 inches away from the
H02S can cause a DTC to set.
6. This step tests whether a good ground circuit is
available.
7. This step tests the integrity of the signal circuit to
the PCM.
8. Certain ATV silicone gasket materials give off
vapors that can contaminate the H02S. There
is also a possibility of silicone contamination
caused by silicone in the fuel. If the sensors
appear contaminated by silicone and all the
silicone sealant is a non-silicone base, advise the
customer to try a different fuel company. A
missing fuel filler restrictor, indicates the customer
may have used leaded fuel.

Engine

Engine Controls - 5.7L

6-1683

DTC P1134 H02S TransitionTime Ratio Bank 1. Sensor 1

Step

Action

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to
Diagnostic Aids

Go to Step B

Go to Step 4

Go to Step 13

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 7

Go to Step 10

Go to Step 12

Go to Step 11

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

)
1

Important: If any DTCs are set (Except P1153), refer to

those DTCs before proceeding with this diagnostic table.
1. Install a scan tool.
2. Idle the engine at the normal operating temperature.
3. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
4. Monitor the Diagnostic Trouble Code (OTC)
Information using the scan tool.
Does the scan tool indicate OTC P1133 test failed?

Did the scan tool also indicate P1153 test failed?

1. Inspect the exhaust system for leaks. Refer to

Exhaust Leakage in Engine Exhaust.
2. If you find an exhaust leak, repair the exhaust as
necessary.
Did you isolate an exhaust leak?

Visually/physically inspect the following items:

Ensure that the H02S is securely installed.
Inspect for corrosion on the terminals.
Test the terminal tension at the H02S and at the
PCM. Refer to lntermittents and Poor Connections
Diagnosis in Wiring Systems.
Inspect for damaged wiring. Refer to lntermittents and
Poor Connections Diagnosis in Wiring Systems.
Did you find a condition in any of the above areas?

Value(s)

1. Disconnect the Bank 1 H02S 1.

6

2. Jumper the H02S low (PCM side) signal circuit to a

ground.
3. Monitor the Bank 1 H02S 1 voltage using the
scan tool.
Is the H02S voltage within the specified range?
1. Jumper the Bank 1 H02S 1 high and low (PCM side)
signal circuits to a ground.
2. Monitor the Bank 1 H02S 1 voltage using the
scan tool.
Is the H02S voltage below the specified value?

350-550 mV

200mV

Important: Before replacing a sensor, determine and

correct the cause of the contamination. Inspect for the
following conditions:
Fuel contamination. Refer to
Alcohol/Contaminants-in-Fuel Diagnosis.
Use of improper RTV sealant.
Engine oil/coolant consumption.
Replace the affected Heated Oxygen sensor. Refer to
H02S Replacement - Bank 1 or H02S Replacement Bank 2.
Is the action complete?

Repair the condition as necessary.

Is the action complete?

Go to Step 13
Go to Step 13

6-1684

Engine Controls - 5.7L

Engine

OTC P1134 H02S Transition Time Ratio Bank 1 Sensor 1 (cont'd)

Step

Action

10

11

12

13
'

14

Value(s)

Repair the open Bank 1 H02S 1 low signal circuit or

grounded Bank 1 H02S 1 high signal circuit. Refer to
lntermittents and Poor Connections Diagnosis in Wiring
Systems.
Is the action complete?

Repair the open Bank 1 H02S 1 high signal circuit or

faulty PCM connections. Refer to lntermittents and Poor
Connections Diagnosis or lntermittents and Poor
Connections Diagnosis in Wiring Systems.
Is the action complete?

Replace the Bank 1 H02S 1. Refer to H02S Replacement

- Bank 1.
Is the action complete?

1. Select the Diagnostic Trouble Code (OTC) option and

' the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number .
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Yes

No

Go to Step 13

Go to Step 13

Go to Step 13

Go to Step 14

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5.7L

6-1685

DTC P1153 H02S Insufficient Switching Bank 2 Sensor 1

!Hot With lgn 1 Energized !

'" - P:;-w;;; - - - - - - - - -

Distribution

I
I

ce1110

J?

ENG SEN
Fuse 10

J6

20 A

"'Underhood
I Electrical
I Center 2
I

L------------.J

Fuse Block
Details
Cell 11

..,.

__ _

'

PNK 539

' , PNK 539

' '

r-------'
'" -

I
I
I
I
I
I
I

+
Bank #1
Lett Front H02S # 1
Left Rear H02S #2

I
I
I

-B;k -; - 2
Right Front

H02S
Low

PCM
c1=RED
c2 =BLU

H02S
High

;.n; #-; - Right Rear

"'Powertrain
I Control
I Module
I (PCM)

H02S
Low

H02S
High

TAN 1671

PPL 1670

L5 -------46 ------------------1 -------41 C2.J ~

Jr.
PPL 1666
PNK 539

TAN 1667

AA

B"'

AA

PNK 539

BA

Bank #2
Right Front
Heated Oxygen
Sensor (H02S) #1

BLK 450

Bank #2
Right Rear
Heated Oxygen
Sensor (H02S) # 2

c
BLK 450

L - - - - - - - ---------------------------'

'

BLK 450' '-- ______ _..,.

-

_..,.

Ground
Distribution
Cell 14

218509

Circuit Description

The engine run time is greater than 2.0 seconds.

The PCM monitors the Heated Oxygen Sensor

(H02S) activity for 100 seconds. During this monitor
period the PCM counts the number of times that
the H02S switches from rich to lean and lean to rich.
A DTC P1153 sets when the PCM determines that
the H02S did not switch enough times.
A lean to rich switch is determined when the H02S
voltage changes from less than 300 mV to greater
than 600 mV. A rich to lean switch is determined when
the H02S voltage changes from more than 600 mV
to less than 300 mV.

The engine speed is greater than 1000 RPM

but less than 2300 RPM.

Conditions for Running the DTC

DTCs P0102, P0103, P0112, P0113, P0117,
P0118, P0125, P0335, P0336, P0351P0358, P1120, P1220, P1221, P1258 not set.
The fuel system is operating in Closed Loop.

The ignition voltage is greater than 9.0 volts.

The engine coolant temperature is greater
than 65C (149F).
The MAF is between 15 g/s and 35 g/s.
The EVAP purge duty cycle is greater than 0%.

Conditions for Setting the DTC

The PCM determines that within 100 seconds the
H02S lean to rich switches are less than 30 and rich
to lean switches are less then 30.

Engine Controls - 5.7L

Engine

Action Taken When the DTC Sets

An oxygen supply inside the H02S is necessary

for proper operation. This supply of oxygen is
provided through the H02S wires. All H02S wires
and connections should be inspected for breaks
or contamination. Refer to H02S Wiring Repairs In
Wiring Systems.

For an intermittent, refer to Symptoms.

6-1686

The PCM illuminates the Malfunction Indicator

Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.

A last test failed (current DTC) clears when the

diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Inspect the H02S signal circuit for being shorted
to a PCM ground. The H02S signal circuit
shorted to a PCM ground will not cause a H02S
low DTC to set, but will set a switching DTC.
A malfunction in the H02S heater circuits will
cause a DTC P1153 to set. Test the H02S heater
circuits for intermittent opens/connections.
Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If the DTC cannot be duplicated, the information
included in the Freeze Frame and/or Failure
Records data can be useful in determining how
many miles since the DTC set. The Fail Counter
and Pass Counter can also be used to determine
how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate vehicle
within the same freeze frame conditions (RPM,
load, vehicle speed, temperature etc.) that
you observed. This will isolate when the DTC
failed.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step determines if the fault is present. This
test may take 5 minutes for the diagnostic
to run.
3. When DTCs P1133 and P1153 are set at the
same time, is good indication that a fuel
contamination condition is present.
4. An exhaust leak 6 to 12 inches away from the
H02S can cause a DTC to set.
6. This step tests whether a good ground circuit is
available.
7. This step tests the integrity of the signal circuit to
the PCM.
8. Certain RTV silicone gasket materials give off
vapors that can contaminate the H02S. There
is also a possibility of silicone contamination
caused by silicone in the fuel. If the sensors
appear contaminated by silicone and all the
silicone sealant is a non-silicone base, advise the
customer to try a different fuel company. A
missing fuel filler restrictor, indicates the customer
may have used leaded fuel.

Engine

Engine Controls - 5.7L

6-1687

OTC P1153 H02S Insufficient Switchihg Barik 2 Sensor 1

Step

!,'ction

Valu.e(s)

Yes

No

Go to Step 2.

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go toStep 3

Go to
Diagnostic Aids

Go to Step 8

Go to Step 4

Go to Step 13

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 7

Go to Step 10

Go to Step 12

Go to Step 11

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Important: If any DTCs are set (Except P1133), refer to

those DTCs before proceeding with this diagnostic table.
1. Install a scan tool.
2. Idle the engine at the normal operating temperature:
3. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
4. Monitor the Diagnostic Trouble Code (OTC)
Information using the scan tool.

Does the scan tool indicate OTC P1153 test failed?

3

Did the scan tool also indicate P1133 test failed?

1. Inspect the exhaust system for leaks. Refer to
Exhaust Leakage in Engine Exhaust.
2. If you find an exhaust leak, repair the exhaust as
necessary.

Qjd you isolate an exha1.1st leak? .

Visually/physically inspect the following items:
Ensure that the Ho2s is. securely installed.

Inspect for corrosion on the terminals.

..
- ..
.
. -~
Test the terminal tension at the H02S and at the PCM
connector. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
~

Inspect for damaged wiring. Refer to Wiring Repairs in

Wiring Systems.
Did you find a condition in any of the above areas?

1. Disconnect the Bank 2 H02S 1.

2. Jumper the H02S low (PCM side) signal circuit to a
ground.
3. Monitor the Bank 2 H02S 1 voltage using the
scan tool.
Is the H02S voltage within the specified range?
1. Jumper the Bank 2 H02S 1 high and low (PCM side)
signal circuits to a ground.
2. Monitor the Bank 2 H02S 1 voltage using the
scan tool.
Is the H02S voltage below the specified value?

350-550 mV

200mV

Important: Before replacing a sensor, determine and

correct the cause of the contamination. Inspect for the
following conditions:
Fuel contamination. Refer to
Alcohol/Contaminants-in-Fuel Diagnosis.

)
9

Use of improper RTV sealant.

Engine oil/coolant consumption.
Replace the affected Heated Oxygen sensor. Refer to
H02S Replacement - Bank 1 or H02S Replacement Bank 2.
Is the action complete?
Repair the condition as necessary.
Is the action complete?

Go to Step 13

Go to Step 13

6-1688

Engine Controls .. 5.7L

Engine

DTC. P1153 H02S Insufficient Switching Bank 2 Sensor 1 {cont'd)

Step

10

11

Action

Repair the open Bank 2 H02S 1 low signal circuit or

grounded Bank 2 H02S 1 high signal circuit. Refer to
Wiring Repairs in Wiring Systems.
Is the action complete?
Repair the ope.n Bank 2 H02S .1 high signal circuit or
faulty PCM connections. Refer to Wiring Repairs or
lntermittents and Poor Connections Diagnosis in Wiring
Systems.

Value(s)

12

13

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.

14

Does the scan tool display any DTCs that you have not
diagnosed?

No

Go to Step 13

Go to Step 13

Go to Step 13

..
'

Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Irita option
using the scan tool.

Yes

'"

Is the action complete?

Replace the Bank 2 H02S 1. Refer to H02S Replacement
- Bank 2.
Is the action complete?

Go to Step 14-.

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5.7L

6-1689

DTC P1154 H02S Transition Time Ratio Bank 2 Sensor 1

IHot With lgn 1 Energized !

.- - P:;-w;;; - - - - - - - - .,.. ., Underhood

I
I
I

Distribution
ce1110

J7
J6

I Electrical
I Center 2
I

ENG SEN
Fuse 10
20 A

Llil

L.------------..1
PNK 539

Fuse Block
Details
Cell 11

..,._ - --.
'

' , PNK 539

' '

r - - - - - - - '- - = - - - - - ~ - - - - - - - - - - - - - - - - - - - - - - ,
I
I
I
I

I
I
I
I
I
I

Bank #1
Left Front H02S #1
Left Rear H02S #2

.- - - -B;;k-;;- - - - - - - - - - - - - - ;an;#-; - - ., Powertrain

I
I
I

Right Front
H02S
Low

PCM
C1=RED
2 =BLU

H02S
High

flight Rear
H02S
Low

H02S
High

I Control
I Module
I (PCM)

L.------------------------..1
5 -----46 ------------------ ------41 C2 .~

PPL 1666

PNK 539

TAN 1667

TAN 1671

PPL 1670

PNK 539

BA

T
I
I
I
I
I

Bank #2
Right Front
Heated Oxygen
Sensor (H02S) # 1

I
I
I
I

BLK 450

Bank #2
Right Rear
Heated Oxygen
Sensor (H02S) # 2

c
BLK 450

L - - - - - - - -------------------------~

'

BLK 450' '-- ______ ~

-

Ground
Distribution
Cell 14

218509

Circuit Description
The PCM continuously monitors the Heated Oxygen
Sensor (H02S) activity for 100 seconds. During
the monitor period the PCM counts the number of
times that the H02S responds from rich to lean and
from lean to rich and adds the amount of time it took to
complete all transitions. With this information, an
average time for all transitions can be determined. The
PCM then divides the rich to lean average by the
lean to rich average to obtain a ratio. A OTC P1154
sets if the H02S ratio is not within range.

Conditions for Running the DTC

i

DTCs P0102, P0103, P0112, P0113, P0117,

P0118, P0125, P0335, P0336, P0351P0358, P1120, P1220, P1221, P1258 not set.
The fuel system is operating in Closed Loop.

The engine run time is greater than 2.0 seconds.

The engine speed is greater than 1000 RPM
but less than 2300 RPM.
The ignition voltage is greater than 9.0 volts.
The engine coolant temperature is greater
than 65C (149F).
The MAF is between 15 g/s and 35 g/s.
The EVAP purge duty cycle is greater than 0%.

Conditions for Setting the DTC

The PCM determines that the H02S transition time
ratio is not at the expected value.

5.7L

Engine

Action Taken When the DTC Sets

An oxygen supply inside the H02S. is necessary

for proper operation. This supply of oxygen is
provided through the .H02S wires. All H02S wires
and connections should be inspected for breaks
or contamination. Refer to H02S Wiring Repairs In
Wiring Systems.
For an intermittent, refer to Symptoms.

6-1690

Engine Controls

!"

The PCM illuminates the Malfunction Indicator

Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC 6tears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

:Oiagnostic Aids
Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If the OTC cannot be duplicated, the information
included in the Freeze Frame and/or Failure
Records data can be useful in determining how
many miles since the OTQ set. The Fail Counter
and Pass Counter can also be used to determine
how many ignition cycles the. diagnostic
reported a pass and/or a fail. Operate vehicle
within the same freeze frame conditions (RPM,
load, vehicle speed, temperature etc.) that
you observed. This will isolate when the OTC
failed.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.

2. This step determines if the fault is present. This

test may take 5 minutes for the diagnostic to
run. For any test that requires probing the PCM or
a component harness connector, use the
Connector Test Adapter Kit J 35616-A. Using this
kit will prevent damage to the harness connector
terminals.
3. When OTCs P1134 and P1154 are set at the
pame time, is good indication that a fuel
contamination condition is present.

4.

An exhaust leak 6 to 12 inches away from the

H02S can cause a OTC to set.

6. This step tests whether a good ground circuit is

available.
7. This step tests the integrity of the signal circuit to
the PCM.
8. Certain RTV silicone gasket materials give off
vapors that can contaminate the H02S. There
is also a possibility of silicone contamination
cau.sed by silicone in the fuel. If the sensors
appear contaminated by silicone and all the
silicone sealant is a non-silicone base, advise the
customer to try a different fuel company. A
missing fuel filler restrictor, indicates the customer
may have used leaded fuel.

Engine Controls - 5.7L

Engine

6-1691

DTC P1154 H02S' Transition Time Ratio Bank 2. Sensor 1

Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

)
1

Value(s)

Did the stan tool also indicate P1134 test failed?

1. Inspect the exhaust system for leaks. Refer to

Exhaust Leakage in Engine Exhaust.
2. If you find an exhaust leak, repair the exhaust as
necessary.
Did you isolate an exhaust leak?

Visually/physically inspect the following items:

Ensure that the H02S is securely installed,
Inspect for corrosion on the terminals.
Test the terminal tension at the H02S and at the PCM
connector. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
Inspect for damaged wiring. Refer to Wiring Repairs in
Wiring Systems.
Did you find a condition in any of the above areas?

1. Disconnect the Bank 2 H02S 1.

2. Jumper the H02S low (PCM side) signal circuit to a
ground.
3. Monitor the Bank 2 H02S 1 voltage using the
scan tool.

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to
Diagnostic Aids

Go to Step B

Go to Step 4

Go to Step 13

Go to Step 5

Go to Step 9

Go to Step 6

Go to Step 7

Go to Step 10

Go to Step 12

Go to Step 11

Important: If any DTCs are set (Except P1134), refer to

those DTCs before proceeding with this diagnostic table.
1. Install a scan tool.
2. Idle the angine at the normal operating temperature.
3. Operate the vehicle within the Conditions for Running
the DTC as specified in the supporting text, if
applicable.
4. Monitor the Diagnostic Trouble Code (DTC}
Information using the scan tool.
Does the scan tool indicate DTC P1154 test failed?

Yes

350-550 mV

Is the H02S voltage within the specified range?

1. Jumper the Bank 2 H02S 1 high and low (PCM side}
signal circuits to a ground.

2. Monitor the Bank 2 H02S 1 voltage using the

scan tool.
Is the H02S voltage below the specified value?

200mV

Important: Before replacing a sensor, determine and

correct the cause of the contamination. Inspect for the
following conditions:
Fuel contamination. Refer to
Alcohol/Contaminants-in-Fuel Diagnosis.
Use of improper ATV sealant.
Engine oil/coolant consumption.
Replace the affected Heated Oxygen sensor. Refer to
H02S Replacement - Bank 1 or H02S Replacement Bank 2.
Is the action complete?

Repair the condition as necessary.

Is the action complete?

Go to Step 13
Go to Step 13

6-1692

Engine

Engine Controls.- 5.7L

OTC P1154 H02S Transition Time Ratio Bank 2 Sensor 1 (cont'd)
Action

Step

10

Repair the open Bank 2 H02S 1 low signal circuit or

grounded Bank 2 H02S 1 high signal circuit. Refer to
Wiring Repairs in Wiring Systems.

Value(s)

11

12

Go to Step 13

Is the action complete?

Replace the Bank 2 H02S 1. Refer to H02S Replacement
- Bank 2.

No

Go to Step 13

Is the action complete?

Repair the open Bank 2 H02S 1 high signal circuit or
faulty PCM connections. Refer to Wiring Repairs or
lntermittents and Poor Connections Diagnosis in Wiring
Systems.

Yes

Go to Step 13

Is the action complete?

1. Select the Diagnostic Trouble Code (OTC) option and
the Clear OTC Information option using the scan tool.

13

2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.

4. Operate the vehicle within the Conditions for Running

the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

14

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 14

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5.7L

6-1693

OTC P1258 Engine Coolant Overtemperature - Protection Mode Active

'" - - - - - - - - - - - - - ., Powertrain
sv
I Control

ECT

I Module

It

~ ---~;~~r ~ ------ ~ (PCM) ~

LJiJ

49 C2

.. - "'Instrument
I

I Cluster

A17-I

YEL 410

.J

jt

DKGRN 135

CrGRNJ13s
6~;il;~t

[ ]

AI

"'

Temperature
(ECT)

Sensor

BRN 718
25

C2

.. - - - - 'f" - - - - - - - ., Powertrain
1

ECT

I
I

Sensor
Ground

PCM

g;:~i~

Control

I Module
I
I

(PCM)

It

L------------..1

218500

Circuit Description
In order to reduce the engine temperature the PCM
has the ability to disable a number of fuel injectors
during an engine over temperature condition. The PCM
considers the engine over temperature whenever
the ECT reaches a predetermined temperature. This
DTC sets in order to show that the PCM detected
an over temperature condition and that the system
engaged the protection mode.

Conditions for Running the DTC

DTCs P0117, P0118, P0125 are not set.
The engine is running.

Conditions for Setting the DTC

The engine coolant temperature is greater
than 132C (270F).
The above conditions present for greater
than 10.0 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

6-1694

Engine

Engine Controls - 5.7L

Diagnostic Aids

Test Description

Important: If an overheating condition exists, repair

the overheat condition and change the engine oil
and filter.
Using the Freeze Frame and/or Failure Records data
may aid in locating an intermittent condition. If you
cannot duplicate the DTC, the information included in
the Freeze Frame and/or Failure Records data can
help determine how many miles since the DTC
set. The Fail Counter and Pass Counter can also help
determine how many ignition cycles the di&gnostic
reported a pass and/or a fail. Operate the vehicle
within the same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you observed.
This will isolate when the DTC failed. For an
intermittent condition, refer to Symptoms.

The numbers below refer to the step numbers on the

diagnostic table.
1. A cooling system condition enables the engine
protection mode.

DTC P1258 Engine Coolant Overtemperature - Protection Mode Active

Step

Action

Value(s)

Yes

No

Go to Engine
Overheating in
Engine Cooling

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Engine

Engine Controls;.. 5.7L

6-1695

DTC P1336 Crankshaft Position (CKP) System Variation Not Learned

)

!Loe I

Crankshaft
Position
(CKP)
Sensor

Solid State

[S]
N

~
LTGRN 1867

YEL 573

YELi. .1868
BLK

44 C1 22

62 C2

'" - cKPS;s; - - - - - - - - - - - - - - - - - ,
I
I

i'

11

,gna npu

lReferencJje2v
~ Low

CMP Sensor

..
Ignition
Feed

PCM
C1 = RED
2
C =

El

LU

Powertrain

I Control
I M d I
I . 0 LI
1

~------~---------------J

(PCM)

.&

e ,..

218514

Circuit Description
The Crankshaft Position (CKP) sensor sends pulses to
the PCM as the reluctor wheel teeth rotate past the
CKP sensor. The PCM uses the CKP pulses to
synchronize the ignition and fuel injector operation,
and to time the interval between each CKP pulse. The
PCM determines when an excessive change in
crankshaft speed occurs by comparing each new time
interval with the previous interval. A misfire causes
an unexpected change in the crankshaft speed.
A certain amount of acceleration/deceleration is
expected between each firing stroke, but if the
crankshaft speed changes more than an expected
amount, the PCM interprets this as a misfire.
The interval between CKP sensor pulses is extremely
small. At high engine speeds, slight variations in
the following components make misfire detection
difficult:

Important: A PCM power disconnect with the ignition

ON may erase the stored pulse value and set the
OTC P1336.
Disconnecting the PCM will not erase the learned
Crankshaft Position System Variation as long as the
ignition switch is in the OFF position.
Important: Reprogramming the PCM does not require
running the Crankshaft Position System Variation
Learn Procedure unless the PCM is new or from
another vehicle.
A OTC P1336 sets if the Crankshaft Position System
Variation is not within an acceptable range, or can
not be learned.

Conditions for Running the DTC

There are no crankshaft position (CKP) or camshaft
position (CMP) sensor DTCs

Conditions for Setting the DTC

Crankshaft

The PCM has not learned the Crankshaft Position

System Variation

Reluctor wheel

Action Taken When the DTC Sets

CKP sensor
The PCM learns variations during the Crankshaft
Position System Variation Learning Procedure. The
PCM compensates for these variations when
performing detect misfire calculations. Only a scan
tool can command the PCM to perform the Crankshaft
Position System Variation Learning Procedure again.
Perform the learning procedure after the following
actions:
A PCM replacement
Any operation or repair involving the crankshaft,
the CKP sensor, or the CKP sensor to reluctor
wheel gap relationship.
An engine replacement.
The ignition switch is in the ON position until the
battery is drained.

The PCM illuminates the Malfunction Indicator

Lamp (MIL) when the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Freeze Frame and/or the Failure
Records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

6-1696

Engine Controls - 5.7L

Engine

Diagnostic Aids

Test Description

If the Crankshaft Position System Variation Learn

Procedure cannot be learned, inspect for the following
conditions:

The number(s) below refer to the step number(s) on

the diagnostic table.

A chipped or damaged reluctor wheel

Incorrect alignment of the CKP sensor to the
reluctor wheel
Excessive crankshaft run-out
Interference in the signal circuit to the CKP sensor
Incorrect ratio of crankshaft to camshaft pulses

Important: If the PCM receives an incorrect crankshaft

to camshaft ratio the PCM will not allow the scan
tool to enable the learn procedure.
Engine diagnostic misfire is not operable when the
engine is above 1000 RPM and DTC P1336 is set.
When the learn procedure is in progress and the
engine speed is at 4000 RPM, a decrease in engine
speed will occur. During the engine coast down,
the PCM monitors the CKP sensor signal and stores
the pattern. This pattern is used to determine if
the crankshaft speed variations are due to misfire.

2. The PCM enal:>les the learn process after 65C

(150F) is reached. Engine deceleration occurs
when the learn procedure is in progress. The PCM
monitors and records the CKP sensor signal
during engine coast-down conditions.

3. Test in Progress on the scan tool indicates the

PCM is performing the learn procedure. If the
PCM receives an incorrect crankshaft to camshaft
pulse ratio, an incorrect transmission range
signal input, corrupted communication, or no
change in the brake switch input, the learn
procedure will not be allowed.
4. If a repair is necessary due to a condition which
prevented the learn procedure from enabling,
the Crankshaft Position System Variation Learning
Procedure must be performed.
5. The ignition must be in the OFF position for at
least 1O seconds after the learn procedure is
complete and the engine RPM has returned to
idle. The PCM saves the signal data after
these conditions are met.

Engine

Engine Controls - 5.7L

6-1697

DTC P1336 Crankshaft Position (CKP) System Variation Not Learned

Step

Action
Did you perform the Powertrain On-Board Diagnostic
(OBD) System Check?

)
3

Perform the Crankshaft Position System Variation Learning

Procedure as follows.
1. Install the .scan tool.
2. Apply the vehicle's parking brake.
3. Block the drive wheels.
4. Clol:ie the hood.
5. Place the vehicle's transmission in Park (A!T) or
Neutral (Mff).
6. Idle the. engine until the specified engine coolant
temperature value is reached,
7. Turn OFF.all the accessories.
8. Apply the brakes for the duration of the procedure.
Important: While the learn procedure is in progress,
release the throttle immediately when the engine starts to
decelerate. The engine control is returned to the operator
and the engine will respond to throttle position after the
learn procedure is complete.
9. Enable the. Crankshaft Position System Varic1tion
Learning Procedure with the scan toot
10. Slowly raise the engine RPM to the specified value.
11. Immediately release the throttle when the engine
speed decreases.
Does the scan tool indicate the Learn Status: Learned This
Ignition?
Attempt the Crankshaft Position System Variation Learn
Procedure as many times as the specified value.
Does the scan tool indicate the Learn Status: Learned This
Ignition?
Inspect the Crankshaft Position (CKP) sensor and the
crankshaft reluctor wheel for damage. Refer to
Diagnostic Aids.
Did you find a condition?
Turn OFF the ignition for 15 seconds.
Is the action complete?
Replace the Crankshaft Position (CKP) sensor and/or
reluctor wheel. Refer to Crankshaft Position Sensor
Replacement or Crankshaft and Bearings Removal in
Engine Mechanical 5.7L.
ls the action complete? ,
1. Select the Diagnostic Trouble Code (DTC) option and
the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (DTC). option and
the Specific DTC option, then enter the DTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this diagnostic ran and
passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Value(s)

Yes

Go to Step 2

No
Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 5

Go to Step 3

Go to Step 5

Go to Step 4

Go to Step 6

Go to
Diagnostic Aids

65C (150F)
4000RPM

Go to Step 7

Go to Step 7

Go to Step B

Go to Step 2

Go to the
applicable
DTC table

System OK

6-1698

Engine Contr:ols , 5.7l:

OTC P1380 Misfire Detected

'!'

Engine

Rough Road :Data .Not Availabl~

Circuit Description

Conditions for Clearing th.e MIUDTC

'

The PCM detects engine misfire by detecting variations

in crankshaft deceleration between firing strokes.
For accurate detection of engin~ misfire the PCM must
distinguish between crankshaftdeceleration caused
by actual misfire and deceleration caused by
rough road conditions. The ABS Brake System can
detect if the vehicle is on a rough road based on wheel
acceleration/deceleration data supplied by the wheel
speed sensors. If the ABS system detects rough
road above a predetermined threshold, this information
is sent to the PCM via serial data. The PCM can
then take the rough road into account when calculating
misfire. Even if the ABS is malfunctioning and
cannot detect rough roads, the misfire diagnostic will
continue to run. However, if a misfire DTC sets,
this additional DTC also sets indicating that rough road
data was not available during the misfi~e calculation
due to an ABS System malfunction.

Conditions for Running the OTC

DTCs P0101, P0102, P0103, P0121, P0122,
P0123, P0335, P0336, P0742 not set.
The vehicle speed is greater than 10.0 mph.
The engine load is less than 60%.
The engine misfire is detected (DTC P0300 set).
The engine speed is less than 3200 RPM.

Conditions for Setting .the OTC

An ABS system malfunction exists preventing the
PCM from receiving rough road detection data.

Action Taken When the OTC Set$

The PCM illuminates the Malfunction Indicator
Lamp (MIL) on the second consecutive drive
trip that the misfire diagnostic runs and fails. This
DTC can only set if the MIL 1s already ON for
misfire.
The PCM records the operating conditions at U1e
time the diagnostic fails. The PCM stores this
information in the Freeze Frame and/or Failure
Records.

'

'

The PCM turns the MtL OFF after three

consecutive ignition cycles that the diagnostic
runs and does not fail.
A lasuest fa:iled (current DTC) cle~'rs.when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not. report any failures.
Use a scan tool in order to clear,theMIUDTC.

Diagnostic Aids
1

Using the Freeze Frame and/or Fajiure Record.s data

may aid in locating an intermittent condition. If you
cannot duplicate ttte OTC, the information included in
the Freeze Frame and/or Failure Records data can
help determine how many miles since the OTC
set. The Fail Counter and Pass Counter can also help
determine 'tiow many ignition 9yc!es t.he diagnostic
reported a pass and/or a 'fail. Operate vehicle
within the same freeze frame conditioris (RPM, load,
vehicle spe.ed, temperature etc.) tl;\at. ybV observed.
This will isolate when the DTC failed. For an
intermittent condition, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
dia~mc:,stic tab,le.
1 . Service the ABS system before diagnosing for a
misfire, because an actual engine misfire may
or may not~x:jst The following two examples
illustrate how this DTC can be set with or without
an actual engine misfire:
There was an actual engine misfir~ during an
ABS system malfunction.
The vehicle operator drovt3 on a rough road,
the ABS system could not detect this due to
a malfunction, and the PCM interpreted
the variations in. crankshaft speed caused by
the rough road as a.misfire.

DTC P1380 Misfire Detected - Rough Road Data Not Available

Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Value(s)

Yes

N9

Go tb A
Powertrain On
Go to'.A
, Board Diagnostic
Diagnostic ,
(OBD) $ysti;m
System Check in
Antilock Brakes ,,
Check
':

::

Engine

Engine Controls - 5.7L

6-1699

OTC P1404 EGR Exhaust Gas Recirculation (EGR) Closed Position Performance

sv - - - - sv - - - - -

Powertrain ..
Control I Reference

;
5

Module : A/C Refrigerant

- -

> ._

S~s~ _ _ _

GRY 705

Pressure
I Sensor
I Signal

0_

L..1il

J ;~~-~:_ti_~~_ _ _ _
c....;...

Manifold
Absolute

I r4==i I

Pressure

BRN 1456

..._-=------A~ (MAP)
8

GRY 435

BLK 552

63

Sensor
Ground

LT GRN 432

ORN/BLK 469

62 C1

;R-

34

-1- -u;. -- -1~ --

sensor
Ground ~

EGR
Valve
Ground

I
_

Sensor

1-----I-.-

GAY 416

BLK 407

A/C-R;;lg';'ra;

.,

64C2

RED/BLK 380

- ~-

66 C2

::::1___ ~-11. .

I ~ I
C

LT BLU 697

I...__.!,,..._..

Sensor

38

Pressure

65

GRY 474

Refrige~~

- -

EGR
MAP
Valve
5V
. __________ -~ontro~ ______________ ~~e~e-n~e- _

(PCM) I Pressure
~

EGA
Plntle
Position

48

26

-lvl;P - - Sensor,
Signal

C2

-r~ -

~ Powertrain

MAP
Sensor
Ground

PClvl
C1=RED
C2 = BLU

Control

I
I

I
I

Module
(PCM)

>

I~

L-----------------------------------------J
218502

Circuit Description

Conditions for Running the OTC

This diagnostic tests for an EGR valve that is stuck

open. The PCM determines that the EGR valve
is stuck open if the actual EGR position and the
learned .closed EGR position vary by more than
a predetermined value. The PCM tests for a stuck
valve when the desired EGR position is at 0%.
The PCM commands the EGR valve to 100% during
certain driving conditions in order to clear a possible
restriction from the EGR valve if the PCM determines
that the valve is stuck open. The PCM retests for a
stuck valve when the desired EGR position returns to
0%. A failure timer increments if the stuck EGR
valve condition is still present. This DTC sets when
the timer reaches a predetermined value.

The ignition voltage is greater than 11.7 volts.

Conditions for Setting the DTC

The actual EGR pintle position is greater
than 0.29 volts when the valve is commanded closed.

Action Taken When the OTC Sets

The PCM disables the EGR valve for the ignition cycle.

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL) when the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Freeze Frame and/or the Failure
Records.

6-1700

Engine

Engine Controls - 5.7L

Conditions for Clearing the MIL/OTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
Important: The PCM terminals C1-24 and C2-24 are
the Sensor Ground Jumper terminals. This OTC
sets if the jumper is open or the connection between
the jumper and the PCM is faulty. Inspect for
proper terminal tension/connections at the PCM
harness connector before replacing the PCM.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. If OTC P1635 sets at the same time, this indicates
that the 5.0 volt reference circuit is either shorted
to a ground or shorted to a voltage. The 5.0 volt
reference circuit is internally connected
within the PCM.

3. This step tests for open EGA valve when the

valve should be closed.
5. This step tests for an EGA pintle position voltage
that is out of range. The EGA pintle position
voltage should be between 0.14 and 1.07 volts
at idle.

6. Using Freeze Frame and/or Failure Records data

may aid in locating an intermittent condition. If
you cannot duplicated the OTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the OTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the OTC failed. For an
intermittent condition, refer to Symptoms
8. This tests whether the ground circuit is available
to the EGA valve. Test for poor electrical
connections at the EGA valve. Refer to Repairing
Connector Terminals in Wiring Systems.
17. The PCM terminals C1-24 and C2-24 are the
Sensor Ground Jumper terminals. This OTC sets if
the jumper is open or the connection between
the jumper and the PCM is faulty.

DTC P1404 EGR Exhaust Gas Recirculation (EGR) Closed Position Performance
Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to
DTCP1635 5
Volt Reference 1
Circuit

Go to Step 3

Go to Step 4

Go to Step 5

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

1. Install the scan tool.

2. Idle the engine.
3. Monitor the Diagnostic Trouble Code (OTC)
Information using the scan tool.
Did OTC P1635 fail this ignition?

Idle the engine.

Is the idle quality poor?

1. Idle the engine.

2. Disconnect the EGR valve electrical connector.
Does the idle quality return to normal?

1. Turn ON the ignition leaving the engine OFF.

2. Observe the EGR pintle position voltage display on
the scan tool.
Is the EGR pintle position voltage within the
specified value?

Go to Step 13

Go to Step 15

Go to Step 6

Go to Step 7

0.14-1.0?V

Engine

Engine Controls - 5.7L

6-1701

DTC P1404 EGR Exhaust Gas Recirculation (EGR) Closed Position Performance (cont'd)
Step

Action

Value(s)

Yes

No

Go to Step 7

Go to
Diagnostic Aids

Go to Step 8

Go to Step 10

Go to Step 9

Go to Step 11

Go to Step 14

Go to Step 16

Go to Step 18

Go to Step 17

Go to Step 18

Go to Step 12

Go to Step 18

Go to Step 17

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this OTC and record the parameters.
3. Turn OFF the ignition for 15 seconds.

10

4. Idle the engine.

5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions for Running
the OTC.
6. Select the Diagnostic Trouble Code (OTC) option, the
Specific OTC option, then enter the OTC number
which was set using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?
1. Disconnect the EGR valve electrical connector.
2. Observe the EGA pintle position voltage display on
the scan tool.
Is the EGR pintle position voltage below the
specified value?
Probe the EGR pintle position ground circuit at the EGR
valve harness connector with the test lamp J 34142-8
connected to B+. Refer to Probing Electrical Connectors in
Wiring Systems.
Does the test lamp illuminate?
Measure the voltage at the 5.0 volt reference circuit to
ground using the DMM J 39200.
Is the voltage greater than the specified value?
1. Turn OFF the ignition.
2. Disconnect the PCM connector C2 located on the
same side of the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test for a short to voltage on the EGR valve signal
circuit.

0.14V

5.0V

4. If you find the EGR valve signal circuit shorted, repair

the circuit as necessary. Refer to Wiring Repairs in
Wiring Systems.
Did you find and correct the condition?

11

12

)
/

1. Test for an open EGR pintle position ground circuit.

2. If you find the EGR pintle position ground circuit
open, repair the circuit as necessary. Refer to Wiring
Repairs in Wiring Systems.
Did you find and correct the condition?
1. Turn OFF the ignition.
2. Disconnect the PCM connector C2 located on the
same side of the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the EGR pintle position ground circuit for a poor
connection at the PCM. Refer to lntermittents and
Poor Connections Diagnosis in Wiring Systems.
4. If you find a poor connection at the EGR valve
ground circuit, repair the circuit as necessary. Refer
to Repairing Connector Terminals in Wiring Systems.
Did you find and correct the condition?

6-1702

EAgine Controls - 5.7L

Engine

DTCP1404 EGR Exhaust Gas Recirculation (EGR) Closed Position Performance (cont'd)
Step

Action

Value(s)

13

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side of the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test the EGR valve ground circuit for a short to
voltage.
4. Correct the condition as necessary. Refer to Wiring
Repairs in Wiring Systems.
Did you find and correct the condition?

14

Repair the 5.0 volt reference circuit for a short to voltage.

Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

1. Remove the EGR valve.

2. Inspect the EGR valve for debris that is interfering
with the valve movement. Refer to EGR System
Cleaning
3. Repair as necessary if you find a condition.
Did you find and correct the condition?

Replace the EGR valve. Refer to EGR Valve

Replacement.
Is the action complete?

15

16

17

18

19

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.

Replace the PCM.

Is the action complete?

No

Go to Step 18

Go to Step 17
-

Go to Step 18

Go tq Step 18

Go to Step 16

Go to Step 18

..

.,,

Yes

Go to Step 18

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

Select the Capture Info option and the Review Info using
the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

"'~'

Go to Step 19

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5.7L

6-1703

DTC P1415 Secondary Air Injection (AIR) System Bank 1

!Hot At All Times!

~ P;~ -

I Distribution

AIR PUMP

cen 10

.,

MlnlFusa I

25 A

H6

Underhood

I Electrical

Center 1

L1il

L----- ----J

ORN 1440

ORN 1440

,.

--

E9

ORN 1440
ORN 1440

ORN 1440

- - - -Ft - - - - - - - - Es - - - - Fs
AIR

65

- - - ., Underhood
I

. - - . . . . . - - - - - - - AJA

as

Sol
Relay

30

116

Pump
Relay

Electrical

I Center 2

I
I
I
I

87

----J
RED 78

PNK/BLK 429
PNK/BLK 429

O[]

PNK/BLK 429

PPL 421

Secondary
Air Injection (AIR)
Bleed Valve
Solenoid

31

Secondary
Air
Injection

II

(AIR)

L-...---....::i:.--1

Pump

BLK 150

J-

BAN 436
30 C2

;~m~ - - - - - ~

~~l:n:1:- - ,

I
I

--T

I
I

Relay

Control

---T

6~~:~rain

I Module
I (PCM)

Relay
Control

I
PCM

l.,A~

C1=RED
C2=BLU

I~
I

L---------------J
L

BLK 150

__,..

Ground
Distribution
Cell14

218550

Circuit Description
An AIR pump is used on this vehicle to lower tail pipe
emissions on start-up. The PCM supplies a ground
to the AIR pump relay, which energizes the AIR pump.
The PCM monitors the H02S voltages to diagnose
the AIR system.

During the AIR test the PCM activates the AIR pump
during closed loop operation. When the AIR is
activated, the PCM monitors the H02S voltages and
short term fuel trim values for both banks of the
engine. If the AIR system is operating properly, the
H02S voltages should go low and the short term fuel
trim should go high.
If the PCM determines that the H02S voltages for
both banks did not respond as expected during
the tests, DTC P041 O sets. If only one sensor

responded, the PCM sets either a DTC P1415 or

P1416 to indicate on which bank the Al R system is
inoperative.

Conditions for Running the OTC

DTCs P0101, P0102, P0103, P0107, P0108,
P0112, P0113, P0117, P0118, P0300, P0325,
P0327, P0335, P0441, P0502, P0503, and H02S
DTCs not set.
The engine operating.
The engine operates for greater than 15 seconds
in short term fuel trim cells 2, 5, and 20.
Engine speed is greater than 550 RPM.
Maximum air flow is 22 g/s .
ECT is greater than 50C (122F).
IAT is greater than 10C (50F).
Ignition voltage is greater than 11.6 volts.
Engine load is less than 30%.

6-1704

Engine Controls - 5.7L

Conditions for Setting the DTC

H02S voltage does not go below 222 mV for
0.9 seconds when the AIR pump is enabled during
closed operation.
Short term fuel trim does not go above a
predetermined amount when the AIR pump is
enabled during closed operation.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIL/DTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Engine
Diagnostic Aids
Casting flash in the exhaust manifold may restrict
the amount of air flow necessary to affect the
H02S voltage. If you suspect this, remove the air
pipe from the manifold and inspect the passage.
Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
isolates when the DTC failed.
For an intermittent condition, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. A check valve that flows in both directions causes
heat damage to the AIR system components.

Engine

Engine Controls - 5.7L 6-1705

DTC P1415 Secondary Air Injection (AIR) System Bank 1

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to
Diagnostic Aids

Go to Step 3

Go to Step 6

Go to Step 4

Go to Step 7

Go to Step 5

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Important: Before proceeding with this diagnostic table,

ensure that the AIR pump is operating and that air is
present at the AIR pump outlet. IF the AIR pump is
inoperative refer to OTC P0410 Secondary Air Injection
(AIR) System for further diagnosis.
1. Install a scan tool.
2. Idle the engine in Closed Loop.
3. Turn OFF all the accessories.

350mV

4. Monitor the Bank 1 Sensor 1 {Left Front) H02S

voltage display on the Engine 1 Data List using a
scan tool.
5. Enable the AIR pump using a scan tool.
6. Observe and record the Bank 1 Sensor 1 (Left Front)
H02S voltage, as the AIR pump is enabled.
Does the H02S voltage drop below the specified value?
Visually/physically inspect all hoses and pipes for:

Did

Being connected
Clamps are secure on pipes and hoses
No kinks, holes, or pinched hoses/pipes
Components with evidence of heat damage
you isolate a condition?

1. Disconnect the hose from the check valve at the left

exhaust manifold.
2. Enable the AIR pump using a scan tool.

Is air present at the hose outlet?

Repair the restriction or blockage in AIR hoses/pipes
between the left exhaust manifold and the point where the
system branches to both sides of the engine.
Is the action complete?

Repair the condition found.

Is the action complete?

Replace the check valve. Refer to AIR Check Valve/Pipe

Replacement - Bank 1.
Is the action complete?

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.

Go to Step 8

Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 8

Go to Step 8

Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.

Go to Step 9

Go to Step 2

Go to the
applicable
OTC table

System OK

6;.1706

Engine

Engine Controls -5.7L.

DTC P1416 Secondary Air Injection (AIR) System Bank 2

r -

- -

!Hot Af. All

Timesl

Power
Distribution
I ce1110

Underhood
I Electr1cal
MinlFuse I Center 1
-

- -

"'

AIR PUIIAP

25 A
I
----.I

L-~---

ORN 1440
ORN 1440

ORN 1440

.. - -

ORN 1440
-

-F9- -

ORN 1440

E9
r'.'.'85~---__;,,~ AIR
Sol
Relay

Es - - - - FS - - - ., Underhood
I

r - - T " " " - - - ~... AIR

85

Pump
Relay

---------FBJ ----ES

I
I
I
I

Electrical
Center 2

____ ...

BRN 436

RED 78

PNK/BLK 429
PNK/BLK 429

PNK/BLK 429

31

Secondary
Air
Injection
(AIR)
,___ _ _....z.___,Pump

BLK 150

--..

30 C2

I
J
I
I

----f

Solenoid

Relay
Control

----f

Powertrain

I Control
I Module
I (PCM)
I

Pump

Relay
Control

>

PCM
C1=RED
C2=BW

'"-A

~--~------------J

....
'l
I... -

BLK 150

BRN 436

'" - - --------../'>.
Air- - - - - z; - - - - - - ,

8
Secondary
Air Injection (AIR)
Bleed Valve
Solenoid

PPL 421

__.,.

Ground
Distribution
Cell14

218550

.Circuit Description
An AIR pump is used on this vehicle to lower tail pipe
:emissions on start-up. The PCM supplies a ground
to the AIR pump relay, which energizes the AIR pump.
The PCM monitors the H02S voltages to diagnose
the AIR system.
During the AIR test the PCM activates the AIR pump
during closed loop operation. When the AIR is
activated, the PCM monitors the H02S voltages and
short term 'fuel trim values for both banks of the
engine. If the AIR system is operating properly, the
H02S voltages should go low and the short term fuel
trim should go high.
If the PCM determines that the H02S voltages for
both banks did not respond as expected during
the tests, OTC P041 O sets. If only one sensor

responded, the PCM sets either a OTC P1415 or

P1416 to indicate on which bank the AIR system is
inoperative.

Conditions for Running the DTC

DTCs P0101, P0102, P0103, P0107, P0108,
P0112, P0113, P0117, P0118, P0300, P0325,
P0327, P0335, P0441, P0502, P0503, and H02S
DTCs not set.
The engine operating.
The engine operates for greater than 15 seconds
in short term fuel trim cells 2, 5; and 20.
Engine speed is greater than 550 RPM.
Maximum air flow is 22 g/s.
ECT is greater than 50C (122F).
IAT is greater than 10C (50F).
Ignition voltage is greater than 11.6 volts.
Engine load is less than 30%.

Engine
Conditions for Setting the DTC

H02S voltage does not go below 222 mV for

0.9 seconds when the AIR pump is enabled during
closed operation.
Short term fuel trim does not go above a
predetermined amount when the AIR pump is
enabled during closed operation.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three

consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC .

Engine Controls - 5.7L

6-1707

Diagnostic .Aids
Casting flash in the exhaust manifold may restrict
the amount of air flow necessary to affect the
H02S voltage. If this is suspected, remove the air
pipe from the manifold and inspect the passage.
Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the DTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
isolates when the DTC failed.
For an intermittent condition, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. A check valve that flows in both directions causes
heat damage to the AIR system components.

6-1708

Engine

Engine Controls - 5.7L

DTC P1416 Secondary Air Injection (AIR) System Bank 2

Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

Important: Before proceeding with this diagnostic table,

ensure that the AIR pump is operating and that air is
present at the AIR pump outlet. IF the AIR pump is
inoperative refer to OTC P041 O Secondary Air Injection
(AIR) System for further diagnosis.
1. Install scan tool.
2. Engine idling in Closed Loop.
3. Turn OFF all accessories.
4. Monitor the Bank 2 Sensor 1 (Right Front) H02S
voltage display on the Engine 1 Data List using a
scan tool.
5. Enable the AIR pump using a scan tool.
6. Observe and record the Bank 2 Sensor 1 (Right
Front) H02S voltage, as the AIR pump is enabled.
Does the H02S voltage drop below the specified value?

Value(s)

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to
Diagnostic Aids

Go to Step 3

Go to Step 6

Go to Step 4

Go to Step 7

Go to Step 5

350mV

Visually/physically inspect all hoses and pipes for:

Being connected
Clamps are secure on pipes and hoses
No kinks, holes, or pinched hoses/pipes
Components with evidence of heat damage
Did you isolate a condition?

1. Disconnect the hose from the check valve at the right

exhaust manifold.
2. Enable the AIR pump using a scan tool.
Is air present at the hose outlet?

Repair the restriction or the blockage in the AIR

hoses/pipes between the right exhaust manifold and the
point where the system branches to both sides of the
engine.
Is the action complete?

Repair the condition found.

Is the action complete?

Replace the check valve. Refer to AIR Check Valve/Pipe

Replacement - Bank 2.
Is the action complete?

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Yes

Go to Step B
Go to Step B

Go to Step B

Go to Step 9

Go to Step 2

Go to the
applicable
OTC table

System OK

Engine

Engine Controls - 5.7L 6-1709

OTC P1441 Evaporative Emission (EVAP) System Flow During Non-Purge

l Hot With lgn Relay Energi2ed l

.. - - - - -

- - - - ., Underhood
I
ENG CTRL I Electrical
MiniFuse
Center 2
1

I Power
I Distribution

I
I
L

Cell 10

15 A

JM;'"l

LJ:!J

_,J

PNK 239
PNK 239

Fuse Block
Details

PNK
239

PNK 239

PNKI 239

PNK 239

PN:I 239

PNK
239

Cell11

Evaporative
Emission
[ ] (EVAP)
Canister

Evaporative
Emission
[ ] (EVAP)
Canister
B
Purge

BI ~:~

Valve

WHT 1310

DK GRN/WHT 428

WHTI1310

WHT11310

-------E~;; -;- 1
--1

45

~ - - - - - ;v; - Canister
Purge
Valve
Control

I
I
I

I
I

------------

PCM
Cl=RED
C2=BLU

3 C1

Canister
Vent
Valve

Control

~ Pcowertrain

ontro 1
I Module

I (PCM)
I

.&

I~
I

~----------------------~

218692

Circuit Description

The barometric pressure is greater than 75 kPa.

The PCM monitors the amount of vacuum/pressure in

the EVAP system by monitoring the fuel tank
pressure sensor signal. The PCM seals the EVAP
system by commanding the EVAP Purge Solenoid
OFF and the EVAP vent valve ON. The PCM monitors
the fuel tank pressure sensor in order to determine
if the EVAP Purge Solenoid is leaking vacuum to the
EVAP system. This DTC sets if the vacuum in the
EVAP system is greater than a predetermined value
within a predetermined time.

The fuel level is between 15% and 85% of

full capacity.

Conditions for Running the OTC

DTCs P0107, P0108, P0112, P0113, P0121,
P0122, P0123, P0420, P0430, P0500, P0502,
P0503, P1111, P1112, P1114, P1115, and H02S
DTCs are not set.
The ignition voltage is between 10.0 volts and
17.0 volts.

The engine coolant temperature is between 4 C

(39F) and 30C (86F).
The intake air temperature is between 4C (39F)
and 30C (86F).
The start up engine coolant and intake air
temperatures are within 9C (16F) of each other.
The EVAP Purge Solenoid duty cycle is 0%.
The TP angle is between 0% and 99.6%.

Conditions for Setting the OTC

The EVAP system develops a vacuum greater than a
predetermined value when purge is not commanded.

5..171 o Engine ,controls ;. s. 7L

Action Taken When the DTC Sets
The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle

that the diagnostic runs and fails.

The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Conditions for Clearing the MIUDTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic

runs and does not fail.

A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

Engine
Diagnostic Aids.
Before replaci11g any components, visually/physically
inspect for the following:
Mis-routed harness.
Rubbed through wire insulation
Broken wire inside the insulation
Kinked or damaged vacuum hoses
Physically damaged system components
Inspect components and vacuum lines for traces
of carbon or other contaminants. The presence
of foreign material may be causing a restriction in
the system or preventing the solenoid valve
from closing properly. Either condition may cause
a DTC to $St.
.For an intermittent condition, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
Diagnostic Table.
:t This step tests for a EVAP Purge Solenoid Valve
tliat is leaking vacuum to the EVAP system
when EVAP system purge is not commanded by
the PCM.
Inspect for possible carbon contamination of the
EVAP Purge Solenoid Valve and the purge line.

DTC P1441 Evaporative Emission (EVAP) System Flow During Non-Purge

Step

Action

Value(s)

Yes

Did you perform the Powertrain On-Bm~rd Diagnostic

(OBD) System Check?

Go to Step 2
1. Disconnect the EVAP Purge line from the EVAP
Purge Solenoid Valve.
2. Connect a vacuum gauge (in. Hg.) to the solenoid
purge port.
3. Idle the engine.
4. Command the EVAP Purge Solenoid Valve OFF with
a scan tool.
Does the vacuum gauge indicate a vacuum?

Important: Inspect for carbon contamination. Refer to

EVAP System Cleaning.
Replace the EVAP Purge Solenoid Valve. Refer to EVAP
Canister Purge Solenoid Valve Replacement.
Is the action complete?

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan too!.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using tha scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC a~ specified in the supporting text, if

applicable.
Does the scan tool indicate thatthis test ran and passed?

Select the Capture Info option and the R,eviel(II Info option
u~ingthe scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 3

No
Go to A
Powertrain On
Board Diagnostic
(OBD) System .
Check

Go to
Diagnostic Aids

'

Go to Step 4

Go .to Step 5

Go to Step 2

(
Go to the
applicable OTC.

System OK.

Engine

EngineControls - 5.7L

6-1711

DTC P1539 Air Conditioning (A/C) Clutch Feedback Circuit High Voltage

Hot In RUN Or START

.. - -

G7

G6
1..

Fuse Block

........

Details

Cell11

- - - - - - - ., Underhood
Power
I
.
A/C
Distribution I Electrical
CRUISE .., Cell 10
Center 2
MiniFuse""
15A

PNK 139

- - ----------,
PNK 139
PNK 139

- - - ., Underhood
AIC
I Electrical
I
COMP Center 2

as

I
I
I
I

Relay

DK GRN/WHTr~~~ - - - -

I
I

59

DK GAN 59

14

59

DKGRN

- - - - ~~: 1- - - - - - - -P:M _:-~:_-~f-A~ ----- ~6~~:~~ain

Relay

Controi--

+I

C1=RED

C2=BLU

J.,
sv

II

.,..

A/C Refngerant

AIC

NC Refrigerant

Pressure Sensor

Request

Signal

Pressure Sensor
_

I1.

L2w

.I

r. - - - - - - I
010
08

p:l;"l

I
I

___

47IC1
DK GRN/WHT 762

AIC Refrigerant
PressureSensor
Ground

7I_________ 66IC2

RED/BL~ 380

GR; 474

tI

IG:J

63

I Jt,
I ~,,~

~ Compressor
A/C

I~

A/C
Diode

Clutch

B
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218753

Circuit Description

Conditions for Setting the DTC

The PCM activates the A/C clutch relay when the

PCM detects an A/C request. Voltage is present at
both the A/C compressor clutch and the A/C
clutch status terminal at the PCM when the relay is
activated.

Voltage is detected on the A/C status circuit for more

than 15.0 seconds after the PCM has disengaged
the A/C clutch relay.

A DTC P1539 sets if the PCM detects voltage on the

A/C clutch status terminal when the system has
not requested the A/C.
A short to voltage at any point in the A/C status
circuit, or the A/C relay contacts are stuck, sets a
DTC P1539.

Conditions for Running the DTC

The A/C is not requested.

Action Taken When the DTC Sets

The PCM stores the DTC information into memory
when the diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL) will not
illuminate.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Failure Records.

6-1712

Engine Controls - S.7L

Conditions for Clearing the MU.JDTC

A History OTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other non-emission related diagnostic.
A last test failed (Current OTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
The A/C status circuit goes to the A/C compressor
clutch and to the A/C clutch relay. Inspect all
circuits going to these components.
For an intermittent condition, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. If the PCM detects a voltage on the A/C status
circuit with the A/C OFF the scan tool indicates
the A/C status as ON.

Engine
3. H the scan tooldisplayed YES in the RAN column
and INT in the FAIL column, this indicates an
intermittent condition is present. Inspect the A!C
status circuit for an intermittent short to B+. Using
the. FFeeze Frame and/or the Failure Records
data aids in locating an intermittent condition. If
you can not duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data determines how many miles since
the OTC set. The Fail Counter and the Pass
Counter can also be used to determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speeci, temperature etc.) that the PCM recorded.
This isolates when the OTC failed.
4. The relay is shorted internally if the scan tool
indicates that the test passed.
7. This OTC will not report a pass. The scan tool
status for this OTC will never report a pass.
The scan tool will only display when the diagnostic
fails. The repair is not complete if the scan tool
indicates that the diagnostic ran and failed.

Engine

Engine Controls - 5.7L

6-1713

DTC P1539 Air Conditioning (A/C) Clutch Feedback Circuit High Voltage

Step

Value(s)

Yes

Go to Step 2

No
Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 6

Action
Did you perform the Powertrain On-Board Diagnostic
(OBD) System Check?

Important: Diagnose DTC P1545 first if it is set.

1. Install a scan tool.
2. Idle the engine with the A/C OFF.
3. Monitor the A/C Status display on the Engine 1 Data
List using a scan tool.
Does the scan tool indicate the A/C Status is ON?

1. Turn ON the ignition leaving the engine OFF.

2. Review the Freeze Frame and/or Failure Records
data for this DTC and observe the parameters.
3. Turn OFF the ignition for 15 seconds.
4. Idle the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that need to be
met before the PCM will run this diagnostic, where
applicable, are listed in Conditions for Running
the DTC.
6. Select the Diagnostic Trouble Code (DTC) option and
the Specific DTC option, then enter the DTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

Important: For underhood electrical center relay terminal

identification, refer to Electrical Center Identification in
Wiring Systems.
1. Turn OFF the ignition.
2. Remove the A/C clutch relay from the underhood
electrical center 2.
3. Idle the engine for 30 seconds.
4. Monitor the Diagnostic Trouble Code (DTC)
Information using the scan tool.
Does the scan tool indicate that DTC P1539 failed?
Repair the short to B+ on the A/C clutch status circuit.
Refer to Wiring Repairs in Wiring Systems.
Is the action complete?
Replace the A/C clutch relay. Refer to Compressor Relay
Replacement in HVAC Systems Manual.
Is th.e action complete?
1. Select the Diagnostic Trouble Code (DTC) option and
the Clear DTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (DTC) option and
the Specific DTC option, then enter the DTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the DTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test failed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 7

Go to Step 7

Go to Step 2

Go to Step 8

Go to the
applicable
DTC table

System OK

6-1714

Engine Controls - 5.7L

Engine

OTC P1545 A/C Compressor Clutch Relay Control Circuit

I
lS1
A

IHot In RUN Or START I

.. - -G7 - - - - ~w;; - ., Underhood
A/C
CRUISE
MiniFuse
15A

G6

Distribution:
Cell 10

I
I

lL 0 c

Electrical
Center 2

-------J

L--

PNK 139

Fuse Block
Details
Cell11

-+- - -

PNK 139

PNK 139
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85

I
Electrical
COMP I Center 2

87

Relay

------

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Underhood

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DK GRN/WHT 459

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A/C Refrigerant
Pressure Sensor
Signal

A/C

NC Refrigerant
Pressure Sensor
SV Reference

I Control
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I (PCM)

A/C
SClutct h
ta us

IC1

47
DK GRN/WHT 762

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DK GRN/WHTI762
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/C

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Control

A/C Refrigerant
Pressure sensor

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DKGRN5-9-------.

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Clutch
Relay
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Control. . --

~G::GR:

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63

BLK

~efrigerant
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Pressure

C1
407

A
[ ] A/C

Compressor
Clutch

A/C

Diode

B
BLK-45_0_ _ _ _~
BLK 450
Ground

BLK 450

Distribution
Cell14

.I

218753

Circuit Description
Ignition voltage is supplied directly to the A/C
compressor clutch relay coil. The PCM controls the
relay by grounding the control circuit via an internal
switch called a driver. The primary function of the
driver is to supply the ground for the controlled
component. Each driver has a fault line which the
PCM monitors. When the PCM commands a
component ON, the voltage of the control circuit
should be low (near O volts). When the PCM is
commanding the control circuit to a component OFF,
the voltage potential of the circuit should be high
(near battery voltage). If the fault detection circuit
senses a voltage other than what the circuit expects,
the fault line status changes causing the DTC
to set.

The relay controls t.he high curre.nt flow to the A/C

compressor clutch. This allows the PCM driver to only
have to handle the relatively low current used by
the relay.

Conditions for Running the DTC

DTCs P0113, P0500, P0502, P0560, P0562,
P1133, P1153, P1154 are not set.
The engine speed is greater than 600 RPM.

Conditions for Setting the DTC

The PCM detects that the commanded state of
the driver and the actual state of the control
circuit do not match.
All conditions present for a minimum of
10.0 seconds.

(
\

Engine
Action Taken When the OTC Sets

The. PCM stores the OTC information into memory

when the diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL) will not
illuminate.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM. stores this
information in the Failure Records.

Conditions for Clearing the MIL/DTC

A History DTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other non-emission related diagnostic.
A last test failed (Current DTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Using the Freeze Frame and/or Failure Records data
may aid in locating an intermittent condition. If you
,cannot duplicate the OTC, the information included in
the Freeze Frame and/or Failure Records data can
help. determine how many miles since the DTC
set. The Fail Counter and Pass Counter can also help
determine how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate vehicle
within the same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you observed.
This will isolate when the DTC failed. For an
intermittent condition, refer to Symptoms.

Engine Controls !i.7L 61715

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Listen for an audible click when the relay operates.
Command both the ON and the OFF states as
necessary.
3. In order to detect excessive current flow energize
the relay for. 2 minutes. Energizing the relay for
2 minutes warms the relay coil. When the relay is
warm the coH may open (the curren.t draw
drops to 0), or short (the cwrent goes above
0.75 Amps).
5. Identify and test the correct relay coil terminals to
avoid improper diagnosis.
7. Listen for an audible click when the relay operates.
Repeat the procedure as necessary.
13. If no trouble is found in the control circuit or the
connection at the PCM, the PCM may be
faulty, however, this is an extremely unlikely
failure.

14. The repair is not complete if the scan tool

indicates that the diagnostic ran and .failed.

6-1716

Engine Controls - 5.7L

Engine

DTC P1545 A/C Compressor Clutch Relay Control Circuit

Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

1. Turn ON the ignition leaving the enginJ OFF.

2. Command the relay ON and OFF using a scan tool.
Does the relay turn ON and OFF when commanded?
1. Turn OFF the ignition.
2. Disconnect the PCM connector C1 located on the
opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.
3. Turn ON the ignition.
Important: If the DMM goes to O replace the relay.
4. Measure the current from the relay control circuit in
the PCM harness connector to a ground for
2 minutes using the DMM J 39200 set on the
40 Amp scale.
Does the current draw measure less than the value shown
(but not O)?

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Step 5

Go to
Diagnostic Aids

Go to Step 4

0.75A

Important: For underhood electrical center relay terminal

identification, refer to Electrical Center Identification in
Wiring Systems.
1. Turn OFF the ignition.
2. Disconnect the relay from the underhood electrical
center 2.
3. Measure the resistance from the relay control circuit
in the PCM harness connector to a ground using the
DMM J39200.
Does the DMM display infinite resistance?

Important: For underhood electrical center relay terminal

identification, refer to Electrical Center Identification in
Wiring Systems.
1. Turn OFF the ignition.
2. Disconnect the relay from the underhood electrical
center 2.
3. Connect the test lamp J 34142-8 between the A/C
Clutch relay control circuit and the ignition feed circuit
at the underhood electrical center 2.
4. Turn ON the ignition.
5. Command the relay ON and OFF using a scan tool.
Does the test lamp turn ON and OFF with each
command?

Probe the A/C Clutch relay ignition feed circuits in the

underhood electrical center 2 with the test lamp J 34142-B
connected to a ground.
Does the test lamp illuminate for both circuits?

(
Go to Step 12

Go to Step 10

Go to Step 8

Go to Step 6

Go to Step 7

Go to Step 11

Engine

Engine Controls - 5.7L

6-1717

DTC P1545 A/C Compressor Clutch Relay Control Circuit (cont'd)

Step

Action

Value(s)

Yes

No

Go to Step 9

Go to Step 10

Go to Step 14

Go to Step 12

Go to Step 14

Go to Step 13

1. Turn OFF the ignition.

2. Reconnect the relay.

3. Disconnect the PCM connector C1 located on the
opposite side of the manufacturer's logo. Refer to

PCM Replacement/Programming.

4. Turn ON the ignition.

5. Momentarily probe the relay control circuit in the PCM

harness connector with a fused jumper wire
connected to a ground.
Does the relay turn ON when the circuit is grounded and
OFF when the circuit is opened?
1. Inspect for poor connections at the relay. Refer to
lntermittents and Poor Connections Diagnosis in
Wiring Systems.

2. If you find a poor connection, repair as necessary.

Refer to Repairing Connector Terminals in Wiring

Systems.
Did you find and correct the condition?
1. Inspect for poor connections at the PCM. Refer to
lntermittents and Poor Connections Diagnosis in
Wiring Systems.
9

2. If you find a poor connection, repair as necessary.

Refer to Repairing Connector Terminals in Wiring

Systems.
Did you find and correct the condition?
10

Repair the fat lty relay control circuit. Refer to Wiring

Repairs in Wiring Systems.

11

Repair the faulty relay battery feed circuit. Refer to Wiring

Repairs in Wiring Systems.

Replace the A/C clutch relay. Refer to Compressor Relay

Replacement in HV AC Systems Manual.

13

Replace the PCM.

Is the action complete?

Go to Step 14

Is the action complete?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.

Go to Step 14

Is the action complete?

12

Go to Step 14

Is the action complete?

Go to Step 14

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.

2. Idle the engine at the normal operating temperature.

14

3. Select the Diagnostic Trouble Code (OTC) option and

the Specific OTC option, then enter the OTC number
using the scan tool.

4. Operate the vehicle within the Conditions for Running

the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test passed?

15

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 15

Go to Step 2

Go to the
applicable
OTC table

System OK

6-1718

Engine Controls.;. 5.7L

Engine

DTC P1546 Air Conditioning {A/C) Clutch Feedback Circuit Low Voltage
! Hot In RUN Or START!

,. - G7
G6
L--

- - -

-P-;;-~ - .,Underhood

NC
Distribution:
CRUISE Cell 10

MiniFuse
15A

Electrical
Center 2

-------.I

.... - - ----------,
PNK 139
PNK 139

Fuse Block
Details
Cell11

PNK 139

.--------DlO

DB

85

A/C

Diode

.I

218753

Circuit Description
The PCM will activate the A/C clutch relay when the
PCM detects that A/Chas been requested. When
the PCM activates the relay, voltage should be present
at both the A/C compressor clutch and the A/C
clutch status circuit at the PCM.

Conditions for Running the OTC

The A/C is requested.

Conditions for Setting the OTC

The PCM commands the A/C ON and the PCM does
not detect a voltage on the A/C clutch status line
for more than 5.0 seconds,

Action Taken When the OTC Sets

The PCM stores the DTC information into memory
when the diagnostic runs and fails.

The Malfunction Indicator Lamp (MIL) will not

illuminate.
The PCM records the operating conditions at the
time the. diagnostic fails. The PCM stores this
information in the Failure Records.

Conditions for Clearing the MIL/OTC

A History DTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other non-emiMion related diagnostic.
A last test failed (Current DTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUDTC.

Engine Controls - 5.7L

Engine
Diagnostic Aids

The following may cause an intermittent:

Mis-routed harness
Rubbed through wire insulation
Broken wire inside the insulation
For an intermittent condition, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step tests the operation of the A/C
compressor clutch. The PCM disables the A/C
compressor clutch when this OTC is set.
3. Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the OTC, the information
included in the Freeze Frame and/or Failure
Records data can help determine how many miles
since the OTC set. The Fail Counter and Pass
Counter can also help determine how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that you observed. This
will isolate when the OTC failed.

6-1719

4. This step verifies whether ignition voltage is

available at the relay.

5. This step determines if the A/C relay is at fault or

the A/C status circuit is at fault. If the A/C clutch
engages, this indicates that the A/C Status circuit
is OK.
6. If the A/C Status is displayed as OFF, this
indicates the A/C status circuit is open between
the splice and the PCM. If the A/C Status is
displayed as ON, this indicates a faulty connection
at the A/C compressor relay or: a faulty relay.
12. This OTC will not report a pass. The scan tool
status for this OTC will never report a pass.
The scan tool will only display when the diagnostic
fails. The repair is not complete if the scan tool
indicates that the diagnostic ran and failed.

OTC P1546 Air Conditioning (A/C) Clutch Feedback Circuit Low Voltage
Step

Action
Did you perform the Powertrain On-Board Diagnostic
(OBD) System Check?

1. Install a scan tool.

2. Idle the engine with the A/C ON for the specified
length of time.
Does the A/C clutch operate properly?

Value{s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080)
System Check

Go to Step 3

Go to Step 4

Go to Step 4

Go to
Diagnostic Aids

5 minutes

1. Turn ON the ignition leaving the engine OFF.

2. Review Freeze Frame and/or Failure Records data
for this OTC and note parameters.

3. Turn OFF the ignition for 15 seconds.

4. Idle the engine.
5. Operate the vehicle within the conditions required for
this diagnostic to run, and as close to the conditions
recorded in Freeze Frame/Failure Records as
possible. Special operating conditions that you need
to meet before the PCM will run this diagnostic,
where applicable, are listed in Conditions .for Setting
the OTC.
6. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

6-1720

Engine Controls - 5.7L

Engine

OTC P1546 Air Conditioning (A/C) Clutch Feedback Circuit Low Voltage (cont'd)
Step

Action

Value(s)

Yes

No

Important: For underhood electrical center relay terminal

identification, refer to Electrical Center Identification in
Wiring Systems.
1. Turn OFF the ignition.

2. Disconnect the A/C clutch relay from the underhood

electrical center 2.
3. Turn ON the ignition leaving the engine OFF.

4. Probe the ignition feed circuit at the A/C relay

terminal (switch side of relay) with the test lamp
J 34142-8 to a ground. Refer to Probing Electrical
Connectors in Wiring Systems.
Does the test lamp illuminate?

Jump the ignition feed circuit to the A/C clutch status

circuit (load) at the underhood electrical center 2 using a
fused jumper wire. Refer to Using Fused Jumper Wires in
Wiring Systems.
Does the A/C clutch engage?
Monitor the A/C Status display on the Engine 1 Data List
using the scan tool with the fused jumper still installed.

Replace the A/C clutch relay. Refer to Compressor Relay

Replacement in HV AC Systems Manual.
Is the action complete?

Go to Step 10

Go to Step 7

Go to Step B

Go to Step 12

Repair the open A/C clutch status circuit from the splice to
the PCM. Refer to Wiring Repairs in Wiring Systems.
Did you find and repair the condition?

Repair the open ignition feed circuit to A/C relay. Refer to

Wiring Repairs in Wiring Systems.
Is the action complete?

Repair the open in A/C status circuit from A/C relay to

splice. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

11

Go to Step 6

10

Go to Step 9

Does the scan tool indicate the A/C Status as ON?

Important: Inspect for poor A/C clutch relay connections
before replacing the relay. Refer to Wiring Repairs in
Wiring Systems.

Go to Step 5

Go to Step 12

Go to Step 11

Go to Step 12

Go to Step 12

Go to Step 12

12

1. Select the Diagnostic Trouble Code (OTC) option and

the Clear OTC Information option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (OTC) option and
the Specific OTC option, then enter the OTC number
using the scan tool.
4. Operate the vehicle within the Conditions for Running
the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this failed?

13

Select the Capture Info option and the Review Info option
using the scan tool.
Are any DTCs displayed that have not been diagnosed?

'

Go to Step 2

Go to Step 13

Go to the
applicable
DTC table

System OK

Engine Controls - 5.7L

Engine

6-1721

OTC P1626 Theft Deterrent Fuel Enable Signal Lost

.. ---.,Body
I Theft
I
Deterrent
Control
I
I
Fuel Enable Module
~s~n1::_ _ ~ (BCM)

DKB:1:: ~
DK

BLUI229
11

C1

r - - - Thett - - - - - - - - ,

Powertrain

Deterrent

Control

Fuel'
Enable

I
I

PCM

IC1=REDI
C2 = BLU

I Module
I
I

(PCM)
~

L-------------~~
218705

Circuit Description
The Vehicle Theft Deterrent system consists of the
following components:
Powertrain Control Module (PCM)
Body Control Module (BCM)
Ignition Lock and Key
The Vehicle Theft Deterrent system is designed to
disable vehicle operation if the incorrect key or starting
procedure is used. The Body Control Module enables
the crank circuit to the starter and sends a signal
to the PCM if the correct key is being used. If
the proper signal does not reach the PCM on the fuel
enable circuit, the PCM will not pulse the injectors
ON and thus not allow the vehicle to continue to
operate, even if the crank circuit is bypassed. The
proper signal is between 40-60 Hz and is measured
using the DC scale on the DMM.

Conditions for Running the OTC

The Engine is running or cranking.

Conditions for Setting the OTC

The PCM does not receive the correct signal from
the Body Control Module.
The condition is present for less than 1.0 second.

Action Taken When the OTC Sets

The PCM stores the DTC information into memory
when the diagnostic runs and fails.
The Malfunction Indicator Lamp (MIL) will not
illuminate.
The PCM records the operating conditions at the
time the diagnostic fails. The PCM stores this
information in the Failure Records.
The engine starts and then stalls or the starter
does not engage.

Conditions for Clearing the MIUDTC

A History DTC will clear after forty consecutive
warm-up cycles, if no failures are reported by
this or any other non-emission related diagnostic.
A last test failed (Current DTC) will clear when the
diagnostic runs and does not fail.
Use a scan tool in order to clear the MIUDTC.

Diagnostic Aids
Inspect the GAGE fuse for an open. The GAGE
fuse open casues DTC P1626 to set. Refer to
Wiring Repairs In Wiring Systems.
If the engine starts and then stalls, the Body
Control Module is not suppling the appropriate
signal or the theft deterrent fuel enable circuit is
open, shorted to a ground, or shorted to a voltage.
Using the Freeze Frame and/or Failure Records
data may aid in locating an intermittent condition.
If you cannot duplicate the DTC, the information
included in the freeze frame and/or failure records
data can help determine how many miles since
the DTC set. The Fail counter and the Pass
counter can also aid in determining how many
ignition cycles the diagnostic reported a pass
and/or a fail. Operate the vehicle within the same
freeze frame conditions (RPM, load, vehicle
speed, temperature etc.) that the PCM recorded.
This will isolc;1te when the DTC failed.
For an intermittent condition, refer to Symptoms.

6-1722

Engine

Engine Controls - 5.7L

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. An engine that does not crank and a OTC P1626
is set, indicates that there is a theft deterrent
system condition. An incorrect ignition key or an
incorrect starting procedure causes a no crank
condition.
For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.

3. An engine that does not crank indicates there is a

condition with the Body Control Module.
4. This step determines if the Powertrain Control
Module is capable of sending a 5.0 volt signal to
the BCM.
5. This step determines if the Body Control Module
is capable of sending a signal to the PCM. The
Body Control Module sends the PCM a 40-60 Hz
signal.
6. This step determines if the condition is intermittent.
If the engine starts and continues to operate, you
may have corrected the condition during
diagnoses. Inspect all connections at the BCM
and the PCM.

OTC P1626 Theft Deterrent FueJ Enable Signal Lost

Action

Step

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Goto
Diagnostic Aids

Go to. Step 4

Go to Vehicle
Theft Deterrent
(VTD) System
Check in Theft
Deterrent

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

1. Turn ON the ignition leaving the engine OFF.

2. Use the scan tool to clear the DTCs.
3: Select the Diagnostic Trouble Code (OTC) option and
the specific OTC option, then enter the OTC number
using the. scan tool.
Does the scan tool indicate that this diagnostic failed this
ignition?

Does the engine crank?

1. Turn OFF the ignition.

2. Disconnect the BCM connector. Refer to Body
Control Module Replacement in Body Control
System.
3. Turn ON the ignition leaving the engine OFF.
4. Measure the voltage at the fuel enable circuit at the
BCM harness connector using the DMM J 39200.
IS the voltage near the specified voltage?

'

5.0 Volts

Go to Step 5

Go to Step 7

Go to Step 6

Go to Step 8

Go to
Diagnostic Aids

Go to Step 9

1.
2.
3.
4.

Turn OFF the Ignition.

Reconnect the BCM.
Turn ON the Ignition leaving the engine OFF.
Select the DC volts and the Hertz (Hz) scale using
the DMM J 39200.
5. Backprobe one lead of the DMM J 39200 to the theft
deterrent fuel enable circuit at the BCM harness
connector and the other lead to ground using the
DMM J39200.
Is the hertz signal within the specified range?

1. Capture Info using the scan tool.

2. Clear the DTCs.
3. Attempt to start the engine.
Does the engine start and continue to operate?

40-60Hz

Engine

Engine Controls - 5.7L

6-1723

OTC P1626 Theft Deterrent Fuel Enable Signal Lost (cont'd)

Action

Step

Value(s)

Yes

No

Go to Step 12

Go to Step 9

Go to Step 12

Go to Step 11

Go to Step 12

Go to Step 10

1. Test the theft deterrent fuel enable circuit for the

following:

An open

A short to ground

A short to B+
2. If you find a circuit condition repair as necessary.
Refer to Wiring Repairs in Wiring Systems.
Did you find and correct the condition?
1. Inspect the terminal tension for the fuel enable circuit
at the BCM harness connector. Refer to lntermittents
and Poor Connections Diagnosis in Wiring Systems.

2. If you find a poor connection, repair as necessary.

Refer to Repairing Connector Terminals in Wiring

Systems.
Did you find and correct the condition?
1. Inspect the terminal tension for the fuel enable circuit
at the PCM harness connector. Refer to lntermittents
and Poor Connections Diagnosis in Wiring Systems.
9

2. If you find a poor connection, repair the terminal as

necessary. Refer to Repairing Connector Terminals in

Wiring Systems.
Did you find and correct the condition?

10

\:
11

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?
Replace the Body Control Module. Refer to Body Control
Module Replacement in Body Control Systems.

Go to Step 12

Is the action complete?

Go to Step 12

1. Select the Diagnostic Trouble Code (OTC} option and

the Clear OTC Information option using the scan tool.

2. Idle the engine at the normal operating temperature.

3. Select the Diagnostic Trouble Code (OTC) option and
12

the Specific OTC option, then enter the OTC number

using the scan tool.

4. Operate the vehicle within the Conditions for Running

the OTC as specified in the supporting text, if
applicable.
Does the scan tool indicate that this test ran and passed?

13

)
I

Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Go to Step 13

Go to Step 2

Go to the
applicable
OTC table

System OK

6-1724

Engine

Engine Controls - 5.7L

DTC P1635 5 Volt Reference 1 Circuit

v - - - - 5~

Powertrain " 5
Control I Reference
Module : A/C Refrigerant
(PCM) 1Pressure

>

- ;; 5

EGR
SV
Reference

Sensor

--- ::-- ":' _-::

EGR
Valve
Control

- ~ -

.,
I

MAP
5V
Reference

38

64 C2

LT BLU 697

GRY 705

:
I

=- "'.'"-":' _-: _-:. =-- '.:"-":' -- -:: =-- '.:"-":' _-:. =-- ::--":' _-:. =-- ::--":' _-::_ -

65

GRY 474

GRY 416

E
Exhaust Gas

Recirculation
(EGR)
.__.....__ _.......__ ____.._....... Valve

~I

Refrige~~
Pressure
~
Sensor ....__....:..._ _ _ _......,
C

.-~
--I- - - .
I

BRN 1456

GRY 435

BLK 552

RED/BLK 380

LTGRN 432
ORN/BLK 469

BLK 407

1-----

66 C2
~ A/C-R;ir;g";ra;
I
I
I

Pressure
Sensor
Signal

63

Manifold
Absolute
Pressure
(MAP)
Sensor

tJ

62 C1 9

34

Sensor
Ground

Sensor
Ground

I
I
I

EGA
Valve
Ground

-r~ -

26

48

-----------

.I~ - - ;R- -1- -5; - - - -1-~

--------

---------

-M;:-P - , --

Sensor
Signal

C2

MAP
Sensor
Ground

PCM

EGA
PinUe

C1=RED
C2 = BLU

~ Powertrain
I
I
I

Control
Module
(PCM)

>

I
I~

Position

L-----------------------------------------J
218502

Circuit Description
The PCM uses a common 5.0 Volt Reference 1 circuit
as a sensor feed. This circuit supplies 5 Volts to
the following sensors:
The A/C Pressure sensor
The MAP sensor
The EGR valve
The PCM monitors the voltage on the 5.0 Volt
Reference 1 circuit. This DTC sets if the voltage is out
of range.

Conditions for Running the DTC

The ignition switch is in the RUN position.

Conditions for Setting the DTC

The 5.0 volt reference circuit is out of range.
All above conditions are present for greater
than 2 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

Engine

Engine Controls - 5.7L

Conditions for Clearing the MIUDTC

)

The PCM turns the MIL OFF after three

consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current DTC) clears when the
diagnostic runs and does not fail.
A History DTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUDTC.

6-1725

Test Description
The numbers below refer to the step numbers on the
diagnostic table.

Diagnostic Aids
Using the Freeze Frame and/or Failure Records data
may aid in locating an intermittent condition. If you
cannot duplicate the DTC, the information included in
the Freeze Frame and/or Failure Records data can
help determine how many miles since the DTC
set. The Fail Counter and Pass Counter can also help
determine how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate vehicle
within the same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you observed.
This will isolate when the DTC failed. For an
intermittent condition, refer to Symptoms.

2. The 5.0 volt reference circuits for the sensors

listed are tied together inside the PCM. This step
separates the 5.0 volt reference circuits and
isolates the 5.0 volt reference circuit which
is shorted to voltage.
3. The 5.0 volt reference circuits for the sensors
listed are tied together inside the PCM. This step
separates the 5.0 volt reference circuits and
isolates the 5.0 volt reference circuit which
is shorted to ground.
4. This step isolates the 5.0 volt reference circuit
from the sensor signal circuit.

OTC P1635 5 Volt Reference 1 Circuit

Step

Action
Did you perform the Powertrain On-Board Diagnostic
(OBD) System Check?

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Go to Step 5

Go to
Diagnostic Aids

1. Turn OFF the ignition.

2. Disconnect the PCM harness connector C2 located
on the same side as the manufacturer's logo. Refer
to PCM Replacement/Programming.
3. Turn ON the ignition leaving the engine OFF.
4. Connect the DMM J 39200 to ground.
5. Probe the PCM harness connector 5.0 volt reference
circuits for the following components:
The MAP sensor
The EGR valve
The A/C Pressure sensor
Do any of the circuits measure greater than the
specified value?
1.
2.
3.
4.

Turn OFF the ignition.

Connect the test lamp J 34142-8 to B+.
Turn ON the ignition leaving the engine OFF.
Probe the PCM harness connector 5.0 volt reference
circuits for the following components:
The MAP sensor
The EGR valve
The A/C Pressure sensor
Does the test lamp illuminate for any of the circuits?

5.1V

6-1726

Engine Controls - 5.7L

Engine

OTC P1635 5. Volt Reference 1 Circuit (cont'd)

Value(s)

Step

Action

1. Disconnect the electrical connector at the sensor that

measured greater than the specified value.
2. Probe the affected 5.0 volt reference circuit at the
PCM harness connector using the DMM J 39200 to
ground.
Does the DMM display a voltage greater than the
specified value?

5.1V

1. Disconnect the electrical connector at the sensor that

illuminated the test lamp.
2. Probe the affected 5.0 volt reference circuit at the
PCM harness connector using the test lamp
J 34142-8 connected to B+.
Is the test lamp illuminated?

o.ov

1. Connect the test lamp J 34142-8 to B+.

2. Turn ON the ignition leaving the engine OFF.
3. Probe the signal circuit at the affected sensor.
Is the test lamp illuminated?

Repair the short to voltage on the appropriate 5.0 volt

reference circuit. Refer to Wiring Repairs in Wiring
Systems.
Is the action complete?

Repair the short to ground on the appropriate 5.0 volt

reference circuit. Refer to Wiring Repairs in Wiring
Systems.
Is the action complete?

Repair the short to voltage on the appropriate sensor

signal circuit. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Repair the short to ground on the appropriate sensor

signal circuit. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the action complete?

13

1. Select the Diagnostic Trouble Codes (OTC) option

and the Clear OTC Information option using the
scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Specific OTC option under the Diagnostic
Trouble Code (DTC) option using a scan tool.
4. Operate vehicle within the Conditions for Running the
OTC as specified in the supporting text if applicable.
Does the scan tool indicate that this test ran and passed?

14

Select the Capture Info option and the Review Info option
using the scan tool.
Are any DTCs displayed that you have not diagnosed?

10

11

12

No

1. Connect the DMM J 39200 to ground.

2. Turn ON the ignition leaving the engine OFF.
3. Measure the voltage on the signal circuit at the
affected sensor.
Does the DMM display a voltage greater than the
specified value?

Yes

Go to Step 8

Go to Step 6

Go to Step 9

Go to Step 7

Go to Step 10

Go to Step 12

Go to Step 11

Go to Step 12

Go to Step 13

Go to Step 13

Go to Step 13

Go to Step 13

Go to Step 13

Go to Step 14
Go to applicable
OTC table

System OK

Engine

Engine Controls - 5.7L

6-1727

OTC P1639 5 Volt Reference 2 Circuit

'" - - - - - - - - - - - - - - - - - - - - - - - - - - - - ., Powertrain
1
I Control
5V
I
I
TP Sensor
Fuel Tank
Module
1 (PCM)
5V
Pressure Sensor
1

'--~f'::m~e
43

----------------5~R,::e'.:,n~-

---------------- ------------ -----

596

GRY
Antilock
Brakes

_ _.

-67

C2

L2w

GRY 598

GRY
596

Cell 44

GRY 596

. fI

c l,

B ,

DKBLU 417

ORN/BLK 469

BLK

452
DKBLU 417

I
:

Sensor1
Signal

Anti lock
Brakes
Cell 44

DKGRN 890

- .

1-----

. . _______________________ .??

1 ----------

.,,_
Sensor
Ground

Ground
- - - - - Distribution
Ce1114

ORN/BLK 469

BLK 452

12 ... _______ ?~
-

.BLK 452

417

.I

DKBLU

~ TP

Fuel Tank
Pressure
Sensor

Throttle
, - Position
Sensor (TP)

..
.

Fuel Tank
Pressure
Sensor
Signal

C2

75 C1

I -~

Sensor
Ground

PCM -

C1 = RED

C2 =BLU

~ Powe rt rain

Control

I Module
:

(PCM)

'---------------------------------------~~
218503

Circuit Description
The PCM uses a common 5.0 Volt Reference circuit
as a sensor feed to the Fuel Tank Pressure sensor,
the Fuel Tank Level sensor and, the TP sensor.
The PCM monitors the voltage on the 5.0 Volt
Reference circuit. This OTC sets if the voltage is out
of range.

Conditions for Running the DTC

The engine operating.

Conditions for Setting the DTC

The 5.0 volt reference circuit is out of range.
The above condition is present for greater
than 2 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp on the second consecutive ignition cycle
that the diagnostic runs and fails.
The PCM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the PCM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive ignition
cycle, the PCM records the operating conditions
at the time of the failure. The PCM writes the
conditions to the Freeze Frame and updates the
Failure records.

6~1728

Engine Controls - 5.7L

Conditions for Clearing the MIL/DTC

The PCM turns the MIL OFF after three
consecutive ignition cycles that the diagnostic
runs and does not fail.
A last test failed (current OTC) clears when the
diagnostic runs and does not fail.
A History OTC clears after forty consecutive
warm-up cycles, if this or any other emission
related diagnostic does not report any failures.
Use a scan tool in order to clear the MIUOTC.

Diagnostic Aids
A fuel level sensor signal circuit that is shorted to B+
may set this OTC.
If no circuit condition can be found, test the affected
component.
Using the Freeze Frame and/or Failure Records data
may aid in locating an intermittent condition. If you
cannot duplicate the OTC, the information included in
the Freeze Frame and/or Failure Records data can
help determine how many miles since the OTC
set. Th~ Fail Counter and Pass Counter can also help
determine how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate vehicle
wit~in the same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you observed.
This will isolate when the OTC failed. For an
intermittent condition, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
Diagnostic Table.
2. A short to B+ on the signal circuit for any of the
sensors listed will only affect that sensor's
voltage. This step tests for a short to B+ on the
signal circuit. Observe that the TP sensor
signal circuit is an input to the Accelerator and
Servo Control Module (ASM). Keep this in
mind when testing the TP sensor signal circuit.
3. This step determines if the 5.0 volt reference
circuit is shorted to B+.
4. This steps determines if the short to voltage on
the 5.0 volt reference circuit is forward or
rearward of connector C210.

Engine
5. This step separates the 5.0 volt reference circuit
into two individual circuits since the 5.0 volt
reference circuits are tied together inside of the
PCM. This step.tests for the TP sensor 5.0 volt
reference circuit for being shorted to a circuit in the
PCM harness.

6. This step tests for the Fuel Tank Pressure sensor

5.0 volt reference circuit for being shorted to a
circuit in the PCM harness.

7. This step tests for a short to B+ on the TP sensor

5.0 volt reference circuit.

8. This step tests for a short to B+ on the Fuel Tank

Pressure sensor 5.0 volt reference circuit.

9. This step tests for a short to ground on the TP

sensor 5.0 volt reference circuit.

10. This steps determines if the short to ground on

the 5.0 volt reference circuit is forward or
rearward of connector C210.
11. This step separates the 5.0 volt reference circuit
into two individual circuits since the 5.0 volt
reference circuits are tied together inside of the
PCM. This step tests for the TP sensor 5.0 volt
reference circuit for being shorted to a ground.
12. This step tests for the Fuel Tank Pressure sensor
5.0 volt reference circuit for being shorted to a

ground.
13. This step energies the fuel pump feed circuit in
order to determine if the fuel pump circuit is
shorted to the Fuel Tank Pressure sensor 5.0 volt
reference circuit.

14. This steps determines if the short to voltage on

the Fuel Tank Pressure sensor 5.0 volt reference
circuit is forward or rearward of connector C210.
15. This step energies the fuel pump feed circuit in
order to determine if the fuel pump circuit is
shorted to the Fuel Tank Level sensor 5.0 volt
reference circuit.
16. This steps determines if the short to voltage on
the Fuel Tank Level sensor 5.0 volt reference
circuit is forward or rearward of connector C21 o.

Engine

Engine Controls - 5.7L

6-1729

OTC P1639 5 Volt Reference 2 Circuit

Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

1. Install a scan tool.

2. Idle the engine.
3. Monitor the sensor voltage for the TP sensor, the
Fuel Tank Level sensor and, the Fuel Tank Pressure
sensor using the scan tool.
Are any of the voltages above the specified value?

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 17

Go to Step 3

Go to Step 4

Go to Step 9

Go to Step 5

Go to Step 20

Go to Step 30

Go to Step 6

Go to Step 30

Go to Step 7

Go to Step 18

Go to Step B

Go to Step 21

Go to Step 31

4.5V

1. Disconnect the TP sensor electrical connector.

2. Idle the engine.

3. Probe the TP sensor 5.0 volt reference circuit at the

TP sensor harness connector using the DMM
J 39200 connected to a ground.
Is the voltage greater than the specified value?

5.4V

Important: Additional DTCs set when connector C21 O is

disconnected.
1. Turn OFF the ignition.
2. Disconnect the 8-way C21 O connector located behind
the passenger side kick panel.
3. Idle the engine.
4. Probe the TP sensor 5.0 volt reference circuit at the
TP sensor harness connector using the DMM
J 39200 connected to a ground.
Is the voltage greater than the specified value?

5.4V

1. Disconnect the PCM connector C2 located on the

same side as the nianufacture's logo. Refer to PCM
Replacement/Programming.
2. Test the harness continuity between the TP sensor
5.0 volt reference circuit and all other circuits in the
disconnected PCM connector. Refer to Testing for
Continuity in Wiring Systems.
Do any of the circuits indicate a resistance within the
specified range?

0-5Q

Test the harness continuity between the Fuel Tank

Pressure sensor 5.0 volt reference circuit and all other
circuits in the disconnected PCM connector. Refer to
Testing for Continuity in Wiring Systems.

0-5Q

Do any of the circuits indicate a resistance within the

specified range?

1. Turn ON the ignition.

2. Probe the TP sensor 5.0 volt reference circuit in the
disconnected PCM harness using the DMM J 39200
connected to a ground. Refer to Probing Electrical
Connectors in Wiring Systems.
Is the voltage greater than the specified value?

5.4V

1. Turn ON the ignition.

2. Probe the Fuel Tank Pressure sensor 5.0 volt
reference circuit in the disconnected PCM harness
using the DMM J 39200 connected to a ground.
Is the voltage greater than the specified value?

5.4V

6-1730

Engine Controls.- 5~7L

Engine

DTC P1639 5 VoltReference 2 Circuit (cont'd)

Step

10

Action

1. Turn ON the ignition leaving the engine OFF.

2. Probe the TP sensor 5.0 volt reference circuit at the
TP sensor harness connector with the test lamp
J 34142-8 connected to B+. Refer to Probing
Electrical Connectors in Wiring Systems.
Is the test lamp illuminated?
Important: Additional DTCs set when connector C210 is
disconnected
1. Turn OFF the ignition.
2. Disconnect the 8-way C21 Oconnector located behind
the passenger side kick panel.
3. Idle the engine.

Value(s)

Yes

No

'

(
Go to Step .10

Go to Step 13

Go to Step 11

Go to Step 27

Go to Step28

Go to Step 12

4. Probe the TP sensor 5.0 volt reference circuit at the

TP sensor harness connector with the test lamp
J 34142-8 connected to B+.
Is the test lamp illuminated?

1. Disconnect the PCM connector C2 located on the

11

12

13

same side as the manufacture's logo. Refer to PCM

Replacement/Programming.
2. Test the continuity between the TP sensor 5.0 volt
reference circuit and battery ground in the
disconnected PCM connector. Refer to Testing for
Continuity in Wiring Systems.
Is the resistance within the specified range?
Test the continuity between the Fuel Tank Pressure
sensor 5.0 volt reference circuit and ground in the
disconnected PCM connector using the DMM J 39200
connected to a ground. Refer to Testing for Continuity in
Wiring Systems.
Is the resistance within the specified range?
1. Disconnect the PCM connector C2 located on the
same side as the manufacture's logo. Refer to PCM
Replacement/Programming.
2. Remove the Fuel Pump relay from the underhood
electrical center 2.
3. Jumper the Fuel Pump relay battery feed circuit to
the Fuel Pump drive circuit using a fused
jumper wire.
4. Probe the Fuel Tank Pressure sensor signal circuit in
the disconnected PCM harness the DMM J 39200
connected to a ground.

Q-5Q

0-5Q
Go to Step 26

Go to Step 31

Go to Step 14

Go to Step 15

Go to Step 15

Go to Step 22

OV

Is the voltage greater than the specified value?

Important: Additional DTCs set when connector C210 is
disconnected.

14

1. Leave the fused jumper installed.

2. Turn OFF the ignition.
3. Disconnect the 8-way C210 connector located behind
the passenger side kick panel.
4. Probe the Fuel Tank Pressure sensor signal circuit in
the disconnected PCM harness using the DMM
J 39200 connected to a ground.
Is the voltage greater than the specified value?

OV

Engine. Controls - 5.7L

Engine

6-1731

OTC P1639 5 Volt Reference 2 Circuit (cont'd)

Step

Action

Value(s)

15

1. Leave the fused jumper installed.

2. Probe the Fuel Tank Level sensor signal circuit in the
disconnected PCM harness using the DMM J 39200
connected to a ground.
Is the voltage greater than the specified value?

OV

Important: Additional DTCs set when connector C210 is

disconnected.
1. Leave the fused jumper installed.
2. Turn OFF the ignition.
3. Disconnect the 8-way C210 connector located behind
the passenger side kick panel.
4. Probe the Fuel Tank Level sensor signal circuit in the
disconnected PCM harness using the DMM J 39200
connected to a ground.
Is the voltage greater than the specified value?

ov

Repair the short to voltage on the affected signal circuit.

Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

16

17

18

19

20

21

1. Disconnect the ASM. Refer to Accelerator and Servo

Control Module (ASM) Replacement in Antilock Brake
System.
2. Probe the TP sensor 5.0 volt reference circuit at the
disconnected PCM harness connector using the DMM
J 39200 connected to a ground.
Is the voltage greater then the specified value?

Repair the short to voltage on the Fuel Tank Pressure

sensor 5.0 volt reference circuit between the C21 O
connector and the fuel tank. Refer to Wiring Repairs in
Wiring Systems.
Is the action complete?

23

24

Repair the short to voltage on the Fuel Tank Level sensor

signal circuit between the C210 connector and the fuel
tank. Refer to Wiring Repairs in Wiring Systems.

25

Is the action complete?

Go to Step 24

Go to A
Diagnostic
System Check in
Antilock Brake
System

Go to Step 32

Go to Step 32

Go to Step 32

Go to Step 32

Go to Step 32

Is the action complete?

Repair the short to voltage on the Fuel Tank Level sensor
signal circuit between the C21 O connector and the PCM.
Refer to Wiring Repairs in Wiring Systems.

Go to Step 25

Go to Step 32

Is the action complete?

Repair the short to voltage on the Fuel Tank Pressure
sensor signal circuit between the C210 connector and the
PCM. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Go to Step
Diagnostic Aids

Go to Step 19

Is the action complete?

22

Go to Step 16

5.4V

Repair the short to voltage on the Fuel Tank Pressure

sensor signal circuit between the C210 connector and the
fuel tank. Refer to Wiring Repairs in Wiring Systems.

No

Go to Step 32

Repair the short to voltage on the TP sensor 5.0 volt

reference circuit. Refer to Wiring Repairs in Wiring
Systems.
Is the action complete?

Repair the short to voltage on the Fuel Tank Pressure

sensor 5.0 volt reference circuit between the C21 O
connector and the PCM. Refer to Wiring Repairs in Wiring
Systems.

Yes

Go to Step 32

6-1732

Engine Controls - 5.7L

Engine

DTC P1639 5 Volt Reference 2 Circuit (cont'd)

Step

Action

Value(s)

Repair the short to ground on the Fuel Tank Pressure

sensor 5.0 volt reference circuit between the C21 O
connector and the PCM. Refer to Wiring Repairs in Wiring
Systems.
Is the action complete?

Repair the short to ground on the Fuel Tank Pressure

sensor 5.0 volt reference circuit between the C21 O
connector and the fuel tank. Refer to Wiring Repairs in
Wiring Systems.
Is the action complete?

1. Disconnect the ASM. Refer to Accelerator and Servo

Control Module (ASM) Replacement in Antilock Brake
System.
2. Probe the TP sensor 5.0 volt reference circuit at the
disconnected PCM harness connector using the test
lamp J 34142-B connected to B+.
Is the test lamp illuminated?

29

Repair the short to ground on the TP sensor 5.0 volt

reference circuit. Refer to Wiring Repairs in Wiring
Systems.
Is the action complete?

30

Repair the circuits that are shorted together. Refer to

Wiring Repairs in Wiring Systems.
Is the action complete?

26

27

28

31

32

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.

Replace the PCM.

Is the action complete?
1. Select the Diagnostic Trouble Code (DTC) option and
the Clear DTC option using the scan tool.
2. Idle the engine at the normal operating temperature.
3. Select the Diagnostic Trouble Code (DTC) option and
the Specific DTC option, then enter the DTC number
using the scan tool.
4. Operate vehicle within the Conditions for Running the
DTC as specified in the supporting text, if applicable.

33

No

(
Go to Step 32

Go to Step 32

Go to Step 29

Go to A
Diagnostic
System Check in
Antilock Brake
System

Go to Step 32

Go to Step 32

Go to Step 32

Does the scan tool indicate that this test ran and passed?
Select the Capture Info option and the Review Info option
using the scan tool.
Does the scan tool display any DTCs that you have not
diagnosed?

Yes

Go to Step 33

Go to applicable
DTC table

System OK

Engine Controls - 5.7L

Engine

6-1733

Symptoms

Intermittent

Important Preliminary Checks Before Starting

Important: Check for improper installation of electrical

components if an intermittent condition exists.
Inspect for aftermarket theft deterrent devices, lights
and cellular phones. Ensure that no aftermarket
equipment is connected to the Class 2 circuit. If you
can not locate an intermittent condition, a cellular
phone signal communication may cause the condition.

Perform the A Powertrain On Board Diagnostic

(080) System Check before using the Symptom
Tables, and verify all of the following are true:
The PCM and MIL (Service Engine Soon) are
operating correctly.
There are no DTC(s) stored.
Ensure that the engine coolant temperature is not
above 130C (266F). This condition causes the
PCM to operate in Engine Coolant Over
Temperature-Fuel Disabled Mode. While in
Engine Coolant Over Temperature-Fuel Disabled
Mode, the PCM turns the fuel off to four
cylinders at a time in order to keep engine
temperatures from reaching damaging levels. The
system perceives Engine Coolant Over
Temperature as a lack of power, miss, or rough
idle. If the vehicle is operating in Engine Coolant
Over Temperature-Fuel Disabled Mode, refer
to Engine Overheating in Engine Cooling
for diagnosis.
The scan tool data is within the normal operating
range, refer to Engine Scan Tool Data List.
Verify the customers concern, and locate the
correct symptom in the table of contents.
Check the items indicated under that symptom.

Visual/Physical Check
Several of the symptom procedures ask for a Careful
Visual/Physical Check. This step is extremely
important, it can lead to correcting a condition without
further tests and can save valuable time. This
check includes:
The PCM grounds for being clean, tight, and in
the proper location. Refer to Ground Distribution
Schematics in Wiring Systems.
Vacuum hoses for splits, kinks, and proper
connections, as shown on the Vehicle Emission
Control Information label. Check thoroughly for any
type of leak or restriction. Refer to Emission
Hose Routing Diagram.
The Mass Air Flow (MAF) sensor installation. The
arrows on the plastic portion of the sensor must
point toward the engine.
The air intake ducts for being collapsed or for
having damaged areas.
Air leaks at throttle body mounting area, Mass Air
Flow (MAF) sensor, and the intake manifold
sealing surfaces.
The ignition wires for cracking, hardness, proper
routing and carbon tracking. Refer to Spark
Plug Wires Not Operating Properly in Engine
Electrical.
The engine harness wiring and terminals for
proper connections, pinches or cuts. Refer
to Harness Routing Views in Wiring Systems.

Important: The condition may or may not turn ON

the Malfunction Indicator Lamp (MIL) or store a OTC.
DO NOT use the Diagnostic Trouble Code (OTC)
tables for intermittent conditions. The fault must
be present in order to locate the condition.
Faulty electrical connections or wiring cause most
intermittent conditions. Perform a careful
visual/physical check for the following conditions:
Poor mating of the connector halves or a terminal
not fully seated in the connector body (backed
out). Refer to lntermittents and Poor Connections
Diagnosis in Wiring Systems.
An improperly formed or damaged terminal. Refer
to lntermittents and Poor Connections Diagnosis
in Wiring Systems.
Reform or replace connector terminals in the
circuit in order to insure proper contact tension.
Refer to Repairing Connector Terminals in Wiring
Systems.
Poor terminal to wire connection requires removing
the terminal from the connector body in order
to check.
Road test the vehicle with a Digital Multimeter (DMM)
J 39200 connected to the suspected circuit. An
abnormal voltage when the malfunction occurs is a
good indication that there is a malfunction in the circuit
being monitored.
Use a scan tool in order to help detect intermittent
conditions. The GM Techline equipment (Scan Tool)
has several features that you can use to locate
an intermittent condition. Use the following features to
find intermittent faults:
You can trigger the Snapshot feature in order to
capture and store engine parameters within the
scan tool when the malfunction occurs. You
can then review this stored information in order to
see what caused the malfunction.
Using a Scan Tools Freeze Frame buffer or
Failure Records buffer can also aid in locating an
intermittent condition. Review and capture the
information in the Freeze Frame and/or Failure
record associated with the intermittent OTC being
diagnosed. Drive the vehicle in the conditions
that were present when the OTC originally set.

5;.1734

Engine Controls - 5.7L

Engine

Important: If the intermittent condition exists as a

start and then stall, check for DTC(s) relating to the
theft deterrent system. Check for improper installation
of electrical options such as lights, cellular phones etc.
Any of the following may cause an intermittent
MalfL,1,nction Indicator Lamp (MIL) with no stored DTC:
The ignition coils shorted to a ground, arcing at
the ignition wires or the spark plugs.
The PCM grounds, refer to Ground Distribution
Schematics in Wiring Systems.
The Ignition Control (IC) wires for being routed to
close to the secondary ignition wires, coils, or
the generator. Ensure that all of the circuits from
ttie PCM to the ignition coils have good
connections.
An open diode across the A/C compressor clutch
and other open diodes.

Use the following tables when diagnosing a symptom

concern.

Hard Start
Surges/Chugg/es

Lack of Power, Sluggishness, or Sponginess

Detonation/Spark Knock
Hesitation, Sag, Stumble
Cuts Out, Misses
Poor Fuel Economy
Rough, Unstable, or Incorrect Idle and Stalling
Dieseling, Run-On
Backfire

Hard Start
Checks

Action

Definition: Engine cranks OK, but does not start for a long time. Does eventually run, or may start but immediately dies.
Preliminary

Refer to Symptoms, Important Preliminary Checks Before Starting.

Check the PCM grounds for being clean, tight and in the proper locations. Refer
to Ground Distribution Schematics.
Search for bulletins.

Sensor/System

Check the Engine Coolant Temperature (ECT) sensor for being shifted in value.
Connect a scan tool. Compare the Engine Coolant Temperature against the
Intake Air Temperature (IAT) on a cold engine. The ECr and IAT sensor values
should be within 3C (5F) of each other. If the ECT sensor is out of range
with the IAT sensor, check the resistance of the ECT sensor. Refer to
Temperature vs Resistance for resistance specifications. Replace the ECT
sensor if the resistance is not within the specification. If the sensor is within th1;1
specification, repair ECT signal circuit for high resistance.
Check the Mass Air Flow sensor installation. A MAF sensor that is incorrectly
installed may cause a hard start. Important: The embossed arrows on the MAF
sensor indicate the direction of the intake air flow. The arrows must point toward
the engine. Install the MAF in the proper direction. Refer to MAF Sensor
Replacement.

Fuel System

Check the fuel pump rel,ay operation. The fuel pump should turn ON for
2 seconds when you turn on the ignition. Refer to Fuel Pump Relay Circuit
Diagnosis.
A faulty in-tank fuel pump check valve allows the fuel in the lines to drain t>ack
to the tank after the engine stops. To check for this condition, refer to Fuel
System Diagnosis.
Check both injector fuses for being open. An open injector fuse causes four
injectors and four ignition coils not to operate~ Replace the fuse. Inspect the
injector circuits and the ignition coil circuits for an intermittent short to ground.
Check for a low fuel pressure condition. Refer to Fuel System Diagnosis.
Check for a restricted fuel filter. Refer to Fuel System Diagnosis.
Check for a contaminated fuel condition. Refer to Alcohol/Contaminants-in-Fuel
Diagnosis.

Engine Controls - 5.7L

Engine

6-1735

Hard Start (cont'd)

Action

Checks

Ignition System

Check both injector fuses tor being open. An open injector fuse causes four
ignition coils and four injectors not to operate. Replace the fuse. Inspect the
ignition coil circuits and the injector circuits for an intermittent short to ground.
Check for proper ignition voltage output with spark tester J 26792. Refer to
Electronic Ignition System Diagnosis.
Remove the spark plugs and check for the following:

Engine Mechanical

-Wet plugs
-Cracks
-Wear
- Improper gap
- Burned electrodes
- Heavy deposits
Refer to Engine Electrical.
Determine the cause of the fouling before replacing the spark plugs if the spark
plugs are gas or oil fouled.
Check for bare or shorted ignition wires. Refer to Spark Plug Wires Not
Operating Properly in Engine Electrical.
Check for loose ignition coil grounds. Refer to Electronic Ignition System
Diagnosis.
Check the spark plugs for proper heat range.

Excessive oil in the combustion chamber-Leaking valve seals. Refer to Oil

Consumption Diagnosis in Engine Mechanical 5.7L.
Low cylinder compression. Refer to Engine Compression Test in Engine
Mechanical 5.7L.
Combustion chambers for excessive carbon buildup. Clean the chambers using
Top engine cleaner. Follow the instructions on the can.
For incorrect basic engine parts. Inspect the following:
- Cylinder heads
- Camshaft
- Pistons, etc.

Surges/Chuggles
Checks

Action

Definition: Engine power variation under steady throttle or cruise. Feels like the vehicle speeds up and slows down with no
change in the accelerator pedal position.
Preliminary

Refer to Symptoms, Important Preliminary Checks Before Starting.

Search for bulletins.
Check the PCM grounds for being clean, tight and in the proper locations. Refer
to Ground Distribution Schematics in Wiring Systems.
Be sure the driver understands the operation of the transmission torque
converter clutch and NC compressor operation as explained in the owners
manual. Inform the customer how the TCC and the NC clutch operates.

Sensor/System

Check the Heated Oxygen Sensors (H02S). The Heated Oxygen Sensors
(H02S) should respond quickly to different throttle positions. If they do not,
check the H02S for silicon or other contaminates from fuel or the use of
improper RTV sealant. The sensors may have a white powdery coating and
result in a high but false signal voltage (rich exhaust indication). The PCM will
then reduce the amount of fuel delivered to the engine causing a severe
driveability condition. For more information, Refer to Information
Sensors/Switches Description.
Check the MAF sensor connections. Repair or replace terminals. Refer to
Repairing Connector Terminals in Wiring Systems.

6-1736

Engine Controls - 5.7L

Engine
Surges/Chuggles (cont'd)

Checks
Fuel System

Action
Check for a low fuel pressure condition. Refer to Fuel System Diagnosis.
Check for a restricted fuel filter. Refer to Fuel System Diagnosis.
Check for a contaminated fuel condition. Refer to Alcohol/Contaminants-in-Fuel
Diagnosis.
Check that each injector harness is connected to the correct injector/cylinder
according to the firing order (firing order: 1-8-7-2-6-5-4-3). Relocate injector
harnesses as necessary.
Check the items that cause an engine to run rich (long term fuel trim near
-13%). For a rich condition, refer to OTC P0132 H02S Circuit High Voltage
Bank 1 Sensor 1 and OTC P0152 H02S Circuit High Voltage Bank 2 Sensor 1.
Check the items that can cause an engine to run lean (long term fuel trim near
23%). For a lean condition, refer to OTC P0131 H02S Circuit Low Voltage
Bank 1 Sensor 1 and OTC P0151 H02S Circuit Low Voltage Bank 2 Sensor 1.

Ignition System

Wet down the secondary ignition system with water from a spray bottle. Wetting
down the secondary ignition system may help locate damaged or deteriorated
components. Look/listen for arcing or misfiring as you apply the water.
Check for proper ignition voltage output with spark tester J 26792. Refer to
Electronic Ignition System Diagnosis.
Remove the spark plugs and check for the following:
-Wet plugs
- Cracks
-Wear
- Improper gap
- Spark plugs for proper heat range
- Burned electrodes
- Heavy deposits
An improper spark plug gap will cause a driveability concern. Do the spark plug
gapping using a wire gauge gap tool (J 41319). Refer to Spark Plug
Replacement in Engine Electrical. Determine the cause of the fouling before
replacing the spark plugs if spark plugs are gas or oil fouled. Refer to
OTC P0172 Fuel Trim System Rich Bank 1 and OTC P0175 Fuel Trim System
Rich Bank 2 for diagnosis of the rich condition or Oil Consumption Diagnosis in
Engine Mechanical 5.7L for diagnosis of the oil fouling condition.
Check for loose ignition coil grounds. Refer to Electronic Ignition System
Diagnosis.

Engine Mechanical

Ensure that the engine coolant temperature is not above 130C (266F). This
condition causes the PCM to operate in Engine Coolant Over temperature-Fuel
Disabled Mode. While in Engine Coolant Over temperature-Fuel Disabled Mode, 1he
PCM turns fuel off to four cylinders at a time to keep engine temperatures from
reaching damaging levels. The system perceives Engine Coolant Over
temperature-Fuel Disabled Mode as a lack of power, miss, or rough idle. If the
vehicle operates in Engine Coolant Over temperature-Fuel Disabled Mode, refer to
Engine Overheating in Engine Cooling for diagnosis.

Additional Checks

Visually (physically) check vacuum hoses for splits, kinks, and proper
connections and routing as shown on Vehicle Emission Control
Information label.
Check the TCC operation. A TCC applying too soon can cause the engine to
spark knock. Refer to Torque Converter Clutch Diagnosis in Automatic
Transmission 4L60E.

l;:ngine Controls - 5.7L

Engine

6-1737

Lack of Power, Sluggishness, or Sponginess

Checks

Action

Definition: Engine delivers less than expected power. Little or no increase in speed when the accelerator pedal is pushed
down part way.
Preliminary Checks

Refer to Symptoms,, Important Preliminary Checks Before Starting.

Search for bulletins.
Check the PCM grounds for being clean, tight and in the proper locations. Refer
to Ground Distribution Schematics in Wiring Systems.
Remove the air filter element and check for dirt or for being restricted. Refer to
Air Cleaner Element Replacement and replace as necessary.

Fuel System Checks

Check both injector fuses for being open. An open injector fuse causes four
ignition coils and four injectors not to operate. Replace the fuse. Inspect the
ignition coil circuits and the injector circuits for an intermittent short to ground.
Check for a low fuel pressure condition. Refer to Fuel System Diagnosis.
Check for a restricted fuel filter. Refer to Fuel System Diagnosis.
Check for a contaminated fuel condition. Refer to Alcohol/Contaminants-in-Fuel
Diagnosis.
Check the items that cause an engine to run rich (long term fuel trim
near -13%). For a rich condition, refer to OTC P0132 H02S Circuit High Voltage
Bank 1 Sensor 1 and OTC P0152 H02S Circuit High Voltage Bank 2 Sensor 1.
Check the items that can cause an engine to run lean (long term fuel trim
near 23%). For a Lean condition, refer to OTC P0131 H02S Circuit Low Voltage
Bank 1 Sensor 1 and OTC P0151 H02S Circuit Low Voltage Bank 2 Sensor 1.

Sensor/System

Use a scan tool in order to monitor the KS system for excessive spark retard activity.
Refer to Knock Sensor System Description.

Ignition System

Check both injector fuses for being open. An open injector fuse causes four
ignition coils and four injectors not to operate. Replace the fuse. Inspect the
ignition coil circuit and the injector circuits for an intermittent short to ground.
Wet down the secondary ignition system with water from a spray bottle. Wetting
the secondary ignition system may help locate damaged or deteriorated
components. Look/listen for arcing or misfiring as water is applied.
Check for. proper ignition voltage output with spark tester J 26792.
Remove the spark plugs and check for the following:
- Wet plugs
- Cracks
-Wear
- Improper gap
- Spark plugs for proper heat range
- Burned electrodes
- Heavy deposits
An improper spark plug gap will cause a driveability concern. Do the spark plug
gapping using a wire gauge gap tool (J 41319). Refer to Spark Plug
Replacement in Engine Electrical. Determine the cause of the fouling before
replacing the spark plugs if spark plugs are gas or oil fouled. Refer to
OTC P0172 Fuel Trim System Rich Bank 1 or OTC P0175 Fuel Trim System
Rich Bank 2 tor diagnosis of the rich condition, or Oil Consumption Diagnosis in
Engine Mechanical 5.7L for diagnosis of the oil fouling condition.
Check for loose ign'ition coil grounds. Refer to Electronic Ignition System
Diagnosis.

6-1738

Engine Controls - 5.7L

Engine

Lack of Power, Sluggishness, or Sponginess {cont'd)

Checks
Engine Mechanical

Action
Ensure that the engine coolant temperature is not above 130C (266F). This
condition causes the PCM to operate in Engine Coolant Over temperature-Fuel
Disabled Mode. While in Engine Coolant Over temperature-Fuel Disabled Mode,
the PCM will turn fuel off to four cylinders at a time to keep engine temperatures
from reaching damaging levels. The system perceives the Engine Coolant Over
temperature-Fuel Disabled Mode as a lack of power, miss, or rough idle. If the
vehicle operates in Engine Coolant Over temperature-Fuel Disabled Mode, refer
to Engine Overheating in Engine Cooling for diagnosis.
Excessive oil in combustion chamber-Leaking valve seals. Refer to Oil
Consumption Diagnosis in Engine Mechanical 5. 7L.
Low cylinder compression. Refer to Engine Compression Test in Engine
Mechanical 5.7L.
For incorrect basic engine parts. Inspect the following:

- Camshaft
- Cylinder heads
- Pistons, etc.
Additional Checks

Check the
- Inspect
- Inspect
- Inspect

exhaust system for possible restrictions. Check for the following:

the exhaust system for damaged or collapsed pipes.
the exhaust manifold for a collapsed inner wall.
the mufflers for heat distress or possible internal failure.

- Inspect for possible plugged Three-Way catalytic converters. Refer to

Restricted Exhaust System Check.
Check Torque Converter Clutch (TCC) for proper operation. Refer to forque
Converter Clutch Diagnosis in Automatic Transmission 4L60E.

Detonation/Spark Knock
Checks

Action

Definition: A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change
with throttle opening.
Preliminary Checks

Refer to Symptoms, Important Preliminary Checks Before Starting.

Search for bulletins.
Check the PCM grounds for being clean, tight, and in the proper locations. Refer
to Ground Distribution Schematics in Wiring Systems
If the scan tool readings are normal (refer to supporting text of the Powertrain
On-Board Diagnostic (080) System Check) and there are no engine mechanical
faults, fill the fuel tank with a premium gasoline that has a minimum octane
reading of 92 and re-evaluate the engine's performance.

Fuel System

Check for a low fuel pressure condition. Refer to Fuel System Diagnosis.
Check for a restricted fuel filter. Refer to Fuel System Diagnosis.
Check for a contaminated fuel condition. Refer to Alcohol/Contaminants-in-Fuel
Diagnosis.
Check the items that cause an engine to run rich (long term fuel trim
near -13%). For a rich condition, refer to OTC P0132 H02S Circuit High Voltage
Bank 1 Sensor 1 and OTC P0152 H02S Circuit High Voltage Bank 2 Sensor 1.
Check the items that can cause an engine to run lean (long term fuel trim
near 23%). For a Lean condition, refer to OTC P0131 H02S Circuit Low Voltage
Bank 1 Sensor 1 and OTC P0151 H02S Circuit Low Voltage Bank 2 Sensor 1.

Ignition System

Check the spark plugs for being the proper heat range.

Engine Cooling System

Check for obvious overheating conditions:

Low engine coolant. Refer to Engine Cooling System Specifications in Engine
Cooling for the type and amount of engine coolant to be used.
Restricted air flow to the radiator or restricted coolant flow through the radiator.
Inoperative electric cooling fan circuits. Refer to Electric Cooling Fan Diagnosis.

Engine

Engine Controls - 5.7L

6-1739

Detonation/Spark Knock ( cont'd)

Action

Checks

Engine Mechanical

Check for the following engine mechanical conditions:

Excessive oil in combustion chamber-Leaking valve seals. Refer to Oil
Consumption Diagnosis in Engine Mechanical 5. 7L.
Low cylinder compression. Refer to Engine Compression Test in Engine
Mechanical 5.7L.
Combustion chambers for excessive carbon buildup. Clean the combustion
chamber by using top engine cleaner. Follow the instructions on the can.
Check for incorrect basic engine parts. Inspect the following:
- Camshaft
- Cylinder heads
- Pistons, etc.

Additional Checks

Check the Park/Neutral Position (PNP) switch operation. Refer to PNP Switch
Diagnosis.
Check the TCC operation. The TCC applying too soon can cause the engine to
spark knock. Refer to Torque Converter Clutch Diagnosis in Automatic
Transmission 4L60E.

Hesitation, Sag, Stum.hie

Checks

Action

Definition: Momentary lack of response as the accelerator is pushed down. Can occur at any veh.icle speed. Usually more
pronounced when first trying to make the vehicle move, as.from a stop sign. May cause the engine to stall if severe enough.
Preliminary

Refer to Symptoms, Important Preliminary Checks Before Starting.

Search for bulletins.
Check the PCM grounds for being clean, tight, and in the proper locations. Refer
to Ground Distribution Schematics in Wiring Systems.

Sensor/System
Fuel System

Check the MAP sensor 9peration.

Check for a low fuel pressure condition. Refer to Fuel System Diagnosis.
Check for a restricted fuel filt.er. Refer to Fuel System Diagnosis.
Check for a contaminated fuel condition. Refer to Alcohol/Contaminants-in-Fuel
Diagnosis.
Check both injector fuses for being open. An open injector fuse causes four
ignition coils and four injectors not to operate. Replace the fuse. Inspect the
ignition coil circuits and the injector circuits for an intermittent short to ground.
Perform the injector balance test. Refer to Fuel Injector Balance Test for
procedure.
Check the items that cause an engine to run rich (long term fuel trim
near -13%). For a rich condition, refer to OTC P0132 H02S Circuit High Voltage
Bank 1 Sensor 1 and OTC P0152 H02S Circuit High Voltage Bank 2 Sensor 1.
Check the items that can cause an engine to run lean (long term fuel trim
near 23%). For a Lean condition, refer to OTC P0131 H02S Circuit Low Voltage
Bank 1 Sensor 1 and OTC P0151 H02S Circuit Low Voltage Bank 2 Sensor 1.

6-1740

Engine

Engine Controls - 5.7L

Hesitation, Sag, Stumble {cont'd)
Action

Checks
Ignition System

Wet down the secondary ignition system with water from a spray bottle. Wetting
down the secondary ignition system may help locate damaged or deteriorated
components. Look/listen for arcing or misfiring as you apply water.
Check for proper ignition voltage output with spark tester J 26792. Refer to
Electronic Ignition System Diagnosis.
Remove the spark plugs and check for the following:
-Wet plugs
-Cracks
-Wear
- Improper gap
- Spark plugs for proper heat range
- Burned electrodes
- Heavy deposits
An improper spark plug gap will cause a driveability concern. Do the spark plug
gapping using a wire gauge gap tool (J 41319). Determine the cause of the
fouling before replacing the spark plugs if spark plugs are gas or oil fouled.
Refer to OTC P0172 Fuel Trim System Rich Bank 1 and OTC P0175 Fuel Trim
System Rich Bank 2 for diagnosis the rich condition or Oil Consumption
Diagnosis in Engine Mechanical 5.7L for diagnosis of the oil fouling condition.
Check for loose ignition coil grounds. Refer to Electronic Ignition System
Dif!!gnosis.

Engine Cooling System

Check the engine thermostat for proper operation and for proper heat range. Refer
to Thermostat Diagnosis in Engine Cooling.

Additional Checks

Check the generator output voltage. Refer to Charging System Check in Engine
Electrical. Repair the charging system if the generator output voltage is less than 9
volts or more than 16 volts.

Cuts Out, Misses

Checks

Action

Definition: Steady pulsation or jerking that follows engine speed, usually more pronounced as engine load increases. This
condition is not normally felt above 1500 RPM or 48 km/h (30 mph}. The exhaust has a steady spitting sound at idle or
low speed.
Preliminary

Refer to Symptoms, Important Preliminary Checks Before Starting.

Search for bulletins.
Verify the PCM grounds for being clean, tight and in the proper locations. Refer
to Ground Distribution Schematics in Wiring Systems.
Remove the air filter element and inspect for dirt or for being restricted. Refer to
Air Cleaner Element Replacement. Replace as necessary.

Fuel System

Perform the injector balance test. Refer to Fuel Injector Balance Test for
procedure.
Test for a low fuel pressure condition. Refer to Fuel System Diagnosis.
Test for a restricted fuel filter. Refer to Fuel System Diagnosis.
Test for a contaminated fuel condition Refer to Alcohol/Contaminants-in-Fuel
Diagnosis.
Inspect items that cause an engine to run rich (long term fuel trim near -13%).
For a rich condition, refer to OTC P0132 H02S Circuit High Voltage Bank 1
Sensor 1 and OTC P0152 H02S Circuit High Voltage Bank 2 Sensor 1.
Inspect items that can cause an engine to run lean (long term fuel trim
near 23%). For a Lean condition, refer to OTC P0131 H02S Circuit Low Voltage
Bank 1 Sensor 1 and OTC P0151 H02S Circuit Low Voltage Bank 2 Sensor 1.

Sensor/System

Use a scan tool in order to monitor the KS system for excessive spark retard activity.

Engine Controls - 5.7L

Engine

6-1741

Cuts Out, Misses (cont'd)

Action

Checks
Ignition System

Wet down the secondary ignition system with water from a spray bottle. Wetting
down the secondary ignition system may help locate damaged or deteriorated
components. Look/listen for arcing or misfiring as you apply water.
Test for proper ignition voltage output with spark tester J 26792.
Remove the spark plugs and inspect for the following:
- Correct heat range.
-Wet plugs
- Cracks
-Wear
- Improper gap
- Burned electrodes
- Heavy deposits
An improper spark plug gap will cause a driveability condition. Do the spark plug
gapping using a wire gauge gap tool (J 41319). Determine the cause of the
fouling before replacing the spark plugs if the spark plugs are gas or oil fouled.
Refer to OTC P0172 Fuel Trim System Rich Bank 1 and OTC P0175 Fuel Trim
System Rich Bank 2 for diagnosis of the rich condition or Oil Consumption
Diagnosis in Engine Mechanical 5.7L for diagnosis of the oil fouling condition.
Visually/Physically inspect the Secondary ignition for the following:
- Ignition wires arcing to ground
- Ignition wires for proper routing
- Ignition coils for cracks or carbon tracking

Engine Mechanical

Inspect engine mechanical for the following:

- Test compression. Refer to Engine Compression Test in Engine
Mechanical 5.7L.
- l3ticking or leaking valves. Refer to Valve Train Diagnosis in Engine
Mechanical 5.7L.
- Worn camshaft lobes. Refer to Valve Train Diagnosis in Engine
Mechanical 5.7L.
- Valve timing. Refer to Valve Train Diagnosis in Engine Mechanical 5.7L.
- Bent push rods. Refer to Valve Train Diagnosis in Engine Mechanical 5.7L.
- Worn rocker arms. Refer to Valve Train Diagnosis in Engine Mechanical 5. 7L.
- Broken valve springs. Refer to Valve Train Diagnosis in Engine
Mechanical 5.7L.
- Excessive oil in combustion chamber-Leaking valve seals. Refer to Oil
Consumption Diagnosis in Engine Mechanical 5.7L.
For incorrect basic engine parts. Inspect the following:
- Camshaft
- Cylinder heads
- Pistons, etc.

Additional Checks

Inspect exhaust system for possible restrictions. Inspect for the following:
- Inspect the exhaust system for damaged or collapsed pipes.
- Inspect the exhaust manifold for a collapsed inner wall.

- Inspect the mufflers for heat distress or possible internal failure.

- Inspect for possible plugged Three-Way catalytic converters. Refer to
Restricted Exhaust System Check.
Electromagnetic Interference (EMI) on the reference circuit can cause an engine
miss condition A sudden increase in RPM with little change in actual engine
RPM change indicates EMI is present. Inspect routing of secondary ignition
wires, high voltage components (Near Ignition Control circuits) if a condition
exists.
Inspect the intake manifold and the exhaust manifold passages for casting flash.
Refer to Intake Manifold Clean and Inspect and Exhaust Manifold Clean and
Inspect in Engine Mechanical 5.7L.

6-1742

Engine Controls - 5.7L

Engine
Poor Fuel Economy

Checks

Action

Definition: Fuel economy, as measure~ by an actual road test, is noticeably lower than expected. Also, economy is
noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test.
Preliminary

Refer to Symptoms, Important Preliminary Checks Before Starting.

Search for bulletins.
Verify the PCM grounds for being clean, tight, and in the proper locations. Refer
to Ground Distribution Schematics in Wiring Systems.
Document the owners driving habits.
Is the A/C ON or the Defroster mode ON full time?
- Are the tires at the .correct pressure? Refer to Tire Inflation Pressure
Specifications in Maintenance and Lubrication.
- Is there excessively heavy loads being carried?
- Is the acceleration rate too much, too often?

Fuel System

Remove the air filter element and inspect for dirt or for being restricted. Refer to
Air Cleaner Element Replacement. Replace as necessary.
Perform the injector balance test. Refer to Fuel Injector Balance Test for
procedure.
Test for a low fuel pressure condition. Refer to Fuel System Diagnosis.
Test for a restricted fuel filter. Refer to Fuel System Diagnosis.
Test for a contaminated fuel condition Refer to Alcohol/Contaminants-in-Fuel
Diagnosis.
Verify that each injector harness is connected to the correct injector/cylinder .
according to the firing order (firing order: 1-8-7-2-6-5-4-3). Relocate injector
harnesses as necessary.
Test for injectors that are shorted internally. Compare the injector resistance.
Injector resistance should be within one ohm of each other. Refer to Fuel lnj Coil
Test - ECT Between 10-35 Degrees C.
Inspect for foreign material accumulation in the throttle bore, coking on the
throttle valve, or on the throttle shaft. Also inspect for throttle body tampering.
Inspect items that cause an engine to run rich (long term fuel trim near -13%).
For a rich condition, refer to DTC P0132 H02S Circuit High Voltage Bank 1
Sensor 1 and DTC P0152 H02S Circuit High Voltage Bank 2 Sensor 1.
Inspect items that can cause an engine to run lean (long term fuel trim
near 23%). For a Lean condition, refer to DTC P0131 H02S Circuit Low Voltage
Bank 1 Sensor 1 and DTC P0151 H02S Circuit Low Voltage Bank 2 Sensor 1.

Sensor/System

Inspect the air intake system and crankcase for air leaks.
Test the crankcase ventilation valve for proper operation. Place a finger over the
inlet hole in the valve end several times. The valve should snap back. If not,
replace the valve.
Test for proper calibration of speedometer. Connect the Signal Generator
J 33431-8 to the VSS electrical connector. Turn ON the ignition with the tester
ON and monitor the speedometer. The speedometer should indicate 86 km/h
(54 mph). If not, refer to Speedometer Inaccurate (J 38522 Available) in
Instrument Panel, Gauges, and Console.
Use a scan tool in order to monitor the KS system for excessive spark retard
activity. Refer to Knock Sensor System Description.

Engine

Engine Controls - 5.7L

6-1743

Poor Fuel Economy (cont'd)

Action

Checks

Ignition System

Test tor proper ignition voltage output with spark tester J 26792.
Remove the spark plugs and inspect tor the following:
-Wet plugs
- Cracks
-Wear
- Improper gap
- Burned electrodes
- Heavy deposits
An improper spark plug gap will cause a driveability condition. Do the spark plug
gapping using a wire gauge gap tool (J 41319). Refer to Spark Plug
Replacement. Determine the cause of the fouling before replacing the spark
plugs it spark plugs are gas or oil fouled. Refer to OTC P0172 Fuel Trim System
Rich Bank 1 and OTC P0175 Fuel Trim System Rich Bank 2 tor diagnosis of the
rich condition or Oil Consumption Diagnosis in Engine Mechanical 5.7L tor
diagnosis of the oil fouling condition.
Visually/Physically inspect the secondary ignition tor the following:
- Ignition wires arcing tP ground
- Ignition wires tor proper routing
Wetting down the secondary ignition system with water from a spray bottle may
help locate damaged or deteriorated components. Look/listen tor arcing or
misfiring as you apply water.
Inspect tor loose ignition coil grounds. Refer to Electronic Ignition System
Diagnosis.

Engine Cooling System

Inspect the engine coolant level tor being low. Refer to Draining and Filling
Cooling System (VB) in Engine Cooling.
Test the engine thermostat tor proper operation and tor the correct heat range.
Refer to Thermostat Diagnosis in Engine Cooling.

Engine Mechanical

Inspect engine mechanical tor the following:

- Test compression. Refer to Engine Compression Test in Engine
Mechanical 5. 7L.
- Sticking or leaking valves. Refer to Valve Train Diagnosis in Engine
Mechanical 5.7L.
- Worn camshaft lobe(s). Refer to Valve Train Diagnosis in Engine
Mechanical 5.7L.
- Valve timing. Refer to Valve Train Diagnosis in Engine Mechanical 5.7L.
- Bent push rods. Refer to Valve Train Diagnosis in Engine Mechanical 5.7L.
- Worn rocker arms. Refer to Valve Train Diagnosis in Engine Mechanical 5.7L.
- Broken valve springs. Refer to Valve Train Diagnosis in Engine
Mechanical 5.7L.
- Excessive oil in combustion chamber-Leaking valve seals. Refer to Oil
Consumption Diagnosis in Engine Mechanical 5.7L.
For incorrect basic engine parts. Inspect tor the following:
- Camshaft
- Cylinder heads
- Pistons, etc.

6-1744

Engine

Engine Controls - 5.7L

Poor Fuel Economy (cont'd)
Checks

Additional Checks

Action

Visually (physically) inspect the vacuum hoses for splits, kinks, and proper
connections and routing as shown on Vehicle Emission Control Information
label. Refer to Emission Hose Routing Diagram.
Verify the TCC operation. The scan tool should indicate a RPM drop, when the
system commands the TCC ON. Refer to Torque Converter Clutch Diagnosis in
Automatic Transmission.
Inspect the exhaust system for a possible restriction. Inspect for the following:
- Inspect the exhaust system for damaged or collapsed pipes.
- Inspect the exhaust manifold for a collapsed inner wall.
- Inspect the mufflers for heat distress or possible internal failure.
- Inspect for possible plugged Three-Way catalytic converters. Refer to
Restricted Exhaust System Check.
Electromagnetic Interference (EMI) on the reference circuit can cause an engine
miss condition. A scan tool can usually detect EMI by monitoring the engine
RPM. A sudden increase in RPM with little change in actual engine RPM
change, indicates EMI is present. Inspect routing of secondary ignition wires,
high voltage components (Near Ignition Control circuits) if a condition exists.
Test PNP switch circuit. Refer to PNP Switch Diagnosis.
Inspect for faulty motor mounts.
Inspect the intake and the exhaust manifold passages for casting flash. Refer to
Intake Manifold Clean and Inspect and Exhaust Manifold Clean and Inspect in
Engine Mechanical 5.7L.

Rough, Unstable, or Incorrect Idle and Stalling

Checks

Action

Definition: Engine runs unevenly at idle. If severe, the engine or vehicle may shake. Engine idle speed may vary in RPM.
Either condition may be severe enough to stall the engine.
Preliminary Checks

Refer to Symptoms, Important Preliminary Checks Before Starting ..

Search for bulletins.
Verify the PCM grounds for being clean, tight and in the proper locations. Refer
to Ground Distribution Schematics in Wiring Systems.
Remove and inspect the air filter element for dirt, or for being restricted. Refer to
Air Cleaner Element Replacement. Replace as necessary.

Fuel System

Perform the injector balance test. Refer to Fuel Injector Balance Test for
procedure.
Test for a low fuel pressure condition. Refer to Fuel System Diagnosis.
Test for a restricted fuel filter. Refer to Fuel System Diagnosis.
Test for a contaminated fuel condition. Refer to Alcohol/Contaminants-in-Fuel
Diagnosis.
Verify that each injector harness is connected to the correct injector/cylinder
according to the firing order (firing order: 1-8-7-2-6-5-4-3). Relocate injector
harnesses as necessary.
Test for injectors that are shorted internally. Compare the injector resistance.
Injector resistance should be within one ohm of each other. Refer to Fuel lnj Coil
Test - ECT Between 10-35 Degrees C.
Inspect items that cause an engine to run rich (long term fuel trim near -13%).
For a rich condition, refer to OTC P0132 H02S Circuit High Voltage Bank 1
Sensor 1 and OTC P0152 H02S Circuit High Voltage Bank 2 Sensor 1.
Inspect items that can cause an engine to run lean (long term fuel trim
near 23%). For a Lean condition, refer to OTC P0131 H02S Circuit Low Voltage
Bank 1 Sensor 1 and OTC P0151 H02S Circuit Low Voltage Bank 2 Sensor 1.

Sensor/System

Test the crankcase ventilation valve for proper operation. Place a finger over
inlet hole of the valve end several times. The valve should snap back. If not,
replace the valve.
Use a scan tool in order to monitor KS system for excessive spark retard
activity.

Engine

Engine Controls - 5.7L

6-1745

Rough, Unstable, or Incorrect Idle and Stalling (cont'd)

Checks
Ignition System

Action
Test for proper ignition voltage output with spark tester J 26792. Refer to
Electronic Ignition System Diagnosis for procedure.
Remove spark plugs and inspect for the following:
-Wet plugs
- Cracks
-Wear
- Improper gap
- Burned electrodes
- Heavy deposits
An improper spark plug gap will cause a driveability condition. Do the spark plug
gapping using a wire gauge gap tool (J 41319). Refer to Spark Plug
Replacement in Engine Electrical. Determine the cause of the fouling before
replacing the spark plugs. Refer to OTC P0172 Fuel Trim System Rich Bank 1
and OTC PO 175 Fuel Trim System Rich Bank 2 for diagnosis of the rich
condition or to Oil Consumption Diagnosis in Engine Mechanical 5.7L for
diagnosis of the oil fouling condition.
Visually/Physically inspect Secondary ignition for the following:
- Ignition wires for cross firing
- Ignition wires arcing to ground
- Ignition wires for proper routing
Wet down the secondary ignition system with water from a spray bottle. Wetting
down the secondary ignition system may help locate damaged or deteriorated
components. Look/listen for arcing or misfiring as you apply water.
Inspect for loose ignition coil grounds. Refer to Electronic Ignition System
Diagnosis.

Engine Mechanical

Inspect engine mechanical for the following:

- Test compression. Refer to Engine Compression Test in Engine
Mechanical 5.7L.
- Sticking or leaking valves. Refer to Valve Train Diagnosis in Engine
Mechanical 5.7L.
- Worn camshaft lobe(s). Refer to Engine Compression Test in Engine
Mechanical 5.7L.
- Valve timing. Refer to Engine Compression Test in Engine Mechanical 5.7L.
- Bent push rods. Refer to Engine Compression Test in Engine
Mechanical 5.7L.
- Worn rocker arms. Refer to Engine Compression Test in Engine
Mechanical 5.7L.
- Broken valve springs. Refer to Engine Compression Test in Engine
Mechanical 5.7L.
- Excessive oil in combustion chamber-Leaking valve seals. Refer to Oil
Consumption Diagnosis in Engine Mechanical 5.7L.
For incorrect basic engine parts. Inspect the following:
- Camshaft
- Cylinder heads
- Pistons, etc.

6-1746

Engine Controls - 5.7L

Engine

Rough, Unstable, or Incorrect Idle and Stalling (cont'd)

Checks
Additional Checks

Action
Inspect the exhaust system for possible restrictions. Inspect for the following:
- Inspect the exhaust system tor damaged or collapsed pipes.

- Inspect the exhaust manifold for a collapsed inner wall.

- Inspect the mufflers tor heat distress or possible internal failure.
- Inspect for possible plugged Three-Way catalytic converters. Refer to
Restricted Exhaust System Check in Engine Exhaust.
Electromagnetic Interference (EMI) on the reference circuit can cause an engine
miss condition A sqm tool can usually detect EMI by monitoring the engine
RPM. A sudden increase in RPM with little change in actual engine RPM
change, this indicates that EMI is present. It a condition exists, inspect routing of
secondary ignition wires or high voltage components near ignition control
circuits.
Test the PNP switch circuit. Refer to PNP Switch Diagnosis.
Inspect for faulty motor mounts.
Inspect the intake manifold and the exhaust manifold passages for casting flash.
Refer to Intake Manifold Clean and Inspect and Exhaust Manifold Clean and
Inspect in Engine Mechanical 5.7L.

Dieseling, Run-On
Checks

Action

Definition: Engine continues to run after key is turned OFF, but runs very rough. It the engine runs smooth, inspect the
ignition switch and the ignition switch adjustment.
Preliminary Checks

Fuel System

Refer to Symptoms, Important Preliminary Checks Before Starting.

Search tor bulletins.
Inspect the PCM grounds tor being clean, tight and in the proper locations.
Refer to Ground Distribution Schematics in Wiring Systems.
Inspect the injectors tor a leaking condition. Refer to Fuel System Diagnosis tor
procedure.

Backfire
Checks

Actions

Definition: Fuel ignites in the intake manifold or in the exhaust system, making a loud popping noise.
Preliminary Checks

Refer to Symptoms, Important Preliminary Checks Before Starting.

Search tor bulletins.
Inspect the PCM grounds tor being clean, tight and in the proper locations.
Refer to Ground Distribution Schematics in Wiring Systems.

Fuel System

Test tor a low fuel pressure condition. Refer to Fuel System Diagnosis.
Test tor a restricted fuel tilter. Refer to Fuel System Diagnosis.
Test tor a contaminated fuel condition. Refer to Alcohol/Contaminants-in-Fuel
Diagnosis.
Verity that each injector harness is connected to the correct injector/cylinder
according to the firing order (firing order: 1-8-7-2-6-5-4-3). Relocate injector
harnesses as necessary.

Engine

Engine Controls - 5.7L

6-1747

Backfire (cont'd)
Actions

Checks

Sensor/System

Inspect the Secondary Air Injection (AIR) system. Refer to Secondary AIR
Injection System Description.
Inspect the Air intake system and crankcase for air leaks.
Test the crankcase ventilation valve for proper operation. Place a finger over
inlet hole in valve end several times. The valve should snap back. If not, replace
the valve.
Test for proper calibration of speedometer. Connect Signal Generator J 33431-8
to VSS electrical connector. Ignition ON, tester ON and monitor the
speedometer. The speedometer should indicate 86 km/h (54 mph}. Refer to
Speedometer Inaccurate (J 38522 Available) in Instrument Panel, Gauges and
Console.
Use a scan tool in order to monitor the KS system for excessive spark retard activity.
Refer to Knock Sensor System Description.

Ignition System

Test for proper ignition voltage output with spark tester J 26792.
Test for an intermittent ignition system malfunction in the following circuits:
- Intermittent ignition control circuit.
- Use the scan tool's Snapshot feature in order to help locate an intermittent
ignition failure.
Remove spark plugs and inspect for the following:

Engine Cooling System

\
I

-Wet plugs
- Cracks
-Wear
- Improper gap
- Burned electrodes
- Heavy deposits
An improper spark plug gap will cause a driveability concern. Do the spark plug
gapping using a wire gauge gap tool (J 41319). Refer to Spark Plug
Replacement in Engine Electrical. Determine the cause of the fouling before
replacing the spark plugs if the spark plugs are gas or oil fouled. Refer to
OTC P0172 Fuel Trim System Rich Bank 1 and OTC P0175 Fuel Trim System
Rich Bank 2 for diagnosis of the rich condition or Oil Consumption Diagnosis in
Engine Electrical for diagnosis of the oil fouling condition.
Visually/Physically inspect secondary ignition for the following:
- Ignition wires for cross firing
- Ignition wires arcing to ground
- Ignition coils arcing to ground
Wet down the secondary ignition system with water from a spray bottle. Wetting
down the secondary ignition system may help locate damaged or deteriorated
components. Look/listen for arcing or misfiring as you apply the water.
Inspect for loose ignition coil grounds. Refer to Electronic Ignition System
Diagnosis.

Inspect the engine coolant level for being low. Refer to Loss of Coolant in
Engine Cooling.
Test the engine thermostat for proper operation or for the wrong heat range.
Refer to Thermostat Diagnosis in Engine Cooling.

6-1748

Engine Controls - 5.7L

Engine
Backfire (cont'd)

Checks

Engine Mechanical

Actions

Inspect engine mechanical for the following:

- Test compression. Refer to Engine Compression Test in Engine
Mechanical 5. 7L.
- Sticking or leaking valves. Refer to Valve Train Diagnosis in Engine
Mechanical 5.7L.
- Worn camshaft lobe(s). Refer to Valve Train Diagnosis in Engine
Mechanical 5.7L.
-

Valve timing. Refer to Valve Train Diagnosis in Engine Mechanical 5.7L.

Bent push rods. Refer to Valve Train Diagnosis in Engine Mechanical 5.7L.
Worn rocker arms. Refer to Valve Train Diagnosis in Engine Mechanical 5.7L.
Broken valve springs. Refer to Valve Train Diagnosis in Engine
Mechanical 5.7L.

- Excessive oil in combustion chamber-Leaking valve seals. Refer to Oil

Consumption Diagnosis in Engine Mechanical 5.7L.
- Low cylinder compression
For incorrect basic engine parts. Inspect the following:
- Camshaft
- Cylinder heads
- Pistons, etc.
Additional Checks

Visually (physically) inspect the vacuum hoses for splits, kinks, and proper
connections and routing. Refer to Emission Hose Routing Diagram.
Inspect the intake manifold and the exhaust manifold passages for casting flash.
Test the TCC operation. The scan tool should indicate an RPM drop when the
TCC is commanded ON. Refer to Torque Converter Clutch Diagnosis in
Automatic Transmission 4L60E.
Inspect the exhaust system for possible restrictions. Inspect the following:
- Inspect the exhaust system for damaged or collapsed pipes.
- Inspect the exhaust manifold for a collapsed inner wall.
- Inspect the mufflers for heat distress or possible internal failure.

- Inspect for possible plugged Three-Way catalytic converters. Refer to

Restricted Exhaust System Check.
Electromagnetic Interference (EMI) on the reference circuit can cause an engine
miss condition. A scan tool can usually detect EMI by monitoring the engine
RPM. A sudden increase in RPM with little change in actual engine RPM
change, may indicate that EMI is present. If a condition exists, inspect the
routing of the secondary ignition wires or high voltage components near ignition
control circuits.
Check the PNP switch circuit. Refer to PNP Switch Diagnosis.
Check for faulty motor mounts.
Check the intake manifold and the exhaust manifold passages for casting flash.
Refer to Intake Manifold Clean and Inspect and Exhaust Manifold Clean and
Inspect in Engine Mechanical 5.7L.

Engine

Engine Controls - 5.7L

6-1749

Restricted Exhaust System Check

Action

Step

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 4

Go to Step 3

Go to Step 4

Go to Symptoms

Go to Step 5

Go to Step 6

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

1. Remove the front H02S sensor on the side of the

engine that is suspected of being restricted. Refer to
H02S Replacement - Bank 1 or H02S Replacement
- Bank 2.
2. Install the Exhaust Back Pressure tester J 35314-A
in place of the H02S sensor.
3. Idle the engine at normal operating temperature.
4. Observe the exhaust system back pressure reading
on the gauge.
Does the reading exceed the specified value?

8.6 kPa
(1.25 psi)

1. The Exhaust Backpressure Gauge still installed.

2. Increase engine speed to 2,000 RPM.
3. Observe the exhaust system back pressure reading
on the gauge.
Does the reading exceed the specified value?

20.7 kPa (3 psi)

1. Turn OFF the engine.

2. Re-install the front H02S sensor.
3. Remove the rear H02S sensor on the side of the
engine that is suspected of being restricted. Refer to
H02S RAplacement - Bank 1 or H02S Replacement
- Bank 2.
4. Install the Exhaust Back Pressure tester J 35314-A
in place of the rear H02S sensor.
5. Idle the engine.
6. Increase the engine speed to 2,000 RPM.
7. Observe the exhaust system back pressure reading
on the gauge.
Does the reading exceed the specified value?

20.7 kPa (3 psi)

Repair the restriction in the exhaust system after the

Catalytic Converter. Inspect exhaust system for the
following:

Collapsed pipe
Heat distress
Internal muffler failure
Is the action completed?
Replace the Catalytic Converter on the affected side of the
engine. Refer to Oxidation Catalytic Converter
Replacement (Left) or Oxidation Catalytic Converter
Replacement (Right) in Engine .Exhaust.
Is the action completed?

System OK

System OK

6-1750

Engine Controls - 5.7L

Engine

A/C Request Circuit Diagnosis

! Hot In RUN Or START!

G7

r -

P:;w;; - , Underhood

A/C
Distribution:
CRUISE Cell 10
MiniFuse
I

G6

15A

-------J

L--

PNK 139

Fuse Block
Details

+- - - ----------,

Cell11

PNK

PNK 139
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A/C Refrigerant
Pressure Sensor
Signal

A/C
Request

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Clutch
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A/C Refrigerant
Pressure Sensor
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A/C
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can 14

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218753

Circuit Description
The A/C clutch relay is PCM controlled to delay A/C
clutch engagement after the A/C is turned ON.
This allows the PCM to adjust engine RPM before the
A/C clutch engages. The PCM will engage the A/C
clutch any time A/C has been requested unless any of
the following conditions exist:
High coolant temperature.
Low A/C system pressure.
High A/C system pressure.
Wide open throttle.
High engine RPM.
When the heater and A/C control is placed in the A/C
mode, a 12 volt signal is sent to the PCM. When
the PCM receives this signal the PCM will ground the
A/C clutch relay control circuit to energize the A/C
relay. This is shown on the scan tool as A/C
request YES.

When a request for A/C has been detected by the

PCM, the PCM will ground the A/C clutch relay control
circuit, the relay contacts will close, and current will
flow through the relay to the A/C compressor clutch.
When A/C request has been detected by the PCM, the
cooling fan(s) will be turned ON when A/C pressure
is above a predetermined pressure.

Diagnostic Aids
Ensure no PCM DTC(s) are stored before using this
table. The PCM will not activate the A/C clutch with a
stored OTC.

Test Description
The numbers below refer to numbers on the
diagnostic table.
2. A/C DTCs will disable the A/C system. Repair A/C
DTCs before proceeding.

Engine Controls - 5.7L

Engine
3. The request circuit is shorted to a voltage if the
scan tool displays A/C request as YES.

6-1751

5. A condition exists with the request circuit between

the PCM and the HVAC Controller or the HVAC
Controller is malfunctioning if the test lamp did not
illuminate.

A/C Request Circuit Diagnosis

Action

Step

Did you perform the Powertrain On-Board Diagnostic

(080) System Check?
1

Are any A/C DTCs set?

Value(s)

Yes

No

Go tostep 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to applicable
OTC table.

Go to Step 3

Go .to Step 8

Go to Step 4

System OK

Go to Step 5

Go to Step 10

Go to Step 6

Go to Step 7

Go to Step 11

Go to Step 12

Go to Step 9

System OK

Go to Step 9

1. Install the scan tool.

2. Idle the engine with the A/C OFF.
3. Monitor A/C request on the ENG 1 data list using a
scan tool.
Does the scan tool indicate A/C request as YES?

Turn ON the A/C.

Does the scan tool indicate A/C request as YES?

1. Turn OFF the ignition.

2. Disconnect the PCM connector C1 located on the
opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.
3. Turn ON the ignition leaving the engine OFF.
5

4. Probe the A/C request circuit at the PCM electrical

harness connector using the DMM J 39200
connected to ground. Refer to Probing Electrical
Connectors in Wiring Systems.
5. Turn the A/C to the ON position,
Does the DMM display near the specified value when the
A/C is enabled?

B+

1. Turn OFF the ignition.

2. Remove the HVAC Controller. Refer to Control
Assembly Replacement in HVAC Manual.
3. Test the A/C request circuit for continuity between the
HVAC Controller and the PCM using the DMM
J 39200. Refer to Testing for Continuity in Wiring
Systems.
Does the DMM indicate continuity?

Probe the A/C request circuit at the PCM harness

connector using the test lamp J 34142-8 connected to B+.
Does the test lamp illuminate?

Inspect the A/C request circuit for a short to voltage.

Repair the circuit as necessary if a short to voltage is
found. Refer to Wiring Repairs in Wiring Systems.
Did you find and correct the condition?

Important: Before replacing the HVAC Controller, refer to

Functional Check in HVAC Manual.
Replace the HVAC Controller. Refer to Control Assembly
Replacement in HVAC Manual.
Is the action complete?

System OK

6-1752

Engine Controls - 5.7L

Engine

A/C Request Circuit Diagnosis (cont'd)

Step

Action

Value(s)

Yes

No

1. Inspect for poor connections at the PCM. Refer to

lntermittents and Poor Connections Diagnosis in

Wiring Systems.

10

2. If you find a poor connection, repair as necessary.

Refer to Repairing Connector Terminals in Wiring

Systems.
Did you find and correct the condition?

11

12

Repair the open A/C request circuit between the HVAC

Controller and the PCM. Refer to Wiring Repairs in Wiring
Systems.
Is the action complete?
Repair the grounded A/C request circuit between the
HVAC Controller and the PCM. Refer to Wiring Repairs in
Wiring Systems.

System OK

13

System OK

Is the action complete?

Important: Program the replacement PCM. Refer to PCM
Replacement/Programming.
Replace the PCM.
Is the action complete?

Go to Step 13

System OK

System OK

Engine

Engine Controls - 5.7L

6-1753

A/C Refrigerant Pressure Sensor Circuit Diagnosis

! Hot In RUN Or START!

.- - G7

- - - -

P-:;-w; - , Underhood

A/C
Distribution:
CRUISE
Cell 10
MiniFuse
I
15A
I

G6

Electrical
Center 2

L2.w

-------.1

L--

PNK 139

Fuse Block
Details
Cell11

---------,

....... - -

PNK 139

PNK 139

~ ; - - - - ~
- - - ., Underhood
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Electrical
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A/C Refrigerant
P'.essure Sensor
Signal

A/C
Request

5V

NC Refri.gerant
Pressure Sensor
sv Reference

A: -

Clutch

Status

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218753

Circuit Description
The PCM cycles the A/C compressor clutch in order to
optimize the performance of the A/C system. The
PCM determines when to cycle the A/C compressor
clutch by monitoring the A/C Refrigerant Pressure
sensor.
The A/C Refrigerant Pressure sensor is also used by
the PCM in order to enable the cooling fans when
the A/C compressor head pressure reaches a
predetermine value.
The PCM energizes the A/C compressor clutch when
the engine speed is less than 4300 RPM and the
A/C system is requested. If you request the A/C at
engine speeds greater than 4300 RPM, the PCM will
not energize the A/C compressor clutch until the
engine speed decreases to less than 3950 RPM.

Any one of the following conditions disables the A/C

compressor clutch.
The throttle is commanded to Wide Open
Throttle (WOT).
The A/C head pressure is greater than
2854 kPa (414 psi).
The A/C head pressure is less than
241 kPa (35 psi).
The ignition voltage is less than 10 volts.
The engine speed is greater than 5594 RPM.
The engine coolant temperature is greater
than 125C (257F).
The PCM also disables the A/C compressor when
curtain DTCs set.

6-1754

Engine

Engine Controls - 5.7L

Diagnostic Aids
Inspect the harness going to the A/C clutch and going
to the PCM for intermittent connections. While the
engine is operating with the A/C enabled, move related
electrical connectors and harnesses. This may aid
in locating an intermittent fault.
For an intermittent, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step tests if the PCM can turn the A/C
compressor ON.

3. This step tests for an A/C refrigerant pressure

sensor that is at a fixed value (stuck).
4. Test the connections at the compressor first if the
scan tool indicates that the A/C clutch is ON.
5. Inspect the A/C clutch status circuit before
replacing the A/C refrigerant pressure sensor.
Also, a low refrigerant charge in the A/C system
can cause a A/C system performance condition.
7. The PCM's A/C clutch status circuit may not
detect voltage when the A/C is commanded ON if
the B+ supply circuit to the A/C relay is
intermittent. Inspect the relay connections and
operation.

A/C Refrigerant Pressure Sensor Circuit Diagnosis

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to Step 6

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

Important: If DTCs P0530, P1545, and P1546 are set,

use those tables.

1. Idle the engine.

2. Turn ON the A/C.
Does the A/C clutch engage?

1. Observe the A/C High Side pressure display on the

Engine 1 Data List using the scan tool.
3

2. Turn OFF the A/C for 1O seconds.

3. Turn ON the A/C for 1O seconds.
Did the A/C High Side pressure increase more than the
specified value when the A/C controls were turned ON?

4 psi

1. Inspect for a poor connection at the A/C Refrigerant

Pressure Sensor. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
2. If you find a poor connection, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

Important: Before replacing the sensor, test the A/C

system for the correct charge. An A/C system that does
not have the correct charge will cause DTC P0530 to set.
Replace the A/C Refrigerant Pressure Sensor. Refer to
A/C Refrigerant Pressure Sensor Replacement in HVAC
Systems Manual.
Is the action complete?

Does the scan tool indicate the A/C clutch ON?

Repair the intermittent A/C clutch circuit from the A/C relay
to the splice. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

(
Go to
Diagnostic Aids

Go to Step 4

System OK

Go to Step 5

System OK
Go to Step 8

Go to Step 7

System OK

1. Turn OFF the ignition.

2. Disconnect the A/C compressor clutch harness
connector.

3. Probe the A/C compressor clutch B+ supply circuit to

the battery ground using the test lamp J 34142-8.
4. Idle the engine.
5. Turn ON the A/C.
Does the test lamp illuminate?

(
Go to Step 9

Go to Step 11

Engine

Engine Controls - 5.7L

6-1755

A/C Refrigerant Pressure Sensor Circuit Diagnosis {cont'd)

Step

Action
Probe the A/C compressor clutch B+ supply circuit to the
A/C compressor clutch ground circuit using the test lamp
J 34142-8.

Value(s)

10

11

Repair the open A/C clutch ground circuit.. Refer to Wiring

Repairs in Wiring Systems.
Is the action complete?

Go to Step 12

System OK

Is the action complete?

12

Go to Step 10

Is the action complete?

Repair the open or the shorted A/C clutch B+ supply
circuit.. Refer to Wiring Repairs in Wiring Systems.

No

Does the test lamp illuminate?

Repair the faulty A/C clutch connection or the open A/C
clutch coil.. Refer to Repairing Connector Terminals in
Wiring Systems.

Yes

System OK

System OK

6-1756

Engine

Engine Controls - 5.7L

Electric Cooling Fan Diagnosis

.. - - -

I Power
Distribution
I
Cell10
I

L1

- - - - ., Underhood
COOL FAN : Electrical
MaxiFuse
Center 1

RED

lS]

-402- - - ...
40 A

L-----

RED 402

!Loe j

!Hot At All Times!

RED 402
~ - - - - - - ., Underhood
I J7 COOLING FAN : Electrical
MiniFuse
Center 1
I J6

I._

______ ...
10A

RED 402

ORN 1640
ORN 1640

ORN 1640

~- ----C3

85
- - - -3~

...

86

87

81

C1

1- D-K

I
I

j---

--------------,

_z
~--

Cool Fan 1
Relay

C4
Cool Fan 2
Relay

85

409

88

ca

85

30

Cool Fan3
Relay

86

86

- - - __ - -8~ _ - -

DK
LT BLU
GRN 335

DK
GRN 335
43 C1

ORN 1640

C6

B3

Underhood
Electrical
Center 1

DKBLU 473

!6_ - - - _ - - __ - - G_!_O

810

______ ...

89

WHT 504
WHT 504
'--~~~~~~~...lf'-~-.Jf'--~----a
DK BLU 473
WHT 504
DK BLU 473
BLK 150

GAY 532

BLUI473
28

Cooling
Fan 1
Relay
Control

C2
\

j---

Cooling
Fan 2 and 3
Relay
Control

Powertrain
I Control
I Module ..
I (PCM) ~

.,
PCM
Cj=RED

BLK 150

I-*-*C2=BLU I
L~----~----------J

BLK 150

_..,.

Ground
Distribution
Cell14

-!218709

Circuit Description:
The cooling fans are controlled by the PCM based on
various inputs. Ignition voltage is supplied to all
three cooling fan relay coils. The PCM controls cooling
fan relay #1 by providing the ground path. The
PCM controls cooling fan relays #2 and #3 together
by p_roviding a ground path. The left and right
cooling fans are connected in series. This will enable
both f~ns on low speed when the fan #1 relay is
energized. When all three fan relays are energized,
both _tans will operate at high speed. The high speed is
possible because the fan relays are wired in a
parallel circuit. When the PCM detects that certain
DTCs are set, the PCM will enable the cooling fans.
The PCM will enable the engine cooling fans when
certain Diagnostic Trouble Codes are set. The
PCM will also enable the cooling fans after the ignition

is turned off. When engine coolant temperature

exceeds 140C (284F) and the ignition is turned off,
the cooling fans will be enabled on low speed.

Diagnostic Aids
If the owner complained of an overheating problem,
determine if the complaint was due to an actual
boil over, or the warning indicator light illuminated, or
the engine coolant temperature gauge indicated
overheating. The gauge accuracy can also be checked
by comparing the Engine Coolant Temperature
~ECT) ~enso~ reading using a scan tool and comparing
its reading with the gauge reading. If the engine is
actually overheating and the gauge indicated
ove~heating, but the cooling fan is not coming ON, the
Engine Coolant Temperature (ECT) sensor has
probably shifted out of calibration and should be
replaced.

Engine

Engine Controls - 5.7L

If the engine is overheating and the cooling fans are

ON, the cooling system should be checked, refer
to Engine Overheating in Engine Cooling.
The PCM will command low speed fans ON at 108C
(226F) and OFF at 103C {217F) and, high speed
fans ON at 113C {235F) and OFF at 108C {226F).

6-1757

Test Description
The numbers below refer to numbers on the
diagnostic table.
2. The PCM will enable the engine cooling fans
when certain Diagnostic Trouble Codes are
set. Go to applicable OTC Table first before
proceeding with this table.
3. Allow engine coolant temperature to cool below
100C (212F) before proceeding with diagnosis.

Electric Cooling Fan Functional Check

Step

Action

Value(s)

Yes

No

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Go to applicable
OTC Table

Go to Step 3

Go to A/C
Request Circuit
Diagnosis

Go to Step 4

Go to Cooling
Fan table #1

Go to Step 5

Go to Step 6

Go to Cooling
Fan table #2

Go to Step 7

Go to Cooling
Fan table #3

Go to Cooling
Fan table #1

Go to Step B

System OK

Go to Step 9

Go to Functional
Check in HVAC
Systems.

Go to A/C
Request Circuit
Diagnosis

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Are any DTCs set?

Important: Engine coolant temperature must be below the

specified value for all of the cooling fan diagnoses.

1. Idle the engine.

2. Turn the A/C OFF.
3. Monitor the A/C Request parameter using the
scan tool.
Does the scan tool display the A/C request as YES?

100C (212F)

1. Turn OFF the ignition.

2. Turn. ON the ignition leaving the engine OFF.
Are the cooling fans ON?

Command the cooling fan relay #1 ON using a scan tool.

Are both cooling fans ON?

Command the cooling fan relays #1, #2 and #3 ON using

a scan tool.
Do both cooling fans switch to high speed?

1. Using a scan tool, exit outputs.

2. Idle the engine leaving the A/C OFF.
Are the cooling fans ON?

Turn the A/C ON.

Are the cooling fans ON?

Does the scan tool display A/C request as YES?

'

6-1758

Engine Controls - 5.7L

Engine

Test Description
The numbers below refer to the step numbers in the
diagnostic table.
2. This step determines if the cooling fan relay
contacts are stuck closed.
3. This step determines if there is a short to voltage
on circuit 532.

4. Any test that requires probing a component or a

component harness connector, use the Connector
Test Adaptor Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals. Refer to Using Connector Test
Adapters.
5. This step determines if the cooling fan relay
contacts are stuck closed.

Electric Cooling Fan Table #1

Step

Action

Did you perform the Cooling Fan Functional Check?

1

1. Turn ON the ignition leaving the engine OFF.

2. Disconnect the cooling fan relay #1.

Value(s)

Yes

No

Go to Step 2

Go to
Cooling Fan
Functional Check

Go to Step 6

Go to Step 3

Go to Step 4

Go to Step 5

Go to Step 7

Go to StepB

Go to Step 10

Go to Step 9

Are both of the cooling fans OFF?

3

Disconnect the cooling fan relay #3.

Are poth of the cooling fans OFF?

1. Turn OFF the ignition.

2. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
3. Disconnect the left cooling fan electrical connector.
4. Probe the cooling fan electrical connector terminal B
using the test lamp J 34142-8 connected to ground.
5. Turn ON the ignition leaving the engine OFF.
Does the test lamp illuminate?

Disconnect the cooling fan relay #2.

Are both of the cooling fans OFF?

Replace the cooling fan relay #1. Refer to Cooling Fan

Relay Replacement in Engine Cooling.
Is the action complete

Go to
Cooling Fan
Functional Check

Repair circuit 409 for a short to B+. Refer to Wiring

Repairs in Wiring Systems.
Is the action complete

Go to
Cooling Fan
Functional Check

Repair circuit 532 for a short to B+. Refer to Wiring

Repairs in Wiring Systems.
Is the action complete

Go to
Cooling Fan
Functional Check,

Repair circuit 504 for a short to B+. Refer to Wiring

Repairs in Wiring Systems.
Is the action complete?

Go to
Cooling Fan
Functional Check

10

Replace the cooling fan relay #2. Refer to Cooling Fan

Relay Replacement in Engine Cooling.
Is the action complete?

Go to
Cooling Fan
Functional Check

Engine

Engine Controls - 5.7L

6-1759

Test Description

3. This step tests for an inoperative cooling fan relay.

The numbers below refer to the step numbers in the

diagnostic table.

5. This step tests for an open left cooling fan motor.

When the left cooling fan terminals are connected,
the right cooling fan should operate on
high speed.

2. Any test that requires probing a component or a

component harness connector, use the Connector
Test Adaptor Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals. Refer to Using Connector Test
Adapters.

7. This step is testing for a short to ground between

the left cooling fan motor and cooling fan
relay #3.

Electric Cooling Fan Table #2

Step

Action

Value(s)

Did you perform the Cooling Fan Functional Check?

1

1. Turn ON the ignition leaving the engine OFF.

2. Disconnect cooling fan relay #1.
3. Probe the cooling fan relay #1 terminal 83 at the
underhood electrical center using the test lamp
J 34142-B connected to ground.
Does the test lamp illuminate?

Yes

No

Go to Step 2

Go to
Cooling Fan
Functional Check

Go to Step 3

Go to Step 11

Go to Step 12

Go to Step 4

Go to Step 5

Go to Step 13

Go to Step 22

Go to Step 6

Go to Step 14

Go to Step 7

Go to Step B

Go to Step 16

Go to Step 17

Go to Step 9

Important: Leave jumper in place for remainder of

this table.

Connect a fused jumper wire between the cooling fan relay

#1 terminals 83 and C1 at the underhood electrical center.
Refer to Using Fused Jumper Wires in Wiring Systems.
Do both cooling fans turn ON?
1. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
2. Disconnect the left cooling fan electrical connector.
3. Probe the left cooling fan electrical connector terminal
8 using the test lamp J 34142-B connected to
ground.
Does the test lamp illuminate?

1. Disconnect the cooling fan relay #3.

2. Probe the cooling fan relay #3 terminal

test lamp J 34142-B connected to 8+.
Does the test lamp illuminate?

ca using the

1. Install the cooling fan relay #3.

Important: Leave jumper in place for remainder of
this table.
2. Connect a fused jumper wire between left cooling fan
electrical connector terminals A and 8. Refer to Using
Fused Jumper Wires in Wiring Systems.
Does the right cooling fan turn ON?

1. Disconnect the cooling fan relay #3.

2. Probe the cooling fan relay #3 terminal ca at the
underhood electrical center using the test lamp
J 34142-B connected to ground.
Does the test lamp illuminate?

Important: Leave the jumper in place for remainder of

this table.

Connect a fused jumper wire between the cooling fan

relay #3 terminals ca and 89 at the underhood electrical
center. Refer to Using Fused Jumper Wires in Wiring
Systems.
Does the right cooling fan turn ON?

6-1760

Engine Controls - 5.7L

Engine

Electric Cooling Fan Table #2 (cont'd}

Step

Action

Value(s)

Yes

No

1. Disconnect the right cooling fan electrical connector.

2. Probe the right cooling fan electrical connector
terminal B using the test lamp J 34142-8 connected
to ground.
Does the test lamp illuminate?

10

Probe the right cooling fan electrical connector terminal A

using the test lamp J 34142-8 connected to B+.
Does the test lamp illuminate?

11

Repair the cooling fan relay B+ supply circuit. Refer to

Wiring Repairs in Wiring Systems.
Is the action complete?

Go to
Cooling Fan
Functional Check

12

Replace the #1 Cooling fan relay. Refer to Cooling Fan

Relay Replacement in Engine Cooling.
Is the action complete?

Go to
Cooling Fan
Functional Check

13

Repair the open circuit between the cooling fan relay #1

and the left cooling fan motor. Refer to Wiring Repairs in
Wiring Systems.
Is the action complete?

14

1. Inspect for poor connections at the left cooling fan

motor. Refer to lntermittents and Poor Connections
Diagnosis in Wiring Systems.
2. If you find a poor connection, repair the condition as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Did you find and correct the condition?

15

Replace the LH fan motor. Refer to Cooling Fan Motor

Replacement - Electric in Engine Cooling.
Is the action complete?

16

Repair the open circuit between the LH cooling fan

electrical connector terminal A and the cooling fan relay #3
terminal C8. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

17

Replace the #3 cooling fan relay. Refer to Cooling Fan

Relay Replacement in Engine Cooling.
Is the action complete?

(
Go to Step 10

Go to Step21

Go to Step 18

Go to Step20

Go to
Cooling Fan
Functional Check

Go to
Cooling Fan
Functional Check
Go to
Cooling Fan
Functional Check
Go to
Cooling Fan
Functional Check
Go to
Cooling Fan
Functional Check

Go to Step 15

1. Inspect for poor connections at the right cooling fan

motor. Refer to lntermittents and Poor Connections
Diagnosis in Wiring Systems.

18

2. If you find a poor connection, repair the condition as

necessary. Refer to Repairing Connector Terminals in
Wiring Systems.

Go to
Cooling Fan
Functional Check

Did you find and correct the condition?

19

20

Replace the RH fan motor. Refer to Cooling Fan Motor

Replacement - Electric in Engine Cooling.
Is the action complete?
Repair the open ground circuit. Refer to Wiring Repairs in
Wiring Systems.

Go to
Cooling Fan
Functional Check

Go to
Cooling Fan
Functional Check

Is the action complete?

21

Repair the open circuit between the cooling fan relay #3

and the RH cooling fan motor. Refer to Wiring Repairs in
Wiring Systems.

22

Repair the short to ground between the left cooling fan

motor and relay #3. Refer to Wiring Repairs in Wiring
Systems.

Go to
Cooling Fan
Functional Check

Go to
Cooling Fan
Functional Check

Is the action complete?

Is the action complete?

Go to Step 19

Engine

Engine Controls - 5.7L

Test Description
The numbers below refer to the step numbers in the
diagnostic table.

6-1761

9. This step tests the cooling fan relay #2 control

circuit.

5. This step tests the cooling fan relay #3 control

circuit.

Electric Cooling Fan Table #3

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to
Cooling Fan
Functional Check

Go to Step 3

Go. to Step B

Go to
Cooling Fan
Functional Check

Go to Step 4

Go to Step 5

Go to Step 11

Go to step 6

Go to Step 13

Go to Step 16

Go to Step 7

Go to Step 17

Go to Step 15

Go to Step 9

Go to Step 11

Go to Step 10

Go to Step 13

Go to Step 12

Go to Step 14

Did you perform the Cooling Fan Functional Check?

1. Turn ON the ignition leaving the engine OFF.

2. Command the cooling fan relays #1, #2 and #3 ON
using the scan tool.
Is the right cooling fan operating at high speed?
Is the left cooling fan operating at high speed?

1. Remove the cooling fan relay #3.

2. Probe the cooling fan relay #3 terminal BB at the
underhood electrical center using the test lamp
J 34142-8 connected to ground.
Does the test lamp illuminate?

1. Probe the cooling fan relay #3 terminal C10 at the

underhood electrical center using the test lamp
J 34142-8 connected to B+.
2. Command the cooling fan relays #2 and #3 ON using
the scan tool.
Does the test lamp illuminate?

Connect a fused jumper wire between the cooling fan relay

#3 terminals CB and 810 at the underhood electrical
center. Refer to Using Fused Jumper Wires in Wiring
Systems.
Does the left cooling fan turn ON?

Probe the cooling fan relay #3 terminal 810 at the

underhood electrical center using the test lamp J 34142-8
connected to B+.
Does the test lamp illuminate?

1. Turn ON the ignition leaving the engine OFF.

2. Disconnect the cooling fan relay #2.
3. Probe the cooling fan relay #2 terminals C4 and C6
at the underhood electrical center using the test lamp
J 34142-8 connected to ground.
Does the test lamp illuminate for both terminals?

1. Probe the cooling fan relay #2 terminal 84 at the

underhood electrical center using the test lamp
J 34142-8 connected to B+.
2. Command the cooling fan relays #2 and #3 ON using
the scan tool.
Does the test lamp illuminate?

Jumper the cooling fan relay #2 terminals C4 and 86 at

the underhood electrical center using a fused jumper wire.
Refer to Using Fused Jumper Wires in Wiring Systems.
Does the right cooling fan turn ON?

Repair the cooling fan relay B+ circuit for an open. Refer

to Wiring Repairs in Wiring System.
Is the action complete?

~;

10

11

Go to
Cooling Fan
Functional Check

6-1762

Engine Controls - 5.7L

Engine

Electric Cooling Fan Table #3 (cont'd)

Step

12

Action

Replace the #2 Cooling fan relay. Refer to Cooling Fan

Relay Replacement in Engine Cooling.

Value(s)

14

Repair the cooling fan relay control circuit for an open.

Refer to Wiring Repairs in Wiring System.
Is the action complete?
Repair circuit 504 for an open. Refer to Wiring Repairs in
Wiring System.

Go to
Cooling Fan
Functional Check

Go to
Cooling Fan
Functional Check

Go to
Cooling Fan
Functional Check

Is the action complete?

15

Repair the open ground circuit between cooling fan relay

#3 and the splice. Refer to Wiring Repairs in Wiring
Systems.

Is the action complete?

16

Replace the #3 cooling fan relay. Refer to Cooling Fan

Relay Replacement in Engine Cooling.
Is the action complete?

No

Is the action complete?

13

Yes

Goto
Cooling Fan
Functional Check
Go to
Cooling Fan
Functional Check

1. Inspect for poor relay connections at the underhood

17

electrical. Refer to lntermittents and Poor

Connections Diagnosis in Wiring Systems.
2. If you find a poor connection, repair the condition as
necessary. Refer to Repairing Connector Terminals in
Wiring Systems.
Is the action complete?

Goto
Cooling Fan
Functional Check

Engine

Engine Controls - 5.7L

6-1763

PNP Switch Diagnosis

Rear

Compartment

Lid

Release
Cell134

Llil

BTSI
Cell138

' " - / - - - - ,Park/

I Neutral

ORN/BLK 434

ORN/BLK 434

1 I Position

I p

1~
R ,

I
I
I

I Switch

2 ,.~

--. N@ ~---
------

. _______

I
...I

A
ORN/BLK 434

BLK/WHT 451

- - - --,
I

BLK/WHT 451

Switch
Signal

PCM
c1= RED
C2=BLU

I Control
I Module

. _____________ ...I

C1

'" - - PNP - - - - - - - - - , Powertrain

I
I

Ground
Distribution
Cell14

BLK/WHT 451

ORN/BLKI 434

32

(PCM)

--

.,.J

BLK 451

218724

Circuit Description
The Park/Neutral Position (PNP) switch contacts are
closed to ground in park and neutral. The PCM applies
voltage (about 12.0 Volts) to the switch. When the
gear selector is in the park or neutral position, the PNP
switch is closed and the PCM senses low signal
voltage (low engine load). When the gear selector is in
reverse or a drive range, the PNP switch opens,
and the PCM senses high signal voltage (high engine
load). The PCM will increase the idle air rate to
compensate for the additional load on the engine when
the transmission is in gear.
Some of the PCMs other uses for the PNP signal are:
Vehicle Speed Sensor (VSS) diagnostics
Exhaust Gas Recirculation (EGA) operation

Diagnostic Aids
A PNP switch that does not close or an open
circuit may cause the engine idle speed to
drop when the vehicle is shifted into gear.
A switch that will not open or the signal _circuit
shorted to ground will cause the EGA system
to be inoperative, possibly resulting in excessive
spark knock.
Inspect all related wiring and connectors including
the connections at the PCM. These may cause
an intermittent malfunction. Inspect for damaged,
corroded or pushed out terminals.
For an intermittent, refer to Symptoms.

6-1764

Engine Controls - 5.7L

Engine
PNP Switch Diagnosis

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Step4

Go to
Diagnostic Aids

Go to Step 7

Go to Step 10

Go to Step 5

Go to Step 13

Go to Step 6

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Install the scan tool.

Turn ON the ignition leaving the engine OFF.
Monitor the scan tool with the transmission in Park.
Shift the transmission to Neutral while monitoring the
scan tool.
Does the scan tool indicate Park/Neutral for both
positions?

Shift the transmission into drive.

Does the scan tool indicate Drive (-R-D321 )?

1. Disconnect the Park/Neutral Position switch

connector. Refer to Park/Neutral Position Switch
Replacement in Automatic Transmission 4L60-E.
2. Jumper the PNP harness connector terminals A and
B using a fused jumper wire. Refer to Using Fused
Jumper Wires in Wiring Systems.
Does the scan tool indicate Park/Neutral?

Probe terminal Bin the PNP switch harness connector

using a fused jumper wire connected to ground.
Does the scan tool indicate Park/Neutral?

1.
2.
3.
4.

1. Leave the fused jumper wire in place.

2. Turn OFF the ignition.
3. Disconnect the PCM connector C1 located on the
opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.
4. Probe the PNP circuit at the PCM harness connector
using the test lamp J 34142-B connected to B+. Refer
to Probing Electrical Connectors in Wiring Systems.
Does The test lamp illuminate?

Disconnect the Park/Neutral Position switch connector.

Refer to Park/Neutral Position Switch Replacement in
Automatic Transmission 4L60-E.
Does the scan tool indicate Drive (-R-D321 )?

1. Turn OFF the ignition.

2. Disconnect the PCM connector C1 located on the
opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.
3. Turn ON the Ignition.
Does the scan tool indicate Drive (-R-D321)?

1. Inspect for a poor connection at the PCM. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

Go to Step 9

Go to Step 11

Go to Step 10

Go to Step 8

Go to Step 12

Go to Step 15

Go to Step 16

Go to Step 15

Engine

Engine Controls - 5.7L

6-1765

PNP Switch Diagnosis (cont'd)

Step

Action

Value(s)

10

1. Inspect the adjustment of the PNP switch. Refer to

Park/Neutral Position Switch Replacement in
Automatic Transmission 4L60-E.
2. Inspect for poor connections at the PNP switch. Refer
to lntermittents and Poor Connections Diagnosis in
Wiring Systems.
3. If you find a poor connection, or PNP switch out of
adjustment, repair as necessary. Refer to Repairing
Connector Terminals in Wiring Systems.
Did you find and correct the condition?

Repair open PNP signal circuit. Refer to Wiring Repairs in

Wiring Systems.
Is the repair complete?

Repair PNP signal circuit shorted to ground. Refer to

Wiring Repairs in Wiring Systems.
Is the repair complete?

Repair the open PNP ground circuit. Refer to Wiring

Repairs in Wiring Systems.
Is the repair complete?

11

12

13

14

Replace the PNP switch. Refer to Park/Neutral Position

Switch Replacement in Automatic Transmission 4L60-E.

16

No

Go to Step 16

Go to Step 14

Go to Step 16

Go to Step 16

Go to Step 16

Go to Step 16

Is the repair complete?

15

Yes

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.
Replace the PCM.
Is the repair complete?

Operate the vehicle within the conditions under which the

original symptom was noted.
Does the system now operate properly?

Go to Step 16

System OK

Go to Step 2

6.-1766

Engine Controls .. 5:7L

Engine

Engine Oil Level Sensor/Switch Diagnosis

,. -: - 0 I1
Level
I Indicator

-i

Instrument
Cluster

>

L2w

Ais--.J~

BRNIW~l,173
'

BRN/WHT 1173

BRN 1174

-----1 r----.
76 . . ._ C2

mOil
~~;f~h
A

B
BLK!WHT 451

Ground
Distribution
Cel114

.-- -

~
I
I
I

I
I

41

Oil
Level

Oil

Level
Switch

Lamp

C1

f - - - - -I -PzM - ~ Powertrain
1
1c1 = 1 Control
---1
Module

Control

RED
C2=BLU I

(PCM)

I ..
I~
I

Input

L-----------------------J

BLK 451

218757

Circuit Description

Test Description

The Oil Level switch is a normally open switch. When

the oil level is within an acceptable range the Oil
Level switch closes. The switch opens when
the engine oil level drops below a predetermined
amount. The PCM tests the Engine Oil Level switch
circuit with the ignition ON (engine OFF). The
PCM monitors the engine coolant temperature to
ensure proper engine oil drain back to the oil pan.
When the engine is colder the engine oil drain
back process takes a greater amount of time.

The numbers below refer to the step numbers on the

diagnostic table.
6. This step tests the Oil Level sensor signal circuit
between the PCM and the sensor.
7. This step tests the Oil Level sensor ground circuit
between the PCM and the sensor.
8. This step tests for an open in the Oil Level sensor
signal circuit between the PCM and the Oil Level
sensor.
9. This step tests the Oil Level signal circuit for a
short to ground.
18. This step Clears the Low Oil Level message. The
engine coolant temperature should decrease by
10C (18F).

Engine Controls - 5.7L

Engine

6-1767

Engine Oil Level Sensor/Switch Diagnosis

Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

Value(s)

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Step 17

Go to Step 6

Go to Step 4

Go to Step 6

Go to Step 5

Go to Step 18

Go to
Diagnostic Aids

Go to Step 7

Go to Step 8

Go to Step 10

Go to Step 11

Go to Step 9

Go to Step 12

Go to Step 13

Go to Step 14

Go to Step 18

Go to Step 16

1. Ensure the vehicle is on a level surface.

2. Inspect the engine oil level.
Is the oil level within range?

1. Install a scan tool.

2. Monitor the Engine Oil Level parameter using a
scan tool.
Does the scan tool display Low Oil Level as YES?

Is the customers concern that the engine oil level was low
and the Low Oil Level indicator never illuminated?

Is the customers concern that oil was just added or that an

oil change was just done and the Low Oil Level indicator
did not clear?

Yes

1. Turn ON the ignition leaving the engine OFF.

2. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
3. Disconnect the Oil Level sensor electrical connector.

4. Measure the voltage at the signal circuit at the

B+

Engine Oil Level sensor electrical connector to a

known good ground using the DMM J 39200. Refer to
Measuring Voltage in Wiring Systems.
Is the voltage at the specified value?

Measure the voltage from the signal circuit to the ground

circuit at the Engine Oil Level sensor electrical connector
using the DMM J 39200. Refer to Measuring Voltage in
Wiring Systems.

B+

Is the voltage at the specified value?

1. Turn OFF the ignition.

2. Disconnect the PCM connector C1 located on the
opposite of the manufacturer's logo. Refer to PCM
Replacement/Programming.
3. Test continuity of the Engine Oil Level sensor signal
circuit using the DMM J 39200. Refer to Testing for
Continuity in Wiring Systems.
Does the DMM indicate continuity?

Probe the Engine Oil Level sensor signal circuit using the
Test Lamp connected to B+. Refer to Probing Electrical
Connectors in Wiring Systems.
Does the test lamp illuminate?

1. Test the terminal tension of the Oil Level sensor

electrical connector. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.

10

11

12

2. If you find a poor connection, repair the connection

as necessary. Refer to Repairing Connector
Terminals in Wiring Systems.
Did you find and correct the condition?

Repair the open ground circuit. Refer to Wiring Repairs in

Wiring Systems.
Is the action complete?

Repair the open signal circuit. Refer to Wiring Repairs in

Wiring Systems.
Is the action complete?

Go to Step 18

Go to Step 18

6-1768

Engine Controls - 5.7L

Engine

Engine Oil Level Sensor/Switch Diagnosis (cont'd)

Step

13

14

15

Action

Value(s)

Repair the short to ground in the signal circuit. Refer to

Wiring Repairs in Wiring Systems.
Is the action complete?

1. Inspect the PCM for faulty connections. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If faulty connections are found, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.

Replace the PCM.

Is the action complete?

Yes

No

Go to Step 18

Go to Step 18

Go to Step 15

Go to Step 18

16

Replace the Engine Oil Level sensor.

Is the action complete?

17

Add the appropriate amount of oil.

Is the action complete?

Go to Step 18
Go to Step 18

1. Start and idle the engine.

2. Allow the engine to reach the specified temperature.
18

Important: The ignition must remain OFF for a minimum

of one hour.

3. Turn OFF the ignition for one hour.

Is the action complete?

90C (194F)

System OK

Engine

Engine Controls - 5.7L

6-1769

Low Engine Oil Level Indicator Diagnosis

\

r ;;. 1

I
I

~vel

Indicator

Instrument
I Cluster
I ..

l....!il

A15--.J~
BRN/WHT 1173
,;

BRN/WHT 1173

BAN 1174

76,.... C2

~
I
I

Ground
Distribution
Cel114

.,._ -

C1

- - - - - -;2v - - - - -L;;:,- - - - - - -, -P~M -.~~~:;~fain

BLK/WHT 451

lI

41

I
I
I

Oil
Level
Switch
Input

~!e1 }
Lamp "---T
Control

jg~:~~~1 1(PCM)
Module
I
I

I ..
I~
I

L-----------------------J

11

BLK 451

218757

Circuit Description

Test Description

Ignition voltage is supplied directly to the Oil Level

Lamp. The PCM controls the lamp by grounding the
control circuit via an internal switch called a driver. The
primary function of the driver is to supply the ground
for the component being controlled.

The numbers below refer to the step numbers on the

diagnostic table.

Diagnostic Aids
This table assumes the Engine Oil Level switch is
operating properly. Monitor the Engine Oil Level
parameter on the scan tool. If the Engine Oil Level
parameter displays low, refer to Engine Oil Level
Sensor/Switch Diagnosis.

2. If the Low Oil Level lamp is ON, ensure that the

oil level is within range. If the customers concern
is that the lamp never comes ON and the oil
level is low, refer to Engine Oil Level
Sensor/Switch Diagnosis for further diagnosis.
8. If no trouble is found in the control circuit or the
connection at the PCM, the PCM may be
faulty, however, this is an extremely unlikely
failure.

6-1770

Engine Controls - 5.7L

Engine

Low Engine Oil Level Indicator Diagnosis

Action

Step

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

Value(s)

1. Turn OFF the ignition.

2. Disconnect the PCM connector C2 located on the
same side as the manufacturer's logo. Refer to PCM
Replacement/Programming
3. Turn ON the ignition.
Is the Low Oil Level lamp OFF?

With a fused jumper wire connected to ground, probe the

lamp control circuit in the PCM harness connector.
Is the Low Oil Level lamp ON?

Repair the lamp control circuit for a short to ground. Refer

to Wiring Repairs in Wiring Systems.
Is the repair complete?

Important:
1. Program the replacement PCM. Refer to PCM
Replacement/Programming.
2. Perform the CKP System Variation Learn Procedure.

Replace the PCM.

Is the action complete?

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Engine Oil
Level
Sensor/Switch
Diagnosis

Go to Step 3

Go to Step 4

Go to Step 5

Go to Step 6

Go to Step 7

System OK

(
System OK

Did you find and correct the condition?

Test for the following conditions:
Faulty indicator.
Open ignition feed to the indicator Refer to Wiring
Repairs in Wiring Systems.
Control circuit open or shorted to B+. Refer to Wiring
Repairs in Wiring Systems.
Is the repair complete?

No

Important: Verify the engine oil level before proceeding

with this diagnostic table. If the engine oil level is within
range and the oil level parameter displays low, refer to
Engine Oil Level Sensor/Switch Diagnosis
1. Turn ON the ignition leaving the engine OFF.
2. Monitor the Engine Oil Level parameter on the
scan tool.
Does the Oil Level parameter display Low?

1. Inspect for poor connections at the PCM. Refer to

lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.

Yes

Go to Step B

System OK

System OK

Engine

Engine Controls - 5.7L

6-1771

Fuel Injector Balance Test

)
FUEL INJECTOR
- - TESTER+

LOW VEHICLE BATTERY

READY TO TEST

TEST IN PROGRESS

AMPERAGE SUPPLY SELECTOR SWITC

Coil Test

Balance Test

4amp
2.Samp
o.samp

4amp
0.5-2.5

amp

B+

PUSH TO START TEST

J 39021
17713

Legend
(1) First Reading

Test Description
Caution: Wrap a shop towel around the fuel
pressure connection in order to reduce the risk of
fire and personal injury. The towel will absorb
any fuel leakage that occurs during the connection
of the fuel pressure gauge. Place the towel in an
approved container when the connection of
the fuel pressure gauge is complete.
4. The engine coolant temperature must be below
the operating temperature in order to avoid
irregular fuel pressure readings due to Hot Soak
fuel boiling.

.(2) Second Reading

5. The fuel pressure should be within the specified

range. If the fuel pressure is not within the
specified range, go to Fuel System Diagnosis.

6. The fuel pressure should reach a steady value. If

the fuel pressure does not reach a steady value,
go to Fuel System Diagnosis.
7. If the pressure drop value for each fuel injector is
within 1O kPa (1.5 psi) of the average pressure
drop value, the fue.l injectors are flowing properly.
Calculate the pressure drop value for each fuel
injector by subtracting the second pressure
reading from. the first pressure reading. Refer to
the illustration above.

6-1772

Engine

Engine Controls - 5.7L

Fuel Injector Balance Test

Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check

Go to Step 3

Go to Fuel lnj
Coil Test - ECT
Between
10-35 Degrees C

Go to Step 4

Go to Step 5

Did you perform the Fuel Injector Coil Test Procedure?

Is the engine coolant temperature above the

specified value?

94C (201F)

Allow the engine to cool below the specified value.

Is the engine coolant temperature below the
specified value?

94C (201 F)

Caution: Wrap a shop towel around the fuel pressure

connection in order to reduce the risk of fire and
personal injury. The towel will absorb any fuel leakage
that occurs during the connection of the fuel pressure
gauge. Place the towel in an approved container when
the connection of the fuel pressure gauge is complete.
1. Turn OFF the ignition.
2. Connect the J 34730-1A fuel pressure gauge to the
fuel pressure test port.
3. Turn ON the ignition leaving the engine OFF.
4. Install the scan tool.
5. Energize the fuel pump using the scan tool.
6. Place the bleed hose of the fuel pressure gauge into
an approved gasoline container.
7. Bleed the air out of the fuel pressure gauge.
8. Again energize the fuel pump using the scan tool.
9. Wait for the fuel pressure to build.
Important: The fuel pump will run for approximately
2 seconds. Energize the fuel pump as necessary in order
to achieve the highest possible fuel pressure.
10. Observe the reading on the fuel pressure gauge while
the fuel pump is running.
Is the fuel pressure within the specified limits?

38Q-410 kPa
(55-60 psi)

After the fuel pump stops, the fuel pressure may vary
slightly, then should hold steady.
Does the fuel pressure remain constant within the
specified value?

380-410 kPa
(55-60 psi)

Go to Step 5

Go to Step 6

Go to Fuel
System
Diagnosis

Go to Step 7

Go to Fuel
System
Diagnosis

Engine Controls - 5.7L

Engine

6-1773

Fuel Injector Balance Test (cont'd)

Step

Action

Value(s)

Yes

No

Go to Step 8

Go to Symptoms

Go to Step 9

Go to Symptoms

1. Connect the J 39021 fuel injector tester to a fuel

injector.
2. Set the amperage supply selector switch on the fuel
injector tester to the Balance Test 0.5-2.5 amp
position.
3. Energize the fuel pump using the scan tool in order to
pressurize the fuel system.
4. Record the fuel pressure indicated by the fuel
pressure gauge after the fuel pressure stabilizes. This
is the 1st pressure reading (1).

5. Energize the fuel injector by depressing the Push to

Start Test button on the fuel. injector tester.
6. Record the fuel pressure indicated by the fuel
pressure gauge after the fuel pressure gauge needle
has stopped moving. This is the 2nd pressure
reading (2).
7. Repeat steps 1 through 6 for each fuel injector.
8. Subtract the 2nd pressure reading from the 1st
pressure reading for one fuel injector. The result is
the pressure drop value.
9. Obtain a pressure drop value for each fuel injector.
10. Add all of the individual pressure drop values. This is
the total pressure drop.

10 kPa (1.5 psi)

11. Divide the total pressure drop by the number of fuel

injectors. This is the average pressure drop.
Does any fuel injector have a pressure drop value that is
either higher than the average pressure drop or lower than
the average pressure drop by the specified value?

Notice: Do not repeat any portion of this test before

running the engine in order to prevent the engine from
flooding
Re-test any fuel injector that does not meet the
specification. Refer to the procedure in step 7.
Does any fuel injector still have a pressure drop value that
is either higher than the average pressure drop or lower
than the average pressure drop by the specified value?

Replace the faulty fuel injector(s). Refer to Fuel Injector

Replacement.
Is the replacell)ent complete?

1O kPa (1.5 psi)

System OK

6-1774

Engine

Engine Controls - 5.7L

Fuel lnj Coil Test - ECT Between 10-35 Degrees C

J392000MM

LOW VEHICLE BATTERY

R!ADY TO TEST

mvn.....
V-DCe,
m.A
V-AC
. ..
A

TEST IN PROGRESS
AMPERAGE SUPPLY SELECTOR SWITCH
Coil Test

Cl Cl Cl.Cl
ClC]Cl

FUEL INJECTOR
- TESTER +

OFF.

Balance Test

4amp

4amp

2.Samp

0.5-2.5

+.

00

amp

O.Samp

PUSH TO START TEST

B+

J 39021

(
17707

Test Description
Caution: Wrap a shop towel around the fuel
pressure connection in order to reduce the risk of
fire and personal injury. The towel will absorb
any fuel leakage that occurs during the connection
of the fuel pressure gauge. Place the towel in an
approved container when the connection of
the fuel pressure gauge is complete.
2. The engine coolant temperature affects the ability
of the fuel injector tester to detect a faulty fuel
injector. If the engine coolant temperature is NOT
between 10C and 35C (50F and 95F), go
to Fuel lnj Coil Test - ECT Outside
10-35 Degrees C.
3. The first second of the voltage displayed by the
DMM may be inaccurate due to the initial
current surge. Therefore, record the lowest voltage
displayed by the DMM after the first second of
the test. The voltage displayed by the DMM should
be within the specified range (refer to the
Example). The voltage displayed by the DMM
may increase throughout the test as the fuel
injector windings warm and the resistance of the

fuel injector windings changes. An errat.ic

voltage reading (large fluctuations in voltage that
do not stabilize) indicates an intermittent
connection within the fuel injector.

Example
Resistance
Ohms

Voltage Specification at 10C-35C

. {$0F-95F}

11.4-12.6

5.5-6.6V

Fuel Injector
Number
1

2
3
4
5
6
7

Voltage Reading

Pass/Fail

6.3
5.9
6.2
6.1
4.8
6.0
5.0
5.3

p
p
p
p
F

p
F
F

Engine

Engine Controls - 5.7L

6-1775

Fuel lnj Coil Test - ECT Between 10-35 Degrees C

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Fuel lnj
Coil Test - ECT
Outside
10-35 Degrees C

Go to Step 4

Go to Fuel
Injector
Balance Test

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

1. Connect the scan tool.

2. Check the engine coolant temperature.
Is the engine coolant temperature within the specified
limits?

10C-35C
(50F-95F)

1. Turn the ignition OFF.

Notice: In order to prevent flooding of a single cylinder and
possible engine damage, relieve the fuel pressure before
performing the fuel injector coil test procedure.
2. Relieve the fuel pressure. Refer to the Fuel Pressure
Relief Procedure.
3. Access the fuel injector electrical connectors as
required.

4. Connect the J 39021 fuel injector tester to B+ and

ground.
5. Set the amperage supply selector switch on the fuel
injector tester to the Coil Test 0.5 amp position.
6. Connect the leads from the J 39200 Digital Multi
Meter (DMM) to the fuel injector tester. Refer to the
illustration associated with the test description.
7. Set the DMM to the tenths scale (0.0).
8. Connect the fuel injector tester to a fuel injector.
Important: Check the engine coolant temperature again in
order to ensure that the correct chart is being used.
9. Press the Push to Start Test button on the fuel
injector tester.
10. Observe the voltage reading on the DMM.
Important: The voltage reading may rise during the test.
11. Record the lowest voltage observed after the first
second of the test.
12. Repeat steps 8 through 11 tor each fuel injector.
Did any fuel injector have an erratic voltage reading (large
fluctuations in voltage that do not stabilize) or a voltage
reading outside of the specified limits?
Replace the faulty fuel injector(s). Refer to Fuel Injector
Replacement.
Is the replacement complete?

5.5-6.6V

Go to Fuel
Injector
Balance Test

6-1776

Engine Controls - 5.7L

Engine

Fuel lnj Coil Test - ECT Outside 10-35 Degrees C

J 39200 DMM

LOWVEHICLE8ATTERY

READY TO TEST

TEST IN PROGRESS

mvn-.
V-DCemA
V-AC
A
OFF
A

AMPERAGE SUPPLY SELECTOR SWITCH

Coil Test
4amp
2.Samp
o.samp

CJCJCJCJ
CJCJCJ

FUEL INJECTOR
- TESTER +

Balance Test
4amp

00

0.5-2.5
amp

PUSH TO START TEST

B+

J 39021

17707

Test Description
Caution: Wrap a shop towel around the fuel
pressure connection in order to reduce the risk of
fire and personal injury. The towel will absorb
any fuel leakage that occurs during the connection
of the fuel pressure gauge. Place the towel in an
approved container when the connection of
the fuel pressure gauge is complete.
2. The engine coolant temperature affects the ability
of the fuel injector tester to detect a faulty fuel
injector. If the engine coolant temperature
is between 10C-35C (50F-95F), go to Fuel lnj
Coil Test - ECT Between 10-35 Degrees C.
3. The first second of the voltage displayed by the
DMM may be inaccurate due to the initial
current surge. Therefore, record the lowest voltage
displayed by the DMM after the first second of
the test. The voltage displayed by the DMM may
increase throughout the test as the fuel injector
windings warm and the resistance of the fuel
injector windings changes. An erratic voltage
reading (large fluctuations in voltage that do not
stabilize) indicates an intermittent connection
within the fuel injector. From the voltages
recorded, identify the highest voltage, excluding
any voltages above 9.5 volts. Subtract each
voltage that is not above 9.5 volts from the highest

voltage. Record each subtracted value (refer to

the Example). The subtracted value for any
fuel injector must not exceed 0.6 volt. A fuel
injector with a subtracted value that is greater
than 0.6 volt is faulty. Replace the fuel injector. A
fuel injector with a recorded voltage above
9.5 volts is also faulty. Replace the fuel injector.

Example

Highest Voltage Reading

Acceptable Subtracted
Value Above/Below
10C-35C (50F-95F)

0.6 V

7.1 V
Injector
Number

Voltage

Subtracted
Value

Pass/Fail

9.8

6.6

0.5

F
p

6.9

0.2

5.8

1.3

7.0

0.1

F
p

7.1

0.0

9.6

6.0

1.1

Engine

Engine Controls - 5.7L

6-1777

Fuel lnj Coil Test - ECT Outside 10-35 Degrees C

Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?
1

1. Connect the scan tool.

2. Check the engine coolant temperature.
Is the engine coolant temperature outside the specified
limits?

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 3

Go to Fuel lnj
Coil Test - ECT
Between
0-35 Degrees C

Go to Step 4

Go to Fuel
Injector
Balance Test

10C-35C
(50F-95F)

1. Turn the ignition OFF.

Notice: In order to prevent flooding of a single cylinder and
possible engine damage, relieve the fuel pressure before
performing the fuel injector coil test procedure.
2. Relieve the fuel pressure. Refer to the Fuel Pressure
Relief Procedure.

3. Access the fuel injector electrical connectors as

required.
4. Connect the J 39021 fuel injector tester to B+ and
ground.

5. Set the amperage supply selector switch on the fuel

injector tester to the Coil Test 0.5 amp position.
6. Connect the leads from the J 39200 Digital Multi
Meter (DMM) to the fuel injector tester. Refer to the
illustration associated with the test description.
7. Set the DMM to the tenths scale (0.0).
8. Connect the fuel injector tester to a fuel injector.
Important: Check the engine coolant temperature again in
order to ensure that the correct chart is being used.
9. Press the Push to Start Test button on the fuel
injector tester.
10. Observe the voltage reading on the DMM.
Important: The voltage reading may rise during the test.
11. Record the lowest voltage observed after the first
second of the test.
12. Repeat steps 8 through 11 for each fuel injector.
13. Identify the highest voltage reading recorded other
than those above 9.5 volts.
14. Subtract any other voltage reading recorded from the
highest voltage reading recorded.
15. Repeat step 14 for all the remaining fuel injectors.
. Is any value that resulted from subtraction greater than the
specified value?

0.6V

Replace any fuel injector that had any of the following:

A subtracted value exceeding 0.6 volts.

An initial reading above 9.5 volts.
An erratic reading.
Refer to Fuel Injector Replacement.
Is the replacement complete?

Go to Fuel
Injector
Balance Test

6-1778

Engine Controls -5.7L

Engine

Fuel Injector Circuit Diagnosis

!Hot In RUN, BULB TEST And START!

'" - - - - - I

Power

~~
Cell 10

I
I

J11
J 10

L------

f Hot In RUN, BULB TEST And START!

- - - - - - - - - - - - - - - - - - - - - - - - - - - - .., Underhood
I

INJ 2
Mini Fuse
15 A

J9
J8

PNK

PNK/WHT 639
PNK
639

PNK 639

839

PNK 839

'" 3.,

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3
l}j
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Fuel

}jector

Fuse Block
Details
Cell11

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PNK 839

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Fuse Block
Details
Cell11

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INJ 1
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15 A
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PNK 639

PNK 639

PNK 639

PNK 639

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31
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~jecto'l tllJ ~jector }tctor
tector lll tctor il J ~jector tllJ ~jector
Fuel

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B
LT GRN/BLK
1745

PNK 839

Fuel

Bv
LT
BLU/
BLK 844

Powertrain
Control
Module>
(PCM)~ 23,A. ___ 1?

A
'"

Fuel

Bv
DK
BLU/WHT 878

YEL/
BLK 846
18

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Fuel

Bv

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,.

Fuel

33

Fuel

BLK/WHT 845

BLK 1744

PNK/BLK 1746

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RED/BLK 877
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27

C1

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I
I
I

P~M

c1 - RED
c2 - BLU

---1 "---1 "--1

Fuel ~
Injector 2
Driver

Fuel ~ Fuel ~
Injector 4 lnj~ctor 6
Driver
Driver

---1

Fuel ~
Injector B
Driver

---1

Fuel ~
Injector 1
Driver

---1

Fuel ~
Injector 3
driver

---1

Fuel ~
Injector 5
Driver

---1 :

Fuel ~
Injector 7
Driver

1
I

~---------------------------------------------J

218755

Circuit Description

Test Description

The PCM will enable an injector on the intake stroke

of each cylinder. Individual cylinder fuel control is
referred to as Sequential Multiport Fuel Injection (SFI).
Ignition voltage is supplied directly to the fuel
injectors. The PCM controls each injector by grounding
the control circuit via an internal switch called a
driver. The primary function of the driver is to supply
the ground for the component being controlled.

The numbers below refer to the step numbers on the

diagnostic table.

Diagnostic Aids
If an injector is disconnected while the engine is
operating the injector driver will be disabled for
the entire ignition cycle.
When the injector driver is disabled, an engine
misfire will be apparent and a misfire OTC
will set.
For an intermittent condition, refer to Symptoms.

2. This step determines if a malfunction is present.

For any test that requires probing the PCM or a
component harness connector, use the Connector
Test Adapter Kit J 35616-A. Using this kit
prevents damage to the harness connector
terminals.

Engine

Engine Controls - 5.7L

3. There are two ways to isolate a malfunctioning

injector circuit:
OTC P0300 indicates a misfire is present. So
use misfire current counters to locate the
cylinder that is misfiring.
If no misfire OTC is present, Start and idle the
engine while monitoring misfire current
counters. If a misfire is present, the misfire
current counters increase for a cylinder
that has a misfire.

6-1779

6. Test injector connections before replacing the

injector. A faulty connection causes an inoperative
injector.
9. Tests for an ignition feed circuit that is shorted to
ground.
Disconnecting the PCM allows using the DMM
J .39200 to test continuity of the circuits. This will aid in
locating an open or shorted circuit.

Fuel Injector Circuit Diagnosis

Step

Action

Did you perform the Powertrain On-Board Diagnostic

(OBD) System Check?

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Step 4

Go to Step 3

Go to Step 17

Go to
Diagnostic Aids

Go to Step 5

Go to Step 8

Go to Step 6

Go to Step 10

Go to Step 7

Go to Step 11

System OK

Go to Step 15

Important: This table assumes that there are no Ignition

Coil/Module circuit malfunctions or mechanical
malfunctions. If you were not sent here from OTC P0300,
refer to OTC P0300 before proceeding with this table.
2

1. Install the scan tool.

2. Start and idle the engine.
3. Monitor all the Misfire Cur. Counters on the Misfire
Data List (There are a total of 8 counters. One
counter per cylinder) using a scan tool.
Are any of the Misfire Cur. Counters incrementing?

Monitor the Misfire Hist. Counters on the Misfire Data List

(There are a total of 8 counters. One counter per cylinder)
using a scan tool.
Does any of the Misfire Hist. Counters indicate a number
other than 0.0 counts?

Are the injector fuses OK?

1. Turn OFF the ignition.

2. Disconnect the injector(s) harness that the Misfire Cur

counter was incrementing for.
3. Turn ON the ignition leaving the engine OFF.

4. Using the test lamp J 34142-8 connected to ground,

probe the injector harness ignition feed circuit. Refer
to Probing Electrical Connectors in Wiring Systems.
Does the test lamp illuminate?

1. Tum OFF the ignition,

6

2. Connect the injector test lamp (J 34730-2C) to

isolated injector harness.
3. Start engine and idle.
Does the test lamp blink?

1. Inspect the injector harness terminals for proper

terminal tension. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
7

2. If you find a poor connection, repair as necessary.

Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

6-1780

Engine Controls - 5.7L

Engine

Fuel Injector Circuit Diagnosis (cont'd)

Step

Action

Value(s)

Yes

No

1. Turn OFF the ignition.

2. Disconnect the four injector harness connectors
related to the fuse that was open.

3. Using the test lamp J 34142-8 connected to B+,

probe the injector ignition feed circuits of one of the
injector harnesses that are disconnected.
Does the test lamp illuminate?
Important: Return to this diagnostic after you perform the
Fuel Injector Coil Test.
Perform the Fuel Injector Coil Test. Refer to Fuel lnj Coil
Test - ECT Between 10-35 Degrees C.
Did you isolate a fuel injector condition?

(
-

1. Turn OFF the ignition.

2. Disconnect the PCM connector C1 located on the
opposite side of the manufacturer's logo. Refer to
PCM Replacement/Programming.
3. Inspect the PCM connector terminals for poor
connections. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
4. If you find a poor connection, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
5. Test the injector driver circuit for an open, short to
voltage, or short to ground.
Is the injector driver circuit open or shorted?

12

Repair injector driver circuit for an open, short to voltage,

or short to ground. Refer to Wiring Repairs in Wiring
Systems.
Is the action complete?

13

Repair the grounded ignition feed circuit to the injectors.

Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Repair intermittent short to ground in the injector ignition

feed circuit. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Replace the faulty injector(s) that was isolated. Refer to

Fuel Injector Replacement.
Is the action complete?

11

14

15

16

17

Important: Program the replacement PCM. Refer to PCM

Replacement/Programming.

Replace the PCM.

Is the action complete?
1. Inspect the appropriate injector circuit for the
following:
Poor connections at the injector and the PCM
terminal. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
Intermittent shorts to ground
Intermittent opens
2. If a condition is found, repair the circuit as necessary.
Refer to Wiring Repairs in Wiring Systems.
Did you find and correct the condition?

Go to Step 9

Go to Step 15

Go to Step 14

11.40

Repair the injector ignition feed circuit to isolated injector.

Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

10

Go to Step 13

System OK

Go to Step 12

Go to Step 16

(
\

System OK

System OK

System OK

System OK

System OK

(
System OK

Go to Symptoms

Engine
Fuel Tank Leak Check
Caution: Place a dry chemical (Class 8) fire
extinguisher near the area before performing a
Fuel Tank Leak Check. Before removing the
fuel tank for a suspected leak, make sure that the
fuel pipes or the tubes are not leaking onto the
tank. Once removed, make sure that the fuel is not
leaking around the fuel sender 0-ring. Failure to
follow these precautions may result in personal
injury.
Important: This check requires a fuel sender
assembly, fuel filler cap, and a fuel sender gasket to
be installed in the fuel tank.

Caution: Refer to the Battery Disconnect Caution

in Cautions and Notices.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining
Procedure.
4. Remove the fuel tank. Refer to Fuel Tank
Replacement.
5. Cap the fuel feed pipe, the fuel return pipe, and
the EVAP pipe on the fuel sender assembly.
6. Connect a piece of hose to the vent pipe.
7. Submerge the fuel tank in water or apply a soap
solution to the ou+side of the fuel tank.
8. Apply 7-10 kPa (1-1% psi) air pressure to the
piece of hose on the fuel tank vent pipe. Air
bubbles appearing from the fuel tank indicate
a leak.
9. Replace the fuel tank if it is leaking. Refer to Fuel
Tank Replacement.

Fuel Tank Vent Valve Diagnosis

The fuel tank vent valve is located in the rear of the
vehicle near the fuel tank. The fuel tank vent valve is a
pressure/vacuum relief valve. If the valve is not
functioning properly it could cause excessive pressure
or vacuum to build up in the fuel tank. The result
may be possible fuel discharge when removing the fuel
filler cap or possible damage to the fuel tank or the
fuel sender.
1. Loosen the fuel filler cap in order to relieve the
tank pressure.
2. Remove the tank vent valve from the vehicle.
3. Wrap the vent valve in a shop towel and shake out
any remaining fuel.
4. Connect the vent valve to a radiator pressure
check device using the appropriate adapters.

Engine Controls - 5.7L

6-1781

5. Slowly apply pressure to the vent valve. The valve

should open at approximately 1V2 psi. If not,
replace the vent valve.
6. Disconnect the vent valve from the pressure
tester.
7. Connect the vent valve to a hand operated
vacuum pump using the appropriate adapters.
8. Slowly apply vacuum to the vent valve. The valve
should open at approximately 1-2" Hg. If not,
replace the vent valve.

Alcohol/Contaminants-in-Fuel Diagnosis
Alcohol-in-fuel can be detrimental to fuel system
components and may cause driveability problems such
as hesitation, lack of power, stall, no start, etc. The
problems may be due to fuel system corrosion
and subsequent fuel filter plugging, deterioration of
rubber components, and/or air-fuel mixture leaning.
Commercial fuel uses various types and
concentrations of alcohol. Some types of alcohol are
more detrimental to fuel system components than
others. If you suspect an excessive amount of alcohol
in the fuel as the cause of a driveability condition,
use the Alcohol-in-Fuel Testing Procedure to detect the
presence of alcohol in the fuel.

Alcohol-in-Fuel Testing Procedure

Draw the fuel sample from the bottom of the tank in
order to detect any water present in the tank. The
sample should be bright and clear. If the sample
appears cloudy, or contaminated with water (as
indicated by a water layer at the bottom of the sample),
do not use this procedure. Go to Fuel System
Cleaning.
1. Fill a 100 ml cylinder with fuel to the 90 ml mark.
2. Add 10 ml of water to bring the total fluid
volume to 100 ml. Install a stopper on the cylinder.
3. Shake the cylinder vigorously for
1O to 15 seconds.
4. Carefully loosen the stopper to release the
pressure.
5. Close the stopper and shake the cylinder
vigorously again for 1O to 15 seconds.
6. Put the graduated cylinder on a level surface for
approximately 5 minutes to allow adequate liquid
separation.
If alcohol is present in the fuel, the volume of the
lower layer, which would now contain both alcohol and
water, will be more than 10 ml. For example, if the
volume of the lower layer increases to 15 ml, it
indicates at least 5 percent alcohol in the fuel. The
actual amount of alcohol may be somewhat more
because this procedure does not extract all of
the alcohol from the fuel.

6-1782

Engine

Engine Controls - 5.7L

Electronic Ignition System Diagnosis

Circuit Description
A Crankshaft Position (CKP) sensor determines the
engine crankshaft position. The sensor is mounted and
protrudes into the rear of the engine block. The
sensor is near a slotted wheel on the crankshaft. The
rotation of the slotted wheel causes a magnetic
flux change in the sensor. This produces a voltage
signal from the electronic Ignition Control Module
(ICM). The signal creates the reference pulses needed
by the Powertrain Control Module (PCM). These
signals trigger the correct ignition coil to fire, at the
correct time.
The ignition system on this engine uses an individual
ignition coil/module for each cylinder. The PCM
controls the ignition system operation. There are eight
Ignition Control (IC) circuits, one per cylinder, that
connect the PCM and the ignition coil/modules. Each
ignition coil/module has a power feed, a chassis
ground circuit, and a reference low circuit. The PCM
causes a spark to occur by grounding the IC
circuit, which signals the ignition module to trigger the
ignition coil and fire the spark plug. The PCM
controls the sequencing and timing. For ignition control
circuit schematics, refer to Bank 1 Ignition System
or Bank 2 Ignition System.

Using Freeze Frame and/or Failure Records data may

aid in locating an intermittent condition. If you
cannot duplicate the OTC, the information included in
the Freeze Frame and/or Failure Records data can
help determine how many miles since the OTC
set. The Fail Counter and Pass Coun.ter can also help
determine how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate vehicle
within the same freeze frame conditions (RPM, load,
vehicle speed, temperature etc.) that you observed.
This will isolate when the OTC failed.
For an intermittent condition, refer to Symptoms.

Test Description
The numbers below refer to the step numbers on the
diagnostic tabl.e.

Diagnostic Aids
The following may cause an intermittent:
Inspect for poor connections. Test for adequate
terminal tension. Refer to lntermittents and
Poor Connections Diagnosis in Wiring Systems.
Corrosion
Mis-routed harness
Rubbed through wire insulation
Broken wire inside the insulation

3. Monitoring the misfire current counters determines

if a fault is present.
4. A good indication that the fuse is open is all the
misfire current counters are incrementing on
one side of the engine. Inspect the ignition feed
circuit for a grounded circuit.

8. If the fuse is open and no condition can be found

with the ignition coil/module circuits, inspect the
injector circuits for being grounded. The INJR1
fuse and INJR2 fuse feed the ignition coil/module
circuits and injector circuits.

Electronic Ignition System Diagnosis

Step

Action
Did you perform the Powertrain On-Board Diagnostic
(OBD) System Check?

Are DTCs P0335, P0336, P0351 - P0358 set?

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check

Go to Applicable
OTC Table

Go to Step 3

Go to Step 4

Goto
Diagnostic Aids

Go to Step 8

Go to Step 5

Important: This table assumes that there are no injector

circuit malfunctions or mechanical malfunctions. If you
were not sent here from OTC P0300, refer to OTC P0300
before proceeding with this table.
1. Install a scan tool.
2. Idle the engine.
3. Using a scan tool, monitor all the Misfire Cur.
counters on the misfire data list. There are a total of
8 counters, one counter per cylinder.
Are any of the Misfire Cur. counters incrementing?

Are the misfire current counters incrementing for all

cylinders on one bank of the engine?

Engine

Engine Controls - 5.7L

6-1783

Electronic Ignition System Diagnosis (cont'd)

,_

Action

Step

Value(s)

Yes

No

Go to Step 6

Go to Step 10

Go to Step 7

Go to Step 13

Go to Step 21

Go to Step 17

System OK

Go to Step 9

1. Turn OFF the ignition.

2. Disconnect the ignition coil/module electrical
connector that corresponds to the Misfire Cur
counter(s) that was incrementing.

3. Turn On the ignition leaving the engine OFF.

4. Probe the ignition feed circuit at the ignition

coil/module electrical connector using the test lamp

J 34142-8 connected to battery ground. Refer to
Probing Electrical Connectors in Wiring Systems.
Does the test lamp illuminate,?

Using the test lamp J 34142-8 probe the ignition feed

circuit at the ignition coil/module electrical connector to the
ignition coil/module ground circuit.

Does the test lamp illuminate?

Using the test lamp J 34142-8 probe the ignition feed

circuit at the ignition coil/module electrical connector to the
ignition coil/module reference low circuit.

Does the test lamp illuminate?

1. Inspect for an open ignition coil/module fuse (INJR1
or INJR2).
8

2. Locate and repair the ignition feed circuit for a

grounded circuit if the fuse is open. Refer to Wiring
Repairs in Wiring Systems.

3. Replace the fuse.

Did you find and correct the condition?

Repair the open in the ignition feed circuit between the

fuse block and the splice. Refer to Wiring Repairs in
Wiring Systems.

Is the action complete?

System OK

1. Disconnect the main ignition coil/module 8-way

connector.

10

2. Probe the ignition feed circuit at the ignition

coil/module main 8-way connector using the test lamp
J 34142-8 connected to battery ground.

Go to Step 11

Does the test lamp illuminate?

11

Repair the open circuit between the splice and the ignition
coil/module connector. Refer to Wiring Repairs in Wiring
Systems.

12

System OK

Is the action complete?

Repair the open ignition feed circuit between the fuse
block (open fuse) and splice. Refer to Wiring Repairs in
Wiring Systems.

Go to Step 12

Is the action complete?

System OK

1. Disconnect the main ignition coil/module 8-way

connector.
13

2. Using the test lamp J 34142-8 probe the ignition feed

circuit at the ignition coil/module main electrical 8-way
connector to the ignition coil/module ground circuit.
Does the test lamp illuminate?

/'

Go to Step 14

Go to Step 16

6-1784

Engine Controls - 5.7L

Engine

Electronic Ignition System Diagnosis (cont'd)

Step

Action

Value(s)

14

1. Test for a poor connection at the main ignition

coil/module electrical 8-way connector. Refer to
lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If you find a poor connection, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.
Did you find and correct the condition?

15

Repair the open ground circuit between the main 8-way

connector and the ignition coil/module connector. Refer to
Wiring Repairs in Wiring Systems.
Is the action complete?

16

Repair the open ground circuit between the ground and

the main 8-way connector. Refer to Wiring Repairs in
Wiring Systems.
Is the action complete?

17

1. Disconnect the main ignition coil/module 8-way

connector.
2. Using the test lamp J 34142-8 probe the ignition feed
circuit at the ignition coil/module main electrical 8-way
connector to the ignition coil/module reference low
circuit. Refer to Probing Electrical Connectors in
Wiring Systems.

18

Go to Step 20

System OK

20

Repair the open reference low circuit between the PCM

and the splice. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

Go to Step 19

System OK

System OK

Did you find and correct the condition?

22

Go to Step 18

19

Replace ignition coil/module. Refer to Ignition Coil

Replacement in Engine Electrical.
Is the action complete?

Go to Step 15

Repair the open reference low circuit between the

main 8-way connector and the ignition coil/module
connector. Refer to Wiring Repairs in Wiring Systems.
Is the action complete?

21

System OK

System OK

Did you find and correct the condition?

1. Test for poor connections at the ignition coil/module

harness connector. Refer to lntermittents and Poor
Connections Diagnosis in Wiring Systems.
2. If you find a poor connection, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.

No

System OK

Does the test lamp illuminate?

1. Inspect for a poor connection at the main ignition
coil/module electrical 8-way connector. Refer to
lntermittents and Poor Connections Diagnosis in
Wiring Systems.
2. If a poor connection is found, repair as necessary.
Refer to Repairing Connector Terminals in Wiring
Systems.

Yes

System OK

Go to Step 22

System OK

Engine
Inspection/Maintenance Status Reset
Procedures

System Status For Satisfying the Federal

Inspection/Maintenance (1/M) Regulations
The scan tool System Info menu includes the System
Status selection.
Several states require that the vehicle pass on-board
(OBD II system) tests for the major diagnostics
prior to having a vehicle 1/M emission inspection. Some
areas may require that the vehicle pass the OBD II
system tests and the 1/M emission inspection in order
to renew license plates.
Using a scan tool, the technician can observe the
System Status (Complete or Not Complete) in order to
verify that the vehicle meets the criteria which
complies with the local area requirements. Using the
System Status display, monitor any of the following
systems or a combination of the systems (depending
on vehicle make and model) for 1/M Readiness:

Engine Controls - 5.7L

Following a OTC Info Clear, battery disconnect, or a

control module replacement, all of the System
Status information will be set to Not Complete.
Refer to the diagnostic support information associated
with each OTC in order to obtain the Conditions for
Running the OTC. The vehicle operating conditions
that the system must meet in order for a OTC to
run are the Conditions for Running the OTC.
The System Status table shows the DTCs that must
run in order for the System Status to indicate a system
test has been Completed.

System Status
System Status

Heated Oxygen Sensor (H02S) Heater

Exhaust Gas Recirculation (EGR)
Evaporative Emission (EV AP)
Secondary Air Injection System (AIR)
Important: The System Status display indicates only if
the PCM has completed the required tests (DTCs).
The System Status display does not necessarily mean
that the test has passed. If a failure indication is
present for a OTC associated with one of the above
systems, that test has failed. Diagnosis and repair are
necessary in order to meet the 1/M requirement.
Verify that the vehicle passes all of the diagnostic tests
associated with the displayed System Status prior to
returning the vehicle to the customer.

DTC(s) Used to Set

System Status

Catalyst

P0420, P0430

H02S

P0133, P0153, P1133,

P1134, P1153, and P1154

H02S Heater

P0135, P0141, P0155,

and P0161

EGR System

P0401

EVAP System

P0440, P0442, P0446,

P1441, or the Service
Bay Test

AIR System

P0410

Catalyst
Heated Oxygen Sensor (H02S)

6-1785

Scan Tool Tests

The scan tool for some systems depending upon the
vehicle make and model include the Service Bay
Tests. Use the Service Bay Tests in order to
test certain systems and reset the System Status to
Complete. The EVAP Service Bay Test is included for
this vehicle. Refer to the Service Bay Tests for
important preliminary instructions.

6-1786

Engine

Engine Controls - 5.7L

Repair Instructions
PCM Replacement/Programming
Service of the PCM should normally consist of either
replacement of the PCM or EEPROM programming.
If the diagnostic procedures call for the PCM to
be replaced, the PCM should be inspected first to see
if it is the correct part. If it is, remove the faulty
PCM and install the nf:lw service PCM.
THE SERVICE PCM EEPROM WILL NOT BE
PROGRAMMED. DTCs P0601 and P0602 indicate the
EEPROM is not programmed or has malfunctioned.
Important: The following must be perform anytime the
PCM is replaced:
1. Programming of the EEPROM
2. The Idle Learn Procedure
3. The CKP System Variation Learn Procedure
4. The Engine Oil Life Monitor Reset Procedure
5. The Functional Check

The following must be perform anytime the PCM is

disconnected or looses power:
1. The Idle Learn Procedure
2. The Functional Check
Notice: Turn the ignition OFF when installing or
removing the PCM connectors and disconnecting or
reconnecting the power to the PCM (battery cable,
PCM pigtail, PCM fuse, jumper cables, etc.) in order
to prevent internal PCM damage.
Important: Ensure that the hood is free of
contaminates (moisture) before servicing the PCM.
The moisture flows into the PCM connector body when
the PCM is disconnected and the hood is opened.

Removal Procedure
Important: Remove any debris from the PCM
connector surfaces before servicing the PCM. Inspect
the PCM module connector gaskets when
diagnosing/replacing the PCM. Ensure that the
gaskets are installed correctly. The gaskets prevent
contaminate intrusion into the PCM.
Notice: Do not touch the connector pins or soldered
components on the circuit board in order to prevent
possible electrostatic discharge (ESD) damage to
the PCM.
Notice: In order to prevent internal damage to the
PCM, the ignition must be OFF when disconnecting or
reconnecting the PCM connector.
1. Disconnect the PCM connectors.

187260

Engine

Engine Controls - 5.7L

6-1787

2. Remove the mounting fasteners from the PCM

bracket.

187250

3. Remove the PCM and mounting bracket assembly

from the engine compartment.
4. Remove the PCM from the mounting bracket.

218731

Installation Procedure
Notice: Do not touch the connector pins or soldered
components on the circuit board in order to prevent
possible electrostatic discharge (ESD) damage to
the PCM.

Notice: In order to prevent internal damage to the

PCM, the ignition must be OFF when disconnecting or
reconnecting the PCM connector.
1. Install the PCM to the mounting bracket.

218731

6-1788

Engine Controls - .5.7L

Engine
2. Install the PCM and mounting bracket assembly
into the vehicle.

187250

3. Reconnect the PCM connectors.

Tighten
Tighten the PCM connector end fasteners to
8 N-m (70 lb in).
4. If a new PCM is being installed, program the
EE PROM.

187260

Engine
PCM Programming

1. Setup - Ensure that the following conditions have

been met:
The battery is fully charged.
The ignition is ON.
The cable connection at the Data Link
Connector (DLC) is secure.
2. Program the PCM using the latest software
matching the vehicle. Refer to Techline
terminal/equipment users instructions.
2.1. If the PCM fails to program, proceed as
follows:
Ensure that all PCM connections
a.re OK.
Inspect the Techline terminal/equipment
for the latest software version.
Attempt to program the PCM. If the PCM
still cannot be programmed properly,
replace the PCM. The replacement PCM
must be programmed.
2.2. Program the replacement PCM.
3. Perform the CKP System Variation Learn
Procedure if a new PCM is installed. Refer to CKP
System Variation Learn Procedure.
4. Perform the Idle Learn Procedure. Refer to PCM
Idle Learn Procedure.
5. Perform the Engine Oil Life Monitor Reset
procedure if a new PCM is installed. Refer
to Engine Oil Life Monitor Reset Procedure.
Functional Check
1. Clear the Diagnostic Trouble Codes (DTCs).
2. Perform the On-Board Diagnostic System Check.
3. Start the engine and idle for one minute.
4. Scan for DTCs using the scan tool.

PCM Idle Learn Procedure

Idle Learn Procedure
Anytime the PCM or the battery is disconnected, the
PCM looses power, or the PCM is reprogrammed,
the PCM's learned idle position is lost. The engine idle
is unstable when the learned idle position is lost.
Perform the following procedure in order to return the
learned idle to the correct position:
Automatic Transmission
1. Turn OFF the ignition.
2. Restore the PCM battery feed.
3. Turn OFF the A/C controls.
4. Set the parking brake and block the drive wheels.
5. Start the engine.
6. Allow the engine coolant temperature to reach
80C (176F)

Engine Controls - 5.7L

7.
8.
9.
10.
11.
12.
13.
14.
15.

6-1789

Shift the transmission selector into the drive range.

Allow the engine to idle for 5 minutes.
Turn ON the A/C controls.
Allow the engine to idle for 5 minutes.
Shift the transmission selector into the park range.
Allow the engine to idle for 5 minutes.
Turn OFF the A/C controls.
Allow the engine to idle for 5 minutes.
Turn OFF the engine for 30 seconds.

Manual Transmission
1. Turn OFF the ignition.
2. Restore the PCM battery feed.
3. Turn OFF the A/C controls.
4. Set the parking brake and block the drive wheels.
5. Transmission in neutral.
6. Start the engine.
7. Allow the engine coolant temperature to reach
80C (176F)
8. Turn ON the A/C controls.
9. Allow the engine to idle for 5 minutes.
10. Turn OFF the A/C controls.
11. Allow the engine to idle for 5 minutes.
12. Turn OFF the engine for 30 seconds.

CKP System Variation Learn Procedure

Important: While the learn procedure is in progress,
release the throttle immediately when the engine
starts to decelerate. The engine control is returned to
the operator and the engine will respond to throttle
position after the learn procedure is complete.
1. Install the scan tool.
2. Apply the vehicle's parking brake.
3. Block the drive wheels.
4. Close the vehicle's hood.
5. Place the vehicle's transmission in Park (A/T) or
Neutral (MIT).
6. Idle the engine until the engine coolant
temperature reaches 65C (150F).
7. Turn OFF all the accessories.
8. Apply the brakes for the duration of the procedure.
Important: If the CKP System Variation Learn
Procedure cannot be completed successfully, refer to
OTC Pt 336 Crankshaft Position (CKP) System
Variation Not Learned for additional diagnostic
information.
9. Enable the Crankshaft Position System Variation
Learn Procedure with the scan tool.
10. Slowly raise the engine speed to 4000 RPM.
11. Immediately release the throttle when the engine
speed decreases.
12. Turn OFF the ignition for 15 seconds after the
learn procedure is completed successfully.

6-1790

Engine Controls - 5.7L

Engine
ECT Sensor Replacement
Removal Procedure
Caution: Refer to Battery Disconnect Caution in
Cautions and Notices.
1. Disconnect the negative battery cable.
2. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information ..
3. Drain the engine coolant. Refer to Draining and
Filling Cooling System (VB) in Engine Cooling.
4. Lower the vehicle.
5. Disconnect the electrical connector from the
ECT sensor.
6. Remove the #1 spark plug wire from the
spark plug.

50967

Notice: Use care when handling the coolant sensor.

Damage to the coolant sensor will affect the operation
of the fuel control system.

7. Remove the ECT sensor.

50974

Engine

Engine Controls - 5.7L

6-1791

Installation Procedure
Notice: Use care when handling the coolant sensor.
Damage to the coolant sensor will affect the operation
of the fuel control system.
1. Coat the Engine Coolant Temperature (ECT}
sensor threads with sealer P/N 12346004 or
the equivalent.
2. Install the ECT sensor.
Notice: Refer to Fastener Notice in Cautions and
Notices.

Tighten
Tighten the ECT sensor to 23 N-m (17 lb ft).
3. Install the #1 spark plug wire onto the spark plug.

50974

4. Connect the ECT sensor electrical connector.

5. Refill the engine coolant. Referto Draining .and
Filling Cooling System (VB) in Engine Cooling.
6. Start the engihe and inspect for leaks.
7. Inspect the engine coolant level. Refer to Draining
and Filling Cooling System (VB) in Engine
Cooling.

50967

MAF Sensor Replacement

Removal Procedure
Important: Take care when handling the MAF. Do not
dent, puncture, or otherwise damage the Honeycell
located at the air inlet end of the MAF. Do not
touch the sensing elements or allow anything including
cleaning solvents and lubricants to come in contact
with them. Use a small amount of a non-silicone based
lubricant on the air duct only, to aid in installation.
Do not drop or roughly handle the MAF.
1. Disconnect the MAF sensor electrical connector.
2. Remove the air intake duct clamps from the
MAF sensor.
3. Remove the air duct from the MAF sensor.
4. Remove the MAF sensor (1) from the air cleaner
assembly.
242662

6-1792

Engine Controls - 5.7L

Engine
Installation Procedure
Important: The embossed arrows on the MAF sensor
indicate the proper air flow direction. The arrows
must point toward the engine.
1. Install the MAF sensor (1) to the air cleaner
assembly.
2. Install the air duct to the MAF sensor.
3. Install the clamps.
4. Connect the electrical connector.

242662

MAP Sensor Replacement

Removal Procedure
Important: Access to the MAP sensor is limited, but
does not require, removal of the intake manifold.
1. Disconnect the MAP sensor electrical connector.

55819

2. Twist the MAP sensor forward ,in order to:,,release

the sensor from the retainer.
3. Pull the sensor upward.

58838

Engine

Engine Controls - 5.7L

6-1793

Installation Procedure

Important: Lightly coat the MAP sensor seal with

clean engine oil before installing the sensor.
1. Install the MAP sensor. Push the MAP sensor
down in order to engage the sensor into the
retainer.

58838

2. Connect the MAP sensor electrical connector.

55819

6-1794

Engine

Engine Controls - 5.7L

H02S Replacement - Bank ,1

Notice: The heated oxygen sensors each use a

permanently attached pigtaH and connector. Do not
remove the pigtail from the heated oxygen sensor.
Damage or removal of the pigtail or the connector
affects proper operation of the heated oxygen sensor.
Handle the oxygen sensor carefully. Do not drop
the oxygen sensor. Keep the in-line connector and the
louvered end free of grease, dirt, or other
contaminants. Do not use cleaning solvents of any
type. Do not repair the wiring, the connector, or
the terminals. Replace the oxygen sensor if the pigtail
wiring, the terminals, or the connector is damaged.
Proper oxygen sensor operation requires an external
air reference. This external air reference is obtained
by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, the connectors, or
the terminals results in the obstruction of the air
reference and degrades the oxygen sensor
performance. A dropped oxygen sensor is a bad
oxygen sensor.

Important: Take care when handling the heated

oxygen sensor. The in-line electrical connector and
louvered end must be kept free of grease, dirt or other
contaminants. Also, avoid using cleaning solvents of
any type. Do not drop or roughly handle the heated
oxygen sensor. A dropped sensor is a bad sensor.

Removal Procedure (Bank 1 Sensor 1)

The heated oxygen sensor may be difficult to remove
when the engine temperature is below 48C (120F}.
Excessive force may damage the threads in the
exhaust manifold or exhaust pipe. It may be necessary
to lower the exhaust system to gain sufficient access
to a H02S and/or it's connector. Refer to Catalytic
Converter Replacement in Engine Exhaust.
1. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
2. Disconnect the H02S electrical connector.
3. Carefully back out the heated oxygen sensor.

247432

Engine

Engine Controls - 5. 7L

6-1795

Installation Procedure (Bank 1 Sensor 1)

Important: A special anti-seize compound is used on

the heated oxygen sensor threads. The compound
consists of graphite suspended in fluid and glass
beads. The graphite will burn away, but the glass
beads will remain, making the sensor easier to
remove. New or service sensors will already have the
compound applied to the threads. If a sensor is
removed from an engine and if for any reason is to be
reinstalled, the threads must have anti-seize
compound applied before reinstallation.
1. Coat the threads of the heated oxygen sensor
with anti-seize compound P/N 5613695, or
equivalent if necessary.

Notice: Refer to Fastener Notice in Cautions and

Notices.
2. Install the heated oxygen sensor.
Tighten
Tighten the H02S to 41 Nm (30 lb ft).
3. Connect the H02S electrical connector.

247432

4. Lower the vehicle.

Removal Procedure (Bank 1 Sensor 2)

The heated oxygen sensor may be difficult to remove
when the engine temperature is below 48C (120F).
Excessive force may damage the threads in the
exhaust manifold or exhaust pipe. It may be necessary
to lower the exhaust system to gain sufficient access
to a H02S and/or it's connector. Refer to Catalytic
Converter Replacement in Engine Exhaust.
1. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
2. Disconnect the H02S electrical connector.

222951

6-1796

Engine Controls - 5.7L

Engine
3. Carefully back out the heated oxygen sensor .

222952

Installation Procedure (Bank 1 Sensor 2)

Important: A special anti-seize compound is used on
the heated oxygen sensor threads. The compound
consists of graphite suspended in fluid and glass
beads. The graphite will burn away, but the glass
beads will remain, making the sensor easier to
remove. New or service sensors will already have the
compound applied to the threads. If a sensor is
removed from an engine and if for any reason is to be
reinstalled, the threads must have anti-seize
compound applied before reinstallation.
1. Coat the threads of the heated oxygen sensor
with anti-seize compound P/N 5613695, or
equivalent if necessary.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the heated oxygen sensor.
Tighten
Tighten the H02S to 41 Nm (30 lb ft).

222952

3. Connect the H02S electrical connector.

4. Lower the vehicle.

222951

Engine

Engine Controls - 5.7L

6-1797

H02S Replacement - Bank 2

Notice: The heated oxygen sensors each use a

permanently attached pigtail and connector. Do not
remove the pigtail from the heated oxygen sensor.
Damage or removal of the pigtail or the connector
affects proper operation of the heated oxygen sensor.
Handle the oxygen sensor carefully. Do not drop
the oxygen sensor. Keep the in-line connector and the
louvered end free of grease, dirt, or other
contaminants. Do not use cleaning solvents of any
type. Do not repair the wiring, the connector, or
the terminals. Replace the oxygen sensor if the pigtail
wiring, the terminals, or the connector is damaged.
Proper oxygen sensor operation requires an external
air reference. This external air reference is obtained
by way of the oxygen sensor signal and heater wires.
Any attempt to repair the wires, the connectors, or
the terminals results in the obstruction of the air
reference and degrades the oxygen sensor
performance. A dropped oxygen sensor is a bad
oxygen sensor.

Removal Procedure (Bank 2 Sensor 1)

Important: Take care when handling the heated

oxygen sensor. The in-line electrical connector and
louvered end must be kept free of grease, dirt or other
contaminants. Also, avoid using cleaning solvents of
any type. Do not drop or roughly handle the heated
oxygen sensor. A dropped sensor is a bad sensor.
Important: The heated oxygen sensor may be difficult
to remove when the engine temperature is below
48C (120F). Excessive force may damage the
threads in the exhaust manifold or exhaust pipe. It
may be necessary to lower the exhaust system to gain
sufficient access to a H02S and/or it's connector.
Refer to Catalytic Converter Replacement in Engine
Exhaust.
1. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
2. Disconnect the H02S electrical connector.
222953

3. Carefully back out the heated oxygen sensor.

Engine

6...1798 Engine Controls - 5.7L

Installation Procedure (Bank 2 Sensor 1)

Important: A special anti-seize compound is used on
the heated oxygen sensor threads. The compound
consists of graphite suspended in fluid and glass
beads. The graphite will burn away, but the glass
beads will remain, making the sensor easier to
remove. New or service sensors will already have the
compound applied to the threads. If a sensor is
removed from an engine and if for any reason is to be
reinstalled, the threads must have anti-seize
compound applied before reinstallation.
1. Coat the threads of the heated oxygen sensor
with anti-seize compound P/N 12377953, or
equivalent if necessary.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the heated oxygen sensor.
Tighten
Tighten the H02S to 41 Nm (30 lb ft).
222954

3. Connect the H02S electrical connector.

4. Lower the vehicle.

222953

Removal Procef:ture (Bank 2 Sensor 2)

Important: The heated oxygen sensor may be difficult
to remove when the engine temperature is below
48C (120F). Excessive force may damage the
threads in the exhaust manifold or exhaust pipe. It
may be necessary to lower the exhaust system to gain
sufficient access to a H02S and/or it's connector.
Refer to Catalytic Converter Replacement in Engine
Exhaust.
1. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
2. Disconnect the H02S electrical connector.

222946

Engine

Engine Controls - 5.7L

6-1799

3. Carefully back out the heated oxygen sensor.

222948

Installation Procedure (Bank 2 .Sensor2)

Important: A special anti-seize compound is used on
the heated oxygen sensor threads. The compound
consists of graphite suspended in fluid and glass
beads. The graphite will burn away, but the glass
beads will remain, making the sensor easier to
remove. New or service sensors will already have the
compound applied to the threads. If a sensor is
removed from an engine and if for any reason is to be
reinstalled, the threads must have anti-seize
compound applied before reinstallation.
1. Coat the threads of the heated oxygen sensor
with anti-seize compound P/N 12377953, or
equivalent if necessary.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the heated oxygen sensor.

Tighten
Tighten the H02S to 41 N-m (30 lb ft).
222948

3. Connect the H02S electrical connector.

4. Lower the vehicle.

222946

6-1800

Engine Controls - 5.7L

Engine
TP Sensor Replacement
1

Removal Procedure
Notice: The TP sensor is an electrical component. Do
not soak the TP sensor in any liquid cleaner or
solvent as damage may result.
1. Disconnect the TP sensor electrical connector.
2. Remove the TP sensor attaching screws (5).
3. Remove the TP sensor (6).
4. Remove the TP sensor 0-ring seal (7).

3
216230

Installation Procedure
1. Install the TP sensor 0-ring seal (7) on the
TP sensor (6).
2. Install the TP sensor (6) on the throttle body (1)
with the throttle valve in the closed position.
Make sure the TP sensor lever lines up with the
TP sensor drive lever on the throttle shaft.

Notice: Refer to the Fastener Notice in Cautions and

Notices.
3. Install the TP sensor attaching screws (5).

Tighten
Tighten the TP sensor attaching screws to
2 N-m (18 lb in).
4. Connect the TP sensor electrical connector.
5. Perform the TP sensor learn procedure. Refer to
Anti-lock Brakes Scan Tool Diagnostics.

3
216230

IAT Sensor Replacement

Removal Procedure
1. Disconnect the IAT sensor (2) electrical connector.
2. Carefully back out the IAT sensor (2) from the
intake air duct.

242662

(
\

Engine

Engine Controls - 5.7L

6;.1801

Installation Procedure

1. Install the IAT sensor (2) into the intake air duct.
2. Connect the IAT sensor (2) electrical connector.,

242662

IAC Valve Replacement

Removal Procedure

1. Disconnect the IAC valve electrical connector.

2. Remove the IAC valve attaching screws (4).
3. Remove the IAC valve (3).
4. Remove the IAC valve 0-ring seal (2).
Notice:
Do Not push or pull on the IAC valve pintle on
IAC valves that have been in service. The
force required to move the pintle may damage the
threads on the worm drive.
Do Not soak the IAC valve in any liquid cleaner or
solvent, as damage may result.
5. Clean the IAC valve 0-ring sealing surface, the
pintle valve seat, and the air passage.
Clean the IAC valve using GM cleaner
1052626 or GM X-66A. Use a shop towel or
parts brush to remove heavy deposits.
If the air passage has heavy deposits, remove
the throttle body tor complete cleaning.
Shiny spots on the pintle or seat are normal,
and do not indicate misalignment or a bent
pintle shaft.
6. Inspect the IAC valve 0-ring tor cuts, cracks, or
distortion. Replace the 0-ring if it is damaged.

3
216230

6-1802

Engine

Engine Controls - 5.7L

Installation Procedure

Important: If installing a new IAC valve, be sure to

replace it with an identical part. The pintle shape of the
IAC valve and the diameter of the IAC valve are
designed for the specific application.
1 . Measure the distance between the tip of the IAC
valve pintle and the mounting surface. If the
distance is greater than 28 mm (1.1 in), use finger
pressure to slowly retract the pintle. The force
required to retract the pintle of a new valve will not
cause damage to the valve.

17065

2. Lubricate the IAC valve 0-ring (2) with clean

engine oil.
3. Install the IAC valve 0-ring (2) on the IAC
valve (3).
4. Install the IAC valve (3).
5. Apply Loctite 262 to the IAC valve attaching
screw threads if necessary.
Notice: Refer to the Fastener Notice in Cautions and
Notices.
6. Install the IAC valve attaching screws (4).
Tighten
Tighten the IAC valve attaching screws to
3 N-m (27 lb in).
7. Connect the IAC valve electrical connector.
8. Perform the Idle Learn Procedure. Refer to PCM
Idle Learn Procedure.
216230

Accelerator Controls Cable Replacement

Removal Procedure

----

1. Remove the left instrument panel insulator. Refer

to Insulator Replacement - IP (Left Side) in
Instrument Panel, Gauges and Console.
2. Disconnect the accelerator cable (3) from the
accelerator pedal lever (2).
3. Squeeze the accelerator cable cover tangs (1)
and push the cable through the dash panel.
4. Disconnect the accelerator cable from the intake
manifold bracket.

12613

Engine

Engine Controls - 5.7L 6-1803

5. Remove the accelerator cable from the slot in tne,.

accelerator cable bracket.
6. Disconnect the accelerator cable from the throttle
body lever.
7. Remove the accelerator cable.

173436

Installation Procedure
1. Install the accelerator cable (3) through the dash
panel. Snap the retainer (1) through the
dash panel.
2. Install the accelerator cable (3) through the slot
in the accelerator pedal lever (2). Seat the
retainer (4) in the accelerator pedal lever (2).

12613

3. Connect the accelerator cable to the throttle

4.

5.
6.

7.

body lever.
Slide the accelerator cable into the slot on the
accelerator cable bracket. Snap the locking tab
into position.
Connect the accelerator cable to the intake
manifold bracket.
Check for complete throttle opening and closing
positions by operating the accelerator pedal. Also
check for poor carpet fit under the accelerator
pedal. The throttle should operate freely without
bind between full closed throttle and wide
open throttle.
Install the left instrument panel insulator. Refer to
Insulator Replacement - IP {Left Side) in
Instrument Panel, Gauges and Console.

173436

6-1804

Engine

Engine Controls - 5.7L

Accelerator Controls Pedal Replacement

Removal Procedure
1. Remove the left instrument panel insulator. Refer
to Insulator Replacement - IP (Left Side) in
Instrument Panel, Gauges and Console.
2. Disconnect the accelerator cable from the
accelerator pedal lever.
3. Remove the retainer clip from the accelerator
pedal pivot pin.
4. Remove the accelerator pedal from the accelerator
pedal lever.

Installation Procedure
1. Install the accelerator pedal to the accelerator
pedal lever.

2. Install the retainer clip to the accelerator pedal

pivot pin.
3. Connect the accelerator cable to the accelerator
pedal lever.
4. Check for complete throttle opening and closing
positions by operating the accelerator pedal. Also
check for poor carpet fit under the accelerator
pedal. The throttle should operate freely without
bind between full closed throttle and wide
open throttle.
5. Install the left instrument panel insulator. Refer to
Insulator Replacement - IP (Left Side) in
Instrument Panel, Gauges and Console.

Throttle Body Assembly Replacement

Removal Procedure
Caution: Refer to 'the Battery Disconnect Caution
in Cautions and Notices.
1. Disconnect the negative battery cable.
2. Partially drain the cooling system in order to
remove the hoses at the throttle body. Refer
to Draining and Filling Cooling System (VB) in
Engine Cooling.
3. Disconnect the IAT sensor and the MAF sensor
electrical connectors.

208553

Engine Controls - 5.7L

Engine

6-1805

4. Remove the air intake duct.

208569

5. Disconnect the TP sensor (2) and IAC valve (1)

electrical connectors.
6. Disconnect the accelerator control cable and the
cruise control cable from the throttle body.
7. Disconnect the crankcase ventilation hose from
the throttle body.

243938

8. Disconnect the coolant hoses from the intake

manifold pipe and the radiator.
9. Remove the throttle body attaching bolts.
10. Remove the throttle body and the gasket. Discard
the gasket.
Notice: In order to prevent damage to the sealing
surfaces, carefully use sharp tools in cleaning the old
gasket from the aluminum surfaces.

222051

6,;,1806

Engine Controls - s~7L

Engine
Important:
Do Not soak the throttle body in cold immersion
type cleaner. The throttle valve has a factory
applied sealing compound (DAG material
is applied to the outside edge of the valve and the
throttle bore) to prevent air bypass at closed
throttle. Strong solvents or brushing will remove
the material. To clean the throttle body following
disassembly, use a spray type cleaner such
as GM X-66A or GM 1052626. Use a shop towel
to remove heavy deposits.
The TP sensor and the IAC valve are electrical
components and should NOT come in contact
with solvent or cleaner, as damage may result.
11. Clean the gasket sealing surfaces.

Installation Procedure
1. Install the throttle body with a new gasket.
Notice: Refer to the Fastener Notice in Cautions and
Notices.

2. Install .the throttle body attaching bolts.

Tighten
Tighten the throttle body attaching bolts to
12 N-m (106 lb in).
3. Connect the coolant hoses to the intake manifold
pipe and the radiator.

222051

4. Connect the crankcase ventilation hose to the

throttle body.
5. Connect the accelerator control cable and the
cruise control cable.
6. Connect the TP sensor (2) and the IAC valve (1)
electrical connectors.

243938

Engine

Engine Controls - 5. 7L

6-1807

7. Install the air intake duct.

208569

8. Connect the IAT sensor and the MAF sensor

electrical connectors.
9. Refill the cooling system. Refer to Draining and
Filling Cooling System (VB) in Engine Cooling.
10. Connect the negative battery cable.
11 . With the engine OFF, check to see that the
accelerator pedal is free. Depress the accelerator
pedal to the floor and release.
12. Perform the Idle Learn Procedure. Refer to PCM
Idle Learn Procedure.

208553

Fuel Pressure Relief Procedure

Caution: Relieve the fuel system pressure before
servicing fuel system components in order to
reduce the risk of fire and personal injury.
After relieving the system pressure, a small
amount of fuel may be released when servicing
the fuel lines or connections. In order to reduce the
chance of personal injury, cover the regulator
and the fuel line fittings with a shop towel before
disconnecting. This will catch any fuel that
may leak out. Place the towel in an approved
container when the disconnection is complete.
Tool Required
J 34730-tA Fuel Pressure Gauge
1 . Turn the ignition OFF.

180378

6-1808

Engine Controls - 5.7L

Engine
Caution: Refer to the Battery Disconnect Caution
in Cautions and Notices.
2. Disconnect the negative battery cable in order to
avoid possible fuel discharge if an accidental
attempt is made to start the engine.
3. Loosen the fuel filler cap in order to relieve the
fuel tank vapor pressure.
4. Connect the J 34730-tA fuel pressure gauge to
the fuel pressure valve. Wrap a shop towel
around the fitting while connecting the gauge in
order to avoid spillage.
5. Install the bleed hose of the gauge into an
approved container.
6. Open the valve on the gauge to bleed the system
pressure. Fuel connections are now safe for
servicing.
7. Drain any fuel remaining in the gauge into an
approved container.

Quick Connect Fitting(s} Service

(Metal Collar}
Removal Procedure
Tools Required
J 34730-tA Fuel Pressure Gauge
J 37088-A Tool Set, Fuel Line Quick-Connect
Separator
1. Relieve the fuel system pressure before servicing
any fuel system connection. Refer to the Fuel
Pressure Relief Procedure.
2. Slide the dust cover from the quick-connect fitting.

12773

Caution: Wear safety glasses when using

compressed air, as flying dirt particles may cause
eye injury.

3. Blow dirt out of the fitting using compressed air.

12776

\i

Engine

Engine Controls - 5.7L

6-1809

4. Choose the correct tool from J 37088-A Tool Set

for the size of the fitting. Insert the tool into the
female connector, then push inward to release the
locking tabs.

12780

5. Pull the connection apart.

Notice: If it is necessary to remove rust or burrs from

a fuel pipe, use emery cloth in a radial motion with
the fuel pipe end in order to prevent damage to
the 0-ring sealing surface.
6. Using a clean shop towel, wipe off the male
pipe end.
7. Inspect both ends of the fitting for dirt and burrs.
Clean or replace the components as required.

12782

Installation Procedure
Caution: In order to reduce the risk of fire and
personal injury, before connecting fuel pipe
fittings, always apply a few drops of clean engine
oil to the male pipe ends.
This will ensure proper reconnection and prevent
a possible fuel leak.
During normal operation, the 0-rings located in
the female connector will swell and may prevent
proper reconnection if not lubricated.
1. Apply a few drops of clean engine oil to the male
pipe end.

66

c=nID~
12784

6-1810

Engine

Engine Controls - 5.7L

2. Push both sides of the fitting together to cause

the retaining tabs to snap into place.

12786

3. Once installed, pull on both sides of the fitting to

make sure the connection is secure.

12787

4. Reposition the dust cover over the quick-connect

fitting.

c )].

12789

Engine

Engine Controls - 5.7L

6-1811

Quick Connect Fitting(s) Service

(Plastic Collar)
Removal Procedure
Tool Required
J 34730-tA Fuel Pressure Gauge
1. Relieve the fuel system pressure before servicing
any fuel system connection. Refer to the Fuel
Pressure Relief Procedure.
Caution: Wear safety glasses when using
compressed air in order to prevent eye injury.
2. Using compressed air, blow any dirt out of
the quick-connect fitting.

.. ..
...

~{:

~ ...

,
155410

Important: Plastic quick connect fittings can be

released either by squeezing the plastic retainer
release tabs (step 3) or by using the appropriate
J 37088-A Fuel Line Quick-Connect Separator Tool
(step 4).

3. Squeeze the plastic retainer release tabs.

12777

4. Choose the correct tool from J 37088-A Tool Set

for the size of the fitting. Insert the tool into the
female connector, then push inward to release the
locking tabs. The plastic retainer will remain on
the female connector.

12780

61812

Engine Controls 5.7L

Engine
5. Pull the connection apart.

12778

Installation Procedure
Caution: In order to reduce the risk of fire and
personal injury, before connecting fuel pipe
fittings, always apply a few drops of clean engine
oil to the male pipe ends.
This will ensure proper reconnection and prevent
a possible fuel leak.
During normal operation, the 0-rings located in
the female connector will swell and may prevent
proper reconnection if not lubricated.
1. Apply a few drops of clean engine oil to the male
fuel pipe end.

_J

155425

2. Push both sides of the quick-connect fitting

together in order to cause the retaining
tabs/fingers to snap into place.

\,

21855

Engine

Engine Controls - 5.7L

6-1813

3. Once installed, pull on both sides of the

quick-connect fitting in order to make sure the
connection is secure.

155399

In-Line Fuel Filter Replacement

Removal Procedure
Important:
There is no service interval tor fuel filter
replacement. Only replace a restricted fuel filter.
Inspect the fuel tank internally and clean the fuel
tank if you find a restricted fuel filter.
Caution: Refer to the Battery .Disconnect Caution
in Cautions and Notices.
.

1. Disconnect the negative battery cable.

2. Relieve the fuel system .pressure. Refer to the
Fuel Pressure Relief Procedure.
3. Raise the vehicle. Referto Lifting and Jacking the
Vehicle in General Information.
4. Clean all the fuel filter connections and the
surrounding areas before disconnecting the
fuel pipes in order to avoid possible contamination
of the fuel system.
5. Disconnect the quick-connect fitting at the fuel
filter inlet (3). Refer to Quick Connect Fitting(s)
Service (Plastic Collar).
6. Disconnect the threaded fitting ( 1) from the fuel
filter outlet.
7. Cap the fuel pipes in order to prevent possible
fuel system contamination.
8. Slide the fuel filter (2) from the bracket (4).
9. Inspect the fuel pipe 0-ring for cuts, nicks,
swelling, or distortion. Replace the 0-ring if
necessary.

12603

Engine

6~1814 Engine Controls - 5.7L

Installation Procedure

1. Slide the fuel 1ilter (2) into the bracket (4).

2. Remove the caps from the fuel pipes.
3. Connect the threaded fitting (1) to the fuel filter
outlet.

Notice: Refer to the Fastener Notice in Cautions and

Notices.

'

4.

5.
6.
7.
8.
12603

9.

Tighten
Tighten the fuel filter fitting to 30 N-m (22 lb ft).
Connect the quick-connect fitting to the fuel filter
inlet (3). Refer to Quick Connect Fitting(s) Service
(Plastic Collar).
Lower the vehicle.
Tighten the fuel filler cap.
Connect the negative battery cable.
Inspect for leaks.
8.1. Turn the ignition switch ON for 2 seconds.
8.2. Turn the ignition switch OFF for
10 seconds.
8.3. Turn the ignition switch ON.
8.4. Check for fuel leaks.
Perform the Idle Learn Procedure. Refer to PCM
Idle Learn Procedure.

Fuel Tank Draining Procedure

Caution:
Never drain or store fuel in an open container
due to the possibility of fire or explosion.
When draining the fuel tank, slowly insert the
hand operated pump device in the fuel tank.
Do Not force.thehand operated pump device in
the fuel tank. Forcing the pump device can
cause the fuel pump to dislocate from the fuel
sender assembly.
1. Remove the fuel fiUer cap.
2. Use a hand operated pump device to drain as
much fuel through the fuel filler pipe as possible.
3. Install the fuel filler cap.

Engine

EngimfControls ... 5.7l 61815

Fuel Tank Replacement

Removal Procedure

Caution: Refer to the Battery Disconnect Caution

in Cautions and Notices.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining
Procedure.
4. Remove the fuel tank filler pocket.
5. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
6. Remove the fuel filler pipe shield.
7. Remove the exhaust system from the catalytic
converter back. Refer to Muffler Replacement in
Engine Exhaust.
8. Remove the exhaust pipe heat shield and the
exhaust muffler heat shield.
9. Remove the rear axle assembly. Refer to Rear
Axle Replacement in Rear Drive Axle.
10. Clean all fuel pipe connections and surrounding
areas before disconnecting the fuel pipes in order
to avoid possible contamination of the fuel
system.
11 . Disconnect the EVAP pipes (1) at the canister (2).
12. Disconnect the fuel return pipe (4) at the rear
quick-connect fitting. Refer to Quick Connect
Fitting(s) Service (Plastic Collar).
13. Disconnect the EVAP purge pipe (3) at the rear
quick-connect fitting. Refer to Quick Connect
Fitting(s) Service (Plastic Collar).
14. Disconnect the fuel feed pipe at the fuel filter inlet.
Refer to Quick Connect Fitting(s) Service (Plastic
Collar).
15. Cap the fuel pipes in order to prevent possible
fuel system contamination.
16. Disconnect the fuel tank vent valve from the rear
brake hose bracket.

21288

183854

6-1816

Engine Controls - 5.7L

Engine
17. Remove the rear pipe clip.

175268

18. Disconnect the fuel sender and the EVAP canister

vent valve electrical connectors.

228629

19. With the aid of an assistant, support the fuel tank.

Notice: Do not bend the fuel tank straps. Bending the
fuel tank straps may damage the straps.
20. Remove the left fuel tank strap attaching bolt (3)
from the underbody bracket (1 ).
21. Lower the left fuel tank strap (2).
22. Remove the EVAP canister vent solenoid and
bracket (4).

173855

Engine

Engine Controls.- 5.7L

6-1817

23. Remove the right fuel tank strap attaching bolt.

24. Lower the right fuel tank strap.
25. Remove the fuel tank.

174089

26. Place the fuel tank in a suitable work area.

27. Remove the fuel tank insulators if necessary.

183852

28. Disconnect .the electrical harness clip (2) from the

fuel tank flange (1).

2
173809

6.;.1818

Engine Controls - 5.7L

Engine
29. Remove the fuel sender assembly (3) and the
rear fuel and EVAP pipes from the fuel tank.
Refer to Fuel Sender Assembly Replacement.

172721

Installation Procedure
1. Install the fuel senderassembly (3) and the rear
fuel and EVAP pipes to the fuel tank. Refer to
Fuel Sender Assembly Replacement.

172721

2. Connect the electrical harness clip (2) to the fuel

tank flange (1 ).

2
173809

Engine

Engine Controls - 5.7L 6-1819

3. Install the right fuel tank insulator.

183852

Important: The fuel sender pipes must route below

the left fuel tank insulator.

4. Align the insulator (2) on the top of the fuel tank

with 15-25 mm (0.6-1.0 in) of the insulator
extending beyond the edge of the fuel tank front
flange (3).
5. Fold the insulator down.
6. Secure the insulator to the flange (4). The
alignment notch on the insulator lines up with the
fuel tank flange edge (1 ).

183856

7. With the 1;1.id of an assistant, position and support

the fuel tank.
8. Position the right fuel tank strap up.
Notice: Refer to the Fastener Notice in Cautions and
Notices.
9. Install the front right fuel tank strap attaching bolt.

174089

6-1820

Engine Controls - 5.7L

Engine
10. Position the EVAP canister vent solenoid
bracket (4) between the left fuel tank strap (2) and
the underbody bracket (1 ).
11. Install the front left fuel tank strap attaching bolt.
Tighten
Tighten the front fuel tank strap attaching bolts to
33 N-m (24 lb ft).

173855

12. Connect the fuel tank vent valve to the rear brake
hose bracket.
13. Remove the caps from the fuel pipes.
14. Connect the fuel feed pipe at the fuel filter inlet.
Refer to Quick Connect Fitting(s) Service
(Plastic Collar).
15. Connect the EV AP purge pipe (3) at the rear
quick-connect fitting. Refer to Quick Connect
Fitting(s) Service (Plastic Collar).
16. Connect the fuel return pipe (4) atthe rear
quick-connect fitting. Refer to Quick Connect
Fitting(s) Service (Plastic Collar).
17. Connect the EVAP pipes (1) to the canister (2).

183854

18. Connect the fuel sender and the EVAP canister

vent valve electrical connectors.

228629

Engine

Engine Controls - 5.7L 6-1821

19. Install the fuel and EVAP pipes into the pipe clip.
20. Align the fuel and EVAP pipes into a flat position.
21. Install the pipe clip bolts.
Tighten
Tighten the pipe clip bolt to 5.5 N-m (49 lb in).
22. Install the rear axle assembly. Refer to Rear Axle
Replacement in Rear Drive Axle.
23. Install the exhaust system heat shields and
attaching screws.
24. Install the exhaust system. Refer to Muffler
Replacement in Engine Exhaust.

175268

25.
26.
27.
28.
29.
30.
31 .

Install the fuel filler pipe shield.

Lower the vehicle.
Install the fuel tank filler pocket.
Refill the fuel tank.
Install the fuel filler cap.
Connect the negative battery cable.
Inspect for leaks.
31.1. Turn the ignition switch ON for 2 seconds.
31.2. Turn the ignition switch OFF for
10 seconds.
31.3. Turn the ignition switch ON.
31.4. Check for fuel leaks.
32. Perform the Idle Learn Procedure. Refer to PCM
Idle Learn Procedure.

21288

Fuel Tank Vent Valve Replacement

Removal Procedure
Caution: Refer to the Battery Disconnect Caution
in Cautions and Notices.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining
Procedure.
4. Remove the fuel tank. Refer to Fuel Tank
Replacement.
5. Disconnect the fuel tank vent valve hose (1) from
the fuel sender pipe.
6. Remove the fuel tank vent valve (2) and hose (1 ).

12605

6-1822

Engine Controls - 5.7L

Engine
Installation Procedure
1. Connect the fuel tank vent valve hose (1J to the
fuel sender pipe.
2. Install the fuel tank. Refer to Fuel Tank
Replacement.
3. Install the fuel tank vent valve (2) to the rear
brake hose bracket (3).
4. Refill the fuel tank.
5. Install the fuel filler cap.
6. Connect the negative battery cable.
7. Inspect for leaks.
7 .1. Turn the ignition switch ON for 2 seconds.
7.2. Turn the ignition switch OFF for
10 seconds.
7.3. Turn the ignition switch ON.
7.4. Check for fuel leaks.
8. Perform the Idle Learn Procedure. Refer to PCM
Idle Learn Procedure.
12605

Fuel Tank Pressure Sensor Replacement

Removal Procedure
Caution: Refer to the Battery Disconnect Caution
in Cautions and Notices.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
3. Drain the.fuel tank. Refer to Fuel Tank Draining
Procedure.
4. Remove the fuel tank. Refer to Fuel Tank
Replacement.
5. Remove the fuel pressure sensor (1 ).

209113

Installation. Procedure
1. Install the fuel pressure sen~or (1 ).
2. Install the fuel tank. Refer to Fuel Tank
3.
4.
5.
6.

3
7.

209113

Replacement.
Refill the fuel tank.
Install the fuel filler cap.
Connect the negative battery cable.
Inspect for leaks.
6.1. Turn the ignition switch ON for 2 seconds.
6.2. Turn the ignition switch OFF for
10 seconds.
6.3. Turn the ignition switch ON.
6.4. Check for fuel leaks.
Perform the Idle Learn Procedure. Refer to PCM
Idle Learn Procedure.

Engine Controls - 5.7L 6-1823

Engine
Fuel Sender Assembly Replacement.
Removal
Procedure
,'

'

Caution: In order to reduce the risk of fire and

personal injury that may result from a fuel
leak, always replace the 'fuel sender gasket when
reinstalling the fuel sender assembly.
Notice: Do Not handle the fuel sender assembly by
the fuel pipes. The amount of leverage generated
by handling the 'fuel pipes could damage the joints.
Caution: Refer to the Battery Disconnect Caution in
Cautions and Notices.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
3. Drain the fuel tank; Refer to Fuel Tank Draining
Procedure.
4. Remove the fuel tank. Refer to Fuel Tank
Replacement.
5. Remove the fuel sender assembly retaining
nuts (1 ), the retaining ring (2), the fuel sender
assembly (3), and the seal (4). Discard the se~I.

172721

Caution: Drain the fuel from the fuel sender

assembly into an approved con.tfliner i1,1. order to.
reduce the risk of fire and personal injury.

Never store the fuel in an open container.

6. Cle.an the seal sealing s~rfaces.

Installation Procedure
1. Install the new seal on the fuel sender assembly.

Important: The fuel pump strainer must be in

horizontal position when the fuel sender ts instatled in
the tank. When installing .the fuel sender assembly,
assure that the fuel pump strainer does not block full

travel of the float arm.

2. Carefully fold the strainer over itself iri oroJr to'
allow the strainer to fit through the opening in .
the fuel tank. Make sure the strainer unfolds once
it is placed in the tank.

172942

6-1824

Engine Controls - 5.7L

Engine
3. Install the fuel sender assembly (3) into the
fuel tank.
Notice: Refer to the Fastener Notice in Cautions and
Notices.
4. Install the fuel sender as~embly retaining nuts (1 ).

5.
6.
7.
8.
9.

172721

10.

Tighten
Tighten the fuel sender assembly retaining nuts
alternately a~d evenly to 6.5 N-m (58 lb in).
Install the fuel tank. Refer to Fuel Tank
Replacement.
Refill the fuel tank.
Install the fuel filler cap.
Connect the negative battery cable.
Inspect for leaks.
9.1. Turn the ignition switch ON for 2 seconds.
9.2. Turn the ignition switch OFF for
10 seconds.
9.3. Turn the ignition switch ON.
9.4. Check for fuel leaks.
Perform the Idle Learn Procedure. Refer to PCM
Idle Learn Procedure.

Fuel Sender Assembly Service

Removal Procedure
Important: This procedure includes all of the following
components:
The fuel pressure sensor
The fuel strainer
The fuel pump
The fuel pressure regulator
The fuel level sensor

209113

Caution: Refer to the Battery Disconnect Caution

in Cautions and Notices.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining
Procedure.
4. Remove the fuel tank. Refer to Fuel Tank
Replacement.
5. Remove the fuel sender assembly. Refer to Fuel
Sender Assembly Replacement.
6. Note the position of the fuel strainer (4) on the
fuel pump and the fuel return flex pipe.
7. Support the fuel sender assembly with one hand
and grasp the strainer (4) with the other hand.
8. Pull the strainer off the pump and the fuel return
flex pipe. Discard the strainer after inspection.
9. Inspect the strainer. Replace a contaminated
strainer and clean the fuel tank.
10. Inspect the fuel pump inlet for dirt and debris.
Replace the fuel pump if you find dirt or debris
in the fuel pump inlet.
11. To replace the fuel pump, proceed to step 13.

Engine

Engine Controls - 5.7L 6-t825

12. To replace the fuel pressure regulator, proceed to

step 16.
13. Disconnect the fuel pump electrical connector.
14. Disconnect the fuel pump flex pipe quick connect
fitting.
15. Remove the fuel pump from the fuel sender
assembly.
16. Disconnect the fuel pressure regulator
quick-connect fitting.
17. Remove the fuel pressure regulator/fuel return flex
pipe assembly.
18. If the fuel sender assembly is being replaced,
proceed to step 19.
19. Remove the fuel level sensor retaining clip (2).
20. Remove the fuel level sensor (3).
21. Remove the fuel pressure sensor (1 ).

Installation Procedure
1.
2.
3.
4.
5.
6.
7.
8.

Install the fuel pressure sensor (1 ).

Install the fuel level sensor (3).
Install the fuel level sensor retaining clip (2).
Install the fuel pressure regulator/fuel return flex
pipe assembly.
Connect the fuel pressure regulator quick-connect
fitting.
Install the fuel pump to the fuel sender assembly.
Connect the fuel pump flex pipe quick connect
fitting.
Connect the fuel pump electrical connector.

Important: Always install a new pump strainer when

replacing the fuel pump.
9. Install a new fuel pump strainer (4) in the same
position as noted during disassembly. Push the
strainer on the bottom of the fuel pump and
the bottom of the fuel return pipe until the strainer
is fully seated.
10. Install the fuel sender assembly. Refer to Fuel
Sender Assembly Replacement.
11. Install the fuel tank. Refer to Fuel Tank
Replacement.
12. Refill the fuel tank.
13. Install the fuel filler cap.
14. Connect the negative battery cable.
15. Inspect for leaks.
15.1. Turn the ignition switch ON for 2 seconds.
15.2. Turn the ignition switch OFF for
10 seconds.
15.3'. Turn the ignition switch ON.
15.4. Check for fuel leaks.
16. Perform the Idle Learn Procedure. Refer to PCM
Idle Learn Procedure.

209113

Engine;

6.11826, Engine Controls - 5.7L

Fuel Pulse Dampener Replacement
Removal Procedure

'...,\
\,";;"-.

..

Caution: Refer to the Battery D.isconnect Caution

in Cautions and Notices.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel
Pressure Relief Procedure.
3. Clean any dirt from the fuel pulse dampener
retaining ring.
4. Remove the fuel pulse dampener retainingring.
5. Discard the fuel pulse dampener retaining ring.
6. Remove the fuel pulse dampener from the fuel rail.
7. Remove the fuel pulse dampener 0-ring.
8. Discard the fuel pulse dampener 0-ring.

217098

Installation Procedure

-e. .

'

1. Install the new 0-ring on the fuel pulse dampener.

2. Lubricate the fuel pulse' dampener 0-ring with
clean engine oil.
3. Push the fuel pulse dampener into the fuel rail.
4. Install the new fuel pulse dampener retaining ring.
5. tighten tne fuel filler cap.
.
6. Connect the' negative battery cable.
7. Inspect for. leaks.
7.1. Turn the ignition switch ON for 2seconds.
7.2. Turn the ignition' switch ()F~ for
10 seconds.
7.3. Turn the ignitjc;,n
~witch ON.
'
.
7.4. Check for fuel leaks.
8, Pe.rform the ldle Learn Procedure. Refer to PCM
Idle Learn Procedure.
\

217098

Fuel Hose/Pipes Replacement (Chassis)

Removal Procedure
Tools Required
J 37088-A, Tool Set, Fuel Line Quick-Connect
Separator

Caution: Refer to tile Battery Disconnect Caution

in Cautions and. Notices.
1. Disconnect the negative battei;y cable.
2. Relieve the fuel system pressure. Refer t.o the
Fuel Pressure Relief Procedure.

3. Qrain the fuel tank. Refer to Fu~/ ank Draining

Procedure.

4. Clean all the fuel and EV AP pipe connections and

the surrounding areas before disconnecting the
pipes in order to avoid possible contamination of
the fuel system.
172963

Engine

Engine Controls .. 5~7L 6~1827

5. Disconnect the engine compartment fuel feed

pipe (2) from the chassis fuel .feed pipe (3) ..
Refer to Quick Connect Fitting(s) Service (Metal
Collar).
6. Disconnect the engine compartment EVAP
pipe (5) from the chassis EVAP pipe (4). Refer to
Quick Connect Fitting(s) Service (Plastic
Collar).
7. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
8. Remove the rear fuel pipe shield attaching
nuts (3) and bolt (6).
9. Remove the rear fuel pipe shield (4).
10. Remove the front fuel pipe shield attaching
nuts (1 ).
11. Remove the front fuel pipe shield (2).

7~

173551

12. Disconnect the fuel feed pipe (1) from the outlet
side of the fuel filter (2). Discard the 0-ring.

'

12603

6-1828

Engine

Engine Controls - 5.7L

13. Disconnect the EVAP purge pipe (3) at the rear

quick connect fitting. Refer to Quick Connect
Fitting(s) SeNice (Plastic Collar).
14. Disconnect the fuel return pipe (4) at the rear
quick connect fitting. Refer to Quick Connect
Fitting(s) SeNice (Plastic Collar).
15. Remove the fuel pipe attaching hardware and the
fuel pipes. Note the position of the fuel pipes for
installation.
16. Inspect the pipes for bends, kinks, and cracks.
Repair or replace the pipes as required.

183854

Repair Procedure
When repairing the fuel or EVAP pipes with hoses,
always replace them with original equipment or parts
meeting GM specifications. Use only reinforced
fuel resistant hose which is identified with the word
Fluoroelastomer or GM 6163-M on the hose.
The inside hose diameter must match the outside pipe
diameter.
Do Not use rubber hose within 100 mm (4 in) of any
part of the exhaust system or within 254 mm (10 in) of
the catalytic converter.
A minimum of 13 mm (112 in) clearance must be
maintained around sharp edges such as flanges, pinch
welds, etc., in order to prevent contact and chafing.
A minimum of 19 mm (% in) clearance must be
maintained around all moving parts.
Cut the ends of the pipe remaining on the car square
with a tube cutter. Using the first step of a double
flaring tool, form a bead on the end of both pipe
sections. If the pipe is too corroded to withstand the
beading operation without damage, the pipe should be
replaced. If a new section of pipe is used, form a
bead on both ends of the pipe also.
Use screw type hose clamps. Slide the clamps onto
the pipe and push the hose 51 mm (2 in) onto
each portion of the fuel pipe.
If more than a 6 in length of pipe is removed, use a
combination of steel pipe and hose so that the
total hose lengths, including the 100 mm (4 in)
additional length will not be more than 254 mm (1 O in)
long. Follow the same routing as the original pipe.

Engine

Engine Controls - 5.7L

6-1829

Installation Procedure

Important:
When replacing the fuel or EVAP pipes, always
replace them with original equipment or parts
that meet the GM specifications for those parts.
The replacement pipes must have the same
type of fittings as the original pipes in order to
ensure the integrity of the connection.
Do Not use copper or aluminum tubing to replace
steel tubing. Only tubing meeting the 124-M
specification or its equivalent is capable of meeting
all pressure, corrosion and vibration characteristics
necessary to ensure the durability standard
required.
1. Position the fuel and EV AP pipes to the frame rail.
Notice: Refer to the Fastener Notice in Cautions
and Notices.
2. Loosely install the number 1 position pipe
clip stud.
3. Loosely install the number 2 position pipe
clip stud.

173403

173409

4. Loosely install the number 3 position pipe

clip stud.
Tighten
Tighten the 3 studs to 5 N,m (44 lb in).

(
173412

6-1830

Engine Controls - 5.7L

Engine
5. Align the fuel and EVAP pipes to the
number 5 and number 6 position.
6. Install the front pipe clip bolts.
Tighten
Tighten the front pipe clip bolts to
4.5 Nm (40 lb in).

173417

7. Align the fuel and EVAP pipes to the number 4

position clamp.
8. Install the pipe clamp stud.
Tighten
Tighten the pipe clamp stud to 5 N-m (44 lb in).

173416

9. Connect the fuel return pipe (4) at the rear quick

connect fitting. Refer to Quick Connect Fitting(s)
Service (Plastic Collar).
10. Connect the EVAP purge pipe (3) at the rear
quick connect fitting. Refer to Quick Connect
Fitting(s) Service (Plastic Collar).

183854

Engine

Engine Controls - 5.7L

64831

11. Connect the fuel feed pipe (1) to the fuel filter (2).

Tighten
Tighten the fuel feed pipe fitting to
30 N-m (22 lb ft).

12603

12. Install the fuel and EVAP pipes into the rear
pipe clip.
13. Align the fuel and EVAP pipes in a flat position.
14. Install the rear pipe clip bolt.

Tighten
Tighten the rear pipe clip bolt to 5.5 Nm (49 lb in).

175268

15. Position the front fuel pipe shield (2) to the 3 fuel
pipe clip studs and the brake pipe clip stud (7).
16. Install the pipe shield nuts (1).
Tighten
Tighten the pipe shield nuts to 5 N-m {44 lb in).
17. Position the rear fuel pipe shield (4) to the fuel
pipe stud and the fuel pipe clip stud (5).
18. Loosely install the pipe shield nuts (3).
19. Install the pipe shield bolt (6).
Tighten
19.1. Tighten the pipe shield bolt to
5 N-m (44 lb in).
19.2. Tighten the pipe shield nuts to
5 Nm (44 lb in).
20. Lower the vehicle.

7t:J
173551

6-1832

Engine Controls - 5.7L

Engine
21 . Connect the engine compartment EVAP pipe (5)
to the chassis EVAP pipe (4). Refer to Quick
Connect Fitting(s) Service (Plastic Collar).
22. Connect the engine compartment fuel feed
pipe (2) to the chassis fuel feed pipe (3). Refer to
Quick Connect Fitting(s) Service (Metal Collar).
23. Refill the fuel tank.
24. Tighten the fuel filler cap.
25. Connect the negative battery cable.
26. Inspect for leaks.
26.1. Turn the ignition switch ON for 2 seconds.
26.2. Turn the ignition switch OFF for
10 seconds.
26.3. Turn the ignition switch ON.
26.4. Inspect for fuel leaks.
27. Perform the Idle Learn Procedure. Refer to PCM
Idle Learn Procedure.

172963

Fuel Hose/Pipes Replacement

(Engine Compartment)
Removal Procedure
Tools Required
J 37088-A Tool Set, Fuel Line Quick-Connect
Separator

172963

Caution: Refer to the Battery Disconnect Caution

in Cautions and Notices.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
3. Clean all the engine compartment connecting fuel
pipe connections and the surrounding areas
before disconnecting in order to avoid possible
contamination of the fuel system.
4. Disconnect the engine compartment fuel feed
pipe (2) at the fuel rail (1 ). Refer to Quick
Connect Fitting(s) Service (Metal Collar).
5. Disconnect the engine compartment EVAP
pipe (5) at the EV AP canister purge
valve (6). Refer to Quick Connect Fitting(s)
Service (Plastic Collar).
6. Disconnect the engine compartment fuel feed
pipe (2) at the chassis fuel feed pipe (4). Refer
to Quick Connect Fitting(s) Service (Metal Collar).
7. Disconnect the engine compartment EVAP
pipe (5) at the chassis EVAP pipe (3). Refer
to Quick Connect Fitting(s) Service
(Plastic Collar).
8. Cap the fuel pipes in order to prevent possible
fuel system contamination.

Engine

Engine Controls -

s. 7L

6-1833

Installation Procedure

1 . Remove the caps from the fuel pipes.

2. Connect the engine compartment fuel feed
pipe (2) to the chassis fuel feed pipe (3). Refer to
Quick Connect Fitting(s) Service (Metal Collar).
3. Connect the engine compartment EVAP pipe (5)
to the chassis EVAP pipe (4). Refer to Quick
Connect Fitting(s) Service (Plastic Collar).
4. Connect the engine compartment fuel feed
pipe (2) to the fuel rail (1 ). Refer to Quick Connect
Fitting(s) Service (Metal Collar).
5. Connect the engine compartment EVAP pipe (5)
to the EVAP canister purge valve (6). Refer to
Quick Connect Fitting(s) Service (Plastic Collar).
6. Tighten the fuel filler cap.
7. Connect the negative battery cable.
8. Inspect for leaks.

8.1 . Turn the ignition switch ON for 2 seconds.

8.2. Turn the ignition switch OFF for
10 seconds.
8.3. Turn the ignition switch ON.
8.4. Inspect for fuel leaks.
9. Perform the Idle Learn Procedurt3. R'efer to PCM
Idle Learn Procedure.

172963

Fuel Hose/Pipes Assembly Replacement

(Rear Pipes)
Removal Procedure
Caution: Refer to the Battery Disconnect Caution
in Cautions and Notices.
1 . Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining
Procedure.
4. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
5. Clean all fuel and EVAP pipe and hose
connections and the surrounding areas before
disconnecting in order to avoid possible
contamination of the fuel system.
6. Remove the fuel tank. Refer to Fuel Tank
Replacement.
7. Fold back the left fuel tank insulator.
8. Remove the rear fuel feed pipe (3), the rear return
pipe (2), the EVAP pipe (1 ), and the fuel tank vent
valve hose (4) from the fuel sender pipes. Refer
to Quick Connect Fitting(s) Service
(Plastic Collar).

----

173576

6..1834 Engine Controls 5.7L

Engine
9. Disconnect the EVAP hose (5) from the EVAP
canister vent solenoid.
10. Remove the rear fuel and EVAP pipes.
11. Cap .the fuel pipes in order to prevent possible
fuel system contamination.

183854

Installation Procedure
1. Remove the caps'from the fuel pipes.
2. Connect the rear fuel feed pipe (3), the rear return
pipe (2), the EVAP pipe (1 ), and the fuel tank vent
valve hose (4) to the fuel sender pipes. Refer.to
Quick Connect Fitting(s) Service (Plastic Collar).

173576

3. Connect the EVAP hose (5) to the EVAP canister

vent solenoid.
4. Install the fuel tank. Refer to Fuel Tank
Replacement.
5. Lower the vehicle.
6. Refill the fuel tank.
7. Connect the negative battery cable.
8. tighten the fuel filler cap.
9. Inspect for leaks.
9.1. Turn the ignition switch ON for 2 seconds.
9.2. Turn the ignition switch OFF for
10 seconds.
9.3. Turn the ignition switch ON.
9.4. Inspect for fuel leaks.
10. Perform the Idle Learn Procedure. Refer to PCM
Idle Learn Procedure.
183854

Engine
Fuel System Cleaning
Fuel Tank Cleaning

Important:
Only use oil free compressed air to blow out the
fuel pipes.
Inspect the fuel tank internally and clean the fuel
tank if you find a plugged fuel filter.

Caution: Refer to the Battery Disconnect Caution

in Cautions and Notices.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining
Procedure.
4. Remove the fuel tank. Refer to Fuel Tank
Replacement.
5. Remove the fuel sender assembly. Refer to Fuel
Sender Assembly Replacement.
6. Inspect the fuel pump strainer. Replace a
contaminated strainer and inspect the fuel pump.
7. Inspect the fuel pump inlet for dirt and debris.
Replace the fuel pump if you find dirt or debris
in the fuel pump inlet.

Engine Controls -5.7L

6-1835

Important: When flushing the fuel tank, handle the

fuel and water mixture as a hazardous material.
Handle the fuel and water mixture in accordance with
all applicable local, state, and federal laws and
regulations.
8. Flush the fuel tank with hot water.
9. Pour the water out of the fuel sender assembly
opening. Rock the tank to be sure that removal
of the water from the tank is complete.
10. Install the fuel sender assembly. Refer fo Fuel
Sender Assembly Replacement.
11. Install the fuel tank. Refer to Fuel Tank
Replacement.
12. Refill the fuel tank.
13. Install the fuel filler cap.
14. Connect the negative battery cable.
15. Inspect for leaks.
15.1. Turn the ignition switch ON for 2 seconds.
15.2. Turn the ignition switch OFF for
10 seconds.
15.3. Turn the ignition switch ON.
15.4. Check for fuel leaks.
16. Perform the Idle Learn Procedure. Refer to PCM
Idle Learn Procedure.

6-1836

Engine Controls - 5.7L

Engine
Fuel Pressure Connection Valve
Replacement
Removal Procedure
1. Clean the area around the fuel pressure
connection with GM X-30A or equivalent.
Caution: Refer to the Battery Disconnect Caution
in Cautions and Notices.
2. Disconnect the negative battery cable.
3. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
4. Remove the fuel pressure connection valve using
a standard valve core removal and installation tool.

217118

Installation Procedure
1. Install the fuel pressure connection valve
assembly using a standard valve core removal and
installation tool.
2. Install the fuel pressure connection valve cap.
3. Tighten the fuel filler cap.
4. Connect the negative battery cable.
5. Inspect for leaks.
5.1. Turn the ignition switch ON for 2 seconds.
5.2. Turn the ignition switch OFF for
10 seconds.
5.3. Turn the ignition switch ON.
5.4. Check for fuel leaks.
6. Perform the Idle Learn Procedure. Refer to PCM
Idle Learn Procedure.

217118

Fuel Rail Assembly Replacement

Removal Procedure
Tools Required
J 37088-A, Tool Set, Fuel Line Quick-Connect
Separator
An eight digit identification number is located on the
fuel rail assembly. Refer to this model identification
number if servicing or part replacement is required.

217103

Engine Controls - 5.7L 6-1837

Engine
Caution: Refer to the Battery Disconnect Caution
in Cautions and Notices.

1. Disconnect the negative battery cable.

2. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
3. Before removal, clean the fuel rail assembly with
a spray type engine cleaner, GM X-30A or
equivalent, if necessary. Follow the package
instructions. Do not soak fuel rails in liquid
cleaning solvent.
Notice:
Remove the fuel rail assembly carefully in order to
prevent damage to the injector electrical connector
terminals and the injector spray tips. Support
the fuel rail after the fuel rail is removed in order
to avoid damaging the fuel rail components.
Cap the fittings and plug the holes when servicing
the fuel system in order to prevent dirt and other
contaminants from entering open pipes and
passages.
4. Disconnect the fuel feed hose (2) from the fuel
rail (1 ). Refer to Quick Connect Fitting(s) Service
(Metal Collar).
5. Disconnect the accelerator cable from the throttle
body and the accelerator cable bracket (without
traction control).
6. Move the accelerator cable aside.

172963

173436

6-1838

Engine Controls - 5.7L

Engine
7. Disconnect the electrical connectors from the fuel
injectors. Identify the connectors to their
corresponding injectors to ensure correct
sequential injector tiring order after reassembly.
8. Disconnect the electrical harness from the fuel rail
brackets.
9. Remove the fuel rail attaching bolts.
10. Remove the fuel rail assembly.
11. Remove the injector lower 0-ring seal from the
spray tip end of each injector.
12. Discard the 0-ring seals.

222050

Installation Procedure
1. Lubricate the new lower injector 0-ring seals with
clean engine oil.
2. Install the new 0-ring seals on the spray tip end
of each injector.
3. Install the fuel rail assembly to the intake manifold.
4. Apply a 5 mm (0.020 in) band of GM
P/N 12345382 threadlock or equivalent to the
threads of the fuel rail bolts.
Notice: Refer to the Fastener Notice in Cautions and
Notices.
5. Install the fuel rail attaching bolts.

222050

Tighten
Tighten the fuel rail attaching bolts to
1O Nm (89 lb in).
6. Connect the injector electrical connectors.
Install each connector on the proper injector in
order to ensure correct sequential injector
firing order.
Rotate the injectors as required in order to
avoid stretching the wire harness.
7. Connect the electrical harness to the fuel rail
brackets.

Engine

Engine Contrbls - 5.7L

6-1839

8. Connect the accelerator cableto the throttle body

and the accelerator cable bracket (without traction
control).

173436

9. Connect the fuel feed hose (2) to the fuel rail fuel
pipe (1 ). Refer to Quick Connect Fitting(s) Service
(Metal Collar).
10. Tighten the fuel filler cap.
11 . Connect the negative battery cable.
12. Inspect for leaks.
12.1. Turn the ignition switch ON for 2 seconds.
12.2. Turn the ignition switch OFF for
1O secon.ds.
12.3. Turn the ignition switch ON,
12.4. Check for fuel leaks.
13. Perform the Idle Learn Procedure. Refer to PCM
Idle Learn Procedure.

172963

Fuel Injector Replacement

Removal Procedure
Important:
Use care in removing the fuel injectors to prevent
damage to the electrical connector pins on the
injector and to prevent damage to the nozzle.
Service the fuel injector as a complete assembly
only. The fuel injector is an electrical component.
Do Not immerse the fuel injector in any type of
cleaner.
The engine oil may be contaminated with fuel if the
fuel injectors are leaking.

(
222050

6-1840

Engine

Engine Controls - 5.7L

Caution: Refer to the Battery Disconnect Caution in

Cautions and Notices.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to the
Fuel Pressure Relief Procedure.
3. Remove the fuel rail assembly. Refer to Fuel Rail
Assembly Replacement.
4. Spread the injector retainer clip to release the
injector from the fuel rail.
5. Remove the fuel injector.
6. Discard the injector retainer clip.
7. Remove the injector 0-ring seals from both ends
of the injector. Discard the 0-ring seals.

217114

Installation Procedure
Important: When ordering new fuel injectors, be sure
to order the correct injector for the application being
serviced.
The fuel irJjector assembly is stamped with a part
number identification (2), a manufacturing date (3), a
week code (1), and a production plant number (4).

69058

',

Engine

Engine Controls - 5.7L

6-1841

1. Lubricate the new injector 0-ring seals with clean

engine oil.
2. Install the new injector 0-ring seals on the
injector.
3. Install a new retainer clip on the injector.
4. Push the fuel injector into the fuel rail injector
socket with the electrical connector facing
outward. The retainer clip locks on to a flange on
the fuel rail injector socket.

217114

5. Install the fuel rail assembly. Refer to Fuel Rail

Assembly Replacement.
6. Tighten the fuel filler cap.
7. Connect the negative battery cable.
8. Inspect for leaks.
8.1. Turn the ignition switch ON for 2 seconds.
8.2. Turn the ignition switch OFF for
10 seconds.
8.3. Turn the ignition switch ON.
8.4. Check for fuel leaks.
9. Perform the Idle Learn Procedure. Refer to PCM
Idle Learn Procedure.

222050

Fuel Pump Relay Replacement

Removal Procedure
1. Turn OFF the ignition.
2. Remove the cover from the underhood electrical
center number 2 (2).
3. Remove the fuel pump relay by pulling upward.

255043

6-1842

Engine Controls - 5.7L

Engine
Installation Procedure
1. Turn OFF the ignition.
2. Push the relay into the relay center socket.
3. Install the cover Ofl the underhood electrical center
number 2 (2).

255043

EVAP Canister Purge Solenoid Valve

Replacement
Removal Procedure
1. Disconnect the EVAP Purge Solenoid electrical
connector.
2. Disconnect the hoses from the solenoid valve.
3. Remove the EVAP purge solenoid from the
bracket.

218763

Installation Procedure
1. Install the EV AP purge solenoid valve to the
bracket.
2. Connect the hoses to the solenoid valve.
3. Connect the electrical connector to the EVAP
purge solenoid valve.

218763

Engine

Engine Controls - 5.7L 6-1843

EVAP Vent Valve Replacement

Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the

Vehicle in General Information.
2. Detach the EVAP canister vent valve (2) from the
EVAP canister vent valve bracket (1 ).

465810

3. Disconnect the EVAP canister vent valve electrical

connector.
4. Loosen the vent hose clamp and remove the vent
hose from the EVAP vent valve.
5. Remove the EVAP canister vent valve from the
vehicle.

228629

Installation Procedure
1. Connect the vent hose to the EV AP canister vent
valve and tighten the hose clamp.
2. Connect the EVAP canister vent valve electrical
connector.

228629

6-1844

Engine Controls - 5.7L

Engine
3. Install the EVAP canister vent valve (2) to the
EVAP canister vent valve bracket (1 ).
4. Lower the vehicle.

465810

EVAP Canister Replacement

Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
2. Remove the left rear tire.
3. Remove the left rear inner wheel well shield.

229123

4. Disconnect the hoses from the canister.

5. Remove the canister and mounting bracket from
the canister body bracket.
6. Release the canister from the mounting bracket.

187227

Engine

Engine Controls - 5.7L

6-1845

Installation Procedure

1. Install the new canister to the canister bracket.

2. Install the new canister to the canister body
bracket.
3. Connect the hoses to the cani~ter.
4. Install inner wheel well shield.
5. Install wheel and tire assembly.
6. Lower the vehicle.

187227

EVAP System Cleaning

1. Turn OFF the ignition,

2. Remove the purge solenoid vacuum line from the
solenoid.

3. Remove the EVAP purge solenoid from the

engine.
4. Lightly tap the purge solenoid on a clean work
area looking for carbon particles or carbon dust
exiting either of the vacuum ports.
5. Reinstall the components and continue with the
published service manual DTC procedures if no
carbon release is evident.
6. Continue with this service procedure if carbon is
being released from the component.

218763

7. Remove the charcoal canister from the vehicle.

Refer to EVAP Canister Replacement.
8. Ensure the main cylinder valve is turned off on the
EVAP purge/pressure diagnostic station J 41413.
9. Disconnect the black hose that connects
the nitrogen cylinder to the cart J 41413 at
the pressure regulator by unscrewing the knurled
nut on the regulator.
10. Connect one end over the open fitting of the
J 41413 pressure regulator using a section of
vacuum line.
11. Connect the remaining end to the purge solenoid
end of the EVAP purge line at the vehicle.
12. Turn on the main nitrogen cylinder valve and
continue to blow any debris from the purge
line for 15 seconds.
13. Return the EVAP Pressure/Purge Diagnostic
Station J 41413 to its original condition by
re-installing the black hose disconnected in step 9.
229123

6-1846

Engine Controls - 5.7L

Engine
14. Idle the engine at the normal operating
temperature.
15. Open the throttle until .engine speed reaches
2000 RPM.
16. Connect the EVAP diagnostic cart J 41413 to the
vehicle EVAP service port and turn the 4 position
switch to Purge.
17. Idle the engine at the normal operating
temperature.
18. Open the throttle until engine speed reaches
2000 RPM.
19. Note the H20 vacuum gauge on the EVAP cart.
Vacuum should read greater than 15 in. H20.
20. Inspect the vacuum supply to the EVAP purge
valve if the vacuum is less than 15 in. H20.
21. Continue with the published service diagnostics if
the vacuum is greater than 15 in. H20.

Crankshaft Position Sensor Replacement

Removal Procedure
Important: The PCM Idle Learn Procedure must be
performed whenever the battery is disconnected. Refer
to PCM Idle Learn Procedure. Perform the CKP
System Variation Learn Procedure when the
Crankshaft Position sensor is removed or replaced.
1. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
2. Remove the starter. Refer to Starter Motor
Replacement (5. 7L VB) in Engine Electrical.

211621

3. Disconnect the Crankshaft Position (CKP) sensor

electrical connector.

56592

Engine

Engine Controls 5;7L 6-1847

4. Remove the CKP sensor retaining bolt.

5. Remove the CKP sensor.

55322

Installation Procedure
1. Install the CKP sensor.
2 .. Install the CKP sensor retainin~ bolt.
Notice: Refer to Fastener Notice in Cautions and.
Notices.
Tighten
Tighten the. CKP sensor to 25 Nm (18 lb ft).

55322

3. Connect the CKP sensor electrical connector.

56592

6-1848

Engine Controls - 5.7L

Engine
4. Install the starter. Refer to Starter Motor
Replacement (5. 7L VB) in Engine Electrical.
5. Lower the vehicle.
6. Connect the negative battery cable.
7. Perform the CKP System Variation Learn
Procedure. Refer to CKP System Variation Learn
Procedure.
8. Perform the Idle Learn Procedure. Refer to PCM
Idle Learn Procedure.

211621

Camshaft Position Sensor Replacement

Removal Procedure
Caution: Refer to Battery Disconnect Caution in
Cautions and Notices.
1. Disconnect the negative battery cable.
2. Remove the intake manifold. Refer to Intake
Manifold Replacement in Engine Mechanical 5.7L.
3. Remove the Camshaft Position (CMP) sensor
electrical connector.
Important: Clean the area around the CMP before
removal in order to avoid debris from entering
the engine.
4. Remove the CMP sensor retaining bolt.
5. Remove the CMP sensor.

55308

Installation Procedure
1. Install the CMP sensor.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the CMP sensor retaining bolt.

3.
4.
5.
6.

55308

Tighten
Tighten the CMP to 25 Nm (18 lb ft).
Connect the CMP sensor electrical connector.
Install the intake manifold. Refer to Intake Manifold
Replacement in Engine Mechanical 5.7L.
Connect the negative battery cable.
Perform the Idle Learn procedure. Refer to PCM
Idle Learn Procedure.

Engine

Engine Controls - 5.7L

6-1849

Knock Sensor Replacement

Removal Procedure

1. Remove the intake manifold. Refer to Intake

Manifold Replacement in Engine Mechanical 5.7L.
2. Remove the Knock Sensor wiring harness
assembly.

54608

3. Remove the Knock Sensor.

54612

Installation Procedure
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Install the Knock Sensor.

Tighten
Tighten the Knock Sensor to 15 Nm (11 lb ft).

54612

6-1850

Engine Controls - 5.7L

Engine
2. Install the Knock Sensor wiring harness assembly.
3. Install the intake manifold. Refer to Intake
Manifold Replacement in Engine Mechanical 5.7L.
4. Connect the negative battery cable.
5. Perform the idle learn procedure. Refer to PCM
Idle Learn Procedure.

54608

Secondary AIR Injection Pump

Replacement
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
2. Remove the left hand side lower close-out panel.
3. Remove the hoses from the AIR pump.

243928

4. Disconnect the electrical connector from the .

AIR pump.
5. Disconnect the electrical connector from the AIR
Bleed Valve Solenoid.

245568

Engine

Engine Controls - 5.7L

6-1851

6. Remove the AIR pump mounting bolts from the

bracket.
7. Remove the AIR pump.

256161

Installation Procedure
1. Install the AIR pump.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the mounting bolts.

Tighten
Tighten the. AIR pump bolts to 9.0 N-m (80 lb in).

256161

3. Connect the electric connectors to the AIR pump.

245568

6-1852

Engine Controls - 5.7L

Engine
4.
5.
6.
7.

Connect the hoses to the AIR pump.

Install the left hand side close-out panel.
Lower the vehicle.
Test the AIR system for proper operation.

243928

AIR Check Valve/Pipe

Replacement - Bank 2
Removal .Procedure

178464

Caution: Allow the engine to cop/ before servicing

the secondary air injection AIR system ih order
to reduce the chance of severe burns.
1. Remove the clamps and AIR hoses from the AIR
system right pipe.
2. Disconnect the AIR hose from the check valve.
3. Unscrew the check valve from the AIR pipe.
4. Remove the right AIR pipe from the manifold.
5. Before replacing a check valve, test the valve for
proper operation.
5.1. Install a vacuum pump to the nipple side of
the check valve, AIR pump side.
5.2. Pump the vacuum pump to 1O inches Hg.
and observe the gauge.
5.3. Replace the check valve if the vacuum
bleeds down to zero within 5 seconds.

Engine

Engine Controls - 5.7L

6-1853

Installation Procedure

Notice: Refer to Fastener Notice in Cautions and

Notices.
1. Screw the check valve onto the AIR pipe.
Tighten
Tighten the check valve to 23 Nm (17 lb ft).
2. Connect the right AIR pipe to the exhaust
manifold.
Tighten
Tighten the AIR pipe to the exhaust manifold to
20 N-m (15 lb ft).
3. Install the hose and the clamp to the check valve.
4. Test the AIR system for proper operation.

178464

AIR Check Valve/Pipe

Replacement - Bank 1
Removal Procedure
Caution: Allow the engine to cool before servicing
the secondary air injection AIR system in order
to reduce the chance of severe burns.
1. Remove the check valve clamp.
2. Disconnect the AIR hose from the check valve.
3. Unscrew the check valve from the AIR pipe.
4. Remove the left AIR pipe from the manifold.
5. Before replacing a check valve, test the valve for
proper operation.
5.1. Install a vacuum pump to the nipple side of
the check valve, AIR pump side.
5.2. Pump the vacuum pump to 1O inches Hg.
and observe the gauge.
5.3. Replace the check valve if the vacuum
bleeds down to zero within 5 seconds.
178463

Installation Procedure
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Screw the check valve onto the AIR pipe.
Tighten
Tighten the check valve to the AIR pipe to
23 Nm (17 lb ft).
2. Connect the AIR pipe to the exhaust manifold.
Tighten
Tighten the AIR pipe to the exhaust manifold to
20 Nm (15 lb ft).
3. Install the AIR hose to the check valve.
4. Install the check valve clamp.
5. Test the AIR system for proper operation.

178463

6-1854

Engine Controls - 5.7L

Engine
Secondary Air Injection Solenoid Relay
Replacement
Removal Procedure
1. Turn OFF the ignition.
2. Remove the cover from the underhood electrical
center #2 (2).
3. Remove the AIR solenoid relay.

255043

Installation Procedure
1. Turn OFF the ignition.
2. Install the AIR solenoid relay.
3. Install the cover to the underhood electrical
center #2 (2).
4. Test the AIR system for proper operation.

255043

Secondary Air Injection Pump Relay

Replacement
Removal Procedure
1. Turn OFF the ignition.
2. Remove the cover from the underhood electrical
center #2 (2).
3. Remove the AIR pump relay.

255043

Engine

Engine Controls - 5.7L

6-1855

Installation Procedure

1. Turn OFFthe ignition.

2. Install the AIR pump relay.
3. Install the cover to the underhood electrical
center #2 (2).
4. Test the AIR system for proper operation.

255043

Secondary Air lnj Bleed Valve Sol

Replacement
Removal Procedure
1. Raise the vehicle. Refer to Lifting and Jacking the
Vehicle in General Information.
2. Remove the left hand side lower close-out panel.

243928

3. Disconnect the electrical. connector .from the AIR

Bleed Valve Solenoid.
4. Remove the AIR hose from the AlFt Bleed Valve
Solenoid.
5. Remove the vacuum hose from the AIR Bleed
Yalve Solenoid.
6. Remove the AIR Bleed Valve Solenoid.

245568

6-1856

Engine Controls - 5.7L

Engine
Installation Procedure
1. Install the AIR Bleed Valve Solenoid.
2. Install the vacuum hose to the AIR Bleed Valve
Solenoid.
3. Install the AIR hose to the AIR Bleed Valve
Solenoid.
4. Connect the electrical connector from the AIR
Bleed Valve Solenoid.

245568

5. Install the left hand side close-out panel.

6. Lower the vehicle.
7. Test the AIR system for proper operation.

243928

EGR Valve Replacement

Removal Procedure
Important: Do not try to disassemble the EGR valve.
Service only as a complete assembly.
Important: Carefully note the position of the EGR
valve before removal. Do not rotate the EGR
valve 180 degrees.
1. Remove the electrical connector.
2. Remove the valve to flange attaching bolts.
Notice: The EGR valve is an electrical component.
Soaking the EGR valve in a liquid cleaner or a solvent
causes damage to the valve.
3. Remove the EGR valve.
4. Remove the flange gasket.
5. Clean the EGR valve gasket surface.
178487

Engine Controls - 5. 7L 6-1857

Engine
Installation Procedure

1. Install the.new flange gasket

2. Install the linear EGR valve.
Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Install the valve to flange bolts.
TigHten

3.1. Tighten the bolts the first time to

10 Nm (89 lb in) each.
3.2. Tighten the bolts a final time to
25 Nm (18 lb ft) each.
4. Install the electrical connector.

178487

EGA Pipe Replacement

Removal Procedure

Caution: A void breathing fumes and swallowing

EGR exhaust deposits when removing components
for cleaning as bodily injury may result.
1. Remove the EGR valve. Refer to EGR Valve
Replacement.
2. Remove the EGR pipe to intake manifold bolts.
3. Remove the EGR pipe to exhaust manifold bolts.
4. Remove the EGR pipe mounting bolts from
the right cylinder head.
5. Remove the EGA pipe.

178489

Installation Procedure
1.
2.
3.
4.

Install the EGR

Install the EGR
Install the EGR
Install the EGR
Replacement.

pipe.
pipe to exhaust manifold bolts.
pipe to intake manifold bolts.
valve. Refer to EGR Valve

(
178489

6-1858

Engine

En.gine Controls - .5.7L

EGR System Cleaning

178489

Caution: Avoid breathing fumes and swallowing

EGR exhaust deposits when removing components
for cleaning as bodily injury fT!ay result.
1. Remove the EGR valve.
2. Depress the pintle several times using a pencil
eraser or other suitable soft instrument. The
pintle should move in and out smoothly. Replace
the valve if it exhibits tendencies to stick. Refer
to EGR Valve Replacement.
3. Try to rotate the EGR valve connector housing.
Repeat for the coif housing. Replace the valve if
it exhibits any looseness. Refer to EGR
Valve Replacement.
4. Inspect the EGR valve pintle and seat for deposits.
Use a cloth or other suitable soft device to
remove the deposits. Remove all loose particles.
Replace the valve if the deposits are such
that the pintle/base interface can not be cleaned
adequately to allow the pintle to seal against
the seat. Damage to the powdered metal EGA
valve base occurs if cleaned with solvents, sharp
tools, wire brush/wheel or sand blasting.
Cleaning by tbese methods is n9t recqmmended.
5. Remove the EGR pipe.
6. Clean the passages with a wire brush; .Remove all
loose particles.
7. Install the EGR pipe.

Air Cleaner Element Replacement

Removal Procedure
1. Release the top cover latches (4).
2. Lift the top of the air cleaner housing (5) up.
3. Pull out the air filter element. Ensure the air filter
frame remains with the housing.
4. Inspect the air filter element for dust, dirt, or
water. Clean or replace the air filter element if
required.

243934

Engine

Engine Controls - 5.7L

61859

Installation Procedure

1. Install the air filter element into the air cleaner

housing.
2. Install the air cleaner housing top cover (5) to the
lower assembly. Ensure the rear locating tabs on
the air cleaner cover slip into the retainers
located on the lower portion of the air cleaner
housing.
3. Secure the top cover latches (4).

243934

Air Cleaner Assembly Replacement

Removal Procedure

Notice: If the Mass Air Flow (MAF) sensor is installed

backwards, the system will go rich. An arrow cast ,
into the plastic portion of the sensor indicates proper
air flow direction. The arrow must point toward the
engine.
1. Release the top cover latches (4).
2. Remove the plastic rivets {1) securing the air
intake resonator (2).
3. Loosen the clamp at the air duct between the
MAF sensor and the resonator (2).

243934

4. Disconnect the IAT sensor (2) connector.

5. Lift the top of the air cleaner housing and the
resonator off as an assembly.

242662

6-1860

Engine Controls - 5.7L

Engine
6. Remove the 4 fasteners securing the air cleaner
assembly (3) to the tie bar.
7. Lift the lower air cleaner assembly off.

243934

Installation Procedure
1. Position the lower air cleaner assembly (3) onto
the tie bar. Ensure the rubber isolators fit properly
on to the top of the radiator.
2. Fasten the lower air cleaner assembly (3) to the
tie bar support.
3. Secure the upper air cleaner and resonator
assembly (2) to the MAF sensor
4. Secure the resonator to the lower air cleaner
assembly using the plastic rivets (1 ).

243934

5. Connect the IAT sensor (2) connector.

6. Tighten the clamp on the air duct at the MAF
sensor (1).

242662

Engine

7. Secure the top cover latches (4). Ensure the rear

locating tabs on the air cleaner cover slip into the
retainers located on the lower portion of the air
cleaner housing.

Engine Controls - 5.7L 6-1861

1

243934

Engine Oil Life Monitor Reset Procedure

Description
The PCM monitors various engine parameters to
determine when an oil change should be done. The
PCM sends a message to the Instrument Panel Cluster
(IPC) when an oil change is needed. The PCM
monitors the following to determine when an oil change
should occur:
Engine Speed
Engine coolant temperature
Engine load
Intake Air Temperature
Vehicle mileage

Resetting The Oil Life Monitor

Important:
Repair any TP sensor DTCs before proceeding
with the reset procedure.
If the Engine Oil Life Monitor is reset due to a
PCM replacement, advise the customer. The
customer has two options:
- Change the engine oil and filter.
- Determine when the last engine oil change
occurred. Monitor the vehicle mileage and
change the engine oil and.filter at the
next recommended service interval.
1. Turn ON the ignition leaving the engine OFF.
2. Cycle the accelerator pedal from a closed throttle
to a wide open throttle (WOT) 3 time
within 5 seconds. The Change Oil message
flashes for 5 seconds when reset.
3. Change the engine oil and filter. Refer to Engine
Oil and Oil Filter Change in Engine Mechanical.

6-1862

Engine Controls - 5.7L

Engine

Description and Operation

Powertrain Control Module Description

Manual transmission

The Powertrain Control Module (PCM) is designed to

maintain exhaust emission levels while maintaining
excellent driveability and fuel efficiency. The PCM
controls the following operations:
Fuel control
Ignition Control (IC)
Knock Sensor (KS) system
Automatic transmission shift functions

Cruise Control Enable (if so equipped)

Generator (if so equipped)
Evaporative Emission (EV AP) Purge
A/C Clutch Control
Cooling Fan Control
Secondary Air Injection (AIR) (if so equipped)
Exhaust Gas Recirculation (EGR) (if so equipped)

Powertrain Control Module

158606

Legend

(1) Connector C1 (Red) opposite the

manufacturer's logo
The Powertrain Control Module (PCM) is located in
the engine compartment. The PCM is the control
center of the vehicle. It controls the following:
Fuel metering system.
Transmission shifting.
Ignition timing.
On-board diagnostics for powertrain functions.

(2) Connector C2 (Blue) same side as the

manufacturer's logo
The PCM constantly monitors the information from
various sensors, and controls the systems that affect
vehicle performance. The PCM also performs the
diagnostic function of the system. It can recognize
operational problems. The PCM also alerts the driver
through the MIL (Malfunction Indicator Lamp).
When the PCM detects a malfunction, it stores a
diagnostic trouble code (DTC). A DTC stored,
will identify the problem areas. This will aid the
technician in making repairs.

Engine
The PCM supplies either 5.0 or 12.0 volts to power
various sensors or switches. This is done through
resistances in the PCM. The resistance is so high in
value that a test lamp will not illuminate when
connected to the circuit. In some cases, even an
ordinary shop voltmeter will not give an accurate
reading because its resistance is too low. Therefore, a
digital voltmeter (J 39200) with at least 1O megaohms
input impedance is required to ensure accurate
voltage readings.
The PCM controls output circuits such as the injectors,
IAC, cooling fan relays, etc. by controlling the
ground or the power feed circuit through transistors or
a device called an Output Driver Module.

Torque Management
Torque Management is a function of the PCM that
reduces engine power under certain conditions. Torque
Management is performed for the following reasons:
1. To prevent overstress of the powertrain
components.
2. To prevent damage to the vehicle during certain
abusive maneuvers.
3. To reduce engine speed when the IAC is out of
the normal operating range.
The PCM monitors the following sensors and engine
parameters to calculate engine output torque:
Air/Fuel ratio
Mass Air Flow
Manifold Absolute Pressure
Intake Air Temperature
Spark Advance
Engine Speed
Engine Coolant Temperature
A/C Clutch Status
The PCM monitors the torque converter status, the
transmission gear ratio, and the engine speed in order
to determine if torque reduction is required. The
PCM retards the spark as appropriate to reduce engine
torque output if torque reduction is required. The
PCM also shuts off the fuel to certain injectors
to reduce the engine power In the case of an abusive
maneuver.
The following are instances when engine power
reduction is likely to be experienced:
During transmission upshifts and downshifts.
Heavy acceleration from a standing start.
The IAC is out of the normal operating range.
When the driver is performing stressinducing (abusive) maneuvers such as shifting
into gear at high throttle angles or shifting
the transmission from reverse to drive to create a
rocking motion.

Engine Controls - 5.7L

s-,1863

The driver is unlikely to notice the torque management

actions in the first two instances. The engine power
output will be moderate at full throttle In the
other two cases.
The PCM calculates the amount of spark retard
necessary to reduce the engine power by the desired
amount The PCM disables the fuel injectors for
cylinders 1, 4, 6, and 7 in the case of an abusive
maneuver.

PCM Function
The PCM supplies a buffered voltage to various
sensors and switches. The PCM controls most
components with electronic switches which complete a
ground circuit when turned ON.

Use of Circuit Testing Tools

Do not use a test lamp in order to diagnose the
Poyvertrain electrical systems unless specifically
instructed by the diagnostic procedures. Use the
Connector Test Adapter Kit, J 35616-A whenever.
diagnostic procedures call for probing any connectors.

PCM Service Preca.utions

The PCM is designed to withstand normal current
draws associated with vehicle operations. Avoid
overloading any circuit. When testing for. opens or
shorts, do not ground any of the PCM circuits unless
instructed. When testing for opens or shorts, do
not apply voltage to any of the PCM circuits unless
instructed. Only test these circuits with a digital
voltmeter J 39200, while the PCM connectors remain
connected.

Aftermarket (Add-On) Electrical And

Vacuum Equipment
Aftermarket (Add-On) Electrical and Vacuum
Equipment is defined as any equipment installed on a
vehicle after leaving the factory that connects to
the vehicle's electrical or vacuum systems. No
allowances have been made in the vehicle design for
this type of equipment.
Notice: Do not attach add-on vacuum operated
equipment to this vehicle. The use of add-on vacuum
equipment may result in damage to vehicle
components or systems.
Notice: Connect any add-on electrically operated
equipment to the vehicle's electrical system at
the battery (power and ground) in order to prevent
damage to the vehicle.
Add-On electrical equipment, even when installed to
these strict guidelines, may still cause the Powertrain
system to malfunction. This may also include
equipment not connected to the vehicle's electrical
system such as portable telephones and radios.
Therefore, the first step in diagnosing any Powertrain
problem is to eliminate all aftermarket electrical
equipment from the vehicle. After this is done, if the
problem still exists, diagnose the problem in the normal
manner.

6-1864

Engine

Engine Controls - 5.7L

Electrostatic Discharge Damage

Notice: In order to prevent possible Electrostatic
Discharge damage to the PCM, Do Not touch
the connector pins or the soldered components on the
circuit board.
Electronic components used in the control systems are
often designed in order to carry very low voltage.
Electronic components are susceptible to damage
caused by electrostatic discharge. Less than 100 volts
of static electricity can cause damage to some
electronic components. There are several ways for a
person to become statically charged. The most
common methods of charging are by friction and by
induction. An example of charging by friction is a person
sliding across a car seat. Charging by induction occurs
when a person with well insulated shoes stands near a
highly charged object and momentarily touches ground.
Charges of the same polarity are drained off leaving the
person highly charged with the opposite polarity. Static
charges can cause damage. Therefore, it is important to
use care when handling and testing electronic
components.

Engine Controls Information

The driveability and emissions information describes
the function and operation of the PCM.
The engine controls Information contains the following:
Component Locations
Wiring Diagrams
PCM Terminal End View and Terminal Definitions
Powertrain On-Board Diagnostic (OBD)
System Check
Diagnostic Trouble Code Tables (DTCs)
The Component System includes the following items:
Component and circuit description
On-vehicle service for each sub-system
Functional checks and Diagnostic Tables
The DTCs also contain diagnostic support information
containing circuit diagrams, circuit or system
information, and helpful diagnostic information.

Inspect all wires in the engine compartment for

the following items:
- Proper connections
- Burned or chafed spots
- Pinched wires
- Contact with sharp edges
- Contact with hot exhaust manifolds
This visual and physical inspection is very important.
Preform the inspection carefully and thoroughly.

Basic Knowledge Of Tools Required

Important: Lack of basic knowledge of this powertrain
when performing diagnostic procedures could result
in incorrect diagnosis or damage to powertrain
components. Do not attempt to diagnose a powertrain
problem without this basic knowledge.

A basic understanding of hand tools is necessary in

order to effectively use this information.

System Status and Drive Cycle For

Inspection/Maintenance
The System Status selection is included in the scan
tool System Info menu.
Several states require that the 1/M (OBD II system)
pass on-board tests for the major diagnostics prior to
having a vehicle emission inspection. This is also
a requirement to renew license plates in some areas.
Using a scan tool, the technician can observe the
System Status (complete or not complete) in order to
verify that the vehicle meets the criteria to comply
with local area requirements. Using the System Status
display, any of the following systems or combination
of systems may be monitored for 1/M Readiness:
The Catalyst
The EV AP system
The H02S
The H02S Heater

Maintenance Schedule

The EGR System

Refer to the General Motors Maintenance Schedule of

the appropriate service category for the maintenance
that the owner or technician should perform in order to
retain emission control performance.

The AIR system

Visual and Physical Underhood Inspection

Perform a careful visual and physical underhood
inspection when performing any diagnostic procedure
or diagnosing the cause of an emission test failure.
This can often lead to repairing a problem without
further steps. Use the following guidelines when
performing a visual and physical inspection:
Inspect all vacuum hoses for the following
conditions:
- Correct routing
- Pinches
- Cuts
- Disconnects

Important: The System Status display indicates only

whether or not the test has been completed. The
System Status display does not necessarily mean that
the test has passed. If a Failed Last Test indication
is present for a OTC associated with one of the above
systems, diagnosis and repair is necessary in order
to meet the 1/M requirement. Verify that the vehicle
passes all of the diagnostic tests associated with the
displayed System Status prior to returning the
vehicle to the customer. Refer to the Typical Drive
Cycle ta,ble (more than one drive cycle may be
needed) to use as a guide to complete the 1/M System
Status tests.

Following a OTC info clear, System Status will clear

for one or all of these systems. Following a battery
disconnect or a PCM replacement, all System Status
information will clear.

Engine Controls - 5.7L

Engirne

6-1865

Typical Drive Cycle

Diagnostic Time Schedule for 1/M Readiness

What is Monitored?

Vehicle Drive Status

Cold Start, coolant temperature less than 50C (122F)

Idle 2.5 minutes in Drive (Auto) Neutral (Man), A/C and rear
defogger ON

H02S Heater, Misfire, Secondary Air, Fuel Trim,

EVAP Purge

A/C off, accelerate to 90 km/h (55 mph), 1/2 throttfe.

Misfire, Fuel Trim, Purge

3 minutes of Steady State - Cruise at 90 km/h (55 mph)

Misfire, EGA, Secondary Air, Fuel Trim, H02S, EVAP Purge

Clutch engaged (Man), no braking, decelerate to

32 km/h (20 mph)

EGA, Fuel Trim, EVAP Purge

Accelerate to. 90-97 km/h (55-60 mph), 3/4 throttle

Misfire, Fuel Trim, EVAP Purge

5 minutes of Steady State Cruise at 90-97 km/h (55-60 mph) Catalyst Monitor, Misfire, EGA, Fuel Trim, H02S,
EVAP Purge
Decelerate, no braking. End of Drive Cycle
Total time of OBD II Drive Cycle 12 minutes

Primary System Based Diagnostics

EGA, EVAP Purge

There are primary system based diagnostics which

evaluate the system operation and their effect on
vehicle emissions. The primary system based .
diagnostics are listed below with a brief description of
the diagnostic functionality.

reference provided to it. This clean air reference is

obtained by way of the oxygen sensor wires. Any
attempt to repair the wires, connectors or terminals
could result in the obstruction of the air reference. Any
attempt to repair the wires, connectors or terminals
could degrade oxygen sensor performance.

Oxygen Sensor Diagnosis

Catalyst Monitor Heated Oxygen Sensors

Diagnose the Fuel Control Heated Oxygen Sensors

for the following conditions:
Heater Performance (time to activity on cold start)
Slow Response
Response Time (time to switch R/L or UR)
Inactive Signal (output steady at bias voltage approximately 450 mV)
Signal Fixed High
Signal Fixed Low
Diagnose the Catalyst Monitor Heated Oxygen
Sensors for the following functions:
Heater Performance (time to activity on cold start)
Signal fixed low during steady state conditions.
Inactive Sensor.

In order to control emissions of Hydrocarbons (HC),

Carbon Monoxide (CO), and Oxides of Nitrogen (NOx),
the system uses a three-way catalytic converter.
The catalyst within the converter promotes a chemical
reaction which oxidizes the HC and CO present in
the exhaust gas, .converting them into harmless water
vapor and carbo.n dioxide. The catalyst also reduces
NOx, converting it to nitrogen.

Fuel Control Heated Oxygen Sensors

The main function of the fuel control heated oxygen
sensor is to provide the PCM with exhaust stream
information in order to allow proper fueling and
maintain emissions within acceptable levels. After the .
sensor reaches the operating temperature, the
sensor generates a voltage inversely proportional to
the amount of oxygen present in the exhaust gases.
The PCM uses the signal voltage from the fuel control
heated oxygen sensors in a closed loop in order to
adjust the fuel injector pulse width. While in a closed
loop, the PCM can adjust fuel delivery in order to
maintain an air to fuel ratio which allows the
best combination of emission control and driveability.
If the oxygen sensor pigtail wiring, connector or
terminal are damaged, replace the entire oxygen
sensor assembly. Do not attempt to repair the wiring,
connector, orterminals. In order for the sensor to
function properly, the sensor must have a clean air

The PCM has the ability to monitor this process using

the post heated oxygen sensors. The pre-sensors
produce an output signal which indicates the amount
of oxygen present in the exhaust gas entering the
three-way catalytic converter. The post sensor
produces an output signal which indicates the oxygen
storage capacity ,of the catalyst; this in turn indicates
the catalyst's ability to convert exhaust gases
efficiently. If the catalyst is operating efficiently, the pre
H02S signal will be far n'lore active than that
produced by the post H02S.
In addition to catalyst monitoring, the post heated
oxygen sensor has a limited role in controlling
fuel delivery. If the post H02S signal indicates a high
or low oxygen content for an extended period of
time while in a closed loop, the PCM adjusts the fuel
delivery slightly in order to compensate.

Catalyst Monitor Diagno$tic Operation

The catalyst monitor diagnostic measures oxygen
storage capacity of the catalyst converter. In order to
do this, the heated sensors are installed before
and after the Three-Way Catalyst (TWC). Voltage
variations between the sensors allow the PCM
to determine .the catalyst emission performance.

6-1866

Engine Controls - 5.7L

E.ngine

As a catalyst becomes less effective in promoting

chemical reactions, the catalyst's capacity to store and
release oxygen generally degrades. The catalyst
monitor diagnostic is based on an correlation between
conversion efficiency and oxygen storage capacity.
A good catalyst (e.g. 95% hydrocarbon conversion
efficiency) shows a relatively flat output voltage on the
post-catalyst heated oxygen sensor (H02S). A
degraded catalyst (65 % hydrocarbon conversion)
shows a greatly increased activity in output voltage
from the post catalyst H02S.
The post-catalyst H02S is used to measure the
oxygen storage and release capacity of the catalyst. A
high oxygen storage capacity indicates a good
catalyst; low oxygen storage capacity indicates a
failing catalyst. The TWC and the H02S must be at
operating temperature in order to achieve correct
oxygen sensor voltages like those shown in the
Post-Catalyst H02S Outputs graphic.
The catalyst monitor diagnostic is sensitive to the
following conditions:
Exhaust leaks
H02S Contamination
Alternative fuels
Exhaust system leaks may cause the following:
Prevent a degraded catalyst from failing the
diagnostic
Cause a false failure for a normally functioning
catalyst
Prevent the diagnostic from running
Some of the contaminants that may be encountered
are phosphorus, lead, silica, and sulfur. The presence
of these contaminants prevent the TWC diagnostic
from functioning properly.

Three-Way Catalyst Oxygen Storage Capacity

operating properly, the post-catalyst (2) oxygen

sensor will have significantly less activity than the
pre-catalyst (1) oxygen sensor. The TWC stores
oxygen during its normal reduction and oxidation
process. The TWC releases oxygen during its normal
reduction and oxidation process. The PCM calculates
the oxygen storage capacity using the difference
between the pre-catalyst and post-catalyst oxygen
sensor's voltage levels.

/
14446

Whenever the voltage levels of the post-catalyst (2)

oxygen sensor nears the voltage levels that of
the pre-catalyst (1) oxygen sensor, the catalysts
efficiency is degraded.
Aftermarket H02S characteristics may be different
from the original equipment manufacturer sensor. This
may lead to a false pass or a false fail of the catalyst
monitor diagnostic. Similarly, if an aftermarket
catalyst does not contain the same amount of cerium
as the original part, the correlation between oxygen
storage and conversion efficiency may be altered
enough to set a false DTC.

Misfire Monitor Diagnostic Operation

________

The misfire monitor diagnostic is based on crankshaft

rotational velocity (reference period) variations.
The PCM determines crankshaft rotational velocity
using the crankshaft position sensor and camshaft
position sensor. When a cylinder misfires the
crankshaft slows down momentarily. By monitoring the
crankshaft and camshaft position sensor signals,
the PCM can calculate when a misfire occurs.

For a non-catalyst damaging misfire, the diagnostic is

required to monitor a misfire present for
between 1000-3200 engine revolutions.

For catalyst damage misfire, the diagnostic responds

to the misfire within 200 engine revolutions.
14442

The PCM must monitor the Three-Way catalyst

system (TWC) for efficiency. In order to accomplish
this, the PCM monitors the pre-catalyst and
post-catalyst oxygen sensors. When the TWC is

Rough roads may cause false misfire detection. A

rough road applies torque to the drive wheels and drive
train. This torque can intermittently decrease the
crankshaft rotational velocity. The PCM detects this as
a false misfire.

Engine

Engine Controls - 5.7L 6-1867

When the TCC has disabled as a result of misfire
detection, the TCC will re-enabled after approximately
3200 engine revolutions if no misfire is detected.
The TCC remains disabled whenever the misfire is
detected, with or without a DTC set. This allows
the misfire diagnostic to reevaluate the system.

On automatic transmission equipped vehicles, the

Torque Converter Clutch (TCC) will disable whenever
a misfire is detected. Disabling the TCC isolates
the engine from the rest of the drive line and minimizes
the effect of the drive wheel inputs on crankshaft
rotation.

CYL1
MISFIRES

CYL2
MISFIRES

0-200-0

HISTORY
1356

..
CYLS 5-8
CYL 3
CYL
(AS APPLICABLE)
MISFIRES MISFIRES
MISFIRES

4000

HISTORY

HISTORY

HISTORY
4

HISTORY

\/
IDENTIFY
AND FILL
ACCUMULATOR

CRANKSHAFT
POSITION SENSOR
CAMSHAFT
POSITION SENSOR

RUN
MISFIRE
DIAGNOSIS

CHECKS
ACCUMULATORS

REPORT
MISFIRE

DIAGNOSTIC
EXECUTIVE

SETS
DTC

17379

Whenever a cylinder misfires, the misfire diagnostic

counts the misfire and notes the crankshaft position at
the time the misfire occurred.

A current and a history misfire counter is maintained

for each cylinder. The misfire current counters (Misfire
Cur #1 - 8) indicate the number of firing events out
of the last 200 cylinder firing events which were
misfires. The misfire current counters displays real
time data without a misfire DTC stored. The misfire

history counters (Misfire Hist #1 - 8) indicate the total

number of cylinder firing events which were misfires.
The misfire history counters displays O until the misfire
diagnostic has failed and a DTC P0300 is set. Once
the misfire DTC sets, the misfire history counters
will be updated every 200 cylinder firing events. The
Misfire counters graphic illustrates how these
misfire counters are maintained.

6-1868

Engine Controls - 5.7L

When crankshaft rotation is erratic, the PCM detects a

misfire condition. Because of this erratic condition,
the data that is collected by the diagnostic can
sometimes incorrectly identify which cylinder is
misfiring. The Misfire Counters graphic shows there
are misfires counted from more than one cylinder.
Cylinder #1 has the majority of counted misfires. In this
case, the Misfire Counters would identify cylinder #1
as the misfiring cylinder. The misfires in the other
counters were just background noise caused by the
erratic rotation of the crankshaft. If the number of
accumulated misfires is sufficient for the diagnostic to
identify a true misfire, the diagnostic will set
OTC P0300 - Misfire Detected.
Use Techline equipment to monitor the misfire counter
data on applicable vehicles. Knowing which specific
cylinder(s) misfire can lead to the root cause. Using the
information in the misfire counters, will identify which
cylinder(s) are misfiring. If the counters indicate
cylinders number 1 and 4 misfired, look for a circuit or
component common to both cylinders.
The misfire diagnostic may indicate a fault due to a
temporary fault not necessarily caused by a vehicle
emission system malfunction. Examples include the
following items:
Contaminated fuel
Running out of fuel
Fuel fouled spark plugs
Basic engine fault

Fuel Trim System Operation

The Fuel Trim system monitors the averages of
short-term and long-term fuel trim values. If these fuel
trim values stay at their limits for a calibrated period
of time, a malfunction is indicated. The fuel trim
diagnostic compares the average of short and
long-term fuel trim values. If either value is within the
thresholds, a pass is recorded. If either value is
outside the thresholds, a rich or lean fuel Trim OTC
will set.

Engine
Intake Air Temperature (IAT) sensor
Crankshaft Position (CKP) sensor
Knock Sensor (KS)
Throttle Position (TP) sensor
Engine Coolant Temperature (ECT) sensor
Camshaft Position (CMP) sensor
Manifold Absolute Pressure (MAP) sensor
In addition to the circuit continuity and rationality
check, the. ECT sensor is monitored for its ability to
achieve a steady state temperature to enable
closed loop fuel control.

Output Components
Diagnose the output components for the proper
response to PCM commands. Components where
functional monitoring is not feasible will be monitored
for circuit continuity and out-of-range values if
applicable.
Output components to be monitored include, but are
not limited to the following circuits:
Idle Air Control (IAC) Motor
EVAP system
Electronic transmission controls
A/C relay
Cooling fan relay
VSS output
MIL control
Cruise control inhibit (if so equipped)

Wiring Harness Service

Comprehensive component monitoring diagnostics are

required to monitor emissions-related input and
output Powertrain components.

Replace the wire harnesses with the proper part

number replacement. When splicing signal wires into a
harness, use the wiring that has high temperature
insulation.
Consider the low amperage and voltage levels utilized
in the Powertrain control systems. Make the best
possible bond at all splices. Use rosin-core solder in
these areas.
Molded-on connectors require complete replacement
of the connector. Splice a new connector into the
harness. Replacement connectors and terminals are
listed in Group 8.965 in the Standard Parts Catalog.
Fo.r wiring repair, refer to Wiring Repairs.

Input Components

Connectors and Terminals

The PCM monitors the input components for circuit

continuity and out-of-range values. This includes
performance checking. Performance checking refers to
indicating a fault when the signal from a sensor
does not seem reasonable (i.e. a Throttle Position
(TP) sensor that indicates high throttle position at low
engine loads or MAP voltage). The input components
may include but are not limited to the followirig
sensors:
The Vehicle Speed (VSS) sensor
The Accelerator Pedal Position (APP) sensor (if
so equipped)
Mass Air Flow (MAF) sensor

In order to prevent shorting between opposite

terminals, use care when probing a connector and
when replacing terminals. Damage to the components
could result.
Always use jumper wires between connectors for
circuit checking.
Never probe through Weather-Pack seals.
The connector test adapter kit J 35616-A, or the
equivalent, contains an assortment of flexible
connectors used to probe terminals during diagnosis.
Fuse remover and test tool BT-8616, or the
equivalent, is used for removing a fuse and to adapt
the fuse holder to a DVM for diagnosis.

Comprehensive Component Monitor

Diagnostic

Engine

Engine Controls - 5.7L 6-1869

Open circuits are often difficult to locate by sight

because oxidation or terminal misalignment are hidden
by the connectors. Merely wiggling a connector on a
sensor, or in the wiring harness may temporarily
correct the open circuit. Oxidized or loose connections
may cause intermittent problems.
Be certain the type of connector and terminal before
making any connector or terminal repair.
Weather-Pack and Com-Pack Ill terminals look similar,
but are serviced differently.

All of the sensors and the input switches can be

diagnosed through the use of a scan tool. The
following is a short description of how the sensors and
switches can be diagnosed by using a scan tool.
The scan tool can also be used in order to compare
the values for a normal running engine with the engine
being diagnosed.

The scan tool displays engine coolant temperature in

degrees. When the engine starts the engine coolant
temperature should rise steadily to about 90C (194F)
then stabilize when thermostat opens. The engine
coolant temperature and intake air temperature should
be close to each other if the engine has not been
run for several hours (overnight). The following OTCs
set when the PCM detects a malfunction in the
ECT sensor circuit:
OTC P0117 ECT Sensor Circuit Low Voltage.
OTC P0118 ECT Sensor Circuit High Voltage.
OTC P0125 Excessive Time to Closed Loop.
OTC P1114 ECT Sensor CKT Intermittent Low
Voltage.
OTC P1115 ECT Sensor CKT Intermittent High
Voltage.
Specifications contains a table to check for sensor
resistance values relative to temperature.

Engine Coolant Temperature (ECT) Sensor

Mass Air Flow (MAF) Sensor

Information Sensors/Switches Description

13578

Legend
(1) ECT Electrical Connector
(2) Connector Tab
(3) Engine Coolant Temperature (ECT} Sensor

The engine coolant temperature sensor is a thermistor

(a resistor which changes value based on temperature)
mounted in the left cylinder head. Low coolant
temperature produces a high resistance
(100,000 ohms at -38C/-39F} while high
temperature causes low resistance (70 ohms at
130C/266F).
The PCM supplies a 5.0 volt signal to the engine
coolant temperature sensor through a resistor in the
PCM and measures the voltage. The voltage will
be high when the engine is cold. The voltage will be
low when the engine is hot. The PCM calculates
the engine coolant temperature by measuring
the voltage. The engine coolant temperature affects
most systems the PCM controls.

13487

The Mass Air Flow (MAF) sensor measures the

amount of air which passes through it. The PCM uses
this information to determine the operating condition
of the engine in order to control the fuel delivery.
A large quantity of air indicates acceleration. A small
quantity of air indicates deceleration or idle.

6-1870

Engine

Engine Controls - 5.7L

The scan tool reads the MAF value and displays it in

grams per second (g/s). The MAF sensor displays
between 6 g/s - 9 g/s at idle on a fully warmed
up engine. The MAF sensor values should change
rather quickly on acceleration, but the MAF sensor
values should remain fairly stable atany given RPM.
The following DTCs set when the PCM detects a
malfunction in the MAF sensor circuit:
DTC P0101 Mass Air Flow System Performance.
DTC P0102 MAF Sensor Circuit Low. Frequency.
DTC P0103 MAF Sensor Circuit High Frequency.

Intake Air Temperature {IAT) Sensor

The Intake Air Temperature (IAT) sensor is a

thermistor which changes value based on the
temperature of air entering the engine. Low
temperature produces a high resistance
(100,000 ohms at -38C/-39F). A high temperature
causes low resistance (70 ohms at 130C/266F). The
PCM supplies ff 5.0 volt signal to the sensor through
a resistor in the PCM and measures the voltage.
The voltage will be high when the incoming air is cold,
and low when the air is hot. The PCM calculates
the incoming air temperature by measuring the IAT
voltage. The IAT sensor signal is used to adjust spark
timing according to incoming air density.
The scan tool displays temperature of the air entering
the engine, which should read close to ambient air
temperature when engine is cold. The temperature
should rise as underhood temperature increases. If the
engine has not been run for several hours (overnight)
the IAT sensor temperature and engine coolant
temperature should read close to each other. The
following DTCs set if the PCM detects a malfunction in
the IAT sensor circuit:
DTC P0112 IAT Sensor Circuit Low Voltage.
DTC P0113 IAT Sensor Circuit High Voltage.
DTC P1111 IAT Sensor CKT Intermittent
High Voltage.

DTC P1112 IAT Sensor CKT Intermittent Low

Voltage.

13643

Legend
(1) Intake Air Temperature (IAT) Sensor
(2) Electrical Harness Connector

Engine

Engine Controls - 5.7L 6-1871

Manifold Absolute Pressure (MAP) Sensor

247435

The Manifold Absolute Pressure (MAP) sensor (#1)

responds to changes in the intake manifold pressure.
The pressure changes as a result of engine load
and speed. The map sensor converts this to a voltage
output.
A closed throttle on engine coast down produces a
relatively low map output voltage. A wide open throttle
produces a high map output voltage. This high
output voltage is produced because the pressure
inside the manifold is the same as outside the
manifold. The MAP is inversely proportional to what is
measured on a vacuum gauge. The MAP sensor is
used for the following:
Altitude determination.
Ignition timing control.
Speed density fuel management default.

OTC P0107 MAP Sensor Circuit Low Voltage or

OTC P0108 MAP Sensor Circuit High Voltage set
when the PCM detects a malfunction in the MAP
sensor circuit.

6-1872

Engine

Engine Controls - 5.7L

Heated Oxygen Sensors (H02S) Cutaway

Front Heated Oxygen Sensors (H02S)

5
1

13576

Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)

Four Wire In-Line Connector

Heater Termination
Water Shield Assembly
Sensor Lead
Flat Seat Shell
Seat Gasket
Outer Electrode and Protective Coating
Rod Heater
Inner Electrode
Zirconia Element
Insulator
Clip Ring
Gripper

The Heated Oxygen Sensors are mounted in the

exhaust system where they can monitor the oxygen
content of the exhaust gas stream. The oxygen
present in the exhaust gas reacts with the sensor to
produce a voltage output. This voltage should
constantly fluctuate from approximately 100 mV (high
oxygen content - lean mixture) to 900 mV (low
oxygen content~ rich mixture). The heated oxygen
sensor voltage can be monitored with a scan tool. The
PCM calculates what fuel mixture command to give
to the injectors (lean mixture - low H02S voltage = rich
command, rich mixture - high H02S voltage = lean
command) by monitoring the voltage output of
the oxygen sensors.
The PCM sets the following DTCs when the PCM
detects an H02S signal circuit that is low:
DTC P0131 Bank 1 left front H02S.
. DTC P0151 Bank 2 right front H02S.
DTC P0137 Bank 1 left rear H02S.
DTC P0157 Bank 2 right rear H02S.
The PCM sets the following DTCs when the PCM
detects an H02S signal circuit that is high:
DTC P0132 Bank 1 left front H02S.
DTC P0152 Bank 2 right front H02S.
DTC P0138 Bank 1 left rear H02S.
DTC P0158 Bank 2 right rear H02S.
The PCM sets the following DTCs when the PCM
detects no. H02S activity:
DTC P0134 Bank 1 left front H02S.
DTC P0154 Bank 2 right front H02S.
DTC P0140 Bank 1 left rear H02S.
DTC P0160 Bank 2 right rear H02S.
A fault in the heated oxygen sensor heater element or
its ignition feed or ground results in an increase in
time to Closed Loop fuel control. Thismay cause
increased emissions, especially at start-up. The
following DTCs set when the PCM detects a
malfunction in the H02S heater circuits:
DTC P0135 Bank 1 left front H02S heater.
DTC P0155 Bank 2 right front H02S heater.
DTC P0141 Bank 1 left rear H02S heater.
DTC P0161 Bank 2 right rear H02S heater.
The PCM also has the ability to detect H02S
response, switching, transition time, and incorrect ratio
voltage problems. The PCM stores a DTC that
indicates degraded H02S performance if a H02S
response switching, transition time, or ratio problem is
detected.

Engine Controls - 5.7L 6-1873

Engine
Rear Heated Oxygen Sensors (H02S)

To control emissions of Hydrocarbons (HC), Carbon

Monoxide (CO), and Oxides of Nitrogen (NOx), a
three-way catalytic converter is used. The catalyst
within the converter promotes a chemical reaction
which oxidizes the HC and CO present in the exhaust
gas, converting them into harmless water vapor
and carbon dioxide. The catalyst also reduces NOx,
converting it to nitrogen. The PCM has the ability
to monitor this process using the Bank 1 H02S 2 and
the Bank 2 H02S 2 heated oxygen sensors. The
front H02S sensors produces an output signal which
indicates the amount of oxygen present in the
exhaust gas entering the three-way catalytic converter.
The rear H02S sensors produces an output signal
which indicates the oxygen storage capacity of
the catalyst; this in turn indicates the catalysts ability
to convert exhaust gases efficiently. If the catalyst
is operating efficiently, the front sensors will produce a
far more active signal than that produced by the
rear sensors.
The catalyst monitor sensors operate the same as the
fuel control sensors. Although the Bank 1 H02S 2
and Bank 2 H02S 2 sensors main function is catalyst
monitoring, they also play a limited role in fuel
control. If a sensor output indicates a voltage either
above or below the 450 millivolt bias voltage for
an extended period of time, the PCM will make a slight
adjustment to fuel trim to ensure that fuel delivery is
correct for catalyst monitoring

Throttle Position (TP) Sensor

The PCM calculates fuel delivery based on throttle

valve angle (driver demand). A broken or loose
TP sensor may cause intermittent bursts of fuel from
an injector. This may cause an unstable idle
because the PCM detects the throttle is moving.
The following DTCs set when the PCM detects a
malfunction with the TP sensor circuits:
OTC P0121 TP Sensor Circuit Insufficient Activity.
OTC P0122 TP Sensor Circuit Low Voltage.
OTC P0123 TP Sensor Circuit High Voltage.
OTC P1121 TP Sensor CKT Intermittent High
Voltage.
OTC P1122 TP Sensor CKT Intermittent Low
Voltage.

Park/Neutral Position (PNP) Switch

(Automatic Transmission)
The PNP switch indicates to the PCM when the
transmission is in park, neutral, or drive. This
information is used for the EGR and IAC valve
operation. Refer to Electrical Diagnosis for more
information on the PNP switch. The PNP switch is part
of the neutral/start and backup light switch assembly.
Refer to Park/Neutral Position Switch diagnosis.
Important: Idle quality will be affected if the vehicle is
driven with the PNP switch disconnected. Having
the switch disconnected may also cause a VSS OTC
to set.

Fuel Level Sensor

1

2
3

13572

The Throttle Position (TP) sensor is a potentiometer.

The TP sensor is connected to the throttle shaft
on the throttle body. The PCM calculates throttle
position by monitoring the voltage on the signal line.
The TP sensor signal changes as the throttle
valve angle is changed (accelerator pedal moved).
The TP sensor signal voltage is low at a closed throttle
position. The TP sensor signal voltage increases as
the throttle valve opens so that at Wide Open Throttle
(WOT), the output voltage should be above 4.0 volts.

209113

The PCM uses the fuel level sensor input in order to

determine the amount of fuel in the fuel tank. The PCM
disables the engine misfire diagnostic when the fuel
level is too low and the EVAP system diagnostic when
the fuel level is either too high or too low. The PCM
also controls the fuel gauge based on the fuel
level input.

6-1874

Engine Controls - 5.7L

Engine

Fuel Tank Pressure Sensor

The knock sensor system is used to detect engine

detonation. The knock sensors produce an AC voltage
which is sent to the PCM. The PCM retards the
spark timing based on signals from the KS sensors.
The amount of AC voltage produced by the sensors is
determined by the amount of knock. The PCM then
adjusts the Ignition Control (IC) to reduce the

spark .knock.

A/C. Request Signal

The A/C request circuit signals the PCM when an A/C
mode is selected at the A/C control head. The
PCM uses this information in order to enable the A/C
compressor clutch and to adjust the idle speed
before turning ON the A/C clutch. The PCM disables
the A/C compressor clutch if the A/C request signal
is not available to the PCM. For vehicles equipped with
CJ2 A/C, the A/C request is sent via Clas.s 2 Serial
Data communications.
Refer to A/C Clutch Circuit Diagnosis for A/C wiring
diagrams and diagnosis of A/C electrical system.
18839

The Fuel Tank Pressure sensor is a sensor much

like that of the common MAP sensor. The Fuel Tank
Pressure sensor measures the difference between
the outside air pressure and the air pressure (or
vacuum) in the fuel tank.
The Fuel Tank Pressure sensor mounts to the fuel
tank sending unit. A three wire electrical harness
connects the sensor to the PCM. The PCM supplies a
5.0 volt reference voltage and a ground to the
sensor. The sensor will return a voltage between
0.1 and 4.9 volts on the signal circuit.

A/C Refrigerant Pressure Sensor

This signal is used by the PCM in order to enable the
cooling fans when the A/C compressor head
pressure reaches a predetermined value. OTC P0530
sets if a fault is present in the A/C refrigerant
pressure sensor circuit. The PCM disables the A/C
compressor clutch when the PCM sets an A/C system
OTC. Refer to the A/C Refrigerant Pressure Sensor
Circuit Check if the A/C refrigerant pressure
sensor is stuck.

Vehicle Speed Sensor (VSS)

Knock Sensors (KS)

13640

13635

A Knock Sensor (KS) system is used in order to

control spark knock. The KS system is designed to
retard spark timing up to 20 in order to reduce spark
knock in the engine. This allows the engine to use
maximum spark advance to improve driveability
and fuel economy.

The Vehicle Speed Sensor (VSS) is a pulse counter

type input that informs the PCM how fast the vehicle is
traveling. The VSS system uses an inductive sensor
mounted in the tail housing of the transmission
and a toothed reluctor wheel on the tail shaft. The
teeth of the reluctor wheel alternately interfere with the
magnetic field of the sensor creating an induced
voltage pulse as the reluctor rotates.

Engine

Engine Controls - 5.7L 6-1875

The VSS produces an AC voltage signal that increases

with vehicle speed. The PCM processes this signal
and sends it to the following components:

Camshaft Position Sensor (CMP)

Instrument Panel
Radio control head
Chime Module
Cruise Control Module

Crankshaft Position Sensor (CKP)

55308

55322

The crankshaft position sensor provides the PCM with

crankshaft speed and crankshaft position. The PCM
utilizes this information in order to determine if an
engine misfire is present. The PCM monitors the CKP
sensor for momentarily drop in crankshaft speed in
order to determine if a misfire is occurring. A
OTC P0300 sets when the PCM detects a misfire.
The PCM also monitors the CKP sensor signal circuit
for malfunctions. The PCM sets a OTC P0335 or a
OTC P0336 when the CKP sensor is out of the normal
operating range.

The Camshaft Position sensor is mounted through the

top of the engine block at the rear of the valley
cover and works in conjunction with a 1X reluctor
wheel on the camshaft. The reluctor wheel is inside
the engine immediately in front of the rear cam
bearing. The PCM provides a 12 volt power supply to
the CMP sensor as well as a ground and a signal
circuit.
The PCM uses the Camshaft Position sensor in order
to determine whether a cylinder is on a firing or
exhaust stroke. The reluctor wheel interrupts a
magnetic field produced by a magnet within the CMP
sensor as the camshaft rotates. The CMP sensor's
internal circuitry detects this and produces a
signal which is the PCM reads. The PCM uses this
1X signal in combination with the Crankshaft Position
sensor 24X signal in order to determine the
crankshaft position and stroke. This diagnostic for the
Camshaft Position sensor checks for a loss of
Camshaft Position sensor signal. The PCM also
monitors the CMP sensor signal circuit for
malfunctions. The following OTCs set when the PCM
detects a CMP sensor that is out of the normal
operating range.
OTC P0341 Camshaft Position Sensor (CMP)
Circuit Performance.
OTC P0342 Camshaft Position Sensor (CMP)
Circuit Low Voltage.
OTC P0343 Camshaft Position Sensor (CMP)
Circuit High Voltage.

6-1876

Engine

Engine Controls - 5.7L

PCM Controlled Air Conditioning

Description
In order to improve engine operation, and protect the
A/C compressor and A/C clutch during Wide Open
Throttle (WOT) performance, the A/C compressor
operation is controlled by the PCM.
This A/C system consists of the following components:
The heater and A/C control
The A/C refrigerant pressure sensor
The A/C clutch relay
The A/C compressor clutch
The PCM.
When the heater and A/C control is placed in the A/C
mode, a request signal is sent to the PCM. The
PCM will then energize the A/C clutch relay, unless
abnormally high or low A/C pressure is detected by the
A/C refrigerant pressure sensor. The PCM will also
turn the cooling fans ON when A/C is requested. The
A/C clutch relay is controlled by the PCM so that
the PCM can increase idle speed before turning ON
the clutch or disable the clutch during WOT, or
high coolant temperature.
The PCM energizes the A/C clutch whenever the
engine is running less than 4895 RPM and A/C has
been requested, unless any of the following conditions
are met:
Wide Open Throttle (WOT).
A/C head pressure greater than 410 psi or less
than O psi (as determined by the A/C refrigerant
pressure sensor).
Ignition voltage less than 10 volts.
Engine speed greater than 5594 RPM.
ECT greater than 125C (257F).
The A/C Request Table should be used for diagnosing
the C60 A/C request circuit only. For CJ2 A/C
systems, refer to HVAC for diagnosis. Refer to HVAC
for diagnosing the refrigerant portion of the system.
The scan tool will be used in diagnosing the system.
The PCM has the ability to display the following
parameters:
A/C request input to the PCM
A/C compressor status
A/C system pressure
A/C clutch ON or OFF status

Engine Cooling Fan Description - Electric

The electric cooling fans are used to cool engine
coolant flowing through the radiator. The fans are also
used to cool the refrigerant flowing through the A/C
condenser.
The electric cooling fans are controlled by the PCM.
The PCM controls the ground path for the three cooling
fan relays. The relays are used to control the high
current flow to power the cooling fan motors. Both fans
operate together. When minimum cooling is required,
the PCM energizes cooling fan relay #1 and both
fans operate at low speed, since the fans are
connected in series through cooling fan relay #3.

Cooling fan relay #2 is open (not energized) and is not

used for low speed operation of the fans. When
maximum cooling is required, the PCM energizes all
three cooling fan relays. The left fan is still powered
through cooling fan relay #1 , but is now grounded
through cooling fan relay #3. The right fan is
now powered directly through cooling fan relay #2 and
both fans operated at high speed.
The PCM will also enable the cooling fans after the
ignition is turned off. When the engine coolant
temperature exceeds 113C (235F) and the ignition is
turned off, the cooling fans will be enabled on low
speed for 150 seconds.

Low Speed Cooling Fans

The low speed cooling fans are controlled by the PCM
based on the following inputs:
The A/C system.
The Engine Coolant Temperature (ECT) sensor.
The Vehicle Speed Sensor (VSS).
The PCM will turn the cooling fans on low speed when
any of the following conditions exist at idle:
Certain PCM Diagnostic Trouble Codes (DTCs)
are set.
The ECT above 108C (226F).
The A/C high side pressure above 215 psi.
Once the low speed fans are turned ON by Engine
Coolant Temperature, the PCM will turn the fans OFF
when that temperature has dropped about 4C (7F).
If the low speed cooling fans are turned ON by
high A/C head pressure, the PCM will turn the fans
OFF when the pressure has dropped to 190 psi.
The minimum ON time for the low speed cooling fans
is 50 seconds.
The cooling fans are turned OFF at certain vehicle
speeds. Adequate airflow through the A/C condenser
and radiator occurs with vehicle movement to
properly cool the A/C refrigerant and engine coolant
without the assistance of the cooling fans.

High Speed Cooling Fans

The High Speed Cooling Fans are controlled by the
PCM based on the following inputs:
The A/C system.
The Engine Coolant Temperature (ECT) sensor.
The Vehicle Speed Sensor (VSS).
The PCM will enable both fans on high speed when
any of the following conditions exist:
Certain PCM Diagnostic Trouble Codes
(DTCs) set.
The ECT above 112C (234F).
The A/C high side pressure above 248 psi.
Once the high speed cooling fans are turned ON by
the Engine coolant temperature, the PCM will turn the
fans OFF when that temperature has dropped about
4C (7F). If the high speed cooling fans are turned ON
by high A/C head pressure, the PCM will turn the
fans OFF when the pressure has dropped to 208 psi.
The minimum ON time for the high speed cooling
fans is 30 seconds.

Engine

Engine Controls - 5.7L

Fuel Supply Component Description

System Overview
The fuel tank stores the fuel supply. An electric fuel
pump, located in the fuel tank with the fuel sender
assembly, pumps fuel through an in-line fuel filter to
the fuel rail assembly. The pump provides fuel at
a pressure greater thar::t is needed by the injectors. The
fuel pressure regulator, part of the fuel sender
assembly, keeps fuel available to the injectors at a
regulated pressure. A separate pipe returns unused
fuel to the fuel tank.

6-1.877

over tightened. To install the cap, turn the cap

clockwise until you hear three audible clicks. This
indicates that the cap is correctly torqued and
fully seated.

Fuel Sender Assembly

Fuel Tank Vent Valve

The fuel tank vent valve is located in the rear of the
vehicle near the fuel tank. The fuel tank vent valve is a
pressure/vacuum relief valve. When the fuel tank
pressure exceeds a specified pressure, the valve
opens allowing the tank pressure to bleed off. When
the fuel tank is in a vacuum condition, the vent
valve opens when the vacuum is within a specified
range allowing fresh air to be pulled in.

Fuel Tank
The fuel tank stores the fuel supply. The fuel tank is
located in the rear of the vehicle. The fuel tank is held
in place by two metal straps that attach to the frame.
The fuel tank is made of steel and is coated internally
with a special corrosion inhibitor.

Fuel Tank Filler Pipe

The fuel tank filler pipe has a built-in restrictor and
deflector in order to prevent refueling with leaded fuel.

Fuel Filler Cap

. 173450

Notice: If a fuel tank filler cap requires replacement,

use only a fuel tank filler cap with the same features.
Failure to use the correct fuel tank filler cap can
result in a serious malfunction of the fuel and EVAP
system.
The fuel tank filler pipe has a tethered fuel filler cap.
The cap requires a quarter of a turn to remove it.
A torque-limiting device prevents the cap from being

216242

The fuel sender assembly is inside the fuel tank

attached to the top of the fuel tank. The fuel sender
assembly consists of the following major components:
The fuel level sensor (3).
The fuel tank pressure sensor (1 ).
The fuel pump (7).
The fuel pressure regulator (8).
The fuel pump strainer (6) .

6-1878

Engine Controls - 5.7L

Engine

Fuel Pump

Fuel Pump Strainer

The fuel pump strainer attaches to the lower end of
the fuel pump and the lower end of the fuel return pipe.

The fuel pump strainer is made of woven plastic.

The functions of the fuel pump strainer are to
filter contaminants ahd to wick fuel. The fuel pump
strainer is self-cleaning and normally requires no
maintenance. Fuel stoppage at this point indicates that
the fuel tank contains an abhormal amount of
sediment or water. Clean the fuel tank and replace a
plugged fuel pump strainer with a new one.'

In-Line Fuel Filter

216242

The fuel pump (7) attaches to the fuel sender

:assembly inside the fuel tank. The fuel pump is an
electric high pressure gear rotor pump. The fuel pump
pumps fuel to the fuel rail assembly at a specified
flow and pressure. Excess fuel returns to the fuel tank
by the return pipe. The fuel pump delivers a constant
flow of fuel to the engine even during low fuel
conditions and aggressive vehicle maneuve.rs. The
PCM controls the electric fuel pump operation through
a fuel pump relay. The fuel pump flex pipe has a
quick-connect fitting. The fuel return hose attaches to
the fuel pressure regulator (8). The fuel pump flex
pipe acts to dampen the fuel pulses and noise
generated by the fuel pump.

Fuel Pressure Regulator Assembly

The fuel pressure regulator is a part of the fuel sender
assembly fuel return pipe. The fuel pressure regulator
is a diaphragm operated relief valve. A software
bias compensates the injector on-time because the
fuel pressure regulator is not referenced to manifold
vacuum. The fuel injector pulse width varies with
the signal from the MAP sensor. With the ignition ON
and the engine OFF, system fuel pressure at the
pressure test connection should be 380-41 O kPa
(55-60 psi). If the pressure is too low, poor
performance could result. If the pressure is too high,
excessive odor and a Diagnostic Trouble Code
(DTC) P0132, P0152, P0172 or P0175 may result.
Refer to Fuel System Diagnosis for information
on diagnosing fuel pressure conditions.

12628

The fuel feed pipe has a steel fuel filter installed

ahead of the fuel injection system. The paper filter
element (2) traps particles in the fuel that may damage
the injection system. The filter housing (1) is made
to withstand maximum fuel system pressure, exposure
to fuel additives, and changes in temperature. The
fuel filter has a quick-connect inlet fitting and a
threaded outlet fitting. The threaded fitting is sealed
with an 0-ring. There is no service interval for fuel filter
replacement. Replace a restricted fuel filter.

Fuel Feed and Return Pipes

The fuel feed pipe carries fuel from the fuel tank to the
fuel rail assembly. The fuel return pipe carries fuel
from the T-connector located on the outlet side of the
fuel filter back to the fuel tank. The fuel pipes
consist of three sections:
The rear fuel pipe assemblies are located from
the top of the fuel tank to the chassis fuel
pipes. The rear fuel pipes are constructed
of nylon.
The chassis fuel pipes are located under the
vehicle and connect the rear fuel pipes to
the engine compartment connecting .fuel pipe.
These pipes are constructed of steel.
The engine compartment connecting fuel pipe
connects the chassis fuel pipe to the engine
fuel rail. This fuel pipe is constructed of nylon.

\
I

',

Engine

Engine Controls - 5.7L 6-1879

Nylon Fuel Pipes

EVAP Pipes and Hoses

Caution: In order to Reduce the Risk of Fire and

Personal Injury:

The EV AP pipes extend from the fuel sender assembly

and the EVAP canister vent solenoid to the EVAP
canister. The EV AP purge pipe extends from the EV AP
canister to the EVAP purge valve in the engine
compartment. The rear pipes and the engine
compartment pipe are con.structed of nylon. The
chassis EVAP purge pipe is constructed of steel.

If nylon fuel pipes are nicked, scratched or

damaged during installation, Do Not attempt to
repair the sections of the nylon fuel pipes.
Replace them.
When installing new fuel pipes,. Do Not
hammer directly on the fuel harness body c/lps
as it may damage the nylon pipes resulting
in a possible fuel leak.

Enhanced Evaporative Emission (EVAP)

Service Port

Always co.ver nylon vapor pipes with a .wet

towel before using a torch near them. Also,
never expose the v~hicle to temperatures .
higher than 115C (239F} for more. than one
hour, or more than 90C (194F) for any
extended period.
Before connecting fuel pipe fittings,. always
apply a few drops of clean engine oil to
the male pipe ends. This will ensure proper
reconnection and prevent a possible fuel leak.
(During normal operation, the 0-rings
located in the female connecto,: will swell and
may prevent proper reconnection if not
lubricated.)

Nylon fuel pipes are designed to perform the same job

as the steel or flexible fuel pipes or hoses that they
replace. Nylon pipes are constructed to withstand
maximum fuel system pressure, exposure to
fuel additives, and changes in temperature. There are
three sizes of nylon pipes used: 3/& in ID for the
fuel feed, 5/16 in ID for the fuel return, and 1/2 in ID
for the vent. Heat resistant rubber hose and/or
corrugated plastic conduit protect the sections of the
pipes that are e~posed to chafing, high temperature or
vib.ration.
Nylon fuel pipes are somewhat flexible and can be

formed around, gradual turns under the vehicle.

However, if nylon fuel pipes are forced into sharp
bends, the pipes will kink and restrict the fuel
flow. Also, once exposed to fuel, nylon pipes may
become stiffer and are more likely to kink if bent too
far. Take special care when working on a vehicle with
nylon fuel pipes.

Quick-Connect Fittings
Quick-connect fittings provide a simplified means of
installing and connecting fuel system components. The
fittings consist of a unique female connector and a
compatible male pipe end. 0-rings, located inside the
female connector, provide the fuel seal. Integral
locking tabs or fingers hold the fittings together.

Fuel Pipe 0-Rings

0-rings seal the threaded connections in the fuel
system. Fuel system 0-ring seals are made of special
material. Service the 0-ring seals with the correct
service part.

21046

The enhanced EVAP service port is located in the

EVAP pipe in the engine compartment near the purge
solenoid. The service port is identified by a green
colored cap. The port contains a schrader valve and a
fitting to allow the connection of the J 41413 EVAP .
Pressure/Purge Diagnostic Station for diagnosis of the
evaporative emission system.

Fuel Metering Modes of Operation

Modes of Operation
The PCM looks at voltages from several sensors to
determine how much fuel to give the engine. The fuel
is delivered under one of several conditions called
modes. The PCM controls all modes.

Star:ting Mode
With the ignition switch in the ON position (before
engaging the starter), the PCM energizes the
fuel pump relay for two seconds allowing the fuel
pump to build.up pressure. The PCM first checks
speed density, then switches to the Mass Air Flow
(MAF) sensor. The PCM also uses the Engine Coolant
Temperature (ECT), Throttle Position (TP), and
Manifold Absolute Pressure (MAP) sensors to
determine the proper air/fuel ratio for starting. This
ranges from 1.5: 1 at -36C (-33F) to 14. 7: 1 at 94C
(201 F) running temperature. The PCM controls
the amount of fuel delivered in the starting mode by
changing the pulse width of the injectors. This is done
by pulsing the injectors for very short times.

6-1880

Engine

Engine Controls - 5.7L

Clear Flood Mode

Battery Voltage Correction Mode

If the engine floods, clear the engine by pushing the

accelerator pedal down all the way. The PCM
then pulses the injectors at an air/fuel ratio of 20:1.
The PCM holds this injector rate as long as the throttle
stays wide open and the engine speed is below
300 RPM. If the throttle position becomes less
than 80 percent, the PCM returns to the starting mode.

When battery voltage is low, the PCM compensates

for the weak spark delivered by the ignition system in
the following ways:

Run Mode

Fuel Cutoff Mode

The run mode has two conditions called Open Loop

and Closed Loop. When the engine is first started, and
engine speed is above a predetermined RPM, the
system begins Open Loop operation. The PCM ignores
the signal from the H02S and calculates the air/fuel
ratio based on inputs from the ECT, MAF, MAP,
and TP sensors. The system stays in Open Loop until
meeting the following conditions:

To prevent possible engine damage from over-speed,

the PCM cuts off fuel from the injectors when the
engine speed is above approximately 5800 RPM. Also,
see Rapid Deceleration in Deceleration Mode.

Both H02S have varying voltage output, showing

that they are hot enough to operate properly.
(This depends on temperature.)
The ECT sensor is above a specified temperature.
A specific amount of time has elapsed after
starting the engine.
Specific values for the above conditions exist for each
different engine, and are stored in the Electrically
Erasable Programmable Read Only Memory
(EEPROM). The system begins Closed Loop operation
after reaching these values. In Closed Loop, the
PCM calculates the air/fuel ratio (injector on-time)
based on the signal from various sensors, but mainly
the H02S. This allows the air/fuel ratio to stay
very close to 14. 7: 1.

Acceleration Mode
When the driver pushes on the accelerator pedal, air
flow into the cylinders increases rapidly, while fuel
flow tends to lag behind. To prevent possible
hesitation, the PCM increases the pulse width to the
injectors to provide extra fuel during acceleration.
The PCM determines the amount of fuel required
based on throttle position, coolant tempe.rature,
manifold air pressure, mass air flow and engine speed.

Deceleration Mode
When the driver releases the accelerator pedal, air
flow into the engine is reduced. The PCM looks at the
corresponding changes in throttle position, manifold
air pressure and mass air flow. The PCM shuts
OFF fuel completely if the deceleration is very rapid,
or for long periods (such as long closed throttle
coast-down). The fuel shuts OFF in order to protect
the warm-up three-way catalytic converters.

Increasing the amount of fuel delivered.

Increasing the idle RPM.
Increasing ignition dwell time.

Fuel Metering System Component

Description
The fuel metering system consists of the
following parts:
The fuel supply components (fuel tank,
pump, pipes).
The fuel pump electrical circuit.
The fuel rail.
The fuel injectors.
The fuel pressure regulator.
The throttle body.
The Idle Air Control (IAC) valve.
The Throttle Position (TP} sensor.

System Overview
The fuel tank stores the fuel supply. An electric fuel
pump, located in the fuel tank with the fuel sender
assembly, pumps fuel through an in-line fuel filter to
the fuel rail assembly. The pump provides fuel at
a pressure greater than is needed by the injectors. The
fuel pressure regulator, part of the fuel sender
assembly, keeps fuel available to the injectors at a
regulated pressure. A separate pipe returns unused
fuel to the fuel tank.

Fuel Pump Electrical Circuit

When the ignition switch is in the ON position (before
engaging the starter), the PCM energizes the fuel
pump relay for two seconds, cat,Jsing the fuel pump to
pressurize the fuel system. If the PCM does not
receive ignition reference pulses (engine cranking or
running) within two seconds, it shuts OFF the fuel
pump relay, causing the fuel pump to stop.

Engine

Engine Controls - 5.7L 6-1881

Fuel Rail Assembly

Fuel Pulse Dampener

216234

217109

It positions the injectors (1) in the intake manifold.

The fuel pulse dampener attaches inside a housing on

the fuel rail assembly. The fuel pulse dampener is
diaphragm operated, with fuel pump pressure on one
side and spring pressure on the other side. The
function of the dampener is to dampen fuel pulsation.

It distributes fuel evenly to the injectors.

Accelerator Controls

. It integrates the fuel pulse dampener (2) into the

fuel metering system.

The accelerator control system is cable operated.

There are no linkage adjustments, therefore use the
specific cable for each application.

The fuel rail assembly attaches to the engine intake

manifold. The fuel rail assembly performs the following
functions:

Fuel Injectors
The top-feed fuel injector assembly is a solenoid
operated device, controlled by the PCM, that meters
pressurized fuel to a single engine cylinder. The
PCM energizes the injector solenoid, which opens a
ball valve, allowing fuel to flow past the ball valve, and
through a recessed flow director plate. The director
plate has multiple machined holes that control the fuel
flow, generating a conical spray pattern of finely
atomized fuel at the injector tip. Fuel is directed at the
intake valve, causing it to become further atomized
and vaporized before entering the combustion
chamber. An injector stuck partly open can cause a
loss of pressure after engine shutdown. Consequently,
long cranking times would be noticed on some
engines.

6-1882

Engine Controls - 5.7L

Engine

Throttle Body Assembly

Idle Air Control (IAC) Valve

2
216232

The throttle body assembly attaches to the intake

manifold. The throttle body controls air flow into the
engine, thereby controlling engine output. The vehicle
operator opens the throttle valve within the throttle
body through the accelerator controls. During engine
idle, the throttle valves are almost closed. A fixed
air bypass orifice and the Idle Air Control. (IAC)
valve (2) handle the air flow control. Engine coolant
flows through the coolant cavity on the bottom of
the throttle body in order to prevent throttle valve icing
during cool weather operation. The throttle body
also provides the location for mounting the Throttle
Position (TP) sensor ( 1).

10172

The purpose of the IAC valve is to control engi_ne idle

speed, while preventing stalls due to changes in
engine load. The IAC valve (1 ), mounted in the throttle
body, controls the bypass air around the throttle
valve (2). By moving a conical valve known as a
pintle (3), in, towards the seat (to decrease air flow);
or out, away from the seat (to incre~se air flow), a
controlled amount of air can be bypassed. If engine
speed is too low, more air is bypassed to increase
RPM. If engine speed is too high, less air is bypassed
to decrease RPM. The PCM moves the IAC valve
in small steps, called counts. These can be measured
and displayed by a scan tool, which plugs into the
Data Link Connector (DLC). The PCM calculates the
proper position of the IAC valve during idle based
on battery voltage, coolant temperature, engine load,
and engine RPM. If the RPM drops below specification
and the throttle valve is closed, the PCM senses a
near stall condition and calculates a new valve position
in .order to prevent stalling.
Engine idle speed is a function of total air flow
into the engine. Idle speed is based on IAC
valve pintle position + crankcase ventilation valve
flow + throttle valve opening + bypass orifice
air flow + calibrated vacuum loss through
accessories.
Controlled idle speed is programmed into the
PCM, which determines the correct IAC valve
pintle position to maintain the desired idle speed
for all engine operating conditions and loads.

Engine
The minimum idle air rate is set at the factory with
a stop screw. This setting allows enough air flow
by the throttle valves to cause the IAC valve
pintle to be positioned a calibrated number
of steps (counts), from the seat, during controlled
idle operation.
If the IAC valve is disconnected and reconnected
with the engine running, the idle speed may be
wrong. If this occurs, reset the IAC valve by
depressing the accelerator pedal slightly, start and
run the engine for five seconds, then turn the
ignition OFF for ten seconds.

Throttle Position (TP) Sensor

The TP sensor attaches to the side of the throttle
body opposite the throttle lever. It senses the throttle
valve angle and relays that information to the
PCM. The PCM requires knowledge of throttle angle
to generate the required injector control signals
(pulses).

Short Term Fuel Trim Description

The short term fuel trim is a PCM erasable memory

register. The neutral value for the short term fuel trim is
0%. Any deviation from 0% indicates the short term
fuel trim is changing the injector pulse width. The
amount of pulse width change depends on how far the
short term fuel trim value is from 0%. The short
term fuel trim is rich when the scan tool indicates a
negative number. The short fuel trim is lean when the
scan tool indicates a number greater than 0. The
short term fuel trim changes the injector pulse width
by adding to or subtracting from the base pulse
width equation. As the PCM monitors the oxygen
sensors input, it is constantly varying the short term
fuel trim value. The value is updated very quickly,
therefore the short term fuel trim only corrects for short
term mixture trends. The correction of long term
mixture trends is the function of long term fuel trim.
When the PCM determines that the Short Term
Fuel Trim is out of the operating range, one of the
following DTCs will set:
DTC P0171 Fuel Trim System Lean Bank 1.
DTC P0172 Fuel Trim System Rich Bank 1.
DTC P0174 Fuel Trim System Lean Bank 2.
DTC P0175 Fuel Trim System Rich Bank 2.

Long Term Fuel Trim Description

The long term fuel trim is a matrix of cells arranged by
RPM and MAP. Each cell of t'1e long term fuel trim
is a register like the short term fuel trim. As the engine
operating conditions change, the PCM will switch
from cell to cell to determine what long term fuel trim
factor to use in the base pulse width equation.

Engine Controls - 5.7L 6-1883

While in any given cell, the PCM also monitors the
short term fuel trim. If the short term fuel trim is
far enough from 0%, the PCM will change the long
term fuel trim value. Once the long term fuel trim value
is changed, it should force the short term fuel trim
back toward 0%. If the mixture is still not correct (as
judged by the PCM), the short term fuel trim will
continue to have a large deviation from the ideal 0%.
In this case, the long term fuel trim value will
continue to change until the short term fuel trim
becomes balanced. Both the short term fuel trim and
long term fuel trim have limits which vary by
calibration. If the mixture is off enough so that long
term fuel trim reaches the limit of its control and
still cannot correct the condition, the short term fuel
trim would also go to its limit of control in the
same direction. If the mixture is still not corrected by
both short term fuel trim and long term fuel trim at their
extreme values, a Fuel Trim Diagnostic Trouble
Code (DTC) will likely result. When the PCM
determines that the Long Term Fuel Trim is out of the
operating range, the following DTCs will set:
DTC P0171 Fuel Trim System Lean Bank 1.
DTC P0172 Fuel Trim System Rich Bank 1.
DTC P0174 Fuel Trim System Lean Bank 2.
DTC P0175 Fuel Trim System Rich Bank 2.
Under the conditions of power enrichment, the PCM
sets the short term fuel trim to 0% and freezes it there
until power enrichment is no longer in effect. This is
done so the Closed Loop factor and the long term fuel
trim will not try to correct for the commanded
richness of power enrichment.

Speed Density System Description

_The speed density system is only needed when there
is a Mass Air Flow (MAF) sensor malfunction. If
the PCM detects a malfunction with the MAF sensor
circuit, the PCM will default to speed density fuel
management.
Three sensors provide the PCM with the basic
information for the fuel management portion of its
operation. That is, three specific signals to the PCM
establish the engine speed and air density factors. The
engine speed signal comes from the ignition system.
Air density is derived from IAT and MAP sensor
inputs. The IAT sensor measures the air temperature
that is entering the engine. The IAT signal works
in conjunction with the MAP sensor to determine air
density. As the intake manifold pressure increases, the
air density in the intake manifold also increases and
additional fuel is required. This information from
the IAT and MAP sensors is used by the PCM to
control injector pulse width.

6-1884

Engine Controls - 5.7L

Engine
EVAP Canister

EVAP Control System Operation

Description

i\

l}
~

.!],
@
@

II

ll...~::.::. ::.::.-_-_-A____ J_L_J

5
AIR FLOW FROM
AIR SEPARATOR

-+,

FUELVAPOR

---. PURGEDVAPOR

11795
12722

Legend
(1) Purge Line
(2) Vapor From Fuel Tank
(3) Air

The Evaporative Emission (EVAP) Control system

used on all vehicles is the charcoal canister storage
method. This method transfers fuel vapor from the fuel
tank to an activated carbon (charcoal) storage
device (canister) t.o hold the vapors when the vehicle
is not operating. When the engine is operating,
the fuel vapor i s ~ from the carbon element by
intake air flow and consumed in the normal combustion
\ process.

Legend
(1) Purge Tube to Solenoid
(2) Buffer Tube
(3) Charcoal Bed
(4) EVAP Charcoal Canister
(5) Volume Compensator
(6) Fresh Air Inlet from Air Separator
(7) Liquid Fuel Trap
(8) Vapor Tube from Fuel Tank

Engine Controls - 5.7L 6-1885

Engine
EVAP System
The evaporative system includes the following
components:
Fuel tank

---

Evaporative emission canister vent solenoid

Fuel tank pressure sensor
Fuel pipes and hoses

--------

--------<.

Vapor lines
Fuel cap
~ - - Evaporative emission canister
Purge lines
Purge valve solenoid

--~

EVAP System Operation

18839

The EVAP canister purge ~~e varies

according to the operating conditions determined by
the mass air flow, the fuel trim, the engine coolant
temperature, and the intake air temperature. For
certain EV AP tests, the diagnostic will be disabled if
the TP angle increases to above 75%.
The evaporative leak detection diagnostic strategy is
based on applying vacuum to the .EVAP system
and monitoring for vacuum decay.
The fuel level sensor input to the PCM is used to
determine if the fuel level in the tank is correct to run
the EVAP diagnostic tests. To ensure sufficient
volume in the tank to begin the various diagnostic
tests, the fuel level must be between ~J&%-

Results of Incorrect Operation

218763

The EVAP purge solenoid valve allows manifold

vacuum to purge the canister. The Powertrain Control
Module (PCM) supplies a ground to energize the
EVAP purge solenoid valve (purge on). The EVAP
purge solenoid control is Pulse Width Modulated
(PWM) or turned on and off several times a second.

Poor idle, stalling and poor driveability can be

caused by the following:
- Malfunctioning purge solenoid.
- Damaged canister.
- Hoses/lines split, cracked and/or not
connected properly.
Evidence of fuel loss or fuel vapor odor can be
caused by the following:
- Liquid fuel leaking from the fuel lines
- Cracked or damaged canister
- Inoperative canister control valve
- Vacuum hoses that are:
- Disconnected
- Mis-routed
- Kinked
- Deteriorated
- Damaged

6-1886

Engine Controls - 5.7L

Engine

228634

The evaporative leak detection diagnostic strategy is

based on applying vacuum to the EVAP system
and monitoring vacuum decay.
The PCM monitors vacuum level via the fuel tank
pressure sensor input. At an appropriate time,
the EVAP purge solenoid and the EVAP vent solenoid
are turned on, allowing engine vacuum to draw a
small vacuum on the entire evaporative emission
system. After the desired vacuum level has been
achieved, the EVAP purge solenoid is turned
off, sealing the system. A leak is detected by
monitoring tor a decrease in vacuum level over a
given time period, all other variables remaining
constant. A small. leak in the system causes
OTC P0442 to be set.
If the desired vqcuum level cannot be achieved in the
test described above, a large leak or afaulty EVAP
purge solenoid is indicated. This can be caused by the
following conditions:
Disconnected or faulty fuel tank pressure sensor.
Missing or faulty fuel cap.
Disconnected, damaged, pinched, or blocked
EVAP purge line.
Disconnected or damaged EVAP vent hose.
Disconnected, damaged, pinched, or blocked fuel
tank vapor line.
Disconnected or faulty EVAP canister solenoid.
Disconnected or faulty EVAP vent solenoid.
Open ignition feed circuit to the EVAP vent or
purge solenoid.
Damaged EVAP canister.

Any of the above conditions sets OTC P0440.

A restricted or blocked EVAP canister vent path is
detected by drawing vacuum into the EVAP system.
The PCM turns off the EV AP vent solenoid and
the EVAP purge solenoid (EVAP vent solenoid Open,
EVAP purge PWM 0%). The PCM monitors the
fuel tank pressure sensor input. With the EVAP vent
solenoid open, any vacuum in the system should
decrease quickly unless the vent is blocked. A
blockage is caused by the following conditions:
Faulty EVAP vent solenoid (stuck closed).
Plugged, kinked, or pinched vent hose.
Shorted EVAP vent solenoid driver circuit.
Plugged evaporative canister.
If any of the above conditions are present,
OTC P0446 sets.
The PCM tests for conditions that cause the EVAP
system to purge continuously by commanding
the EVAP vent solenoid on and the EV AP purge
solenoid off (EVAP vent solenoid CLOSED, EVAP
purge PWM O %). If fuel tank pressure level increases
during the test, a continuous purge flow condition is
indicated. This can be caused by the following
conditions:
EVAP purge solenoid leaking.
EVAP purge and engine vacuum source lines
switched at the EVAP purge solenoid.
EVAP purge solenoid driver circuit grounded.
If any of the above conditions are present,
OTC P1441 set&.
Refer to the appropriate DTCs for further diagnostic
procedures regarding the EVAP system.

Visual Check of Evaporative Emission

Canister
Cracked or damaged, replace the canister.
Fuel leaking from the canister, replace canister
and inspect lines and line routing.

Electronic Ignition System Description

Ignition System Overview
The electronic ignition system controls fuel combustion
by providing a spark to ignite the compressed
air/fuel mixture at the correct time. To provide optimum
engine performance, fuel economy, and control of
exhaust emissions, the PCM controls the spark
advance of the ignition system. The Electronic ignition
system has the following advantages over a
mechanical distributor system:
No moving parts.
Less maintenance.
Remote mounting capability.
No mechanical load on the engine.
More coil cool down time between firing events.
Elimination of mechanical timing adjustments.
Increased available ignition coil saturation time.

Engine Controls - 5.7L 6-1887

Engine
The electronic ignition system does not use the
conventional distributor and coil. The ignition system
consists of the following components/circuits:
Eight ignition coils/modules
Eight Ignition Control (1C) circuits
Camshaft Position (CMP) sensor
1X Camshaft reluctor wheel
Crankshaft Position (CKP) sensor
24X Crankshaft reluctor wheel
Related connecting wires
Powertrain Control Module (PCM)

Crankshaft Position Sensor and

Reluctor Wheel

Observe that as long as the PCM receives the

Crankshaft Position sensor 24X signal, the engine will
start. The PCM can determine top dead center for
all cylinders by using the Crankshaft Position sensor
24X signal alone. The Camshaft Position sensor
1X signal is used by the PCM to determine if
the cylinder at top dead center is on the firing stroke,
or the exhaust stroke. The system attempts
synchronization and looks for an increase in engine
speed indicating the engine started. If the PCM
does not detect an increase in engine speed, the PCM
assumes it incorrectly synchronized to the exhaust
stroke and re~synchronizes to the opposite cam
position. A slightly longer cranking time may be a
symptom of this condition.

Camshaft Position Sensor

65872
55308

The Crankshaft Position (CKP) sensor is located in

the right rear of the engine, behind the starter.
The CKP sensor is a dual magneto resistive type
sensor. This sensor is not speed dependent. The dual
micro switches monitor both notches of the reluctor
wheel for greater accuracy. The CKP sensor works in
conjunction with a 24X reluctor wheel. The reluctor
wheel is mounted on the rear of the crankshaft.
The 24X reluctor wheel uses two different width '
notches that are 15 degrees apart. This Pulse Width
Encoded pattern allows cylinder position identification
within 90 degrees of crankshaft rotation. In some
cases, cylinder identification can. be located in 45
degrees of crankshaft rotation. This reluctor wheel also
has dual track notches that are 180 degrees out of
phase. The dual track design allows for quicker starts
and accuracy.
The PCM also receives a 4X signal from the
Crankshaft Position sensor. The PCM utilizes the 4X
signal for the following:
Misfire
Tachometer output
Spark control
Fuel control
Certain diagnostics

The Camshaft Position (CMP) sensor is mounted

through the top of the engine block at the rear of the
valley cover. The CMP sensor works in conjunction
with a 1X reluctor wheel on the camshaft. The
CMP sensor is used to determine whether a cylinder
is on the firing or the exhaust stroke. As the
camshaft rotates, the reluctor wheel interrupts a
magnetic field produced by a magnet within the
sensor. The CMP sensor internal circuitry detects this
and produces a signal which is used by the PCM.
The PCM uses this signal in co.mbination with
the CKP 24X..signal to determine crankshaft position
and stroke.

6-1888

Engine Controls - 5.7L

Engine

Observe that as long as the PCM receives the

Crankshaft Position sensor 24X signal, the engine will
start. The PCM can determine top dead center for
all cylinders by using the Crankshaft Position sensor
24X signal alone. The Camshaft Position sensor
1X signal is used by the PCM to determine if
the cylinder at top dead center is on the firing stroke,
or the exhaust stroke. The system attempts
synchronization and looks for an increase in engine
speed indicating the engine started. If the PCM
does not detect an increase in engine speed, the PCM
assumes it incorrectly synchronized to the exhaust
stroke and re-synchronizes to the opposite cam
position. A slightly longer cranking time may be a
symptom of this condition.

j
)

Ignition Coils/Module

65292

The ignition feed circuits are fused separately for each

bank of the engine. The two fuses also supply
power to the injectors for that bank of.the engine.
Each coil/module is serviced separately.
This system puts out very high ignition energy for plug
firing. The ignition wires are shorter so less energy
is lost to ignition wire resistance. Also, since the firing
is sequential, each coil has seven ignition events
to saturate as opposed to the three in a waste spark
arrangement. Futhermore, no energy is lost to the
resistance of a waste spark system.

Circuits Affecting Ignition Control

To properly control ignition timing, the PCM relies on
the following information:
211648

The ignition system on this vehicle features a multiple

coil ignition and is known as coil near plug. The
secondary ignition wires are short compared with a
distributor ignition system wire. Eight ignition
coils/modules are individually mounted above each
cylinder on the rocker covers. The coils/modules
are fired sequentially. There is an Ignition Control (IC)
circuit for each ignition coil/module. The eight
ignition control circuits are connected to the PCM. All
ignition timing decisions are made by the PCM,
which triggers each coil/module individually. The
ignition coil/modules are supplied with the following
circuits:
Ignition feed circuit
Ignition control circuit
Ground circuit
Reference low circuit

Engine load (manifold pressure or vacuum)

Atmospheric (barometric) pressure
Engine temperature
Intake air temperature
Crankshaft position
Engine speed (RPM)
The Ignition Control (IC) system consists of the
following components:
Ignition coil/modules
24X crankshaft position sensor
Powertrain Control Module (PCM)
All connecting wires
The Ignition Control utilizes the following to control
spark timing functions:
24X signal - The 24X crankshaft position sensor
sends a signal to the PCM. The PCM uses this
signal to determine crankshaft position. The PCM
also utilizes this signal to trigger the fuel
injectors.
Ignition Control (IC} circuits - The PCM uses
these circuits to trigger the ignition coil/modules.
The PCM uses the crankshaft reference signal
to calculate the amount of spark advance needed.

Engine
Noteworthy Ignition Information

There are important considerations to point out when

servicing the ignition system. The following
Noteworthy Information will list some of these to help
the technician in servicing the ignition system.
The ignition coils secondary voltage output
capabilities are very high - more than 40,000 volts.
Avoid body contact with secondary high voltage
ignition components when the engine is running,
or personal injury may result!
The 24X crankshaft position sensor is the most
critical part of the ignition system. If the sensor
is damaged so that pulses are not generated, the
engine will not start!
Crankshaft position sensor clearance is very
important! The sensor must not contact the
rotating interrupter ring at any time, or sensor
damage will result. If the interrupter ring is bent,
the interrupter ring blades will destroy the sensor.
Ignition timing is not adjustable. There are
no timing marks on the crankshaft balancer or

timing chain cover.

Be careful not to damage the secondary ignition
wires or boots when servicing the ignition
system. Rotate each boot to dislodge it from the
plug or coil tower before pulling it from either .
a spark plug or the ignition coil. Never pierce a
secondary ignition wire or boot for any testing
purposes! Future problems are guaranteed
if pinpoints or test lights are pushed through the
insulation for testing.

Engine Controls - 5. 7L 6-1889

The PCM uses information from the engine coolant
temperature sensor in addition to RPM to calculate
spark advance values as follows:
High RPM = more advance
Cold engine = more advance
Low RPM = less advance
Hot engine = less advance
Therefore, detonation could be caused by high
resistance in the engine coolant temperature sensor
circuit. Poor performance could be caused by low
resistance in the engine coolant temperature sensor
circuit.
If the engine cranks but will not run or immediately
stalls, the Engine Cranks But Will Not Run diagnostic
table must be used to determine if the failure is in
the ignition system or the fuel system. If DTC P0300,
P0341 , P0342, P0343, P0335, P0336 is set, the
appropriate diagnostic trouble code table must be used
for diagnosis.

Knock Sensor Syste111 Description

Knock Sensor

Powertrain Control Module (PCM)

The PCM is responsible for maintaining proper spark
and fuel injection timing for all driving conditions.
To provide optimum driveability and.emissions, the
PCM monitors input signals from the following
components to calculate Ignition Control (IC) spark
timing:
The Engine Coolant Temperature (ECT) sensor.
The Intake Air Temperature (IAT) sensor.
The Mass Air Flow (MAF) sensor.
The Knock Sensor
The Trans Range inputs from Transaxle Range
switch.
The Throttle Position (TP) sensor.
The Vehicle Speed Sensor (VSS).

Results of Incorrect Operation

An Ignition control circuit that is open, grounded, or
shorted to voltage will set an ignition control circuit
DTC. If a fault occurs in the IC output circuit when the
engine is running, the engine will experience a
misfire. DTCs P0351-P0358 will set when a
malfunction is detected with an Ignition Control circuit.
When an Ignition control DTC sets, the PCM
disables the injector for the appropriate cylinder.

13635

Varying octane levels in gasoline can cause detonation

in some engines. Detonation is sometimes called
spark knock. Detonation is caused by an uncontrolled
explosion (burn) in the combustion chamber. This
uncontrolled explosion could produce a flame
front opposite that of the normal flame front produced
by the spark plug. The rattling sound normally
associated with detonation is the result of two or more
opposing pressures (flame fronts) colliding within
the combustion chamber. Though light detonation is
sometimes considered normal, heavy detonation could
result in engine damage.
To control spark knock, a Knock Sensor (KS) system
is used. This system is designed to retard spark
timing up to 20 degrees to reduce spark knock in the
engine. This allows the engine to use maximum
spark advance to improve driveability and fuel
economy.

6-1890

Engine Controls - 5.7L

Engine

The knock sensor system is used to detect engine

detonation. The knock sensor(s) produce an AC
voltage which is sent to the PCM. The PCM will retard
the spark timing based on signals from the KS
sensors. The amount of AC voltage produced by the
sensors is determined by the amount of knock.
The PCM then adjusts the Ignition Control (IC) to
reduce the spark knock.

Knock Sensor Cutaway

Secondary AIR Injection System

Description
The Secondary Air. Injection (AIR) system helps
reduce Hydrocarbon (HC), Carbon Monoxi.de (CO),
and Oxides of Nitrogen (NOx) exhaust emissions.
It also heats up the warm up 3-way catalytic
converters quickly on engine start-up so conversion of
exha;ust gases can occur sooner.
The system includes the following:
AIR pump - The AIR pump is mounted to the
lower left front of the engine Compartment
and supplies the air to the AIR system. The
electric air pump pressurizes fresh air and pumps
it to the check valves near the exhaust manifolds.
The AIR pump is controlled by the PCM.
Battery voltage to the Al R pump is controlled by
the AIR pump relay. An integral stop valve,
prevents air flow through the pump during OFF
periods. When the PCM provides a ground ci.rcuit
for the secondary AIR pump relay, battery
voltage is allowed to power up the Al R pump and

integral stop valve.

13690

Legend
(1) Shunt Resistor
(2) Piezo Crystal

The scan tool has several positions for diagnosing the

KS circuit.
Knock Retard indicates the amount of spark the
PCM is removing from the IC spark advance in
response to the signal from the knock sensors.
Spark indicates the amount of spark advance
being commanded by the PCM on the IC circuit.
OTC P0325 indicates an internal PCM malfunction
related to the KS system. OTCs P0327 and
P0332 indicates that a Knock sensor or Knock sensor
circuit is malfunctioning. If these DTCs are set,
Refer to applicable OTC table.

Vacuum Bleed Valve - This valve helps prevent

vacuum buildup within the Al.A system, which
could prevent the integral stop valve from opening.
The bleed valve is controlled by the air pump
relay and is energized when the AIR pump
is commanded ON. If the vacuum relief system is
not functioning, the vacuum will cause the AIR
pump integral stop valve not to open. This
may result in no air flow to the exhaust manifolds
or delay the delive.ry of air which may not allow '
the diagnostic to pass.
Check valves - The check valves prevent back
flow of exhaust gases into the Al R pump. in
the event of an exhaust backfire.
Necessary plumbing.
- Hoses
- Pipes
- Clamps

Engine

Engine Controls - 5.7L

AIR System (Typical)

@7

...............;

6-1891

MAP is greater than 96 kPa with VSS over

60 mph.

MAP is less than 20 kPa.

c:

ECT less than -10C (14F).

3-way catalytic converters over temperature
detected.
Short and long term fuel trim are not in the
normal range .
Power enrichment is detected.

Results of Incorrect Operation

If no air (oxygen) flow enters the exhaust stream at
the exhaust ports, HC and CO emission levels will be
too high.

Air flowing to the exhaust ports at all times could

increase temperature of the warm up 3-way catalytic
converter.

424996

Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)

Intake Manifold
Exhaust Manifold
Check Valve
AIR Injection Hose
From Air Cleaner Assem.bly
AIR Pump
Vacuum Bleed Valve
Check Valve
Exhaust Manifold

The AIR pump with iritegral stop valve is controlled by

the PCM. The PCM will turn ON the AIR pump by
providing the ground to c9mplete the circuit which
energizes the AIR.pump relay. When air to the exhaust
ports is desired, the PCM will turn ON the integral
stop valve and then the AIR pump.
The PCM turns ON the AIR pump during startup any
time engine coolant temperature is above -10c
(14F). The AIR.pump operates tor a maximum of
240 seconds, or until the system ,enters Closed Loop
operation. At the same time the PCM turns the
AIR pump OFF, it also de-energizes the integral stop
valve solenoid so no air is directed to the
exhaust ports.
The AIR system will be disabled under the following

conditions:
When the PCM recognizes a condition and sets a
diagnostic trouble code.
When the fuel system is operating in Closed Loop.
The AIR pump has been ON for 240 seconds.

Engine Speed is greater than 2825 RPM.

Diagnostic Trouble Codes P0410, P0412, P1415, and

P1416 will set if there is a malfunction in the
following components:
The AIR pump.
The AIR pump relay.
Hoses or pipes that are leaking.
The Check valves that are leaking.
Circuits going to the AIR pump and the AIR
pump relay.
The vacuum bleed valve.

AIR Pump
The AIR pump is a regenerative turbine type which is
permanently lubricated and requires no periodic
maintenance.
The engine should be at normal operating temperature
in neutral at idle. Using the scan tool enable the AIR
pump system. Select H02S voltages tor both
Bank 1 and Bank 2 H02S. The H02S voltages tor
both sensors should remain under 350 mV because air
is being directed to the exhaust ports. It the H02S
voltages remain low during the Output Test, the AIR
pump and integral stop valve are operating
satisfactorily. It the H02S voltage does not remain low
when the AIR pump is enabled, inspect tor the
following:
For voltage at the Air Pump when it is energized.
For a seized AIR pump.
Hoses, pipes and all connections for leaks and
proper routing.
For air flow going to the exhaust ports.
AIR pump tor proper mounting.
Hoses and Pipes tor deterioration or holes.

6-1892

Engine Controls - 5.7L

Engine

EGR System Description

Operation

EGR Valve

)
2

~---3

~---4

11696
14441

Purpose
An Exhaust Gas Recirculation (EGR) system is used
in order to lower Oxides of Nitrogen (NOx) emission
levels. The EGR system accomplishes this by feeding
small amounts of exhaust gas back into the
combustion chamber. High combustion temperatures
cause NOx. Combustion temperatures are reduced
when the air/fuel mixture is diluted with the
exhaust gases.

Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)

Cap-Sensor
Sensor-EGR Pintle Position
Pole Piece-Primary
Bobbin and Coil Assembly
Sleeve-Armature
Valve-Pintle
Armature and Base Assembly

The EGR valve is designed to accurately supply

exhaust gases to the engine without the use of intake
manifold vacuum. The EGR valve controls the
exhaust flow into the intake manifold from the exhaust
manifold through an orifice with a PCM controlled
pintle. The PCM controls the pintle position using
inputs from the Engine Coolant Temperature (ECT}
sensor, the Throttle Position (TP) sensor, and the
Manifold Absolute Pressure (MAP) sensor. The PCM
commands the EGR valve in order to supply the
correct amount of exhaust gas recirculation for the
current engine operating conditions. This can be
monitored on a scan tool as the Desired EGR Position.
The PCM monitors the position of the EGR valve
through a feedback signal. The PCM supplies
a 5.0 volt reference and a ground to the EGR valve. A
voltage signal representing the EGR valve pintle
position is sent to the PCM from the EGR valve. This
feedt;>ack signal can also be monitored on a scan
tool and is the actual position of the EGR pintle. The
Actual EGR Position should always be near the
commanded or Desired EGR Position.

Engine

Engine Controls - 5.7L 6-1893

The EGR valve is usually activated under the following

conditions:
The engine is warm.
The engine is above the idle speed.

Diagnosis

+__

11699

Legend
(1)
(2)
(3)
(4)

Linear EGR Valve

Exhaust Gas
To Cylinders
Pintle

Too much EGR flow causes any of the following

conditions to occur:
The engine stalls after a cold start.
The engine stalls during closed throttle conditions.
The vehicle surges during a cruise condition.
A rough idle.
A OTC P0300 (misfire detected).
Too little or no EGR flow allows the combustion
temperatures to increase. This causes the following
symptoms:
Spark knock (detonation)
Engine overheating
Emission test failure
OTC P0401
Poor fuel economy
The EGR flow diagnosis is included in the OTC P0401
diagnostic table. The EGR pintle position and the
EGR valve control circuit diagnosis are covered
in OTCs P0404, P0405, and P1404. Go to the
appropriate OTC table for diagnosis if an EGR
diagnostic trouble code is stored.

\.

Crankcase Ventilation System Description

A closed crankcase ventilation system is used to
provide a more complete scavenging of crankcase
vapors. Fresh air from the thrott.le body is supplied to
the crankcase, mixed with blow-by gases and
then passed through a crankcase ventilation valve into
the intake manifold.
The primary control is through the crankcase
ventilation valve which meters the flow at a rate
depending on manifold vacuum. To maintain idle
quality, the crankcase ventilation valve restricts the
flow when intake manifold vacuum is high. If abnormal
operating conditions arise, the system is designed
to allow excessive amounts of blow-by gases to back
flow through the crankcase vent tube into the
engine air inlet to be consumed by normal combustion.
The engine ventilation system was developed to
minimize oil consumption and ensure that oil ingestion
could not occur during vehicle limit handling
maneuverers. Filtered fresh air is routed from up
stream of the throttle blade to the front of the right
rocker cover via a formed rubber hose. To reduce the
potential of oil pullover into the throttle bore area
due to back flow of the ventilation system, the fitting in
the right side rocker cover is located between a
shield from the rocker arms. Blowby gases are routed
from the rear of both rocker covers, through molded
nylon lines to a tee fitting located on the centerline of
the engine at the rear of the intake manifold. From
there, a single nylon line carries the foul air gases
through an externally mounted, horizontal PCV valve
and enters the intake manifold behind the
throttle body.
The dual draw system was develop to meet the limited
handling maneuver requirements. During sustained
maximum lateral accelerations, the outboard
rocker cover may fill with oil. The dual draw system
passively switches, allowing the PCV valve to draw on
the rocker cover with the least resistance. This
results in the system drawing on the air filled, or
inboard rocker cover and eliminates oil pullover due to
drawing on the oil-filled outboard rocker cover.

6-1894

Engine Controls - 5.7L

Engine

Crankcase Ventilation System Routing

2

PCV Cutaway
PCV Cutaway

4
256919

Legend
(1 )
(2}
(3)
. (4)

13636

Throttle Body
Fresh air
PCV Valve
Return air

Legend
(1) Check Valve

Results of Incorrect Operation

A plugged PCV valve or hol'!e may cau.se:
Rough idle.
Stalling or slow idle speed.
Oil leaks.
Sludge in engine.
.
A leaking valve or hose would cause:
Rough idle.
Stalling.
High idle speed.

Engine

Engine Controls 5.7L 6~1895

Air Intake System Description

Air Cleaner Location

(
218754

Legend
(1) Air Cleaner Housing
The air intake system draws' outside air through the
front of the remotely mounted air'cleaner assembly (1)
and filter element. The air is then routed through
the MAF sensor and then into the throttl.e body to the

intake manifold. The air is then directed into the intake

manifold runners, through cylinder heads and into
the cylinders.

6-1896

Engine Controls - 5.7L

Engine

Air Cleaner Housing and Resonator

11

10

247788

Legend

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)

Air cleaner housing top cover

Seal
Air intake duct to resonator
Clamp
Air intake duct to top cover retainer
Intake Air Temperature (IAT) sensor
Clamp
Air intake resonator

If the Mass Air Flow (MAF) sensor is installed

backwards, the system will go rich. An arrow cast into
the plastic portion of the sensor indicates proper air
flow direction. The arrow must point toward the engine.

(9)
(10)
(11)
(12)
(13)
(14)
(15)

Air intake duct to throttle body

Mass Airflow (MAF) sensor
Isolator
Air cleaner housing lower assembly
Front retaining clips
Air filter element frame
Air filter element

Engine Controls - 5.7L 6~1897

Engine

Special Tools and Equipment

Illustration

Illustration

Tool Number/Description

Tool Number/Description

J 34142-B
Test Light

J 34730-405
Injector Test Light
5382

385603

J 23738-A
Vacuum Pump

J 39200
Digital Multi-meter
5386

3430

J 39194-B

Oxygen Sensor Wrench

J 34730-E
Fuel Pressure Gauge Kit
5388

5377

J 34730-1A
Fuel Pressure Gauge

J 26792
Spark Tester
5389

5381

Tech 2 Kit 7000081

50062

6-1898

Engine

Engine Controls - 5.7L

IUustration

Tool Number/Description

Tool Number/Description

Illustration

J 33431-8
Signal Generator and
Instrument Panel Tester

J 35689-A
Metri-Pack Terminal Kit

5395

9194

J 28742,A
Weather Pack Terminal
Remover

5396

J37287
Inlet and Return Fuel Line
Shut-off Adapters

13541

J 37027-A
IAC Motor Analyzer

5399

J 39021
Fuel Injector Coil/Balance
Tester

5380

J 35616-A
Connector Test Adapter Kit

8917

J 39021~380
Fuel Injector Test Harness

385606

J35314-A
Exhaust Back Pressure
Tester

13544

J 37088-A
Fuel Line Quick Connect
Separator

12366

Engine

Engine Controls - 5.7L 6-1899

Illustration

Tool Number/Description

Illustration

Tool Number/Description

J 41413

J 41416

Pressure/Purge Diagnostic
Station

227620

Ultrasonic Leak Detector

69758

6-1900

Engine

Engine Exhaust

Engine Exhaust
Specifications

)
Fastener Tightening Specifications

Application
Catalytic Converter Hanger Bolt
Catalytic Converter Heat Shield Bolt
Catalytic Converter Bolt
Crossover Pipe Nut
Exhaust Heat Shield Bolt
Exhaust Manifold Pipe Bolt
Exhaust Muffler Clamp Bolt
Exhaust Muffler Hanger Bolt
Exhaust Muffler Heat Shield Bolt
Exhaust Pipe Hanger Nut
Exhaust Pipe Hanger Bracket Bolt
Exhaust Pipe Heat Shield Bolt
Heated Oxygen Sensor

Nm

Lbs Ft

41
2.0
25
35
2.0
35
68
9.5
2.0
20
9.5
2.0
42

30

Lbs In

18

18
26

18

26
50

84
18

15

84
18

31

GM SPO Group Numbers

GM SPO Group Number

Application

3.690
3.705
3.701
3.705
3.609
3.616
3.705
3.682
3.682
3.685

Catalytic Converter Heat Shield

Exhaust Heat Shield
Exhaust Muffler
Exhaust Muffler Heat Shield
Exhaust Pipe
Exhaust Pipe Heat Shield
Exhaust Tail Pipe Extension
Heated Oxygen Sensor
Oxidation Catalytic Converter
Three Way Catalytic Converter (With Exhaust Manifold Pipe)

Diagnostic Information and Procedures

Internal Muffler Rattles/Loss of Power
Step

Action

Value(s)

Remove the muffler.

Visually inspect the muffler.
Is there a restriction in the muffler?

Replace the muffler. Refer to Muffler Replacement Muffler

Replacement
Does the vehicle still have a loss of power and/or internal
rattles?

Inspect the catalytic converter.

Is the honeycomb broken in the catalytic converter?

Replace the catalytic converter. For the three-way catalytic

converter, refer to Catalytic Converter Replacement
Catalytic Converter Replacement
For the oxidation catalytic converter, refer to Oxidation
Catalytic Converter Replacement (Left) Oxidation Catalytic
Converter Replacement (Left) or Oxidation Catalytic
Converter Replacement (Right) Oxidation Catalytic
Converter Replacement (Right).
Does the vehicle still have a loss of power and/or internal
rattles?

Yes

No

Go to Step 2

Go to Step 3

Go to Step 3

System OK

Go to Step 4

System OK

System OK

Engine

Engine Exhaust 6-1901

Exhaust Leakage

Action

Step

Value(s)

Check for a leaks .at the pipe joints.

Are there any leaks?

Tighten the fasteners at the leaking joint(s) to

specifications. Refer to Fastener Tightening Specifications
Are there still a leaks?

Yes

Go to Step 2

No
-

System OK

Exhaust Noise
Step

Action

When cold and after a warmup, check for heat shields that
contact the exhaust pipes.
Are the heat shields misaligned or loose?
Tighten the heat shield fasteners to the value given.
Is there still exhaust noise?

Check for leaks at the manifold or the pipe connections.

Are there leaks?

Tighten the leaking connections according to

specifications. Refer to Fastener Tightening Specifications
Is there still a exhaust noise?

Inspect the muffler.

Is the muffler burned or.blown out?

2 Nm .(18 lb in)

Replace the muffler.

Is there still exhaust noise?

Look for a burned or rusted exhaust pipe.

Is the exhaust pipe burned or rusted?

Replace the muffler.

Is there still exhaust noise?

Check for a leak at the exhaust crossover pipe at the

manifold flange.

,.

10

Repair the leak.

Is there still exhaust noise?

11

Check for a cracked or broken manifold.

Is the manifold cracked or broken?

12

Replace the manifold. Refer to Exhaust Manifold

Replacement in Engine Mechanical.
Is there still exhaust noise?

Check for a leak between the manifold and the

cylinder head.
Is there a leak?

Tighten the manifold-to-cylinder head fasteners to

specifications.
Is there still exhaust noise?

14

No

Go to Step 2

Go to Step 3

Go to Step 3

System OK

Go to Step 4

Go to Step 5

Go to Step 5

System OK

Go to Step 6

Go to Step 7

Go to Step 7

System OK

Go to Step B

Go to Step 9

Go to Step 9

System OK

Go to Step 10

Go to Step 11

Go to Step 11

System OK

Go to Step 12

Go to Step 13

Go to Step 13

System OK

Is there a leak?

13

Yes

Value(s)

Go to Step 14

System OK

6-1902

Engine Exhaust

Engine

Repair Instructions
Catalytic Converter Replacement
Removal Procedure
1.. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Remove the exhaust manifold pipe bolts at the
exhaust manifolds.

222949

3. Disconnect the electrical connector from the

heated oxygen sensor.

222946

Engine

Eingine Exhaust .6-1903

4. Remove the heated oxygen sensor from the

. 3 way catalytic converter.

222948

.5. Loosen the muffler clamp bolt at the 3 way

catalytic converter.
6. Remove the 3 way catalytic converter from the
exhaust muffler.

21662

7. Remove the catalytic converter hanger bolts.

8. Remove the catalytic converter hanger from the
3 way catalytic converter.

21664

6-1904

Engine Exhaust

Engine
Installation Procedure
1. Install the catalytic converter hanger to the 3 way
catalytic converter.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the catalytic converter hanger bolts.

Tighten
Tighten the catalytic converter hanger bolts to
41 N,m (30 lb ft).

21664

3. Install the 3 way catalytic converter to the exhaust

muffler.
4. Tighten the exhaust muffler clamp bolt at the
3 way catalytic converter.
Tighten
Tighten the exhaust muffler clamp bolt to
68 Nm (50 lb ft).

21662

5. Install the exhaust manifold pipe bolts at the

exhaust manifolds.
5.1. Loosely install the exhaust manifold pipe
bolts to the manifolds.
5.2. Tighten the bolts to specifications
alternating back and forth from the right to
the left manifold flanges.
Tighten
Tighten the exhaust manifold pipe bolts to
35 N-m (26 lb ft).

222949

Engine

Engine Exhaust 6-1905

6. Install the heated oxygen sensor to the 3 way

catalytic converter.

Tighten
Tighten the heated oxygen sensor to
42 N-m (31 lb ft).

222948

7. Connect the heated oxygen sensor electrical

connector.
8. Lower the vehicle.

222946

Oxidation Catalytic Converter

Replacement (Left )
Removal Procedure
1 . Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Disconnect the heated oxygen sensor electrical
connector.

222951

6-1906 Engine Exhaust

Engine
3. Remove the heated oxygen sensor from the left
oxidation catalytic converter:

222952

4. Remove the exhaust manifold pipe nuts to the

exhaust manifold.

220599

5. Remove the catalytic converter nuts attaching the

left oxidation catalytic converter to.the right
converter.
6. Remove the left oxidation catalytic converter from
the vehicle.

220600

Engine

Engine Exhaust 6-1901

Installation Procedure
1. Install the left oxidation catalytic converter to the
vehicle.

Notice: Refer to Fastener Notice in Cautions and

Notices.
2. Install the catalytic converter nuts attaching the
left oxidation catalytic converter to the right
converter.
Tighten
Tighten the catalytic converter nuts to
25 N-m (18 lb ft).

220600

3. Install the exh{lust manifold pipe nurs to the.

exhaust manifold.

Tighten
Tighten the exhaust manifold pipe nuts to
.35 Nm (26 lb ft).

220599

4. Install the heated oxygen sensor to the left

oxidation catalytic converter.

Tighten
Tighten the heated oxygen sensor to
42 N-m (31 lb ft).

222952

6-1908

Engine Exhaust

Engine
5. Connect the heated oxygen sensor electrical
connector.
6. Lower the vehicle.

222951

Oxidation Catalytic Converter

Replacement (Right)
Removal Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Disconnect the heated oxygen sensor electrical
connector.

222953

3. Remove the heated oxygen sensor from the right

oxidation catalytic converter.

222954

Engine

Engine Exhaust 6-1909

4. Disconnect the rear heated oxygen sensor

rosebud clip from the transmission brace.
5. Disconnect the rear heated oxygen sensor
electrical connector.

222955

6. Remove the rear heated oxygen sensor from

behind the right oxidation catalytic converter.

222964

7. Remove the exhaust manifold pipe nuts to the

right exhaust manifold.

220594

6-191 O Engine Exhaust

Engine
8. Remove the catalytic converter nuts attaching the
right oxidation catalytic converter to the left
converter.

220600

9. Remove the catalytic converter hanger bolts.

10. Remove the catalytic converter hanger from the
hanger bracket.

222969

11. Loosen the exhaust muffler clamp attaching the

right oxidation catalytic converter to the exhaust
muffler.
12. Reposition the muffler clamp.
13. Remove the right oxidation catalytic converter by
sliding the converter out of the exhaust muffler.

222968

Engine

Engine Exha;ust

6-1911

Installation Procedure

1. Install the right oxidation catalytic converter by

sliding the converter into the exhaust muffler.
2. Position the muffler clamp.

Notice: Refer to Fastener Notice ir, Cautions a:nd

Notices.
3. Tighten the exhaust muffler clamp attaching the
right oxidation catalytic converter to the exhaust
muffler.
Tighten
Tighten the exhaust muffler clamp bolt to
68 Nm (50 lb ft).

222968

4. Install the' catalytic converter hanger to the hanger

bracket.
5. Install the catalytic converter hanger bolts.

Tighten
Tighten the catalytic converter hanger bolts to
41 Nm (30 lb ft).

222969

6. Install the exhaust manifold pipe nuts to the

exhaust manifold.
TightenTighten the exhaust manifold pipe bolts to
35 Nm (26 lb ft).

220594

6-1912

Engine Exhaust

Engine
7. Install the catalytic converter nuts attaching the
right oxidation catalytic converter to the left
converter.

Tighten
Tighten the catalytic converter nuts to
25 N-m (18 lb ft).

220600

8. Install the heated oxygen sensor behind the right

oxidation catalytic converter.
Tighten
Tighten the heated oxygen sensor to
42 N-m (31 lb ft).

222964

9. Connect the rear heated oxygen sensor electrical

connector.
10. Connect the rear heated oxygen sensor rosebud
clip from the transmission brace.

222955

Engine

Engine Exhaust 6-1913

11. Install the heated oxygen sensor to the right

oxidation catalytic converter.
Tighten
Tighten the heated oxygen sensor to
42 Nm (31 lb ft).

222954

12. Connect the oxygen sensor electrical connector.

13. Lower the vehicle.

222953

Muffler Replacement
Removal Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Remove the drivers side rear tire.
3. Support the rear axle with jack stands.

222971

6-1914

Engine Exhaust

Engine
4. Remove the passenger side rear stabilizer bar
end link.

222972

5. Disconnect the passenger side rear shock from

the rear axle.
6. Remove the rear track bar. Refer to Track Bar
Replacement in Rear Suspension.

222973

7. Remove the torque arm bolts at the rear axle.

8. Lower the rear axle slightly.

222974

Engine

Engine Exhaust 6-1915

9. Remove the passenger side rear coil spring and

bushing.

222975

10. Loosen the exhaust muffler clamp attaching the

exhaust muffler to the right catalytic converter.

11 . Reposition the exhaust muffler clamp.

12. Lower the axle completely.
13. Remove the muffler by rotating the assembly
while sliding the muffler out from the rear of
the vehicle.

222968

Installation Procedure
1. Install the exhaust muffler to the vehicle.
2. Raise the axle slightly.
3. Position the exhaust muffler clamp.
Notice: Refer to Fastener Notice in Cautions and
Notices.
4. Tighten the exhaust muffler clamp attaching the
muffler to the right catalytic converter.
Tighten
Tighten the exhaust muffler clamp bolt to
68 Nm (50 lb ft).

222968

6-1916

Engine Exhaust

Engine
5. Install the passenger side rear coil spring and
bushing.

222975

6. Raise. the axle completely.

7. lnstaffthe torque arm bolts at the rear axle.
Tighten
Tighten the torque arm bolts to
130 Nm (96 lb ft).
Tighten to torque arm nuts to
132 Nm (97 lb ft).
8. Install the rear track bar. Refer to Track Bar
Replacement in Rear Suspension.

222974

9. Connect the passenger side rear shock to the

rear axle.
Tighten
Tighten the reqr shock nuts 'to 90 N-m (66 lb ft).

222973

Engine

Engine Exhaust

6-1917

10. Connect the passenger side rear stabilizer bar

end link.
Tighten
Tighten the end link nut to 17 N,m (131b ft).
11 . Remove the rear axle support.

222972

12. Install the drivers side rear tire

Tighten
Tighten the wheel nuts to 120 N-m (89 lb ft).

222971

Converter Hanger Assembly Replacement

(3.SL Automatic}
Removal Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Support the catalytic converter.
3. Remove the catalytic converter hanger bolts.
4. Remove the catalytic converter hanger from the
front hanger bracket.

21664

Engine

6-1918 Engine Exhaust

5. Remove the rear axle torque arm nuts.

6. Remove the rear axle torque arm inner

bracket bolts.

7. Remove the catalytic converter front hanger

bracket from the vehicle.

222998

Installation Procedure
1. Install the catalytic converter front hanger bracket
to the vehicle.
2. Install the rear axle torque arm inner bracket bolts.

Notice: Refer to Fastener Notice in Cautions and

Notices.
3. Install the rear axle torque arm nuts.
Tighten
Tighten the rear axle torque arm nuts to
45 N-m (33 lb ft).

222998

4. Install the catalytic converter hanger to the front

hanger bracket.
5. Install the catalytic converter hanger bolts.
Tighten
Tighten the catalytic converter hanger bolts to
41 Nm (30 lb ft).
6. Remove the support from the catalytic converter.
7. Lower the vehicle.

21664

Engine

Engine Exhaust

6-1919

Converter Hanger Assembly Replacement

(5.7L Auto/Man)

Removal Procedure
1. Raise and suitaply support ,the vehicle. Referto
Lifting and Jacking the Vehicle in General
Information.

''

2. Support the catalytic converter.

3. Remove the catalytic converter hanger bolts.
4. Remove the hanger from the bracket.

222969

5. Remove the rearaxle torque arm bracket nuts: >

6. Remove the catalytic convert~r hanger bracket/

222993

Installation Procedure
1 . Install the catalytic converter hanger to the
bracket.
2. Install the catalytic converter bracket to the rear
axle torque arm inner bracket.

Notice: Refer to Fastener Notice in Cautions and

Notices.
3. Install the rear axle torque arm bracket nuts.
Tighten
Tighten the rear axle torque arm bracket nut to
41 N-m (30 lb ft).

21624

6-1920

Engine Exhaust

Engine
4. Install the catalytic c.onverter hanger bolts.
Tighten
Tighten the converter hanger bolts to
41 Nm (30 lb ft).
5. Remove the support from the catalytic converter.
6. Lower the vehicle.

21685

Converter Hanger Assembly

Replacement (3.SL Man)
Removal Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Support the catalytic converter.
3. Remove the catalytic converter hanger bolts.
4. Remove the hanger from the bracket.

"
'~

"

21664

222996

5. Remove the rear axle torque arm bracket nuts.

6. Remove the catalytic converter front hanger
bracket.

\,

Engine

Engine Exhaust 6-1921

Installation Procedure
1. Install the catalytic converter front hanger bracket.

Notice: Refer to Fastener Notice in Cautions and

Notices.
2. Install the rear axle torque arm bracket nuts.

Tighten
Tighten the rear axle torque arm bracket nut to
45 N-m (33 lb ft)

222996

3. Install the hanger to the bracket.

4. Install the catalytic converter hanger bolts.
Tighten
Tighten the converter hanger bolts to
41 N-m (30 lb ft)
5. Remove the support from the catalytic converter.
6. Lower the vehicle.

21664

Exhaust Muffler Hangers

Replacement (3.SL V6)
Removal Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Support the exhaust muffler.
3. Remove the exhaust muffler hanger bolts.

222976

6-1922

Engine Exhaust

Engine
4. Remove the exhaust muffler rubber-hanger from
the muffler.

222982

Installation Procedure
1. Install the exhaust muffler rubber hanger to the
muffler.

222982

Notice: Refer to Fastener. Notice in,;Ca\,Jtions and .,

Notices.

2. Install the exhaust muffler hanger bolts.

Tighten
.
Tighten the. exhaust muffler hanger bolts to
9.5 Nm (84 lb in).
3. Remove the exhaust muffler support.
4. Lower the vehicle.

222976

Engine Exhaust 6~1923

Engine
Exhaust Muffler Hangers
Replacement (5. 7L VS)
(

Removal Procedure
1. Raise and suitably support the vehicle .. Refer to .
Lifting and Jacking the Vehicle in General
Information.
2. Support the exhaust muffler.
3. Remove the exhaust pipe hanger nut.

222989

4. Remove the exhaust pipe hanger bracket bolts.

5. Remove the exhaust muffler interior hanger
bracket.

2220n

Installation Procedure
1. Install the exhaust muffler interior hanger bracket.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the exhaust pipe hanger bracket bolts.

Tighten
Tighten the exhaust pipe hanger bracket bolts to
9.5 N-m (84 lb in).

(
222977

6-1924

Engine Exhaust

Engine
3. Install the exhaust pipe hanger nut.
Tighten
Tighten the exhaust pipe hanger nut to
20 N-m (15 lb ft).
4. Remove the support from the exhaust muffler.
5. Lower the vehicle.

222989

Converter Heat Shield Replacement

Removal Procedure
1. Remove the catalytic converter. Refer to Catalytic
Converter Replacement or Oxidation Catalytic
Converter Replacement (Right).
2. Remove the catalytic converter heat shield bolts.
3. Remove the catalytic converter heat shield.

223001

Installation Procedure
1. lnstall,the catalytic converter heat shield.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the converter heat shield bolts.
Tighten
Tighten the catalytic converter heat shield bolts to
2 Nm (18 lb in).
3. Install the catalytic converter. Refer to Catalytic
Converter Replacement or Oxidation Catalytic
Converter Replacement (Right).

223001

Engine

Engine Exhaust 61925

Exhaust Heat Shield Replacement

Removal Procedure
1. Remove the catalytic converter. Refer to Catalytic
Converter Replacement or Oxidation Catalytic
Converter Replacement (Right).
2. Remove the exhaust heat shield bolt.

223003

3. Unhook the exhaust heat shield from the converter

heat shield.
4. Remove the exhaust heat shield.

223006

Installation Procedure
1. Install the exhaust heat shield.
2. Hook the exhaust heat shield to the converter
heat shield.

223006

6-1926

Engine Exhaust

Engine
Notice: Refer to Fasten.er Notice in Cautions and
Notices.

3. Install the exhaust heat shield .bolt.

Tighten
Tighten the exhaust heat shield bolt to
2.0 N-m (18 lb in).
4. Install the catalytic converter. Refer to Catalytic
Converter Replacement or Oxidation Catalytic
Converter Replacement (Right).

223003

Exhaust Pipe and Muffler Heat Shields

Replacement
Removal Procedure
1. Remove the exhaust muffler. Refer to Muffler
Replacement.
2. Remove the exhaust pipe heat shield bolts.
3. Remove the exhaust pipe heat shield.

21701

4. Remove the exhaust muffler heat shield bolts.

223008

Engine

Engine Exhaust 6-1927

5. Remove the exhaust muffler heat shield bolt.

223010

6. Remove the exhaust muffler heat shield bolts and

bracket.

7. Remove the exhaust muffler heat shield.

223012

Installation Procedure
Install the exhaust muffler heat shield.
Notice: R~fer ,to Fastener Notice in Cautions ~nd
Notices.
Install the exhaust muffler heat shield bracket
and bolts.
,
Tighten
Tighten the muffler heat shield bolts to
2.0 N-m (18 lb in).

(
223012

6-1928

Engine Exhaust

Engine
Install the exhaust muffler heat shield bolt.
Tighten
Tighten the exhaust muffler heat shield bolt to
2.0 N-m (18 lb in).

223010

Install the exhaust muffler heat shield bolts.

Tighten
Tighten the muffler heat shield bolts to
2.0 N-m (18 lb in).

223008

Install the exhaust pipe heat shield.

Install the exhaust pipe heat shield bolts.
Tighten
Tighten the exhaust pipe heat shield bolts to
2.0 N-m (18 lb in).

Install the exhaust muffler. Refer to Muffler

Replacement.

21701

Engine Exhaust 6-1929

Engine

Description and Operation

Exhaust System Description

Catalytic Converter

Notice: In order to prevent overheating of the floor

panel or damage to the passenger compartment,
insulation, and trim materials, check the underbody for
adequate clearance when inspecting or replacing
the exhaust system components.
The 3.8L (VIN K) engine equipped vehicles without
RPO Y87 (performance enhancement package)
use the following components:
A three-way catalytic converter
A single outlet exhaust muffler
The 3.8L (VIN K) engine equipped vehicles with
RPO Y87 use the following components:
A three-way catalytic converter
A dual outlet muffler
The 5.7L (VIN G) engine equipped vehicles use the
following components:
A dual three-way plus oxidation catalytic converter
(oxidation catalytic converter)
A dual outlet muffler
Periodic maintenance of the exhaust system is not
required. If the vehicle is raised for other service,
check the condition of the complete exhaust system.
Inspect the complete exhaust system, nearby body
parts, and the rear compartment lid for the following
conditions:
Broken or damaged parts
Mispositioned or missing parts
Open seams
Holes
Loose connections
Other deterioration that could permit exhaust
fumes to seep into the rear compartment or
the passenger compartment.
Check the rear compartment for dust or water, which
may indicate a problem in this area.
Correct any faulty areas immediately.

Caution: Prolonged operation of a misfiring or

flooded engine may cause the catalytic converter
to overheat. Damage to the catalyst, the operating
vehicle, or personal injury may result.
Notice: When jacking or lifting the vehicle from the
frame side rails, be certain that the lift pads do
not contact the catalytic converter. This may damage
the converter.
Notice: In order to avoid damage to the catalyst, use
unleaded fuel only.
The catalytic converter is an emission control device
added to the exhaust system in order to reduce
pollutants from the exhaust gas stream.
The three-way catalytic converter burns three types of
exhaust gases:
Carbon monoxide (CO)
Hydrocarbons (HC)
Oxides of nitrogen (NOx)
The oxidation catalytic converter burns the same
gases, but uses an air pump/smog pump to force
added oxygen into the catalytic converter. The
additional oxygen forces the converter to run hotter
and to burn exhaust gases more effectively.
A single bed ceramic monolith style brick catalytic
converter is used in combination with two types
of catalyst
Oxidation catalyst
Three-way (reduction/oxidation) catalyst
The catalysts have coatings that contain platinum and
palladium. These coatings burn the unwanted
exhaust emissions.

Exhaust Muffler
The exhaust muffler is a tri-flow design.
V6 engines without RPOs Y87 use a single outlet
muffler.
V6 engines with RPO Y87 use a dual outlet
muffler.
The 5.7L (VIN G) engine uses the dual outlet muffler.

6-1930

Engine

Engine Exhaust

Hangers
Important: The installation of the exhaust system
hangers is very important, as improperly installed
hangers can cause annoying vibrations that can be
difficult to diagnose.
The type of hanger used to support the exhaust
system on this vehicle is a conventional rubber block.
The rubber block is a rigid hanger with a feature
that supports the exhaust system in case a rubber
block is broken.

Clamps and Welded Connections

Caution: Exhaust may enter the vehicle and cause
personal injury if the slip joints are not coated
with exhaust system sealer before assembly.
There are no welded connections on this exhaust
system. There is one slip joint that joins the catalytic
converter to the muffler. One clamp connects the
exhaust system slip joint.
The type of clamp used to connect the exhaust
system slip joint is a single nut compression clamp.

On-Vehicle Service and Component

Replacement
Exhaust system service includes the replacement of
the following items:
The c;atalytic converter
The catalytic converter and the exhaust muffler
hangers
The complete exhaust system
The exhaust heat shield
The exhaust muffler

Exhaust System Clearance Dimensions

Make all checking dimensions on a cold exhaust
system.
If the specified dimensions cannot be met, there is a
quality deficiency in a component. Correct the
deficiency.

Table of Contents

Transmission!Transaxle

7-1

Section 7

Transmission/Transaxle
Manual Transmiss.ion - M49 ...........................7-5
Specifications .................................................. 7-5
Fastener Tightening Specifications ................. 7-5
Lubrication Specifications ...............................7-5
Diagnostic Information and Procedures ......... 7-5
Transmission Shifts Hard ...............................7-5
Gear Clash When Shifting Gears ................... 7-6
Transmission Noisy ........................................7-6
Transmission Jumps Out of Gear ., ................ 7-6
Transmission Does Not Shift into One Gear ...... 7-7
Transmission Locked in One Gear ................. 7-7
Repair Instructions .......................................... 7-8
Manual Transmission Fluid Level Check ........ 7-8
Transmission Support and Mount Assembly ... 7-9
Control Assembly .........................................7-11
Control Lever Boot Assembly ....................... 7-12
Shift Control Closeout Boot Replacement ..... 7-13
Shift Control Knob Replacement .................. 7-14
Mainshaft Rear Oil Seal ...............................7-14
Backup Lamp Switch Replacement .............. 7-15
Vehicle Speed Sensor ........................ , ........ 7-17
Transmission Oil Drain and Fill .................... 7-18
Transmission Replacement (Removal) .......... 7-19
Transmission Replacement (Installation) ....... 7-22
Description and Operation ............................7-26
Manual Transmission ...................................7-26
Special Tools and Equipment ....................... 7-27

Manual Transmission - MM6 ............... ,........ 7-28

Specifications ................................................7-28
Fastener Tightening Specifications ............... 7-28
Lubrication Specifications ............................. 7-28
Diagnostic Information and Procedures ....... 7-28
Transmission Shifts Hard .............................7-28
Transmission Shifts Hard into Reverse ......... 7-29
Gear Clash When Shifting Gears ................. 7-29
Transmission Noisy ...................................... 7-30
Transmission Jumps Out of Gear ................. 7-30
Transmission Does Not Shift into
One Gear ................................................. 7-30
Transmission Locked in One Gear ............... 7-31
Clunk on Acceleration or Deceleration .......... 7-31
Oil Leak Diagnosis .......................................7-32
Repair Instructions ........................................7-33
Manual Transmission Fluid Level Check ...... 7-33
Transmission Support and Mount Assembly ... 7-34
Control Assembly ......................................... 7-36
Control Lever Boot Assembly ....................... 7-37

Shift Control Closeout Boot Replacement ..... 7-38

Control Lever Handle Assembly ................... 7-39
Shift Control Knob Replacement .................. 7-40
Mainshaft Rear Oil Seal ...............................7-41
Backup Lamp Switch Replacement .............. 7-41
Vehicle Speed Sensor .................................7-43
Reverse Lockout Solenoid ............................ 7-44
Gear SelecVSkip Shift Solenoid
Replacement ............................................7-45
Transmission Oil Drain and Fill .................... 7-46
Transmission Vent Tube Replacement ......... 7-47
Transmission Replacement (Removal) .......... 7-47
Transmission Replacement (Installation) ....... 7-51
Description and Operation ............................7-54
Manual Transmission ................................... 7-54
Special Tools and Equipment ....................... 7-55

Automatic Transmission - 4L60-E ............... 7-56

Specifications ................................................7-56
Temperature vs Resistance .......................... 7-56
Fastener Tightening Specifications
(Unit Repair) .............................................7-56
Scan Tool Data Value Examples (3.8L) ....... 7-57
Scan Tool Data Value Examples (5.7L) ....... 7-58
Transmission Scan Tool Data
Definitions (3.8L) ...................................... 7-60
Transmission Scan Tool Data
Definitions (5.7L) ......................................7-62
Diagnostic Trouble Code
Identification (3.8L) ...................................7-65
Diagnostic Trouble Code
Identification (5.7L) ...................................7-67
Fluid Capacity ..............................................7-69
Range Reference .........................................7-70
Shift Solenoid Valve State and Gear Ratio ... 7-70
Shift Speed ..................................................7-70
TFP Manual Valve Position Switch Logic ..... 7-71
Line Pressure ..............................................7-71
Diagnostic Information and Procedures ....... 7-72
Functional Test Procedure ........................... 7-72
Schematic and Routing Diagrams ................ 7-73
Automatic Transmission Schematic
References ...............................................7-73
Automatic Transmission Schematic Icons ..... 7-73
Automatic Transmission Controls
Schematics ...............................................7-74

7-2

Table of Contents

Component Locator .......................................7-79

Automatic Transmission
Components (VIN K) ................................7-79
Automatic Transmission
Components (VIN G) ................................7-81
Automatic Transmission Electronic
Component Views (Internal) ...................... 7-83
AT lnline Harness Connector End View ....... 7-84
Visual Identification ....................................... 7-85
AT Internal Connector End Views ................ 7-85
Diagnostic Information and Procedures ....... 7-87
OTC P0218 Transmission Fluid
Overtemperature (3.8L) ............................. 7-87
OTC P0218 Transmission Fluid
Overtemperature (5.7L) .............................7-89
OTC P0502 Vehicle Speed Sensor Circuit
Low Input (3.8L) ....................................... 7-92
OTC P0502 Vehicle Speed Sensor Circuit
Low Input (5.7L) ...................................... .7-95
OTC P0503 Vehicle Speed Sensor Circuit
Intermittent (3.8L) ..................................... 7-98
OTC P0503 Vehicle Speed Sensor Circuit
Intermittent (5.7L) ...................................7-101
OTC P0711 TFT Sensor Circuit Range/
Performance (3.8L) ................................. 7-104
OTC P0711 TFT Sensor Circuit Range/
Performance (5.7L) ................................. 7-108
OTC P0712 Transmission Fluid
Temperature (TFT) Sensor Circuit Low
Input (3.8L) .............................................7-112
OTC P0712 Transmission Fluid
Temperature (TFT) Sensor Circuit Low
Input (5.7L) ............................................. 7-116
OTC P0713 Transmission Fluid
Temperature (TFT) Sensor Circuit High
Input (3.8L) .............................................7-120
OTC P0713 Transmission Fluid
Temperature (TFT) Sensor Circuit High
Input (5.7L) .............................................7-124
OTC P0719 Brake Switch Circuit Low
Input (3.8L) ............................................. 7-128
OTC P0719 Brake Switch Circuit Low
Input (5.7L) .............................................7-131
OTC P0724 Brake Switch Circuit High
Input (3.8L) ............................................. 7-134
OTC P0724 Brake Switch Circuit High
Input (5.7L) .............................................7-136
OTC P0740 TCC Enable Solenoid Circuit
Electrical (3.8L) ........................................ 7-138
OTC P0740 TCC Enable Solenoid Circuit
Electrical (5.7L) .......................................7-141
OTC P0742 TCC System Stuck On (3.8L) .... 7-144
OTC P0742 TCC System Stuck On (5.7L) .... 7-147
OTC P0748 Pressure Control Solenoid
Circuit Electrical (3.8L) ............................7-150
OTC P0748 Pressure Control Solenoid
Circuit Electrical (5.7L) ............................ 7-154
OTC P0751 1-2 Shift Solenoid Valve
Performance (3.8L) .................................7-158
OTC P0751 1-2 Shift Solenoid Valve
Performance (5.7L) ................................. 7-161

Transmission/Transaxle
OTC P0753 1-2 Shift Solenoid Circuit
_ Electrical (3.8L) .......................................7-164
OTC P0753 1-2 Shift Solenoid Circuit
Electrical (5.7L) .......................................7-168
OTC P0756 2-3 Shift Solenoid Valve
Performance (3.8L) ................................. 7-172
OTC P0756 2-3 Shift Solenoid Valve
Performance (5.7L) .................................7-175
OTC P0758 2-3 Shift Solenoid Circuit
Electrical (3.8L) ....................................... 7-178
OTC P0758 2-3 Shift Solenoid Circuit
Electrical (5.7L) .................. ,..... , .............. 7-182
OTC P0.785 3-2 Shift Solenoid Circuit
Electrical (3.8L) .......................................7-186
OTC P0785 3-2 Shift Solenoid Circuit
Electrical (5.7L) ....................................... 7-190
OTC P1810 TFP Valve Position Switch
Circuit (3.8L) ........................................... 7-194
OTC P1810 TFP Valve Position Switch
Circuit (5.7L) ...........................................7-198
OTC P1860 TCC PWM Solenoid Circuit
Electrical (3.8L) ................... , ................... 7-202
OTC P1860 TCC PWM Solenoid Circuit
Electrical (5.7L) ....................................... 7-206
OTC P1870 Transmission Component
Slipping (3.8L) ........................................7-210
OTC P1870 Transmission Component
Slipping (5.7L) ........................................7-215
2nd Gear Start Switch and Indicator Lamp
Circuit Check (3.8L Only) ........................ 7-220
Transmission Fluid Checking Procedure ..... 7-222
Line Pressure Check Procedure ................. 7-223
Electrical/Garage Shift Procedure ............... 7-224
Road Test Procedure .................................7-224
Noise and Vibration Analysis ...................... 7-226
Flexplate/Torque Converter Vibration Test .... 7-226
Torque Converter Clutch Diagnosis ............ 7-226
Torque Converter Clutch Shudder .............. 7-227
AT Wiring Harness Check .......................... 7-228
Component Resistance ..............................7-230
TFP Manual Valve Position Switch
Resistance Check ...................................7-231
Electronic Component Malfunctions ............ 7-233
Oil Pressure High or Low ...........................7-234
Harsh Shifts ............................................... 7-234
Inaccurate Shift Points ............................... 7-235
1st Gear Range Only - No Upshift ............. 7-235
Slips in 1st Gear ........................................7-235
Slipping or Rough 1-2 Shift ........................ 7-236
No 2-3 Shift or 2-3 Shift Slips, Rough or
Hunting ...................................................7-236
2nd/3rd Gear Only or 1sV4th Gears Only ... 7-237
Third Gear Only .........................................7-237
3-2 Flare or Tie-Up ....................................7-237
No 3-4 Shift, Slips or Rough 3-4 Shift ........ 7-237
No Reverse or Slips in Reverse ................. 7-238
No Part Throttle or Delayed Downshifts ..... 7-238
Harsh Garage Shift .................................... 7-239
No Overrun Braking - Manual 3-2-1 ........... 7-239

f"\

Transmission/Transaxle

No TCC Apply ...........................................7-239

Torque Converter Clutch Shudder .............. 7-240
No TCC Release .......................................7-240
Drives in Neutral ........................................7-240
2nd Gear Start ...........................................7-240
No Park .....................................................7-240
Oil Out the Vent ........................................7-241
Vibration in Reverse and Whining Noise
in Park ...................................................7-241
Ratcheting Noise ........................................7-241
No Drive in All Ranges .............................. 7-241
No Drive in Drive Range ............................ 7-241
Front Oil Leak ............................................ 7-241
Delay in Drive and Reverse ....................... 7-241
Fluid Leak Diagnosis and Repair ............... 7-242
Repair Instructions ......................................7-244
Parts Cleaning and Inspection .................... 7-244
BTSI Solenoid Replacement ....................... 7-245
Park Lock Cable Replacement ................... 7-246
Shift Cable Replacement ............................ 7-249
Floor Shift Control Replacement ................. 7-252
Park/Neutral Position Switch Replacement ... 7-253
AT Fluid/Filter Changing ............................. 7-255
Oil Cooler Line Replacement ..................... 7-258
2-4 Servo ...................................................7-266
Pressure Regulator Replacement ............... 7-269
Filler Tube Replacement (V8) ..................... 7-271
Filler Tube Replacement (V6) ..................... 7-273
Torque Converter Cover
Replacement (V8) ...................................7-275
Torque Converter Cover
Replacement (V6) ...................................7-276
Valve Body and Pressure Switch
Replacement ...........................................7-278
Control and Shift Solenoids Replacement ... 7-284
TCC PWM Solenoid, TCC Solenoid,
and Wiring Harness ................................7-287
Extension Housing Rear Oil Seal ............... 7-291
Case Extension Assembly .......................... 7-292
Accumulator Assembly ...............................7-294
Vehicle Speed Sensor Replacement ........... 7-299
Transmission Replacement (5.7L) ............... 7-301
Transmission Replacement (3.8L) ............... 7-307
AT Oil Cooler Flushing ...............................7-314
Do Not Use Air Tools ................................7-315
Description and Operation .......................... 7-316
Transmission ID Information .......................7-316
Transmission General Information .............. 7-317
Preliminary Checking Procedure ................. 7-317
Transmission Fluid Checking Procedure ..... 7-317

Table of Contents

7-3

Automatic Transmission Diagnosis ............. 7-318

Electronic Component Description .............. 7-319
Torque Converter Clutch Electrical
Controls ..................................................7-322
Electrical Connector ...................................7-323
Component Locator .....................................7-324
Transmission Component Location ............. 7-324
Special Tools and Equipment ..................... 7-356

Clutch .............................................................7-359
Specifications ..............................................7-359
Fastener Tightening Specifications ............. 7-359
Sealers and Lubricants ..............................7-359
Diagnostic Information and Procedures ..... 7-359
Preliminary Checking Procedure ................. 7-359
Clutch Spin Down Time .............................7-360
Clutch Does Not Disengage ....................... 7-360
Clutch Slipping ...........................................7-361
Clutch Grabbing ........................................ 7-361
Clutch Rattle (Trans Click) ......................... 7-362
Release Bearing Noisy with Clutch
Engaged .................................................7-362
Clutch Noisy During Engagement ............... 7-363
Pedal Stays on Floor (Clutch Disengaged) .... 7-363
Clutch Pedal Hard to Push ........................ 7-363
Clutch Pedal Spongy .................................7-364
Squeaky Clutch Pedal ................................ 7-364
Rapid Driven Plate Wear ........................... 7-365
Repair Instructions ...................................... 7-366
Clutch Pedal Replacement ......................... 7-366
Clutch Master Cylinder Replacement .......... 7-371
Clutch Actuator Cylinder Replacement ........ 7-373
Hydraulic Clutch Bleeding .......................... 7-374
Clutch Anticipate Switch Replacement ........ 7-375
Clutch Pedal Position Switch Replacement ... 7-376
Clutch Housing Replacement ..................... 7-378
Pilot Bearing Replacement ......................... 7-378
Clutch Pressure Plate and Clutch Driven
Plate (3.8L) ............................................7-379
Clutch Pressure Plate and Clutch Driven
Plate (5.7L) ............................................ 7-380
Clutch Pressure Plate Adjustment
(Off Vehicle (5.7L Only)) ......................... 7-381
Release Bearing Replacement ................... 7-382
Description and Operation .......................... 7-383
Principal Components ................................7-383
Clutch Driving Members ............................. 7-383
Clutch Driven Members ..............................7-383
Clutch Operating Members ......................... 7-383
Special Tools and Equipment ..................... 7-384

Transmission/Transaxle

7-4 Table of Contents

BLANK

Transmission!Transaxle

Manual Transmission - M49

7-5

Manual Transmission - M49

Specifications
Fastener Tightening Specifications.
Specification
Application
Backup Lamp Switch
Clutch Actuator Cylinder Bolts
Flywheel Housing Bolt~/Nuts
Flywheel Housing Cover Bolts
Shift Control Closeout Boot Bolts
Shift Control Knob

English

Metric
38Nm

28 lb ft
71 lb in
70 lb ft

8Nm
95Nm

801bin
18 lb in

9Nm
2Nm
3Nm
10Nm
75Nm
28Nm
SONm
SONm
27Nm
17Nm
48Nm
57Nm

Speed Sensor Bolt

Transmission Bolts
Transmission Brace Bolts (left side to engine)
Transmission Brace Bolts (left side to transmission)
Transmission Brace Bolts (right side)
Transmission Case Drain/Fill Plug
Transmission Control Lever Bolts
Transmission Mount Bolts
Transmission Mount Nut
Transmission Support Bolts
Wiring Harness Clip Bolt

.,

271!:> in
891bin
55 lb ft
21 lb ft
37 lb ft
37 lb ft
20 lb ft
13 lb ft
35 lb ft
42 lb ft
42 lbft
971b in

57Nm
11 Nm

Lubrication Specifications

Application

Liters

Dexron Ill, IIE

Gallons

Quarts

4.1

3.9

Diagnostic Information and Procedures

Transmission Shifts Hard
Probable Cause

The clutch pedal travel is incorrect.

Air is in the clutch hydraulic system.

The transmission shift control is
binding or damaged.
The transmission contains the
incorrect type of transmission fluid.

Action

1. Check for a clutch pedal restriction.

2. Remove any restrictions from the clutch pedal.
3. Ensure that the driver is fully depressing the clutch.
Bleed the air from the clutch hydraulic system. Refer to Hydraulic Clutch Bleeding in
Clutch.
1. Remove the transmission shift control.
2. Inspect the transmission shift control and replace if necessary. Refer to Control
.
Assembly.
Drain the transmission fluid, then fill the transmission with the correct type of fluid.
Refer to Transmission Oil Drain and Fill.

The clutch pressure plate and/or

clutch driven plate are defective.

1. Inspect the clutch pressure plate and clutch driver plate.

2. Replace the clutch pressure plate and/or the clutch. driven plate, if necessary.
Refer to Clutch Pressure Plate and Clutch Driven Plate (3.BL) in Clutch.

There is an internal bind in the

transmission, caused by the shift
forks, selector plates, or
synchronizers.

1. Remove the transmission. Refer to Transmission Replacement (Removal).

2. Disassemble and inspect the transmission.
3. Replace worn or damaged components as necessary. Refer to
Transmission/Transaxle/Transfer Case Unit Repair Manual.
4. Install the transmission. Refer to Transmission Replacement (Installation).

7-6

Manual Transmission - M49

Transmission!Transaxle

Gear Clash When Shifting Gears

Probable Cause
The clutch is not fully releasing
(disengaging)
Air is in the clutch hydraulic system.

Action
Verify that the clutch is releasing properly.

Refer to Clutch Spin Down Time in Clutch.

Bleed the air from the clutch hydrG1,ulic system.
Refer to Hydraulic Clutch Bleeding in Clutch.

The transmission shift control is worn

or damaged.

1. Remove the transmission shift control.

2. Inspect the shift control and replace if necessary.
Refer to Control Assembly.

The transmission fluid level is low.

Inspect the transmission fluid level and add the proper fluid as necessary.
Refer to Transmission Oil Drain and Fill.

The transmission contains the

incorrect type of transmission fluid.

Drain the transmission fluid, then fill with the transmission with the correct type
of.fluid.
Refer to Transmission Oil Drain and Fill.

The transmission gearshift

components or synchronizers are
worn or damaged.

1. Remove the transmission.

Refer to Transmission Replacement. (Removal)

2. Disassemble and inspecrthe transmission for worn or damaged gearshift or

synchronizers

Replace worn or damaged components as necessary.

Refer to the Transmission/Transaxle/Transfer Case Unit Repair Manual.

3. Install the transmission.

Refer to Transmission Replacement (Installation).

Transmission Noisy

Probable Cause
The transmission fluid level is low.

Action

Inspect the transmission fluid level and add the proper fluid as necessary.
Refer to Transmission Oil Drain and Fill.

The transmission contains the

incorrect type of transmission fluid.
The transmission shift control
closeout boot is loose or damaged.

Drain the transmission fluid, then fill the transmission with the correct type of fluid.
Refer to Transmission Oil Drain and Fill.

1. Inspect the transmission shift control closeout boot.

2. Position and tighten the closeout boot to specification, or replace the boot as
necessary.
Refer to Shift Control Closeout Boot Replacement.

The transmission gear or bearing

components are worn or damaged.

1. Remove the transmission.

Refer to Transmission Replacement (Removal).
.2. Disassemble and inspect the transmission .
3. Replace worn or damaged components as necessary.
Refer to the Transmission/Transaxle/Transfer Case Unit Repair Manual.
4. Install the transmission.
Refer to Transmission Replacement (Installation).

Transmission Jumps Out of Gear

Probable Cause

Action

DEFINITION: Gear disengagement occurs during normal operation.

The transmission shift control
closeout boot is not positioned
correctly.

1. Inspect the transmission shift control closeout boot positioning.

2. Reposition or replace the closeout boot, if necessary.
Refer to Shift Control Closeout Boot Replacement

The transmission shift control is loose

or damaged.

1. Remove the transmission shift control.

2. Inspect the shift control and replace if necessary.
Refer to Control Assembly.

Manual Transmission - .M49

TransmissionfTransaxle

7-7

Transmission Jumps Out of Gear (cont'd)

Probable Cause

Action

The engine and/or transmission

mounts are loose or damaged.

1. Inspect the engine mounts.

2. Tighten to specifications or replace as necessary.

s:

Refer to Engine Mount Replacement

Inspect the transmission mount.

4. Tighten to specifications or replace as necessary.

Refer to Transmission Support and Mount Assembly.
The clutch housing is loose or
misaligned.

1.
2.
3.
4.

The transmission has worn or

damaged internal components.

1. Remove the transmission.

Inspect the clutch housing bolts,

Tighten to specifications or replace as necessary.
Inspect the clutch housing positioning.
Reposition or replace the clutc.h housing, if necessary.

Refer to Transmission Replacement (Removal).

2. Disassemble the transmission and inspect the internal components for wear or
damage.
Refer to the Transmission!Transaxle!Transfer Case Unit Repair Manual.
3. Install the transmission.
Refer to Transmission Replacement (Installation).

Transmission Does Not Shift into One Gear

Probable Cause
The transmission shift control is worn,
binding or damaged.

Action

1. Remove the transmission shift control.

2. Inspect the shift control and replace if necessary.
Refer to Control Assembly.

Damaged or worn synchronizers.

1. Remove the transmission.

Refer to Transmission Replacement (Removal).

2. Disassemble and inspect the transmission.

3. Replace worn or damaged components as necessary.
Refer to Transmission!Transaxle!Transfer Case Unit Repair Manual.

4. Install the transmission.

Refer to Transmission Replacement (Installation).

Transmission Locked in One Gear

Probable Cause
There is an internal bind in the
transmission caused by a shift fork.

Action

1. Remove the transmission.

Refer to Transmission Replacement (Removal).

2. Disassemble and inspect the transmission for a dented or damaged shift fork.
Replace worn or damaged components as necessary.
Refer to the Transmission!Transaxle!Transfer Case Unit Repair Manual.

3. Install the transmision.

Refer to Transmission Replacement (Installation).
Incorrectly assembled or broken shift
mechanism or damaged geartrain
components.

1. Remove the transmission.

Refer to Transmission Replacement (Removal).
2. Disassemble and inspect the transmission.
Replace worn or damaged components as necessary.
Refer to the Transmission!Transaxle!Transfer Case Unit Repair Manual.

3. !nsta!! the transmision.

Refer to Transmission Replacement (Installation).

7-8

Transmission/Transaxle

Manual Transmission - M49

Repair lnstructio.ns
. Manual Transmission Fluid level Check
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Clean any dirt from around the fill plug.
3. Remove the transmission case fill plug.

71531

4. Check that the transmission fluid level is even

with the bottom ot the fill plug hole.
5. Add Dexron-111 transmi$sion fluid, if necessary.

2327

Transmission/Transaxle

Manual Transmission - M49

7-9

Notice: Refer to Fastener Notice in Cautions and

Notices.

6. Install the transmission case fill plug.

Tighten
Tighten the transmission case fill plug to
27 Nm (20 lb ft).
7. Lower the vehicle.

71531

Transmission Support and Mount .

Assembly
Removal Procedure

1. Raise and suitably support the vehicle. Refer to

Lifting and Jacking the Vehicle in General
Information.
2. Support tfle vehicle with safety stands.
3. Support the transmission with a
transmission stand.
4. Remove the transmission mount nut (2).

441398

5. Remove the transmission support bolts (2).

6. Remove the. transmission support (1 ).

(
441395

7-10

Manual Transmission - M49

Trarismission/Transaxle
7. Remove the transmission mount bolts.

8. Remove the transmission mount.

33323

Installation Procedure
1. Install the transmission mount
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the transmission mount bolts.

Tighten
Tighten the transmission mount bolts to
48 N,m (36 lb ft).

33323

3. Install the transmission support (1 ).

4. Install the transmission support bolts (2).
Tighten
Tighten the transmission support bolts (2) to
57 Nm (43 lb ft).

441395

Transmission/Transaxle

Manual Transmission .. M49

7..11

5. Install the transmission mount nut (2).

Tighten
Tighten the transmission mount nut (2) to
57 N-m (43 lb ft).
6. Remove the support from the transmission.
7. Remove the vehicle safety stands.
8. Lower the vehicle.

441398

Control Assembly
Removal Procedure
1. Remove the control lever boot. Refer to Control
Lever Boot Assembly.
2. Remove transmission control bolts.

33330

3. Clean the old sealant from the extension housing

and the transmission control sealing surface.

33331

7-12

Manual Transmission - M49

Transmission!Transaxle
Installation Procedure
1. Apply a continuous 3 mm (0.125 in) bead of RTV
sealant on the extension housing-to-control
sealing surface. Use GM P/N 12345739 or
equivalent.

38411

Notice: Refer to Fastener Notice in Cautions and

Notices.

2. Install the transmission control bolts.

Tighten
Tighten the transmission control lever bolts to
17 Nm (13 lb ft).
3. Install the control lever boot. Refer to Control
Lever Boot Assembly

33330

Control Lever Boot Assembly

1

Removal Procedure
1. Remove the shift control closeout boot. Refer to
Shift Control Closeout Boot Replacement.
2. Remove the control lever boot retainer (3).
3. Remove the control lever boot (1) from the
control (2).

471876

Transmission!Transaxle

Manual Transmission - M49 7-13

Installation Procedure
1. Install the control lever boot (1) to the control (2).
2. Install the control lever boot retainer (3).
3. Install the shift control clos.eout boot. Refer to
Shift Control Closeout Boot Replacement.

471876

Shift Control Closeout Boot Replacement

Removal Procedure
1. Remove the front floor console. Refer to Console
Replacement - Front Floor in Instrument Panel,
Gauges and Console.
2. Remove the control closeout boot bolts.
3. Remove the shift control closeout boot.

33326

Installation Procedure
1. Install the shift control closeout boot.
Notice: Refer to Fastener Notice in Cautions and
Notices.
'
2. Install the shift control closeout boot bolts.
Tighten
Tighten the shift control closeout boot bolts to
2 N-m (18 lb in).
3. Install the front floor console trim plate. Refer to
Console Replacement - Front Floor in Instrument
Panel, Gauges and Console.

(
33326

7-14

Manual Transmission - M49

Transmission!Transaxle
Shift Control Knob Replacement
Removal Procedure
1. Set the park brake.

2. Place the transmission in neutral.

3. Unscrew the shift control knob (1) from the
control.

441403

Installation Procedure
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Install the shift control knob (1) to the control.

Tighten
Tighten the shift control knob (1) to
3 Nm (27 lb in).
2. Release the park brake.

441403

Mainshaft Rear Oil Seal

Removal Procedure
Tools Required
J 23907 Slide Hammer
J 26941 Extension Housing Seal Remover
1 . Remove the propeller shaft. Refer to Propeller
Shaft Replacement - Two Piece in Propeller Shaft.
2. Remove the output shaft seal using J 23907 and
J26941.

J 26941

33333

Transmission!Transaxle

Manual Transmission - M49 7-15

Installation Procedure
Tools Required
J 21426 Extension Housing Seal Installer
1. Install the output shaft seal using J 21426.

33336

2. Lubricate the inside diameter of the seal with

transmission fluid. Use Dexron Ill transmission
fluid or equivalent.
3. Install the propeller shaft. Refer to Propeller Shaft
Replacement - Two Piece in Propeller Shaft.
4. Check the transmission fluid level. Refer to
Manual Transmission Fluid Level Check.

38639

Backup Lamp Switch Replacement

Removal Procedure
1. Disconnect the backup lamp switch electrical
connector.
2. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

33339

7-16

Manual Transmission - M49

Transmission/Transaxle
3. Remove the backup lamp switch.

33340

Installation Procedure
1. Apply pipe sealant with Teflon to the threads of
the backup lamp switch. Use GM PIN 1052080 or
the,equivalent.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the backup lamp switch.

Tighten
The backup lamp switch to 38 Nm (28 lb ft).

33340

3. Connect the. backup lamp switch electrica.1

connector.
4. Lower the vehicle.

33339

Transmission/Transaxle

Manual Transmission - M49 7-17

Vehicle Speed Sensor

Removal Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Disconnect the speed sensor electrical connector.

33345

3. Remove the speed sensor bolt.

4. Remove the speed sensor.
5. Remove the speedometer driven gear, if
necessary.

33350

Installation Procedure
1. Install the speedometer driven gear, if necessary.
2. Install the speed sensor.
Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Install the speed sensor bolt.
Tighten
Tighten the speed sensor bolt to 10 N-m (89 lb in).

(
33350

7-18

Manual Transmission - M49

Transmissionrrransaxle
4. Connect the speed sensor electrical connector.
5. Lower the vehicle.

33345

Transmission Oil Drain and Fill

Draining Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Clean away all dirt and debris from the
transmission fluid drain plug area.
3. Remove the drain plug.
4. Allow the system to drain.
Notice: Refer to Fastener Notice in Cautions and
Notices.
5. Install the transmission fluid drain plug.
Tighten
Tighten the transmission case drain plug to
27 Nm (20 lb ft).

33380

Filling Procedure
1. Clean away all dirt and debris from U1e
transmission fluid fill plug area.
2. Remove the fill plug.
3. Fill the transmission with DEXRON-111
transmission fluid, until even with the bottom of
the fill plug hole.

4. Install the transmission fluid fill plug

Tighten
Tighten the transmission case fill plug to
27 Nm (20 lb ft).
5. Lower the vehicle.

2327

Transmission/Transaxle

Manual Transmission - M49

7-19

Transmission Replacement (Removal)

Removal Procedure
Tools Required
J 3289-20 Bench Mount Holding Fixture Base
J 36842 Transmission Holding Fixture
J 42055 Transmission Support Fixture
J 36221 Hydraulic Clutch Line Separator
1. Remove the control assembly. Refer to Control
Assembly.
2. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
3. Drain the transmission fluid.
4. Remove the propeller shaft. Refer to Propeller
Shaft Replacement - Two Piece in Propeller Shaft.
5. Support the rear axle with jack stands.
6. Remove the rear axle torque arm. Refer to
Torque Arm Replacement in Rear Suspension.
7. Remove the catalytic converter. Refer to Catalytic
Converter Replacement in Engine Exhaust.
8. Disconnect the wire harness connectors from the
speed sensor (1) and the backup lamp switch (3)
on the left side.
9. Remove the wiring harness clip bolt (2).

33364

472129

7-20

Manual Transmission - M49

Transmission/Transaxle
10. Remove the wiring harness. clip bolt (1) from the
right side.
11. Remove the starter motor. Refer to Starter Motor
Replacement (3.BL V6) in Engine Electrical.

1
472132

12. Remove the left transmission brace bolts (2, 3).

13. Remove the left transmission brace (1).

349561

14. Remove the right transmission brace

bolts (2, 3, 4).
15. Remove the right transmission brace (1 ).

448855

Transmission!Transaxle

Manual Transmission - M49

7-21

16. Remove the flywheel housing cover bolts (2).

17. Remove the flywheel housing cover (3) from the
transmission (1 ).

349560

18. Using J 36221, depress the white circular release

ring on the actuator cylinder hose and
simultaneously pull.lightly on the mas~er cylinder
hose to disconnect.
19. Protect bothh~se coupling ends from dirt and.
damage.
20. Support the engine with a salety stand.
21. Install the J.4:2055 to the transmissionjack.
22. Support the transmission with the
transmission jack.
23. Remove the transmission support and mount.
Refer to Transmission Support and Mount
Assembly.

43255

24. Remove the flywheel housing belts (.1, 2) and

nuts (3).
25. Slowly lower the manual transmission (4) from the
vehicle.
26. Remove the vent hose from the transmission.
27. Remove the clutch bleeder from ttie actuating

cylinder.
28. Remove the clutch line from the actuating
cylinder.

441492

7-22

Manual Transmission - M49

Transmission/Transaxle
29. Remove the clutch actuator cylinder bolts (1 ).
30. Remove the clutch actuator cylinder (2).

2
43256

31. Remove the transmission bolts (3).

32. Remove the bellhousing (1) from the
transmission (2).
33. Install the J 36842 to the transmission, if
necessary.
34. Remove the transmission from the
transmission stand.
35. Install the transmission to the J 3289-20 if
necessary.

472967

Transmission Replacement (Installation)

Installation .Proc~dure
1. Remove the transmission from the J 3289-20 if
nece~sary.
2. Install. the transmission to the jack stand.
3. Remove the J 36842 from the transmission, if
necessary.
4. Install the bellhousing (1) to the transmission (2).
Notice: Refer to Fastener Notice in Cautions and
Notices.
5. Install the transmission bolts (3).

Tighten
Tighten the transmission bolts (3) to
75 Nm (55 lb ft).

472967

TransmissionfTransaxle

Manual Transmission - M49

7-23

6. Install the clutch actuator cylinder (2).

7. Install the clutch actuator cylinder bolts (1).

Tighten
Tighten the clutch actuator cylinder bolts (1) to
8 N-m (71 lb in).
8. Install the clutch line to the actuating cylinder.
9. Install the clutch bleeder to the actuating cylinder.

2
43256

1O. Slowly raise the manual transmission (4) to the

vehicle,
11. Install the flywheel housing bolts (1, 2) and
nuts (3).

12.
13.
14.
15.

Tighten
Tighten the flywheel housing bolts (1, 2) and
nuts (3) to 95 N-m (70 lb ft).
Install the transmission support and mount. Refer
to Transmission Support and Mount Assembly.
Remove the transmission jack.
Remove the J 42055 from the transmission jack.
Remove the engine safety stand.

441492

Important: DO NOT rely on an audible click or a

visual verification of the clutch hydraulic hose quick
connect fitting connection.
16. Connect the clutch actuator cylinder hose to the
clutch master cylinder hose.
Push together the clutch hydraulic hose quick
connect fittings, then pull back on the fittings to
verify engagement.
17. Check the clutch hydraulic hoses for twists
or kinks.

43255

7-24

Manual Transmission - M49

Transmission/Transaxle
18. Install the flywheel housing cover (3) to the
transmission (1 ).
19. Install the flywheel housing cover bolts J2).
Tighten
Tighten the flywheel housing cover bolts (2) to
9 Nm (80 lb in).

349560

20. Install the right transmission brace (1 ).

21. Install the right transmission brace bolts (2, 3, 4).
Tighten
Tighten the right transmission brace bolts (2, 3, 4)
to 50 N-m (37 lb ft).

448855

22. Install the left transmission brace (1 ).

23. Install the left transmission brace bolts (2, 3).
Tighten
Tighten the left transmission brace bolt (2) (to
transmission) to 50 Nm (37 lb ft).
Tighten the left transmission brace bolt (3)
(to engine) to 28 Nm (21 lb ft).
24. Install the starter motor. Refer to Starter Motor
Replacement (3.BL V6) in Engine Elect.rical.

349561

Transmission!Transaxle

Manual Transmission - 1\1149 7-25

25. Install the wiring harness clip bolt (1) to the right
side of the transmission.
Tighten
Tighten the wiring harness clip bolt (1) to
11 N-m (97 lb in).

472132

26. Install the wiring harness clip bolt (2) to the left
side of the transmission.

27.
28.

29.
30.
31.

Tighten
Tighten the wiring harness clip bolt (2) to
11 Nm (97 lb in).
Connect the speed sensor (1) and backup lamp
switch (3) electrical connectors.
Install the catalytic converter. Refer to Catalytic
Converter Replacement in Engine Exhaust.
Install the rear axle torque arm. Refer to Torque
Arm Replacement in Rear Suspension.
Remove the rear axle jack stands.
Install the propeller shaft. Refer to Propeller Shaft
Replacement - Two Piece in Propeller Shaft.

472129

32. Fill transmission with fluid.

33. Lower the vehicle.
34. Install the control assembly. Refer to Control
Assembly.
35. Bleed the clutch hydraulic system. Refer to
Hydraulic Clutch Bleeding in Clutch.

2327

7-26

Manual Transmission - M49

Transmission!Transaxle

Description and Operation

Manual Transmission

37221

The Borg Warner TS model is a S-speed 77 mm

manual transmission assembly.
The Borg Warner TS model is the only manual
transmission for the 3.8L (RPO L36) engine.
Identify the manual transmission assembly as follows:
Calculate the forward gears
Measure the distance between the centerline of
the output shaft and the counter gear

Notice: Use only DEXRON-111 Automatic

Transmission Lubricant for this manual transmission
assembly. Other lubricants or additives may damage
the blocker ring friction material or the adhesives.
The Borg Warner model TS S-speed manual
transmission has the following features:
Fully synchronized
Blocker ring synchronizers
Sliding mesh reverse gear
Three-piece synchronizer rings for first speed and
second speed gears consisting of steel inner and
outer cones and a tapered metal ring that is
lined on both sides with friction material similar to
automatic transmission friction plates
Independent and separately replaced
synchronizer cones
3RD speed and 4TH speed gear blocker rings
that are conventional in appearance and are
lined with friction material
A brass STH speed gear blocker ring
Tapered roller bearings that support the mainshaft
and the countershaft (Must be shimmed for
proper end play)
Caged roller bearings for 1ST speed through
4TH speed gears
A aluminum transmission case
The manual transmission control is mounted on top of
the extension housing.
The manual transmission control cannot be adjusted.
The manual transmission control must be serviced
independently of the manual transmission.

Manual Transmission - M49

Transmission!Transaxle

7-27

Special Tools and Equipment

Illustration

Tool Number/ Description

Tool Number/ Description

Illustration

J 36842

J 42055

Transmission Holding
Fixture

Transmission Support
Fixture

37234
95523

J 36621
J 3289-20

Hydraulic Clutch Line

Separator

Holding Fixture

105916
4850

J 26941
J 23907

Drive Sprocket Support

Bearing Cup

Slide Hammer

163042
4855

7-28

Manual Transmission - MM6

Transmission/Transaxle

Manual Transmission - MM6

Specifications
Fastener Tightening Specifications
Application

Nm

Lb Ft

27

20

Backup Lamp Switch

Lbln

Clutch Actuator Cylinder Bolt

71

Clutch Housing Bolt

50

37

Control Lever Handle Bolt

25

18

Reverse Lockout Assembly Bolt

18

13

Reverse Lockout Solenoid

40

30

Shift Control Bolt

18

13

Shift Control Closeout Bolt

18

Shift Control Knob

27

Skip Shift Solenoid

40

30

Transmission Bolt

50

37

Transmission Drain/Fill Plug

27

20

Transmission Mount Bolt

48

35

Transmission Mount Nut

105

77

Transmission Support Bolt

57

42

Vehicle Speed Sensor Bolt

10

89

Lubrication Specifications
Application

Liters

Dexron Ill, IIE

Gallons

Quarts

3.9

4.1

Diagnostic Information and Procedures

Transmission Shifts Hard
Probable Cause

The clutch pedal travel is incorrect.

Action

1. Check for a clutch pedal restriction.

2. Remove any restrictions from the clutch pedal.
3. Ensure that the driver is fully depressing the clutch.

Air is in the clutch hydraulic system.

The transmission shift control is
binding or damaged.

Bleed the air from the clutch hydraulic system.

Refer to Hydraulic Clutch Bleeding in Clutch.
1. Remove the transmission shift control.
2. Inspect the shift control and replace if necessary.
Refer to Control Assembly.

The transmission contains the

incorrect type of transmission fluid.

Drain the transmission fluid, then fill the transmission with the correct type of fluid.
Refer to Transmission Oil Drain and Fill.

The clutch pressure plate and/or

clutch driven plate are defective.

1. Inspect the clutch pressure plate and clutch driven plate.

2. Replace the clutch pressure plate and/or clutch driven plate, if necessary.
Refer to Clutch Pressure Plate and Clutch Driven Plate (5.7L) in Clutch.

There is an internal bind in the

transmission, caused by the shift
forks, selector plates, or
synchronizers.

1. Remove the transmission.

Refer to Transmission Replacement (Removal).
2. Disassemble and inspect the transmission for worn parts.
Refer to Transmission/Transaxle/Transfer Case Unit Repair Manual.
3. Install the transmission.
Refer to Transmission Replacement (Installation).

i/

TransmissionfTransaxle

Manual Transmission - MM6 7-29

Transmission Shifts Hard into Reverse

Probable Cause
Action
DEFINITION: The transmission will shift into REVERSE with high effort, or the transmission will not shift into REVERSE.
The reverse lockout solenoid circuit is
1. Inspect the function of the reverse lockout solenoid circuit.
not functioning properly, or the
2. Inspect the function of the reverse lockout solenoid.
reverse lockout solenoid is defective.
3. Repair or replace components as necessary.
For inspection of t~e reverse lockout solenoid circuit and the reverse lockout
solenoid function, refer to OTC POB01 Reverse Inhibit Solenoid Control
Circuit in Engine Controls - 5.7L.
For the reverse lockout solenoid replacement, refer to Reverse Lockout
Solenoid.
The reverse lockout mechanism is
1. Remove the transmission.
not functioning properly.
Refer to Transmission Replacement (Removal).
2. Remove the reverse lockout mechanism and inspect for function, wear or
damage.
Replace worn or damaged components as necessary.
Refer to Transmission/Transaxle/Transfer Case Unit Repair Manual.
3. Install the transmission.
Refer to Transmission Replacement (Installation).
There is an internal bind in the
1. Remove the transmission.
transmission, caused by the
Refer to Transmission Replacement (Removal).
synchronizer.
2. Disassemble and inspect the transmission for worn or damaged components.
Replace worn or damaged components as necessary.
Refer to Transmission/Transaxle/Transfer Case Unit Repair Manual.
3. Install the transmission.
Refer to Transmission Replacement (Installation).

Gear Clash When Shifting Gears

Probable Cause
The clutch is not fully releasing
(disengaging).
Air is in the clutch hydraulic system.
The transmission shift control is worn
or damaged.

The transmission fluid level is low.

The transmission contains the
incorrect type of transmission fluid.
The transmission gearshift
components or synchronizers are
worn or damaged.

Action
Verify that the clutch is releasing properly.
Refer to Clutch Spin Down Time in Clutch.
Bleed the air from the clutch hydraulic system.
Refer to Hydraulic Clutch Bleeding in Clutch.

1. Remove the transmission shift control.

2. Inspect the shift control and replace if necessary.
Refer to Control Assembly.
Inspect the transmission fluid level and add the proper fluid as necessary.
Refer to Manual Transmission FIL.iid Level Check.
Drain the transmission fluid, then fill the transmission with the correct type of fluid.
Refer to Transmission Oil Drain and Fill.
1. Remove the transmission.
Refer to Transmission Replacement (Removal).
2. Disassemble and inspect the transmission for worn or damaged gearshift
components or synchronizers.
Replace worn or damaged components as necessary.
Refer to Transmission/Transaxle/Transfer Case Unit Repair Manual.
3. Install the transmission.
Refer to Transmission Replacement (Installation).

7-30

Manual Transmission - MM6

Transmission/Transaxle
Transmission Noisy

Probable Cause

Action

The transmission fluid level is low.

Inspect the transmission fluid level and add the proper fluid as necessary.
Refer to Manual Transmission Fluid Level Check.

The transmission contains the

incorrect type of transmission fluid.

Drain the transmission fluid, then fill the transmission with the correct type of fluid.
Refer to Transmission Oil Drain and Fill.

The transmission shift control

closeout boot is loose or damaged.

1. Inspect the transmission shift control closeout boot.

2. Position and tighten the closeout boot to specifications, or replace the boot as
necessary.
Refer to Shift Control Closeout Boot Replacement.

The transmission gears or bearing

components are worn or damaged.

1. Remove the transmission.

Refer to Transmission Replacement (Removal).
2. Disassemble and inspect the transmission.
3. Replace worn or damaged components as necessary.
Refer to Transmissionrrransaxlerrransfer Case Unit Repair Manual.
4. Install the transmission.
Refer to Transmission Replacement (Installation).

Transmission Jumps Out of Gear

Probable Cause

Action

DEFINITION: Gear disengagement occurs during normal operation.

The transmission shift control
closeout boot is not positioned
correctly.

1. Inspect the transmission shift control closeout boot positioning.

2. Reposition or replace the closeout boot, if necessary.
Refer to Shift Control Closeout Boot Replacement.

The transmission shift control is loose

or damaged.

1. Remove the transmission shift control.

2. Inspect the shift control and replace if necessary.
Refer to Control Assembly.

The engine and/or the transmission

mounts are loose or damaged.

1. Inspect the engine mounts.

2. Tighten to specifications or replace as necessary.
Refer to Engine Mount Replacement (Right Side) or Engine Mount
Replacement (Left Side).
3. Inspect the transmission mount.
Tighten to specifications or replace as necessary.
Refer to Transmission Support and Mount Assembly.

Transmission Does Not Shift into One Gear

Probable Cause

Action

The gear select (skip shift) solenoid

circuit is not functioning properly, or
the gear select (skip shift) solenoid is
defective: SECOND and THIRD
gears only.

1. Inspect the function of the gear select (skip shift) solenoid circuit.
2. Inspect the function of the gear select (skip shift) solenoid.

The transmission shift control is worn,

binding or damaged.

1. Remove the transmission shift control.

2. Inspect the shift control and replace if necessary.

3. Repair or replace components as necessary.

For inspection of the gear select (skip shift) solenoid circuit and the gear
select (skip shift) solenoid function, refer to OTC P0803 Skip Shift Solenoid
Control Circuit in Engine Controls - 5.7L.
For the gear select (skip shift) solenoid replacement procedure, refer to
Gear Select/Skip Shift Solenoid Replacement.

Refer to Control Assembly.

Transmission/Transaxle

Manual Transmission - MM6 731

Transmission Does Not Shift into One Gear (cont'd)

Probable Cause
Worn, damaged or incorrectly
assembled selector plates, interlock
plate, or selector arm.

Action

1. Remove the transmission.

R~fer to Transmission Replacement (Removal).

2. Disassemble and inspect the transmissi.on.

3. Replace worn or dci.maged co1T1ponents.as necesscl.ry.
Refer to the Transmissiontrransaxle!fransfer Case Unit Repair Manual.

4, Install the transmission.

Refer to Transmission Replacement (Installation).
Damaged or worn synchronizer
sleeves or hubs.

1. Remove the transmission.

Refer to Transmission Replacement (Removal).

2. Disassemble and inspect the transmission.

3. Replace worn or damaged c:omponents as necessary.
Refer to Transmission/Transaxleftransfer Case Unit Repair Manual.

4. Install the transmission.

Refer to Transmission Replacement (Installation).

Transmission Locked in One Gear

Probable Cause
There is an internal bind in the
transmission, caused by a shift rail or
shift fork.

Action

1. Remove the transmission.

Refer to Transmission Replacement (Removal).

2. Disassemble and inspect the transmission for the following:

Worn or broken shift rail
Bent or damaged shift fork
Replace worn or damaged components as necessary
Refer to Transmission!fransaxle/Transfer Case Unit Repair Manual.
3. Install the transmission.
Refer to Transmission Replacement (Installation).
Incorrectly assembled or broken shift
mechanism, or damaged geartrain
components.

1. Remove the transmission.

Refer to Transmission Replacement (Removal).
2. Disassemble and inspect the transmission.

3. Replace worn or damaged components as necessary.

Refer to Transmission!fransaxle!fransfer Case Unit Repair Manual.

4. Install the transmission. Refer to Transmission Replacement (Installation).

Clunk on Acceleration or Deceleration

Probable Cause
The engine mounts are loose or
damaged.

'

Action
1. Inspect the engine mounts.
2. Tighten to specifications or replace as necessary.
Refer to Engine Mount Replacement (Right Side) or Engine Mount Replacement
(Left Side) in Engine Mechanical - 5.7L.

The clutch driven plate hub is

defective.

1. Inspect the clutch driven plate hub for damage.

2. Replace the clutch driven plate, if necessary.
Refer to Clutch Pressure Plate and Clutch Driven Plate (5. 7L) in Clutch.

The propeller shaft universal joints

are worn.

1. Inspect the universal joints.

2. Replace the universal joints as necessary.
Refer to Universal Joints Replacement in Propeller Shaft.

7..32

Manual Transmission .. MM6

Transmission/Transaxle
Oil Leak Diagnosis

Pr9bable Cause
The transmission contains an
excessive amount of fluid.

Action

1. Check the transmission fluid level.

2. Adjust the transmission fluid level as necessary.

'

Refer to Manual Transmission Fluid Level Check.

The transmssion vent or vent hose is
plugged.
The transmission has worn or
damaged seals.

Clear or replace the transmission vent or vent hose.

Refer to Transmission Vent Tube Replacement.

1. Rimove the transmission.

Refer to Transmission Replacement (Removal).
2. Inspect the tr.ansmission seal for wear or damage.
Refer to the TransmissionfTransaxlefTransfer Case Unit Repair Manual.
3. Install the transmission.
Refer to Transmission Replacement (Installation).

Transmission!Transaxle

Manual Transmission - MM6 7-33

Repair Instructions
Manual Transmission Fluid Level Check
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle.
2. Clean any dirt from around the fill plug.
3. Remove the transmission fill plug from the
transmission.

71531

4. Check that the transmission fluid level is even

with the bottom of the fill plug hole.
5. Add Dexron-111 transmission fluid, if necess~ry.

2327

7-34

Manual Transmission - MM6

Transmission/Transaxle
Notice: Refer to Fastener Notice in Cautions and
Notices.

6. Install the transmission fill plug to the transmission.

Tighten
Tighten the transmission fill plug to
27 Nm (20 lb ft).
7. Lower the vehicle.

71531

Transmission Support and Mount

Assembly
Removal Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle.
2. Support the transmission with a transmission jack.
3. Remove the transmission mount nut (2) and
washer.

441398

4. Remove the transmission support bolts (2).

5. Remove the transmission support (1 ).

441395

TransmissionfTransaxle

Manual Transmission - MM6 7-35

6. Remove the transmission mount bolts.

7. Remove the transmission mount.

210517

Installation Procedure
1. Install the transmission mount.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the transmission mount bolts.
Tighten
Tighten the transmission mount bolts to
48 Nm (36 lb ft).

210517

3. Install the transmission support (1 ).

4. Install the transmission support bolts (2).
Tighten
Tighten the transmission support bolts (2) to
57 Nm (43 lb ft).

441395

7-36

Manual Transmission - MM6

TransmissionfTransaxle
5. Install the transmission mount nut (2) and washer.
Tighten
Tighten the transmission mount nut (2) to
105 N-m (77 lb ft).
6. Remove the transmission jack.
7. Lower the vehicle.

441398

Control Assembly
Removal Procedure
1. Remove the shift control closeout boot. Refer to
Shift Control Closeout Boot Replacement.
2. Remove shift control bolts.
3. Remove the shift control.
4. Clean the old sealant from the housing and the
shift control sealing surfaces.

-~

33332

Installation Procedure
1 . Apply sealant GM P/N 12345739 or the equivalent
to the mating surface of the cover plate.

38411

Transmission/Transaxle

Manual Transmission - MM6

7-37

2. Install the shift control.

Notice: Refer to Fastener Notice in Cautions and
Notices.
3 .. Install the shift control bolts.

Tighten
Tighten the shift control bQlts to 18 Nm (13 lb ft).
4. Install the shift control closeout boot. Refer to Shift
Control Closeout Boot Replacement.

-~

33332

Control Lever Boot Assembly

Removal Procedure
1 . Remove the shift control closeout boot. Refer to
Shift Control Closeout Boot Replacement.
2. Remove the control lever boot (1) from the control

lever (2).

476074

Installation Procedure
1. Install the control lever boot (1) to the control
lever (2).
2. Install the shift control closeout boot. Refer to
Shift Control Closeout Boot Replacement.

476074

7-38

Manual Transmission - MM6

Transmission/Transaxle
Shift Control Closeout Boot Replacement
Removal Procedure
1. Remove the front floor console. Refer to Console
Replacement - Front Floor in Instrument Panel,
Gauges and Console.
2. Remove the control lever handle bolts (2).
3. Remove the control lever handle (1 )..

33327

4. Remove the shift control closeout boot bolts (1 ).

5. Remove the shift control closeou1 boot. (2).

33329

Installation Procedure
1. Install the shift control closeout boot (1 ).
2. Push the shift control closeout boot (1) down until
it seats on the controt.

441475

Transmission/Transaxle

Manual Transmission - MM6

7-39

Notice: Refer to Fastener Notice in Cautions and

Notices.

3. Install the shift control closeout boot bolts (1 ).

Tighten
Tighten the shift control closeout boot bolts (1) to
2 N-m (18 lb in).

33329

4. Install the control lever handle (1).

5. Install the control lever handle bolts (2).

Tighten
Tighten the control lever handle bolts (2) to
25 Nm (18 lb ft).
6. Install the front floor console. Refer to Console
Replacement - Front Floor in Instrument Panel,
Gauges and Console.

33327

Control Lever Handle Assembly

Removal Procedure
1. Remove the front floor console. Refer to Console
Replacement - Front Floor in Instrument Panel,
Gauges and Console.
2. Remove the control lever handle bolts (2).
3. Remove the control lever handle (1 ).

33327

7-40

Manual Transmission - MM6

Transmission/Transaxle
Installation Procedure
1. Install the control lever handle (1) to the shift
control.
Notice: Refer to Fastener Notice in Cautions and
Notices.

2. Install the control lever handle bolts (2).

Tighten
Tighten the control lever handle bolts (2) to
25 N-m (18 lb ft).
3. Install the front floor console. Refer to Console
Replacement - Front Floor in Instrument Panel,
Gauges and Console.

33327

Shift Control Knob Replacement

Removal Procedure
1. Set the park brake.
2. Place the transmission control in neutral.
3. Unscrew the control lever knob (1 ).

441471

Installation Procedure
1. Push the shift lever boot (2) down to access the
lever threads.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Screw the shift control knob (1) onto the shift
control lever.

Tighten
Tighten the shift control knob (1) to
3 N-m (27 lb in).
3. Rotate the Hurst shift control knob (1) until the
face is parallel to the instrument panel.
4. Place the transmission in gear.
5. Release the park brake.

441471

Transmission!Transaxle

Manual Transmission - MM6

7-41

Mainshaft Rear Oil Seal

Removal Procedure
Tools Required
J 23907 Slide Hammer
J 26941 Extension Housing Seal Remover
1. Remove the propeller shaft. Refer to Propeller
Shaft Replacement - One Piece in Propeller Shaft.
2. Remove the main shaft seal using J 23907
and J 26941

J 23907

J 26941
349689

Installation Procedure

Tools Required
J 39440 Extension Housing Seal Installer
1. Install the main shaft seal using J 39440
2. Lubricate the inside diameter of the seal. Use only
Dexron-111 automatic transmission fluid.
3. Install the propeller shaft. Refer to Propeller Shaft
Replacement - One Piece in Propeller Shaft.
4. Inspect the transmission fluid level. Refer to
Manual Transmission Fluid Level Check
Notice: Use only DEXRON-111 Automatic
Transmission Lubricant for this manual transmission
assembly. Other lubricants or additives may damage
the blocker ring friction material or the adhesives.
5. Add transmission fluid, if necessary.

J 39440
349677

Backup Lamp Switch Replacement

Removal Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Disconnect the electrical connector (1) from the
backup lamp switch (2).

349720

7-42

Manual Transmission - MM6

Transmission/Transaxle
3. Remove the backup lamp switch

38364

Installation Procedure
1. Apply pipe sealant with Teflon to the threads of
the backup lamp switch. Use GM P/N 1052080 or
equivalent.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the backup lamp switch.

Tighten
Tighten the backup lamp switch to
27 Nm (20 lb ft).

38364

3. Connect the electrical connector (1) to the backup

lamp switch (2).
4. Lower the vehicle.

255673

TransmissionlTransaxle

Manual .Transmission - MM6

7-43

Vehicle Speed Sensor

Removal Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Disconnect the electrical connector (1) from the
vehicle speed sensor (2).

349947

3. Remove the bolt attaching the vehicle speed

sensor.

4. Remove the vehicle speed sensor.

349950

Installation Procedure
1. Install a new 0-ring seal to the vehicle speed
sensor.
2. Install the vehicle speed sensor.
Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Install the vehicle speed sensor bolt.

Tighten
Tighten the vehicle speed sensor bolt to
10 N-m (89 lb in).

349950

7~44

Manual Transmission ;. MM6

TransmissionfTransaxle
4. Install the electrical connector (1) to tt)e vehicle
speed sensor (2).
5. Lower the vehicle.

349947

Reverse Lockout Solenoid

Removal Procedure
Tools Required
J 41099 Solenoid Socket
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle.
2. Disconnect the electrical connector (1) from the
reverse lockout solenoid (2).
3. Place a drain pan under the transmission in case
any fluid drips out.

2
349932

4. Remove the reverse lockout solenoid using

J41099.
5. Remove the reverse lockout assembly bolt.
6. Remove the reverse lockout assembly, if
necessary.

349934

Transmission!Transaxle

Manual Transmission ..... MM6

7-45

Installation Procedure

Tools Required
J 41099 Solenoid Socket
1. Install the reverse lockout assembly, it necessary.
Notice: Refer to Fastener Notice in Cautions ahd
Notices.
2. Install the reverse lockout assembly bolt

Tighten
Tighten the reverse lockout assembly bolt to
18 N-m (13 lb ft).
3. Install the reverse lockout solenoid using the
J 41099.
Tighten
Tighten the reverse lockout solenoid to
40 N-m (30 lb ft).
4. Remove the drain pan.
349934

5. Connect the electrical connector (1) to the re~erse

lockout solenoid (2).
6. Check the transmission fluid level. Refer to
Manual Transmission Fluid Level Check.
7. Lower the vehicle.

349932

Gear Select/Skip Shift Solen0td

Replacement
Removal Procedur~
1. Remove the transmission. Refer tq Transmis$ion
Replacement (Removal).
2. Remove the skip shift solenoid from the
transmission.

33363

7-46

Manual Transmission - MM6

TransmissionfTransaxle
Installation Procedure
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Install the skip shift solenoid to the transmission.
Tighten
Tighten the skip shift solenoid to 40 Nm (30 lb ft).
2. Install the transmission. Refer to Transmission
Replacement (Installation).

33363

Transmission Oil Drain and Fill

Draining Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Clean away all dirt and debris from the
transmission fluid drain plug area.
3. Remove the drain plug.
4. Allow the system to drain.
Notice: Refer to Fastener Notice in Cautions and
Notices.
5. Install the transmission fluid drain plug.
Tighten
Tighten the transmission fluid drain plug to
27 Nm (20 lb ft).

33370

Filling Procedure
1. Clean away all dirt and debris from the
transmission fluid fill plug area.
2. Remove the transmission fluid fill plug.
3. Fill the transmission with DEXRON-111
transmission fluid, until even with the bottom of
the fill plug hole.
4. Install the transmission fluid fill plug.
Tighten
Tighten the transmission fluid fill plug to
27 N,m (20 lb ft).

5. Lower the vehicle.

71531

Transmission!Transaxle

Manual Transmission - MM6

7-47

Transmission Vent Tube Replacement

Removal Procedure

1. Remove the transmission support. Refer to

Transmission Support and Mount Assembly.
2. Remove the propeller shaft. Refer to Propeller
Shaft Replacement -.One Piece in Propeller Shaft.
3. Remove the torque arm. Refer to Torque
Arm Replacement in Rear Suspension.
4. Lower the tail shaft of the transmission enough to
access the transmission bolt (2).
5. Remove the transmission bolt (2).
6. Remove the vent tube (3) from the vent pipe.

474579

Installation Procedure
1. Install the vent tube (3) to the vent pipe.

Notice: Refer to Fastener Notice in Cautions and

Notices.
2. Install the transmission bolt (2).

3.
4.
5.
6.

Tighten
Tighten the transmission bolt (2) to
50 N-m (37 lb ft).
Rai.se the tail shaft of the transmission.
Install the torque arm. Refer to Torque Arm
Replacement in Rear Suspension.
Install the propeller shaft. Refer to Propeller Shaft
Replacement - One Piece in Propeller Shaft.
Install the transmission support. Refer to
Transmission Support and Mount Assembly.

474579

Transmission Replacement (Removal)

Removal Procedure
Tools Required
J 3289-20 Bench Mount Holding Fixture Base
J 36842 Transmission Holding Fixture
J 42055 Transmission Support Fixture
J 36221 Hydraulic Clutch Line Separator
1. Remove the transmission control. Refer to Control
Assembly.
2. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
3. Remove the transmission oil drain plug.
4. Drain the oil from the transmission.
5. Support the rear axle with safety stands.
33370

7.;.45

Manual Transmission - MM6

Transmission/Transaxle
6. Remove the propeller shaft. Refer to Propeller
Shaft Replacement - One Piece in Propeller Shaft.
7. Remove the rear axle torque arm. Refer to Torque
Arm Replacement in Rear Suspension.
8. Remove the right side catalytic converter. Refer to
Oxidation Catalytic Converter Replacement
(Right) in Engine Exhaust.
9. Disconnect the oil level sensor electrical
connector.
10. Remove the starter motor. Refer to Starter Motor
Replacement (5.7L VB) in Engine Electrical.

220633

477352

11. Remove the rosebud clip (1) from the

transmission.
12. Disconnect the backup lamp switch electrical
connector (2).

Transmissionrrransaxle

Manual',Transmission- MM6

7-49

13. Disconnect the following :electrical connectors:

Skip shift solenoid (1)
Reverse lockout solenoid (2)
Vehicle speed sensor (3)
Oxygen sensor (5)
14. Remove the push in retainer (4) and wiring
harness bracket.
15. Support the engine with safety stands.

3
477355

16. Using'J 36221, depress the white circular release

ring on the actuator cylin9er hose and
,
simultaneously RUii lightly on the master cylipder
hose to disconnect. ,
'
,

17. Protect both hose coupling end$ frqn:, dirt and

damage.
18. Install the J 42055 to the transmission jack.
19. Support the transmission with a transmission jack.
20. Position and firmly secure the J 42055 with the
transmission jack to the transmission.
21. Remove the transmission support. Refer to
Transmission Support and Mount Assembly.
22. Slowly lower the transmission to access the
transmission bolts.

43255

23. Remove the transmission bolts (2),

24. Remove the transmission (1) from the vehicle

210528

7-50

Manual Transmission - MM6

Transmission/Transaxle
25. Remove the transmission vent tube bolt (2).
26. Remove the transmission vent tube (3).

474579

27.
28.
29.
30.

Remove the clutch

Remove the clutch
Remove the clutch
Remove the clutch
transmission case.

actuator cylinder bolts (1).

actuator cylinder (2).
housing bolts.
housing from the

2
43256

31. Install the J 39430 to the transmission.

32. Remove the transmission from J 42055 and the
transmission jack.
33. Mount the transmission on a workbench using
J 3289-20.

J 3289-20

74206

Transmission/Transaxle

Manual Transmission - MM6

7-51

Transmission Replacement (Installation)

Installation Procedure
1 . Remove the transmission from the J 3289-20
mounted on the workbench.
2. Position and firmly secure the J 42055 mounted
on the transmission jack to the transmission.

J 3289-20

3. Remove the J 39430 from the transmission.

4. Install the clutch housing to the transmission case.
Notice: Refer to Fastener Notice in Cautions and
Notices.
5. Install the clutch housing bolts.

Tighten
Tighten the clutch housing bolts to
50 N-m (37 lb ft).

74206

6. Install the clutch actuator cylinder (2).

7. Install the clutch actuator cylinder bolts (1).

Tighten
Tighten the clutch actuator cylinder bolts (1) to
8 N-m (71 lb in).

2
43256

8. Install the transmission vent tube (3) to the vent.

9. Install the transmission vent tube bolt (2).

Tighten
Tighten the transmission bolt (2) to
50 N-m (37 lb ft).

\.

474579

7-52

Manual Transmission

MM6

transmis,sion/Tr.ansaxle
10. Install the. traasmission ('1) to the vehi,cle.
11. Slowly raise the transmission until in placE:l.
12. In.stall the transmission bolts (2).
Tighten
Tigl:lten the transmission, bolt (2) to
50 N:m (3"1' lb ft) ..
13. Install the transmission. support. Refer to
Transmission Support and Mount Assembly.
14. Remove the transmission jack from the
transmission.
15. Remove the J 42055 from the transmission jack.

210528

Important: DO NOT rely on an audible click <;>r a

visual verification of the clutch hydraulic hose quick

connect fitting connection.

;'

16. Conne9t the clutch ac~uator cylinderhase to the

clutch master cylinder hose.
17. Push together the clutch hydraulic hose quick
connect fittings, then pull back on the fittings to
verify engagement.
18. Check the clutch hydraulic hoses for kinks or
twists.
19. Remove the engine safety stands.

20. Install the wiring harness bracket and pu 9t;i in

retainer (4).
'
.
'
21. Connect the following electrical connectors:

3
477355

Oxygen sensor. (5)

Vehicle speed sensor (3)
Reverse lockout solenoid (2)
Skip shift solenoid (1)

Transmission/Transaxle

Manual Transmission - MM6 7.,53

22. Connect the backup lamp switch electrical

connector (2).
23. Install the rosebud clip (1) to the transmission.
24. Install the starter motor. Refer to Starter
Motor Replacement (5.7L VB) in Engine Electrical.

477352

25. Connect the oil level sensor electrical connector.

26. Install the right side catalytic converter. Refer to
Oxidation Catalytic Converter Replacement
(Right) iri Engine Exhaust
27. Install the rear axle torque arm. Refer to Torque
Arm Replacement in Rear Suspension.
28. Install the propeller shaft. Refer to Propeller Shaft
Replacement - One Piece in Propeller Shaft.
29. Remove the rear axle safety stands.
30. Install the transmission oil drain plug.
Tighten
Tighten the transmission oil drain plug to
27 N-m (20 lb ft).

~
220633

31. Remove the transmission fluid fill plug.

32. Refill the transmission with fluid.
33. Bleed the clutch hydraulic system. Refer to
Hydraulic Clutch Bleeding in Clutch.
34. Lower the vehicle.
35. Install the transmission control. Refer to Control
Assembly.

71531

7-54

Manual Transmission - MM6

Transmission/Transaxle

Description and Operation

Manual Transmission
Manual transmissions are identified by the number of
forward gears and the measured distance between
the centerline of the output shaft and the counter gear.
The 6-speed, 85 mm manual transmission
(RPO MM6), used in the Camaro/Firebird, incorporates

the following features:

An aluminum case.
Fully synchronized gearing with an enhanced
synchronizer cone arrangement:
- Triple-cone: FIRST, SECOND
- Double-cone: THIRD, FOURTH,
FIFTH, SIXTH
- Single-cone: REVERSE
An internal shift rail mechanism.
Tapered roller bearings supporting the mainshaft
and countershaft.
Caged roller bearings under all speed gears.
Solenoid inhibit of SECOND and THIRD gears.
Solenoid inhibit of REVERSE gear during
predefined forward motion.

Gear Select (Skip Shift)

To ensure good fuel economy and compliance with
federal fuel economy standards, SECOND and THIRD
gears are inhibited when shifting out of FIRST gear
under the following conditions:
1. Coolant temperature is above 50C (122F).
2. Vehicle speed is between 20 and
29 km/h (12 and 19 mph)
3. Throttle is opened 35 percent or less.
Reverse Lockout
A reverse lockout system (consisting of a reverse
lockout solenoid which operates a reverse lockout
mechanism) is utilized to prevent shifting into
REVERSE gear when the vehicle is moving forward at
a speed of 5 km/h (3mph) or more.
Vehicle Speed Sensor
The vehicle speed sensor (VSS) is a pulse counter
type input that informs the PCM how fast the vehicle is
traveling. The VSS system uses an inductive sensor
mounted in the tail housing of the transmission
and a toothed reluctor wheel on the tail shaft. The
teeth of the reluctor wheel alternately interfere with the
magnetic field of the sensor creating an induced
voltage pulse as the reluctor rotates.

Transmission/Transaxle

Manual Transmission - MM6 7-55

Special Tools and Equipment

Illustration

Tool Number/ Description

Tool Number/ Description

J 42055

J 39430

Transmission Support
Fixture

Transmission Holding
Fixture

95523

37232

J 41099

J 36621

Gear SelecVReverse
Lockout Solenoid Socket

Hydraulic Clutch Line

Separator

37237

105916

J 3289-20

J 26941

Holding Fixture

Drive Sprocket Support

Bearing Cup

4850

163042

J 23907
Slide Hammer

4855

Illustration

Transmission/Transaxle

7~56 Automatic Transmission - 4L60-E

Automatic Transmission - 4L60-E

Specifications
Temperature vs Resistance
Temperature

. Minimum
Resistance

Nominal
Resistance

Maximum
Resistance

Signal

oc

volts

-40

-40

90636

100707

110778

5.00

-22

-30

47416

52684

57952

4.78

-4

-20

25809

28677

31545

4.34

14

--'10

14558

16176

17794

3.89

Temperature

'

..

~F .

,'

(-1

32

8481

9423

10365

3.45

50

10

5104

5671

6238

3.01

68

20

3164

3515

3867

2.56

86

30

2013

2237

2461

1.80

104

~o .
so

1313

1459

1605

1.10

876

973

1070

3.25

140

60

600

667

734

2.88

158

70

420

467

514

2.56

176

~o
go

299

332

365

2.24

1l:)4

217

241

265 .

1.70

212

100

159

177

195

1.42

230

110

119

132

145

1.15

248

120

89.9

99.9

109.9

0.87

266

130

69.1

76.8

84.5

0.60

284

140

53.8

59.8

65.8

0.32

302

150

42.5

47.2

51.9

0.00

122

.~,A

,.

Fastener Tightening Specifications (Unit Repair)

Specification
Application

Accumulator Cover to Case Bolt

Case Extension to Case Bolt
Case Extension to Case Bolt (4WD Shipping)

'

..

Metric

English

8.0-14.0 Nm

6-10 lb ft

42.0-48.0 Nm

35.0-39.4 lb fl

11.2-22.6 N-m

8.3-16.7 lb ft

Converter Housing to Case Screw

65.0-75.0 N-m

48-'55 lb ft

Cooler Pipe Connector

35.0-41.0 N,m

26-30 lb ft

Detent Spring to Valve Body Bolt

20.0-27.0 N-m

15-20 lb ft

8.0-14.0 N-m

6-10 lb ft

Forward Accumulator Cover to Valve Body Bolt

Line Pressure Plug

8.0-14.0 Nm

6-101bft

Manual Shaft to Inside Detent Lever Nut

27.0-34.0 N,m

20-25 lb ft

Oil Passage Cover to Case Bolt

8-14.0 N-m

6-10 lb ft

Park Brake Bracket to Case Bolt

27.0-34.0 Nm

20-25 lb ft

Plate to Case Bolt (Shipping)

27.0-34.0 N-m

20-25 lb ft

Plate to Converter Bolt (Shipping)

27.0-34.0 N,m

20-25 lb ft

Plug Assembly, A!frans Oil Pan (C/K)

30-40 N-m

22.1-29.5 Nm

Plug Assembly, A!frans Oil Pan (Y)

28-32 Nm

20.7-23.6 N,m

Pressure Control Solenoid Bracket to Valve Body Bolt

8.0-14.0 Nm

6-101bft

Pump Assembly to Case Bolt

26.0-32.0 N,m

19-24 lb ft

Pump Cover to Pump Body Bolt

20.0-27.0 N,m

15-20 lb ft

..

Transmissionn:ransaxle

Automatic Transmission - 4L60:-E

7-57

Fastener Tightening Speciticaticms (Unit Repair) (confd)

Specificatidn
''

Application

Metric

...

Solenoid Assembly to Case Bolt

6-10 lb ft

Speed Sensor Retainer Bolt :.'..

10.5.,-13.5 Nm

7.7-tO.lbft

Stud, A/Trans Case Extension (Y-car)

18.0-22.0 Nm

. Transmission Fluid Pressure Manual Valve Position Switch to Valve

Body Bolt

1$-,-16 lbft
"

8.0-14.0 N-m

.. ,

6-10 lb ft

Transmission Oil Cooter Pipe Fitting

35.0-41.0 N,m

26-30 lb ft

Transmission Oil Pan to Case Bolt

9.5-13.8 Nm

7-101bft

8.0-14.0 Nm

6-10, lb ft

...

Valve Body to Case Bolt

Scan Tool Data Value Examples (3.8L)

If you have completed the On-Board Diagnostic (OBD)
system check, if the diagnostics are functioning
properly, and if no DTCs are displayed, you may use
the Typical Scan Tool. Data Values in the table
below for comparison. These values are an average of
display values recorded from normally operating
vehicles.

Important: You .should never use a scan tool that

displays faulty data. The condition should be reported
to the manufacturer. The use of a faulty scan tool
can result in misdiagnosis and the unnecessary
replacement of parts.
Tech 2 Parameter

English

..

8.0-14.0Nm

Engine Torque
TP Sensor
.,.
TPAngle
Engine Speed
Transmission OSS
Vehicle Speed
Current Gear
1-2 Sol.
2-3 Sol.
3-2 Downshift Sol.
Speed Ratio
1-2 Sol. Open/Short to GND
1-2 Sol. Short to Volts
2-3 Sol. Open/Short to GND
2-3 Sol. Short to Volts
3-2 Sol. Open/Short to GND
3-2 Sol. Short to Volts
TFP Sw. A/B/C
ECT
Trans. Fluid Temp.
TFT Sensor
IAT

Only the;parameters listed below are used .in this

manual for diagnosing. If a scan tool displays other
parameters, the values are not recommended. by
Genera.I Motors for use in diagnosis.
The. va:lu'es below were recorded under .the following
. conditions:
Engine is at Idle
Upper radiator hose is hot
Closed throttle
Gear is in Park or Neutral
Closed Loop
Accessories are OFF

s can T00IDt
aa VI
a ue Exam pies (3 BL VINK)
'
Units Displayed

NIJ1 (lb ft)

volts
percent
RPM

'"

RPM
mph (km/h)
1,2,3,4
On/Off
On/Off
On/Off
RatjQ . ,
Yes/No
Yes/No
Yes/No.
Yes/No
Yes/No
Yes/No
On/Off
(OF)
(OF)

Typical Scan Values

varies
0.30-0.90 V
0%
varies
0
0
1
On
On
On
8.00:1
No
.. No

Hot Mode
PC Sol. Actual Current

On/Off
amps

No
No
No
No
Off/On/Off
varies
varies
varies
varies
Off
varies (0.1-1.1 amps)

PC Sol~noid Ref. Current

amps

varies (0.1.-1.1 amps)

oc
oc

volts

oc (OF)

PC Solenoid Duty Cycle

percentage

varies

TCC Brake Switch

Open/Closed

Closed

Transmission!Transaxle

7-58 Automatic Transmission - 4L60-E

Scan Tool- Data Value Examples (3.8L, VIN K) (cont'd)

Tech 2 Parameter
TCC Enable
TCC Duty Cycle
TCC Slip Speed
TCC Enable Open/Short to GND _
TCC Enable Short to Volts
TCC Duty Cycle Open/Short
to GND
TCC Duty Cycle Short to Volts
Adaptable Shift
Latest Shift
--1-2 Shift Time
2-3 Shift Time

3A Shift Time
Engine Run T_ime
Ignition Voltage.
Cruise
A/C Clutch
2nd Gear Start
1-2 Shift Error
Current TAP Cell
Current TAP Memory
Maximum Tap
1-2 TAP Cells (4-16)

Units Displayed
Yes/No
Percentage
RPM
Yes/No

Yes/No

0%
+/- 50 RPM from the Engine Speed
Nq
No

Yes/No

No

Yes/No
Yes/No ..

No
No

seconds
seconds

-Or/Off
Yes/No
seconds
0-16
-16 to +16
Yes/No

If you have completed the On-Board Diagnostic (OBD)

system check, if the diagnostics are functioning
properly, and if no DTCs are displayed, you may use
the Typical Scan Tool Data Values in the table
below for comparison. These values are an averag~ of
display values recorded from normally operating
vehicles.
Important: Never- use a scan tool that displays faulty
data. Report the condition to the manufacturer.
The use of a faulty scan ,tool can _result in misdiagnosis
and the unnecessary replacement of parts.

'

varies
varies
varies
Disabled
Off
No
0.00
varies
varies
No
varies

--

L.

psi

Scan Tool Data Value Examples (5.7L)

varies
varies
-- varies

--

seconds
seconds
,hr/min/secVolts
Enabled/Disabled

Typical Scan Values

No

Only ttie ~ra.meters listed below are .used in this

manual
diagnosing. If a scan tool displays other
parameters, the values are not recommended by
General Motors for use in diagnosis.
The values below were recorded under the following
conditions:
Engine is at Idle
Upper radiator hose is hot
Closed throttle
Gear is in Park or Neutral
Closed Loop
Accessories are OFF

for

Scan Tool Data Value Examples (5.7 L, VIN G)

Tech 2 Parameter

Units Displayed

Engine Torque

N-m (lb ft)

TP Angle

percent

Typical Scan Values

-

,.

0%
-

TP Sensor

volts

0.30-0.90 V

Engine Speed

RPM

varies

Transmission OSS

RPM

Vehicle Speed

mph (km/h)

Current Gear

1,2,3,4

--

varies
-

"""'

1-2 SoL

On/Off

On

2-3 Sol.

On/Off

On

3-2 Downshift Sol.

On/Off

On

Speed Ratio

Ratio

8.00:1

1-2 Sol. Open/Short to GND

Yes/No

No

1-2 Sol. Short to Volts -

Yes/No

No

--(

Transmissionffransaxle

Automatic Transmission - 4L60-E

Scan Tool Data Value Examples (5.7 L, VIN G) (cont'd)

Tech 2 Parame,er

Units Di~played

2-3 SoL Open/Short to GND

Yes/No

No

Yes/No

No

3-2 Downshift Sol. Open/Short

.
to GND

Yes/No

No

3-2 Downshift Sol. Short to Volts

Yes/No

No

TFPSw. NB/C

On/Off
(OF)

Off/On/Off

2-;3 Sol; Short to Volts

ECT
.Trans..Fluid Temp.
TFT Sensor

,,

oc
oc (OF)

varies
varies

volts

varies

'

oc (OF)

varies

Hot Mo<;i13

On/Off

Off

PC Sol. Actual Current

amps

varies (0.1-1.1 amps)

.. amps
percentage

varies (0.1-1.1 amps)

PC Sol. Duty Cycle

TCC BrakeSwltch

Open/Closed

Closed

TCC Enable

Yes/No

No

IAT

PC Sol.. Ref. Current ,

varies

TCC Mode

0-5

TCC Duty Cycle

Percentage

0%

TCC Slip Speed

RPM

+/- 50 RPM from the Engine Speed

TCC Enable Open/Short to GND

Yes/No

No

Typical Scan Value$

TCC Enable Short to Volts

Yes/No

No

TCC Duty Cycle Open/Short

to GND

Yes/No

No

TCC Duty Cycle Short to Volts

Yes/No

No

seconds

varies

Latest Shift
i

1-2 Shift Time

seconds

varies

2-3 Shift Time

seconds

varies

3-4 Shift Time

seconds

varies

Adaptable Shift

Yes/No

No

Engine Run Time

hr/min/sec

varies

Ignition Voltage

Volts

varies

A/C Clutch

On/Off

Off

1-2 Shift Error

seconds

0.00

2-3 Shift Error

seconds

0.00

Current TAP Cell

0-16

varies

Current. TAP Memory

. -16 to +16

varies

1-2 TAP Cell (4-16)

psi

varies

2-3 TAP Cell (4-16)

psi

varies

7-59

7-60

AutomaticTransmission - 4L60-E

Transmission Scan Tool Data

Definitions (3.8L)
1-2 Tap Cell (4-16): Displays kPa or psi. This
parameter displays the amount of pressure varied from
a calibrated base line pressure for shifts. Each TAP
Cell is based on a calibrated shift torque value.
Each TAP Cell value is calculated from the last shift
time. This cell pressure is used in addition to the
calibrated base line pressure to adjust the apply of a
clutch or band during the next shift.
1-2 Shift Error: Displays a range of -6.38 to
+6.38 seconds. This parameter is the difference
between the desired 1-2 shift time and the actual
1-2 shift time. A positive number indicates the actual
shift time was longer than the desired shift time. This
value is only accurate if the Adaptable Shift parameter
indicates Yes.
1-2 Shift Time: Displays a range of
0.00-6.38 seconds. This parameter is the actual time
of the last 1-2 shift. The shift time is based on the.
engine RPM drop after the commanded 1~2 shift. This
value is only accurate if the Adaptable Shift
parameter indicates Yes.
1-2 Sol.: Displays ON or OFF. This parameter is the
commanded state of the 1-2 shift solenoid valve.
ON represents a commanded energized state (current
is flowing through the solenoid). OFF represents a
non-commanded state (current is not flowing through
the solenoid).
1-2 Sol. Open/Short to GND: Displays Yes or No.
This parameter indicates if an open or short to
ground exists in the 1-2 shift solenoid valve feedback
signal to the PCM. This parameter is valid only
when the 1-2 shift solenoid is commanded OFF.
1-2 Sol. Short to Volts: Displays Yes or No. This
parameter indicates if a short to voltage exists in
the 1-2 shift solenoid valve feedback signal to
the PCM. This parameter is valid only when the
1-2 shift solenoid is commanded ON.
2-3 Shift Time: Displays a range of
0.00-6.38 seconds. This parameter is the actual time
of the last 2-3 shift. The shift time is based on the
engine RPM drop after the commanded 2-3 shift. This
value is only accurate if the Adaptable Shift
parameter indicates Yes.
2-3 Sol.: Displays ON or OFF. This parameter is the
commanded state of the 2-3 shift solenoid valve.
ON represents a commanded energized state (current
is flowing through the solenoid). OFF represents a
non-commanded state (current is not flowing through
the solenoid).
2-3 Sol. Open/Short to GND: Displays Yes or No.
This parameter indicates if an open or short to
ground exists in the 2-3 shift solenoid valve feedback
signal to the PCM. This parameter is valid only
when the 2-3 shift solenoid is commanded OFF.
2-3 Sol. Short to Volts: Displays Yes or No. This
parameter indicates if a short to voltage exists in
the 2-3 shift solenoid valve feedback signal to
the PCM. This parameter is valid only when the
2-3 shift solenoid is commanded ON.

Transmissionrrransaxle
2nd Gear Start: Displays Yes or No. This parameter
indicates when a 2nd gear start has been requested.
When Yes is displayed, the PCM de-energizes the
1-2 shift sblenoid and the vehicle starts off in 2nd gear
for increased trac.tion ir, slippery conditions (following
gears will shift as normal). A hard acceleration condition
(wide open throttle) overrides the 2nd gear start and the
vehicle starts off in 1st gear.
3-2 Downshift Sol.: Displays On or Off. This
parameter indicates if the 3-2 shift solenoid valve
assembly is currently commanded On or Off.
The solenoid commarn;led state is based on the
transmission temperature. The solenoid Will change
states during a 3-2 downshift to regulate the
appropriate pressure. The commanded state of the
solenoid occurs at approximately 30 mph with a throttle
increase.
3-2 Sol. Op~n/Short to GND: Displays Yes or No.
This parameter indicates if an open or short to ground
exists in the 3-2 shift solenoid valve assembly feedback
signal to the PCM. This parameter is valid only when
the 3-2 shift solenoid is.commanded Off.
3-2 Sol. Short to Volts: Displays Yes or No. This
parameter indicates if a short ,to voltage exists in ..
the 3-2 shift solenoid valve assembly feedback signal
to the PCM. This parameter is valid only when the
3-2 shift solenoid is commanded On.
3-4 Shift Error: Displays a range of -6~38 to
+6.38 seconds. This parameter is thedifference
between the desired 3-4 shift time and the actual
3-4 shift time. A positive number indicates the actual
shift time was longer than the desired shift time. This
value is only accurate if the Adaptable Shift parameter
indic;ates Yes.
3-4 Shift, Time: Displays a range of
0.00-6.38 seconds. This parameter is the actual time
of the last 3-4 shift. The shift time is based on the
engine RPM drop after the commanded 3-4 shift. This
value is only accurate if the Adaptable Shift

parameter indicates Yes.

A/C Clutch: Displays On or Off. This parameter
indicates the commanded state of the A/C control
relay. The clutch should be engaged when On
displays.
Adaptable Shift: Displays Yes or No. Yes indicates
that the proper operating conditions were all within the
proper operating range.during the last shift and tharthe
shift time was accurate. This shift information is then
used through the adaptive function in order to update
the adapt cells. No indicates that not all of the operating
conditions were met in order to enable this function and
that the adapt cells were not updated.
Cruise: Displays Enabled or Disabled. This
parameter indicates whether the PCM is allowing
cruise operation. The PCM has the ability to disable
cruise control under certain conditions.
Current Gear: Displays 1, 2, 3 or 4. This parameter
indicates the current commanded state of the shift
solenoids.

Transmission/Transaxle
Current TAP {Transmission Adaptive Pressure)
Cell: Displays a TP cell range of 0-16. This
parameter indicates the current throttle position cell
used for line pressure modification (adaptation).
ECT (Engine Coolant Temperature): Displays a
range of ~40C to 151C (-40F to 304F). This
parameter is the i~put signalof the engine co.olant
temperature sensor. The engine coolant temperature
is high (151C) when the signal voltage is low
(0 V), and the engine coolant temperature is low
(-40C) whe1flhe signal voltage is high (5 V).
Engine Run Time: Displays a range of
0:00:00-1 12: 15 hr/min/sec. This parameter
measures how iong the engine has been operating.
When the ignition switch is turned OFF, the value
is reset to zero.

Ir

Engine Speed: Displays a range of 0-8192RPM.

This parameter indicates the rotational speed of
the engine expressed as revolutions per minute.
Engine Torque: Displays a range of 0-9999 1.b ft.
This parameter ind,icates the amount of torque that is
delivered f.rom the engine.
,!

'

Hot Mode: .Displays On or Off. This parameter

monitors transmission temperature. On indicates that
the transmission temperature has exceeded
135C (275F).
IAT (Intake Air Temperature): Displays a range of
-40C to 215C (-:-40F to 419f). The IAT sensor
is a thermistor that is used tomonitor the temperature
of the air ehterfng the intake manifold. The PCM
applies 5 volts to the sensor on a 5 volt reference
circuit. When the air is cool, the resistance in
the sensor will be high. If the air is warm, the sensor
resistance will be low and the PCM will sense a
low voltage signal. The PCM converts the signal of the
IAT sensor to degrees Celsius. Intake air temperature
is used by the PCM to adjust fuel delivery and
spark timing.
Ignition Voltage: Displayi, a range of 0.0-25.5 V.
This represents the system voltage measured by

the PCM. at it's ignition feed.

Latest Shift: Displays a range of
0.00 to 6.38"seconds; This parameter is the actual
shift time of the last upshift. This value is only accurate
if the Adaptable Shift parameter indicates Yes.
Maximum TAP {Transmission Adaptive
Pressure): Displays Yes or No. This parameter
indicates when line pressure modification (adaptation)
has reached its limit. Yes indicates that the limit
has been reached. No indicates that the limit has not .
been reached.
PC Sot.. Actual Current: Displays a range of .
0.00-1.10 amps. This parameter is the actual current
of the pressure control solenoid circuit at the control
module. Zero amp (no current flow) indicates
actual higher line pressure. Actua) lower line pressure
is indicated by 1.1 amps (high current flow).

Automatic Transmission - 4L60-E

7-61

PC Solenoid Duty Cycle: Displays a range of

0-100%. This parameter is the commanded state of
the pressure control solenoid expressed as.a
percent of energized ON time. Zero percent indicates
zero ON time (non-energized) or no current flow.
Approximately 60% at idle indicates maximum ON time
(energized) or. high current flow.
PC Sol. Ref. (Reference) Current: Displays a range
of 0.00-1 .1 O amps. This parameter is the commanded
current of the pressure control solenoid circuit.
Zero amp (no current flow) indicates commanded
higher line pressure. Commanded lower line pressure
is indicated by 1.1 amps (high current flow).
Speed Ratio: Displays a range of 0.00:1-8.00:1.
This parameter indicates engine speed divided
by transmission output speed. This value is used to
estimate transmission gear ratio.
TCC Brake Switch: Displays Open or Closed. This
parameter indicates the state of the brake switch
circuit input. Open indicates a zero voltage input (brake
switch open, brake pedal applied). Closed indicates
a B+ voltage input (brake switch closed, brake
pedal released).
TCC Duty Cycle: Displays a range of 0-100%. This
parameter is the commanded percentage of ON
time of the TCC PWM solenoid. Approximately 90%
represents an ON (energized) commanded state.
Zero percent represents an OFF (non-energized)
commanded state. This commanded state is applied
at a vehicle speed between approximately
0-16 km/h (0-10 mph).
TCC Duty Cycle Open/Short to GND: Displays Yes
or No. This parameter indicates whether an open or
a shOrt to ground exists in the TCC PWM solenoid
valve.feedback signal to the PCM. This parameter is
valid only when the TCC PWM solenoid is commanded
OFF (duty cycle is 0%).
TCC Duty Cycle Short to Volts: Displays Yes or
No. This parameter indicates whether a short to
voltage exists in the TCC PWM solenoid valve
feedback signal to the PCM. This parameter is valid
only when the TCC PWM solenoid is commanded ON
(duty cycle is at maximum).
TCC Enable: Displays Yes or No. This parameter is
the commanded state of the TCC solenoid. Yes
indicates a commanded energized state (current is
flowing through the solenoid). No. indicates a
commanded non-energized state (current is not .
flowing through the solenoid). This commanded state
occurs at various vehicle speeds between
applications.
TCC Enable Open/Short to GND: Displays Yes or
No. This parameter indicates whether an open or a
short to ground exists in the TCC solenoid valve
feedback signal to the PCM. This parameter is valid
only when the TCC solenoid is commanded OFF.
TCC Enable Short to Volts: Displays Yes or No.
This parameter indicates whether a short to voltage
exists in the TCC solenoid valve feedback signal to the
PCM. This parameter is valid only when the TCC
solenoid is commanded ON.

7-62

Automatic Transmission - 4L60-E

TCC Slip Speed: Displays a range of

-4080 to 4079 RPM. This parameter is the difference
between transmission output speed and engine
speed. A negative value indicates that the engine
speed is less than the output speed (deceleration). A
positive value indicates that the engine speed is
greater than the output speed (acceleration). A value
of zero indicates that the engine speed is equal to
the output speed (TCC applied}.
TFT (Transmission Fluid Temperature)
Sensor: Displays a range of 0.00-5.00 V. When the
transmission fluid is cold, the sensor resistance is
high and the PCM will sense high signal voltage. As
the transmission fluid temperature warms to a
normal operating temperature, the sensor resistance
becomes less and the voltage decreases.
TFP Switch A/B/C: Displays On/Off, On/Off, On/Off.
These parameters are the three inputs from the
Automatic Transmission Fluid Pressure Manual Valve
Position Switch Assembly. On represents a O voltage
signal. Off represents a B+ voltage signal.
TP (Throttle Position) Angle: Displays a range of
0-100%. The TP angle is computed by the PCM
from the TP sensor voltage. The TP angle should read
0% at idle and 100% at Wide Open Throttle (WOT).
TP (Throttle Position) Sensor: Displays a range of
0.00-5.00 volts. The TP sensor is used by the
PCM to determine the amount of throttle demanded by
the driver. Voltage is below 1 volt at idle and above
4 volts at Wide Open Throttle (WOT).
Trans. Fluid Temp.: Displays a range of -40C to
151C (-40F to 304F). This parameter is the
input signal of the transmission fluid temperature
sensor. Transmission fluid temperature is high (151 C)
when signal voltage is low (0 V), and transmission
fluid temperature is low (-40) when signal voltage is
high (5 V).
Transmission OSS (Output Speed
Sensor): Displays a range of 0-8192 RPM. This
parameter indicates the rotational speed of the
transmission output shaft expressed as revolutions per
minute.
Vehicle Speed: Displays a range of 0-255 km/h
(0-158 mph). This parameter is the input signal from
the vehicle speed sensor assembly.

Transmission Scan Tool Data

Definitions (5.7L)
1-2 Tap Cell (4-16): Displays kPa or psi. This
parameter displays the amount of pressure varied from
a calibrated base line pressure for shifts. Each TAP
Cell is based on a calibrated shift torque value.
Each TAP Cell value is calculated from the last shift
time. This cell pressure is used in addition to the
calibrated base line pressure to adjust the apply of a
clutch or band during the next shift.

2-3 Tap Cell (4-16): See 1-2 Tap Cell (4-16)

1-2 Shift Error: Displays a range of -6.38 to
+6.38 seconds. This parameter is the difference
between the desired 1-2 shift time and the actual

Transmission/Transaxle
1-2 shift time. A positive number indicates that the
actual shift time was longer than the desired shift time.
This value is only accurate if the Adaptable Shift
parameter indicates Yes.
1-2 Shift Time: Displays a range of
0.00-6.38 seconds. This parameter is the actual time
of the last 1-2 shift. The shift time is based on the
engine RPM drop after the commanded 1-2 shift. This
value is only accurate if the Adaptable Shift
parameter indicates Yes.
1-2 Sol.: Displays ON or OFF. This parameter is the
commanded state of the 1-2 shift solenoid valve.
ON represents a commanded energized state (current
is flowing through the solenoid). OFF represents a
non-commanded state (current is not flowing through
the solenoid}.
1-2 Sol. Open/Short to GND: Displays Yes or No.
This parameter indicates if an open or short to
ground exists in the 1-2 shift solenoid valve feedback
signal to the PCM. This parameter is valid only
when the 1-2 shift solenoid is commanded OFF.
1-2 Sol. Short to Volts: Displays Yes or No. This
parameter indicates if a short to voltage exists in
the 1-2 shift solenoid valve feedback signal to
the PCM. This parameter is valid only when the
1-2 shift solenoid is commanded ON.
2-3 Shift Error: Displays a range of -6.38 to
+6.38 seconds. This parameter is the difference
between the desired 2-3 shift time and the actual
2-3 shift time. A positive number indicates that
the actual shift time was longer than the desired shift
time. This value is only accurate if the Adaptable
Shift parameter indicates Yes.
2-3 Shift Time: Displays a range of
0.00-6.38 seconds. This parameter is the actual time
of the last 2-3 shift. The shift time is based on the
engine RPM drop after the commanded 2-3 shift. This
value is only accurate jf the Adaptable Shift
parameter indicates Yes.
2-3 Sol.: Displays ON or OFF. This parameter is the
commanded state of the 2-3 shift solenoid valve.
ON represents a commanded energized state (current
is flowing through the solenoid). OFF represents a
non-commanded state (current is not flowing through
the solenoid).
2-3 Sol. Open/Short to GND: Displays Yes or No.
This parameter indicates if an open or short to
ground exists in the 2-3 shift solenoid valve feedback
signal to the PCM. This parameter is valid only
when the 2-3 shift solenoid is commanded OFF.
2-3 Sol. Short to Volts: Displays Yes or No. This
parameter indicates if a short to voltage exists in
the 2-3 shift solenoid valve feedback signal to
the PCM. This parameter is valid only when the
2-3 shift solenoid is commanded ON.
3-2 Downshift Sol.: Displays On or Off. This
parameter indicates if the 3"2 shift solenoid valve
assembly is currently commanded On or Off.
The solenoid commanded state is based on the
transmission temperature. The solenoid will change
states during a 3-2 downshift to regulate the

Transmissionrrransaxle

7-63

appropriate pressure. The commanded state of the

solenoid occurs at approximately 30 mph with a throttle
increase.

Engine Torque: Displays a range of 0-9999 lbs ft.

This parameter indicates the amount of torque
that is delivered from the engine.

3-2 Downshift Sol. Open/Short to GND: Displays

Yes or No. This parameter indicates if an open or short
to ground exists in the 3-2 shift solenoid valve assembly
feedback signal to the PCM. This parameter is valid
only when the 3-2 shift solenoid is commanded OFF.

Hot Mode: Displays On or Off. This parameter

monitors transmission temperature. On indicates that
the transmission temperature has exceeded
135C (275F).

3-2 Downshift Sol. Short to Volts: Displays Yes or

No. This parameter indicates if a short to voltage
exists in the 3-2 shift solenoid valve assembly
feedback signal to the PCM. This parameter is valid
only when the 3-2 shift solenoid is commanded ON.
3-4 Shift Time: Displays a range of
0.00-6.38 seconds. This parameter is the actual time
of the last 3-4 shift. The shift time is based on the
engine RPM drop after the commanded 3-4 shift. This
value is only accurate if the Adaptable Shift
parameter indicates Yes.
A/C Clutch: Displays On or Off. This parameter
indicates the commanded state of the A/C control
relay. The clutch should be engaged when On
displays.
Adaptable Shift: Displays Yes or No. Yes indicates
that the proper operating conditions were all within
the proper operating range during the last shift and that
the shift time .was accurate. This shift information is
then used through the adaptive function in order
to update the adapt cells. No indicates that not all of
the operating conditions were met in order to
enable this function and that the adapt cells were not
updated.
Current Gear: Displays 1, 2, 3 or 4. This parameter
indicates the current commanded state of the shift
solenoids.
Current TAP (Transmission Adaptive Pressure)
Cell: Displays a TP cell range of 0-16. This
parameter indicates the current throttle position cell
used for line pressure modification (adaptation).
Current TAP (Transmission Adaptive Pressure)
Memory: Displays a range of -16 to + 16 psi.
This parameter is the amount of pressure that is added
to base line pressure to adjust the holding effort of a
clutch or band, while shifting.
ECT (Engine Coolant Temperature): Displays a
range of -40C to 151C (-40F to 304F). This
parameter is the input signal of the engine coolant
temperature sensor. The engine coolant temperature
is high (151 C) when the signal voltage is low
(0 V), and the engine coolant temperature is low
(-40) when the signal voltage is high (5 V).

\.

Automatic Transmission - 4L60-E

Engine Run Time: Displays a range of

0:00:00-18: 12: 15 hr/min/sec. This parameter
measures how long the engine has been operating.
When the ignition switch is turned OFF, the value
is reset to zero.
Engine Speed: Displays a range of 0-8192 RPM.
This parameter indicates the rotational speed of
the engine expressed as revolutions per minute.

IAT (Intake Air Temperature): Displays a range of

-40C to 215C (-40F to 419F). The IATsensor is a
thermistor that is used to monitor the temperature of the
air entering the intake manifold. The PCM applies
5 volts to the sensor on a 5 volt reference circuit. When
the air is cool, the resistance in the sensor will be high.
If the air is warm, the sensor resistance will be low and
the PCM will sense a low voltage signal. The PCM
converts the signal of the IAT sensor to degrees
Celsius. Intake air temperature is used by the PCM to
adjust fuel delivery and spark timing.
Ignition Voltage: Displays a range of 0.0-25.5 V.
This represents the system voltage measured by
the PCM at it's ignition feed.
Latest Shift: Displays a range of 0.00-6.38 seconds.
This parameter is the actual time of the last upshift.
This value is only accurate if the Adaptable Shift
parameter indicates Yes.
PC Sol. Actual Current: Displays a range of
0.00-1.10 amps. This parameter is the actual current
of the pressure control solenoid circuit at the control
module. Zero amp (no current flow) indicates
actual higher line pressure. Actual lower line pressure
is indicated by 1.1 amps (high current flow).
PC Sol. Duty Cycle: Displays a range of 0-100%.
This parameter is the commanded state of the
pressure control solenoid expressed as a percent of
energized ON time. Zero percent indicates zero
ON time (non-energized) or no current flow.
Approximately 60% at idle indicates maximum ON
time (energized) or high current flow.
PC Ref. (Reference) Current: Displays a range of
0.00-1.10 amps. This parameter is the commanded
current of the pressure control solenoid circuit.
Zero amp (no current flow) indicates commanded
higher line pressure. Commanded lower line pressure
is indicated by 1.1 amps (high current flow).
Speed Ratio: Displays a range of 0.00:1-8.00:1.
This parameter indicates engine speed divided
by transmission output speed. This value is used to
estimate transmission gear ratio.
TCC Brake Switch: Displays Open or Closed. This
parameter indicates the state of the brake switch
circuit input. Open indicates a zero voltage input (brake
switch open, brake pedal applied). Closed indicates
a B+ voltage input (brake switch closed, brake
pedal released).
TCC Duty Cycle: Displays a range of 0-100%. This
parameter is the commanded percentage of ON time of
the TCC PWM solenoid. Approximately 90% represents
an ON (energized) commanded state. Zero percent
represents an OFF (non-energized) commanded state.
This commanded state is applied at a vehicle speed
between approximately 0-16 km/h (0-10 mph).

7..54

Automatic Transmission - 4L60-E

TCC Duty Cycle Open/Short to GND: Displays Yes

or No. This parameter indicates whether an open or
a short to ground exists in the TCC PWM solenoid
valve feedback signal to the PCM. This parameter is
valid. only when the TCC PWM solenoid is commanded
OFF (duty cycle is 0%).
TCC Duty Cycle Short to Volts: Displays Yes or
No. This parameter indicates whether a short to
voltage exists in the TCC PWM solenoid valve .
feedback signal to the PCM. This parameter is valid
only when the TCC PWM solenoid is commanded ON
(duty cycle is at maximum).
TCC Enable: Displays Yes or No. This parameter is
the commanded state of the TCC solenoid. Yes
indicates a commanded energized state (current is
flowing through the solenoid). No indicates a
commanded non-energized state (current is not
flowing through the solenoid). This commanded state
occurs at various vehicle speeds between
applications.

Transmission!Transaxle
value. When variable TCC apply pressure stops
(Apply Mode), maximum TCC pressure is used.
Five (5) or Coast Mode indicates that the PCM
co.mrnands apply of the TCC. when the transmission is
in fourth gear and the throttle and vehicle speed
are not high enough to enable Apply Mode,. but high
eriough to keep the TCC applied. When Coast Mode is
active, TCC apply pressure is set to a predetermined
amount.
TCC (Torque Converter Clutct"!) Slip
Speed: Displays a range of -4080 to 4079 RPM.
This parameter is the difference between transmission
output speed and engine speed. A negative value
indicates that the engine speed is less than the output
speed (deceleration). A positive value indicates that
the engine speed is greater than the output speed
(acceleration). A value of zero indicates that the engine
speed is equal to the output speed (TCC applied).

TCC Enable Open/Short to GND: Displays Yes or

No. This parameter indicates whether an open or a
short to ground exists in the TCC solenoid valve
feedback signal to the PCM. This parameter is valid.
only when the TCC solenoid is commanded OFF.

TFT (Transmission Fluid Temperature)

Sensor: Displays a range of o.oo.:...5.00 V. When the
transmission fluid is cold, the sensor resistance is
high and the PCM will sense high signal voltage. As
the transmission fluid temperature warms to a
normal operating temperature, the sensor resistance
becomes less and the voltage decreases.

TCC Enable Short to Volts: Displays Yes or No.

This parameter indicates whether a short to voltage
exists i.n the TCC solenoid valve feedback signal to the
PCM. This parameter is valid only whenthe TCC
solenoid is commanded ON.

TFP Switch .AJB/C: Displays On/Off, On/Ott, On/Off.

These parameters are the three inputs from the
Automatic Transmission Fluid Pressure Manual Valve
Position Switch Assembly. On represents a O voltage
signal. Off represents B+ voltage signal.

TCC Mode: Displays a range of O through 5.

Zero (0) or Off Mode indicates .that the PCM
commands the TCC OFF at a calibrated minimum
throttle. The calibrated minimum throttle is different at
low vehicle speeds than it is at high vehicle speeds.
Off Mode is also active when the transmission is in the
wrong gear range, the engine or the transmission is
cold, the brake input indicates that the brakes are ON,
a downshift or upshift is initiated, the engine is at
idle, the transmission is in Hot Mode or a misfire is
detected. One (1) or Release Mode indicates that the
PCM commands the release of the TCC. Two (2)
or Apply Mode indicates that the PCM commands the
apply of the TCC. Apply pressure varies based on
normal or performance operations, hot conditions or if
the cruise control is active. Apply Mode is used
under normal driving conditions. All apply pressure is
dependent on throttle position and vehicle speed.
Three (3) or Apply Enable Mode indicates that
enabling conditions are met for applying the TCC
(enabling conditions include vehicle speed, gear
selection, transmission temperature, throttle angle,
brake switch status, etc.). Four (4) or Locked
Mode indicate.s that the PCM commands full capacity
of the TCC when the transmission is in fourth gear
and the vehicle speed is greater than a calibrated

TP (Throttle Position) Angle: Displays a range of

0-100%. The TP angle is computed by the PCM
from the TP Sensor voltage. The TP angle should read
0%at idle and 100% at Wide Open Throttle (WOT).

TP (Throttie Position) Sensor: Displays a range of

0.00-5.00 volts. The TP Sensor is used by the
PCM to determine the amount of throttle demanded by
the driver. Voltage is below 1 volt at idle and above
4 volts at Wide Open Throttle (WOT).
Trans. Fluid Temp'.: Displays a range of -40C to .
151 C (-40F to 304F). This parameter is tt:ie

input signal of the transmission fluid temperature

sensor.Transmission flurd temperature is high (151C)
when signal voltage is low (O V), and transmission
fluid temperature is low (-40C) wheh signal voltage is
high (5 V).
Transmission OSS (Output Speed
Sensor): Displays a range of 0-8192 RPM. This
parameter indicates the rotational speed of the
transmission output shaft expressed as revolutions per
minute.
Vehicle Speed: Displays a range of 0-255 km/h
(0-158 mph). This parameter is the input signal from
the vehicle speed sensor assembly.

Transmission/Transaxle

Automatic Transmission - 4L60-E

7-65

Diagnostic Trouble Code Identification (3.8L)

OTC

P0218

P0502

Description

Transmission Fluid
Overtemperature

Vehicle Speed Sensor CircuitLow Input

P0503

Vehicle Speed Sensor CircuitIntermittent

P0711

Transmission Fluid Temperature

Sensor CircuitRange/Performance

OTC Type*

OTC P0218 stores in PCM history

The PCM freezes shift adapts from being
updated

OTC P0502 stores in PCM history

The PCM commands second gear only
The PCM commands maximum line
pressure
The PCM freezes shift adapts from being
updated
The PCM inhibits TCC engagement

OTC P0503 stores in PCM history

The PCM commands a soft landing to
second gear below 2500 RPM
The PCM commands maximum line
pressure
The PCM inhibits TCC engagement
The PCM inhibits 4th gear if the
transmission is in hot mode
The PCM freezes shift adapts from being
updated

OTC P0711 stores in PCM history

The PCM uses a transmission fluid
temperature default value based on engine
coolant, engine run time and IAT at startup
The PCM freezes shift adapts from being
updated

OTC P0712 stores in PCM history

The PCM uses a transmission fluid
temperature default value based on engine
coolant, engine run time and IAT at startup
The PCM freezes shift adapts from being
updated

(
P0712

Transmission Fluid Temperature

Sensor Circuit-Low Input

Default Action

P0713

Transmission i=luid Temperature

Sensor Circuit-High Input

OTC P0713 stores in PCM history

The PCM uses a transmission fluid
temperature default value based on engine
coolant, engine run time and IAT at startup
The PCM freezes shift adapts from being
updated

P0719

Brake Switch Circuit-Low Input

OTC P0719 stores in PCM history

The PCM disregards the brake switch input
for TCC scheduling

P0724

Brake Switch Circuit-High Input

OTC P0724 stores in PCM history

P0740

Torque Converter Clutch Enable

Solenoid Circuit-Electrical

OTC P0740 stores in PCM history

The PCM inhibits TCC engagement
The PCM inhibits 4th gear if the
transmission is in hot mode
The PCM freezes shift adapts from being
updated

P0742

Torque Converter Clutch

System-Stuck ON

OTC P0742 stores in PCM history

The PCM freezes shift adapts from being
updated

P0748

Pressure Control Solenoid

Circuit-Electrical

OTC P0748 stores in PCM history

The PC Sol. Valve is OFF
The PCM freezes shift adapts from being
updated

7-66

TransmissionJTransaxle

Automatic Transmission - 4L60-E

Diagnostic Trouble Code Identification (3.8L) (cont'd)

DTC

P0751

P0753

P0756

P0758

Description

1-2 Shift Solenoid ValvePerformance

1-2 Shift Solenoid CircuitElectrical

2-3 Shift Solenoid ValvePerformance

2-3 Shift Solenoid CircuitElectrical

P0785

3-2 Shift Solenoid CircuitElectrical

P1810

Transmission Fluid Pressure

Manual Valve Position Switch
Assembly Circuit Malfunction

DTCType*

Default Action

OTC P0751 stores in PCM history

The PCM commands 02 line pressure
The PCM inhibits 3-2 downshifts if the
vehicle speed is greater than
48 km/h (30 mph)
The PCM freezes shift adapts from being
updated

OTC P0753 stores in PCM history

The PCM commands 02 line pressure
The PCM inhibits 3-2 downshifts if the
vehicle speed is greater than
48 km/h (30 mph)
The PCM freezes shift adapts from being
updated

OTC P0756 stores in PCM history

The PCM commands third gear only
The PCM commands maximum line
pressure
The PCM inhibits TCC engagement
The PCM freezes shift adapts from being
updated

OTC P0758 stores in PCM history

The PCM commands 3rd gear only
The PCM commands maximum line
pressure
The PCM inhibits TCC engagement
The PCM freezes shift adapts from being
updated

OTC P0785 stores in PCM history

The PCM commands a soft landing to
3rd gear
The PCM inhibits TCC engagement
The PCM commands maximum line
pressure
The PCM inhibits 4th gear if the
transmission is in hot mode
The PCM freezes shift adapts from being
updated

OTC 1810 stores in PCM history

The PCM commands 02 line pressure
The PCM commands a 04 shift pattern
The PCM freezes shift adapts from being
updated

TransmissionJTransaxle

Automatic Transmission - 4L60-E

7-67

Diagnostic Trouble Code Identification (3.8L) (cont'd)

DTC

P1860

P1870

Description

Torque Converter Clutch Pulse

Width Modulation Solenoid
Circuit-Electrical

Transmission Component Slipping

DTC Type*

Default Action

DTC P1860 stores in PCM history

The PCM inhibits TCC engagement
The PCM inhibits 4th gear if the
transmission is in hot mode
The PCM freezes shift adapts from being
updated

DTC P1870 stores in PCM history

The PCM inhibits TCC engagement
The PCM commands maximum line
pressure
The PCM inhibits 4th gear if the
transmission is in hot mode
The PCM freezes shift adapts from being
updated

*DTC Types: A-Emission-related, turns the MIL ON after the first failure. B-Emission-related, turns the MIL ON after two
consecutive trips with failure. C-Non-emission-related, turns the service lamp ON after the first failure.
D-Non-emission-related, no lamps.

Diagnostic Trouble Code Identification (5.7L)

DTC
P0218

P0502

P0503

P0711

P0712

Description
Transmission Fluid
Overtemperature

Vehicle Speed Sensor CircuitLow Input

Vehicle Speed Sensor CircuitIntermittent

Transmission Fluid Temperature

Sensor CircuitRange/Performance

Transmission Fluid Temperature

Sensor Circuit-Low Input

DTCType*

Default Action

DTC P0218 stores in PCM history

The PCM freezes shift adapts from being
updated

DTC P0502 stores in PCM history

The PCM commands second gear only
The PCM commands maximum line
pressure
The PCM freezes shift adapts from being
updated
The PCM inhibits TCC engagement

DTC P0503 stores in PCM history

The PCM commands a soft landing to
second gear
The PCM commands maximum line
pressure
The PCM inhibits TCC engagement
The PCM inhibits 4th gear if the
transmission is in hot mode
The PCM freezes shift adapts from being
updated

DTC P0711 stores in PCM history

The PCM uses a transmission fluid
temperature default value based on engine
coolant, engine run time and IAT at startup
The PCM freezes shift adapts from being
updated

DTC P0712 stores in PCM history

The PCM uses a transmission fluid
temperature default value based on engine
coolant, engine run time and IAT at startup
The PCM freezes shift adapts from being
updated

7-68

Transmission/Transaxle

Automatic Transmission - 4L60E

Diagnostic Trouble Code Identification (5.7L) (cont'd)

DTC Type*

Default Action

P0713

Transmission Fluid Temperature

Sensor Circuit-High Input

DTC P0713 stores in PCM history

The PCM uses a transmission fluid
temperature default value based on engine
coolant, engine run time and IAT at startup
The PCM freezes shift adapts from being
updated

P0719

Brake Switch Circuit-Low Input

OTC P0719 stores in PCM history

The PCM disregards the brake switch input
for TCC scheduling

P0724

Brake Switch Circuit-High Input

DTC

Description

OTC P0724 stores in PCM history

P0740

Torque Converter Clutch Enable

Solenoid Circuit-Electrical

OTC P0740 stores in PCM history

The PCM inhibits TCC engagement
The PCM inhibits 4th gear if the
transmission is in hot mode
The PCM freezes shift adapts from being
updated

P0742

Torque Converter Clutch System

Stuck-ON

OTC P0742 stores in PCM history

The PCM freezes shift adapts from being
updated

P0748

Pressure Control Solenoid

Circuit-Electrical

OTC P0748 stores in PCM history

The PC Sol. valve is OFF
The PCM freezes shift adapts from being
updated

OTC P0751 stores in PCM history

The PCM commands 02 line pressure
The PCM inhibits 3-2 downshifts if the
vehicle speed is greater than
48 km/h (30 mph)
The PCM freezes shift adapts from being
updated

OTC P0753 stores in PCM history

The PCM commands 02 line pressure
The PCM inhibits 3-2 downshifts if the
vehicle speed is greater than
48 km/h (30 mph)
The PCM freezes shift adapts from being
updated

OTC P0756 stores in PCM history

The PCM commands third gear only
The PCM commands maximum line
pressure
The PCM inhibits TCC engagement
The PCM freezes shift adapts from being
updated

OTC P0758 stores in PCM history

The PCM commands 3rd gear only
The PCM commands maximum line
pressure
The PCM inhibits TCC engagement
The PCM freezes shift adapts from being
updated

P0751

P0753

P0756

P0758

1-2 Shift Solenoid ValvePerformance

1-2 Shift Solenoid CircuitElectrical

2-3 Shift Solenoid ValvePerformance

2-3 Shift Solenoid CircuitElectrical

Automatic Transmission - 4L60-E

Transmission/Tran.saxle

7-69

Diagnostic Trouble Code Identification (5.7L) (cont'd)

OTC

Description

OTC Type*

Default Action

..

DTC P0785 stores in PCM history

The PCM commands a soft landing to
3rd gear
The PCM inhibits TCC engagement
The PCM commands maximum line
pressure
The PCM inhibits 4th gear if the
transmission is in hot mode
The PCM freezes shift adapts from being
updated

DTC P1860 stores in PCM history

The PCM inhibits TCC engagement
The PCM inhibits 4th gear if the
transmission is in hot mode
The PCM freezes shift adapts from being
updated

-
P0785

3-2 Shift Solenoid Circuit-'Electrical

P1810

Transmission Fluid Pressure

Manual Valve Position Switch
Assembly Circuit Malfunction

P1860

Torque Converter Clutch Pulse

Width Modulation Solenoid
Circuit-Electrical

DTC 181 O stores in PCM history

The PCM commands D2 line pressure
The PCM commands a D4 shift pattern
The PCM freezes shift adapts from bein~
updated

DTC P1870 stores in PCM history

The PCM inhibits TCC engagement
The PCM commands maximum line
pressure
P1870
Transmission Component Slipping
B
The PCM inhibits 4th gear if the
transmission is iri hot mode
The PCM freezes shift adapts from being
updated
*DTC Types: A-Emission-related, turns the MIL ON after the first failure. B-Emission-related, turns the MIL ON after two
consecutive trips with failure. C-Non-emission-related, turns the .service lamp ON after the first failure.
D-Non-emission-related, no lamps.

Fluid Capacity
Specification
Metric

English

Pan Removal

4.7 liters

5 quarts

Overhaul

10.6 liters

11 quarts

Application

7-70

Transmission/Transaxle

Automatic Transmission - 4L60-E

Range Reference

Range

Park

Reverse Neutral

Gear

OD

1st

2nd

3rd

4th

1st

2nd

3rd

1st**

2nd

1st

2nd***

1-2 Shift
Solenoid

ON*

ON*

ON*

ON

OFF

OFF

ON

ON

OFF

OFF

ON

OFF

ON

OFF

2-3 Shift
Solenoid

ON*

ON*

ON*

ON

ON

OFF

OFF

ON

ON

OFF

ON

ON

ON

ON

2-4 Band

Reverse
Input
Clutch

Overrun
Clutch

Forward
Clutch

Forward
Sp rag
Clutch
Assembly

3-4
Clutch

Lo/Roller
Clutch

Lo/Rev
Clutch

A = Applied H = Holding ON = The solenoid is energized. OFF = The solenoid is de-energized. *Shift Solenoid state is a
function of vehicle speed and may change if the vehicle speed increases sufficiently in Park, Reverse or Neutral. However,
this does not affect the operation of the transmission. **Manual Second-First gear is electronically prevented under normal
operating conditions. ***Manual First-Second gear is only available above approximately 48-56 km/h (30-35 mph}.

Shift Solenoid Valve State and Gear Ratio

Gear

1-2 Shift
Solenoid

2-3 Shift
Solenoid

Gear Ratio

ON

ON

3.059:1

OFF

ON

1.625:1

OFF

OFF

1.000:1

OFF

0.696:1

ON

Shift Speed
3.8L (L36)
3-1@

3-2@

+/-

Min
+/2-3
100
100
3-1
TCC
RPM
RPM
Apply
Wide
Wide
@ 12%
1-2 Shift @ +/- 2-3 Shift @ +/- 3-4 Shift @ +/- Output Output Open
Open
250 RPM Output 200 RPM Output 150 RPM Output Shaft Shaft Throttle Throttle Throttle
(RPM)
Shaft Speed
Shaft Speed
Shaft Speed
Speed Speed
Shift
Shift

% of TPS

12

Trans Cal

Axle

3.08

619

3.42

590

25

50

I 950 I 1239
I 95311226

12

I
I

25

50

12

25

50

1115 1735 2354 21481305614584

N/A

785

1445

5500

1363

10901172512315 20881340515039

N/A

772

1453

5700

1362

Transmissionrrransaxle

Automatic Transmission - 4L60-E

7-71

5.7L (LS1)
3-1@ 3-2@
Min
+/+/3-1
TCC
100
2-3
100
Wide
Apply
Wide
RPM
RPM
1-2 Shift @ +/- 2-3 Shift @ +/- 3-4 Shift @ +/- Output Output Open
Open @ 12%
250 RPM Output 200 RPM Output 150 RPM Output Shaft Shaft Throttle Throttle Throttle
(RPM)
Shaft Speed
Shaft Speed
Shaft Speed
Shift
Speed Speed Shift
12

2.73

474

3.23

478

I 657 I 1168
I 696 I 1218

% of TPS
Trans Cal

Axle

A
B

25

50

12

25

50

12

25

50

839 I 120512153 12041182515475

870 I 126112218 1261 187015829

N/A

657

N/A

696

Range
Signal A

Range
Signal B

Range
Signal C

Park

OFF

ON

OFF

Reverse

ON

ON

OFF

Neutral

OFF

ON

OFF

04

OFF

ON

ON

03

OFF

OFF

ON

02

OFF

OFF

OFF

01

ON

OFF

OFF

Illegal

ON

OFF

ON

Illegal

ON

ON

ON

5900
5900

1569
1566

Line Pressure

TFP Manual Valve Position Switch Logic

Gear
Position

1460
1522

Pressure Control Solenoid

Current (Amp)

Approximate Line
Pressure (PSI)

2.2U3.8U4.3L
0.00
0.10
0.20

172-192
171-191
166-186

0.30
0.40
0.50
0.60

160-180
151-171
140-160
127-147

0.70
0.80
0,90

110-130
91-111

1.00
1.10
4.8U5.0U5.3U5.7L

70-90
58-78
51-71

0.00
0.10
0.20
0.30
0.40

203-223
202-222
195-215
189-209
176-196

0.50
0.60
0.70
0.80

163-183
146-166
125-145
102-122

0.90

75-95
59-79
51-71

1.00
1.10

7-72

Automatic Transmission - 4L60-E

TransmissionfTransaxle

Diagnostic Information and Procedures

Functional Test Procedure
Action

Step

Value(s)

Perform the Transmission Fluid Checking Procedure.

Is the fluid level correct?

Yes

Go to Step 2

Check for PCM trouble codes, both current and history.

Go Jo Diagnostic
Trouble Code
Identification
(3.SL) or
Diagnostic
Trouble Code
Identification
(5.71..)

Are PCM trouble codes present?

2. Perform the Road Test Procedure;

Is a harsh or soft shift condition present
IS the vehicle's perfbrmance poor?

5
6

7
8

Is the engagement into Drive or Reverse delayed or

missing?
Perform the Line Pressure Check Procedure.
Is the line pressure correct?
Inspect the transmission wire llarness connectors and the
transmission range switch.

Go to Step 4

Go to Step 12

Go to Step 7

Go to Step 5

Go to Torque
Converter Clutch
Diagnosis

Go to Step 6

Go to Step 7

Go to Step 9

Go to Step 8

Go to Symptom
Diagnosis Tables

System OK

Go to Symptom
Diagnosis Tables

Go to
Flexplate!Torque
Converter
Vibration Test

Go to Step 10

Go to Fluid Leak
Diagnosis and
Repair

Go to Step 11

Go to Symptom
Diagnosis Tables

Go to Step 12

System OK

Go to Step 1

Was the condition found and corrected?

Is vibration or noise a concern?
9
'

Is the fluid leaking?

10

11
12

Are other transmission conditions present?

Was the condition corrected?

Go to Step 3

Was the condition duplicated?

1. Perform the Electrical/Garage Shift Procedure.

No

TransmissionJTransaxle

Automatic Transmission - 4L60-E

Schematic and Routing Diagrams

Automatic Transmission Schematic References
Section Number Subsection Name

Reference on Schematic
Ground Distribution Cell-14

8 - Wiring Systems

Power Distribution Cell-10

8 - Wiring Systems

Automatic Transmission Schematic Icons

Icon

Icon Definition
Refer to ESD Notice in Cautions and Notices.

19384

Refer to 080 II Symbol Description Notice in Cautions and Notices.

19385

7-73

Automatic Transmission Controls Schematics (2nd Gear Clutch Anticipated Switch)

........
I

........
r - - - I Fuse Block

!Hot In Run!
- - -

.,::..

, IP

)>

IF

TURN B/U
use
1Block
Fuse 2
_ _ JI
I... _ _ _ _ _ _ _
E1_ _
20A
I Details
cen 11

F1

a5

0.8 BRN 141

0.35GRY 48

[ZJ
O

Fuse Block
Details
Cell11

Cruise

-I
+- - - -

:::,

en

Control
Clutch

0.8 BRN 141

Anticipate
~

Switch

I
I
I

0.35 BLK/WHT 451

A -------------~

- Illumination

o~~~7

C270

A13

!:!!.

~ ~~~r

CD 2nd
Ge?'

(Momentary

lnd1cator

:::,

I Start
I Switch
I

l~~c: --------------- ---- ~

B

0.35
BRN/ 1571
WHT

0.35GRY 48

en

-1- --A

~ -F

0.35 BLK/WHT 451

ii1

8207

0.35 PPL/WHT 1572

g~gg~

9?Q~~ -- -- -- -- - - -- -- - - -- -- - - -- ~

P100

r -

8215
0.35 BLK/WHT
----------JJr--=-=4'-'5==1=.:...:..:...:..!...J

0.8
BLK/WHT
B

c~~~

0.8
BLK/WHT 451

.1

----------Aic!~~o

Distribution

.......,Ce_.11..,14__

~ - -

$110

0.35 PPL/WHT 1572

c.f ---------------------~-~:

0.35 BRN/WHT 1571 .

A
~~-~.~1.;.5:25
. .. ,

0.35 GRY 48

.?J
Clutcil1- ----- -2~Ge;1----------------18

Ground

0.35
BRN/ 1571
WHT

r - I
Anticipate
I
Switch
I
signa1
I

_________________

C2

2 C1

-,-2nd Gear-

Indicator
Control

Indicator
--1Control

- - - - - - P
C1=BCLMU

,Powertrain
I Control
IMOdUle

.&

3 BLK/WHT 451
I
~
=
=
=
C2=CLEAR
I (PCM) ~
G110 ._ _______________________________________________ ...

193722

...

Automatic Transmission Controls Schematics (Brake Switch, TCC Solenoid)

!Hot In flun, Bulb Test And Start)
r - - - - I Power
I Distribution
ce1110

ENG SEN

MinlFuse

.. ___________

I
I

20A

" iHot In Run, Bulb Test And Start!

"'Underhood
Electrical
1 Center 2
I

...

!Loe

EN(3CTRL I

Electrical
2

Mlnlfuse I Center
15A
I

I
I

- ... - - "' Underhood

I Power
Distribution
I Cell10

----------,

0.8 PNK 539

B C105
0.8 PNK 539
8104
- - - - - - - -

P110

't

0.5 PNK 239

Fuse Bl

Fuse

Details
Cell11

G C100

Details
Cell 11

~
~

::::i
...

r--------------~--- --------------------,

Transmission

C C2
r -

I
I
I

Stop Lamp
I Switch
I (Open with
TCC/Shift. I brake pedal
-

--- Switch

0.5 RED 839

0.5 RED 839

L--

Clutch
Solenoid

[_05~1-~~)05T:}"

0.8
PPL 420

H C230

P110

o ue

(PCM) I

0.5 RED 839

0.5 RED 839

Signal

0.5 TAN/BU< 422

"

--T Control

[]1 !~1!n~idift []1 ~!n!':

(2-

0.5 YELJBLK 1223

----------~~

. Valve
--Teontrol

(1- 2SS)
Valve -

3 SS)
Valve

0.5 LT GRN 1222

0.5WHT 687

_________ !~

79

Vatite

.,,.

(3- 2

~:~+ =~ 05~1= --MLT~lm---_l

=1----- -------------,-:;~~---7-T~~.-;~
30 C1

~!n!~dift
SS)
Valve

0.5 BRN 418

0.8
PPL 420

M d I I

0.5 RED 839

Clutch
Pulse Width

D C2

Po~e:;:~~

..

: []1 ~:.~er []11 6::.~r []1

I
I

----J

I
I
I

"I

Interrupt .1 depressed)

I
I

0.5 PNK 239

Automatic

0.8 PNK 539

C2

44

-,-3=-2ss- - -

Valv
Assembly
Control

4 C1

Valve
Assembly
Control

---T Control

-,--';~~~-=.-.:.-..:} ~~;- - - - - ~

---T

---T

Valve

cii"
t/)

8107 - - - - - - --:- - - , .J

GIC230

::s
t/)
:3

Jescl

0.5 PNK 239

0.8 PNK 539

ock

D>

PCM
C1=BW .
c 2 =cLEAJ'I

I
I

.. -- - --- - - - - - - - - - - - - - - - - --- - - - - - - - - - - - - - - - - --- - _; - - - - --- :.. - - --- - - "

193106

s
::,

D)

:,
UJ
D)

><
ci"

Automatic .Transmission Controls Schematics {Trans Range)

'r--.- - - - - - - - - - - - - - - - - - - - - - - - - .... - - - - - ., Powertrain

:
~--------------------------------"'~.._.
----------17 ------------68
.
transmission ,
Range A
.
Input

I
I

Transmission
Range B
Input

22 C1

Transmission
Range C
Input

TFT
Sensor
Signal

57

0.5 PNK 1224 .

I
1

0.5 DK BLU 1225

Module (PCM)

BTSI,
Ceil138

0.5 VEl.JBLK 1227

0.5 RED 1226

JEsc!

Hatch
Release
Ceil134

.,.

C2

R
-

~1

-.-

0.5DKBLUt225 -

el

REV

DA

:::::r
(I)

LO
Switch

0.5BRN1;227 -

Ar

- - -

- -

- -

- -

(TFP) Manual
~=:osttlon

0.5 LT BLU 1229

B~
0.5GRYi20 _ _ _ _ _ _

- __ - - __ - ___

. .
II ~, P
\ : ..,:.....
I.. R-

,.

r-i

I
I

0.5GRY 720
5121

I
I

,,
-

Sensor

'

I
I. -

-- -

.. -

PC SOL

Ground

______ ~

1. . - - - -

'

.!
Ground

F C220
0.35
ORN/BLK 434 . 0.8 BLK/WHT 451

Distribution
Cell14

_______ _1!, C2
t.....- - - PNP

it' ..

..
-

... -

... - -

I.

----

.Switch
' ..

'

.
'~ -

12V
-

C1 = BLU
C2=CLEAR

PCM

....J

Powertra.m
I Control . .
I Module (PCM)

- - - - - - - -

PCs.01..
Valve High . .

Valve Low, .

=
-

- - - - -,

0.5.
RED/BLK 1228

.
-

I
I
I

P110

___________4

35
-

','
.-2

1Go

J C230 0.8 BLK/WHT 451

0.35GRY 720

..

0.35 BLK/WHT 451

_ _ ,..:.,.:~_ __ _

A/CPressure .,_ _ _ _ _
Sensor

Neutral
I Position
switch
I

~--------"'

0.5 PPL 1228

0.5 LT BLU/WHT 1229

" -

. 02

- _ -

:::,

..

$215
- _ - - - _ - -

(I)

" - -;;r.- - - - - , Park

. .. . Automatic .
-Pr.ssure
Transmissiqn : Control SolenOid
Fluid Pressure ' (PC, SOL) Valve

., __ Switch

.,,.
- ___ -

3
iii"

0.35 ORN/BLK
$234-----------"----~
434
0.35
ORN/BLK 434
Automatic
Transmission
B

04
Switch

03
Switch

Switch

a
c;

-I

- -0.50RNl226 -

r- - 0.5PNiJ;224

:J>

:~~

'

.,

.&

~
192118

;
m

-I

Automatic Transmission Controls Schematics (Transmission Control)

IHot With lgn 1 Relay Energized I

r -

I
I
I

J7

- - -

- -

!Hot With lgn 1 Relay Energized!

-

- -

- - -

ENG SEN
MiniFuse
20 A

J6

L-

- - - - -

- - -

Power
Distribution
Cell 10

- -

- - -

- - -

- -

G9
GS

--------------------------------

- -

- , Underhood

- - - -

~
~
~

Electrical
I Center 2
I

ENG CTRL
MiniFuse
15 A

~--------~

,,,

0.5 PNK 239

0.8PNK 539
B

!Loe I

C105

Fuse Block
Details
Cell11

0.5 PNK
239

8182
0.5 PNK 239

0.8PNK 539

__ _.

$104

~io

0.8 PNK 539

I
L

TCC/Shnt

t-- :::pt
-

DLI c2

I Lamp

I Switch

o.5

~ (Open with
~==I

420

BU< 422

Valve

0.5 RED 839

0.5 RED 839

0.5 RED 839

Clutch Pulse
Width
Modulation

~c~~
SOL)
Valve

BI

0.5 TAN 418 -

!;!n!~c\"
(3- 2 SS)
Valve
Assembly

BI

[]1

.~;!n!~dnt
(2-3 SS)
Valve

[]i

""'f

D)

:::,
ti)
D)

er><

)>

c
0

BI

Bl

D)

0.5 WHT 687 -

0.5
TAN/BLK 422

0.8P~1:10

==I

~1!ns~:
(1- 2 SS)
Valve

0.5 YEL 1223

0.5 LT GRN 1222 -

-I
""I

A
0.5
LT GAN 1222

0.5 WHT 687

32 ----0~~~: :

:::,

>

ti)

:lJ
;

34 ----~ 1:____ ~ M~i

ti)

s
:::,

,I. - - - - - - - - - - - - - - - - - - - - - - - - - - --- - - -PWM

- - - - - - 3-2
- -SS- - - - - ~-A--.- -1--2 - - - - - - - - ,I
2 -3
I
I

0
:::,

D)

H C230

TCC/Cruise Brake
Switch
Input

-
ti)

Automatic
Transmission

0.5 RED 839

Clutch
Solenoid
(TCC SOL)

. 0.35 PP

839

I :::rter []1 ~~~er []1

C2

-1- - - - , Stop

r---------------- --------------------,

G C230

tn

0.5 PNK
239

8107
0.5 PNK 239
E

P110

:::,

0.5 PNK 239

0.8 PNK 539

C100

PCM
C1=RED
C2=BLU

TCC SOL
Valve
Control

TCC
Valve
Control

SOL

Valve Assembly
Control

SS
Valve

ConitOI

SS
Valve
control

.s.

ren

I
I

C)
I

~------------------------------------------------------------J

.......
I
.......
192883

.......

Automatic Transmission Controls Schematics (Transmission Controls)

" - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,Powertram
II

Tranamlssion
Range A

lnpul

Transmission
Range B

Transmission
Rahge c

-= _-; =-- ::-_-= _-:. =---= lnpul =--::-_-= _-:. =-- Input

25

22

_ _ _ _ _ _ _

61

I~~

C1

Signal

13

1
_ _ ..1

-a

Hatch
Release

Module (PCM)
I

TFT
Sensor

)>

CeU134

~.

BTSI

3
5

Cell 138

C2
0.5 ORN/BLK 434

0.5 PNK 1224

0.5 DK BLU 1225

0.5 RED 1226

0.5 YEL/BLK 1227

REV

~- ~

03
. Switch

LO
Switch

D4

Transmission
Fluid
Temperature
(TFT)
Sensor

02
.. Switch

,Park/
Neutral
1 I Position
/ ' switch

::::,
.i::,.

I
I

re,)

0I

L-------.1

0.35
BLKJWHT 451
C230

0.5 PPL 1228

$215

-----..,

0.8 BLKJWHT 451

F C220

0.5G:Yr452

--------------------------------------------c

0.8 BLKJWHT 451

0.35
2
I~
R ORN/ 434 I .. N@ o ..
I
.
+--
BLK

(PC SOL.) Valve

0.5 LT BLU 1229

fl)

Ic::::-i
- I

:~~osltk>n

3
;

r -~- -

Pressure
Control Solenoid

Automatic
Transmission
Fluid Pressure

(TFP) Manual

Switch

::::,

Automatic
Transmission

,. 0.5P~Kr224 - - - - 0.50KBi1;;25 - - 0.50~Nr226 - - - - 0.5B~f227 - - - - - - - - - - - - - - ,

Switch

D)
fl)

.--.....- - - - - - - - . . . - - - - - -........- - - - - - - - - - ,

......
""I

0.35 ORN/BLK
434

8234

P110
0.5
RED/BLK 1228
0.5 LT BLU/WHT 1229
0.35
ORN/BLK 434

0.5 ORN/BLK 1057

14
Powertram" - - - - - - Control I
PCM
Module(PCM) I C1 =.RED
.

,:~ L -

Sensor Ground

C2

39
--------

36

PCSOL.- Valve Low

32

-PCSOL. Valve High

- - - - - ...,

3BLK 451

C1

PNP - Switch
Signal

C2=BLU

8110

I
I

..1

G110

217187

___ /

Transmission/Transaxle

Automatic Transmission - 4L60-E

Component Locator
Automatic Transmission Components (VIN K)
Name
Automatic
Transmission
(V6 VINK)
Cruise Control/Clutch
Anticipate Switch
(V6 VINK)

Location
Behind the engine

Mounted in the clutch pedal bracket

Cruise Control (Clutch)

Switch
Mounted in the clutch pedal bracket
(VB VIN G Manual)

Locator View

Connector End View

. Antilock Brakes System

Component Views in
ABS Traction Control

Cruise Control
Component Views in
Cruise Control
Harness Routing Views
in Wiring Systems

Cruise Control
Connector End Views
in Cruise Control
Cruise Control
Connector End Views
in Cruise Control
Engine Electrical
Connector End Views
in Starting and
Charging

Park Neutral Position

Switch

Under the center console, on the base

of the shift control lever

Powertrain Control
Module (PCM)
(V6 VIN K)

On the right side of the engine

compartment, rear of the wheelhouse

Harness Routing Views

in Wiring Systems

Powertrain Control
Module (PCM) (V8
VIN G)

On the right side of th!3 engine

compartment, rear of the wheelhouse

Engine Controls
Component Views in
Engine Controls 5.8L

Second Gear Start

Switch (V6 VIN K)
(Chevrolet)

In the center of the IP, above the HVAC

control

Antilock Brakes System

Component Views in
ABS Traction Control

Stop Lamp Switch

Mounted on the brake pedal bracket

Cruise Control
Component Views in
Cruise Control

Stop Lamp/TCC
Switch (Automatic)

Mounted on the brake pedal bracket

Underhood Electrical
Center 2

In the left front corner of the engine

compartment

Engine Controls
Component Views in
Wiring Systems

Lighting Systems
Connector End Views
in Lighting Systems
-

Vehicle Speed Sensor

On the rear left side of the transmission
(Manual)

Antilock Brakes System

Component Views in
ABS Traction Control

Engine Controls
Connector End Views
in Engine Controls

Vehicle Speed Sensor On the rear right side of the

(Automatic)
transmission

Antilock Brakes System

Component Views in
ABS Traction Control

Engine Controls
Connector End Views
in Engine Controls

C100 (10 cavities)

Engine to forward lamp harness, in the

engine compartment, above the right
wheelhouse

Harness Routing Views

in Wiring Systems

lnline Harness
Connector End Views
in Wiring Systems

C105 (8 cavities)

Engine to forward lamp harness, in the

engine compartment, above the right
wheelhouse

Harness Routing Views

in Wiring Systems

lnline Harness
Connector End Views
in Wiring Systems

C200A (17 cavities)

Forward lamp to IP harness, between

the left kick panel and the steering
column

Harness Routing Views

in Wiring Systems

lnline Harness
Connector End Views
in Wiring Systems

C200B (18 cavities)

Forward lamp to IP harness, between

the left kick panel and the steering
column

Harness Routing Views

in Wiring Systems

lnline Harness
Connector End Views
in Wiring Systems

C200D (48 cavities)

Part of the IP harness, between the left

kick panel and the steering column

Harness Routing Views

in Wiring Systems

lnline Harness
Connector End Views
in Wiring Systems

C210 (10 cavities)

IP to engine harness, under the right

side of the IP, behind the knee bolster

Harness Routing Views

in Wiring Systems

lnline Harness
Connector End Views
in Wiring Systems

7-79

780

Transmission!Transaxle

Automatic Transmission - 4L60-E

Automatic Transmission Components (VINK) (cont'd)

Location

Name

Locator View

Connector End View

lnline Harness
Connector End Views
in Wiring Systems

C220 (10 cavities)

IP to engine harness, unde; the right

side of the IP, behind the knee bolster

Harness Routing Views

in Wiring Systems

C270 (2 cavities)

IP harness of the cruise control

harness, near the brake/clutch pedal
bracket

Harness Routing Views

in Wiring Systems

Attached to the rear of the left

cylinder he&d ,

Harness Routing Views

in Wiring Systems

G110 (V6 VINK)

In the front of the engine, bolted to the

pulley above the A/C clutch connector

Harness Routing Views

in Wiring Systems

P100

Left side in the dash panel, engine to

the passenger compartment

Harness Routing Views

in Wiring Systems

P110

,. Right side in the dash panel, engine to

Harness Routing Views

in Wiring Syst,ems

8'104 (V8VIN G)

in the engine harness, approximately

t 4 cm (5.5 in) from the powertrain
control module (PCM) breakout

8104 (V6VIN K)

In the engine harness, approximately

7 cm {2.3 in) from the right knock
sensor breakout

Sf07 (V8 VIN G)

In the engine harness, main branch,

approximately 7 cm (2.8 in) from the
powertrain control module (PCM)
breakout

8107 (V6 VIN K)

In the. engine harness, main branch,

approximately 21 cm (8.3 in) from the
powertrain control module (PCM)
breakout

8110 (V8 VIN G)

In the engine harness, main branch,

approximately 20 cm (7.9 in) from the
powertrain control module (PCM)
breakout

8110 (V6 VIN K)

In the engine harness, approximately

4 cm (1.6 in) from the powertrain control
module (PCM) breakout

8121 (V6 VIN K)

In the engine harness, main branch,

approximately 8 cm (3.1 in) from the
powertrain control module (PCM)
breakout

8182

In the forward lamp harness,

approximately 15 cm (6 in) from the UH
electrical center 1 breakout

8207

In the IP harness, main branch,

approximately 4 cm (1.6 in) from the
data link connector (DLC) breakout

8215

In the IP harness, main branch,

approximately 11 cm (4 in) from the
antenna cable breakout

In the IP harness, main branch,

approximately 5 cm (2 in) from the body
control module (BCM) breakout

..

G110 (V8 VIN G)

"

the passenger compartment

,.

8234 (Automatic)

Automatic Transmission - 4L60-E

Tr:ansmission/Transaxle

Automatic Transmissio11 Components {VIN G,) ,

.Name.
Automatic
Transmission
(V6 VINK)
Cruise Control/Clutch
Anticipate Switch
(V6 VINK)

Locator View

Connector End View

Antilock Brakes System

Component Views in .
ABS Traction Control

Location
Behind the engine

M.o.!Jnted in the clutch pedal bracket

c
Cruise Control (Qlutch)
Switch
Mounted ir\the clutch pedal bracket
(VB VIN G Manual)

'

Cruise Control
Component Views In
Cr.uise Control
'

Cruise Control
Connector End Views
inCruise Controf'

Harness Routing Views

in Wiring Systems

Gruis(;]. Qpntrol
Connector End Views
in Cruise Control
Engine Electric~/
Connector End Views
in Starting and
Charging

Park Neutral Position

Switch

Under the centerconsole, on the base

of the shift cdhtr'ol lever

Powertrain Control
Module (PCM)
(V6 VINK)

On the right side. of the engine

compartment, rear of the wheelhouse

Powertrain Control
Module (PCM)
(VB VIN G)

On the right side of the engine

compartment, rear of the wheelhouse

Second Gear Start

Switch (V6 VINK)
(Chevrolet)

In the center of the IP, above the HVAC

control

Stop Lamp Switch

Mounted on the brake pedal bracket

,,
,,

. Harness Routing Views

in Wiring Systems

,;''

,,

Engine Co,r,.trols
ComponentViews.in
Engine.Controls 5.BL

Mounted on the brake pedal bracket

Underhood Electrical
Center 2

In the left front corner of the engine

compartment

Vehicle Speed Sensor

On the rear left side of the transmission
(Manual)
Vehicle Speed Sensor On the rear right side of the
(Automatic)
transmission

Antilock Brakes System

Component Views in
ABS Tractiora Control

Cruise Control
Component Views in
. Cruise Control

Stop Lamp/TCC
Switch (Automatic)

~-

,,

Lighting Systems
Connector End Views
in Lighting Systems

Engine Con.trots
Component. Views in
Er1gine Controls 5.8L
Antifock Brakes, Sy.stem
Component Views, ,in
ABS Traction Qontrol

Engine Controls
Connector End Views
in Engine Ccintrols

. Antil9c~. Brakes System

ComponentViews in
ABS Traction Control

Engine 9cmtrols
Connector End Views
i,n Engine Controls

C100 (10 cavities)

Engin~ to forward lamp ham~ss, in. ttie

engine compartment, above the right
wheelhouse

Har,iess Routing Views

in Wiring Systems

lnline H~rness . ,
Connector End Views
in Wiring Systems

C105 (8 cavities)

Engine to forward lamp harness, in the.

engine compartment, above the right
wheelhouse

Harness Routing Vtews

in Wiring Systems

/,:,line Harness
Connector End Views
in Wiring Systems

C200A ( 17 cavities)

Forward lamp to IP harness, between

the left kick panel and the steering
column

Harness Routing Views

in Wirfng Systems

lnline Harness
Connector End Views
in Wiring: Systems

C200B ( 18 cavities)

Forward lamp to IP harness, between

the left kick panel and the steering
column

Harness Routing Views

in Wiring Systems

lnline Harness
Connector End Views
in Wiring Systems

C200D (48 cavities)

Part of the IP harness, between the left

kick panel and the steering column

Harness Routing Views

in Wiring Systems

/nline Harness
Connector End Views
in Wiring Systems

C210 (10 cavities)

IP to engine harness, under the right

side of the IP, behind the knee bolster

Harness Routing Views

in Wiring Systems

/nline Harness
Connector End Views
in Wiring Systems

C220 (10 cavities)

IP to engine harness, under the right

side of the IP, behind the knee bolster

Harness Routing Views

in Wiring Systems

lnline Harness
Connector End Views
in Wiring Systems

7;.s:1

7-82

Automatic Transmission - 4L60E

Transmission!Transaxle

Automatic Transmission Components (VIN G) (cont'd)

Name

Locator View

Location

Connector End View

C270 (2 cavities)

IP harness of the cruise control

harness, near the brake/clutch pedal
bracket

Harness Routing Views

in Wiring Systems

G110 (VS VIN G)

Attached to the rear of the left

cylinder head

Harness Routing Views

, in Wiring Systems

GHO (V6 VIN K)

In the front of the engine, bolted to the

pulley above the A/C clutch connector

Harness Routing. Views

in Wiring Systems

P100

Left side in tbe c;lash panel, engine to

the passenger compartment

Harness Routing Views

in Wiring Systems

P110

Right side in the dash panel, engine to

the passenger compartment

Harness Routing Views

in Wiring Systems

8104 (VS VIN G)

in the engine harness, approximately

14 cm (5.5 in) from the powertrain
control module (PCM) breakout

8104 (V6 VIN K)

In the engine hl:!-rness, approximately

7 cm (2.3 in) from the right knock
sensor breakout

8107 (VS VIN G)

In the engine'harriess, main branch,

approximately 7 cm (2.8 in) from the
powertrain contrql module (PCM)
breakout

,_

8107 (V6 VIN K)

In the engine harness, main branch,

approximately 21 cm (8.3 in) from the
powertrain control module (PCM)
breakout

8110 (VS VIN G)

In the engine harness, main branch,

approximately 20 cm (7.9 in) from the
powertrain control module (PCM)
breakout

8110 (V6 VIN K)

In the engine harness, approximately

4 cm (1.6 in) from the powertrain control
module (PCM) breakout

8121 (V6 VINK)

In the engine harness, main !'.)ranch,

approximately 8 cm (3.1 in) from the
powertrain contro.1 module (PCM)
breakout
' .

8182

In the forward lamp harness,

approximately 15 cm (6 in) from the UH
electrical center 1 breakout

8207

In the IP harness, main branch,

approximately 4 cm (1.6 in) from the
data link connector (DLC) breal<out

82.15

In the IP hame~s. main branch,

approximately 11 cm (4 in) from the
antenna cable breakout

In the IP harness, main branch,

approximately 5 cm (2 in) from the body
control module (BCM) breakout

'

'

8234 (Automatic)

Transmissionrrransaxle

Automatic Transmission - 4L60-E

7-83

Automatic Transmission Electronic

Component Views (Internal)
Electronic Component Locations

326657

Legend

(36) Vehicle Speed Sensor (VSS)

(66) Torque Converter Clutch (TCC) Solenoid
Valve
(69) Automatic Transmission Fluid Pressure
(TFP) Manual Valve Position Switch
(367a) 1-2 Shift Solenoid (SS) Valve

(367b)
(377)
(394)
(396)

2-3 Shift Solenoid (SS) Valve

Pressure Control (PC) Solenoid Valve
3-2 Shift Solenoid (SS) Valve Assembly
Torque Converter Clutch Pulse Width
Modulation (TCC PWM) Solenoid Valve

Transmission/Transaxle

7-84 AutomaticTransmission - 4L60-E

AT lnline Harness Connector End View
Automatic Transmission Wiring Harness
Assembly 20-way Connector,

Transmission Side

Automatic Transmi~sion. Wiring Harness

Assembly 20-way Connector, Engine Side

5892

13270

Connector Part
Information

12160545
20-way F Micro-Pack 1OOW
Seri,s (GRY) .
Circuit
No:

12146497
20-way F Micro-Pack 1OOW
Series (GRY)
Circuit
No.

Pin

Wire Color

Function

0.8
LTGRN

1222

,1-2 Shift Solenoid

(1-2 SS) Valve Control

Rin

Wire co'1or:

0.5
LTGRN

1222

1-2 Shift Solenoid

(1-2 SS) Valve Control

0.8
YEUBLK

1223

2-3 Shift Solenoid

(2-3 SS) Valve Control

0.5YEL

1223

2-3 Shift Solenoid

(2-3 SS) Valve Control.

0.8
RED/BLK

1228

Pressure Control
Solenoid (PC Sol.}
Valve HIGH

0.5 PPL

1228

Pressure Control
Solenoid (PC Sol.)
Valve HIGH

0.8 LT
.BLU/WHT

1229

PC Sol. Valve LOW

0.5 LT BLU

1229

PC Sol. Valve LOW

0.8PNK

1020

Transmission
Solenoid Power

0.5 RED

839

Transmission
Soleno!a'P?wer

0.8
YEUBLK

1227

0.5 BRN

1227

Transmission Fluid
Temperature (TFT)
Sensor HIGH

Transmission Fluid
Temperature (TFT}
Sensor HIGH

"!

FunctiQlil

Connector Part
Information

0.5 GRY

452

TFT Sensor LOW

0.5 PNK

1224

Range Signal A

0.5 ORN

1226

Range Signal C

0.5
DK BLU

1225

Range Signal B

0.5 WHT

687

3-2 Shift Solenoid

(3-2 ,ss) Valve
Assembly Control

0.5 BLK

422

Torque Conerter Clutch

Solenoid (TCC Sol.)
Valve Conlrol

0.5 TAN

418

Torque Converter Clutch

Pulse Width Modulation
Solenoid (TCC PWM
Sol.) Valve Control

0.8 BLK

470

tFT Sensor LOW

N
p

0.8 PNK

1224

Range Signal A

0.8 RED

1226

Range Signal C

0.8
DK BLU

1225

Range Signal B

0.8 WHT

687

3-2 Shift Solenoid

(3-2 SS) Valve
Assembly Control

0.8
TAN/BLK

422

Torque Converter Clutch

Solenoid (TCC Sol.)
Valve Control

418

Torque Converter Clutch

Pulse Width Modulation
Solenoid (TCC PWM
Sol.} Valve C.ontrol

.. 0.8 BRN

Transmission/Transaxle

Automatic Transmission - 4L60-E 7-85

Visual Identification
2-3 Shift Solenoid (SS) Valve Connector,
Wiring Harness Side

AT Internal Connector End Views

Automatic Transmission Fluid Pressure
(TFP) Manual Valve Position Switch
Connector, Wiring Harness Side

Lq;J c~::n::~J 0

rn

......

~
, 'C

168424

12162213
Conn SF M/P 150.2
P2S (NAT)

Connector Part
Information

Pin

Wire Color

Circuit
No.

GRA

452

TFT Sensor Ground

PNK

1224

Range Signal A Input

BRN

Pin

Wire Color

RED

YEL

ORN

1226

Range Signal C Input

DKBLU

1225

Range Signal B Input

/

rn

Function

839A

Transmission
Solenoid Power:

1223

2-3 Shift Solenoid Valve

Cont,rol

Torque Converter Clutch Pulse Width

Modulated (TCC PWM) Solenoid Valve
Connector, Wiring Harness Side

1-2 Shift Solenoid (SS) Valve Connector,

Wiring Harness Side

Circuit
No.

1227

,168428

12162201
Conn 2F M/P 150.2
P2~ (NAT)

Connector Part
Information

Function
Transmission Fluid
Temperature (TFT)
Sensor Signal

......

rn

'

168428

Connector Part
Information

Pin

Wire Color

Circuit
No.

RED

.839E

TAN

418

168428

Connector Part
Information

12162201
Conn 2F M/P 150.2
P2S (NAT)

Pin

Wire Color

Circuit
No.

RED

8398

Transmission
Solenoid Power

LTGRN

1222

1-2 Shift Solenoid Valve

Control

Function

12162202
Conn 2F M/P 150.2
P2S (BLU)
Function
Transmission
Solenoid Power
Torque Converter Clutch
Pulse Width Modulated
Solenoid Valve Control

7-86

Automatic Transmission - 4L60-E

3-2 Shift Solenoid (SS) Valve Assembly

Connector, Wiring Harness Side
r

rn

Transmission/Transaxle
Torque Converter Clutch (TCC) Solenoid
Valve Connector, Wiring Harness Side

-.....,

1111

1111
168427

Pin
A

.Circuit
No.

Wire Color
WHT

Connector Part
Information

12146094
Conn 2F M/P 150.2 P2S
(MD GRY)

Connector Part
Information

687

RED

839C

Function
3-2 Shift Solenoid Valve
Assembly Control
Transmission
Solenoid Power

Pressure Control (PC) Solenoid Valve

Connector, Wiring Harness Side
:

~ 0j
168421

Connector Part
Information

12146800
Conn 2F M/P 480 SPL (NAT)

Pin

Wire Color

PPL

LTBLU

..

Circuit
No.
'

168419

Function

1228

Pressure Control (PC)

Solenoid Valve HIGH
Control

1229

PC Solenoid Valve LOW

Control

10478128
CBL Solenoid Valve

Pin

Wire Color

Circuit
No.

RED

8390

Transmission
Solenoid Power

BLK

422A

Torque Converter Clutch

Solenoid Valve Control

Function

Transmission/Transaxle

Automatic Transmission - 4L60-E

7-87

Diagnostic Information and Procedures

DTC P0218 Transmission Fluid Overtemperature (3.8L)

(
154212

Circuit Description
The flow of transmission fluid starts in the bottom pan
and is drawn. through the filter, control valve body
assembly, transmission case and into the oil pump
assembly. The oil pump assembly pressurizes the fluid
and directs it to the pressure regulator valve where
it becomes the main suppty of fluid to the various
components and hydraulic circuits in the transmission.
Hot fluid exiting the torque converter flows through
the converter clutch apply valve and into the
transmission cooler lines to the oil cooler located in
the vehicle radiator (and auxiliary cooler if equipped).
From the cooler, fluid returns to cool and lubricate
the front of the transmission. In forward drive ranges,
D4 fluid from the manual valve is routed through
an orificed cup plug in the rear of the transmission
case to feed the rear lube fluid circuit.
If the PCM detects a high transmission fluid
temperature for a long period of time, then DTC P0218
sets. DTC P0218 is a type D DTC.

Conditions for Setting the DTC

No TFT Sensor DTCs P0712 or P0713
The TFT is greater than 130C (266F).
All conditions met for 1O minutes (600 seconds).

Action Taken When the DTC Sets

The PCM does not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM freezes shift adapts from being updated.
DTC P0218 stores in PCM history.

Conditions for Clearing tbe OTC

A scan tool can clear the DTC from the PCM
history: The PCM clears the DTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the DTC default actionswhen
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Diagnostic Aids
DTC P0218 may set approximately 600 seconds
after DTC P0711 has set. If DTC P0711 is also
set, follow the diagnostic table for DTC P0711
before proceeding to the diagnostic table for
DTC P0218. Repairing the condition that caused
DTC P0711 will likely eliminate DTC P0218.

7-88

Automatic Transmission -,4L60-E

The TFT display on the scan tool should rise

steadily to a normal operating temperature,
then stabilize.
Verify the customer's driving habits, trailer towing,
etc. Trailer towing should occur in 03.

..

Step

Transmission!Transaxle
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. OTC P0711 may cause OTC P0218 to set.
4. This step checks for air flow restrictions or
damage which may result in the transmission
overheating.

DTC P0218 Transmission Fluid Overtemperature (3.8L)

Action
'
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080)
System Check

Go to Step 3

Go to
Transmission
Fluid Checking
Procedure

Go to
Diagnostic Aids

Go to Step 4

Go to Step 7

'
Go to Step 5

Go to Step 7

Go to Step 6

Go to Step 7

Go to
Diagnostic Aids

System OK

Go toBtep 1

Value(s)

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the scan tool
in order to record the Failur<':l Records for reference. Using
the Clear Info function will erase the stored Failure
Records from the PCM.
3. Record the OTC Failure Records, then clear
the DTC(s).
4. Perform the transmission fluid- checking procedure.
Refer to 4L60-E Transmission Fluid Checking
Procedure.
Was the fluid checking procedure performed?
Is OTC P0711 also set?

1. Inspect the engine cooling system and transmission

cooling system for the following conditions:

Air flow restrictions

Air flow blockage

Debris
2. Inspect the transmission cooling system for damaged
cooler lines.
Was a condition found?

Perform the line pressure check procedure.

Refer to 4L60-E Line Pressure Check Procedure.
Was a condition found?

Inspect the torque converter stator for damage ..

Refer to Torque Convt;rter Clutch Diagnosis.
Was a condition found?

In order to veri'fy your repair, perform the following

procedure:
1. Select OTC.
2. Select Clear Info.
3. Ensure that the following conditions are met:
With the engine OFF, the ignition switch is in the
RUN position.
The scan tool indicates a TFT less than 129C
(264F) for at least 5 seconds.
4..Select Specific OTC. Enter OTC P0218.
Has the test run and passed?

Transmission/Transaxle

Automatic Transmission - 4L60-E

7-89

OTC P0218 Transmission Fluid Ovenemperature (5.7L)

~.

LJI

154212

Circuit Description
The flow of transmission fluid starts in the bottom pan
and is drawn through the filter, control valve body
assembly, transmission case and into the oil pump
assembly. The oil pump assembly pressurizes the fluid
and directs it to the pressure regulator valve where
it becomes the main supply of fluid to the various
components and hydraulic circuits in the transmission.
Hot fluid exiting the torque converter flows through
the converter clutch apply valve and into the

transmission cooler lines to the oil cooler located in

the vehicle radiator (and auxiliary cooler if equipped).
From the cooler, fluid returns to cool and lubricate
the front of the transmission. In forward drive ranges,
D4 fluid from the manual valve is routed through
an orificed cup plug in the rear of the transmission
case to feed the rear lube fluid circuit.
When the PCM detects a high transmission fluid
temperature for a long period of time, then DTC P0218
sets. DTC P0218 is a type D DTC.

790

Automatic Transmission - 4L60-E

Conditions for Setting the DTC

No TFT Sensor DTCs P0712 or P0713.
The TFT is greater than 130C (266F).
All conditions met for 10 minutes (600 seconds).

Action Taken When the DTC Sets

The PCM does not illuminate the Malfunction
Indicator Lamp (MIL).
,.
,, .
The PCM freezes shift adapts from being updated.
DTC P0218 stores in PCM history.

Conditions for Clearing the OTC

A scan tool can clear the OTC from the PCM
history. The PCM clears the DTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the DTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Transmission/Transaxle
Diagnostic Aids
The TFT displayed on the scan tool should rise
steadily to a normal operating temperature,
then stabilize.
Verify t.he cusJQmer's driving habits, trailer towing,
etc. Trailer towing should occur in 03.
DTC P0218 may set approximately 600 seconds
. after DTC P0711 has set. If DTC P0711 is also
~t. follow the diagnostic table for DTC P0711
before proceeding to the diagnostic table for
DTC P0218. Repairing the condition that caused
. OTC P0711 win likely eliminate DTC P0218.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. DTC P0711 may cause DTC P0218 to set.
4. This step checks for air flow restrictions or
damage which may result in the transmission
overheating.

Transmission!Transaxle

Automatic Transmission - 4L60-E

7-91

OTC P0218 Transmission Fluid Overtemperature (5.7L)

Step

Action
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?

Value(s)

Yes

Go to Step 2
'

(
5

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan tool in
order to record the Failure Records for reference. Using
the Clear Info function will erase the stored Failure
Records from the PCM.
3. Record the OTC Failure Records, then clear
the DTC(s).
4. Perform the transmission fluid checking procedure.
Refer to 4L60-E Transmission Fluid Checking
Procedure.
Was the Transmission Fluid Checking Procedure
performed?
Is OTC P0711 also set?
1. Inspect the engine cooling system and transmission
cooling system for the following conditions:
Air flow restrictions
Air flow blockage
Debris.
2. Inspect the transmission cooling system for damaged
cooler lines.
Was a c9ndition found? .
Perform the line check procedure.
Refer to 4L60-E Line Pressure Check Prqcedure.
Was a condition found?
Inspect the torque converter stator for damage.
Refer to Torque Converter Clutch Diagnosis.
Was a condition found?
In order to verify your r~pair, perform the following
procedure:
1. Select OTC.
'
2. Select Clear Info.
3. Ensure that the following conditions are met:
With the engine OFF, the ignition switch is in the
RUN position.
The scan tool indicates a TFT less than 129C
(264F) for at least 5 seconds.
4. Select Specific OTC. Enter OTC P0218.
Has the test run and passed?

No
Go to A
Powertrain On
Board Diagnostic
(080)
System Check

Go to Step 3
Go to
Diagnostic Aids

Go to
Transmission
Fluid Checking
Procedure
Go to Step 4

Go to Step 7

Go to Step 5

Go to Step 7

Go to Step 6

Go to Step 7

Go to
Diagnostic Aids

System OK

Go to Step 1

7-92

Automatic Transmission - 4L60-E

Transmission/Transaxle

DTC P0502 Vehicle Speed Sensor Circuit Low Input (3.SL)

~ V e h i c l e Speed
~ S e n s o r (VSS)

0.35 YEL 400

0.35 PPL 401

64

65 C1

'" - - - - - -vss - - - - vss - - - - - , Powertrain

I
I

High

Low

I CO'ntrol
I
I Module>
1 (PCM)~

1..---------' --------.J
193763

Circuit Description
The Vehicle Speed Sensor Assembly (VSS Assy.)
provides vehicle speed information to the Powertrain
Control Module (PCM). The VSS Assy. is a Permanent
Magnet (PM) generator. The PM generator produces
a pulsing AC voltage as rotor teeth on the
transmission output shaft pass through the sensor's
magnetic field. The AC voltage level and the number of
pulses increase as the speed of the vehicle increases.
The output voltage varies from a minimum of
0.5 volts AC at 100 RPM to more than 100 volts at
8000 RPM. The PCM converts the pulsing voltage to
vehicle speed. The PCM uses the vehicle speed
signal to determine shift timing and Torque Converter
Clutch (TCC) scheduling.
If the PCM detects a low vehicle speed when there is
a high engine speed in a drive gear range, then
OTC P0502 sets. OTC P0502 is a type B OTC.

Conditions for Setting the DTC

OTC P0502 sets if the following conditions occur two
consecutive times:
No MAP Sensor OTCs P0107 or P0108
No TP Sensor OTCs P0122 or P0123
No TFP Val. Position Sw. OTC P1810
The transmission is not in Park or Neutral
The TP angle is greater than 12%.

The engine vacuum is 0-105 kPa.

The engine speed is greater than 3000 RPM.
The engine torque is 40-,.400 lb ft.
The transmission output speed is less
than 150 RPM.
All conditions met for 2.5 seconds,

Action Taken When the DTC Sets

The PCM illuminates the Malfunction indicator
Lamp (MIL}.
The PCM commands second gear only. ;
The PCM commands maximum line pressure.
The PCM inhibits TCC engagement.
The PCM freezes shift adapts from being updated.
OTC P0502 stores in PCM history.

Conditions for Clearing the MIL/DTC

The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
A scan tool can clear the OTC from the PCM
history. The PCM clears the OTC from the
PCM his,ory if the vehicle compl~tes 40 warm-up
cycles without a failure reported.
The PCM cancels the OTC default actions when
. the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Transrnission(Transaxle

Automatic Transmission-~ 4L60-E

Diagnostic Aids

Inspect the wiring at the PCM, the Vehicle Speed

Sensor (VSS) connector and a\1 other circuit
connecting points for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture Intrusion
- Corrosion

7-93

.W11~n diagnosing fonm intermittent short or open

condition, massage the wiring harness while
watching the test equipment for a change.
Test circuits 400 and 401 for Electromagnetic
Interferences (EMI) induced by a wiring harness
incorrectly ro_uted too near the spark plug wires.

Test Description
.The numbers below refer to the step numbers on the
diagnostic table.
3. This step tests the VSS.Assembly circuit.
5. This step tests the integrity of the VSS Assembly.

DTC P0502 Vehicle Speed Sensor Circuit Low Input (3.8L)

Action

Step

Value(s)

Yes

No

Gq to Step 2

Goto A
Powertrain On
Boa.rd Diagnostic
(080)
System Check

Was the Powertrain On-Board Diagnostic (OBD) System

..
Check performed?

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the scan tool
in order to record the Freeze Frame and Failure Records
for reference. Using the Clear Info function will erase the
stored Freeze Frame and Failure Records from the PCM.
3. Record the DTC Freeze Frame and Failure Records,
then clear the DTC(s).
4. Raise and support the drive axle assembly .
. 5. Start the .engine.
6. Place the transmission in any drive range.
With the drive wheels rotating, does the Transmission
OSS increase with the drive wheel speed?
1. Turn the ignition OFF.
2. Disconnect the C1 (blue) PCM connector.
3. Using J 39200 Digital Multimeter (DMM) and
J 35616-A Connector Test Adapter Kit, measure the
resistance between harness connector
terminals C1 -64 and C1-65.
Is the resistance within the specified range?
Measure the resistance from terminal C1-64 to ground.
Is the resistance greater than the specified value?
1.
2.
3.
4.

Place the transmission in Neutral.

Select AC volts.
Hold one rear wheel from turning.
Rotate the other rear wheel by hand, ensuring that
the driveshaft is turning.
Is the voltage greater than the specified value?
1. Disconnect the engine wiring harness from the
VSS Assy.
2. Measure the resistance of the VSS Assy.
Is the resistance within the specified range?

'

Go to
Diagnostic Aids

Go to Step 3

Go to Step 4

Go to Step 6

Go to Step 5

Go to Step 7

Go to Step 11

Go to Step 9

Go to Step B

Go to Step 10

1470-2820 Q

50KQ

0.5 volts

1470-2820 Q

7-94

Automatic Transmission - 4L6o.. e

Transmission!Transaxle

OTC P0502 Vehicle Speed Sensor Circuit Low Input (3.8L) (cont'd)
Step

10

11

12

Action

Value(s)

1. Inspect circuits 400 (YEL). and 401 (PPL) for a short

to ground.
2. Repair the circuits if necessary.
Refer to General Electrical Diagnosis Procedures.
Did you find a short to ground condition?

1. Inspect circuits 400 (YEL) and 401 (PPL) for an open.

Refer to General Electrical Diagnosis Procedures.
2. Repair the circuits if necessary.
Refer to Wiring Repairs.
Did you find an open condition?

1. Remove the VSS Assy.

2. Inspect the output shaft speed sensor rotor for
damage or misalignment.
Did you find a damaged condition?

Replace the VSS Assy.

Refer to Vehicle Speed Sensor Replacement.
Is the replacement complete?

Replace the PCM. Refer to PCM

Replacement/Programming.
Is the replacement complete?

In order to verify your repair, perform the following

procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle, so that the transmission output
speed is greater than 250 RPM for 2 seconds.
4. Select Specific DTC. Enter DTC P0502.
Has the test run and passed?

Yes

No

)
Go to Step 12

Go to
Diagnostic Aids

Go to Step 12

Go to
Diagnostic Aids

Go to Step 12

Go to Step 10
-

Go to Step 12
-

Go to Step 12

System OK

Go to Step 1

Transmissionrrransaxle

Automatic Transmission - 4L60-E

7-95

DTC P0502 Vehicle Speed Sensor Circuit Low Input (5.7L)

.. :. ____ I
D

Vehicle Speed

.
I r t .Sensor (VSS)

LJ:J

0.35 YEL 400

0.35 PPL 401

7 , ________71 ' C1

'" - - - - - -vss - - - - vss - - - - - , Powertrain

I
I

High

Low

I Control
I
I Module"
1 (PCM)~

L------ -----------~

168434

Circuit Description
The Vehicle Speed Sensor Assembly (VSS Assy.)
provides vehicle speed information to the Powertrain
Control Module (PCM). The VSS Assy. is a Permanent
Magnet (PM) generator. The PM generator produces
a pulsing AC voltage as rotor teeth on the
transmission output shaft pass through the sensor's
magnetic field. The AC voltage level and the number of
pulses increase as the speed of the vehicle increases.
The output voltage varies from a minimum of
0.5 volts AC at 100 RPM to more than 100 volts at
8000 RPM. The PCM converts the pulsing voltage to
vehicle speed. The PCM uses the vehicle speed
signal to determine shift timing and Torque Converter
Clutch (TCC) scheduling.
If the PCM detects a low vehicle speed when there is
a high engine speed in a drive gear range, then
DTC P0502 s~ts. DTC P0502 is a type B DTC.

Conditions for Setting the DTC

DTC P0502 sets if the following conditions occur two
consecutive times:
No MAP Sensor OTCs P0107 or P0108.
No TP Sensor DTCs P0122 or P0123.
No TFP Val. Position Sw. OTC P1810.
The transmission is not in Park or Neutral.
The TP angle is greater than 15%.
The engine vacuum is 0-105 kPa.

The engine speed is greater than 3000 RPM.

The engine torque is 30-400 lb ft.
The transmission output speed is less
than 150 RPM.
All conditions met tor 2.5 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL).
The PCM commands second gear only,
below 2500 RPM.
The PCM commands maximum line pressure.
The PCM inhibits TCC engagement.
Th.e PCM freezes shift adapts from being updated.
DTC P0502 stores in PCM history.

Conditions for Clearing the MIL/DTC

The PCM turns OFF the MIL after three
consecutive trips without a faih.,ire reported.
A scan tool can clear the OTC from the PCM
history. The PCM clears the DTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the DTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

7-96

Automatic Transmission - 4L60-E

Transmission/Transaxle

Diagnostic Aids
Inspect the wiring at the PCM, the Vehicle Speed
Sensor (VSS) connector and all other circuit
connecting points for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
When diagnosing for an intermittent short or open
condition, massage the wiring harness while
watching the test equipment for a change.

Test circuits 400 and 401 for Electromagnetic

Interferences (EMI) induced by a wiring harness
incorrectly routed too near the spark plug wires.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Disable the traction control system when
performing this step. When the ignition key is
cycled to the OFF position and then cycled back
ON,.the traction control system defaults to ON.
3. This step tests the VSS Assy. circuit.
5. This step tests the integrity of the VSS Assy.

DTC P0502 Vehicle Speed Sensor Circuit Low Input (5.7L)

Action

Step

Value(s)

Yes

No

Go toStep2

Go to A
Powertrain On
Board Diagnostic
(080)
System Check

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

1. Install the Scan Tool.

2. With the engine OFF, turn the ignitiontswitch to the
RUN position.

Important: Before clearing the DTCs,.use the scan tool in

order to record the Freeze Frame and Failure Records for
reference. Using the Clear Info function will erase the
stored Freeze Frame and Failure Records from the PCM.

3. Record the OTC Freeze Frame and Failure Records,

then clear the DTC(s).
4. Raise and support thf;l drive axle assembly.
5. Start the engine.
6. Disable the traction control system.
7. Place the transmission in any drive range.
With the drive wheels rotating, does the Transmission
OSS increase with t~e drive wheel speed?
1. Turn the ignition OFF.
2. Disconnect the C1 (red) PCM connector.
3. Using the J 39200 Digital Multimeter (DMM) and the
J35616-A Connector Test Adapter Kit, measure the
resistar:ice between harness connector terminals C1-7
and C1-71.
Is the re~istance within the specified range?
Measure the resistance from terminal C1-7 to ground.
Is the resistance greater than the specified value?

Go to
Diagnostic Aids

Go to Step 3

Go to Step 4

Go to Step 6

1470-2020 n

50KQ

Go to Step 7

Go to Step 5
..

1.
2.
3.
4.

Place the transmission in Neutral.

Select AC volts.
Prevent one rear wheel from turning.
Rotate the other rear wheel by hand, ensuring that
the driveshaft is turning.
Is the voltage greater than the specified value?

0.5 volts

Go to Step 11

Go to Step 9

"Fransmission/Transaxle

Automatic Transmission .. 4L60-E

7-97

DTC P0502 Vehicle Speed Sensor Circuit Low. Input (5.7L) (confd)
Step

Action

Value(s)

1. Disconnect the engine wiring harness from the

VSS Assy.

Yes

No

Go to Step B

Go to Step 10

Go to Step 12

Go to
Diagnostic Aids

Go to Step 12

Go to
Diagnostic Aids

Go to Step 12

Go to Step 10

1410-2a20 n

2. Measure the resistance of the VSS Assy.

Is the resistance within the specified range?
1. Inspect circuits 400 (YEL) and 401 (PPL) for a short
to ground condition.

Refer to General Electrical Diagnosis Procedures.

2. Repair the circuits if necessary.

Refer to Wiring Repairs.
Did you find a short to ground condition?
1. Inspect circuits 400 (YEL) and .401 (PPL) for an open.
Refer to General Electtic~I Diagnosis Procedures.

2. Repair the circuits if necessary:

Refer to Wiring Repa11s.
Did you find an open condition?
1. Remove theVSS Assy.

2. Inspect the output shaft speed sensor rotor for

damage or misalignment.

Did you find a damaged condition?

R'eplace the VSS Assy.
10

Refer to Vehicle Speed Sensor Replacement.

Is the replacement complete?

Go to Step 12

Replace the PCM.

11

Re:fer to PCM Replacement/Programming.

Is the replacement complete?

Go to Step 12

'

In order to verify your repair, perform the following

procedure1
1. Select OTC.
12

2. Select Clear Info.

3. Operate the vehicle, so that the .transmission output

'

speed is greater than 250 RPM for 2 seconds.

4. Select Specific

ore. Enter OTC P0502.

Has the test run and passed?

'

System OK

Gd to Step 1

7-98

Automatic Transmission - 4L60-E

Transmission!Trans.axle

DTC P0503 Vehicle Speed Sensor Circuit Intermittent (3.SL)

I
IS]
JLoc

~ Vehicle Speed

te=:JJ
B"

Sensor (V$S)

IN

0.35 YEL 400

0.35 PPL 401

64
, ________
.
65C1
...,.

'" - - - - - -vss - - - - tss - - - - - ., Powertrain

High

Low

I Control .

I
I Module
I (PCM)M

L------------------J
193763

Circuit O~scription

Not in fuel cutoff.

The Vehicle Speed Sensor Assembly (VSS Assy.)

provides vehicle speed information to the Powertrain
Control Module (PCM). The VSS Assy. is a Permanent
Magnet (PM) generator. The PM generator produces a
pulsing AC voltage as rotor teeth on the transmission
output shaft pass through the sensor's magnetic field.
The AC voltage level and the number of pulses increase
as the speed of the vehicle increases. The output
voltage varies from a minimum of 0.5 volts AC at
100 RPM to more than 100 volts at 8000 RPM. The
PCM converts the pulsing voltage to vehicle speed. The
PCM uses the vehicle speed signal to determine shift
timing and Torque Converter Clutch (TCC) scheduling.
When the PCM detects an unrealistically large drop in
the vehicle speed, then DTC P0503 sets. DTC P0503
is a type B DTC.

The time since the last gear range change is

greater than 6 seconds.

Conditions for Setting the OTC

DTC P0503 sets if the following conditions occur two
consecutive times:
No TFP Val. Position Sw. DTC P1810.
The engine speed is greater than 450 RPM tor
5 seconds.

The transmission output speed rise does not

exceed 600 RPM within 6 seconds.
The transmission.output speed drops by greater
than 1300 RPM for 2 seconds when not in
Park/Neutral.

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL).
The PCM commands a soft landing to second
gear when the engine speed is less
than 2500 RPM.
The PCM inhibits TCC engagement.
The PCM commands maximum line pressure.
The PCM inhibits 4th gear if the transmission is in
hot mode.
The PCM freezes shift adapts from being updated.
DTC P0503 stores in PCM history.

Transmission!Transaxle

Automatic Transmission '." 4L60-E

Conditions for Clearing the MIUDTC

Poor terminal tension

The PCM turns OFF the MIL after three

consecutive tr.ips without a failure reported.
A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the DTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.
.

- A chafed wire
- A broken wire inside the insulation
Moisture Intrusion
- Corrosion
When diagnosing for an intermittent short or open
condition, massage the wiring harness while
watching the test equipment for a change.
Test circuits 400 and 401 for Electromagnetic
Interferences (EMI) induced by a wiring harness
incorrectly routed near the spark plug wires.

Diagnostic Aids
Inspect the wiring at the PCM, the Vehicle Speed
Sensor (VSS) connector and ali other circuit
connecting points for the following conditions:
- A bent terminal
- A backed out terminal
- Adamaged terminal

7-99

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step tests the VSS Assy. circuit.
5. This step tests the integrity of the VSS Assy.

OTC P0503 Vehicle Speed Sensor Circuit Intermittent (3.8L)

Step

Action

Value(s)

No

Yes

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Go to Step

4
/ (

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the scan tool
in order to record the Freeze Frame and Failure Records
for reference. Using the Clear Info function will erase the
stored Freeze Frame and Fai.lure Records from the PCM.
3. Record the OTC Freeze Frame and Failure Records,
then clear the DTC(s).
4. Raise and support the drive axle assembly.
5. Start the engine.
6. Disable the traction control system if equipped.
7. Place the transmission in any 03 range.
8. With the drive wheels rotating, slowly accelerate to
2000 engine RPM and hold. Road test the vehicle if
necessary.
Does the transmission OSS drop or fluctuate more than
the specified value?

1300 RPM

1. Turn the ignition OFF.

2. Disconnect the C1 (blue) PCM connector.
3. Using J 39200 Digital Multimeter (DMM) and
J 35616-A Connector Test Adapter Kit, measure the
resistance between harness connector
terminals C1-64 and C1-65.
Is the resistance within the specified range?

1470-2820 Q

Measure the resistance from terminal C1-64 to ground.

Is the resistance greater than the specified value?

Go to A
Powertrain On
Board Diagnostic
(PBD)
System Check

50KQ

Go to Step 3

Go to
Diagnostic Aids

Go to Step 4

Go to Step 6

Go to Step 5

Go to Step 7

7.;100

Automatic Transmission - 4L60-E

TransmissionlTransaxle

DTC P0503 Vehicle Speed Sensor Circuit Intermittent ,(3.SL) (cont'd)

Value{s)

Action ..

Step

No

Yes

1. Place the transmission in Neutral.

'

2. Select AC volts.
..
3. Hold one rear wheel from turning.

0.5 volts

4. Rotate the other.rear wheel by hand, ensuring that

the driveshaft is turning.

Is the Voltage greater than the specified value?

1. .Disconnect the engine 'fViring harf')ess from the

VSS Assy.

2.:

Measure the resistance of the

vss Assy.

Is the resistance within the specified range?

'

'

'

Go tq Step 11

Go,tqStep 9

1410-2s20 n
',.

-J'

Go to St(:)p B

Go to St(:)p 1O

Go to Step 12

Go to
Diagnostic Aids

'

1. Inspect circuits 400 (YEL) and 401 (PPL) for a short

to ground.

Refer to General Electrical Diagnosis Procedures.

2. Repair the circuits' if necessary.
Refer to Wiring Repairs.
Did you find a short !O ground condition?

1. Inspect circuits 400 (YEL) and 401 (PPL) for an open.

Refer to General Electric.al Diagnosis Proc(:)(Jur(:)s.

,,

2. Repiii.ir the circuits if necessary.

Refer to Wiring Repairs.
Did you fir,d an open condition?

Go to
Go to Step 12

Diagnostic Aids

damage or misalignment.
Did you find a damaged condition?

Go to Step 12

Go to Step 10

Replace the VSS Assy.

Refer to Vehicle Speed Sensor Replacement.
Is the replacement complete?

Go to Step 12

1. Remove the VSS Assy.

9

10

11

2. Inspect the output shaft speed sensor rotor for

Replace the PCM. Refer to PCM

Replacem,ent!Programming.
Is the replacement complete?

Go to Step 12

In order to verify your repair, perform the following

procedure:
1. Select OTC.
12

2. Select Clear Info.

3. Operate the vehicle, ensuring that the transmission
outpt,Jt speed drop is less than 500 RPM for
3 seconds and output speed is greater than 600 RPM
for 3 seconds.
4. Select Specific OTC. Enter OTC P0503.
Has the test run and passed?

System OK

Go to Step 1

'

Transmission/Transaxle

Automatic Transmission - 4L60-E

7-101

DTC P0503 Vehicle Speed Sensor Circuit Intermittent (5.7L)

Li

Vehicle Speed
- ~ - Sensor (VSS)

IB .

0.35 YEL 400

0.35 PPL 401

7 ________71 ' C1

'" - - - - - -vss - - - - vss - - - - - ,I Powertrain

I
I

High

Low

Control

I
I Module>
1 (PCM)~

~----- -----------J

168434

Circuit Description
The Vehicle Speed Sensor Assembly (VSS Assy.)
provides vehicle speed information to the Poweftrain
Control Module (PCM). The VSS Assy. is a Permanent
Magnet (PM) generator. The PM generator produces
a pulsing AC voltage as rotor teeth on the
transmission output shaft pass through the sensor's
magnetic field. The AC voltage level and the number of.
pulses increase as the speed of the vehicle increases.
The output voltage varies from a minimum of
0.5 volts AC at 100 RPM to more than 100 volts at
8000 RPM. The PCM converts the pulsing voltage to
vehicle speed. The PCM uses the vehicle speed
signal to determine shift timing and Torque Converter
Clutch (TCC) scheduling.
When the PCM detects an unrealistically large drop in
vehicle speed, then DTC P0503 sets. DTC P0503
is a type B DTC.

Conditions for Setting the DTC

DTC P0503 sets if the following conditions occur two
consecutive times:
No TFP Val. Position Sw. DTC P1810.
The time since the last gear range change is
greater than 6 seconds.
The engine speed is greater than 450 RPM for
5 seconds.
Not in fuel cutoff.

Transmission output speed rise does not exceed

600 RPM within 6 seconds.
The transmission output speed drop is greater
than 1300 RPM for 3 seconds when not in
Park/Neutral.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL).
The PCM commands a soft landing to
second gear.
The PCM commands maximum line pressure.
The PCM inhibits TCC engagement.
The PCM inhibits 4th gear if the transmission is in
hot mode.
The PCM freezes shift adapts from being updated.
DTC P0503 stores in PCM history.

Conditions for Clearing the MIUDTC

The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the DTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

7-102

Automatic Transmission - 4L60-E

Transmission/Transaxle

Diagnostic Aids
Inspect the wiring at the PCM, the Vehicle Speed
Sensor (VSS) connector and all other circuit
connecting points for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
When diagnosing for an intermittent short or open
condition, massage the wiring harness while
watching the test equipment for a change.

Test circuits 400 and 401 for Electromagnetic

Interferences (EMI) induced by a wiring harness
incorrectly routed too near the spark plug wires.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. Disable the traction control system when
performing this step. When the ignition switch is
cycled OFF and then back ON, the traction control
system defaults to ON.

3. This step tests the VSS Assy. circuit.

5. This step tests the integrity of the VSS Assy.

DTC P0503 Vehicle Speed Sensor Circuit Intermittent (5.7L)

Action

Step

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080)
System Check

Go to Step 3

Go to
Diagnostic Aids

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.

Important: Before clearing the DTCs, use the scan tool in

order to record the Freeze Frame and Failure Records for
reference. Using the Clear Info function will erase the
stored Freeze Frame and Failure Records from the PCM.

3. Record the DTC Freeze Frame and Failure Records,

then clear the DTC(s).
4. Raise and support the drive axle assembly.

1300 RPM

5. Start the engine.

6. Disable the traction control system.
7. Place the transmission in 03 range.

8. With the drive wheels rotating, slowly accelerate to

2000 engine RPM and hold. (Road test the vehicle if
necessary.)
Does the Transmission OSS drop or fluctuate more than
the specified value?
1. Turn the ignition OFF.
2. Disconnect the C1 (red) PCM connector.

3. Using the J 39200 Digital Multimeter (DMM) and the

. J 35616-A Connector Test Adapter Kit, measure the
resistance between harness connector terminals C1-7
andC1-71.

1470-2820 Q
,.

Is the resistance within the specified range?

Measure the resistance from terminal C1-7 to ground.

Is the resistance greater than the specified value?

50KQ

Go to Step 4

Go to Step 6

Go to Step 5

Go to Step 7

Go to Step 11

Go to Step 9

1. Place the transmission in Neutral.

2. Select AC volts.

3. Hold one rear wheel from turning.

0.5 volts

4. Rotate the other rear wheel by hand, ensuring that

the driveshaft is turning.
Is the voltage greater than the specified value?

Automatic Transmission - 4L60-E

TransmissionlTransaxle

7-103

DTC P0503 Vehicle Speed Sensor Circuit Intermittent (5.7L) (cont'd)

Step

Action

Value(s)

Yes

No

Go to Step B

Go to Step 10

Go to Step 12

Go to
Diagnostic Aids

Go to Step 12

Go to
Diagnostic Aids

Go to Step 12

Go to Step 10

1. Disconnect the engine wiring harness from the

6

10

11

12

VSS Assy.
2. Measure the resistance of the VSS Assy.
Is the resistance within the specified range?

1470-2a20 n

1. Inspect circuits 400 (YEL) and 401 (PPL) for a short

to ground.
Refer to General Electrical Diagnosis Procedures.
2. Repair the circuits if necessary.
Refer to Wiring Repairs.
Did you find a short to ground condition?

1. Inspect circuits 400 (YEL) and 401 (PPL) for an open

circuit.
Refer to General Electrical Diagnosis Procedures.
2. Repair the circuits if necessary.
Refer to Wiring Repairs.
Did you find an open condition?

1. Remove the VSS Assy.

2. Inspect the output s~aft speed sensor rotor for
damage or misalignment.
Did you find a damaged condition?

Replace the VSS Assy.

Refer to Vehicle Speed Sensor Replacement.
Is the replacement colT)plete?

Replace the PCM.

Refer to PCM Replacement/Programming.
Is the replacement complete?

In order to verify your repair, perform the following

procedure:
1. Select DTC.
2. Select Clear Info.
3. Operate the vehicle, ensuring that the transmission
output speed drop is less than 500 RPM for
3 seconds and output speed is greater than 600 RPM
for 3 seconds.
4. Select Specific DTC. Enter DTC P0503.
Has the test run and passed?

Go to Step 12

Go to Step 12

System OK

Go to Step 1

7-104

Automatic Transmission -4L60-E

Transmissiontrransaxle

DTC P0711 TFT Sensor Circuit Range/Performance (3.8L)

[SJ
I

REV

Auiomatic
Trans mission
Fluid Pressure
(TFP) llilanual
Valve Position
Switch

03

Switch

_ Switch

LO
Switch

Transmission
Fluid
Temperature
(TFT)
Sensor

02
- Switch

_ _ _ _ _ _ _ _ - _ , _ _ _ _ _ _ , _ _ _ _ _ o. 5 Gl::G.s2

_ _ _ _ . ___ _
20 -Way Connector

M
0.5 GRY 720
Sensors
Cel120

- -

S121

O.SGRY 720

-I- --,

35 C2
r -

I
I
I

Powertrain

sensor

Ground

I Control
I Module (PCM)
I

L-----..1

>

193768

Circuit Description
The Automatic Transmission Fluid Temperature (TFT)
Sensor is part of the Automatic Transmission Fluid
Pressure Manual Valve Position Switch (TFP
Val. Position Sw.). The TFT Sensor is a resistor, or
thermistor, which changes value based on
temperature. The sensor has a negative-temperature
coefficient. This means that as the temperature
increases, the resistance decreases, and as the
temperature decreases, the resistance increases. The
Powertrain Control Module (PCM) supplies a 5 volt
reference signal to the sensor on circuit 1227
and measures the voltage drop in the circuit. When
the transmission fluid is cold, the sensor resistance is
high and the PCM detects high signal voltage. As the

fluid temperature warms to a normal operating

temperature, the resistance becomes less and the
signal voltage decreases. The PCM uses this
information to control shift quality and torque converter
clutch apply.
When the PCM detects one of the following unusual
conditions, then OTC P0711 sets.
An unrealistically large change in transmission
temperature
A transmission temperature which remains
constant for a period of time in which a
measurable amount of change is expected
OTC P0711 is a type O OTC.

Transmission/Transaxle

Automatic Transmission -4L60-E

Conditions for Setting the OTC

4: If the Engine Run Time is greater

than 300 seconds and No Intake Air
Temperature (IAT) OTCs P0112 or P0113 are
set and IAT is available and Engine Coolant
Temperature (ECT) is between 40 and
125C (104 and 257F) and:
IAT at startup is less than 15C (59F),
then the default TFT is equal to the
Engine Coolant Temperature (ECT)
plus 5C (8F).
startup is greater than 35C
IAT
(95F), then the default TFT is equal to
the Engine Coolant Temperature
(ECT) plus 10C (16F).
IAT at startup is between 15 and 35C
(59 and 95F), then the default TFT is
equal to the Engine Coolant
Temperature (ECT).
5. If the Engine Run Time is greater
than 300 seconds and any lhtake Air
Temperature (IAT) OTCs P0112 mP0113 are
set or IAT is NOT available, then the default
TFT is equal to the Engine Coolant
Temperature (ECT).
6. If t.he Engine Run Time is greater
than 300 seconds and ECT is less than 40C
(104F) or more, then the default TFT is
equal to 60C (140F).
The PCM freezes shift adapts from being updated.
OTC P0711 stores in PCM history.

No VSS Assy. OTCs P0502 or P0503.

No Transmission Component Slipping OTC P1870.

The system voltage is 8-16 volts.
The engine is running for 409 seconds.
The vehicle speed is .greater than 8 km/h (5 mph)
for 409 seconds.
The TCC slip speed is greater than 120 RPM for
409 seconds.
The transmission fluid temperature at startup is
between -40 and +21C (-40 and +70F).
The TFT is between -38 and + 151 C
(-36 and +304F).
The engine coolant temperature is greater
than 70C (158F) and has changed by 50C
(90F) since startup.
All of the above conditions are met and either of
the following fail conditions occurs:
- The transmission fluid temperature does riot
change more than 1.50C (2. 7F) for
409 seconds since startup.
- The transmission fluid temperature changes
more than 20c (36F) in 200 milliseconds
14 time within 7 seconds.

Action Taken When the OTC Sets

The PCM does not illuminate the Malfunction
Indicator Larrip (MIL).
The PCM determines a default Transmission Fluid
Temperature (TFT) using the following matrix:
Important: The actions listed below are in order of
highest to lowest priority.

1. If any Engine Coolant Temperature (ECT)

OTCs P0117 or P0118 are set, then the default
TFT is equal to 135C (275F).
2. If the ECT is 125C (257F) or more, then the
default TFT is equal to 135C (275F).
3. If the Engine Run Time is less
than 300 seconds and:
No Intake Air Temperature (IAT) OTCs
P0112 or P0113 are set and IAT is
available, then the default TFT is equal
to IAT.
Any Intake Air Temperature (IAT) OTCs
P0112 or P0113 are set or IAT is NOT
available, then the default TFT is
equal to 90C (194F).

7-105

at

Conditions. for Clearing the OTC

A scan tool can clear the OTC from the. PCM
history. The PCM clears .the OTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the OTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Diagnostic Aids
OTC P0218 may set approximately 600 seconds after
OTC P0711 has set. Follow the diagnostic table for
OTC P0711 before proceeding to the diagnostic table
for OTC P0218. Repairing the condition that caused
OTC P0711 will likely eliminate OTC P0218.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
5. This step tests for an intermittent short or open
condition in the engin~ wiring harness. The
test light is used as a resistor in the circuit.
6. This step determines if the PCM or the TFT
Sensor is causing a steady, unchanging TFT
reading.

7-106

"'fransmissionJTransaxle

Automatic Transmission - 4L60-E

OTC P0711 TFT Sensor Circuit Range/Performance (3.8L)

Step

Action

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Value(s)

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the scan tool
in order to record the Failure Records for reference. Using
the Clear Info function will erase the stored Failure
Records from the PCM.
3. Record the DTC Failure Records, then clear
the DTC(s).
4. Select TFT on the scan tool:
5. Drive the vehicle and observe the scan tool for either
of the following fail conditions:
The TFT does not change more than 1.50C
(2.7F) in 4o!j seconds since startup
The TFT changes more than 20C (36F)
in 200 milliseconds 14 times within 7 seconds
(unrealistic change).
Did either of the fail conditions occur?

1. Turn the ignition OFF.

2. Disconnect the transmiss.ion 20-way connector.
3. Install the J 39775 Jumper Harness on the engine
side of the 20-way connector.
4. Using the J 35616 Connector Test Adapter Kit,
connect a test light from terminal L to terminal M.
5. Turn the ignition switch to the RUN position.
6. While observing the scan tool display, move or
massage the engine wiring harness from PCM
connector C2 to the 20-way connector.

Go to Step2

Goto A
Powertrain On
Board Diagnostic
(080)
System Check

Go to Step 3

Go to
Transmission
Fluid Checking
Procedure

Go to $tep 4

Go to
Diagnostic Aids

Go to Step 6

Go to Step 5

Go to.Step 7

Go to Step 8

Go to Step 11

Go to Step 10

Go to Step 12

Go to Step 11

1.50C (2.7F)

20C (36F)

Does the TFT change by more than the specified value?

No

Perform the transmission fluid checking procedure. Refer

to 4L60-E Transmission Fluid Checking Procedure.
Did you perform the fluid checking procedure?

Did the scan tool display a condition in which the TFT

does not change by more than the specified value
in 409 seconds since startup?

Yes

1. Turn the ignition OFF.

2. Disconnect the transmission 20-way connector.
3. Turn the ignition switch to the RUN position.
Does the scan tool display the same condition as in
Step 4?

1. Inspect circuits 1227 {YEUBLK) and 720 (GRY) of

the engine wiring harness for an intermittent open or
short condition.
Refer to General Electrical Diagnosis Procedures.
2. Repair the circuits if necessary.
Refer to Wiring Repairs.
Did you find an intermittent open or shorted condition?

TransmrssionlTtansaxle

Automatic Transmission 4L60-E

7-107

DTC P0711 TFT Sensor Circuit Range/Performance (3.SL) (cont'd)

Step

Action

Inspect circuit 1227 (BRN) and 452 (GRY) of the

Automatic Transmission Wiring Harness Assembly (A/T
Transmission Wiring Harness Assembly) for an intermittent
open or short condition.

Value(s)

Yes

No

Go to Step 9

Go to Step 10

Refer to Genera/Electrical Diagnosis Procedures.

Did you find an jrJtermittent open or shorted condition?
Replace the A/T Wiring Harness Assembly.
9

10

11

Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring

Harness Replacement.
Is the replacement complete?
Replace the TFT Sensor (the sensor is a part of the TFP
Valve Position Switch).
Refer to Valve Body and Pressure Switch Replacem(tnt.
Is the replacement complete?
Replace the PCM.
Refer to PCM Replacemflnt/Programming.
Is the replacement complete?

Go to Step 12

Go to Step 12

Go to Step 12

In order to verify your repair, perform the following

procedure:
1. Select DTC.
2. Select Clear Info.
3. Drive the vehicle and ensure that the following
conditions are met:
12

The TFT changes by more than 2.25C (4F)

for 11 seconds since startup
The TFT does not change by more than 20C
(36F) within 200 milliseconds for a period of at
least 11 seconds
4. Select Specific DTC. Enter DTC P0711.
Has the test run and passed?

System OK

Go to Step 1

7-108

Automatic Transmission - 4L60-E

TransmissionlTransaxle

DTC P0711 TFT Sensor Circuit Range/Performance (5.7L)

:~; I .. l ~.~.; l.. ~= f.. :~i~I::c~

I
I

:.f~~:.

Signal

t
~
I~

L -

- -

. -

251--------------221----------611~~ YEL/B~Kr~:7

0.5 PNK 12;24

0.5

DK BLU 1225

0:5

RED.1226

- .

fl:'!
L.:.1

.J

.
20- Way Connector

N --------------~ ___________ f _________L"

r -

;5;NJ1;;4- - - - -O.;D~B~uf22~ - - -o.;~Nh2~ - ~-5-B;t~2; - - - - - - - - - ~AT.utomc,lJic_

E

cl

REV

DJ

D3
Switch

$witch

LO
Switch

Al

D4

--

Switch

Transmission
Fluid
Temperature
(TFT)
Sensor

02

ransm1ss1on

Automatic
Transmission
Fluid Pressure
(TFP) Manual
Valve Position
Switch

0.5G

iU:

452

. .

--~---------------------J-----~----~
M

20-Way Connector
0.5 ORN/BLK 1057

'" --I- --.,

14 C2

I Sensor
I Ground
I
~

Powertrain
I Control
I Module (PCM)
I ~

L-----.J

168436

Circuit Description
The Automatic Transmission Fluid Temperature (TFT)
Sensor is part of the Automatic Transmission Fluid
Pressure Manual Valve Position Switch (TFP
Val. Position Sw.). The TFT Sensor is a resistor, or
thermistor, which changes value based on
temperature. The sensor has a negative-temperature
coefficient. This means that as the temperature
increases, the resistance decreases, and as the
temperature decreases, the resistance increases. The
Powertrain Control Module (PCM) supplies a 5 volt
reference signal to the sensor on circuit 1227
and measures the voltage drop in the circuit. When
the transmission fluid is cold, the sensor resistance is
high and the PCM detects high signal voltage. As the

fluid temperature warms to a normal operating

temperature, the resistance becomes less and the
signal voltage decreases. The PCM uses this
information to control shift quality and torque converter
clutch apply.
When the PCM detects one of the following unusual
conditions, then OTC P0711 sets.
An unrealistically large change in transmission
temperature
A transmission temperature which remains
constant for a period of time in which a
measurable amount of change is expected
OTC P0711 is a type O OTC.

Transmission/Transaxle

Automatic 'Transmission - 4L60~

Conditions for Setting the OTC

4. If the Engine Run Tirrie is greater

than 300 secpnds and No Intake Air
Temperature (IAT) DTCs P0112 or PO~ 13 are
set and IATis available and Engine Coolant
Temperature (ECT) is between 40 and
125C (104 and 257F) and:
IAT at startup is less than 15C (59F),
then the default TFT is equal to the .
Engine Coolant Temperature (ECT)
plus 5C (8F);
IAT at startup is greater than 35C
. (95F), then the default TFT is equaLto
the Engine Coolant Temperature
(ECT) plus 10C (16~F).
IAT at startup is between,15 and 35C
(59 and 95F), then the default TFT is
equal to the Engine Coolant
Temperature (ECT),
5. If the Engine Run Time is greater
than 300 seconc;is and any Intake Air
Temperature (IAT) OTCs P0112 or P0113 are
set or IAT is NOT. avail~ble, then the default
TFT is equal to the Engine Coolant
Temperature (ECT).
6. If the Engine R1,m Time is greater
than 300 seconds and ECT is. less than 40C
(104F) or more, then the d~fault TFT is
equal tq 60C (140F).
The PCM freezes shift adapts from being updated.
OTC P0711 stores in .PCM history.

No VSS Assy. DTCs P0502 or P0503.

No Transmission Component Slipping OTC P1870.
The system voltage is 8-16 volts.
The engine is running for 409 seconds.
The vehicle speed is greater than 8 km/h (5 mph)
for 409 seconds.
The TCC slip speed is greater than 120 RPM for
409 seconds.
The transmission fluid temperature at startup is
between -40 and +21 C (-40 and +70F).
The TFT is between -38 and + 151 C
(-36 and +304F).
The engine coolant temperature is greater
than 70C (t58F) and has changed by 50C
(90F) since startup.
All of the above conditions are met and either of
the following fail conditions occurs:
- The transmission fluid temperature does not
change more than 1.50C (2.7F) for
409 seconds since startup.
- The transmission fluid temperature changes
more than 20C (36F) in 200 milliseconds

14 time within 7 seconds.

Action Taken When the OTC Sets

The PCM does not illuminate the Malfunction
Indicator Lamp (MIL).
The PCM determines a default Transmission Fluid
Temperature (TFT) using the following matrix:
Important: The actions listed below are in order of
highest to lowest priority.

1. If any Engine Coolant Temperature (ECT)

DTCs P0117 or P0118 are set, then the default
TFT is equal to 135C (275F).
2. If the ECT is 125C (257F) or more, then the
default TFT is equal to 135C (275F).
3. If the Engine Run Time is less
than 300 seconds and:
No Intake Air Temperature (IAT) DTCs
P0112 or P0113 are set and IAT is
available, then the default TFT is equal
to IAT.
Any Intake Air Temperature (IAT) DTCs
P0112 or P0113 are set or IAT is NOT
available, then the default TFT is
equal to 90C (194F).

CondiUor,s for Clearing the

7109

ore

A scan tool can clear the OTC from the PCM

history. The PCM clears the DTC from tht;i
PCM history if the vehicle completes 40 waniM.ip
cycles without a failure reported.

The PCM cancels the OTC default actions when

the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Diagnostic Aids
OTC P0218 may set approximately 600 seconds after
OTC P0711 has set. Follow the diagnostic table tor
OTC P0711 before proceeding to .ttie diagnostic table
tor OTC P0218. Repairing the condition that caused
OTCP0711 will likely eliminate OTC P0218.

Test Description
The numbers; below refer to the step numb~rs on the '
diagnostic table.
5. This step tests for an intermittent ~hprt pr'open
condition in the engine wiring harness. The
test light is used as a resistor in the circuit.
6. This step determines if the PCM or the TFT
Sensor is causing a steady, unchanging TFT
reading.

l'!'110

Automatic Transmission - 4L60-E

TransmissionfTransaxle

OTC P0711 TFT Sensor Circuit Range/Performance (5. 7L)

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD)
System Check

Go to Step 3

Go to
Transmission
Fluid Checking
Procedure

Go to Step 4

Go to
Diagnostic Aids

Go to Step 6

Go to Step 5

Go to Step 7

Go to Step 8

Go to Step 11

Go to Step 10

Go to Step 12

Go to Step 11

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Perform the transmission fluid checking procedure. Refer

to 4L60-E Transmission Fluid Checking Procedure.
Did you perform the fluid checking procedure?
1. Install the Scan Tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan tool in
order to record the Failure Records for reference. Using
the Clear Info function will erase the stored Failure
Records from the PCM.
3. Record the OTC Failure Records, then clear
the DTC(s).
4. Select TFT on the scan tool.
5. Drive the vehicle and observe the scan tool for either
of the following fail conditions:

The TFT does not change more than 1.50C

(2.7F) in 409 seconds since startup
The TFT changes more than 20c (36F)
in 200 milliseconds 14 times within 7 seconds
(unrealistic change).
Did either Ofthe fail conditions occur?
4

Did the scan tool display a condition in which the TFT

does not dhange by more than the specified value
in 409 seconds since startup?

1.50C (2.7F}

1. Turn the ignition OFF.

2. Disconnect the transmission 20-way connector.

3. Install the J 39775 Jumper Harness on the engine

side of the 20-way connector.
4. Using the J 35616-A Connector Test Adapter Kit,
connect a test light from terminal L to terminal M.
5. Jumthe ignition switch to the RUN position.
6. While observing the scan tool display, move or
massage the engine wiring harness from PCM
connector C2. to the 20-way connector.
Does the TFT change by more than the specified value?

20C (36F)

1. Turn the ignition OFF.

2, Disconnect the transmission 20-way connector.
3. Turn the ignition switch to the RUN position.
Does the scan tool display the same condition as in
Step 4?

1. Inspect circuits 1227 (YEUBLK) and 1057 (ORN/BLK}

of the engine wiring harness for an intermittent open
or short condition.
Refer to General Electrical Diagnosis Procedures.
2. Repair the circuits if necessary.
Refer to Wiring Repairs.
Did you find an intermittent open or shorted condition?

Transmission/Transaxle

Automatic Transmission - 4L60-E

7-111

OTC P0711 TFT Sensor Circuit Range/Performance (5.7L) (cont'd)

Step

(
8

Action

Inspect circuits 1227 (BRN) and 452 (GRY) of the

Automatic Transmission Wiring Harness Assembly (A/T
Wiring Harness Assembly) for an intermittent open or short
condition.

Value(s)

Replace the A/T Wiring Harness Assembly.

Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring
Harness Replacement.
Is the replacement complete?

10

Replace the TFT Sensor (the sensor is a part of the TFP

Valve Position Switch).
Refer to Valve Body and Pressure Switch Replacement.
Is the replacement complete?

11

Replace the PCM.

Refer to PCM Replacement/Programming.
Is the replacement complete?

12

No

Go to Step 9

Go to Step 10

Refer to General Electrical Diagnosis Procedures.

Did you find an intermittent open or shorted condition?

In order to verify your repair, perform the following

procedure:
1. Select OTC.
2. Select Clear Info.
3. Drive the vehicle and ensure that the following
conditions are met:
The TFT changes by more than 2:25C (4F)
for 11 seconds since startup

Yes

Go to Step 12

Go to Step 12

Go to Step 12

The TFT does not change by more than 20C

(36F) within 200 milliseconds for a period of at
least 11 seconds
4. Select Specific OTC. Enter OTC P0711.
Has the test run and passed?

System OK

Go to Step 1

7.:.112

Automatic Transmission - 4L60~E

TransmissionfTransaxle

DTC,P0712 Transmi~sion Fluid Temperature (TFT} Sensor Circuit Low Input (3.8L}

r -

;+- - - - - - - - - ~ - - - - - - ;+- - - - - sv -

: Rantie
Signal . .

I
.1.
t

p::1:~.
,

Raune Tti

Signal
B

Signa.I
C

Sen. sor
Signal

Control
Module (PCM)

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ...I

0.5

Ranue

- - - - - , Powertrain

o,s

0 5 BK

ll

-. ~

20 - Way Connector

0.5 YEL/BLK 227

-o~ ~:uf2~ -----~-~ ~;~h 2~~ --:.: t 227

ol
Al

~;N

-D~

~ TAutoma:ic.
ransm1ss1on

REV

Switch

3
Switch

PN012-2~ - - - - - - -

B::1~.- --:. ~-: I~

>,

LJ:!l

Transmission
Automatic
Fluid Pressure
(TFP) Manual
Position

}___

Valve

D4
Switch

'I

Switch

LO
Switch

Transmission
Fluid
Temperature

D2

... Switch

(TFT)
Sensor

~ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ o.s Glv:G,s2

_ _ _ _ _ _ _ _ _ ...

M ' - - - - 20 - Way Connector

0.5 GRY 720
Sflnsors
Cell20

...-- - -

5121

0.5 GRY 720

-I- --,

35 C2
r -

I sensor
I Ground
I
=

Powertrain
I Control
I Module (PCM)
I >,

L-----..1

193768

Circuit Description
The Automatic Transmission Fluid Temperature (TFT)
Sensor is part of the Automatic Transmission Fluid
Pressure Manual Valve Position Switch (TFP
Val. Position Sw.). The TFT Sensor is a resistor, or
thermistor, which changes value based on
temperature, The sensor has a negative-temperature
coefficient. This means that as the temperature
increases, the resistance decreases, and as the
temperature decreases, the resistance increases. The
Powertrain Control Module (PCM) supplies a 5 volt
reference signal to the sensor on circuit 1227

and measures the voltage drop in the circuit. When

the transmission fluid is cold, the sensor resistance is
high and the PCM detects high signal voltage. As
the fluid temperature warms to a normal operating
temperature, the resistance becomes less and
the signal voltage decreases. The PCM uses this
information to control shift quality and torque converter
clutch apply.
When the PCM detects a continuous short to ground
in the TFT signal circuit or in the TFT Sensor, then
DTC P0712 sets. OTC P0712 is a type O OTC.

Transmission/Transaxle

Automatic Transmission . '". 4L60-E .7-113

Conditions for Setting the, DTC

6. If the Engine Run Time is greater

than 300 seconds and ECT is less than 40C
(104F) or more, then the default TFT'is
0
equal to'60C (140F).
The PCM freezes shift adapts from being updated.
DTC P0712 stores in PCM history.

The system voltage is 8-16 volts.

The ignition switch is in the RUN position.
The TFT Sensor indicates a signal voltage less
than 0.2 volts.
All conditions met for 10 seconds.

Action Taken When the OTC Sets

The PCM does not illuminate the Malfunction
Indicator Lamp (!\(Ill}.
The PCM determines a default Transmission Fluid
Temperature (TFT) using the following matrix: .
Important: The actions listed below are in order of
highest to lowest priority.
1. If any Engine Coolant Temperature (ECT)
DTCs P0117 or P0118 are set, then the default
TFT is equal to 135C (275F).
2. If the ECT is 125C (257F) or more, then the
default TFT is equal to 135C (275F).
3. If the Engine R,. m Time is less
than 300 seconds and:
No Intake Air Temperature (IAT) DTCs
P0112 or P0113 are set and IAT is
available, then the default TFT is equal
to IAT.
Any Intake Air Temperature (IAT) DTCs
P0112 or P0113 are set or IAT is NOT
ava.ilable, then the default TFT is
equal to 90C (194F).
4. If the Engine Run Time is greater
than 300 seconds and No Intake Air
Temperature (IAT) DTCs P0112 or P0113 are
set and IAT is availabl~ and Engine Coolant
Temperature (ECT) is between 40 and
125C (104 and 257F) and:
IAT at startup is less than 15C (59F),
then the default TFT is equal to the
Engine Coolant Temperature (ECT)
plus 5C (8F).
IAT at startup is greater than 35C
(95F), then the default TFT is equal to
the Engine Coolant temperature
.r
(ECT) plus 10C (16F).
IAT at startup is between 15 and 35C
(59 and 95F), then the default TFT is
equal to the Engine Coolant
Temperature (ECT).
5. If the Engine Run Time is greater
than 300 seconds and any Intake Air
Temperature (IAT) DTCs P0112 or P0113 are
set or IAT is NOT available, then the default
TFT is equal to the Engine Coolant
Temperature (ECT).

Conditions for Clearing the OTC

A scan. tool can clear the OTC from the PCM
history. The PCM clears the DTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the DTC default actioni;, when
the fault no longer exists and. the ignition is
OFF long enough in order to power down
. the'PCM.
,

~.\

Diagnostic Aids
Inspect the wiring at the PCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poo~ terminal tension .
- A chafed wire
- A ,broken wire inside the insulation
- Moisture .intrusion
~ Corrosion
When diagnosing for an intermittent short or open
condition, massage the wiring, harness while
'
watching the test equipment for a change.
Use the Temperature vs Resistance 1able when
testing. the TFT Sensor at various. temperature
levels., Test the TFT Sensor. in order to evaluate
the possibility of a skewed (mis-scaled} sensor.
A skewed sensor can result in delayed garage
shifts or TCC complaints.
The scan tool also displays the transmission fluid,
temperature in d~grees. Alter the transmission is ;
operating, the fluid temperature should ri~e
steadily to a normal operating temperature, then
stabilize.

~ Verify customer driving habits, trailer towing, etc ....

TraHerctowing shou.ld occur in 03.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step tests for a short to ground or a skewed
sensor.
4. This step creates an open in the TFT circuit in
order to test for an internal fault.

7-114

Automatic Transmission - 4L60-E

Transmission!Transaxle

OTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input (3.8L)
Step

Value(s)

Action

Yes

No

Go to Step 2

Go to A
PQwertrain On
Board Diagnostic
(OBD)
System Check

Go to Step 3

Go to
Transmission
Fluid Checking
Procedure

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 8

Go to
Diagnostic Aids

Go to Step 6

Go to Step 10

Go to Step 7

Go to
Diagnostic Aids

Go to Step 9

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1
c

Perform the transmission fluid checking procedure. Refer

to '4l60E lransmission Fluid Checking Procedure.
Have you performed the fluid .checking procedure?

1. 1.nstall the Scan Tool.

2. With the engine OFF, turn the ignition switch to the

RUN position.
Important: Before clearing the DTC(s), use the scan tool
in order to record the Failure Records for reference. Using
the Clear Info function will erase the stored Failure
Records from the PCM.
3. Reqord the OTC Failure Records, then clear
the DTC(s).

0.2 volts

Does the scan tool display a TFT Sensor signal voltage

less than the specified value?
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector.

3. With the engine OFF, turn the ignition switch to the

RUN position.

4.92 volts

Does the scan tool display a TFT Sensor signal voltage

greater than the specified value?
1. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector.
5

2. Using the J 39200 Digital Multimeter (DMM) and

J 35616-A Connector Test Adapter Kit, measure the
resistance between terminal L and terminal M.

3088-3942 n at
20C (68F)
159-198 n at
100C (212F)

Is the: resistance within the specified range?

Inspect circuit 1227 (BRN) of the Automat.ic Transmission

Wiring Harness Assembly (A/T Wiring Harness Assembly)
for a short to ground condition.

Refer to General Electrical Diagnosis Procedures.

Did you find a short to ground condition?

1. Disconnect" the AfT Wiring Harn.e~s Assembly at the

TFT Sensor.
2. Measure the resistance of the Tj=:TSensor.
Is the resistance within 1he specified range?

3088-3942;0 at
20C (68F)
159-198 n at
100C (212F)

1. Inspect circuit 1227 (YEUBLK) of the engine wiring

harness for a short to ground condition.
8

Refer to Gene.rat Electrical Diagnosis Procedures.

2. Repair the circuit if necessary.

Refer to Wirinf! Repairs.

"

Did you find a short to ground condition?

Replace the TFT Sensor (this is part of the TFP Val.
Position Sw.).

Refer to Valve Body and Pressure Switch Replacement.

Is the replacement complete?

Go to Step 12

Go to Step 11

Go to Step 12

Replace the A/T Wiring Harness Assembly.

10

Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring

Harness Replacement.
Is the replacement complete?

Go to Step 12

Transmission/Transaxle

Automatic Transmission - 4L60E

7-115

OTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input (3.8L) (cont'd)
Action
No
Value(s)
Yes

Step

11

12

Replace the PCM.

Refer to PCM Replacement/Programming.
Is the replacement complete?

In order to verify your repair, perform the following

procedure:
1. Select DTC.
2. Select Clear Info.
3. With the engine OFF, turn the ignition switch to the
RUN position.
4. Verify that the scan tool indicates a TFT Sensor
signal voltage greater than 0.2 volts for 1O seconds.
5. Select Specific DTC. Enter DTC P0712.
Has the test run and passed?

Go to Step 12

System OK

Go to Step 1

7-116

Automatic Transmission - 4L60-E

Transmission/Transaxl.e

DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input (5.7L)

rr;:-,

,.

s+

B+

: Ran~e
.
Signal
I A .
I

sv

B+

. RaQne
.
..
Signal
B

, Powertrain
1
I Control.
Module (PCM)
I
~
.
I ~

TUFT.

Ranu-e
Signal
C
.

Sensor

Signal

L:Ll

LJil

L----------------------------------'

0.5 p::1~4 --0-5 ~:1~~5 0.:-::1;

D~-

o.s

YEL. /B~KeC.2:7

R
-o~ ~~ ~:u

PNJ12-2~ ------Cl
REV

--- Switch

LO
Switch

_ _ _ _ _ _ _ _

L .

h2~; -----~-~ ~;Nt2~~ --~.: ~;Nt

Er
DI
At
D3

Switch

20 - Way Connector

.
21

ransm1ss1on
Automatic
Transmission
Fluid Pressure
(TFP) Manual
Valve Position
Switch

D4

....

~ ATutoma_tic.

Switch

Transmission
Fluid
Temperature
(TFT)
Sensor

D2

. Switch

- _ _ _ _ _ _ _ _ _ _ _ _ _ _

0.5 GR~Jts2

________ _

20- Way Connector

0.5 ORN/BLK 1057

-I- --,

14 C2
r -

I
I
I

sensor
Ground

Powertrain
I Control
I Module (PCM)
I ~

L-----..1

168436

Circuit Description
The Automatic Transmission Fluid Temperature (TFT)
Sensor is part of the Automatic Transmission Fluid
Pressure Manual Valve Position Switch (TFP
Val. Position Sw.). The TFT Sensor is a resistor, or
thermistor, which changes value based on
temperature. The sensor has a negative-temperature
coefficient. This means that as the temperature
increases, the resistance decreases, and as the
temperature decreases, the resistance increases. The
Powertrain Control Module (PCM) supplies a 5 volt
reference signal to the sensor on circuit 1227

and measures the voltage drop in the circuit. When

the transmission fluid is cold, the sensor resistance is
high and the PCM detects high signal voltage. As
the fluid temperature warms to a normal operating
temperature, the resistance becomes less and
the signal voltage decreases. The PCM uses this
information to control shift quality and torque converter
clutch apply.
When the PCM detects a continuous short to ground
in the TFT signal circuit or in the TFT Sensor, then
DTC P0712 sets. DTC P0712 is a type D DTC.

Transmission/Transaxle

Automatic Transmission - 4L60.. E 7.tn 7

Conditions for Setting the DTC

6. If the Engine Run Time is. greater

than 300 seconds and ECT is less than 40C
(104F) or.more, then the default TFTis
equal to 60C (140"F).
'
The PCM freezes shift adapts from being updated.
DTC P0712 stores in PCM history.

The system voltage is 8-16 volts ..

The ignition switch is in the RUN position.

The TFT Sensor indicates a signal voltage less
than 0.2 volts.
~ All conditions met for 10 seconds.

Action Taken When the DTC Sets

The PCM does not illuminate the Malfunction
Indicator' lamp (MIL).
The PCM determines a default Transmission Fluid
Temperature (TFT) using the following matrix:

Important: The actions listed below are in order of

highest to lowest priority.
1. If any Engine Coolant Temperature (ECT)
DTCs P0117 or P0118 are set, then the default
TFT is equal to 135C (275F).
2. If the ECT is 125C (257F) or more, then the
default TFT is equal to 135C (275F).
3. If the Engine Run Time is less
than 300 seconds and:
No Intake Air Temperature (IAT) DTCs
P0112 or P0113 are set and IAT is
available, then the default TFT is equal
to IAT.
Any Intake Air Temperature (IAT) DTCs
P0112 or P0113 are set or IAT is NOT
available, then the default TFT is
equal to 90C (194F).
4. If the Engine Run Time is greater
than 300 seconds and No Intake Air
Temperature (IAT) DTCs P0112 or P0113 are
set and IAT is available and Engine Coolant
Temperature (ECT) is between 40 and
125C (104 and 257F) and:
IAT at startup is less than 15C (59F),
then the default TFT is equal to the
Engine Coolant Temperature (ECT)
plus 5C (8F).
IAT at startup is greater than 35C
(95F), then the default TFT is equal to
the Engine Coolant Temperature
(ECT) plus 10C (16F).
IAT at startup is between 15 and 35C
(59 and 95F), then the default TFT is
equal to the Engine Coolant
Temperature (ECT).
5. If the Engine Run Time is greater
than 300 seconds and any Intake Air
Temperature (IAT) DTCs P0112 or P0113 are
set or IAT is NOT available, then the default
TFT is equal to the Engine Coolant
Temperature (ECT).

Conditions for Clearing the DT.C

A scan .tool can clear the OTC from. the PCM
history. The PCM cl~ars the OTC fr9m the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the
default actions when
the fault no longer exists and the ignition is
OFF long enough in order t6 power down
the PCM.

otc

Diagnostic Aids
Inspect the wiring at the PCM, the transmission
connector and aH other circuitconnec:ting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broker:i wire inside the irisulation
- Moisture intrusion
- Corrosion
When diagnosing for an intermittent short or open
condition, massage the wiring harness while
watching the test equipment for a change.
Use the Temperature vs Resistance table when
testing the TfT Sensor atvarioustempeJature
levels. Test the TFT Sensor in order to ewaluate
the possibility of a skewed (mis-scaled) sensor.
A skewed sensor can result in delayed garage
shifts or TCC complaints.
The scan tool displays the transmission' fluid
temperature in degrees. After ihe transmission is
operating, the fluid temperature should rise
steadily to a normal operating temperature, then
stabilize.
Verify customer driving habits, trailer towing, etc.
Trailer towing should occur in 03.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.

3. This step tests for a short to ground or a skewed

sensor.

4. This step creates an open in the TFT .circuit in

order to test for an internal fault.

7-118

Automatic Transmission - 4L60-E

Transmission/Transaxle

OTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input (5. 7L)
Action

Step

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080)
System Check

Go to Step 3

Go to
Transmission
Fluid Checking
Procedure

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 8

Go to
Diagnostic Aids

Go to Step 6

Go to Step 10

Go to Step 7

Go to
Diagnostic Aids

Go to Step 9

Go to Step 12

Go to Step 11

Was the Powertrain On-Board Diagnostic (080) System

Check performed~
-

Perform the transmission fluid checking procedure. Refer

to 4L60-E Transmission Fluid Checking Procedure.
Have you performed the transmission fluid checking
procedure?

1. Install the Scar:, Tool.

2. With .the engine OFF, turn the ignition switch to the

RUN position.
Important: Before clearing the DTCs, use the scan tool in
order to record the Failure Records for reference. Using
the Clear Info function will erase the stored Failure
Records from the PCM.
3. Record the OTC Failure .Records, then clear
the DTC(s).
Does the scan tool display a TFT Sensor signal voltage
less than the specified value?
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector.
3. With the engine OFF, turn the ignition switch to the
RUN position.
Does the scan tool display a n=T Sensor signal voltage
greater than the specified value?
1. Install the J 39775 Jumper Harness on the
transmission side of th.e 20-way connector.
2. Using the J 39200 Digital Multimeter (DMM) and the
J 35616-A Connector Test Adapter Kit, measure the
resistance between terminal L and terminal M.

0.2 volts

4.92 volts

3088-3942 Q at
20C (68F)
159-198 Q at
100C (212F)

. Is the resistance within the. specified range?

Inspect circuit 1227 (BRN) of the Automatic Transmission

.Wiring Harness Assembly (A!T Wiring Harness Assembly}
.for a short to ground condition.
Refer to General Electrical Diagnosis Procedures.
Did you find a short to ground condition?
1. Disconnect the AfT Wiring H.arness Assembly at the
TFT Sensor.
2. Measure the resistance of the TFT Sensor.
Is the resistance within the specified range?

3088-3942 Q at
20C (68F)
159-198 n at
100C (212F)

1. Inspect circuit 1227 (YEUBLK) of the engine wiring

harness for a short to ground condition.
Refer to General Electrical Diagnosis Procedures.
2. Repair the circuit if necessary.
Refer to Wiring Repairs.
Did you find a short to ground condition?

Replace the TFT Sensor (this is part of the TFP Val.

Position Sw.).
Refer to Valve Body and Pressure Switch Replacement.
Is the replacement complete?

Replace the A/T Wiring Harness Assembly.

Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring
Harness Replacement.
Is the replacement complete?

10

Go to Step 12

Go to Step 12

Transmissionrrransaxle

Automatic Transmission - 4L60-E

7-119

OTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input (5.7L) (cont'd)
Step

11

12

Action

Value(s)

Replace the PCM.

Refer to PCM Replacement/Programming.
Is the replacement complete?

In order to verify your repair, perform the following

procedure:
1. Select DTC.
2. Select Clear Info.
3. With the engine OFF, turn the ignition switch to the
RUN position.
4. Verify that the scan tool indicates a TFT Sensor
signal voltage greater than 0.2 volts for 10 seconds.
5. Select Specific DTC. Enter DTC P0712.
Has the test run and passed?

Yes

No

Go to Step 12

System OK

Go to Step 1

7-120

Automatic Transmission - 4L60-E

Transmission/Transaxle

DTC P0713 Transmission Fluid Temperature (TFT} Sensor Circuit High Input (3.8L}

:~~ . t
I
I

~~

I 7 r ~~ r :
C

~~?5I~:CM)

I
i,
I~

Signal

)
~

LliJ

L---------------------------------..1
05

p::1:4

o.s

05 DK

o5

PNi<l12-2~ - - - - - - -

cl

Switch

_ _

6B~

0.5 YEL/BLK 1227

P
.
L

ol

D3
Switch

LO

_ _

~-: 1~

20 - Way Connector

-o~~ ~:uf-2~;- ----:~ ~;~h 2~~ --:.: ~;~t 227

REV
Switch

_ _ _ _

B:1225

}
----

A1

~ ATutoma!ic.
Automatic
Transmission
Fluid Pressure
(TFP) tvlanual
Valve Position
Switch

04
Switch

Transmission
Fluid
Temperature
(TFT)
Sensor

D2
Switch

- _ _ _ _ _ _ _ _ _ _ _ _ _ _

0.5 GR~:G_s2

_________

1 ransm1ss1on
I
:

I
I
I
I

M ' - - - - 20 - Way Connector

0.5 GAY 720
Sensors
Cell20

.,...... - -

8121

0.5 GAY 720

-I- --,

35 C2
r -

I
I

Sensor

Ground
=

Powertrain
I Control
I Module (PCM)
I i,

L-----..1

193768

Circuit Description
The Automatic Transmission Fluid Temperature (TFT)
Sensor is part of the Automatic Transmission Fluid
Pressure Manual Valve Position Switch (TFP
Val. Position Sw.). The TFT Sensor is a resistor, or
thermistor, which changes value based on
temperature. The sensor has a negative-temperature
coefficient. This means that as the temperature
increases, the resistance decreases, and as the
temperature decreases, the resistance increases. The
Powertrain Control Module (PCM) supplies a 5 volt
reference signal to the sensor on circuit 1227

and measures the voltage drop in the circuit. When

the transmission fluid is cold, the sensor resistance is
high and the PCM detects high signal voltage. As
the fluid temperature warms to a normal operating
temperature, the resistance becomes less and
the signal voltage decreases. The PCM uses this
information to control shift quality and torque converter
clutch apply.
When the PCM detects a continuous open or short to
power in the TFT signal circuit or the TFT Sensor,
then DTC P0713 sets. DTC P0713 is a type D DTC.

Transmission/Transaxle

Automatic Transmission - 4L60-E

Conditions for Setting the OTC

6: If the Engine Run Time is greater

than 300 seconds and ECT is less than 40C
(104F) or more, then the default TFT is
equal to 60C (140F).
' .
The PCM freezes shift adapts from being updc;tted,
OTC P0713 stores in PCM history.

The system voltage is, 8-16 volts.

The ignition switch is in the RUN position.
The TFT Sensor indicates a signal voltage greater
than:4.92 Volts.

All conditions met tor 409 seconds (6.8 minutes).

Action Taken When the OTC Sets

The PCM does not illuminate the Malfunction
lndicator Lamp (MIL).
The PCM determines a default Transmission Fluid
Temperature (TFT) using the following matrix: .

Important: The actions listed below are in order of

highest to lowest priority.

1. If any Engine Coolant Temperature (ECT)

OTCs P0117 or P0118 are set, then the defc;tult
TFT is equal to 135C (275 9 F).
2. If the ECT is 125C (257F) or more, then the
default TFT is equal to 135C (275F).
3. If the Engine Run Ti.me is less
than 300 seconds and:
No lntake Air Temperature (lAT) OTCs
P0112 or P0113 are set and IAT is
available, then the default TFT is equal
to IAT.
Any Intake Air Temp~rature (IAT) OTCs
P0112 or P0113 are set or IAT is NOT
available, then the default TFT is
equ,al to 90C (194F).
4. If the Engine Run Time is greater
than 300 seconds and No Intake Air
Temperature (IAT) OTCs P0112 or P0113 are
set and IAT is available and Engine Coolant
Temperature (ECT) is between. 40 .and
125C (104 and 257F) and:
IAT at startup is less than 15C (59F),
then the default TFT is equal to the
Engine Coolant Temperature (ECT)
plus 5C (8F).
IAT at startup is greater than 35C
(95F), then the default TFT is equal to
the Engine Coolant Temperature
(ECT) plus 10C (16F).
IAT at startup is between 1.5 and 35C
(59 and 95F}, then the default TFT is

equal to the Engine Coolant

Temperature (ECT).
5. If the Engine Run Time 'is greater
than 300 seconds and any Intake Air
Temperature (IAT) OTCs P0112 or P0113 are
set or IAT is NOT available, then the default
TFT is equal to the Engine Coolant
Temperature (ECT).

\,

Conditions for Clearing the OTC

.

'

7-121

A scan tool can clear the OTC from the PCM

history. The PCM clears the OTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
:
.. ,
The PCM cancels the OTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down.
the PCM.
,,

Diagnostic Aids
Inspect the wiring at the PCM, the 'transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged termina:1
- Poor terminal tension
- A chafed wire
- A broken wire inside the insuiation
- Moisture intrusion
- Corrosion
When diagnosing for an intermittent short or open
condition, massage the wiring harness whi.le
watching the test equipment for acchange.
Use the Temperature vs R~sistance table when
testing the TFT Sensor at various temperature
levels. Test the TFT Sensor in order to evaluate
the possibility of a skewed (mis-scaled) sensor.
A skewed s~nsor can result }n delayed garage
.
shifts or TCC 'complaints. .
The sc~n tqol also displays the transmjssion fluid
temperature in degrees. After the transmission is
operating, the fluid temperature should rise
steadily to a normal operaUng temperature, then

stabilize.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step verifies that a condition exists in the

TFT Sensor circuit.

4. This step simulates a TFT Sensor OTC .P0712. If
the PCM recognizes high temperature, the PCM
and wiring are functioning normally.
5. This step tests the TFT Sensor and Automatic
Transmission Wiririg Harness Assembly (A!T
Wiring Harness Assembly).

7-122

Automatic Transmission - 4L60-E

TransmissionfTransaxle

OTC P0713 Transmission Fluid Temperature {TFT) Sensor Circuit High Input (3.SL)
Step

Action

Value(s)

Was the Powertrain On-Board Diagnostic {OBD) System

Check performed?

No

Go to Step 2

Go to A
Powertrain. On
Board Diagnostic
(080)
System Check

Go to Step 3

. Go to
Transrnissipn
Fluid Checking
Procedure

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 9

Go to
Diagnostic Aids

Go to Step 6

Go to Step 11

Go to Step 7

Go to
Diagnostic Aids

Go to Step B

Yes

Perform the transmission fluid checking procedure.

Refer to 4L60-E Transmission Fluid Checking Procedure.
Have you performed the fluid checking procedure?

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC{s), use the scan tool
in order to record the Failure Records for reference. Using
the Clear Info function will erase the stored Failure
Records from the PCM.
3. Record the OTC Failure Records, then clear
the DTC{s).
Does the scan tool display a TFT Sensor signal voltage
greater than the specified value?

4.92 volts

1. Turn the ignition OFF.

2. Disconnect the transmission 20-way connector.
3. Install the J 39775 Jumper Harness on the engine
side of the 20-way connector.
4. Install a fused ju~per wire from terminal L to
terminal M on the engine harness ..
5. With the engine OFF, turn the ignition switch to the
RUN position.
Does the TFT Sensor signal voltage drop to less than the
specified value?

0.2 volts

.1. Turn the ignitipn OFF.

2. Install the J 39775 Jumper Harness .on the

transmissi~n si,de of the 20-way connector.
3. Using.the J.39200 Digital Multimeter {DMM) and
J 35616-A Connector.Test Adapter Kit, measure the
resistance between terminal L and terminal M.
Is the resis~nce within the specified range?
Inspect circuit 1227 {BRN) and circuit 452 {GRY) of the
Autprnatic Transmission Wiring Harness Assembly {A/T
Wiring Harness Assembly) for an open condition.
Refer to General Electrical Diagnosis Procedures.
Did you find an open condition?
1. Disconnect the A/T Wiring Harness Assembly at the
TFT Sensor.
2. Measure the resistance of the TFT Sensor.
Is the resistance within the specified range?
Replace the TFT Sensor {this is part of. the TFP Val.
Position Sw.).
Refer to Valve. Body and Pressure Switch Replacement.
Is the replacement complete?

3088-3942 n at
20C '(68F)
159-198 n at
100C {212F)

3088-3942 Q at
20C {68F)
159-198 n at
100C {212F)

Go to Step 13

1. Inspect circuit 1227 (YEUBLK) of the engine wiring

harness for an open or short to B+ condition.

Refer to General Electrical Diagnosis Procedures.

2. Repair the circuit if necessary.
Refer to Wiring Repairs.
Did you find an open or short to B+ condition?

Go to Step 13

Go to Step 10

Transmission/Transaxle

Automatic Transmission - 4L60E

7-123

OTC P0713 Transmission Fluic:I Temperature (TFT) Sensor Circuit High Input (3.8L) (conf d) ,
Step

(
10

11

12

13

Action

Value(s)

1. Inspect circuit 720 (GRY) for an open condition.

Refer to General Electrical Diagnosis Procedures.
2. Repair the circuit if necessary.
Refer to Wiring Repairs.
Did you find an ~pen condition?

Replace the A!T Wiring Harness Assembly.

Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring
Harness Replacement.
Is the replacement complete?

Replace the PCM.

Refer to PCM Replacement/Programming.
Is the replacement complete?

In order to verify your repair, perform the following

procedure:
1. Select OTC.
2. Select Clear Info.
3. With the engine OFF, turn the ignition switch to the
RUN position.
4. Verify that the scan tool indicates a TFT Sensor
signal voltage less than 4.92 volts for less
than 409 seconds (6.8 minutes).
5. Select Specific OTC. Enter OTC P0713.
Has the test run and passed?

Yes

No

Go to Step 13

Go to Step 12

Go to Step 13

Go to Step 13

System OK

Go to Step 1

7-124

Automatic Transmission - 4L60-E

Transmissio.n/Jransaxle

DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input (5.7L)

:~; t ~;; t ~ } ,:~ l :~~=::~

I
I

>

I
I~

Signal

L.JiJ

L------------------------------- -~
0.5

p::1224
N

_____

~::1;~

~:1~25 -- 0_5

o5 D~_ _____

0.5 DK BLUh225

cl

REV

0.5 BRNh227

DI

--- Switch

LO
Switch

20 - Way Connector

0.5 ORNh226

03

Switch

fl ___________ p ________L

Er

0.5 PNi<l1224

1 7
YEUB:r
~:

____

Al

~ ATutomaJic.

ransm1ss1on

Automatic
Transmission
Fluid Pressure
(TFP) Manual
Valve Position
Switch

04
Switch

Transmission
Fluid
Temperature
(TFT)
Sensor

D2

sr.,

______ -.- _______________

0.5GRY-J.::52

______ -

20 - Way Connector
0.5 ORN/BLK 1057

-1- --,

14 C2
r -

I
I

Sensor
Ground

Powertrain
I Control
I Module (PCM)
I

L-----..1

>

168436

Circuit Description
The Automatic Transmission Fluid Temperature (TFT)
Sensor is part of the Automatic Transmission Fluid
Pressure Manual Valve Position Switch (TFP
Val. Position Sw.). The TFT Sensor is a resistor, or
thermistor, which changes value based on
temperature. The sensor has a negative-temperature
coefficient. This means that as the temperature
increases, the resistance decreases, and as the
temperature decreases, the resistance increases. The
Powertrain Control Module (PCM) supplies a 5 volt
reference signal to the sensor on circuit 1227

and measures the voltage drop in the circuit. When

the transmission fluid is cold, the sensor resistance is
high and the PCM detects high signal voltage. As
the fluid temperature warms to a normal operating
temperature, the resistance becomes less and
the signal voltage decreases. The PCM uses this
information to control shift quality and torque converter
clutch apply.
When the PCM detects a continuous open or short to
power in the TFT signal circuit or the TFT Sensor,
then DTC P0713 sets. DTC P0713 is a type D DTC.

Transmission!Transaxle

Automatic Transmission - 4L60-E

Conditions for Settingthe OTC

6. If the Engine Run Time is greater

than 300 seconds and ECT is less than 40C
(104F) or more, then the default TFT is
equal to 60C (140F}.
The PCM freezes shift adapts from being updated.
OTC P0713 stores in PCM history.

The system voltage is 8-16 volts.

The ignition switch is in the RUN position.
The TFT Sensor indicates a signal voltage greater
than 4.92 volts.
All conditions met for 409 seconds (6.8 minutes).

Action Taken When the OTC Sets

The PCM does not illuminate the Malfunction
ln.dicator Lamp (MIL).
The PCM determines a default Transmission Fluid
Temperature (TFT} using the following matrix:
Important: The actions listed below are in order of
highest to lowest priority.
1. If any Engine Coolant Temperature (ECT)
OTCs P0117 or P0118 are set, then the default
TFT is equal to 135C (275F).
2. If the ECT is 125C (257F} or more, then the
default TFT is equal to 135C (275F).
3. If the Engine Run Time is less
than 300 seconds and:
No Intake Air Temperature (IAT) OTCs
P0112 or P0113 are set and IAT is
available, then the default TFT is equ 91
to IAT.
Any Intake Air Temperature (IAT) OTCs
P0112 or P0113 are set or IAT is NOT
available, then the default TFT is
equal to 90C (194F).
4. If the Engine Rn Time is greater
than 300 seconds and No Intake Air
Temperature (IAT) OTCs P0112 or P0113 are
set and IAT is available and Engine Coolant
Temperature (ECT) is between 40 and
125C (104 and 257F) and:
IAT at startup is less than 15C (59F},
then the default TFT is equal to the
Engine Coolant Temperature (ECT} plus
5C (8F).
IATat startup is greater than 35C
(95F}, then the default TFT is equal to
the Engine Coolant Temperature
(ECT) plus 10C (16F).
IAT at startup is between 15 and 35C
(59 and 95F}, then the default TFT is
equal to the Engine Coolant
Temperature (ECT}.
5. If the Engine Run Time is greater
than 300 seconds and any Intake Air
Temperature (IAT) OTCs P0112 or P0113 are
set or IAT is NOT available, then the default
TFT is equal to the Engine Coolant
Temperature (ECT).

7-125

Conditions for Clearing the OTC

A scan tool can clear the OTC from the PCM
history. The PCM clears the OTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the OTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM ..

Diagnostic Aids
Inspect the wiring at the PCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent .terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion.
- Corrosion
When diagnosing for an intermittent short or open
condition, massage the wiring harness while
watching the test equipment for a change.
Use the Temperature vs Resistance table when
testing the TFT Sensor at various temperature
levels. Test the TFT Sensor in order to evaluate
the possibility of a skewed (mis-scaled) sensor.
A skewed sensor can result in delayed garage
shifts orTCC complaints.
The scan tool displays the transmission fluid
temperature in degrees. After the transmission is
operating, the fluid temperature should rise
steadily to a normal operating temperature, then
stabilize.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step verifies that a condition exists in the
TFT Sensor circuit.
. 4. This step simulates a T.FT SensorDTC P0712. If
the PCM recognizes high temperature, the PCM
and wiring are functioning normally.
5. This step tests the TFT Sensor and Automatic
Transmission Wiring Harness Assembly (A/T
Wiring Harness Assembly}.

7-126

Automatic Transmission - 4L60-E

Transmission/Transaxle

OTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input (5.7L)
Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080)
System Check

Go to Step 3

Go to
Transmission
Fluid Checking
Procedure

Go to Step 4

Go to
Diagnostic Aids

Go to Step 5

Go to Step 9

Go to
Diagnostic Aids

Go to Step 6

Go to Step 11

Go to Step 7

Go to
Diagnostic Aids

Go to Step B

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Perform the transmission fluid checking procedure.

Refer to 4L60-E Transmission Fluid Checking Procedure.
Have you performed the fluid checking procedure?
1. Install the Scan Tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan tool in
order to record the Failure Records for reference. Using
the Clear Info function will erase the stored Failure
Records from the PCM.
3. Record the DTC Failure. Records, then clear
the DTC(s).

4.92 volts

Does the scan tool display a TFT Sensor signal voltage

greater than the specified value?

1. Turn the ignition OFF.

2. Disconnect the transmission 20-way connector.
3. Install the J 39775 Jumper Harness on the engine
side of the 20-way connector.
4. Install a fused jumper wire from terminal L to
terminal M on the engine harness.
5. With the engine OFF, turn the ignition switch to the
RUN position.
Does the TFT Sensor signal voltage drop to less than the
specified value?

0.2 volts

1. Turn the ignition OFF.

2. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector.
3. Using the J 39200 Digital Multimeter (DMM) and the
J 35616-A Connector Test Adapter Kit, measure the
resistance between terminal L and terminal M.
Is the resistance within specifications?

3088-3942 n at
20C (68F)
159-198 n at
100C (212F)

Inspect circuits 1227 (BAN) and 452 (GAY) of the

Automatic Transmission Wiring Harness Assembly (A!T
Wiring Harness Assembly ) for an open condition.
Refer to General Electrical Diagnosis Procedures.
Did you find an open condition?
1. Disconnect the A!T Wiring Harness Assembly at the
TFT Sensor.
2. Measure the resistance of the TFT Sensor.
Is the resistance within the specified range?

3088-3942 n at
20C {68F)
159-198 n at
100C (212F)

Replace the TFT Sensor {this is part of the TFP Val.

Position Sw.).
Refer to Valve Body and Pressure Switch Replacement.
Is the replacement complete?

1. Inspect circuit 1227 (YEUBLK) of the engine wiring

harness for an open or short to B+ condition.
Refer to General Electrical Diagnosis Procedures.
2. Repair the circuit if necessary.
Refer to Wiring Repairs.
Did you find an open or short to B+ condition?

Go to Step 13

Go to Step 13

Go to Step 10

Transmission/Transaxle

Automatic Transmission - 4L60-E

7-127

OTC P0713 Transmission Fluid Temperature {TFT) Sensor Circuit High Input (5. 7L) (cont'd)
Step

Action

Value(s)

10

1. Inspect circuit 1057 (ORN/BLK) for an open condition.

Refer to General Electrical Diagnosis Procedures.
2. Repair the circuit if necessary.
Refer to Wiring Repairs.
Did you find an open condition?

11

Replace the A/T Wiring Harness Assembly.

Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring
Harness Replacement.
Is the replacement complete?

12

Replace the PCM.

Refer to PCM Replacement/Programming.
Is the replacement complete?

13

In order to verify your repair, perform the following

procedure:
1. Select OTC.
2. Select Clear Info.
3. Ensure that the following conditions are met:
With the engine OFF, the ignition switch is in the
RUN position.
The scan tool indicates a TFT Sensor signal
voltage less than 4.92 volts for 400 seconds
(6.7 minutes.
4. Select Specific otc. Enter OTC P0713.
Has the test run and passed?

Yes

No

Go to Step 13

Go to Step 12

'
Go to Step 13

Go to Step 13

System OK

Go to Step 1

1,

7-128

Automatic Transmission - 4L60-E

Transmissionrrransaxle

DTC P0719 Brake Switch Circuit Low Input (3.8L)

!Hot In Run, Bulb Test And Start!

Pow-:r - - - - - - - - - -

I Distribution
I

J7

ENG SEN
MiniFuse
20A

Cell 10

~
I

C C2
'" - - - - - - ,Brake Switch
I
I
I
I Assembly
.

Unde~hood
Electrical
Center 2

1..------------J
0.8 PNK 539

B C105
0.8 PNK 539
S104
- - - - - - - - -+

0.8 PNK 539

I
I

1,,

Fuse Block

LJiJ

(Openw,th

TCC/Shlft I brake pedal

1---

Interrupt

Switch

______

I depressed)
I

I
I

...

DIC2

Details

Cell11

P110

0.8 PPL 420

0.8 PNK 539

H C230

G C230

P110
0.8 PPL 420
30 C1
'" - B;k; -

I
I
I

Switch
Signal

Powertrain
I Control
I Module
I (PCM)~

L----.1

193773

Circuit Description
The brake switch indicates brake pedal status to the
Powertrain Control Module (PCM). The brake switch is
a normally-closed switch that supplies battery
voltage on circuit 420 to the PCM. Applying the brake
pedal opens the switch, interrupting voltage to the
PCM. When the brake pedal is released, the
PCM receives a constant voltage signal. If the PCM
receives a zero voltage signal at the brake switch
input, and the Torque Converter Clutch (TCC)
is engaged, the PCM de-energizes the Torque
Converter Clutch Solenoid Valve (TCC Sol. Valve).
The PCM disregards the brake switch input for
TCC scheduling if there is a brake switch circuit fault
(Refer to Diagnostic Aids).
When the PCM detects an open brake switch circuit
(0 volts, low input) during accelerations, then
DTC P0719 sets. DTC P0719 is a type D DTC.

Conditions for Setting the DTC

No VSS Assy. DTCs P0502 or P0503.
The PCM detects an open brake switch circuit
(0 volts) for 15 minutes without changing for
2 seconds, and the following events occur seven
consecutive times:
- The vehicle speed is less than
8 km/h (5 mph);
- then the vehicle speed is 8-32 km/h
(5-20 mph) for 4 seconds;
- then the vehicle speed is greater
than 32 km/h (20 mph) for 6 seconds.

Action Taken When the DTC Sets

The PCM does not illuminate the Malfunction
Indicator Lamp (MIL).
DTC P0719 stores in PCM history.

TransmissionfTransaxle

Automatic Transmission - 4L6o~e

Conditions for Clearing the DTC

When diagnosing for an intermittent short or open

condition, massage the wiring harness while
watching the test equipment for a change.

A scan tool can clear the OTC from the PCM

history. The PCM clears the OTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the OTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

If the PCM detects a brake switcn circuit fault,

then the. brake switch input i$ disregarded for TCC
scheduling. The PCM then uses throttle position
and vehicle speed to determine TCC application
and release. Use of these inputs may result
in a noticeable harsh apply or abrupt release of
the TCC.

Diagnostic Aids
Inspect the wiring at the PCM, the brake switch
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion

7-129

Ask about the customer's driving habits. Ask

about unusual driving c0nd.itions (e.g. stop and go,
expressway,
etc.).

. .
Inspect the. brake. switch for proper mounting and
adjustment.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step isolates the brake switch as a source for
setting the OTC.

DTC P0719 Brake Switch Circuit Low lnput(3.8L)

Step

Action

Value(s)

Yes

Go to A
Powertrain On
Board Diagnostic

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

No

(080)
Go to Step 2

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the scan tool
in order to record the Failure Records for reference. Using
the Clear Info function will erase the stored Failure
Records from the PCM.
3. Record the OTC Failure Records, then clear
the DTC(s).
4. Select TCC Brake Switch on the scan tool.
5. Disconnect the brake switch connector from the brake
switch.
6. Connect a test lamp from cavity C of the brake switch
connector to a known good ground.
Is the test lamp ON?

Install a fused jumper from terminal C to terminal D of the

brake switch connector.
Did the TCC Brake Switch status change from Open to
Closed?

Remove the ENG SEN fuse. Inspect the fuse for an open.
Refer to General Electrical Diagnosis Procedures.
Is the fuse open?

1. Inspect circuit 539 (PNK) for a short to ground

condition.
Refer to General Electrical Diagnosis Procedures.
2. Repair the circuit if necessary.
Refer to Wiring Repairs.
Did you find a short to ground condition?

'

System Check

Go to Step 3

Go to Step 4

Go to Step 7

Go to Step 9

Go to Step 5

Go to Step 8

Go to Step 11

Go to Step 6

7-130
Step

TransmissionfTransaxle

Automatic Transmission - 4L60-E

DTC P0719 Brake Switch Circuit Low Input (3.8L) (cont'd)

Value(s)
Action
Yes

No

1. Inspect circuit 420 (PPL) for a short to ground

condition.

Refer to General Electrical Diagnosis Procedures.

2. Repair the circuit if necessary.
Refer to Wiring Repairs.

Go to Step 11

Did you find a short .to ground condition?

7

Replace the brake switch.

Refer to Stop/amp Switch Replacement.
Is the replacement complete?

Go to Step 10

Go to Step 11

1. Inspect circuit 539 (PNK) for an open condition.

Refer to General Electrical Diagnosis Procedures.

10

11

2. Repair the circuit if necessary.

Refer to Wiring Repairs.
Did you find an open condition?

Go to Step 11

1. Inspect circuit 420 (PPL) for an open condition.

Refer to General Electrical Diagnosis Procedures.
2. Repair the circuit if necessary.
Refer to Wiring Repairs.
Did you find an open condition?

Replace the PCM.

Refer to PCM Replacement/Programming.
Is the replacement complete?

In order to verify your repair, perform the following

procedure:
1. Select DTC.
2. Select Clear Info.
3. With the engine OFF, turn the ignition switch to the
RUN position.
4. Apply and release the brake pedal.
5. Verify that the TCC Brake Switch status indicates
Closed (12 volts) for 2 seconds.
6. Select Specific DTC. Enter DTC P0719.
Has the test run and passed?

Go to Step 11

Go to Step 10

Go to Step 11

System OK

Go to Step 1

Automatic Transmission - 4L60E

Transmissionrrransaxle

7-131

OTC P0719 Brake Switch Circuit Low Input (5. 7L)

!Hot In Run, Bulb Test And Start!

Po;;;, - - - - - - - - - -

I Distribution
I

Cell

J7

to
J6

r -

ENG SEN

I Elecfrical

Mini Fuse

Center

20A

L------------J

0.8 PNK 539

B C105
0.8 PNK 539
S104
- - - - - - - - -+

C2

Unde~hood
#2

I
I
I
I
IL,

0.8 PNK 539

Assembly

IO
( penw,t'h
TCC/Shlfl
Interrupt

1--Switch

______

Fuse Block
Details
Cell11

.,Brake Switch
I brake pedal
I depressed)
I
I
I
...

DIC2

P110

0.35 PPL 420

0.8 PNK 539

H C230

G C230

P110
0.8 PPL 420
77 C1

Control I

0;k; - ,I

Module I
~ .(PCM) I

I
I

Powertrain r -

Switch
Signal

L----.1

168437

Circuit Description
The brake switch indicates brake pedal status to the
Powertrain Control Module (PCM). The brake switch is
a normally-closed switch that supplies battery
voltage on circuit 420 to the PCM. Applying the brake
pedal opens the switch, interrupting voltage to the
PCM. When the brake pedal is released, the
PCM receives a constant voltage signal. If the PCM.
receives a zero voltage signal at the brake switch
input, and the Torque Converter Clutch (TCC)
is engaged, the PCM de-energizes the Torque
Converter Clutch Solenoid Valve (TCC Sol. Valve).
The PCM disregards the brake switch input for
TCC scheduling if there is a brake switch circuit fault
(Refer to Diagnostic Aids).
When the PCM detects an open brake switch circuit
(O volts, low input) during accelerations, then
OTC P0719 sets. OTC P0719 is a type D OTC.

\.

Conditions for Setting the OTC

No VSS Assy. DTCs P0502 or P0503.
The PCM detects an open brake switch circuit
(0 volts) for 15 minutes without changing for
2 seconds, and the following events occur seven
consecutive times:
- The vehicle speed is less than
8 km/h (5 mph);
- then the vehicle speed is 8-32 km/h
(5-20 mph) for 4 seconds;
- then the vehicle speed is greater
than 32 km/h (20 mph) for 6 seconds.

Action Taken When the OTC Sets

The PCM does not illuminate the Malfunction

Indicator Lamp (MIL).
OTC P0719 stores in PCM history.

7-132

Automatic Transmission - 4L60-E

Transmission!Transaxle

Conditions for Clearing the OTC

When diagnosing for an intermittent short or open

condition, massage the wiring harness while
watching the test equipment for a change.

A scan tool can clear the DTC from the PCM

history. The PCM clears the DTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels-the DTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

If the PCM detects a brake switch circuit fault,

then the brake switch input is disregarded for TCC
scheduling. The PCM then uses throttle position
and vehicle speed to determine TCC application
and release. Use of these inputs may result
in a noticeable harsh apply or abrupt release of
the TCC.

Diagnostic Aids
Inspect the wiring at the PCM, the brake switch
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion

Ask about the customer's driving habits. Ask

about un.usual driving conditions (e.g. stop and go,
expressway, etc.).
Inspect the brake switch for proper mounting and
adjustment.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step isolates the brake switch as a source for
setting the DTC.

OTC P0719 Brake Switch Circuit Low Input (5.7L)

Step

Value(s)

Action

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080)
System Check

Goto Step 3

Go to Step 4

Go to Step 7

Go to Step 9

Go to Step 5

Go to Step 8

Go to Step 11

Go to Step 6

Was the Powertrain On-Board Diagno$tic (OE!D) System

Check performed?

'
1

?t

1. Install the Scan Tool.

2. With the engjne OFF, tu(n the ignition switch to the
RUN position.
I
.
Important: Before clearing the otcs, use the scan tool in
order to record the Failure Records tor reference. Using
the Clear Into function will erase the stored Failure
Records from the PCM.
3. Record the OTC Failure Records, then clear
the DTC(s).
4. Select TCC Brake Switch on the scan tool.
5. Disconnect the.brake switch connector from the brake
switch.
6. Connect a test lamp from cavity C of the brake switch
connector to a known good ground.
Is the test lamp ON?

Install a fused jumper from terminal C to terminal D of the

brake switch connector.
Did the TCC Brake Switch. status changl;) from Open to
Closed?

Remove the ENG SEN fuse. Inspect the fuse tor an open.
Refer to General Electrical Diagnosis Procedures.
Is the fuse open?

I. Inspect circuit 539 (PNK) tor a short to ground

condition.
Refer to General Electrical Diagnosis Procedures.
2. Repair the circuit it necessary.
Refer to Wiring Repairs.
Did you find a short to ground condition?

Transmission/Transaxle

Automatic Transmission - 4L60E

7-133

OTC P0719 Brake Switch Circuit Low Input (5.7L) (cont'd)

Step

(
6

10

11

Action

1. Inspect circuit 420 (PPL) for a short to ground

condition.
Refer to General Electrical Diagnosis Procedures.
2. Repair the circuit if necessary.
Refer to Wiring Repairs.
Did you find a short to ground condition?
Replace the brake switch.
Refer to Stop/amp Switch Replacement.
Is the replacement complete?
1. Inspect circuit 539 (PNK) for an open condition.
Refer to General Electrical Diagnosis Procedures.
2. Repair the circuit if necessary.
Refer to Wiring Repairs.
Did you find an open condition?
1. Inspect circuit 420 (PPL) for an open condition.
Refer to General Electrical Diagnosis Procedures.
2. Repair the circuit if necessary.
Refer to Wiring Repairs.
Did you find an open condition?
Replace the PCM.
Refer to PCM Replacement/Programming.
Is the replacement complete?
In order to verify your repair, perform the following
procedure:
1. Select OTC.
2. Select Clear Info.
3. With the engine OFF, turn the ignition switch to the
RUN position.
4. Apply and release the brake pedal.
5. Verify that the TCC Brake Switch status indicates
Closed (12 volts) for 2 seconds.,
6. Select Specific OTC. Enter OTC P0719.
Has the test run and passed?

Value(s)

Yes

No

Go to Step 11

Go to Step 10

Go to Step 11

Go to Step 11

Go to Step 11

Go to Step 10

Go to Step 11

System OK

Go tp Step 1

7-134

Automatic Transmission - 4L60-E

Transmission/Transaxle

OTC P0724 Brake Switch Circuit High Input (3~8L}

!Hot In Run, Bulb Test And Start!

;;-;,w-;, - - - - - - - - - Distribution

I
I Cell to

J7

ENG SEN
MiniFuse
20A

~
I
I

Underhood
Electrical
Center 2

L-,-----------J
0.8 PNK 539

B C105
0.8 PNK 539
S104
- - - - - - - - -+

C2

~ - -;- - - - , Brake Switch

1
I
I

0.8 PNK 539

Fuse Block
Details

Cell11

P110
0.8 PNK 539

I
I
I

:Assembly

1---

(M;:-1

Lttl

(Open with
TCC/Shift I brake pedal
Interrupt I depressed)
Switch

I
I
I

.. ______ ..

DIC2
0.8 PPL 420
H C230

GtC230

P110
0.8 PPL 420
30 C1
~

I
I

-:B;k; - ~ Powertrain
Switch
Signal

Control
I Module
I (PCM)~

L----..1

193773

Circuit Description
The brake switch indicates brake pedal status to the
Powertrain Control Module (PCM). The brake switch is
a normally-closed switch that supplies battery voltage
on circuit 420 to the PCM. Applying the brake pedal
opens the switch, interrupting voltage to the PCM.
When the brake pedal is released, the PCM receives a
constant voltage signal. If the PCM receives a zero
voltage signal at the brake switch input, and the Torque
Converter Clutch (TCC) is engaged, the PCM
de-energizes the Torque Converter Clutch Solenoid
Valve (TCC Sol. Valve). The PCM disregards the brake
switch input for TCC scheduling if there is a brake
switch circuit fault.
When the PCM detects a closed brake switch circuit
(12 volts, high input) during decelerations, then
OTC P0724 sets. OTC P0724 is a type O OTC.

Conditions fdr Setting the OTC

No VSS Assy. OTCs P0502 or P0503.
The PCM detects a closed brake switch circuit
(12 volts) without changing for 2 seconds, and
the following E:ivents occur seven
consecutive times:
- The vehicle speed is greater than 32 km/h
(20 mph) for 6 seconds;
- then the vehicle speed is 8-32 km/h
(5-20 mph) for 4 seconds;
- then the vehicle speed is less than
8 km/h (5 mph).

Action Taken When the DTC Sets

The PCM does not illuminate the Malfunction
Indicator Lamp (MIL).
OTC P0724 stores in PCM history.

Conditions for Clearing the DTC

A scan tool can clear the OTC from the PCM
history. The PCM clears the OTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the OTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Transmission/Transax:le

Automatic Transmission - 4L60-E

Diagnostic Aids

When diagnosing for an intermittent short or open

condition, massage the wiring harness while
watching the test equipment for a change.
Ask about the customer's driving habits. Ask
about unusual driving conditions (e.g. stop and go,
expressway, etc.).
Inspect the brake switch for proper mounting and

adjustment.

Inspect the wiring at the PCM, the brake switch

connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation

7-135

Test Description

- Moisture intrusion
- Corrosion

The numbers below refer to the step numbers on the

diagnostic table.
2 .. This step isolates the brake switch as a source for
setting the DTC.

DTC P0724 Brake Switch Circuit High Input (3.SL)

Step

Action
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the scan tool
in order to record the Failure Records for reference. Using
the Clear Info function will erase the stored Failure
Records from the PCM.
3. Record the OTC Failure Records, then clear
the DTC(s).
4. Select TCC Brake Switch on the scan tool.
5. Disconnect the brake switch connector from the brake
switch.
Does the TCC Brake Switch status change from Closed
to Open?
Replace the brake switch.
Refer to Stop/amp Switch Replacement.
Is the replacement complete?
1. Inspect circuit 420 (PPL} for a short to B+ condition.
Refer to General Electrical Diagnosis Procedures.
2. Repair the circuit if necessary.
Refer to Wiring Repairs.
Did you find a short to B+ condition?
Replace the PCM.
Refer to PCM Replacement/Programming.
Is the replacement complete?
In order to verify your repair, perform the following
procedure:
1. Select OTC.
2. Select Clear Info.
3. With the engine OFF, turn the ignition switch to the
RUN position.
4. Apply and release the brake pedal.
5. Verify that the TCC Brake Switch status indicates
Open (0 volts) for 2 seconds.
6. Select Specific OTC. Enter OTC P0724.
Has the test run and passed?

Value(s)

Go to Step 2

No
Go to A
Powertrain On
Board Diagnostic
(080)
System Check

Go to Step 3

Go to Step 4

Yes

-
Go to Step 6

Go to Step 6

Go to Step 5

Go to Step 6

System OK

Go to Step 1

7-136

Automatic Transmission - 4L60-E

Tran'smission/Transaxle

OTC P0724 Brake Switch Circuit High Input (5.7L)

!Hot In Run, Bulb Test And Start!

;;;,w:, - - - - - - - - - -

I Distribution

J7

ENG SEN

I Electrical

Mini Fuse
20A

J6

I Cell.10

C C2

Unde~hood

.... - - - - - - .,Brake Switch

I
I
I
I
I

Center #2

L------------J
0.8 PNK 539
B C105
0.8 PNK 539
8104
- - - - - - - - -+
P110

0.8 PNK 539

I Assembly
.

(Openw,th
TCC/Shift I brake pedal
Interrupt I depressed)

1---Switch

I
I

.. ______

Fuse Block
Details
Cell 11

L..2w

I
...I

DIC2
0.35 PPL 420

0.8 PNK 539

H 0230
GrC230
P110

0.8 PPL 420

77 01

Powertrain r

Contr.ol

Module I
~ (PCM) I

4~

-B;k; - ,
Switch
Signal

I
I

1.----.J

168437

Circuit Description
The brake switch indicates brake pedal status to the
Powertrain Control Module (PCM). The brake switch is
a normally-closed switch that supplies battery
voltage on circuit 420 to the PCM. Applying the brake
pedal opens the switch, interrupting voltage to the
PCM. When the brake pedal is released, the
PCM receives a constant voltage signal. If the PCM
receives a zero voltage signal at the brake switch
input, and the Torque Converter Clutch (TCC)
is engaged, the PCM de-energizes the Torque
Converter Clutch Solenoid Valve (TCC Sol. Valve).
The PCM disregards.the brake switch input for
TCC scheduling if there is a brake switch circuit fault.
When the PCM detects a closed brake switch
circuit (12 volts, high input) during decelerations, then
DTC P0724 sets. DTC P0724 is a type D DTC.

Conditions for Setting the DTC

No VSS Assy. DTCs P0502 or P0503.
The PCM detects a closed brake switch circuit
(12 volts) without changing for, 2 seconds, and
the following events occur seven
consecutive times:
- The vehicle speed is greater than 32 km/h
(20 mph) for 6 seconds;
- then the vehicle speed is 8-32 km/h
(5-20 mph) for 4 seconds;
- then the vehicle speed is less than
8 km/h (5 mph).

Action Taken When the OTC Sets

The PCM does not illuminate the Malfunction
Indicator Lamp (MIL).
DTC P0724 stores in PCM history.

Conditions for Clearing the DTC

A scan tool can clear the DTC from the PCM
history. The PCM clears .the DTC from the
PCM history if. the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the .DTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

TransmissionfTransaxle

Automatic Transmission - 4L60-E 7-137

Diagnostic Aids

When diagnosing for an intermittent short or open

condition, massage the wiring harne$S while
watching the test equipment for a change.
Ask about the customer's driving habits. Ask
about unusual driving conditions (e.g. stop and go,
expressway, etc.).
Inspect the brake switch for proper mounting and
adjustment.

Inspect the wiring at the PCM, the brake switch

connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step isolates the brake switch as a source for
setting the DTC.

OTC P0724 Brake Switch Circuit High Input (5.7L)

Step

"

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080)
System Check

Go to.Step 3

Go to Step 4

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

\.

1. Install the Scah Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan tool in
order to record the Failure Records for reference. Using
the Clear Info function will erase the stored Failure
Records from the PCM.
3. Record the DTC Failure Records, then clear
the DTC(s).
4. Select TCC Brake Switch on the scan tool.
5. Disconnect the brake switch connector from the brake
switch.
Does the TCC Brake Switch status change from Closed
to Open?

Replace the brake switch.

Refer to Stop/amp Switch Replacement.
Is the replacement.complete?

1. Inspect circuit'420 (PPL) for a short to B+ condition.

Refer to Ger1eral Electrical Diagnosis Procedures.
2. Repair the circuit if necessary.
Refer to Wiring Repairs.
Did you find a short to B+ condition?

Replace the PCM..

Refer to PCM Replacement/Programming.
Is the replacement complete?

In order to verify your repair, perform the following

procedure:
1. Select DTC.
2. Select Clear Info.
3. With the engine OFF, turn the ignition switch to the
RUN position.
4. Apply and release the brake pedal.
5. Verify that the TCC Brake Switch status indicates
Open (0 volts) for 2 seconds.
6. Select Specific DTC. Enter DTC P0724.
Has the test run and passed?

Go to Step 6

Go to Step 6

Go to Step 5

Go to Step 6

System OK

Go to Step 1

7-138

Automatic Transmission - 4L60-E

Transmission/Transaxle

DTC P0740 TCC Enable Solenoid Circuit Electrical (3.8L)

20-:-WAY CONNECTOR

E
Automatic~
Transmission

o.s RED

3-2Shift
Solenoid
Valve
Assembly

839

2-3,Shift
Solenoid
Valve

L------

-----..1
0.5 PNK 239
5182 - - - - - 1
0.5 PNK 239

S107

- - -+-

I
I

L:i:iJ

1-2 Shift '.I

Solenoid
Valve

0.5 PNK 239

0.5 RED 839

G C100
0.5 PNK 239

II

Fuse Block
Details
Cell11

Torque
Converter
Clutch
Solenoid
(tCCSOL.)
Valve

Torque
Converter
Clutch
Pulse Width
Modulation
Solenoid
Valve

__________

0.5 BLK 422

---

t;;-

0.5 TAN/BL:

I
...,I

20-WAY CONI\JECTOR

79lc2
Powertrain ~ - - - - - - - - - - - .,
Control
______1 Solenoid
Tcc
I
I
~
I
Module I TCC Solenoid
....., valve
I
~ (PCM) I
Valve
.... Control
~
L
Feedback . _ _ _
~___ ~

193778

Circuit Description
The Torque Converter Clutch Solenoid Valve (TCC
Sol. Valve)ls an electrical device that is used with the
Torque Converter Clutch Pulse Width Modulation
Solenoid Valve (TCC PWM Sol. Valve) in order
to control TCC apply and release. The TCC Sol. Valve
~ttaches to the transmission case assembly extending
into the pump cover. The TCC Sol. Valve receives
ignition voltage through circuit 239. The Powertrain
Control Module (PCM) controls the solenoid by
providing the ground path on circuit 422. The PCM
monitors the Throttle Position (TP) voltage, the vehicle
speed and other inputs in order to determine when
to energize the TCC Sol. Valve.
When the PCM detects a continuous open or a short
to ground in the TCC Sol. Valve circuit or in the
TCC Sol. Valve, then DTC P0740 sets. DTC P0740 is
a type A DTC.

Conditions for Setting the DTC

The system voltage is 8-16 volts_.
The engine speed is greater thin 450 RPM for
8 seconds.
Not in fuel cutoff.
All of the above conditions are met for 5 seconds
and either of the followingfail c01;1ditions occurs
for 5 seconds:
- The PCM command; the solenoid ON and
the voltage input remains high (B+).
- The PCM commands the solenoid OFF and
the voltage input remains low (O volt).

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL).
The PCM inhibits TCC engagement.
The PCM inhibits 4th gear if the transmission is in
hot mode.
The PCM freezes shift adapts from being updated.
DTC P0740 stores in PCM history.

TransmissionfTransaxle

Automatic Transmission - 4L60E 7-139

Conditions for Clearing the MIUDTC

- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
When diagnosing for an intermittent short or open
condition, massage the wiring harness while
watching the test equipment for a change.
With the TCC engaged, the TCC slip speed
should be -20 to +40 RPM.

The PCM turns OFF the MIL after three

consecutive trips without a failure reported.
A scan tool can clear the OTC from the PCM
history. The PCM clears the OTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the OTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Test Description

Diagnostic Aids
Inspect the wiring at the PCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension

The numbers below refer to the. step numbers on the

diagnostic table.
4. This step tests for voltage to the solenoid.
6. This step tests the ability of the PCM and wiring
to control the ground circuit.
8. This step tests the resistance of the TCC Sol.
Valve and the Automatic Transmission Wiring
Harness Assembly (A/T Wiring Harness
Assembly).

DTC P0740 TCC Enable Solenoid Circuit Electrical (3.8L)

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check in Engine
Controls

Go to Step 3

Go to Step 4

Go to Step 12

Go to Step 4

Go to Step 6

Go to Step 5

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the scan tool
in order to record the Freeze Frame and Failure Records
for reference. Using the Clear Info function will erase the
stored Freeze Frame and Failure Records from the PCM.
3. Record the OTC Freeze Frame and Failure Records,
then clear the DTC(s).

Are DTCs P0753, P0758, P0785 and P1860 also set?

1. Inspect the ENG CTRL fuse.

2. If the fuse is open, inspect circuit 239 (PNK), the
solenoids and the A!T Wiring Harness Assembly for a
short to ground. Repair the circuit, the solenoids and
the harness if necessary.
Refer to General Electrical Diagnosis Procedures in Wiring
Systems.
Did you find a short to ground condition?

1. Turn the ignition switch OFF.

2. Disconnect the transmission 20-way connector
(additional DTCs may set).
3. Install the J 39775 Jumper Harness on the engine
side of the 20-way connector.
4. With the engine OFF, turn the ignition switch to the
RUN position.
5. Connect a test tamp from cavity E of the J 39775
Jumper Harness to a known good ground.
Is the test lamp ON?

7.;1.40

Automatic Transmission - 4L60-E

TransmissionfTransaxle

DTC P0740 TCC Enable Solenoid Circuit Electrical (3.BL) (cont'd)

Action

Step

Repair the open or short to ground in ignition feed

circuit 239 (PNK) to the TCC Sol. Valve.
Refer to Wiring Repairs in Wiring Systems.
Is the repair complete?

Value(s)

Yes

No

Go to Step 12

1. Install the test lamp from cavities E to T of the

J 39775 Jumper Harness.

2. Using the transmission output control function on the

scan tool, command the TCC SoL Valve ON and OFF
three times.

Does the test lamp turn ON when the TCC Sol. Valve is
commanded ON, and OFF when commanded OFF?

Go to Step 8

Go to Step 7

Go to Step 12

Go to Step 9

Go to Step 10

Go to Step 11

1. Inspect drcuit 422 (TAN/BLK) of the engine wiring

harness for an open, short to ground or short to
power condition.
7

Refer to General Electrical. Diagnosis Procedures in

Wiring Systems.

2. Repair the circuit if necessary.

Refer to Wiring Repairs in Wiring Systems.
Did you find an open, shor:t to ground or short to power
condition?

1. Install the J 39775 Jumper Harness on the

transmission side of the 20-way connector.

2. Using the J 39200 Digital Multimeter (DMM) and the

J 35616-A Connector Test Adapter Kit, measure the
resistance between terminals T and E.

21-33 n

is the resistance within the specified range?

Replace the PCM.
9

10

Refer to PCM Replacement/Programming in Engine

Controls.
Is the replacement complete?
Measure the resistance between terminal E and ground
and terminal T and ground.

Go to Step 12
250Kn

Are both readings greater than the specified value?

Go to
Diagnostic Aids

Go to Step 11

Replace the A/T Wiring Harness Assembly (this includes

the TCC Sol. Valve).
11

tee

Refer to
PWM Solenoid, TCC Solenoid, and Wiring
Harness Replacement.
Is the replacement complete?

Go to Step 12

In order to verity your repair, perform the following

procedure:
1. Select OTC.
2. Select Clear Into.
3. Drive the vehicle in 04 with the TCC ON and OFF.
Ensure the following conditions are met:
12

The PCM commands the TCC Sol. Valve ON, and

the voltage input drops to zero.

The PCM commands the TCC Sol. Valve OFF,

and the voltage input increases to B+.
All conditions are met for 5 seconds.
4. Select Specific OTC. Enter OTC P0740.
Has the test run and passed?

System OK

Go to Step 1

Transmission/Transaxle

Automatic Transmission - 4L60.. E 7141

DTC P0740 TCC Enable Solenoid Circuit Electrical (5.7L)

. 20 - Way Connector
E
!Hot In Run, Bulb Test And Start!
Power

Distribution
Ceu 10

._

~ ..
ENG CTRL
:
-

Mini Fuse
15A

_____ _ -----J

Underhood
Electrical
Center # 2

Automatic r - - - - - - - - - - .., - - - - .- - - .,
Transmission I
o.s RED. 839
I

~~!n!~~ft

s1a2-----~
0.5 PNK 239 0.5 PNK

Q;S PNK 239

239

II

0.5 PNK 239

- - +

2-3 Shift

I
I
I
I
I
I

1-2Shifl
Solenoid
Valve

0.5 RED 839

G C100

S107

Solenoid
Valve

.I

0.5 PNK 239

Valva
Assembly

Fuse Block
Details
Cell11

.Torque
Converter
Clutch
Pulse Width
Mo'.:lulation
Solenoid
{TCC PWM SOL)
Valve

Torque
Converter
Clutch
Solenoid
(TCC SOL.)
Valve

0.5 BLK 422

I
I
I
I

--- --------------J
o.s TAN/BL:~ 20- Way Connector
Powertrain
C t
on ro

,... I1

Module
(PCM)

321;:

TCC
I
Solenoid I
....., valve
I
... Control
_
= ___ ~

__j
CL...,.-;
_

I
I TCC Solenoid
I
Valve
L
Feedback _

"'

168438

Circuit Description
The Torque Converter Clutch Solenoid Valve (TCC
Sol. Valve) is an electrical device that is used with the
Torque Converter Clutch Pulse Width Modulation
Solenoid Valve (TCC PWM Sol. Valve) in order
to control TCC apply and release. The TCC Sol. Valve
attaches to the transmission case assembly extending
into the pump cover. The TCC Sol. Valve receives
ignition voltage through circuit 239. The Powertrain
Control Module (PCM) controls the solenoid by
providing the ground path on circuit 422. The PCM
monitors the Throttle Position (TP) voltage, the vehicle
speed and other inputs in order to determine when
to energize the TCC Sol. Valve.
When the PCM detects a continuous open or a short
to ground in the TCC Sol. Valve circuit or in the
TCC Sol. Valve, then OTC P0740 sets. OTC P0740 is
a type A OTC.

Conditions f~r Setting the DTC

The system voltage is 8-16 volts.
The engine speed is greater than 450 RPM for
5 seconds.
Not in fuel cutoff.
All of the above conditions are met for 5 seconds
and either of the following fail conditions occurs

for 5 seconds:
- The PCM commands the solenoid ON and
the voltage input remains high (B+).
- The PCM comrr,ands the solenoid OFF and
the voltage input remains low (0 volt).

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL).
The PCM inhibits TCC engagement.
The PCM inhibits.Ath gear if the transmission is in
hot mode.
The PCM freezes shift adapts from being updated.
OTC P0740 stores in PCM history.

7-142

Automatic Transmission - 4L60-E

Transmission/Transaxle

Conditions for Clearing the MIUDTC

The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the
PC.M history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the DTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Diagnostic Aids
Inspect the wiring at the PCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension

- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
When diagnosing for an intermittent short or open
condition, massage the wiring harness while
watching the test equipment for a change.
With the TCC engaged, the TCC slip speed
should be -20 to +40 RPM.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
4. This step tests for voltage to the solenoid.
6. This step tests the ability of the PCM and wiring
to control the ground circuit.
8. This step tests the resistance of the TCC Sol.
Valve and the Automatic Transmission Wiring
Harness Assembly (A/T Wiring Harness
Assembly).

OTC P0740 TCC Enable Solenoid Circuit Electrical (5.7L)

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check in Engine
Controls

Go to Step 3

Go to Step 4

Go to Step 12

Go to Step 4

Go to Step 6

Go to Step 5

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan tool in
order to record the Freeze Frame and Failure Records for
reference. Using the Clear Info function will erase the
stored Freeze Frame and Failure Records from the PCM.
3. Record the OTC Freeze Frame and Failure Records,
then clear the DTC(s).
Are DTCs P0753, P0758, P0785 and P1860 also set?

1. Inspect the ENG CTRL fuse.

2. If the fuse is open, inspect circuit 239 (PNK), the
solenoids and the A!T Wiring Harness Assembly for a
short to ground. Repair the circuit, the solenoids, and
the harness if necessary.
Refer to General Electrical Diagnosis Procedures in Wiring
Systems.
Did you find a short to ground condition?

1. Turn the ignition switch OFF.

2. Disconnect the transmission 20-way connector
(additional DTCs may set).
3. Install the J 39775 Jumper Harness on the engine
side of the 20-way connector.
4. With the engine OFF, turn the ignition switch to the
RUN position.
5. Connect a test lamp from cavity E of the J 39775
Jumper Harness to a known good ground.
Is the test lamp ON?

Automatic Transmission - 4L60-E

TransmissionJTransaxle

7-143

OTC P0740 TCC Enable Solenoid Circuit Electrical (5.7L) (cont'd)

Step

Action

Value(s)

Repair the open or short to ground in ignition feed

circuit 239 (PNK) to the TCC Sol. Valve.
Refer to Wiring Repairs in Wiring Systems.
Is the repair complete?

1. Install the test lamp from cavities E to T of the

J 39775 Jumper Harness.
2. Using the transmission output control function on the
scan tool, command the TCC Sol. Valve ON and OFF
three times.
Does the test lamp turn ON when the TCC Sol. Valve is
commanded ON, and OFF when commanded OFF?

1. Inspect circuit 422 (TAN/BLK) of the engine wiring

harness for an open, short to ground or short to
power condition.
Refer to General Electrical Diagnosis Procedures in
Wiring Systems.
2. Repair the circuit if necessary.
Refer to Wiring Repairs in Wiring Systems.
Did you find an open, short to ground or short to power
condition?

1. Install the J 39775 Jumper Harness on the

transmission side of the 20-way connector.
2. Using the J 39200 Digital Multimeter (DMM) and the
J 35616-A Connector Test Adapter Kit, measure the
resistance between terminals T and E.
Is the resistance within the specified range?
Replace the PCM.
Refer to PCM Replacement/Programming in Engine
Controls.
Is the replacement complete?

No

Go to Step 12

Go to Step 8

Go to Step 7

Go to Step 12

Go to Step 9

Go to Step 10

Go to Step 11

21-33 Q

Go to Step 12

Measure the resistance between terminal E and ground

and terminal T and ground.
Are both readings greater than the specified value?

250KQ

11

Replace the A/T Wiring Harness Assembly (this includes

the TCC Sol. Valve).
Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring
Harness Replacement.
Is the replacement complete?

12

In order to verify your repair, perform the following

procedure:
1. Select OTC.
2. Select Clear Info.
3. Drive the vehicle in 04 with the TCC ON and OFF.
Ensure the following conditions are met:
The PCM commands the TCC Sol. Valve ON, and
the voltage input drops to zero.
The PCM commands the TCC Sol. Valve OFF,
and the voltage input increases to B+.
All conditions are met for 5 seconds.
4. Select Specific OTC. Enter OTC P0740.
Has the test run and passed?

10

Yes

Go to
Diagnostic Aids

Go to $tep 11

Go to Step 12

System OK

Go to Step 1

'7144

Transmission/Transaxle

Automatic Transmission - 4L60-E

DTC P0742 TCC System Stuck On. (3;8L)

Powertrainr - - - - - - - - - - - - - - .,
C t ii
TCC
TCCPWM
I
on ro
Solenoid
Solenoid
I
Module I
Valve
Valve
~ (f:lCM)I
Feedback
Feedback
I

""'6.

I
I

TCC

TCC PWM

Solenoid
Valve
Control

Solenoid
Valve
Control

Llil
!Hot In Run,. Bulb Test And Start!

'" -P;w; - - - - - - - - ~ Underhood

ENG CTRL
MiniFuse
15A

Distribution
Cell 10

...

Automatic
Trarismission

____________ ...

78 C2

79

Center 2

0.5 PNK 239

8182 - - - ..,.. - 1
0.5 PNK 239

r - - - - - - - - - - - - -,
I
I
Torque
I
Converter
Assembly

I Electrical

G C100

I
I

0.5 TAN/BLK422

0.5 PNK 239

- - -+

8107

Fuse Block
Details
Cell11

0.5 BRN 418

0.5 PNK 239
I

I T _______ U _ _ _ _ _ _ _ _ _ _ __..E 20 - Way Connector

0.5 TAN 418

0.5 RED 839

T03-2
TO SHIFT
SOLENOID

v~v_:s_ - -

_.__-_-_-_-_-_-"'_"'-'-"_""'_"--_-_-_-_ _ _
___J
__

SHIFT
SOLENOID
VALVE

~~M!L~ - - - -

- - -

- -

- -

193786

Circuit Description
The Torque Converter Clutch Solenoid Valve (TCC
Sol. Valve) is a normally-open exhaust valve that
is used with the Torque Converter Clutch Pulse Width
Modulation Solenoid Valve (TCC PWM Sol. Valve)
in order to control fluid acting on the converter clutch
apply valve. The
Sol. Valve attaches to the
transmission case assembly extending into the pump
cover. When grounded (energized) by the Powertrain
Control Module (PCM), the TCC Sol. Valve stops
converter signal oil from exhausting. This causes

rec

converter signal oil pressure to increase and move the

converter clutch apply valve against spring force
and into the apply position. In this position, release
fluid is open to an .exhaust port and converter feed fluid
fills the apply fluid, circuit. The converter feed fluid
applies the TCC. When the PCM no longer provides a
ground path, the TCC Sol. Valve ~e-energizes and
apply fluid exhausts, releasing the TCC.
If the PCM detects low torque converter slip when the
PCM commands the TCC OFF, then DTC P0742
sets. DTC P0742 is a type B DTC.

Transmission!Transaxle
Conditions for Setting the DTC

OTC P0742 sets if the following conditions occur three

times per ignition cycle, two consecutive times:
No MAP Sensor DTCs P0107 or P0108.
No TP Sensor DTCs P0122 or P0123.
No VSS Assy. DTCs P,050? or P0503.
No TCC Sol. Valve OTC P0740
No TFP Val. Position Sw. DTC P1810.
No TCC PWM Sol. Valve DTC, P1860.
The TP angle is 13-50%.
The engine speed is greater than 450 RPM for
5 seconds.
Not in fuel cutoff.
The engine speed is 1000-3000 RPM.
The engine torque is 50-400 lbs ft.
The engine vacuum is 0-105 kPa.
The speed ratio is 0.95-1.7 (the speed ratio is
engine speed divided by output speed).
The vehicle speed is 32-104 km/h (20--65 mph).
The commanded gear is not 1st.
The . gear range is 04.
No gear range change within 6 seconds.
The PCM commands the TCC OFF.
The TCC slip speed is -20 to +50 RPM.
All conditions met for 3.8 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL).
The PCM freezes shift adapts from being updated.
DTC P0742 stores in PCM history.

Auto.matic Transmission - 4L60-E

7-145

Conditions for Clearing the MIUDTC

The PCM turns OFF the MIL after three
consecutive trips Without a failure reported.
A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the DTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order. to power down
the PCM.

Diagnostic Aids
The TCC fluid will mechanically apply the TCC,
possibly causing.an engine stall, under the
following conditions:
- .The TCC is mechanically stuck ON
- The parking ~rake is applied
- Any gear range is selected
A stuck TP Sensor rnay set DTC P0742;

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step inspects the mechanical state of the
TCC. When the PCM comml;lnds the TCC
Sol. Valve OFF, the slip speed' should increase.

7-146

Automatic Transmission - 4L60-E

Transmission!Transaxle

DTC P0742 TCC System Stuck On (3.8L)

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080)
System Check

Go to Step 3

Go to
Diagnostic Aids

Go to Step 4

Go to
Diagnostic Aids

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the scan tool
in order to record the Freeze Frame and Failure Records
for reference. Using the Clear Info function will erase the
stored Freeze Frame and Failure Records from the PCM.
3. Record the OTC Freeze Frame and Failure Records,
then clear the DTC(s).
4. Using the scan 1ool, verify the TP Sensor operation.
Are the TP Sensor values within the specified range?
Drive the vehicle in the 04 drive range in fourth gear
under steady acceleration, with a TP angle greater
than 25 percent.
While the displayed TCC Enable status is No, does the
scan tool display a TCC Slip Speed within the
specified range?
The TCC is mechanically stuck ON. Inspect for the
following conditions:
A clogged exhaust orifice in the TCC Sol. Valve.
The converter clutch apply valve is stuck in the apply
position.
A misaligned or damaged valve body gasket.
A restricted release passage.

0.6-5.0 volts

-20 to +50 RPM

Did you find and correct the condition?

Go to Step 5

In order to verify your repair, perform the following

procedure:
1. Select OTC.
2. Select Clear Info.
5

3. Drive the vehicle in 04 under the following conditions:

Hold the throttle at 25% and accelerate to 55 mph.
Ensure that the TCC slip speed is 100 to +2000 RPM
for 3 seconds, with the TCC OFF.
4. Select Specific OTC. Enter DTC P0742.
Has the test run and passed?

System OK

Go to Step 1

Transmission!Transaxle

Automatic Transmission - 4L60-E

7-147

DTC P0742 TCC System Stuck On (5.7L)

Powertrain ~
Control
Module I
~ (PCM) I
~
I

TCC
Solenoid
Valve
Feedback

TCC PWM
Solenoid
Valve
Feedback

TCC
Solenoid
Valve
Control

iHot In Run, Bulb Test And Starti

'" - P;w; - - - "'."' - - - - ., L)nderhood

Distribution
Cell 10

I
I

...

TCC PWM I
Solenoid
I
Valve
I
Control

ENG CTRL
Mini Fuse
15A

Electrical

I Center # 2

___________ ...

LJil

0.5 PNK 239

s1a2------~
0.5 PNK 239 0.5 PNK 239

.. _ _ _ _ _ _ _ _ _ _ _ _ _ _ J

32

G C100

33 C2

Automatic
Transmissi_on

r-------------,
Torque
Converter
Assembly

0.5 PNK 239

I
I
I

0.5 TAN/BLK 422

$107

-----------.

- - -+

Fuse Block
Details
Cell11

0.5 BRN 418

0.5 PNK 239

I

IT

20-Way
Connector

(
0.5 TAN '418
0.5 RED 839

T03-2
SHIFT
SOLENOID
VALVE
ASSEMBLY

168439

Circuit Description
The Torque Converter Clutch Solenoid Valve (TCC
Sol. Valve) is a normally-open exhaust valve that
is used with the Torque Converter Clutch Pulse Width
Modulation Solenoid Valve (TCC PWM Sol. Valve)
in order to control fluid acting on the converter clutch
apply valve. The TCC Sol. Valve attaches to the
transmission case assembly extending into the pump
cover. When grounded (energized) by the Powertrain
Control Module (PCM), the TCC Sol. Valve stops
converter signal oil from exhausting. This causes

converter signal oil pressure to increase and move the

converter clutch apply valve against spring force
and into the apply position. In this position, release
fluid is open to an exhaust port and converter feed fluid
fills the apply fluid circuit. The converter teed fluid
applies the TCC. When the PCM no longer provides a
ground path, the TCC Sol. Valve de-energizes and
apply fluid exhausts, releasing the TCC.
If the PCM detects low torque converter slip when the
PCM commands the TCC OFF, then DTC P0742
sets. DTC P0742 is a type B DTC.

7-148

Automatic Transmission - 4L60-E

Conditions for Setting the DTC

DTC P0742 sets if the following conditions occur three
times per ignition cycle, two consecutive times:
No MAP Sensor DTCs P0107 or P0108.
No TP Sensor DTCs P0122 or P0123.
No VSS Assy. DTCs P0502 or P0503.
No TCC Sol. Valve DTC P0740
No TFP Val. Position Sw. DTC P1810.
No TCC PWM Sol. Valve DTC P1860.
The TP angle is 15-45%.
The engine speed is greater than 450 RPM for
5 seconds.
Not in fuel cutoff.
The engine speed is 1000-3500 RPM.
The engine torque is 40-400 lbs ft.
The engine vacuum is 0-105 kPa.
The speed ratio is 0.65-1.30 (the speed ratio is
engine speed divided by output speed).
The vehicle speed is 32-88 km/h (20-55 mph).
The commanded gear is not 1st.
The gear range is D4.
No gear range change within 6 seconds.
The PCM commands the TCC OFF.
TheTCC slip speed is -20 to +30 RPM.
All conditions met for 4 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction .Indicator
Lamp (MIL).
The PCM freezes shift adapts from being updated.
DTC P0742 stores in PCM history.

Transmissionrrransaxle
Conditions for Clearing the MIUDTC
The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the DTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Diagnostic Aids
The TCC fluid will mechanically apply the TCC,
possibly causing an engine stall, under the
following conditions:
- The TCC is mechanically stuck ON
- The parking brake is applied
- Any gear range is selected
A stuck TP Sensor may set DTC P0742.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step inspects the mechanical st.ate of the
TCC. When the PCM commands the TCC
Sol. Valve OFF, the slip speed sho.uld increase,

Transmissionrrransaxte

Automatic Transmission - 4L60-E

7'-149

DTC P0742 TCC System Stuck O,n (5. 7L)

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080)
System Check

Go to Step 3

Go to
Diagnostic Aids

Go to Step 4

Go to
Diagnostic Aids

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

(
1

,,

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan tool in
order to record the Freeze Frame and Failure Records for
reference. Using the Clear Info function will erase the
stored Freeze Frame and Failure Records from the PCM.
3. Record the OTC Freeze Frame and Failure Records,
then clear the DTC(s).
4. Using the scan tool, verify the TP Sensor operation. ,
Are the TP Sensor values within the normal range (shown
in the value column)?
Drive the vehicle in the 04 drive range in fourth gear
under steady acceleration, with a TP angle greater
than 25 percent.
While the displayed TCC Enable status is No, does the
scan tool display a TCC Slip Speed within the
specified range?
The TCC is mechanically stuck ON. Inspect for the
following conditions:
A clogged exhaust orifice in the TCC Sol. Valve.
The converter clutch apply valve is stuck in the apply
position.
A misaligned or damaged valve body gasket.
A restricted release passage.
Did you find and correct the condition?

0.6-5.0 volts

-20 to +30 RPM

,<

Go to Step 5
,,

In order, to verify your reppir, perform the following

procedure:
,

1. Select DTC.
2. Select Clear Info.
3. Drive the vehicle in 04 under the following conditions:
Hold the throttle at 25% and accelerate to 55 mph.
Ensure that the TCC slip speed is 130 to 2000 RPM
for 4 seconds, with the TCC OFF.
4. Select Specific OTC. Enter OTC P0742.
Has the test run and passed?

..

'

:
,'

"
.1

:;r

,,

'

System OK

Go to Step 1

7-150

Transmission/Transaxle

Automatic Transmission - 4L60-E

DTC P0748 Pressure Control Solenoid Circuit Electrical (3.8L)

Automatic '" - - - - - - - - - - - ,
I
Transmission I
I
I
I
Pressure
I

L2til

Control Solenoid
(PC SOL.) Valve

20 - Way Con nectar

0.5 LT BLU/WHT 1229

0.5
RED/BLK 1228

46

45 C2

PC SOL.
Valve Low

PC SOL.
Valve High

.----------------,p
I

I
I

owertrain

I Control
I Module (PCM)
I>

~---------------J~

193796

Circuit Description
The Pressure Control Solenoid Valve (PC Sol. Valve)
is an electronic device that regulates transmission
line pressure based on the current flow through its coil
winding. The magnetic field produced by the coil
moves the solenoid's internal valve which varies
pressure to the pressure regulator valve. The
Powertrain Control Module (PCM) c.ontrols the PC Sol.
Valve by applying a varying amount of amperage to
the solenoid. The applied amperage can vary
from 0.1 to 1.1 amps. Low amperage (0.1 amp)
indicates high line pressure. High amperage
(1.1 amps) indicates low line pressure. The duty cycle
of the PC Sol. Valve is expressed as a percentage
of energized ON time. Zero percent indicates zero ON
time (non-energized) or no current flow. Approximately

60% at idle indicates maximum ON time (energized)

or high current flow. The PCM determines the
appropriate line pressure for a given load by
comparing the Throttle Position (TP) voltage, the
engine speed and other inputs.
When the PCM detects a continuous open or short to
ground in the PC Sol. Valve circuit or the PC Sol.
Valve, then OTC P0748 sets. OTC P0748 is a
type D OTC.

Conditions for Setting the DTC

The system voltage is 10-16 volts.
The engine is running.
The PC Sol. Valve Duty Cycle reaches its high
limit (approximately 95%) or low limit
(approximately 0%).

Transmission/Transaxle
Action Taken When the OTC Sets
The PCM does not illuminate the Malfunction
Indicator Lamp (MIL).
The PC Sol. Valve is OFF.
The PCM freezes shift adapts from being updated.
DTC P0748 stores in PCM history.

Conditions for Clearing the OTC

A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the DTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Diagnostic Aids
Inspect the wiring at the PCM, the transmission
connector and all other circuit connecting points
tor the following conditions:
- A bent terminal
- A backed out terminal

Automatic Transmission - 4L60-E

7-151

- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
When diagnosing tor an intermittent short or open
condition, massage the wiring harness while
watching the test equipment for a change.
DTC P0748 may set under low voltage conditions
caused by high electrical system demands.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step tests the ability of the PCM to command
the PC Sol. Valve.
3. This step tests the PC Sol. Valve and Automatic
Transmission Wiring Harness Assembly (A!T
Wiring Harness Assembly) tor incorrect resistance.

7.;152

Automatic Transmission - 4L60-E

Transmission/Transaxle

DTC P0748 Pressure Control Solenoid Circuit Electrical (3.8L)

Step

Action
Was the Powertrain On-Board Diagnostic (OBD) System
Check performed?

',

'

Yes

Go to Step 2

No
Go to A
Powertrain On
Board Diagnostic
(OBD)
System Check

Go to
Diagnostic Aids

Go to Step 3

Go to Step 8
Go to Step 5

Go to Step 4
Go to Step 6

Go to Step 18

Go to Step 10

Value(s)

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the scan tool
in order to record the Fai.lure Records for reference. Using
the Clear Info function will erase the stored Failure
Records.from the PCM.
3. Record the OTC Failure Records, then clear
the DTC(s).
4 .. Start the.engine.
5. Using the transmission output control function on the
span tool, apply 0.1 amp through 1.0 amp while
observing PC Sol. Ref. Current and PC Sol. Actual
Current.
ls the PC Sol. Actual Current always within the specified
. value of the PC Sol. Ref. Current?
,
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector.
3. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector.
4. Using the J 39200 Digital Multimeter (DMM) and
J 35616-A Connector Test Adapter Kit, measure the
resistance between terminal C and terminal D.
Is the resistance within the specified range?
ls the resistance greater than the specified value?
Inspect circuit 1228 (PPL) and circuit 1229 (LT BLU) of the
Aff Wiring Harness Assembly for an open condition.
Refer to General Electrical Diagnosis Procedures.
Did you find an open condition?
Is the resistance less than the specified value?

0.16 amp

3-70

70

30

Go to Step 7

Inspect circuit 1228 (PPL} and circuit 1229 (LT BLU) of the

Aff Wiring Harness Assembly for a shorted together

7

condition.
Refer to General Electrical Diagnosis Procedures.
Did you find a shorted condition?

Measure the resistance from terminal C to the

transmission case.
Is the resistance greater than the specified value?

Inspect circuit 1228 (PPL} and circuit 1229 (LT BLU) of the
Aff Wiring Harness Assembly for a short to ground
condition.
Refer to General Electrical Diagnosis Procedures.
Did you find a short to ground condition?

10

Replace the PC Sol. Valve.

Refer to Control and Shift Solenoids Replacement.
Is the replacement complete?

11

1. Disconnect the J 39775 Jumper Harness from the

transmission side of the 20-way connector.
2. Reconnect the transmission 20-way connector.
3. Disconnect the C2 (clear) PCM connector.
4. Using the J 39200 DMM and the J 35616-A
Connector Test Adapter Kit, measure the resistance
between terminal C2-45 and C2-46.
Is the resistance within the specified range?

Go to Step 18

Go to Step 10

Go to Step 11

Go to Step 9

Go to Step 18

Go to Step 10

250KO

Go to Step 20

3-7 0

Go to Step 16

Go to Step 12

Transmissionrrransaxle

Automatic Transmission - 4L60-E

7-153

OTC P0748 Pressure Control Solenoid Circuit Electrical (3.8L) (cont'd)

Step
12

Action
Is the resistance greater than the specified value?

Value(s)
70

13

1. Inspect circuit 1228 (RED/BLK} and circuit 1229

(LT BLU/WHT) of the engine wiring harness for an
open condition.
Refer to General Electrical Diagnosis Procedures.
2. Repair the circuits if necessary.
Refer to Wiring Repairs.
Did you find and correct an open condition?

14

Is the resistance less than the specified value?

30

15

1. Inspect circuit 1228 (RED/BLK) and circuit 1229

(LT BLU/WHT) of the engine wiring harness for a
shorted together condition.
Refer to General Electrical Diagnosis Procedures.
2. Repair the circuits if necessary.
Refer to Wiring Repairs.
Did you find and correct a shorted condition?

16

Using the J 39200 DMM and the J 35616-A Connector

Test Adapter Kit, measure the resistance from
terminal C2-45 to ground.
Is the resistance less than the specified value?

90

17

1. Inspect circuit 1228 (RED/BLK).and circuit 1229

(LT BLU/WHT) of the engine wiring harness for a
short to ground condition.
Refer to General Electrical~:,,,Diagnosis Procedures.
2. Repair the circuits if necessary.
Refer to Wiring Repairs.
Did you find the short to ground condition?

18

Replace the A/T Wiring Harness Assembly.

Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring
Harness Replacement.
Is the replacement complete?

19

20

Replace the PCM.

Refer to PCM Replf!cement!Programming.
Is the replacement complete?
In order to verify your repair, perform the following
procedure:
1. Select DTC.
2. Select Clear Info.
3. Start the engine and ensure that the following
condition is met:
The difference between the PC Sol. Valve actual
return amperage and the desired amperage is less
than 0.16 amp.
4. Select Specific DTC. Enter DTC P0748.
Has the test run and passed?

No
Go to Step 14

Yes
Go to Step 13

Go to Step 20
Go to Step 15

Go to Step 20

Go to Step 19

Go to Step 17

Go to Step 20

Go to Step 20

Go to St~p 20

System OK

Go to Step 1

7-154

Transmission!Transaxle

Automatic Transmission - 4L60-E

DTC P0748 Pressure Control Solenoid Circuit Electrical (5.7L)

Automatic .. - - - - - - - - - - - .,
Transmission I
I
I

Pressure
Control Solenoid
(PC SOL.) Valve

11~1

:"'"1~ ose1= :
L-----------..1
D - - - - - - - -C

20 - Way Connector
0.5 LT BLU!WHT 1229

0.5
RED/BLK 1228

36 -------~9 C2

.----------------,p
.
I
PC SOL.
PC SOL.
owertra1n
Valve Low

Valve High

I Control

I Module (PCM)

L---------------..1~
168441

Circuit Description
The Pressure Control Solenoid Valve (PC Sol. Valve)
is an electronic device that regulates transmission
line pressure based on the current flow through its coil
winding. The magnetic field produced by the coil
moves the solenoid's internal valve which varies
pressure to the pressure regulator valve. The
Powertrain Control Module (PCM) controls the PC Sol.
Valve by applying a varying amount of amperage to
the solenoid. The applied amperage can vary
from 0.1 to 1.1 amps. Low amperage (0.1 amp)
indicates high line pressure. High amperage
(1.1 amps) indicates low line pressure. The duty cycle

of the PC Sol. Valve is expressed as a percentage of

energized ON time. Zero percent indicates zero
ON time (non-energized) or no current flow.
Approximately 60% at idle indicates maximum ON
time (energized) or high current flow. The PCM
determines the appropriate line pressure for a given
load by comparing the Throttle Position (TP) voltage,
the engine speed and other inputs.
When the PCM detects a continuous open or short to
ground in the PC Sol. Valve circuit or the PC Sol.
Valve, then DTC P0748 sets. DTC P0748 is a
type D DTC.

Transmission/Transaxle
Conditions for Setting the OTC
The system voltage is 8-16 volts.
The engine is running.
The PC Sol. Valve Duty Cycle reaches its high
limit (approximately 95%) or low limit
(approximately 0%).

Action Taken When the DTC Sets

The PCM does not illuminate the Malfunction
Indicator Lamp (MIL).
The PC Sol. Valve is OFF.
The PCM freezes shift adapts from being updated.
OTC P0748 stores in PCM history.

Conditions for Clearing the OTC

A scan tool can clear the OTC from the PCM
history. The PCM clears the DTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the DTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Automatic Transmission - 4L60-E

7-155

Diagnostic Aids
Inspect the wiring at the PCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
When diagnosing for an intermittent short or open
condition, massage the wiring harness while
watching the test equipment for a change.
DTC P0748 may set under low voltage conditions
caused by high electrical system demands.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step tests the ability of the PCM to command
the PC Sol. Valve.
3. This step tests the PC Sol. Valve and Automatic
Transmission Wiring Harness Assembly (A/T
Wiring Harness Assembly) for incorrect resistance.

7-156

Transmission!Transaxle

Automatic Transmission - 4L60-E

DTC P0748 Pressure Control Solenoid Circuit Electrical (5.7L)

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD)
System Check

Go to
Diagnostic Aids

Go to Step 3

Go to Step 8
Go to Step 5

Go to Step 4
Go to Step 6

Go to Step 18

Go to Step 10

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan tool in
order to record the Failure Records for reference. Using
the Clear Info function will erase the stored Failure
Records from the PCM.
3. Record the OTC Failure Records, then clear
the DTC(s).
4. Start the engine.
5. Using the transmission output control function on the
scan tool, apply 0.1 amp through 1.0 amp while
observing PC Sol. Ref. Current and PC Sol. Actual
Current.
Is the PC Sol. Actual Current always within the specified
value of the PC Sol. Ref. Current?
1. Turn the ignition OFF.
2. Disconnect the transmission 20-way connector.
3. Install the J 39775 Jumper Harness on the
. transmission side of the 20-way connector.
4. Using the J 39200 Digital Multimeter (DMM) and the
J 35616-A Connector Test Adapter Kit, measure the
resistance between terminal C and terminal D.
Is the resistance within the specified range?
Is the resistance greater than the specified value?

0.16 amp

3-7

70

Inspect circuit 1228 (PPL) and circuit 1229 (LT BLU) of the
A/T Wiring Harness Assembly for an open condition.
Refer to General Electrical Diagnosis Procedures.
Did you find an open condition?

Is the resistance less than the specified value?

3Q

Inspect circuit 1228 (PPL) and circuit 1229 (LT BLU) of the
A/T Wiring Harness Assembly for a shorted together
condition.
Refer to General Electrical Diagnosis Procedures.
Did you find a shorted together condition?

Measure the resistance from terminal C to the

transmission case.
Is the resistance greater than the specified value?

Inspect circuit 1228 (PPL) and circuit 1229 (LT BLU) of the
A/T Wiring Harness Assembly for a short to ground
condition.
Refer to General Electrical Diagnosis Procedures.
Did you find a short to ground condition?

10

Replace the PC Sol. Valve.

Refer to Control and Shift Solenoids Replacement.
Is the replacement complete?

11

1. Disconnect the J 39775 Jumper Harness from the

transmission side of the 20-way connector.
2. Reconnect the transmission 20-way connector.
3. Disconnect the C2 (blue) PCM connector.
4. Using the J 39200 DMM and the J 35616-A
Connector Test Adapter Kit, measure the resistance
between terminal C2-39 and C2-36.
Is the resistance within the specified range?

Go to Step 7

Go to Step 18

Go to Step 10

Go to Step 11

Go to Step 9

Go to Step 18

Go to Step 10

250KQ

Go to Step 20

3-7

n
Go to Step 16

Go to Step 12

Transmission!Transaxle

Automatic Transmission - 4L60-E

7-157

DTC P0748 Pressure Control Solenoid Circuit Electrical (5.7l) (cont'd)

Step
12

13

14

15

16

17

(
18

19

20

Action
Is the resistance greater than the specified value?

1. Inspect circuit 1228 (RED/BLK) and circuit 1229

(LT BLU/WHT) of the engine wiring harness for an
open condition.
Refer to General Electrical Diagnosis Procedures.
2. Repair the circuits if necessary.
Refer to Wiring Repairs.
Did you find and correct an open condition?
Is the resistance less than the specified value?
1. Inspect circuit 1228 (RED/BLK} and circuit 1229
(LT BLU/WHT) of the engine wiring harness for a.
shorted together condition.
Refer to General Electrical Diagnosis Procedures.
2. Repair the circuits if necessary.
Refer to Wiring Repairs.
Did you find and correct the shorted condition?
Using the J 39200 DMM and the J 35616-A Connector
Test Adapter Kit, measure the resistance between terminal
C2-39 to ground.
Is the resistance less than the 'Specified value?
1. Inspect circuit 1228 (RED/BLK} and circuit 1229
(LT BLU/WHT) of the engine wiring harness for a
short to ground condition.
Refer to General Electrical Diagnosis Procedures.
2. Repair the circuits if necessary.
Refer to Wiring Repairs.
Did you find and correct the short to ground condition?
Replace the A/T Wiring Harness Assembly.
Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring
Harness Replacement.
Is the replacement complete?
Replace the PCM.
Refer to PCM Replacement/Programming.
Is the replacement complete?
In order to verify your repair, perform the following
procedure:
1. Select OTC.
2. Select Clear Info.
3. Start the engine and ensure that the following
condition is met:
The engine is running.
The difference between the PC Sol. Valve actual
return amperage and the desired amperage is less
than 0.16 amp.
4. Select Specific OTC. Enter OTC P0748.
Has the test run and passed?

Value(s)
?Q

Yes
Go to Step 13

3Q

No
Go to Step 14

Go to Step 20
Go to Step 15

Go to Step 20

9Q
Go to Step 17

Go to Step 19

Go to Step 20

Go to Step 20

Go to Step 20

System OK

Go to Step 1

7-158

Automatic Transmission - 4L60-E

Transmission/Transaxle

DTC P0751 1-2 Shift Solenoid Valve Performance (3.SL)

!Loe I

~
~
N

....

FL

~SIGA
1-2 SHIFT
SOL VALVE

'

N.0.
ON

'

'
Cl

zC\J

2-3SHIFT
SOL VALVE
N.O.

ON
0

LL

5:w
C/J

42270

Circuit Description
The 1-2 Shift Solenoid Valve (1-2 SS Valve) controls
the fluid flow acting on the 1-2 and 3-4 shift valves.
The 1-2 SS Valve is a normally-open exhaust
valve that is used with the 2-3 Shift Solenoid Valve
(2-3 SS Valve), in order to allow four different shifting
combinations.
When the PCM detects a 1-1-4-4 or a 2-2-3-3 shift
pattern, depending on the state of the mechanical
failure, then OTC P0751 sets. DTC P0751 is a
type A OTC.

Conditions for Setting the OTC

No TP Sensor DTCs P0122 or P0123.

No VSS Assy. DTCs P0502 or P0503.
No TCC Sol. Valve OTC P0740.
No TCC Stuck ON OTC P0742.
No 1-2 SS Valve OTC P0753.
No 2-3 SS Valve OTC P0758.
No 3-2 SS Valve Assy. OTC P0785.
No TFP Val. Position Sw. OTC P1810.
No TCC PWM Sol. Valve OTC P1860.
The engine speed is greater than 450 RPM for
5 seconds.

Not in fuel cutoff.

The gear range is 04.
The vehicle speed is greater than 8 km/h (5 mph).
The transmission fluid temperature is
20-130C (68-266F).
All of the above conditions are met three times
and the combination of Conditions 1, 2, 3 and 4 or
Conditions 1, 2, 3 and 5 occurs three times.

Condition 1
The PCM commands a 1-2 shift.
The TP angle is 10-45%.
The TP angle is constant within +/- 6%.
The vehicle speed is 8-72 km/h (5-45 mph).
Within 2 seconds, the engine speed in 2nd gear is
100 RPM greater than the last speed in 1st gear.
Condition 2
The PCM commands a 2-3 shift.
The TP angle is 7-45%.
The TP angle is constant within +/- 7%.
The vehicle speed is 16-104 km/h (10-65 mph).
Within 2 seconds, the engine speed in 3rd
gear is 100 RPM less than the last speed
in 2nd gear.

Transmission/Transaxle
Condition 3
The PCM commands a 3-4 shift.
The TP angle is 7-45%.
The TP angle is constant within +/- 5%.
The vehicle speed is 48-105 km/h (30-65 mph).
Within 0. 7 seconds, the engine speed in 4th
gear is 10 RPM greater than the last
speed in 3rd gear.

Condition 4
The PCM commands 4th gear.
The TCC is ON.
The TP angle is 7-35%.
The speed ratio is 0.95-1.2.
The TCC slip speed is 200-1000 RPM for
4 seconds.

Condition 5
The PCM commands 4th gear.
The TCC is ON.
The TP is 7-35%.

Automatic Transmission -4L60-E

7-159

Conditions for Clearing the MIUDTC

The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
A scan tool can clear the OTC from the PCM
history. The PCM clears the OTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the OTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Diagnostic Aids
Verify that the transmission meets the
specifications in the 4L60-E Shift Speed table.
Other internal transmission failures may ca1,..1se
more than one shift to occur.

Gear
1
2
3
4

1-2 Shift
Solenoid
ON
OFF
OFF
ON

2-3 Shift
Solenoid
ON
ON
OFF
OFF

Gear Ratio
3.059:1
1.625:1
1.000:1
0.696:1

The speed ratio is 0.65-0.8.

The TCC slip speed is -20 to +70 RPM for
4 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator

Lamp (MIL).
The PCM commands 02 line pressure.
The PCM inhibits 3-2 downshifts if the vehicle
speed is greater than 48 km/h (30 mph).
The PCM freezes shift adapts from being updated.
OTC P0751 stores in PCM history.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step tests that the scan tool commanded all
shifts and au shift solenoid valves responded
correctly, but all the shifts did not occur.

7-160

Automatic Transmission - 4L60-E

Transmission/Transaxle

OTC P0751 1-2 Shift Solenoid Valve Performance (3.8L)

Step

Action

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the scan tool
in order to record the Freeze Frame and Failure Records
for reference. Using the Clear Info function will erase the
stored Freeze Frame and Failure Records from the PCM.
3. Record the OTC Freeze Frame and Failure Records,
then clear the DTC(s).
4. Drive the vehicle in 04 range under the following
conditions:
Accelerate the vehicle, ensuring that the PCM
commands 1st, 2nq, 3rd and 4th gears.
Did you detect a 1-1-4-4 or 2-2-3-3 shift pattern?
Check the shift solenoid/hydraulic circuit for the foilowing
conditions:
An internal malfunction.
Damaged seals on the shift solenoid valves.

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Boa.rd Diagnostic
(OBD)
System Check

Go to Step 3

Go to
Diagnostic Aids

Go to Step 4

Did you find and correct the condition?

In order to verify your repair, perform th.e following
procedure:
1. Select OTC.
2. Select Clear Info.

3. Drive the vehicle in 04 range .under the following

4

conditions (only if traffic and road conditions permit):

Hold the throttle at 20% and accelerate to
88 km/h (55 mph).
If the throttle moves more than 6%, stop the
vehicle and start over.
4. Select Specific DTC. Enter DTC P0751.
Has the test run and passed?

System OK

Go to Step 1

Transmission!Transaxle
.
.

~utomatie Transmissio.n 4~60-E

7-161

OTC P0751 1-2 Shift Solenoid Valve:Performance (5.7L)

(

FL _ _-"---,

1-2 SHIFT
SOL VALVE.
N.O.
ON

'

'
c::l
2

(\J

2-3 SHIFT
SOL VALVE
N.O.

ON
0

u..

ii:
w

(/)

42270

Circuit Description
The 1-2 Shift Solenoid Valve (1-2 SS Valve) controls
the fluid flow acting on the 1-2 and 3-4 shift valves.
The 1-2 SS Valve is a normally-open exhaust
valve that is used with the 2-3 Shift Solenoid Valve
(2-3 SS Valve), in order to allow four different shifting
combinations.
When the PCM detects a 1-1-4-4 or a 2-2-3-3 shift
pattern, depending on the state of the mechanical
failure, then OTC P0751 sets. OTC P0751 is a
type A OTC.

Conditions for Setting the OTC

No TP Sensor OTCs P0122 or P0123.

No VSS Assy. OTCs P0502 or P0503.
No TCC Sol. Valve OTC P0740.
No TCC Stuck ON OTC PO? 42.
No 1-2 SS Valve OTC P0753.
No 2-3 SS Valve OTC P0758.
No 3-2 SS Valve Assy. OTC P0785.
No TFP Val. Position Sw. OTC P1810.
No TCC PWM Sol. Valve OTC P1860.
The engine speed is greater than 450 RPM for
5 seconds.

Not in fuel cutoff.

The gear range is 04.
The vehicle speed is greater than 8 km/h (5 mph).
The transmission fluid temperature is
20-130C (68-266F).
All of the above conditions are met three times
and the combination of Conditions 1, 2, 3 and 4 or
Conditions 1, 2, 3 and 5 occurs three times.

Condition 1
The PCM commands a 1-2 shift.
The TP angle is 10-40%.
The TP angle is constant within +/- 5%.
The vehicle speed is 8-56 km/h (5-35 mph).
Within 2 seconds, the engine speed in 2nd gear is
100 RPM greater than the last speed in 1st gear.
Condition 2
The PCM commands a 2-3 shift.
The TP angle is 10-45%.
The TP angle is constant within +/- 7%.

The vehicle speed is 16-80 km/h (10-50 mph).

Within 2 seconds, the engine speed in 3rd gear is
50 RPM less than the last speed in 2nd gear.

7-162

Automatic Transmission - 4L60-E

Condition 3
The PCM commands a 3-4 shift.
The TP angle is 8-35%.
The TP angle is constant within +/- 7%.
The vehicle speed is 32-105 km/h (20-65 mph).
Within 2 seconds, the engine speed in 4th
gear is 10 RPM greater than the last speed
in 3rd gear.
Condition 4
The PCM commands 4th gear.
The TCC is ON.
The TP angle is 7-35%.
The speed ratio is 0.95-1.20.
The TCC slip speed is 200-1000 RPM for
4 seconds.
Condition 5
The PCM commands 4th gear.

Transmission/Transaxle
Conditions for Cl~aring the MIUDTC
The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the DTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Diagnostic Aids
Verify that the transmission meets the
specifications in the 4L60-E Shift Speed table.
Other internal transmission failures may cause
more than one shift to occur.

Gear
1
2

The TCC is ON.

The TP is 7-35%.

1-2 Shift
Solenoid
ON
OFF
OFF
ON

2-3 Shift
Solenoid
ON
ON
OFF
OFF

Gear Ratio
3.059:1
1.625:1
1.000:1
0.696:1

The speed ratio is 0.65-0.8.

The TCC slip speed is -20 to +40 RPM for
4 seconds.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL).
The PCM commands 02 line pressure.
The PCM inhibits 3-2 downshifts if the vehicle
speed is greater than 48 km/h (30 mph).
The PCM freezes shift adapts from being updated.
DTC P0751 stores in PCM history.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step tests that the scan tool commanded all
shifts and. all shift solenoid valves responded
correctly, but all the shifts did not occur.

Transmissionrrransaxle

Automatic Transmission :- 4L60E

7-163

OTC P0751 1-2 Shift Solenoid Valve Performance (5.7L)

Step

Action

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Value(s)

Check the shift solenoid/hydraulic circuit for the following

conditions:
An internal malfunction.
Damaged seals on the shift solenoid valves.
Did you find and correct the condition?

In order to verify your repair, perform the following

procedure:
1. Select OTC.
2. Select Clear Info.
3. Drive the vehicle in 04 under the following conditions
(only if traffic and road conditions permit):
Hold the throttle at 20% and accelerate to
88 km/h (55 mph).
If the throttle moves more than 5%, stop the
vehicle and start over.
Select
Specific OTC. Enter OTC P0751.
4.
Has the test run and passed?

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080)
System Check

Go to Step 3

Go to
Diagnostic Aids

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan tool in
order to record the Freeze Frame and Failure Records for
reference. Using the Clear Info function will erase the
stored Freeze Frame and Failure Records from the PCM.
3. Record the OTC Freeze Frame and Failure Records,
then clear the DTC(s).
4. Drive the vehicle in 04 range under the following
conditions:
Accelerate the vehicle, ensuring that the PCM
commands 1st, 2nd, 3rd and 4th gears.
Did you detect a 1-1-4-4 or 22-3-3 shift pattern?

Yes

Go to Step 4

System OK

Go to Step 1

7-164

Automatic Transmission - 4L60-E

TransmissionfTransaxle

OTC P0753 1-2 Shift Solenoid Circuit Electrical (3.8L)

!Hot In Run, Bulb Test And Start!

20 - Way Connector

'"-P:;;v; - - - - - - - - ~ Underhood
Distribution
ee1110

ENG CTRL
MiniFuse
15A

I
I

Electrical
Center 2

E
Automatic'" Tee- Transmission I Solenoid

0.5 PNK 239

8107

- - __.

Solenoid
Valve

3-2 Shm

ITCC PWM

- - - - - -,

0.5 PNK 239

839

L----------J
0.5 PNK 239

G C100

o. 5 RED

I Valve

8182

- - - - -,,.- - - - - ;:_;Shift.,

0.5 PNK 239

I
I

,.
Fuse Block
Details
Cell11

I Solen.aid
I Valve

I
I

~1!n~7~11

[]]

'

BI

Solenoid
Valve
Assembly

(1-2$$)
Valve

0.5 LT GRN 1222

-------- ------A

20 - Way Connector
0.5 LT GAN 1222

4 C1

Powertrain ~ - - - - - - - - - - Control,
1 _ 255
Module I 1-2 SS
,._, Valve
~ (PCM) 1
Valve
Control
~
L !'!db!_Ci:._ - - -- - - -

~
1
I
I
..I

193811

Circuit Description
The 1-2 Shift Solenoid Valve (1-2 SS Valve) controls
the fluid flow acting on the 1-2 and 3-4 shift valves.
The 1-2 SS Valve is a normally-open exhaust
valve that is used with the 2-3 Shift Solenoid Valve in
order to allow four different shifting combinations.
The solenoid attaches to the control valve body within
the transmission. The 1-2 SS Valve receives ignition
voltage through circuit 239. The Powertrain Control
Module (PCM) controls the solenoid by providing the
ground path on circuit 1222.
When the PCM detects a continuous open or short to
ground in the 1-2 SS Valve circuit or the 1-2 SS Valve,
then OTC P0753 sets. OTC P0753 is a type A OTC.

Conditions for Setting the DTC

The system voltage is 8-16 volts.
The engine speed is greater than 450 RPM for
5 seconds.

Not in fuel cutoff.

All of the above conditions are met for 5 seconds
and either of the following fail conditions occurs
for 5 seconds:
- The PCM commands the solenoid ON and
the voltage input remains high (B+).
- The PCM commands the solenoid OFF and
the voltage input remains low (0 volts).

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL).
The PCM commands 02 line pressure.
The PCM inhibits 3-2 downshifts if the vehicle
speed is greater than 48 km/h (30 mph).
The PCM freezes shifts adapts from being
updated.
OTC P0753 stores in PCM history.

Transmission/Transaxle

Automatic Transmission - 4L60-E

Conditions for Clearing the MILJDTC

When diagnosing for an intermittent short or open

condition, massage the wiring harness while
watching the test equipment for a change.
An open ignition feed circuit can cause multiple

DTCs to set.

The PCM turns OFF the MIL after three

consecutive trips without a failure reported.
A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the DTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Diagnostic Aids
Inspect the wiring at the PCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion

1-2 Shift
Solenoid
ON
OFF
OFF
ON

Gear
1
2
3
4

2-3 Shift
Solenoid
ON
ON
OFF
OFF

7-165

Gear Ratio
3.059:1
1.625:1
1.000:1
0.696:1

. Test Description
The numbers below refer to the step numbers on the
' diagnosticJable.
4. This step tests the function of the 1-2 SS Valve
ar:id the Automatic Transmission Wiring Harness
Assembly (A/T Wiring Harness Assembly). .
5. This step tests for power to the 1-2 SS Valve from
the ignition through the fuse.
6. This step tests the ability of the PCM and the
wiring to control the ground circuit.
13. This step measures the resistance of the A/T
Wiring Harness Assembly and the 1-2 SS Valve.

DTC P0753 1-2 Shift Solenoid Circuit Electrical (3.8L)

Step

Action

Valu~(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check in Engine
. Controls

Go to Step 3

Go to Step 4

Go to Step 19

Go to Step 5

Go to
Diagnostic Aids

Go to Step 5

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

\.

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the scan tool
in order to record the Freeze Frame and Failure Records
for reference. Using the Clear Info function will erase the
stored Freeze Frame and Failure Records from the PCM.
3. Record the OTC Freeze Frame and Failure Records,
then clear the DTC(s).
Are DTCs P0740, P0758, P0785, and P1860 also set?

1. Inspect the ENG CTRL fuse.

2. If the fuse is open, inspect circuit 239 (PNK), the
solenoids, and the A/T Wiring HarnessAssembly for
short to ground. Repair the circuit, the soler;ioids, and
the harness if necessary.
Refer to General Electrical Diagnosis Procedures in Wiring
Systems.
Did you find a short to ground condition?

Using the transmission output control function on the scan

tool., command the 1~.2 SS Valve ON and OFF three times
while listening to the bottom of the transmission pan (a
stethoscope may be necessary).
Does the solenoid click when commanded?

7-166

Automatic Transmission - 4L60-E

Transmission/Transaxle

DTC P0753 1-2 Shift Solenoid Circuit Electrical (3.8L) (cont'd)

Action

Step

Value(s)

Yes

No

Go to Step 6

Go to Step 7

Go to Step 13

Go to Step B

1. Turn the ignition OFF.

2. Disconnect the transmission 20-way connector
(additional DTCs will set).

3. Install the J 39775 Jumper Harness on the engine

side of the 20-way connector.

4. With the engine OFF, turn the ignition switch to the

RUN position.
5. Connect a test lamp from J 39775 Jumper Harness
cavity E to ground.
Is the test lamp ON?
1. Install a test lamp from J 39775 Jumper Harness
cavity E to cavity A.

2. Using the transmission output control function on the

scan tool, command the 1-2 SS Valve ON, and OFF
three times.
Is the test lamp ON when the 1-2 SS Valve is commanded
ON, and OFF when commanded OFF? ,

Repair the open or short to ground in .ignition feed

circuit 239 (PNK) to the 1-2 SS Valve.

R~fer to Wiring Repairs in Wiring Systems.

Did you find and correct an open or short to ground
condition?
Monitor the test lamp status.
Was the test lamp OFF at all times?

Go to Step 19

Go to Step 9

Go to Step 10

Go to Step 19

Go to Step 12

1. Inspect circuit 1222 (LT GRN) of the engine wiring

harness for an open or short to power cond.ition.

Refer to General Electrical Diagnosis Procedures in
Wiring Systems.

2. Repair the circuit if necessary.

Refer to Wiring Repairs in Wiring Systems.
Did you find an open or short to power condition?
10

Was the test lamp ON at all times?

Go to Step 11

1. Inspect circuit 1222 (LT GRN) of the engine wiring

harness for a short to ground condition.
11

Refer to General Electrical Diagnosis Procedures in

Wiring Systems.

2. Repair the circuit if necessary.

Refer to Wiring Repairs in Wiring Systems.
Did you find a short to ground condition?

Go to Step 19

Go to Step 12

Replace the PCM.

12

13

Refer to PCM Replacement/Programming in Engine

Controls.
Is the replacement complete?

1. Turn the ignition OFF.

2. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector.
3. With the J 39200 Digital Multimeter (DMM) and
J 35616-A Connector Test Adapter Kit, measure the
resistance between terminals A and E.

Go to Step 19

19-31 Q

Is the resistance within the range indicated?

14

1. Disconnect the A/T Wiring Harness Assembly from

the 1-2 SS Valve.
2. Measure the resistance of the 1-2 SS Valve.
Is the resistance within the range indicated?

Go to Step 15

Go to Step 14

Go to Step 17

Go to Step 18

19-31 Q

Automatic Transmission - 4L60E

Transmission/Transaxle

7-167

OTC P0753 1-2 Shift Solenoid Circuit Electrical (3.8L) (cont'd)

Step

15

16

17

18

19

Action

Value(s)

Yes

No

Using J 39200 DMM, measure the resistance between

terminals A and E and ground.
Are both readings greater than the specified value?

250 KQ

Go to
Diagnostic Aids

Go to Step 16

1. Disconnect the A/T Wiring Harness Assembly from

the 1-2 SS Valve.
2. Using the J 39200 DMM, measure the resistance
from the component's terminals to ground.
Are both readings greater than the specified value?

250KQ
Go to Step 17

Go to Step 18

Replace the A/T Wiring Harness Assembly.

Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring
Harness Replacement.
Is the replacement complete?

Replace the 1-2 SS Valve.

Refer to Control and Shift Solenoids Replacement.
Is the replacement complete?

In order to verify your repair, perform the following

procedure:
1. Select DTC.
2. Select Clear Info.
3. Drive the vehicle in D4 range and ensure that the
following conditions are met:
The PCM commands the 1-2 SS Valve ON and
the voltage input drops to zero.
The PCM commands the 1-2 SS Valve OFF and
the voltage input increases to B+.
All conditions are met for 5 seconds.
4. Select Specific DTC. Enter OTC P0753.
Has the test run and passed?

Go to Step 19

Go to Step 19

System OK

Go to Step 1

7-168

Automatic Transmission - 4L60-E

Transmission/Transaxle

OTC P0753 1-2 Shift Solenoid Circuit Electrical {5.7L)

\

!Hot In Run, Bulb Test And Start!

'" -P;w; - - - - - - - - , Underhood

Distribution
Cell 10

ENG CTRL
Mini Fuse

_____ ..
15A

1.------

:
I

Electrical
Center # 2

0.5 PNK 239

8182----~

0.5 PNK 239

0.5 PNK 239

0.5 PNK 239

G C100
0.5 PNK 239

8107

- - -...

20 - Way Connector

Fuse Block
Details
Cell11

0.5 LT GAN 1222

35 C1
Powertrain ~ - - - - - - - - - - Control 1 1 _ 2~

Module I
~ (PCM) 1
~

Valve
Feedback

:e s

~;1

---, Control
.

!
. ___________
...

I
1

168442

Circuit Description
The 1-2 Shift Solenoid Valve (1-2 SS Valve) controls
the fluid flow acting on the 1-2 and 3-4 shift valves.
The 1-2 SS Valve is a normally-open exhaust
valve that is used with the 2-3 Shift Solenoid Valve in
order to allow four different shifting combinations.
The solenoid attaches to the control valve body within
the transmission. The 1-2 SS Valve receives ignition
voltage through circuit 239. The Powertrain Control
Module (PCM) controls the solenoid by providing the
ground path on circuit 1222.
When the PCM detects a continuous open or short to
ground in the 1-2 SS Valve circuit or the 1-2 SS Valve,
then OTC P0753 sets. OTC P0753 is a type A OTC.

Conditions for Setting the OTC

The system voltage is 8-16 volts.
The engine speed is greater than 450 RPM for
5 seconds.
Not in fuel cutoff.
All of the above conditions are met for 5 seconds
and either of the following fail conditions occurs
for 5 seconds:
- The PCM commands the solenoid ON and
the voltage input remains high (B+).
- The PCM commands the solenoid OFF and
the voltage input remains low (0 volts).

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL).
The PCM commands 02 line pressure.
The PCM inhibits 3-2 downshifts if the vehicle
speed is greater than 48 km/h (30 mph).
The PCM freezes shifts adapts from being
updated.
OTC P0753 stores in the PCM history.

Conditions for Clearing the MIUDTC

The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
A scan tool can clear the OTC from the PCM
history. The PCM clears the OTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the OTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

TransmissionfTransaxle

Automatic Transmission - 4L60-E

Diagnostic Aids

Test Description

Inspect the wiring at the PCM, the transmission

connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
When diagnosing for an intermittent short or open
condition, massage the wiring harness while
watching the test equipment for a change.
An open ignition feed circuit cah cause multiple
DTCs to set.

Gear
1
2

3
4

1-2 Shift
Solenoid
ON
OFF
OFF
ON

7-169

2-3 Shift
Solenoid
ON
ON
OFF
OFF

The numbers below refer to the step numbers on the

diagnostic table.
4. This step tests the function of the 1-2 SS Valve
and the Automatic Transmission Wiring Harness
Assembly (A/T Wiring Harness Assembly).
5. This step tests for power to the 1-2 SS Valve from
the ignition through the fuse.
6. This step tests the ability of the PCM and the
wiring to control the ground circuit.
13. This step measures the resistance of the A/T
Wiring Harness Assembly and the 1-2 SS Valve.

Gear Ratio
3.059:1
1.625:1
1.000:1
0.696:1

OTC P0753 1-2 Shift Solenoid Circuit Electrical (5.7L)

Step

Action

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check in Engine
Controls

Go to Step 3

Go to Step 4

Go to Step 19

Go to Step 5

Go to
Diagnostic Aids

Go to Step 5

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Value(s)

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan tool in
order to record the Freeze Frame and Failure Records for
reference. Using the Clear Info function will erase the
stored Freeze Frame and Failure Records from the PCM.
3. Record the DTC Freeze Frame and Failure Records,
then clear the DTC(s).
Are DTCs P0740, P0758, P0785 and P1860 also set?

1. Inspect the ENG CTRL fuse.

2. If the fuse is open, inspect circuit 239 (PNK), the
solenoids, and the AfT Wiring Harness Assembly for
short to ground condition. Repair the circuit, the
solenoids, and the harness if necessary.
Refer to General Electrical Diagnosis Procedures in Wiring
Systems.
Did you find a short to ground condition?

Using the transmission output control function on the scan

tool, command the 1-2 SS Valve ON and OFF three times
while listening to the bottom of the transmission pan (a
stethoscope may be necessary).
Does the solenoid click when commanded?

7-170

Automatic Transmission - 4L60-E

Transmission!Transaxle

DTC P0753 1-2 Shift Solenoid Circuit Electrical (5.7L) (cont'd)

Action

Step

Value{s)

1. Turn the ignition OFF.

2. Disconnect the transmission 20-way connector
(additional DTCs will set).
3. Install the J39775 Jumper Harness on the engine
side of the 20-way connector.
4. With the engine OFF, turn the ignition switch to the
RUN position.
5. Connect a test lamp from J 39775 Jumper Harness
cavity E to ground.

No

)
-

Is the test. lamp, ON?

Yes

1. Install a test lamp from J 39775 Jumper Harness

cavity E to cavity A.
2. Using the transmission output control function on the
scan tool, command the 1-2 SS Valve ON, and OFF
three times.
Is the test lamp ON when the 1-2 SS Valve is commanded
ON, and OFF when commanded OFF?

Go to Step 6

Go to Step 7

Go to Step 13

Go to Step B

Repair the open or short to ground in ignition feed

circuit 239 (PNK) to the 1-2 SS Valve.

Refer to Wiring Repairs in Wiring Systems.

Did you find and correct an open or short to ground
condition?

Go to Step 19

Monitor the test lamp status.

Was the test lamp OFF at all times?

Go to Step 9

Go to Step 10

Go to Step 19

Go to Step 12

1. Inspect circuit 1222 (LT GRN) of the engine wiring

harness for an open or short to power condition.
Refer to General Electrical Diagnosis Procedures in
Wiring Systems.
2. Repair the circuit if necessary.
Refer to Wiring Repairs in Wiring Systems.
Did you find an open or short to power condition?

10

Was the test lamp ON at all times?

11

1. Inspect circuit 1222 (LT GRN) of the engine wiring

harness for a short to ground condition.
Refer to General Electrical Diagnosis Procedures in
Wiring Systems.

Go to Step 11

2. Repair the circuit if necessary.

Refar to Wiring Repairs in Wiring Systems.

Go to Step 19

Did you find a short to ground condition?

12

13

14

Replace the PCM.

Refer to PCM Replacement/Programming in Engine
Controls.
Is the replacement complete?

Go to Step 12

Go to Step 19

1. Turn the ignition OFF.

2. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector.
3. With the J 39200 Digital Multimeter (DMM) and the
J 35616-A Connector Test Adapter Kit, measure the
resistance between terminals A and E.
Is the resistance within the range indicated?

19-31

1. Disconnect the A/T Wiring Harness Assembly from

the 1-2 SS Valve.
2. Measure the resistance of the 1-2 SS Valve.
Is the resistance within the range indicated?

19-31

n
Go to Step 15

Go to Step 14

Go to Step 17

Go to Step 18

Transmissio.n/Transaxle

Automatic TraAsmission - 4L60-E

7-171

OTC P0753 1-2 Shift Solenoid Circuit Electrical (5.7L) (cont'd)

Value(s)

Yes

No

Using the J 39200 DMM, measure the resistance between

terminals A and E and ground.
Are both readings greater than the specified value?

250 KQ

Go to
Diagnostic Aids

Go to Step 16

1. Disconnect the A/T Wiring Harness Assembly from

the 1-2 SS Valve.
2. Using the J 39200 DMM, measure the resistance
from the component's terminals to ground.
Are both readings greater than the specified value?

250KQ
Go to Step 17

Go to Step 18

Step

Action

15

16

17

Replace the A/T Wiring Harness Assembly.

Refer to TCC PWM Solenoid, .TC<;; Solenoid,aod Wiring
Harness Replacement,
.
,
.

Is the replacement complete?

Replace the 1-2 SS Valve.

Refer to Control and Shift Solenoids Beplacement.
18
. Is the replacement complete?
.

19

In .order to verify your repair, perform the. following

procedure:
1. Select DTC.
2. Select Clear lnfb.
~' .,
3. Drive the yehicle in 04 and,eh~ure the fcinowing
conditions are met:
The PCM commands the 1-2 SS Valve ON and
the voltage input drops to zero.
The PCM commands the 1-2 SS Valve OFF and
the voltage input increases to B+.
All conditions are met for 5 seconds.
4. Select Specific OTC. Enter DT.C P0753.
Has the test run and passed?

Go to Step 19

Go to Step 19

System OK

Go to Step 1

1:::t12

Automatic Transmission ... 4L60~E

Transmissionfrransaxle

DTC P0756 2-3 Shift Solenoid. Valve Performance (3.SL)

'
'

03

2-3SHIFT
SOLVALVE
N.O.
ON

cLL

(.)

(.)

<( ..

~
en

' "<t

I
(':)

42270

Circuit Description

The gear range is 04.

The 2-3 Shift Solenoid Valve (2-3 SS Valve) controls

the fluid flow acting on the 2-3 shift valves. The
2-3 SS Valve is a normally-open exhaust valve that is
used with the 1-2 Shift Solenoid Valve (1-2 SS Valve) in
order to allow four different shifting combinations.
When the PCM detects a 1-2-2-1 or a 4-3-3-4 shift
pattern, depending on the state of the mechanical
failure, then DTC P0756 sets. DTC P0756 is a
type A DTC.

The engine vacuum is 0-105 kPa.

Conditions for Setting the OTC

No TP Sensor DTCs P0122 or P0123.

No VSS Assy. DTCs P0502 or P0503.
No TCC Sol. Valve DTC P0740.
No TCC Stuck ON DTC P0742.
No 1-2 SS Valve DTC P0753.
No 2-3 SS Valve DTC P0758.
No 3-2 SS Valve Assy. DTC P0785.
No TFP Val. Position Sw. DTC P1810.
No TCC PWM Sol. Valve DTC P1860.
The vehicle speed is greater than 8 km/h (5 mph).

The engine speed is greater than 450 RPM for

5 seconds.
Not in fuel cutoff.
The transmission fluid temperature is
20-130C (68-266F).
All of the above conditions are met three times
and the combination of Conditions 1 and 2 or
Conditions 2 and 3 occurs three times.
Condition 1

The TP angle is greater than 15%.

First gear is commanded for 1.5 seconds.
The engine torque is 40-400 lb ft.
The speed ratio is 0.65-3.0 (speed ratio is engine
speed divided by output speed).
The transmission output speed is 400-1500 RPM.
The TCC slip speed is O to -3000 RPM for
1 second.
All conditions met for 1.5 seconds.

Transmission/Transaxle
Condition 2
The TP angle is 13-50%.
The TP angle is within +/- 5%.
Third gear is commanded for 2.5-4.4 seconds.
The engine torque is 40-400 lb ft.
The speed ratio in 3rd gear does not drop by
more than 0.35 from the last speed ratio
in 2nd gear.
The TCC slip speed in 3rd gear is 400 RPM
greater than the last TCC slip speed in 2nd gear.
All conditions met for 1 second.

Condition 3
The TP angle is greater than 10%.
Fourth gear is commanded for 1 second.

Automatic Transmission - 4L60E

Conditions for Clearing the MIL/OTC

The PCM turns OFF the MIL after three

consecutive trips without a failure reported.
A scan tool can clear the OTC from the PCM
history. The PCM clears the DTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the DTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Diagnostic Aids
Verify that the transmission meets the
specifications in the 4L60-E Shift Speed table.
Other internal transmission failures may cause
more than one shift to occur.

The engine torque is 0-400 lb ft.

The speed. ratio is 1.68-3.3.
The TCC slip speed is 1000-4000 RPM.
The transmission output speed is 1400-2500 RPM
for 1 second.

7-173

Gear
1
2
3
4

1-2 Shift
Solenoid
ON
OFF
OFF
ON

2-3 Shift
Solenoid
ON
ON
OFF
OFF

Gear Ratio
3.059:1
1.625:1
1.000:1
0.696:1

All conditions met for 2 seconds.

Action Taken When the OTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL).

The PCM commands 3rd gear only.

The PCM inhibits TCC engagement.
The PCM commands maximum line pressure.
The PCM freezes shift adapts from being updated.
DTC P0756 stores on PCM history.

Test Description
The numbers bel.ow refer to the step numbers on the
diagnostic table.
2. This step verifies that the scan tool commanded
all shifts, and all shift solenoid valves ,responded
correctly, but all the shifts did not occur.

1-174 Automatic Transmission - 4L60-E

Transmission!Transaxle

OTC P0756 2-3 Shift Solenoid Valve Performance (3.8L)

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080)
System Check

Go to Step 3

Go to
Diagnostic Aids

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the scan tool
in order to record the Freeze Frame and Failure Records
for reference. Using the Clear Info function will erase the
stored to record the Freeze Frame and Failure Records
from the PCM.
3. Record the OTC Freeze Frame and Failure Records,
then clear the DTC(s).
4. Drive the vehicle in 04 range under the following
conditions:
Accelerate the vehicle, ensuring that the PCM
commands 1st, 2nd, 3rd and 4th gears.
Did you detect a 1-2-2-1 or 4-3-3-4 shift pattern?

Inspect the shift solenoid/hydraulic circuit for the following

conditions:
An internal malfunction
Damaged seals on the shift solenoid valves
Did you find and correct the condition?

Go to Step 4

In order to verify your repair, perform the following

procedure:
1. Select OTC.

2. Select Clear Info.

3. Drive the vehicle in 04 range under the following
conditions (only if traffic and road conditions permit):
Hold the throttle at 40% and accelerate to
64 km/h (40 mph).
Stop the vehicle, engine idling.
Hold the throttle at 15% and accelerate to
80 km/h (55 mph).
4. Select Specific OTC. Enter OTC P0756.
Has the test run and passed?

System OK

Go to Step 1

TransmissionJTransaxle

Automatic Transmission - 4L60-E

7-175

OTC P0756 2-3 Shift Solenoid Valve Performance (5.7L)

LJil

..,.SIGA,_ _-1
'-rn.,.....11--<! 1 - 2 SHIFT

SOL VALVE
N.0.
ON

'
FL__;;:.___
~

'

__,

,-~AFL(To 3-'2 Solenoid)

CJ

zC\J

2-3SHIFT
SOL VAf.VE
.N.O.

ON
Cl

u.
0

u
<{

<t

I
tn

Cf)

42270

Circuit Description
The 2-3 Shift Solenoid Valve (2-3 SS Valve) controls
the fluid flow acting on the 2-3 shift valves. The 2-3 SS
Valve is a normally-open exhaust valve that is used with
the 1-2 Shift Solenoid Valve (1-2 SS Valve) in order to
allow four different shifting combinations.
When the PCM detects a 1-2-2-1 or a 4-3-3-4 shift
pattern, depending on the state of the mechanical
failure, then DTC P0756 sets. DTC P0756 is a
type A DTC.

Conditions for Setting the OTC

No TP Sensor DTCs P0122 or P0123.

No VSS Assy. DTCs P0502 or P0503.
No TCC Sol. Valve DTC P0740.
No TCC Stuck ON DTC P0742.
No 1-2 SS Valve DTC P0753.
No 2-3 SS Valve DTC P0758.
No 3-2 SS Valve Assy. DTC P0785.
No TFP Val. Position Sw. DTC P1810.
No TCC PWM Sol. Valve DTC P1860.

The vehicle speed is greater than 8 km/h (5 mph).

The gear range is D4.
The engine vacuum is 0-105 kPa.
The engine speed is greater than 450 RPM for
5 seconds.
Not in fuel cutoff.
The transmission fluid temperature is
20-130C (68-266F).
All of the above conditions are met three times
and the combination of Conditions 1 and 2 or
Conditions 2 and 3 occurs three times.
Condition 1
The TP angle is greater than 25%.
First gear is commanded for 1.5 seconds.
The engine torque is 40-400 lbs. ft.
The speed ratio is 0.7-3.0 (speed ratio is engine
speed divided by output speed).
The transmission output speed is 400-1500 RPM.
The TCC slip speed is O to -2000 RPM.
All conditions met for 1.5 seconds.

7176

Transmissio.n/Transaxle

Automatic Transmission - 4L60-E

Conditions for Clearing the MIUDTC

Condition 2

The PCM turns OFF the MIL after three

consecutive trips without a failure reported.
A scan tool can clear the OTC from the PCM
history. The PCM clears the OTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the OTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Th~ TP aRgle is 10-50%.

The TP angle is within +/- 7%.
Third gear is commanded for 2-6 seconds.
~

The engine torque is 4Q-400 lbs. ft.

The speed ratio in 3rd gear does not drop by

more than 0.3 from the last speed ratio
in 2nd gear.
The TCC slip speed in 3rd gear is 400 RPM
greater than the last TCC slip speed in 2nd gear.

Diagnostic Aids

All conditions met for 1,5,seconds.

w ,'_'(':' '
~

Verify that the transmission meets the

specifications in the 4L60-E Shift Speed table .
. Other internal transmission failures may cause
more than one shift to occur.

Conditi.on 3
The TP angle is greater than 7%.
Fourth gear is commanded for 1.5 sec.ands.
The engine torque is 0-400 lbs. ft.
.The speed ratio is 1.68-3,0.

Gear
1

The TC.C slip speed is 1000-3000 RPM.

The transmission output speed is
1000-3000 RPM.
.
.

.2

,,-,

'

3
4

1-2 Shift
Solenoid
ON
OFF
OFF
ON

2-3 Shift
Solenoid
ON
ON
OFF
OFF

Gear Ratio
3.059:1
1.625:1
1.000:1
0.696:1

All conditions met for 1 second.

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL).
The PCM commands 3rd gear only.
The PCM inhibits TCC engagement.
The PCM commands maximum line pressure.
The PCM freezes shift adapts from oeing updated.
OTC P0756 stores in PCM history.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
2. This step verifies that the scan tool commanded
all shifts, and all shift solenoids responded
correctly, but all the shifts did not occur.

Transmission/Transaxle

Automatic Trans.mission .. 4L60~E

7-177

DTC P0756 2-3 Shift Solenoid,Valve Performance (5.7L)

Action

Step

Value(s)

,Yes

No

Go to Step 2

Go to A
, Powertrain On
BoaidDiagnostic
(OBD)
System Check

Go to Step 3

Go to
Diagnostic Aids

Was the Pqwertrain On-Board Diagnostic (OBD) System

Check performed?
1

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan tool in
order to record the Freeze Frame and Failure Records for
reference. Using the Clear Info function will erase the
stored Freeze Frame and Failure Records from the PCM.
3. Record the OTC Freeze Frame and Failure Records,
then clear the DTC(s).
4. Drive the vehicle in 04 range under the following
conditions:
Accelerate the vehicle, ensuring that the PCM
commands 1st, 2nd, 3rd and 4th gears.
Did you detect a 1-2-2-1 or 4-3-3-4 shift pattern?

Inspect the shift solenoid/hydraulic circuit for the following

conditions:
An internal malfunction
Damaged seals on the shift solenoid valves.
Did you find and cbrrect the condition?

In order to verify your repair, perform the following

'
procedure:
1. Select OTC.
2. Select Clear Info.
3. Drive the vehicle in 04 under the following conditions
(only if traffic and road conditions permit):
Hold the throttle at 40% ana accelerate to
64 km/h (40 mph).
Stop the vehicle, engine idling.
Hold the throttle at 15% and accelerate to
80 km/h (55 mph).
4. Select Specific OTC. Enter OTC P0756.
Has the test run and passed?

,'

Go to Step 4

'

.,
,

System OK

Go to Step

7-178

Automatic Transmission - 4L60-E

Transmissionrrransaxle

OTC P0758 2-3 Shift Solenoid Circuit Electrical (3.SL)

iHot In Run, Bulb Test And Start!
Power

Distribution
Cen 10

ENG CTRL
MiniFuse

Underhood
I Electrical
Center 2
I

_____ ...
15A

;c- - - - -0 5- - -839- - - - -;-_;s;tt,1

Automatic ...
Transmission: Solenoid

I.

1.-----:--

S182 - - - - - -,
0.5 PNK 239

- - _...

Solenoid
Valve 1

. Valve

Solanoid

[!]

I
I
I

,..
I

Fuse Block
Details
Cell 11

:
I
I

LJil

I Valve

0.5 PNK 239

G C100

S107

RED

I
I TCCPWM

0.5 PNK 239

0.5 PNK 239

I I

20~ Way Connector Loe

E/

'

2 ~3 Shift
Solenoid
(2-3 SS)
Valve

3-2 Shift
Solenoid I
Valve I
Assembly I

0.5 Y:Lr223

I
l
"

:
I
I

L----------------J
B

20- Way Connector

0.5 YEL/BLK 1223

44 C1
Powertrain ~ - - - - - - - - - - - ~
Control 1
2-3 ss I
Module I 2-3SS.
......, Valve
I
(PCM) I Fe~~~=ck
! Control I

.>

~-----------J

)
193819

Circuit Description
The 2-3 Shift Solenoid Valve (2-3 SS Valve) controls
the fluid flow acting on the 2-3 shift valves. The
2-3 SS Valve is a normally-open exhaust valve that is
used with the 1-2 Shift Solenoid Valve in order to
allow four different shifting combinations. The solenoid
attaches to the control v,alve body within the
transmission. The 2-3 SS Valve receivestgnition
voltage through circuit 239. The Powertrain Control
Module (PCM) controls the solenoid by providing
the ground path on circuit 1223.
When the PCM detects a continuous open or short to
ground in the 2-3 SS Valve circuit or the 2-3 SS Valve,
then DTC P0758 sets. DTC P0758 is a
type A DTC.

Conditions for. Setting the OTC

The system voltage is 8-16 volts.
The enginespe~d is 450 RPM for 5 seconds.
Not in fuel cutoff.
All of the above conditions are met for 5 seconds
and either of the following fail conditions occurs
for 5 seconds.
- The PCM commands the solenoid ON and
the voltage input remains high (B+).
- The PCM commands the solenoid OFF and
the voltage input remains low (0 volts).

Automatic Transmission .. 4L60-E 7;.179

Transmission/Transaxle
Action Taken When the OTC Sets

. - A chafed wire

The PCM illuminates the Malfunction Indicator

Lamp (MIL).
The PCM commands third gear only.
The PCM commands maximum line pressure.
The PCM inhibits TCC engagement.
The PCM freezes shift adapts from being updated.
OTC P0758 stores in PCM history.

- A broken wire inside the insulation

- Moisture intrusion
- Corrosion
When diagnosing for an intermittent short or open
condition, massage the wiring harness while
watching the test equipment for a ch~nge.

Conditions for Clearing the MIUDTC

The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
A scan tool can clear the OTC from the PCM
history. The PCM clears the OTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the OTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Diagnostic Aids
Inspect the wiring at the PCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension

Gear
1

2
3
4

1-2 Shift
Solenoid

2-3 Shift
Solenoid

ON
.OFF.
OFF
ON

ON
ON
OFF
OFF

Gear Ratio
3.059:1
1.625:1
1.000:1
O.p96:1

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
4. This step tests the function.qt the 2-3 SS Valve
and the Automatic Transmission Wiring tlarress
Assembly (A/T Wiring Harness Assembly}.
5. This step tests for power to the 2-3 SS Valve from
the ignition through the fuse.

6. This step tests the ability of the PCM and the

wiring to control the ground circuit.
13. This step measures the resistance of the A/T
Wiring Harness Assembly and the 2-3 SS Valve.

OTC P0758 2-3 Shift Solenoid Circuit Electrical (3.SL)

Step

Action

Value(s)

Yes

No

Go to Step.2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check in Engine
Controls

Go to Step 3

Go to Step 4

Go to Step 19

Go to Step 5

Go to
Diagnostic Aias

Go to Step 5

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the scan tool
in order to record the Freeze Frame and Failure Records
for reference. Using the Clear Info function will erase the
stored Freeze Frame and Failure Records from the PCM.
3 .. Record the OTC Freeze Frame and Failure Records,
then clear the DTC(s).
Are DTCs P0740, P0753, P0785 and P1860 also set?

1. Inspect the ENG CTRL fuse.

2. If the fuse is open, inspect circuit 239 (PNK), the
solenoids, and the A/T Wiring Harness Assembly for
a short to ground. Repair the circuit, the solenoids,
and the harness if necessary.
Refer to General Electrical Diagnosis Procedures in Wiring
Systems.
Did you find a short to ground condition?

Using the transmission output control function on the scan

tool, command the 2-3 SS Valve ON and OFF three times
while listening to the bottom of the transmission pan (a
stethoscope may be necessary).
Does the solenoid click when commanded?

Transmissionrrransaxle

7180 Automatic Transmission - 4L60-E

DTC P0758 2-3 Shift Solenoid Circuit Electrical (3.8L) (cont'd)

Step

','.

"""

, Action.

Value(s)

1. Turn the ignition .OFF.

2. Disconnect the transmission.20-way connector
(additional DTCs will set).
3. Install the J 39775 JumperHarness on the engine
side of.the 20-way connector.
4. With the en~ine OFF, turn the ignition switch to the
RUN position.
5. Connect a test lamp from J 39775 Jumper Harness
" cavity E to .ground.
Is the test light ON?
:

or

Was the test lamp OFF at all times?

1. Inspect circuit 1223 (YEC/BLK} of the engine wiring
harness for an open or short to power condition.
Refer to General Electrical .Diagnosis Procedures in
Wiring Systel'T)S.

Go to Step 9

Goto Step 10

Go to Step 19

Go to Step 12

f, ''

11

15

Go to Step 8

1. Inspect circuit 1223 (YEUBLK) of the engine wiring

harness for a short to ground condition.
Refer to General Electrical Diagnosis Procedures in
Wiring Systertls.
2. Repair the circuit if necessary.
Refer to Wiring Repairs in Wiring Systems.
Did you find a short to ground condition?

14

Go to Step 13

Go to Step 19

Monitor the test lamp status, .

13

Go to Step7

Was the t~st lamp ON at all times?

'

Go to Step 6

10

12

No

1. Install. ate.st lamp from cllvity E to cavity B of J 39775

Jumper Harness.

2. Using the transmissionoutput control function on the

scan tool, command the 2-3 SS Valve ON and OFF
three times.
Is the test lamp ON when the 2-3 SS Valve is commanded
OJ\I and OFF when cor:nmanded OFF?
Repair the open or short to ground it'.} ignition feec,i
circuit 239 (PNK) to the 2-3 SS Valve.
Refer to Wlrin~Aepaifs'in Wiring Systems.Did you find and correct an open'
sh.Ort tq ground
condition?

2. Repair the circuit if necessary.

Refer to Wiring Repairs in Wiring Systems.
Did you find an open or short to J)6wer .condition?

Yes

Replace the PCM.

Refer to PCM Replacement/Programming in Engine
Controls.
Is the replacement complete?

Go to Step 11

Go to Step 19

..

..

Go to Step 12

Go to Step 19

1. Turn the ignition OFF.

2. Install the J :)9775 Jumper Harness on the
transmission side of the 20-way connector.
3. With J 39200 Digital Multimeter (DMM) and
.
J 35616-A Connector Test Adapter Kit, measure the .
resistance between terminals B and E.
Is the resistance within the specified range?

19-31 Q

1. Disconnect the A/T Wiring Harness Assembly from

the 2-3 SS Valve.
2. Measure .the resistance of the 2-3 SS Valve.
Is the resistance within the sp~cified range?

19-31 Q

Using J 39200 DMM, measure the resistance between

terminals B and E and ground.
Are both readings gr~ater thar:i the specified value?

250KQ

Go to Step 15

Go to Step 14

Go to Step 17

Go to Step 18

Go to
Diagnostic Aids

Go to Step 16

Transmission!Transaxle

Automatic Transmission - 4L60E

7-181

DTC P0758 2-3 Shift Solenoid Circuit Electrical ,3.8L) (cont'd)

Step

16

17

18

19

Action

1. Disconnect the A/T Wiring Harness Assembly from

the 2-3 SS Valve.
2. Using J 39200 DMM, measure the resistance from
the component's terminals to ground.
Are both readings greater than the value shown?
Replace the A/T Wiring Harness Assembly.
Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring
Harness Replacement.
Is the replacement complete?
Replace the 2-3 SS Valve.
Refer to Control and Shift Solenoids Replacement.
Is the replacement complete?
In order to verify your repair, perform the following
procedure:
1. Select OTC.
2. Select Clear Info.
3. Drive the vehicle in 04 range and ensure that the
following conditions are met:
The PCM commands the 2-3 SS Valve ON and
the voltage input drops to zero.
The PCM commands the 2-3 SS Valve OFF and
the voltage input increases to B+.
All conditions are met tor 5 seconds.
4. Select Specific OTC. Enter DTC P0758.
Has the test run and passed?

Value(s)

Yes

No

Go to Step 17

Go to Step 18

250KQ

Go to Step 19

Go to Step 19

System OK

Go to Step 1

7-182

Transmission!Transaxle

Automatic Transmission - 4L60-E

DTC P0758 2-3 Shift Solenoid Circuit Electrical (5.7L)

20 - Way Connector Loe (

! Hot In Run, Bi.Jib Test And Start!

'"-P;,.;,: - - - - - - - - "'Underhood
Distribution
Cell 10

.. _____ _

ENG CTRL
Mini Fuse

Electrical

I Center

_____ .
15A

#2

Automatic' .. T~C-

Transmission I

0.5 PNK 239

I
I

o.s RED

Solenoid
Valve

839

Assembly

I TCCPWM

0.5 PNK 239

s1a2------.
0.5 PNK 239

G"'C100
0.5 PNK 239

-;_-; s~tt.,
I
solenoid
Valve I

I Solenoid
I Valve

1-2 Shift I
Solenoid I

A
2-3Shifl

Valve

Solenoid
(2-3SS)

I
I
I.

[ ] ] Valve

BI

I
I
I
I

l_----"'""""' -----_j
B

0.5 PNK 239

20 - Way Connector
0.5 YEL/BLK 1223

8107

- - ....

Fuse Block
Details
Cell 11

40 C1

r------------.,

Powertrain I
Control,

Module I

Valve

....,_,

2 _ 3 ss I

Valve
Control

I
I

!
. ___________
.

~ {PCM) 1
~

r----f

2-3SS
Feedback

168443

Circuit Description
The 2-3 Shift Solenoid Valve (2-3 SS Valve) controls
the fluid flow acting on the 2-3 shift valves. The
2-3 SS Valve is a normally-open exhaust valve that is
used with the 1-2 Shift Solenoid Valve in order to
allow four different shifting combinations. The solenoid
attaches to the control valve body within the
transmission. The 2-3 SS Valve receives ignition
voltage through circuit 239. The Powertrain Control
Module (PCM) controls the solenoid by providing
the ground path on circuit 1223.
When the PCM detects a continuous open or short to
ground in the 2-3 SS Valve circuit or the 2-3 SS Valve,
then DTC P0758 sets. DTC P0758 is a
type A DTC.

Conditions for Setting the OTC

The system voltage is 8-16 volts.
The engine speed is 450 RPM for 5 seconds.
Not in fuel cutoff.
All of the above conditions are met for 5 seconds
and either of the following fail conditions occurs
for 5 seconds.
- The PCM commands the solenoid ON and
the voltage input remains high (B+).
- The PCM commands the solenoid OFF and
the voltage input remains low (0 volts).

TransmissionfTransaxle

Automatic Transmission - 4L60-E

Action Taken When the OTC Sets

- A chafed wire

The PCM illuminates the Malfunction Indicator

Lamp (MIL).
The PCM commands third gear only.
The PCM commands maximum line pressure.
The PCM inhibits TCC engagement.
The PCM freezes shift adapts from being updated.
OTC P0758 stores in PCM history.

- A broken wire inside the insulation

- Moisture intrusion
- Corrosion
When diagnosing for an intermittent short or open
condition, massage the wiring harness while
watching the test equipment for a change.

Conditions for Clearing the MIUDTC

The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
A scan tool can clear the OTC from the PCM
history. The PCM clears the OTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the OTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Diagnostic Aids
Inspect the wiring at the PCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension

7-183

2-3 Shift
Solenoid
ON
ON
OFF
OFF

1-2 Shift
Solenoid
ON
OFF
OFF
ON

Gear
1
2
3
4

Gear Ratio
3.059:1
1.625:1
1.000:1
0.696:1

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
4. This step tests the function of the 2-3 SS Valve
and the Automatic Transmission Wiring Harness
Assembly (A/T Wiring Harness Assembly).
5. This step tests for power to the 2-3 SS Valve from
the ignition through the fuse.
6. This step tests the ability of the PCM and the
wiring to control the ground circuit.
13. This step measures the resistance of the A/T
Wiring Harness Assembly and the 2-3 SS Valve.

OTC P0758 2-3 Shift Solenoid Circuit Electrical (5.7L)

Step

Action

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080) System
Check in Engine
Controls

Go to Step 3

Go to Step 4

Go to Step 19

Go to Step 5

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan tool in
order to record the Freeze Frame and Failure Records for
reference. Using the Clear Info function will erase the
stored Freeze Frame and Failure Records from the PCM.
3. Record the OTC Freeze Frame and Failure Records,
then clear the DTC(s).
Are DTCs P0740, P0753, P0785 and P1860 also set?

1. Inspect the ENG CTRL fuse.

2. If the fuse is open, inspect circuit 239 (PNK), the
solenoids, and the A/T Wiring Harness Assembly for
a short to ground. Repair the circuit, the solenoids,
and the harness if necessary.
Refer to General Electrical Diagnosis Procedures in Wiring
Systems.
Did you find a short to ground condition?

7-1'84

Automatic Transmission - 4L60-E

Transmission!Transaxle

OTC P0758 2-3 Shift Solenoid Circuit Electrical (5.7L) (cont'd)

Step

Action

Using the transmission output control function on the scan

tool, command the 2-3 SS Valve ON and OFF three times
while listening to the bottom of the transmission pan
(a stethoscope may be necessary).
Does the solenoid click when commanded?

1. Turn the ignition OFF.

2. Disconnect the transmission 20-way connector
(additional DTCs will set).
3. Install the J 39775 Jumper Harness on the engine
side of the 20-way connector.
4, With the engine OFF, turn the ignition switch to the
RUN position.
5. Connect a test lamp from J 39775 Jumper Harness
cavity E to ground.
Is the test light ON?

"

1. Install a test lamp from cavity E to cavity B of J 39775

Jumper Harness.
2. Using the transmission output control function on the
scan tool, command the 2-3 SS Valve ON and OFF
three times.
Is the test lamp ON when the 2-3 SS Valve is commanded
, ON and OFF when commanded OFF?

Value(s)

Monitor the test lamp status.

Was the test lamp OFF at all times?

11

Was the test lamp ON at all times?

1. Inspect circuit 1223 (YEUBLK) of the engine wiring
harness for a short to ground condition.
Refer to General Electrical Diagnosis Procedures in
Wiring Systems.

12

13

1. Turn the ignition OFF.

2. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector.
3. With the J 39200 Digital Multimeter (DMM) and the
J 35616-A Connector Test Adapter Kit, measure the
resistance between terminals B and E.
Is the resistance within the specified range?

Go to Step 5

Go to Step 6

Go to Step 7

Go to Step 13

Go to Step 8

Go to Step 19

)
Go to Step 9

Go to Step 10

Go to Step 19

Go to Step 12

Go to Step 11

2. Repair the circuit if necessary.

Refer to Wiring Repairs in Wiring Systems.
Did you find a short to ground condition?
Replace t~e PCM.
Refer to PCM Replacement/Programming in Engine
Controls.
Is the replacement complete?

Go to
Diagnostic Aids

Refer to Wiring Repairs in Wiring Systems.

Did you find an open or short to power condition?
10

No

Repair the open or short to ground in ignition feed

circuit .239 (PNK) to the 2-3 SS Valve.
Refer to Wiring Repairs in Wiring Systems.
Did you find and correct an open or short to ground
condition?

1. Inspect circuit 1223 (YEUBLK) of the engine wiring

harness for an open or short to power condition.
Refer to General Electrical Diagnosis Procedures in
Wiring Systems.
2. Repair the circuit if necessary.

Yes

Go to Step 19

Go to Step 12

Go to Step 19

19-31

n
Go to Step 15

Go to Step 14

Automatic .Transmission - 4L60E

Transmission/Transaxle

7-185

DTC P0758 2-3 Shift Solenoid Circuit:Electrical (5.7L} (cont'd)

Step

Action

Value(s)

1. Disconnect the A/T Wiring Harness Assembly from

the 2-3 SS Valve.
2. Measure the resistance of the 2-3 SS Valve.
Is the resistance within the specified range?

19-31 Q

Using the J 39200 DMM, measure the resistance between

terminals B and E and ground.
Are both readings greater than the specified value?

250KQ

16

1. Disconnect the A/T Wiring Harness Assembly from

the 2-3 SS Valve.
2. Using theJ 39200 DMM, measure the resistance
from the component's terminals to ground.
Are both readings greater than the value shown?

250KQ

17

Replace the A/T Wiring Harnl:lSS Assembly.

Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring
Harness Replacement.
Is the replacement col'!lplete?

Replace the 2-3 SS Valve.

Refer to Control and Shift Solenoids Replacement.
Is the replacement compt~te?

In order to verify your repair, perform the following

procedure:
1. Select D.TC.
2. Select Clear Info.
3. Drive the vehicle in 04 and ensure the following
conditions are met:
The PCM commands the 2-3 SS Valve ON and
.the voltage input drops to zero.
The PCM commands the 2-3 SS Valve OFF and
the voltage input increases to B+.
All conditions are met for 5 seconds.
4. Select Specific OTC. Enter OTC P0758.
Has the test run and passed?.

14

15

18

19

Yes

No

Go to Step 17

Goto Step 18

Go to
Diagnostic Aid~

Go to Step 16

Go to Step 17

Go to Step 18

Go to Step 19

Go to Step 19

System OK

Go to Step'1

,,coc

7-186

Automatic Transmission - 4L60-E

TransmissionJTransa.xle

DTC P0785 3-2 Shift' Solenoid Circllit Electrical (3.8L)

!Hot In Run, Bulb Test And Start!

,. - P;~ - - - - - - - - ~ Underhood
I

Distribution
ee1r10

ENG ~TRL
MiniFuse
15A

I
... - -

L'.!:!J

Electrical
Center 2

I
-

.- -

I TCCPWM

0.5 PNK 239

8182 - - - - - -,
0.5 PNK 239
I

G C100
0.5 PNK 239
8107

- - --.

I
I
I

I
I

0.5PNK 239

Fuse Block
Details
ee1i11

2-3 Shift

Solenoid
Valve

~~!n~~~ft

I
I
I

I
I

[]]

(3-2SS)
Valve.
Assembly

Al . .

Solenoid
Valve

0.5 WHT 687

I
I

~--------. _______ j
Se

0.5 WHT 687

20~Way Connector

48 C2
Powertraifi ~ - - - -;- - - - - - - -. ~
Control 1
3-2ss I
Module I 3 - 2 SS
......, Valve
I
Ji (PCM) 1 Valve
.t. Cohtrol I
~
L !e:_db_:,Ci;_ - - -- ..,.. - - J

)
193840

Circuit Description
The 3-2 Shift Solenoid Valve Assembly (3-2 SS Valve
Assy.) is a normally-closed, 3-port, on/off device that
controls the 3-2 downshift. The solenoid attaches to the
control valve body within the transmission. The solenoid
receives ignition voltage through
circuit 239. The Powertrain Control Module (PCM)
controls the solenoid by providing a ground path on
circuit 687. During a 3-2 downshift, the 2-4 band applies
as the 3-4 clutch releases. The PCM varies the timing
between the 3-4 clutch release and the 2-4 band apply
depending on the vehicle speed and the throttle
position.
When the PCM detects a continuous open or short to
ground in the 3-2 SS Valve Assy. circuit or the 3-2 SS
Valve Assy., then OTC P0785 sets. DTC P0785 is a
type ADTC.

Conditions for Setting the DJC

The system voltage is 8-16 volts.
.The engine speed is greater than 450 RPM for
5 seconds.
Not in fuel cutoff.
All of the above conditions are met for 5 seconds
and either of the following fail conditions occurs
for 5 seconds:
- The PCM commands the solenoid ON and
the voltage input ren,ains high (B+).
- The PCM commands the solenoid OFF and
the voltage input remains low (0 volts).

Transmission/Transaxle
Action Taken When the OTC Sets

The PCM illuminates the Malfundioo.ir:iclicator

Lamp (MIL).'
.
Tll~ PCM commands a soft landing to third gear.
The PCM commands maximum line pressure.
'Tf\e PQNI' inhibits TCC engagement.
The PCM inl;libits fourth gear if the transmission is
in hot m'dds.
The PCM freezes shift adapts from being updated.
DTC P0785 stores in PCM history.

Conditions for: Clearing the MIUDTC

The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
A scan tool can clear the DTC from the PCM
history. The PCM clears the D!C from the
PCM.history'if the vehicle completes 40 warm-up
cycies without a failure reported:
The PCM cancels the DTC default actions when
the fault no lpnger exists and the ignition is
OFF long enough in order to power down
the PCM.

Diagnostic Aids
Inspect the wiring at the PCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal

Automatic Transmission - 4L60-E 7-187

:... .A damaged. terrninal
- Poor terminal tension
'""' A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
When diagnosing for a.n intermittent Short or open
condition, massage the wiring harness while
watching the test equipment for a change,

Test Description
The numbers b'elow refer to the step num.bers on the
diagnostic table.

4. This step tests the ability of the PCM to control

the solenoid.
5; This step .tests for power to the 3-2 SS. Valve .
Assembly.
7. This step tests the ability ofcthe PCM and wiring
to control the ground circuit.
9. This step tests the res.istance of the Automatic
T.ransmission Wiring Harness Assembly (A/T
Wiring Harness Assembly) and the 32 SS Valve
Assembly.

7-188 ALJtomatic Transm,ission - 4L60...E

,Transmission!Transaxl6

OTC P0785 3-2 Shift Solenoid Circuit Electrical (3.8L)

Step

Vilue(s)

Action

Yes

No

Go to Step2

Goto A
Powertrain On
f3oard Diagnostic
(OBD) Sgstem
Check in ngine
controls

Was the Powertrain On-Board Dia.gnostic (OBD) System

C.heck performed?

'
1. Install the Scan Tool.
'.

2.

..

2. With the engine, OFF, turn the ignition switch to the

RUN position.
Important: Before clearing the DTC(s), use the scan tool
in order to recor,d. the Freeze Frame an.d Failur~ Records
'for reference. Using the Clear Info function win erase the
stored Freeze Frame and Failure Records from the PCM.
3. Record the OTC Freeze Fra.me ahd Failure Records,
then clear the DTC(s).
Are DTCs P0740, PQ753, P0758, and P1860 also set?
1. Inspect the ENG CTRL fuse.
2. If the fuse is open, inspect circuit 239 (PNK), the
solenoids, and.the A/T. Wiring Harness Assembly for
a short to ground. Repair the circuit, the solenoids,
and the harness if necessary.
Refer to GtJneral Electrical Diagnosis Procedures in Wiring
Systems.
Did you find a short to ground condition?
Using the transmission output control function on the scan
tool, command the 3-2 SS Valve Assembly ON and OFF
three times, while listening to the bottom of the
transmission pan (a stethoscope may be necessary).
Does the solenoid click when commanded?

,.,

,-,

,,:

c;o to Step 3

GotoStep 4

'
G.o to Step 16
''i'

.,

Go 'to St~p 5

Go to
Diagnostic Aids

Go to Step 5

Go to Step 7

Go to Step 6

1. Turn the ignition OFF.

2. Disconnect the transmission 20-way connector
(additional DTCs will be set).
5

3. Install the J 39775 Jumper Harness on the engine

side of the 20-way connector.
4. With the engine OFF, turn the ignition switch to the
RUN position.
5. Connect a test lamp from J 39775 Jumper Harness
cavity E to ground.
Is the test lamp ON?
Repair the open or short to ground in ignition feed
circuit 239 (PNK) to the 3-2 SS Valve Assembly.
Refer to Wiring Repairs in Wiring Systems.
Is the repair complete?

Go to Step 16

"

1. Install a test lamp from cavity E to cavity S of the

J 39775 Jumper Harness.
2. Using the transmission output control function on the
scan tool, command the 3-2 SS Valve Assembly ON
and OFF three times.
Is the test lamp ON when the solenoid is commanded ON,
and OFF when the solenoid is commanded OFF?

Go to Step 9

Go to Step 8

Transmission/Transaxle

Automatic Transmission - 4L60E

7-189

DTC P0785 3-2 Shift Solenoid Circuit Electrical (3.8L) (cont'd)

Step

Action

Value(s}

Yes

No

Go to Step 16

Go to Step 10

Go to Step 12

Go to Step 11

1. Inspect circuit 687 (WHT) of the engine wiring

harness for an open, short to ground or short to
power condition.
8

Refer to General Electrical Diagnosis Procedures in

Wiring Systems.

2. Repair th!;! circuit if necessary.

Refer to Wiring Repairs in Wiring Systems.
Did you find an open, short to ground or short to power
condition?
1. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector.

2. Using the J 39200 Digital Multimeter (DMM) and

J 35616-A Connector Test Adapter Kit, measure the
resistance between terminal E and terminal S.

20-32 n

Is the resistance within the specified range?

Replace the PCM.
10

Refer to PCM Replacement/Programming in Engine

Controls.
Is the replacement complete?

Go to Step 16

1. Disconnect the A/T Wiring Harness Assembly from

the 3-2 SS Valve Assembly.
11

2. Measure the resistance of the 3-2 SS Valve

Assembly.

20-32 n

Is the resistance within the specified range?

12

Measure the resistance between terminal S and ground,

and between terminal E and ground.

250 Kn

Are both measurements greater than the specified value?

Go to Step 14

Go to Step 15

Go to
Diagnostic Aids

Go to Step 13

Go to Step 14

Go to Step 15

1. Disconnect the A/T Wiring Harness Assembly from

the 3-2 SS Valve Assembly.
13

2. Measure the resistance from the component's

terminals to ground.

250 Kn

Are both measurements greater than the specified value?

Replace the A/T Wiring Harness Assembly.
14

Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring

Harness Replacement.
Is the replacement complete?

Go to Step 16

Replace the 3-2 SS Valve Assembly.

15

Refer to Control and Shift Solenoids Replacement.

Is the replacement complete?

Go to Step 16

In order to verify your repair, perform the following

procedure:
1. Select DTC.
2. Select Clear Info.
3. Drive the vehicle in 03 or 04 range and perform a
3-2 downshift. Ensure that the following conditions
are met:
16

The PCM commands the 3-2 SS Valve Assembly

ON and the voltage input drops to zero.

The PCM commands the 3-2 SS Valve Assembly

OFF and the voltage input increases to B+.
All conditions are met for 5 seconds.
4. Select Specific DTC. Enter OTC P0785.
Has the test run and passed?

System OK

Go to Step 1

7-190

Automatic Transmission - 4L60-E

Transmission!Transaxle

DTC P0785 3-2 Shift Solenoid Circuit Electrical (5.7L)

!Hot In Run, Bulb Test And Start!
r -

P-;;-w; - - Distribution
cen 10

~------

ENG CTRL

Mini Fuse
15A

_____

Electrical
Center # 2

I I

20-Way Connector Loe

- - - - - , Underhood

E
Automatic'" T~c- Transmission 1 Solenoid

- - - - -;:,.- - - - - ;_;-s;tt,
I
Solenoid
Valve I

0 5 RED 839

Valve

LJJ

...

TCCPWM

0.5 PNK 239

Solenoid
Valve

s1s2----~
0.5 PNK 239

A
3-2Shift
Solenoid '
(3-2 SS)
.
[ ] ] Valve
Assembly

0.5 PNK 239

1-2Shift I
Solenoid I
Valve I

0.5 PNK 239

I

G C100

osw:1687

1
I

~-------~--------J
s

20 - Way Connector

0.5 PNK 239

0.5 WHT 687

8107

- - -+

Fuse Block
Details
Cell11

cL
34 C1

r----------:----.,

Powertrain I
Control , 3 - 2 SS
Module I Valve Assembly

J,

(PCM) 1 Feedback

3~2ss

Valve Assembly I
......., Control
I

~-------------J

)
168444

Circuit Description
The 3-2 Shift Solenoid Valve Assembly (3-2 SS Valve
Assy.) is a normally-closed, 3-port, on/off device that
controls the 3-2 downshift. The solenoid attaches to the
control valve body within the transmission. The solenoid
receives ignition voltage through circuit 239. The
Powertrain Control Module (PCM) controls the solenoid
by providing a ground path on circuit 687. During a
3-2 downshift, the 2-4 band applies as the 3-4 clutch
releases. The PCM varies the timing between the
3-4 clutch release and t_he 2~4 band apply depending on
the vehicle speed and the throttle position.
When the PCM detects a continuous open or short to
ground in the 3-2 SS Valve Assy. circuit or the 3-2 SS
Valve Assy., then OTC P0785 sets. OTC P0785 is a
type A OTC.

Conditions for Setting the DTC

The system voltage is 8-16 volts.
The engine speed is greater than 450 RPM for
5 seconds.

Not in fuel cutoff.

All of the above conditions are met for 5 seconds
and either of the. following fail conditions occurs
for 5 seconds:
- The PCM commands the solenoid ON and
the voltage input remains high (B+).
- The PCM commands the solenoid OFF and
the voltage input remains low (0 volts).

TransmissionfTransaxle
Action Taken When the DTC Sets
The PCM illuminates the Malfunction Indicator
Lamp (Mil).
The PCM commands a soft landing to third gear.
The PCM commands maximum line pressure.
The PCM inhibits TCC engagement.
The PCM inhibits fourth gear if the transmission is
in hot mode.
The PCM freezes shift adapts from being updated.
OTC P0785 stores in the PCM history.

Conditions for Clearing the MIUDTC

The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
A scan tool can clear the OTC from the PCM
history. The PCM clears the OTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the OTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Diagnostic Aids

(
'

Inspect the wiring at the PCM, the transmission

connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal

Automatic Transmission - 4L60-E

7~.-191

- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
When diagnosing for an intermittent short or open
condition, massage the wiring harness while
watching the test equipment for a change.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
4. This step tests the ability of the PCM to control
the solenoid.
5. This step tests for power to the 3-2 SS Valve
Assembly.
7. This step tests the ability of the PCM and wiring
to control the ground circuit.
9. This step tests the resistance of the Automatic
Transmission Wiring Harness Assembly (A/T
Wiring Harness Assembly) and the 3-2 SS Valve
Assembly.

7-192

Automatic Transmission -4L60-E

Transmission/Transaxle

DTC P0785 3-2 Shift Solenoid Circuit Electrical (5.7L)

Step

Action

Value(s)

Yes

No

Go to Step2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check in Engine
Controls

Go to Step 3

Go to Step 4

Go to Step 16

Go to Step 5

Go to
Diagnostic Aids

Go to Step 5

Go to Step 7

Go to Step 6

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the scan tool
in order to record the Freeze Frame and Failure Records
for reference. Using the Clear Info function will erase the
stored Freeze Frame and Failure Records from the PCM.
3. Record tha OTC Freeze Frame and Failure Records,
then clear the DTC(s).
Are DTCs P0740, P0753, P0758, and P1!;160 also set?

1. Inspect the ENG CTRL fuse.

2. If the fuse is open, inspect circuit 239 (PNK), the
solenoids, and the A/T Wiring Harness Assembly for
a short to ground. Repair the circuit, the solenoids,
and the harness if necessary.
Refer to General Electrical Diagnosis Procedures in Wiring
Systems.
Did you find and correct a short to ground condition?

Using the transmission output control function on the scan

tool, command the 3-2 SS Valve Assembly ON and OFF
three times, while listening to the bottom of the
transmission pan (a stethoscope may be necessary).

Does the solenoid click when commanded?

1. Turn the ignition OFF.

2. Disconnect the transmission 20-way connector
(additional DTCs will be set).

3. Install the J 39775 Jumper Harness on the engine

side of the 20-way connector.
4. With the engine OFF, turn the ignition switch to the
RUN position.
5. Connect a test lamp from J 39775 Jumper Harness
cavity E to ground.
Is the test lamp ON?
Repair the open or short to ground in ignition feed
circuit 239 (PNK) to the 3-2 SS Valve Assembly.
Refer to Wiring Repairs in Wiring Systems.
Is the repair complete?

Go to Step 16

1. Install a test lamp from cavity E to cavity S of the

J 39775 Jumper Harness.

2. Using the transmission output control function on the

scan tool, command the 3-2 SS Valve Assembly ON
and OFF three times.
Is the test lamp ON when the solenoid is commanded ON,
and OFF when the solenoid is commanded OFF?

Go to Step 9

Go to Step 8

Transmtssionrrransaxle

Automatic Transmission 4L60-E

7-193

OTC P0785 3-2 Shift Solenoid Circuit Electrical (S.7L) (cont'd)

Action

Step

Value(s)

Yes

No

Go to Step 16

Go to Step 10

Go to Step 12

Go to Step 11

1. Inspect circuit 687 (WHT) of the engine wiring

harness for an open, short to ground or short to
power condition.
Refer to General Electrical Diagnosis Procedures in
Wiring Systems.
2. Repair the circuit if necessary.
Refer to Wiring Repairs in Wiring Systems.
Did you find an open, short to ground or short to power
condition?

9
L

10

11

12

13

14

15

16

1. Install the J 39775 Jumper Harness on the

transmission side of the 20-way connector.
2. Using the J 39200 Digital Multime.ter (DMM) and the
J 35616-A Connector Test Adapter Kit, measure the
resistance between terminal E and terminal S.
Is the resistance within the specified range?
Replace the PCM.
Refer to PCM Replacement/Programming in Engine
Controls.
Is the replacement complete?

20-32 n

Go to Step 16

1. Disconnect the AfT Wiring Harness Assembly from

the 3-2 SS Valve Assembly.
2. Measure the resistance of the 3-2 SS Valve
Assembly.
Is the resistance within the specified range?

20-32

Measure the resistance between terminal S and ground,

and between terminal E and ground ..
Are both measurements greater than the specified value?

250 KO

1. Disconnect the AfT Wiring Harness Assembly from

the 3-2 SS Valve Assembly.
2. Measure the resistance from the compon~nt's
terminals to ground.
Are both measurements greater than the specified value?

250KQ

Replace the AfT Wiring Harness Assembly.

Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring
Harness Replacement.
Is the replacement complete?

Replace the 3-2 SS Valve Assembly.

Refer to Control and Shift Solenoids Replacement.
Is the replacement complete?

In order to verify your repair, perform the following

procedure:
1. Select OTC.
2. Select Clear Info.
3. Drive the vehicle in 03 or 04 and perform a 3-2
downshift. Ensure the following conditions are met:
The PCM commands the 3-2 SS Valve Assembly
ON and the voltage input drops to zero.
The PCM commands the 3-2 SS Valve Assembly
OFF and the voltage input increases to B+.
All conditions are met for 5 seconds.
4. Select Specific DTC. Enter OTC P0785.
Has the test run and passed?

n
Go to Step 14

Go to Step 15

Go to
Diagnostic Aids

Go to Step 13

Go to Step 14

Go to Step 15

Go to Step 16
-

Go to Step 16

System OK

Go to Step 1

7-194

Automatic Transmission - 4L60-E

TransmissionfTransaxle

DTC P181 O TFP Valve Position .Switch Circuit (3.8.L)

::~~; t
I
I

~;~

rr::-1

t ~; I ,~, f
c

~~:~:;c~

L.J

1 >.

I
_I~

Signal

L-------------------------------~-..1

0.5 p::1:~4

05 B::1225 0~5R-~:1~

o.5

OK

N
.-

Er

PNJ-1224

o.5 DK BLUh22s

cl

REV

o.s ORNh2~~

DI

D3
Switch

Switch

LO
Switch

6B~

0.5 YEL/BLK 1227

P
L

} -- -

20 -Way Connector

- - ~.: ~;NG221

, ATutomaJic.

Al

ransm1ss1on
Aufomatic
Transmission
Fluid Pressure
(TFP) Manual
Valve Position
Switch

D4
Switch

Transmission
Fluid
Temperature
(TFT)
Sensor

D2

sr..

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

0.5 GRY-Jt52

______ -

_.

M ._____ 20 -Way Connector

0.5 GAY 720
Sensors
Cell20

.,..._ - -

8121

0.5 GAY 720

-I- --,

35 C2
T -

I
I

sensor
Ground .

Powertrain
I Control
1 Module (PCM)
I

L-----..1

>

193768

Circuit Description
The Automatic Transmission Fluid Pressure Manual
Valve Position Switch (TFP Val. Position Sw.) consists
of five pressure switches (two normally-closed and
three normally-open) and a Transmission Fluid
Temperature (TFT) sensor combined into one unit.
The combined unit mounts on the valve body.
The Powertrain Control Module (PCM) supplies the
battery voltage for each range signal. By grounding
one or more of the circuits through various
combinations of the pressure switches, the PCM
detects which manual valve position you select. The
PCM compares the actual voltage combination of
the switches to a TFP Val. Position Sw. combination
table stored in memory.

The TFP Val. Position Sw. cannot distinguish between

Park and Neutral because the monitored valve body
pressures are identical. With the engine OFF and
the ignition switch in the RUN position, the TFP Val.
Position Sw. indicates Park/Neutral. Disconnecting the
transmission 20-way connector removes the ground
potential for the three range signals to the PCM. In this
case, with the engine OFF, and the ignition switch
in the RUN position, 02 will be indicated.
When the PCM detects an invalid state of the TFP
Val. Position Sw. or the TFP Val. Position Sw. circuit
by deciphering the TFP Val. Position Sw. inputs,
then OTC P1810 sets. DTC P1810 is a type B OTC.

Transmission/Transaxle
Conditions for Setting the DTC
OTC P1810 sets if any of the following Conditions
occurs two consecutive times:
Condition 1 detects an illegal switch combination.
Condition 2 detects 02, 04 or Rev during an
engine start.
Condition 3 detects Park or Neutral when the
vehicle should be in 04.

Condition 1
The system voltage is 8-16 volts.
The engine speed is greater than 450 RPM for
5 seconds.
Not in fuel cutoff.
The PCM detects an illegal TFP Val. Position
Sw. state.
All conditions met for 60 seconds
Condition 2
No VSS Assy. DTCs P0502 or P0503.
The system voltage is 8-16 volts.
The engine speed is less than 100 RPM for
0.1 second; then
the engine speed is 100-600 RPM for
0.5 second; then
the engine speed is greater than 600 RPM.
The vehicle speed is less than 3 km/h (2 mph).
The detected gear range is 02, 04 or Rev.
All conditions met for 5 seconds
Condition 3
No VSS Assy. DTCs P0502 or P0503.
The selected gear range is 04.
The engine speed is greater than 450 RPM for
5 seconds.
Not in fuel cutoff.
The speed ratio is 0.65-0.75 (the speed ratio is
the engine speed divided by the transmission
output speed).
The system voltage is 8-16 volts.
The TP angle is 7-50%.
The engine torque is 50-450 lbs ft.
The engine vacuum is 0-105 kPa.
The TCC is locked ON.
The detected gear range is Park/Neutral.
All conditions met for 1O seconds

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL).
The PCM commands 02 line pressure.
The PCM commands a 04 shift pattern.
The PCM freezes shift adapts from being updated.
OTC P1810 stores in PCM history.

Automatic Transmission - 4L60-E

7-195

Conditions for Clearing the MIL/DTC

The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
A scan tool can clear the OTC from the PCM
history. The PCM clears the OTC from the
PCM history if the vehicle completes 40 warm-up
- cycles without a failure reported.
The PCM cancels the OTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Diagnostic Aids
Refer to the TFP Valve Position Switch Logic
table for the normal range signals and the
illegal combinations. In the table, ON is O volts,
OFF is 12 volts.
Inspect the wiring at the PCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
When diagnosing for an intermittent short or open
condition, massage the wiring harness while
watching the test equipment for a change.
Refer to TFP Manual Valve Position Switch
Resistance Check or Functional Test Procedure
.for further information.

TFP Manual Valve Position Switch Logic

Gear
Position

Range
Signal A

Range
Signal B

Range
Signal C

Park

OFF

ON

OFF

Reverse

ON

ON

OFF

Neutral

OFF

ON

OFF

04

OFF

ON

ON

03
02
01

OFF

OFF

ON

OFF

OFF

OFF

ON

OFF

OFF

Illegal

ON

OFF

ON

Illegal

ON

ON

ON

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step tests the indicated range signal to the
manual valve actually selected.
4. This step tests for correct voltage from the PCM
to the transmission 20-way connector.

7-196

Automatic Transmission .. 4L60-E

Transmission!Transaxle

DTC P181 O TFP Valve Position Switch Circuit (3.8L)

Step

Action

Was the Powertrain On-Boartl Diagnostic (OBD) System

Check performed?

Perform the following inspections:

Ensure that the transmission linkage from the select
lever_ to the manual valve is,adjusted properly.
Perform the fluid checking procedure.

Value(s)

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
. (OBD)
System Check

Go to Step 3

Did you perform the inspections?

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the scan tool
in order to record 1he Freeze Frame .and Failure Records
for refere.nce. Using the Clear Into function will erase the
stored Freeze Frame and Fail1.ire Records from the PCM.
3. Record the OTC Freeze Frame and Failure Records,
then clear the DTC(s).
4. While the engine is idling at normal operating
temperature, apply the parking brake.

Yes

5. Select each transmission range: P, R, N, 04, 03, 02

and 01.
Does each selected transmission range match the scan
tool TFP Switch A/B/C display?
Refer to the TFP Valve Position Switch Logic table.

Go to
Diagnostic Aids

Go to Step 4

1. Turn the ignition OFF.

2. Disconnect the transmission 20-way connector

(additional DTCs may set).

3, Install the J 39775 Jumper Harness on the engine
side of the transmission 20-way connector.
4. With the engine OFF, turn the ignition switch to the
RUN position.
5. Using the J 39200 Digital Multimeter (DMM) and
J 35616~A. Connector Test Adapter Kit, check the
voltage at connector terminals.N, Rand P.

)
-

Is B+ displayed on all three cfrcuits?

Go to Step 6

Go to Step 5

Go to Step 9

Go to Step 7

Go to Step B

Refer to TFP
Manual Valve
Position Switch
Resistance Check

1. Inspect the circuits that did not indicate B+ for an

5

open or short to ground condition.

Refer to General Electrical Diagnosis Procedures.

2. Repair the circuits if necessary.

Refer to Wiring Repairs.

Did you find an open or short to ground condition?

In orqer to verity that circuit 1224 (PNK), circuit 1225

(DK BLU) and circuit 1226 (RED) are not shorted together,
use a fused jumper to ground on each circuit while
monitoring the scan tool TFP Switch A/B/C display.
When a range signal circuit is grounded, are any other
range signal circuits affected?

Replace the PCM.

Refer to PCM Replacement/Programming.
Is the replacement complete?

Go to Step 9
\

Transmission!Transaxle

Automatic Transmission - 4L60-E 7197

OTC P181 O TFP Valve Position Switch Circuit (3.8L) (cont'd)

Step
8

Action

Value(s)

Repair the affected wiring as necessary.

Refer to Wiring Repairs.
Is the repair complete?

In order to verify your repair, perform th.e foHowing

procedure:
1. Select OTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
3.1. With the engine OFF, turn the ignition switch
to the RUN position for at least 2 seconds.
3.2. Start the vehicle and idle for 5 seconds.
3.3. Drive in 04 until the TCC locks for
10 seconds.
3.4. The engine must be running for at least
60 seconds from start up.
4. Select Specific OTC. Enter OTC P1810.
Has the test run and passed?

Yes

No

Go to Step 9

System OK

Go to Step 1

7-1.98

Automatic Transmission - 4L60-E

TransmissionFTransaxle

OTC P1810 TFP Valve Position Switch Circuit (5.7L)

s+

: Ratine.
Signal

I
I

R~ue. TE!

B+

Ratine
Signal

sv

B+

Signal

Signal

, Powerttain

.S8[1SQf .

- -

Control (PCM)
_Mo.dule

I
_i,
I~

0.5 P::1224 -05p~-~:12~5 - 0:5::~1;:/EL/B:e~~-. 20-.

N

o.s

~ Way

PNJ12-2: --------o~5-D~ ~~uf2~; -----~-~ ~;~h 2~~ --~.: ~~Nh227

Cl
Er
ol
Al
REV

D3
Switch

Switch

LO
Switch

...

~ ATutomaJic.
ranSmlSSl<;>n
Automatic
Transmission
Fluid Pressure

04

Connector

(TFP} llilanual
Valve Position
.Switch

Switch

Transmission

Fluid

02

Temperature
(TF1)

Sensor

sr..

_______________________

O.SGRY-J.:':52

________ -

20-Way Connector

0.5 ORN/BLK 1057

-I- --,

14 C2

Powertrain

r I sensor

I Ground

I._

I Control

I Module (PCM)

_____ .
~

_i,

168436

Circuit Description
The Automatic Transmission Fluid Pressure Manual
Valve Position Switch (TFP Val. Position Sw.) consists
of five pressure switches (two normally-closed and
three normally-open) and a Transmission Fluid
Temperature (TFT) sensor combined into one unit.
The combined unit mounts on the valve body.
The Powertrain Control Module (PCM) supplies the
battery voltage for each range signal. By grounding
one or more of the circuits through various
combinations of the pressure switches, the PCM
detects which manual valve position you select. The
PCM compares the actual voltage combination of
the switches to a TFP Val. Position Sw. combination
table stored in memory.

The TFP Val. Position Sw. cannot distinguish between

Park and Neutral because the monitored valve body
pressures are identical. With the engine OFF and
the ignition switch in the RUN position, the TFP Val.
Position Sw. indicates Park/Neutral. Disconnecting the
transmission 20-way connector removes the ground
potential for the three range signals to the PCM. In this
case, with the engine OFF, and the ignition switch
in the RUN position, 02 will be indicated.
When the PCM detects an invalid state of the TFP
Val. Position Sw. or the TFP Val. Position Sw. circuit
by deciphering the TFP Val. Position Sw. inputs,
then OTC P1810 sets. OTC P1810 is a type B OTC.

Transmission/Transaxle
Conditions for Setting the QTC
DTC P181 O sets if any of the following Conditions
occurs two consecutive times:
Condition 1 detects an illegal switch combination.
Condition 2 detects 02, 04 or Rev during an
engine start.
Condition 3 detects Park or Neutral when the
vehicle should be in 04.

Condition 1
The system voltage is 8-16 volts.
The engine speed is greater than 450 RPM for
5 seconds.
Not in fuel cutoff.
The PCM detects an illegal TFP Val. Position
Sw. state.
All conditions met for 60 seconds
Condition 2
No VSS Assy. DTCs P0502 or P0503.
The system voltage is 8-16 volts.
The engine speed is less than 80 RPM for
0.1 second; then
- the engine speed is 80-550 RPM for
0. 7 second; then
- the engine speed is greater than 550 RPM.
The vehicle speed is less than 3 km/h (2 mph).
The detected gear range is 02, 04 or Rev.
All conditions met for 5 seconds
Condition 3
No VSS Assy. DTCs P0502 or P0503.
The selected gear range is 04.
The engine speed is greater than 450 RPM for
5 seconds.
Not in fuel cutoff.
The speed ratio is 0.65-0.80 (the speed ratio is
the engine speed divided by the transmission
output speed).
The system voltage is 8-16 volts.
The TP angle is 8-45%.
The engine torque is 40-400 lbs ft.
The engine vacuum is 0-105 kPa.
The TCC is locked ON.
The detected gear range is Park/Neutral.
All conditions met for 1O seconds

Action Taken When the DTC Sets

(
\

The PCM illuminates the Malfunction Indicator

Lamp (MIL).
The PCM commands 02 line pressure.
The PCM commands a 04 shift pattern.
The PCM freezes shift adapts from being updated.
DTC P1810 stores in PCM history.

Automatic Transmission - 4L60-E 7-199

Conditions for Clearing the MIL/DTC
The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the DTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Diagnostic Aids
Refer to the TFP Valve Position Switch Logic
table for the normal range signals and the
illegal combinations. In the table, ON is O volts,
OFF is 12 volts.
Inspect the wiring at the PCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal
- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
When diagnosing for an intermittent short or open
condition, massage the wiring harness while
watching the test equipment for a change.
Refer to TFP Manual Valve Position Switch
Resistance Check or Functional Test Procedure
for further information.

TFP Manual Valve Position Switch Logic

Gear
Position

Range
Signal A

Range
Signal B

Range
Signal C

Park

OFF

ON

OFF

Reverse

ON

ON

OFF

Neutral

OFF

ON

OFF

04

OFF

ON

ON

03
02
01

OFF

OFF

ON

OFF

OFF

OFF

ON

OFF

OFF

Illegal

ON

OFF

ON

Illegal

ON

ON

ON

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step tests the indicated range signal to the
manual valve actually selected.
4. This step tests for correct voltage from the PCM
to the transmission 20-way connector.

7-200

TransmissionfTransaxle

Automatic Transmission - 4L60-E

OTC P1810 TFP Valve Position Switch Circuit (5.7L)

Step

Action

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
1

Perform the following inspections:

Ensure that the transmission linkage from the select
lever to the manual valye is adjusted properly.

Value(s)

1. Turn the ignition OFF.

2. Disconnect the transmission 20-way connector
(additional DTCs may set).
3. Install the J 39775 Jumper Harness on .the engine
side of .the 20-way conr,ector.
4. With the engine OFF, turn the ignition switch to the
RUN position.
5. Using the J 39200 Digital Multimeter (DMM) and the
J 35616-A Connector TestAdapterKit, check the
voltage at connector terminals N, Rand P.

,.

Go to Step 3

Go to
Diagnostic Aids

Go to Step 4

)
-

Go to Step 5

Go to Step 6

Refer to Wiring Repairs.

Did you find an open or short to ground condition?

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(080)
System Check

Is B+ displayed on all three circuits?

1. Inspect the circuits that did not indicate B+ for an
open or short to ground condition.
Refer to General Electrical Diagnosis Procedures.
2. Repair the circuits if necessary.

No

Perform the fluid checking procedure.

Did you perform the inspections? .
1. Install the Scan Tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Before clearing the DTCs, use the scan tool in
oreer to record the Freeze Frame and Failure Records for
reference. Using the Clear Info function will erase the
stored Freeze Frame and Failure Records from the PCM.
3. Record the OTC Freeze Frame and Failure Records,
then clear the DTC(s).
4. While the engine is idling at normal operating
temperature, apply the parking brake.
5. Select each transmission range: P, R, N, 04, 03, 02
and 01.
Does each selected transmission range match the scan
tool TFP Switch A/B/C display?
Refer to the TFP Valve Position Switch Logic table.

Yes

Go to Step 7

Go to Step 9

In order to verify that circuit 1224 (PNK), circuit 1225

(DK BLU) and circuit 1226 (RED) are not shorted together,
use a fused jumper to ground on each circuit while
monitoring the scan tool TFP Switch A/B/C display.
When a range signal circuit is grounded, are any other
range signal circuits affected?'

Replace the PCM.

Refer to PCM Replacement/Programming.
Is the replacement complete?

Go to Step 8

Go to TFP
Manual Valve
Position Switch
Rt:!sistance Check

Goto Step 9

Automatic Transmission - 4L60-E 7-201

Transmission/Transaxle

OTC P1810 TFP Valve Position Switch Circuit (5.7L) (cont'd)

Step

Action

Value(s)

Repair the affected wiring as necessary.

Refer to Wiring Repairs.
Is the repair complete?

In order to verify your repair, perform the following

procedure:
1. Select OTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
3.1. With the engine OFF, turn the ignition switch
to the RUN position for at least 2 seconds.
3.2. Start the vehicle and idle for 5 seconds.
3.3. Drive'in 04 until the TCC locks for
10 seconds.
3.4. The engine must be running for at least
60 seconds from start up.
4. SelectSpecific OTC. Enter OTC P1810.
Has the test run and passed?

Yes

No
-

Go to Step 9

System OK

Go to Step 1

7"'.202

Transmission/Iransaxle

Automatic Transmissibn - 4L60-E

DTC P1860

rec PWM s.olenoid Ci.rcuit l!l~trical,{3.8L)

- oc
~

Automatic
Transmission

iHot In Run, Bulb TesfAnd Startt

Power

Distribution
ce1110

ENG CTRL
MiniFuse
15A

L------

-: ~

I
I

I TCC
, '
Solenoid
I Valve

Electrical
Center 2

- - - - - -,

0.5 PNK 239

0.5 PNK 239

0.5 PNK 239
8107

- - ....

~ , - .~ - . ' ~ ,

'o.5 RED 839

1 ~ 2-Shift

Sofehoid
Valve

3-2Shift
I Solenoid
I Valve

-----J

G C100

0.5 PNK 239

S182

IMAIJ

.... ~ "".T"'~:- - . - -

Underhood

: Assembly

_A

[]Lill ~~:~~er

..
I

Fuse Block
Details
Cel111

I
I

I
I

,e~

2-3Shifl
Solenoid
Valve

Clutch
Pulse Width
Modulation
Solenoid
(TCC
PWM SOL.)
Valve

o,-STAN 418

~-~------ . . -~-----~
~o -

UI: .

Way Connector

0.5 BRN 418

=L

78 C2
. r-------------,
Powertram 1
TCC PWM I
Control , TCC PWM
Solenoid I
Module I Solenoid
--, Valve
I
(PCM)I Fe~~~=ck
Control
I

J.

-!
.. ___________
..

193847

Circuit Description
The Torque Converter Clutch Pulse Width Modulation
Solenoid Valve (TCC PWM Sol. Valve) controls the
fluid acting on the converter clutch valve. The
converter clutch valve controls the TCC application
and release. The solenoid attaches to the control valve
body within the transmission. The solenoid receives
ignition voltage through circuit 239. The Powertrain
Control Module (PCM) controls the solenoid by
providing a ground path on circuit 418. Current flows
through the solenoid coil according to the duty
cycle (percentage of ON and OFF time). The TCC
PWM Sol. Valve provides a smooth engagement of the
torque converter clutch by operating during a duty
cycle percent of ON time.
When the PCM detects a continuous open or short to
ground in the TCC PWM Sol. Valve circuit or the
TCC PWM Sol. Valve, then DTC P1860 sets.
DTC P1860 is a type A DTC.

Conditions for Setting the DTC

The system voltage is 8-16 volts.
The engine speed is greater than 450 RPM for
5 seconds.
Not in fuel cutoff.
The PCM commands first gear.
The TCC duty cycle is less than 10% or greater
than 90%.
All of the above conditions are met for 5 seconds
and either of the following fail conditions occurs
for 5 seconds:
- The PCM commands the solenoid ON (90%)
and the voltage input remains high (B+).
- The PCM commands the solenoid OFF (0%)
and the voltage input remains low (0 volt).

Transmission!Transaxle
Action Taken When the OTC Sets
The PCM illuminates the Malfunction Indicator
Lamp. (MIL).
The PCM inhibits TCC engagement.
The PCM inhibits 4th gear if the transmission is in
~ot mo.de.
The PCM freezes shift adapts from being updated.
OTC P1860 stores in PCM history.

Conditions for Clearing the MIUDTC

The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
A scan tool can clear the DTC from the PCM
history. The PCM clears the DTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the DTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Diagnostic Aids
Inspect the wiring at the PCM, the transmission
connector and all other circuit connecting points.
for the followtng conditions:
- A bent terminal
- A backed out terminal

Automatic Transmission - 4L60... E 7-203

- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
When diagnosing for an intermittent short or open
condition, massage tt'\e wiring harness while
watching the test equipment for a change.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
4. This step tests forvoltage to the solenoid.
6. This step tests the ability of the PCM and wiring
to control the ground circuit.
8. This step tests the resistance of the TCC PWM
Sol. Valve and.the Automatic Transmission
Wiring Harness Assembly (A!f Wiring Harness
Assembly).

7-204

Automatic Transmission .. 4L60-E

TransmissionfTransaxle

OTC P1860 TCC PWM Solenoid Circuit Electrical (3.BL)

Step

Action

Value(s)

Yes

No

Goito Step 2

Go to A
Powertraih On
Board Diagnostic
(080) System
Check in Engine
Controls

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?
;,

'

,,

1. Install the Scan Tool.

2. With the engine OFF, turh the ignition switch to the
-' '
RUN position.
2

Important: Before clearing the OTG(~). use, th,~ scan tool

in order to record the Freeze Frame and Failure Records
for reference. Using the Clear, Info function will erase the
stored Freeze Frame and Failure Records from.the PCM.
3. Record the DTC Freeze Frame and Failure Records,
. c then clear the DTC(s) .
''
Are
PO? 40, P0753, P0758 anp .P0785 aJso set?

ores

,'

,,

1. Inspect the ENG CTRL fuse.

2. If the fuse is open, inspect circuit 239 (PNK), the
solenoids and the A!T Wiring Harness Assembly for a
short to ground. Repair the.circuit, the solenoids and
the harness if necessary.
Refer to General Electrical Diagnosis Procedures in Wiring
Systems.
Did you find a short to ground condition?

1. Turn the ignition OFF.

2. Disconnect the transmission 20-way connector
(additional DTCs may set).
3. Install J 39775 Jumper Harness on the engine side of
the 20-way connector.
4. With the engine OFF, turn the ignition switch to the
RUN position.
5. Connect a lest lamp from J 39775 Jumper Harness
cavity E to ground.
Is the test lamp on?

Repair the open or short to ground in ignition feed

circuit 239 (PNK) to the TCC PWM Sol. Valve.
Refer to Wiring Repairs in Wiring Systems.
Is the repair complete?

1. Install the test lamp from cavity E to cavity U of the

J 39775 Jumper Harness.
2. Using the transmission output control function on the
scan tool, command the TCC PWM Sol. Valve ON
and OFF three times.
Does the test lamp turn ON when the TCC PWM Sol.
Valve is commanded ON, and OFF when
commanded OFF?

Goto Step 3

Go to Step 4

Go to Step 15

Go to Step 4

Go to Step 6

Go to Step 5

Go to Step 15

Go to Step B

Go to Step 7

Go to Step 15

Go to Step 9

1. Inspect circuit 418 (BRN) of the engine wiring

harness for an open, short to ground or short to

power condition.
Refer to General Electrical Diagnosis Procedures in
Wiring Systems.
2. Repair the circuit if necessary.
Refer to Wiring Repairs in Wiring Systems.
Did you find an open, short to ground or short to power
condition?

Transmission!Transaxle

Automatic Transmission - 4L60-E

7;.205

OTC P1860 TCC PWM Solenoid Circuit Electrical (3 8L) (cont'd)

Step

'

10

11

12

13

14

15

Action

1. Install J 39775 Jumper Harness on the transmission

side of the 20-way conn~ctor.
2. Using the J 39200 Digital Multimeter (DMM) and the
J 35616-A Connector Test Adapter Kit, measure the
resistance between terminals E and U,
Is the resistance within the specified range?
Replace the PCM.
Refer to PCM Replacement/Programming in Engine
Controls.
Is the replacement complete?
1. Disconnect the A/T Wiring Harness Assembly at the
TCC PWM Sol. Valve.
2. Measure the resistance of the TCC PWM Sol. Valve.
Is the resis.tance within the specified range?
Measure the resistance between terminal E and ground,
and between terminal U and ground.
Are both readings greater than the specified value?
1. Disconnect the A/T Wiring Harness Assembly at the
TCC PWM Sol. Valve.
2. Measure the resistance between each of the
component terminals and ground.
Are both readings greater than the specified value?
Replace the A/T Wiring Harness Assembly.
Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring
Harness Replacement.
Is the replacement complete?
Replace the TCC PWM Sol. Valve.
Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring
Harness Replacement.
Is the replacement complete?
In order to verify your repair, perform the fo.llowing
procedure:
1. Select DTC.
2. Select Clear Info.
3. Drive the vehicle in 04 range with the TCC ON.
Ensure that the following conditions are met:
The PCM commands the TCC PWM Sol. Valve
ON, and the voltage input drops to zero.
The PCM commands the TCC PWM Sol. Valve
OFF, and the voltage input increases to B+.
All conditions met for 5 seconds.
4. Select Specific DTC. Enter DTC P18f;30.
Has the test run and passed?

Value(s)

.No

Yes

..
10-15 fl
Go to Step 11

Go to. $tep 10

Go to Step 15

10-15 n

250 KO

Go to Step 13

Go to Step 14

Go to
Diagnostic Aids

Go to Step 12

Go to Step 13

Go to Step 14

250KO

Go to Step 15

Go to Step 15
;

.\

('

.,

'

'

..

'

System OK

'

Gd to Step 1

7-206

Automatic Transmission - 4L60-E

TransmissionJTransaxle

OTC P1860 TCC PWM Solenoid Circuit Electrical (5.7L)

!Hot In Run, Bulb Test And Start!

,. - P:;-~ - - - - - - - - ., Underhood
Distribution
Cell 10

ENG CTRL
Mini Fuse
15A

L.-~----

Automatic
Transmission

: Electrical

,.----------------.,

Center # 2

TCC
Solenoid
Valve

_...;._.....;_J

0.5 PNK 239

s1a2----~

1-2 Shift
Solenoid
Valve

3-2Shitt
Solenoid
Valve
Assembly

0.5 PNK 239

0.5 PNK 239

Fuse Block
Details
Cell11

L'..tiJ

Torque
Converter
Clutch
[ ] ] Pulse Width
Modulation
Solenoid
B
(TCC PWM SOL)
Valve

G"'C100

- - -+

2-3Shift
Solenoid
Valve

0.5 PNK 239 O.S PNK 2~9

S107

t
. LIE
~:~

8- -

20 - Way Connector

0.5 BRN 418

33 c2
Powertrain '" - - - - - - - - - - - "'
.

.. 1

Control I
Module I
.6.
~

.liiJ4.

TCC PWM
Solenoid
(PCM) I Feedback
Valve

TCCPWM
Solenoid
......, Valve
.._ Control
~

1
I
I
I

L------------'

168445

Circuit Description
The Torque Converter Clutch Pulse Width Modulation
Solenoid Valve (TCC PWM Sol. Valve) controls the
fluid acting on the converter clutch valve. The
converter clutch valve controls the TCC application
and release. The solenoid attaches to the control valve
body within the transmission. The solenoid receives
ignition voltage through circuit 239. The Powertrain
Control Module (PCM) controls the solenoid by
providing a ground path on circuit 418. Current flows
through the solenoid coil according to the duty
cycle (percentage of ON and OFF time). The TCC
PWM Sol. Valve provides a smooth engagement of the
torque converter clutch by operating during a duty
cycle percent of ON time.
When the PCM detects a continuous open or short to
ground in the TCC PWM Sol. Valve circuit or the
TCC PWM Sol. Valve, then DTC P1860 sets.
DTC P1860 is a type A DTC.

Conditions for Setting the DTC

The system voltage is 8-16 volts.
The engine speed is greater than 450 RPM for
5 seconds.
Not in fuel cutoff.
The PCM commands first gear.
The TCC duty cycle is less than 10% or greater
than 90%.
All of the above conditions are met for 5 seconds
and either of the following fail conditions occurs
for 5 seconds:
- The PCM commands the solenoid ON (90%)
and the voltage input remains high (B+).
- The PCM commands the solenoid OFF (0%)
and the voltage input remains low (0 volt).

Transmission!Transaxle
Action Taken When the DTC Sets
The PCM illuminates the Malfunction Indicator
Lamp (MIL).
The PCM inhibits TCC engagement.
The PCM inhibits 4th gear if the transmission is in
hot mode.
The PCM freezes shift adapts from being updated.
OTC P1860 stores in PCM history.

Conditions for Clearing the MIUDTC

The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
A scan tool can clear the OTC from the PCM
history. The PCM clears the OTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the OTC default actions when
the fault no tonger exists and the ignition is
OFF long enough in order to power down
the PCM.

Diagnostic Aids
Inspect the wiring at the PCM, the transmission
connector and all other circuit connecting points
for the following conditions:
- A bent terminal
- A backed out terminal

Automatic Transmission - 4L60-E

7-207

- A damaged terminal
- Poor terminal tension
- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
- Corrosion
When diagnosing for an intermittent short or open
condition, massage the wiring harness while
watching the test equipment for a change.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
4. This step tests for voltage to the solenoid.
6. This step tests the ability of the PCM and wiring
to control the ground circuit.
8. This step tests the resistance of the TCC PWM
Sol. Valve and the Automatic Transmission
Wiring Harness Assembly (A/T Wiring Harness
Assembly).

7-208 Automatic Transmission -.. 4L60-E

TransmissionlTransaxle

DTC P1860 TCC PWM Solenoid Circuit Electrical (5.7L)

Acticm

Step

Value(s)

Yes

No

Go to Step 2

Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check in Engine
Controls

Was the Powertrain On-Board Diagnostic (OBD) System

Check perf()rmed?

'

1. lnsU;lll the Scan Toof.

: -

'

''

2,. With the E:lngine OFF, .turn tile ignition switch to the
RUN position.
Important: Before clearing the DTC(s), use the'scan tool
i~ ,order to recon::t the Freeze Frarrie and Failure Records
for reference. Using the Clear Info function will erase the
stored Freeze Frame and Failure ~~cords from the PCM.
,:3_ Record the c:nc Freeze Frame and Failure Records,
,. , then clear the DTC(s).
4. Are DTCs P0740, P0753, P0758.and 'po785
also set?
,.
,1.; Inspect the ENG CTRL fuse,
, 2. If the fuse is open, inspect circuit ?39 (PNK), the
solenoids and the A/T Wiring Hame~s Assembly for a
short to ground. Repair the circuit, the solenoids, and
the harness if necessary.
Refer to General Electrical Diagnosis Procedures in Wiring
Systems.
Did you find a short to ground condition?

'

(3o to Step 4

Go to Step 3

<;.

Go to Step 15

Go to Step 4

Go to Step 6

Go to Step 5

1. Turn the ignition OFF.

2. Disconnect the transmission 20-way connector
(additional DTCs may set).

3. Install J 39775 Jumper Harness on the engine side of

the connector.
4. With the engine OFF, turn the ignition switch to the
RUN position.

5. Connect a lest lamp from J 39775 Jumper Harness

cavity E to ground.
Is the test lamp on?

Repair the open or short to ground in ignition feed

circuit 239 (PNK) to the TCC PWM Sol. Valve.
Refer to Wiring Repairs in Wiring Systems.
Is the repair complete?

1. Install the test lamp from cavity E to cavity U of the

J 39775 Jumper Harness.
2. Using the transmission output control function on the
scan tool, command the TCC PWM Sol. Valve ON
and OFF three times.
Does the test lamp turn ON when the TCC PWM Sol.
Valve is commanded ON, and OFF when
commanded OFF?

1. Inspect circuit 418 (BRN) of the engine wiring

harness for an open, short to ground or short to
power condition.
Refer to General Electrical Diagnosis Procedures in
Wiring Systems.
2. Repair the circuit if necessary.
Refer to Wiring Repairs in Wiring Systems.
Did you find an open, short to ground or short to power
condition?

Go to Step 15

Go to Step B

Go to Step 7

Go to Step 15

Go to Step 9

Transmission!Transaxle

Automatic Transmission -4L60-E

7-209

DTC P1860 TCC PWM Solenoi!=f Circuit Electrical (5.7L) (cont'd)

Step

10

Action

Value(s)

1. Install J 39775 Jumper Harness on the transmission

side of the 20-way connector.
2. Using the J 39200 Digital Multimeter (DMM) and the
J 35616-A Connector Test Adapter Kit, measure the
resistance between terminals E and U.
Is the resistance within the specified range?

12

Go to. Step 11

Go to Step 10

..

Replace the PCM.

Refer to PCM Replacement/Programming.in Engine
Controls.
Is the replacement complete?

Go to Step 15

1. Disconnect ttJe Alf Wiring Harness Assembly at the

TCC PWM Sol. Valve.,,
2. Measure the resistance ..of the TCC PWM Sol. Valve.

10-15 n

Measure the resistance be~~en term.inal E and:a known

good ground, and between terminal U and groun~.
Are both readings greater than the specified value?

250KQ

1. Disconnect the Alf Wiring Harness Assembly at the

TCC PWM Sol. Valve.
2. Measure the resistanqe .between each of the
component terminal!;
a known good ground.

Go to Step 13

Go to Step 14

Go to
Diagnostic Aids

Go to Step 12

Go to Step 13

Go to Step 14

250KQ

and

Are both readings greater than the specified value?

13

No

10-15 n

Is the resistance within the $pacified range?

11

Yes

Replace the Alf Wiring Harness Assembly.

Refer to TCC PWM Solenoid, TCC Solenoid, and.Wiring
Harness Replacement.
Is the replacement complete?

Go to Step 15

Replace the TCC PWM Sol. Valve.

14

Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring

Harness Replacement.
Is the replacement complete?

Gp to Step 15

In order to verify your repair, perform the following

procedure:
1. Select DTC.
2. Select Clear Info.
3. Drive the vehicle in D4 with the TCC ON. Ensure the
following conditions are met:
15

The PCM commands the TCC PWM Sol. Valve

ON, and the voltage input dr9ps to zer9.
The PCM commands the TCC PWM Sol. Valve
OFF, and the voltage input increases to B+.
All conditions met for 5 seconds.
4. Select Specific DTC. Enter DTC P1860.
Has the test run and passed?

'

1:

System OK

Go to Step 1

7-21 O Automatic Transmission - 4L60-E

TransmissJon/Transaxle

OTC P1870 Transmission Component ~lipping (3.SL)

I - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ""\Automatic
I
Torque

1Transmission
I
I
I

Converter
Assembly

I
I
I
I
I
.1
I
I

LINE(From Pump)

42275

Shift Solenoid
Range
Overdrive

Gear

4th

1-2
ON

2-3
OFF

TCC
Solenoid
ON

TCC PWM
Solenoid
90% (ON)

Circuit Description
The Powertrain Control Module (PCM) monitors the
difference between engine speed and transmission
output speed. In 03 drive range with the TCC
engaged, the engine speed should closely match the
transmission output speed. In 04 drive range, with
the TCC engaged, the TCC slip speed should be

2-4 Band
Applied

Forward
Clutch
Applied

3-4 Clutch
Applied

Torque
Converter
.Clutch
Applied

-20 to +50 RPM. The table above indicates solenoid

states and transmission components that apply, during
4th gear, with the TCC commanded On.
Whenthe PCM detects excessive TCC slip when the
TCC should be engaged, then OTC P1870 sets.
OTC P1870 is a type B OTC.

Transmiss1onJTransaxle
Conditions for Setting the DTC
DTC P1870 sets if the following conditions are met .for
three TCC cycles with reported excessive TCC slip
conditions, two consecutive times.
No TP Sensor DTCs P0122 or P0123.
No VSS Assy. DTCs P0502 or P0503.
No TCC Sol. Valve DTC P07 40.
No 1-2 SS Valve DTC P0753. :
No 2:-3 SS Valve DTC P0758.
No 3-2 SS Valve Assy. DTC P0785.
No TCC PWM Sol. Valve DTC P1860.
The engine speed is greater than 450 RPM for
5 seconds.
Not in fuel cutoff.
The vehicle speed is 48-120 km/h (30-75 mph).
The speed ratio is 0.65-0.98 (the speed ratio
is the engine.speed divided by the output speed).
The engine speed is 1000-3000 RPM.
The engine torque is 40-450 lbs ft.
The gear range is 04.
Not in 1st gear
The TP angle is 8-35%.
The TFT is between 20-1300 (68-266F).
The TCC is commanded On for 5 seconds.
The TCC is ~t maximum duty ~ycle for 3 seconds.
The shift solenoid performance diagnostic
counters are .zero.
The TCC slip speed is 200-800 RPM.
All conditions met for 7 seconds.
Important: The following actions may occur before
the DTC sets.
If the TCC is commanded On and at maximum
apply for 5 seconds, the TP angle is 7-40%,
and the transmission slip counter has incremented
to either 1 or 2 (out of 3 to increment the fail
counter for the current ignition cycle), then
the following slip conditions and actions may
increment the fail counter for the current
ignition cycle:
These conditions must occur sequentially.
- Condition 1 If the TCC slip speed is
200-800 RPM for 7 seconds, then the PCM
will command maximum line pressure
and freeze shift adapts from being updated.

Automatic Transmission - 4L60-E

i_

1..211

Conditi6n 2 If Condition 1 is met and the

TCC slip speed is 200-800 RPM for
7 seconds; then the PCM will command the.
TCC OFF for 1.5 seconds.

- Condition 3 If Condition 2 is met and the

TCC slip speed is 200-800 RPM for
7 seconds, then the fail counter on the
currentignition cycle is incremented.
Two consecutive fail COL!nts are required to
set DT9 P1870 (type B).
The above slip conditions and actions may be
disregarded if the TCC is commanded OFF at any
timEl as a result of. a driving maneuver (sudden
acceleration or deceleration).

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Jndicator
Lamp (Mil).
The PCM inhibits.TCCengagement.
The PCM commands maximum lir;ie prElssure.
The PCM inhibits 4th gear if the transmission is in
. hot mode.
The PCM .freezes shift adapts from being updated.
DTC P1870 stores in PCM history.

Conditions for Clearing the MIUDTC

The PCM turns OFF the MIL after three
consecutive trips without a failure reported.

A scan tool can clear the DTC from the PCM

history. The PCM clears the DTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the DTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM.

Diagnostic Aids
Internal transmission failures could set OTC P1870.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step tests the torque converter for slippage
while in a commanded. lock:-up state.

7-212

TransmissionfTransaxle

Automatic Transmission .. 4L60-E

OTC P1870 Transmission Component Slipping (3.8L)

Action

Step

Value(s)

Was the Powertrain On.Board Diagnostic (OBD) System

Check performed?

1'

No

Go to Step 2

Go .to A
Powertrain On
Board Diagnostic
{080)
System Check

Goto Step 3

Go to
Transmission
Fluid Checking
ProcedtJre

Go to Step 4

Go to
Diagnostic Aids

Go to Step 13

Go to Step 5

Go to Step 13

Go to Step 6

Go to Step 13

Go to Step 7

Go to Step 13

Go to Step 8

'

Yes

'

Perform the transmission fluid checking procedure. Refer

to 4L60-E Transmission Fluid Checking Procedure.
Did you perform the fluid checking procedure?
r.1t1stall the Scan Tool.
2. With the engine OFF, turr\ the ignition switch to the
RUN position,
Important: Before clearing the DTC(s), use the scan tool
in order to record the Freeze Frame and Failure Records
for reference. Using the Clear Info function wm erase the
stored Freeze Frame and Failure Records from the PCM.
3. Record.the. OT,C Freeze Frame and Failure Records,
then clear the DTC(s).
4. Drive the vehicle in 4th gear with the TCC
commanded Or;i.
Is the TCC Slip Speed within the specified .range for
7 seconds?

200-800 RPM

1. Inspect the Torque Cony.erter Clutch Solenoid Valve

(TCC Sol. Valve) for the following conditions:
Internal malfunction (such as sediment or damage)

Damaged seals
2. Inspect the Torque Converter Clutch Pulse Width
Modulation Solenoid Valve (TCC PWM Sol. Valve) for
the following conditions:

Internal malfunction (sch as sediment or damage)

Damaged se.al,s
Did you find a condition?
1. lnspectthe 1-2 Shift Solenoid Valve (1-2 SS Valve)
for the following conditions:
Internal malfunction (such as sediment or damage)

Damaged seals
2. Inspect the 2-3 Shift Solenoid Valve (2-3 SS Valve)
for the following conditions:
Internal malfunction (such as sediment or damage)

Damaged seals
Did you find a condition?
,,

Inspect the valve body assembly for a stuck TCC

signal valve.
Refer fo the Transmission Overhaul Procedure, in Unit
Repair.
Did you find a condition?
Inspect the torque converter assembly for the following
conditions:
Stator roller clutch not holding
Internal damage
Did you find a condition?

Transmission/Transaxle

Automatic Transmission - 4L60-E 7-213

OTC P1870 Transmission Component Slipping (3.8L) (cont'd)

Step

"

Action

Yes

yatue{s).

''

No

,,

Inspect the oil pump assembly for the following conditions:

Stuck converter clutch valve

Converter clutch valve assembled backwards
Mispositioned converter clutch valve retaining ring
Mispositioned pump to case gasket
Restricted orifice cup plugs

Damaged orifice cup plugs

Over-tightened, or unevenly tightened pump body to..
cover bolts
Refer to the Transmission Overhaul Procedure, in Unit
Repair.
Did you find a condition?
'

Go' to Step 13

Inspect the input housing and shaft assembly for the

following conditions:
Cut turbine shaft o-ring seal
Damaged turbine shaft o-ring seal
Restricted turbine shaft retainer and ball as~embly

Go to Step 9

'

Damaged turbine shaft retainer and ball assembly

Refer to the Transmission Overhaul Procedure, in Unit
Repair.
Did you find a condition?

',

.,.

''

Go to .Step 13

Go to Step 10

Inspect the 2-4 band assembly for the following conditions:

Worn 2-4 band
Damaged 2-4 band

10

',

Mispositioned 2-4 band

Misassembled 2-4 band
The band anchor pin is not engaged.
Restricted apply passages in the 2-4 servo assembly
Blocked apply passages in the 2-4 servo assembly
l
Nicks or burrs on the servo pin

Nicks or burrs on the pin bore in the case

Damaged fourth servo piston
Misassembled fourth servo piston
Damaged band apply pin
Incorrect band apply pin

'

'

',

"

Damaged servo bore in the case

Missing piston seals

'

Cut piston seals

Damaged piston seals
Porosity in the pistons
Porosity in the cover
Porosity in the case
Damaged piston seal grooves
Plugged orifice cup plug
Missing orifice cup plug

"

'

'

'

Refer to the Transmission Overhaul Procedure., in Unit

Repair.
Did you find a condition?

..
Go to Step 13

..

Go to Step 11

7-214

Transmission/Transaxle

Automatic Transmission - 4L60-E

OTC P1870 Transmission Component Slipping (3.BL) (cont'd)

Step

Action

Value(s)

Yes

No

Go to Step 13

Go to Step 12

Go to Step 13

Go to
Diagnostic Aids

System OK

Go to Step 1

Inspect the forward clutch assembly for the following

conditions:
Worn clutch plates
Porosity in the forward clutch piston
Damaged forward clutch piston
Missing forward clutch piston inner and outer seals

11

12

1,

13

Cut forward clutch piston inner and outer seals

Damaged forward clutch piston inner and outer seals
Missing input housing to forward clutch housing
o-ring seal
Cut input housing to forward clutch housing o-ring seal
Damaged input housing to forward clutch housing
o-ring seal
Damaged forward clutch housing
Damaged forward clutch housing retainer and ball
assembly
Forward clutch housing retainer and ball assembly is
not sealing.
Refer to the Transmission Overhaul Procedure, in Unit
Repair.
Did you find a condition?
Inspect the 3-4 clutch assembly for the following
conditions:
Worn clutch plates
Porosity in the 3-4 clutch piston
Damaged 3-4 clutch piston
Missing 3-4 clutch inner and outer seals
Cut 3-4 clutch inner and outer seals
Damaged 3-4 clutch inner and outer seals
Damaged 3-4 clutch spring assembly
Damaged 3-4 clutch apply ring
Damaged piston seal grooves
Plugged orifice cup plug
Missing orifice cup plug
Refer to the Transmission Overhaul Procedure, in Unit
Repair.
Did you find a condition?
In order to verify your repair, perform the following
procedure:
1. Select OTC.
2. Select Clear Info.
3. Operate the vehicle under the following conditions:
Drive the vehicle in 04, with the TCC ON, and a
throttle position of 8-35%.
Ensure that the TCC Slip Speed is -20 to
+70 RPM for at least 7 seconds.
4. Select Specific OTC. Enter OTC P1870.
Has the test run and passed?

Transmission/Transaxle

Automatic transmission - 4L60E 7-215

OTC P1870 Transmission Component Slipping {5.7L)

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - """ Automatic
Torque
Transmission
Converter
Assembly

, LINE(From Pump)

42275

Shift Solenoid
Range
Overdrive

Gear

4th

1-2
ON

2-3
OFF

TCC
Solenoid
ON

TCC PWM
Solenoid
90% (ON)

Circuit Description
The Powertrain Control Module (PCM) monitors the
difference between engine speed and transmission
output speed. In 03 drive range with the TCC engaged,
the engine speed should closely match the transmission
output speed. In 04 drive range, with the TCC engaged,
the TCC slip speed should be -20 to +40 RPM. The

\,

2-4 Band
Applied

Forward
Clutch
Applied

3-4 Clutch
Applied

Torque
Converter
Clutch
Applied

table above indicates solenoid states and transmission

components that apply, during 4th gear, with the TCC
commanded ON.
When the PCM detects excessive TCC slip when the
TCC should be engaged, then OTC P1870 sets.
OTC P1870 is a type B OTC.

7-216

Automatic Transmission - 4L60-E

Conditions for Setting the DTC

DTCP1870 sets if the following conditions are met for
three TCC cycles with reported excessive TCC slip
conditions, two consecutive times.
NoTP Sensor DTCs P0122 or P0123.
.No VSS Assy. DTCs P0502 or P0503.
No TCC Sol. Valve DTC P0740.
No 1-2 SS Valve DTC P0753.
No 2-3 SS Valve DTC P0758.
No 3-2 SS Valve Assy. DTC P0785.
No TCC PWM Sol. Valve OTC P1860.
The engine speed is greater than 450 RPM for
5 seconds.
Not in fuel cutoff.
The vehicle speed is 56-105 km/h (35-65 mph)/
The speed ratio is 0.67-0.90 (the speed ratio
is the engine speed divided by the output speed).
The engine speed is 1200-3500 RPM.
The engine torque is 40-400 lbs ft.
The gear range is 04.
Not in 1st gear.
The TP angle is 10-50%.
The TFT is between 20-130C (68-266F).
TCC is commanded On for 5 seconds.
The TCC is at maximum apply for 1 second.
The shift solenoid performance diagnostic
.counters are zero.
The TCC slip speed is 80-800 RPM.
All conditions met for 7 seconds.
lmportantrThe following actions may occur before
the OTC sets..

If the TCC is commanded ON and at maximum

apply for 5 seconds, the TP angle is 10-40%,
.. and the trarismission slip counter h~l:? incremented
tq either 1 or 2 (out of 3.to increment the fail
counter for the current ignition cycle), then
the following slip conditions and actions may
increment the Jail counter for the current
ignition cycle:
These conditions must occur sequentially.
- Condition 1 If the TCC slip speed is
80-800 RPM for 7 seconds, then the PCM
will command maximum line pressure
and freeze shift adapts from being updated.

Transmission/Transaxle
- Condition 2 If Condition 1 is met and the
TCC slip speed is 80-800 RPM for
7 seconds, then the PCM will command the
TCC OFF for 1 .5 seconds.

- Condition 3 If Condition 2 is met and the

TCC slip speed is 80-800 RPM for
7 seconds, then the fail counter on the
current ignition cycle is incremented.
Two consecutive fail counts are required to
set DTC P1870 (type B).
The above slip conditions and actions may be
disregarded if the TCC is commanded OFF at any
time as a result of a driving maneuver (sudden
acceleration or deceleration).

Action Taken When the DTC Sets

The PCM illuminates the Malfunction Indicator
Lamp (MIL).
The PCM inhibits TCC engagement.
The PCM commands maximum line pressure.
The PCM inhibits 4th gear if the transmission is in
hot mode.
The PCM freezes shift adapts from being updated.
DTC P1870 stores in PCM history.

' Conditions for Clearing the MIUDTC

The PCM turns OFF the MIL after three
consecutive trips without a failure reported.
A scan tool can clear the OTC from the PCM
history. The PCM clears the OTC from the
PCM history if the vehicle completes 40 warm-up
cycles without a failure reported.
The PCM cancels the DTC default actions when
the fault no longer exists and the ignition is
OFF long enough in order to power down
the PCM .

Diagnostic Aids
Internal transmission failures could set DTC P1870.

Test Description
The numbers below refer to the step numbers on the
diagnostic table.
3. This step tests the torque converter for slippage
while in a commanded lock-up state.

Automatic Transmiss.ion - 4L60E

Transmissi.onl:Transaxle

7-217

DTC P1870 Transmission Component Slipping (5. 7l.)

Action

Step

Was the Powertrain On-Board Diagnostic (OBD) System

Check performed?

Perform the transmission fluid checking procedure. Refer

to 4L60-E Transmission Fluid Checking Proced11re.
Did you p,arform the fluid checking procedure?
1. Install the Scan Tool.
2. With the engine OFF, turn the ignition switch to the
RUN position.
Important: Befote clearing the OTCs, use the scan tool in
order to record the Freeze Frame and Failure Records for
reference. Using the Clear Info function will erase the
stored Freeze Frame and Failure Records from the PCM.
3. Record the OTC Freeze Frame and Failure Records,
then clear the DTC(s).
4. Drive the vehicle in 4th gear with the TCC
commanded ON.
Is the TCC Slip Speed between the specified values for
7 seconds?

'
3

No

Go to Step2

Go to A
Powertr;:1in On
Board Diagnostic
(080)
System Check

Yes

Value(s)

.'

;3,

Goto
Transmission
Fluid Checking
Procedure

Go to Step 4

Go to
Diagnostic Aids

Go to $tep

80-800 RPM
..

1. Inspect the Torque Converter Clutch Solenoid Valve

(TCC Sol. Valve) for the following conditions:.
I

Internal malfunction (such as sediment or damage)

Damaged seals
'
2. Inspect the Torque Converter Clutch Pulse Width
Modulation Solenoid Valve (TCC PWM Sol. Valve) for
the following conditions:
Internal malfunction (such as sediment or damage)
Damaged seals
Did you find a condition?

1. Inspect the 1-2 Shift Solenoid Valve (1-2 SS Valve)

for the following conditions:
Internal malfunction (such as sediment ?r damage)
Damaged seals
2. Inspect the 2-3 Shift Solenoid Valve (2-3 SS Valve)
for the following conditions:
Internal malfunction (such as sediment or damage)
Damaged seals
Did you find a condition?

Inspect the valve body assembly for a stuck TCC

signal valve.
Refer to the Transmission Overhaul Procedure, in Unit
Repair.
Did you find a condition?

Inspect the torque converter assembly for the following

conditions:
Stator roller clutch not holding
Internal damage
Did you find a condition?

'

Go to Step 13

Go to Step 5

Go.to Step 13

Go to Step 6

Go to Step 13

Go to Step 7

Go to Step 13

Go to Step B

7-218

Transmissionn:ransaxle

Automatic Transmission ..;:4L60-E

DTC P1870 Transmission Component Slipping (5.7L) (cont'd)

Action

Step

Value(s)

Yes

No

Gp to Step 13

Go t9 Step 9

Go to Step 13

Go to Step- 1O

Inspect the oil pump assembly for the following .conditions:

Stuck converter clutch valve

Converter clutch valve assembled backwards
Mispositioned converter clutch valve retaining ring
Mispositioned pump to case gasket
Restricted orifice cup plugs

Damaged orifice cup plugs

Over-tightened, or unevenly tightened pump body to
cover bolts
Refer to the Transmission Overhaul Procedure, in Unit
Repair.
Did you find a condition?

Inspect the input housing and shaft assembly for the

following conditions:
Cut turbine shaft a-ring seal
Damaged turbine shaft a-ring seal
Restricted turbine shaft retainer and ball assembly
Damaged turbine shaft retainer and ball assembly
Refer to the Transmission Overhaul Procedure, in UnJt
Repair.
Did you find a condition?

Inspect the 2-4 band assembly for the following conditions:

10

Worn 2-4 band

Damaged 2-4 band
Mispositioned 2-4 band
Misassembled 2-4 band
The band anchor pin is not engaged.
Restricted apply passages in the 2-4 servo assembly
Blocked apply passages in the 2-4 servo assembly

Nicks or burrs on the servo pin

Nicks or burrs on the pin bore in the case
..
Damaged fourth servo piston
Misassembled fourth servo piston
Damaged band apply pin
Incorrect band apply pin
Damaged servo bore in the case
Missing piston seals
Cut piston seals
Damaged piston seals
Porosity in the pistons
Porosity in the cover
Porosity in the case
Damaged piston seal grooves
Plugged orifice cup plug
Missing orifice cup plug
Refer to the Transmission Overhaul Procedure, in Unit
Repair.
Did you find a condition?

'
Go to Step 13

Go to Step 11

Transmissionrrransaxle

DTC P1870 Transmission Component Slipping (5.7L) (cont'd)

Action
Value(s)
Yes

Step

,;,,

..

11

Automatic
Transmission
- 4L60-E
.,
"

Damaged forward clutch piston inflJ; and outer seals .

Missing input housing to forward clutch hot:Jsing
o-ring seal
Cut input housing to forward clutch housing o-ring seal
Damaged input housing to forward clutch housing
o-ring seal

.'I

Inspect the 3-4 clutch assembly for the following

,,,
conditions:
Worn clutch plates
Porosity in the 3-4 clutch piston
Damaged 3-4 clutch piston

''

'"

Go to Step 13

Go to Step 12

Go to Step 13

Go to
Diagnostic Aids

.'

Missing 3-4 clutch inner and ou.ter .seals

Cut 3-4 clutch inner and outer seals
Damaged 3-4 clutch inner and outer seals
Damaged 3-4 clutch spring assembly

Damaged 3-4 clutch applY, ring

Damaged piston seai grooves
Plugged orifice cup plug
Missing orifice clip plug
Refer to the Transmission Overhaul Procedure, in Unit
Repair.
Did you find a condition?

1,

No

Inspect the forward clutch assembly for the following

conditions:
Worn clutch plates
Porosity in the forward clutch piston
Damaged forward clutch piston
Missing forward clutch piston inner and outer seals
Cut forward clutch piston inner and puter seals

Damaged forward clutch housing

Damaged forward clutch housing retainer and ball
.
assembly
Forward clutch housing retainer and ball assembly is
not sealing.
Refer to the Transmission Overhaul Procedure, in Unit
Repair.
Did you find a condition?

12

In order to verify your repair, perform the foUQvying

procedure:

13

7.;219

'
1. Select OTC.
I
2. Select Clear Info.
3. Operate the vehicle under the following condi.tions:
Drive the vehicle in 04, with ther TCC ON,' and a
.throttle position of 1Oa50%.
Ensure that the TCC Slip Speed is -20 to
+40 RPM for at least 7 seconds.
4. Select Specific DTC. Enter DTC P1870.

Has the test run and passe9?

,'

'

System OK

.Go to Step 1
.,'

7-220

Automatic Transmission - 4L60E

Transmissionrrransa;x:le

2nd Gear Start Switch and Indicator Lamp Circuit Check (3.SL Only).
!Hot In Run!
r - - - I Power
Distribution

F1

.,

Turn

I Cell 10

B/\J

Fuse2

IP

Fuse
k
I
OC
I Bl

L----- ____ _.

20A

0.8 BAN 141

Fuse Block

+- - -

Details

Cell11

S207

c1

0.8 BRN 141

A

r----------------,2d

I n

I
I

Ground
Distribution

I
I

Cell14

Illumination

Lamps

R e l l117
_J

IIAomentary
Contact

1
.

Gear

2nd Gear Start I Start

Indicator Lamp IS 'tch

WI

~-F ---~~~------~
E
B

I
I 0.8 I 0.35 BLKJWHT
I BLl<J S215 451

0.35
PPL,WHT 1572

: WHT 451

1 0.8 F C220

0.35 BRN,WHT 1571

I BLK/
I WHT 451
1
S110

A13

P100
0.35
PPL/WHT 1572

3 BLK/WHT 451
G110

- - - - - - -~- C200

_------.Ai
1

0.35 BRN,WHT 1571

C105
0.35
PPL/WHT 1572

0.35 BRNfWHT 1571

21 C2
r -

I
I
I

2 C1

2nd- - - - - 2nd- - ., Powertrain

Gear
Start

Gear
Indicator

~;~:

control

I Control
I Module .}.
I (PCM)

L----------.1

'1'J4
193756

Circuit Description

Diagnostic Aids.

The 2nd gear start switch enables the operator to

select a 2nd gear start for increased traction in slippery
driving conditions. When the operator selects a
2nd gear start, the 2nd gear start switch input signal
momentarily toggles to zero volts. The PCM then turns
ON the 2nd gear start indicator lamp and de-energizes
the 1-2 shift solenoid valve, enabling second gear.
The 2nd gear start indicator lamp is located within the
2nd gear start switch.

If the electrical circuit checks are OK and 2nd gear

starts are not correct, then a mechanical/hydraulic
malfunction may exist.

During light and medium acceleration conditions, the

vehicle starts in 2nd gear when the 2rid gear start
is selected. However, 2nd gear starts are overridden
and 1st gear starts occur if a hard acceleration
condition (wide open throttle) is requested. A normal
1st gear start is obtained by toggling the 2nd gear start
switch again, or when the ignition switch is cycled
OFF, then ON.

.Test Descrii:>tion
The numbers below refer to the step numbers on the
diagnostic table.
1. This step tests the second gear start switch
circuits.
2. This step tests for a voltage input from the PCM
to the 2nd gear start switch.
3. This step tests for a faulty 2nd gear start switch.
8. This step tests for a voltage input from the fuse to
the 2nd gear start switch.
9. This step tests for a faulty indicator lamp circuit
within the 2nd gear start switch.

Transmission!Transaxle

7-221

Automatic Transmission - 4L60-E

2nd Gear Start Switch and Indicator Lamp Circuit Check (3.8L Only)
Step

Action

Value(s)

1. Install the Scan Tool.

2. With the engine OFF, turn the ignition switch to the
RUN position.
3. Cycle the 2nd. gear start switch while observing
2ND GEAR START on the scan tool.
Does YES display when the switch is first pressed, and
then NO when the switch is pre,ssed again?

Yes

No

Go to Step 6

Go to Step 2

1. Disconnect the 2nd gear start switch connector from

the 2nd gear start switch.
2. Using the J 39200 Digital Multimeter (DMM), check
the voltage input at terminal E of the 2nd gear.start
switch connector.
Is B+ voltage measured?

1. Install a fused jumper between terminals E and F at

the 2nd gear start switch connector.
2. Connect and disconnect the fused jumper lead at
terminal .f while observing the scan tool display.
Does the scan tool status change between YES and NO?

Go to Step 3

Go to Step 5

Go to Step 15

Go to Step 4

Go to Step 17

Go to Step 16

Go to Step 17

Go to Step 16

"

1. Inspect circuit 451 (BLK/WHT) for an open .

.2. Repair the circuit, if necessary;
Refer to General Electrical Diagnosis Procedures.
Did you find open condition?

1. lnspe_ct circuit 1571 (BRN/WHT) for an open or short

to ground condition.
2. Repair the circuit if necessary.
Refer to General Electrical Diagnosis Procedures.
Did you find an open or short to ground condition?

Does the 2nd gear start indicator lamp illuminate when the
switch is first pressed, and then turn Off when the switch
is pressed a second time?

No condition .
found, exit table

Go to Step 7

Does the lamp illuminate .at all times?

Go to Step 13

Go to Step B

Install a test light to ground and probe terminal A of the

second gear start switch connector.
Is the light On?

Go to Step 9

Go to Step 10

Install a test light to ground and probe terminal B of the

second gear start switch connector.
Is the light On?

Goto Step 14

.Go to Step 15

1. Inspect the TURN B/U fuse for an open.

2. Replace .the fuse if necessary.
Is the fuse open?

Go to Step 11

Go to Step 12

1. Inspect circuit 141 (BRN) for a short to ground

condition.
2. Repair the circuit if necessary.
Refer to General Electrical Diagnosis Procedures.
Did you find a short to ground condition?

1. Inspect circuit 141 (BRN) for an open condition.

2. Repair the circuit if necessary.
Refer to General Electrical Diagnosis Procedures.
Did you find an open condition?

1. Inspect circuit 1572 (PPL/WHT) for a short to ground

condition.
2. Repair the circuit if necessary.
Refer to General Electrical Diagnosis Procedures.
Did you find a short to ground condition?

10

11

12

13

Go to Step 17
'

1:

Go to Step 17

Go to Step 17

Go to Step 16

7-222

Automatic Transmission - 4L60-E

Transmission/Transaxle

2nd Gear Start Switch and Indicator Lamp Circuit Check (3.8L Only) (cont'd)
Step

Action

14

1. Inspect circuit 1572 (PPUWHT) for an open condition.

2. Repair the circuit if necessary.
Refer to General Electrical Diagnosis Procedures.
Did you find an open condition?

15

Replace the 2nd gear start switch.

Is the replacement complete?

16

Replace the PCM.

Refer to PCM Replacement/Programming.
Is the replacement complete?

17

After the repair is complete, observe 2ND GEAR START

on the scan tool display, while pressing the 2nd gear start
switch.
Does YES display when the switch is first pressed, and
then NO when the switch is pressed again? And, dbes the
2nd gear start switch indicator lamp turn On after the
second gear start switch is first pressed, and then turn Off
after the 2nd gear start switch is pressed again?

Value(s)

Yes

No

)
Go to Step 17
Go t9 Step 17

Go to Step 16

Go to Step 17

System OK

Go to Step 1

Yes

No

Transmission Fluid Checking Procedure

Action

Step

Value(s)

Check the fluid color.

Is the fluid color red?

Is the fluid level satisfactory?

Check the fluid.

Is the fluid foamy?

Check the fluid level. The proper fluid level should be in

the middle of the X-hatch.
Is the level high?

Fluid will be low.

Add fluid to the proper fluid level.
Is the fluid level satisfactory?

Check for external leaks. Refer to Fluid Leak Diagnosis.

Did you find any leaks?

Correct the leak condition.

Did you correct the leak condition?

Is the fluid level too high?

Remove excess fluid to the proper fluid level.

Is the fluid level satisfactory?

10

1. Check for contaminants in the fluid.

2. Drain the fluid to determine the source of the
contamination.
Did you drain the fluid?

11

Is the fluid color non-transparent pink?

12

Replace the cooler.

Is the replacement complete?

13

Important: Transmission fluid may turn dark with normal

use. This does not always indicate oxidation or
contamination.
The fluid color should be light brown.
Is the fluid color light brown?

Go to Step 2

Go to Step 11

Go to Step 20

Go to Step 3

Go to Step 8

Go to Step 4

Go to Step 9

Go to Step 5

Go to Step 6
Go to Step 7
Go to Step 20
Go to Step9
Go to Step 20

Go to Step 20

Go to Step 10
-

Go to Step 15
Go to Step 12
Go to Step 15

Go to Step 13

Go to Step 14

Transmission!Transaxle

Automatic Transmission - 4L60-E

7-223

Transmission Fluid Checking Procedure (cont'd)

Step

Action

Value(s)

Important: A very small amount of material in the bottom

pan is a normal condition, but large pieces of metal or
other material in the bottom pan require a transmission
overhaul.
Drain the fluid to determine if the fluid is contaminated.
Was the fluid contaminated?

15

Overhaul the transmission. Refer to Unit Repair.

Is the overhaul complete?

16

Flush the cooler.

Has the cooler been flushed?

17

Add new fluid.

Is the procedure complete?

18

Change the fluid and the filter.

Is this procedure complete?

19

Check and correct the fluid level as necessary.

Is the. fluid level satisfactory?

20

Perform the Functional Test,Procedure.

Is the Functional Test Procedure completed?

14

Transmission Fluid Checking Procedure

Yes

No

Go to Step 15

Go to Step 18

Go to Step 16
Go to Step 17
Go to Step 19
Go to Step 19

Go to Step 20
System OK

Line Pressure Check Procedure

1 . Start the engine and operate the vehicle for

15 minutes or until the transmission fluid
reaches an operating temperature of 82-93C
(180-200F).
2. Park the vehicle on a level surface.
3. With your foot on the brake, move the shift lever
through each gear range. Pause for about three
seconds in each range, ending in Park.
4. Apply the parking brake and let the engine idle for
three minutes.
5. Remove the transmission fluid level indicator.
Wipe the indicator clean. Reinsert the indicator.
Give the indicator a full twist in order to close.
6. Wait three seconds and remove the indicator.
7. Read both sides of the indicator. The fluid must be
within the hot cross-hatched area using the lowest
level reading.
174269

Line pressures are calibrated for two sets of gear

ranges-Drive-Park-Neutral and Reverse. This allows
the transmission line pressure to be appropriate for
different pressure needs in different gear ranges:
Gear Range
Drive, Park or Neutral
Reverse

Line Pressure Range

55-189 psi
64-324 psi

Before performing a line pressure check, verify that

the pressure control (PC) solenoid for the transmission
is receiving the correct electrical signal from the PCM:
1. Install a Scan Tool.

7-224

Automatic Transmission - 4L60-E

Caution: Keep the brakes applied at all times in

order to prevent unexpected vehicle motion.
Personal injury may result if the vehicle moves
unexpectedly.
Notice: The transmission may experience harsh, soft
or mushy shifts for up to two days later.
2. Start the engine and set the parking brake.
3. Check for diagnostic trouble codes, including a
stored diagnostic code for the PC solenoid.
4. Repair the vehicle if necessary. Include the
following areas:
Inspect the fluid level
Inspect the manual linkage at the transmission
Install or connect the Scan Tool.
Install or connect the oil pressure gauge at the
line pressure tap.
5. Put the gear selector in Park and set the
parking brake.
6. Start the engine and allow the engine to warm up
at idle.
7. Access the PCS Control test on the Scan Tool.
8. Increase DESIRED PCS in 0.1 amp increments.
Read the corresponding line pressure on the
pressure gauge. Allow the pressure to stabilize for
five seconds after each current charge.
9. Compare your data to the Drive-Park-Neutral line
pressure table below.
If your pressure readings differ greatly from the line
pressure table, refer to the Diagnosis Tables.
The Scan Tool is only able to control the PC solenoid
in Park and Neutral with the vehicle stopped. This
protects the clutches from extremely high or low
pressures in Drive or Reverse ranges.
Refer to the Line Pressure table. The pressures in the
table assume an engine speed of 1500 RPM and a
temperature of 66C (150F). The pressure will
vary with a change in temperature.

Electrical/Garage Shift Procedure

Perform this preliminary test before a hoist test or a
road test in order to make sure that the electronic
control inputs are connected and operating. If you do
not check the inputs before operating the transmission,
you could misdiagnose a simple electrical condition
as a major transmission condition.
A scan tool provides valuable information and must be
used on the Hydra-Matic 4L60-E transmission for
accurate diagnosis.
1. Move the gear selector to PARK, (P) and set the
parking brake.
2. Connect the scan tool to the DLC terminal.
3. Start the engine.
4. Connect the power to the scan tool.
5. Verify that the following signals are present:
Engine speed
Transmission OSS
Vehicle Speed

Transmission!Transaxle

6.

7.
8.

9.

TFP Sw. A/B/C

PRNDL Select
PC Sol. Ref. Current
PC Sol. Actual Current
PC Sol. Duty Cycle
TCC Brake Switch
4WD Low (4WD Only)
ECT
Trans. Fluid Temp.
TP Angle
Ignition Voltage
Monitor the BRAKE SWITCH signal while tapping
the brake pedal with your foot. The BRAKE
SWITCH should be on when the pedal is
depressed. The brake switch should come off
when the brake pedal is released.
Monitor the PRNDL SELECT signal and move the
gear selector through all of the ranges.
Verify that the PRNDL SELECT value matches
the gear range indicated on the instrument panel
or console. Gear selections should be immediate
and not harsh.
Move the gear selector to neutral and monitor the
TP ANGLE signal while increasing and decreasing
the engine RPM with the accelerator pedal. The
TP ANGLE should increase with the engine RPM.

Road Test Procedure

Perform the road test using a scan tool.
Perform this test when the traffic and the road
conditions permit. Observe all safety regulations.
1. Start the engine.
2. Depress the brake pedal.

Important: Gear selections should be immediate and

not harsh.
3. Move the gear selector as follows:
3.1. Park to Reverse.
3.2. Reverse to Neutral.
3.3. Neutral to D4.
4. Perform the same procedure as instructed
previously in the road test:
Upshifts and TCC apply.
The part throttle detent downshift
The full throttle detent downshift
Manual downshifts
Coasting downshifts
Manual gear range selection
Use the scan tool in order to see if any transmission
malfunction codes have been set. If so, perform
the transmission test. After repairing the vehicle,
perform the road test and verify that no codes have
been set again. If no codes have been set and
the condition remains, refer to the Diagnosis Tables
contained in this section. If the condition is suspected
to originate in the torque converter, refer to Torque
Converter Clutch Diagnosis.

TransmissionlTransaxle

Automatic Transmission - 4L60-E

7.;22s

Upshift Control and TCC Apply

Part Throttle Detent Downshift

The PCM calculates the upshift points based primarily

on two inputs: THROTTLE ANGLE and VEHICLE
SPEED. When the PCM says a shift should occur, an
electrical signal goes Jo the shift solenoids which in
turn move the valves to perform the upshift.
The shift speed tables reference the THROTTLE
ANGLE instead of MIN THROTTLE or WOT in. order
to make the shift speed measurement more uniform
and accurate. Use a scan tool in order to monitor the
THROTTLE ANGLE. Some scan tools are
programmed to record shift point information. Check
the instruction manual in order to see if this test
is available.
With the gear selection in 04, do the following:
1. Look at the Shift Speed table contained in this
section and choose a throttle angle of 15 or
20 percent.

2. Set up the scan tool in order to monitor the

THROTTLE ANGLE and the VEHICLE SPEED.
3. Accelerate to the chosen throttle angle and ho!d
the throttle stea~y.

At vehicle speeds of 64-88 km/h (40-55 mph) in

fourth gear, quickly increase the throttle angle.

Important: Shift speeds may vary due to the slight

hydraulic delays responding to electronic controls. A
change from .the original equipment tire size also
affects the shift speeds.

Note when the TCC applies. This should occur in third

or fourth gear. If the apply is not noticed by an
RPM drop, refer to the Torque Converter Clutch
Diagnosis.
The TCC should not apply unless the transmission
has reached a minimum operating temperature of 18C
(64F) Trans. FluidTemp. and an Engine Coolant
Temperature (ECT) of 60C (140F).
4. As the transmission upshifts, note the shift speed
and the commanded gear changes for the
following:
2nd gear
3rd gear
4th gear
5. Repeat steps 1-4, using several different throttle
angles.

Full Throttle Detent Downshift

At vehicle speeds of 64-88 km/h (40-55 mph) in.
fourth gear, quickly increase the throttle angle to the
maximum position.
Verify that the following conditions are met:
The TCC releases.
The transmission downshifts to 2rd gear
immediately.
The 1-2 shift solenoid turns off. The 2-3 shift
solenoid is on.

Verify that the following conditions are met:

The TCC releases.
The transmission downshifts to 3rd gear
immediately.
The 1-2 shift solenoid turns off.

Coasting Downshifts
1. With the gear selector in 04, accelerate to the 4th
gear with the TCC applied.
2. Release the accelerator pedal. Ughtly apply the
brakes. Observe thafthe following occurs:
The TCC releases
The downshifts occur at speeds shown on the
Shift Speed table.

Manual Downshifts
The shift solenoids do not control the initial downshift
during the 4-3 and the 3-2 manual downshifts. All
manual downshifts are hydraulic except the 2-1. The
solenoid states will change during or shortly after
a manual downshift is selected.
1. At vehicle speeds of 64-88 km/h (40-55 mph) in
fourth gear, release the accelerator pedal while
moving the gear selector to 03. Observe the
following:
The TCC releases.
The transmission downshifts to 3rd gear
immediately.
Th~ engin~ slows down the vehicle.
2. Move the gear selector back to 04 and accelerate
to 64-72 km/h (40-45 mph). Release the
accelerator while moving the gear selector to 02
and observe that:
The TCC releases.
The transmission downshifts to the. 2nd gear
immediately.
The engine slows down the vehicle.
3. Move the gear selector back to 04 and accelerate
to 48 km/h (30 mph). Release the accelerator
pedal while moving the gear selector to 01 and
observe the following.conditions:
The TCC releases.
The transmission downshifts to 1st gear
immediately.
The engine slows down the vehicle.

7-226

Automatic Transmission - 4L60-E

Manual Gear Range Selection

Upshifts in the manual gear ranges are controlled by
the shift solenoids.
Perform the following tests by accelerating at
10-15 degrees TP Sensor.
With the vehicle stopped, move the gear selector to
03 and accelerate in,order to observe:

Manual Third (D3)

1-2 shift
2-3 shift
Manua.1 $econ(! (D2)
1. With the vehicle stopped, move the gear selector
to the 02 position and accelerate in order to
observe if the transmission starts and remains in
second gear.
2. Accelerate to 40 km/h (35 mph) and observe the
following:
The 2-3 shift does not occur.
The TCC does not apply.
Manual First (D1)
1. With the vehicle stopped, move the gear selector
to 01.
2. Accelerat13 to 32 km/h (20 mph).
3. Observe the following conditions:
No upshifts occur.
The TCC does not apply.
You can upsh1ft outof first at the fuel cut-off.
Reverse
With the engine stopped, move the gear selector to R
and slowly accelerate in order to observ.e that the
1-2 and 2-3 shift solenoids are ON:
,
Use a scan tool in order to see if any transmission
trouble codes have been set Refer to Trouble Codes
Diagnosis in this section and repair the .vehicle as,
directed. After repairing the .vehicle, perform the hoist
test and verify that the code has not set again.
If the transmission is not performing well and no
trouble codes have been set, tbere may be an
intermittent condition. Check all electrical connections
for damage or'a loose fit. Some scan tools have a
snapshot test which can help catch ah interrnittent
condition that doesn'.t occur long en0l1gh to set a code.
. ..
You may want to read Electronic Component
Description in this ~ection in order to become famlliar
with the transmi?sion conditions caused by
transmission electrical malfunctions.
If no trouble codes have been set and the condition is
suspected to be hydraulic, take the vehicle on a
road test.

Noise and Vibration Analysis

A noise or vibration that is noticeable when the vehicle
is in motion may not be cause by the transmission.
A noise or vibration that is noticeable while the vehicle
is in the P (Park) or the N (Neutral) position with the
engine at idle, but is less noticeable as the RPM
increases, may be the result of poor engine
performance.

TransmissionJTransaxle
Inspect the following components for the conditions
stated:
Tires and wheels - Uneven wear, imbalance,
mixed size.s or types.
Suspension components - alignment and wear;
loose fasteners. Refer to the Suspension
Section:
Engine arid transmission mounts loose bolts.

damage;

Transmission 9ase mounting holes - Missing

bolts, nuts,' . and studs; stripped
threads; cracks.
.
Flywheel - Missing or loose bolts; cracks;
imbalance. For flywheel balancing, refer to Engine
Flywheel Replacement (3.8L) or Engine Flywheel
Replacement (5.7L) in E:ng!ne Mechanical.
Torque converter - Missing or loose bolts or
lugs; missing or loose baiance weights; i.mbalance.
',

Flexplaterrorque Converter Vibration Test

To determine and correct a torque converter
vibration, the following procedure may have to be
performed several times to achieve the best possible
torque converter to flywheel balance.
1. With the engine at idle speed and the transmission
in PARK or NEUTRAL, observe the vibration.
2. Turn the engine OFF.
3. Remoye the torque converter bolts.
Refer to Torque Converter Cover Replacement.
4. Rotate the torque converter one bolt position.
5. Install torque converter. bolts.
Refer to Torque Converter Cover. Replacement.
6. With the engine at idle speed and the transmission
in PARK or NEUTRAL, observe the vibration.
Repeat this procedure until you obtain the best
possible balance.'

Torque Converter Clutch Diagnosis

In order to properly diagnose the Torque Converter
Clutch (TCC) system, perform all of the electrical
testing first. Then do the hydraulic testing.
The TCC is applied by fluid pressure, which is
controlled by a solenoid inside. of the automatic .
transmission assembly. The solenoid is energized by
completing an electrical circuit through a combination
of switches and sensors.

Functional Check Procedure

1. Install a tachometer or a Scan Tool.
2. Operate the vehicle unt.il you reach the proper.
operating temperature.
3. Drive the vehicle at 80-88 km/h (50-55 mph)_with
a light throttle (road load).
4. Maintaining the throttle, lightly touch the brake
pedal. Check for the release of the TCC and a
slight increase in engine speed (RPM).
5. Release the brake. Slowly accelerate and check
for a re-apply of the TCC and a slight decrease in
engine speed (RPM).

Transmission/Transaxle
Torque Converter Evaluation
Torque Converter Stator
The torque converter stator roller clutch can have one
of two different types of malfunctions:
Stator assen:ibly freewheels in both directions.
Stator assembly remains locked up at .all times.
Condition A - Poor Acceleration Low Speed
The car tends to have a poor accele~ation from
a standstill. At speeds above 50-55 km/h (30-35 mph),
the car may act normal. If you note poor acceleration,
you should first determine. that the. exhau.st system
is not blocked and the transmission is .in first gear
when starting out.
If the engine freely accelerates to high RPM in /.
NEUTRAL (N), you can assume that the engine and
exhaust system are normal. Checking for poor
performance in DRIVE and REVERSE helps deJe~mine
if the stator is freewheeling at all times..

Automatic Transmission - 4L60-E

7-227

You find steel particles after fluShing the cooler

and cooler lines.
The pump is damaged or the steel particles
are,fouAd in the converter:
The vehicle has TCC shudder and/or no TCC
apply. Replace only after you have made all
ofthe hydraulic and electrical diagnoses.
(Converter clutch material rnay be glazed).
The converter has an imbalance which cannot
be corrected. (Referto Jhe Converter. Vibration
.Test Procedure).

The. converter is contaminated with engine

coolant containing antifreeze.
Internal failure of stator roller .clutch
Excess end play.
Heavy clutch debris due to overheati~g ,(blue
converter)
Steel particles or clutch iining material found in
fluid filter or on mggnet when no internal parts
in. the unit are worn or damaged O indicates
that the lining material carne from the
converter.

Condition B - Poor Acceleration High Speed

Engine RPM and car speed are limited or restricted at
high speeds. Performance,when accelerating from
a standstill is normal. The engine may overheat. Visual
examination of the converter may reveal.a blue
color from overheating.
If the converter has been removed, the stator roller
clutch can be checked by inserting two fingers into the
splined inner race of the roller clutch and try to turn
the race in both directions. The inner race should turn
freely clockwise, but the inner race should nottum
or be very difficult to turn counterclockwise.

5. The torque converter should not be replaced if

any of the follo".Ving conditions exist:. ,
The oil has an odor, is discolored, and there is
no ~vid~nce of metal or clutch facing particles.

Noise
Torque corwerter whine usuatly is noticed when the
vehicle is stopped and the transmission is in DRIVE or
'REVERSE. The noise increases when the engine
RPM increases. The noise stops when the vehicle is
moving or when the torque converter clutch is
applied because both halves of the converter are
turning at the same speed.
Perform a stall test to make sure the noise actually is
coming from the converter:
1. Place a foot on the brake.
2. Put the gear selector in DRIVE.

The vehicle has been exposed to high mileage

(only). The exception may be where the
. torque converter clutch damper plate liAing has
seen excess wear by the vehicles operated
in heavy an.d/or constant traffic, such as a taxi,
deliver or police use.

Important: This noise should not be confused with the

pump whine noise which is usually noticeable in
PARK, NEUTRAL and all other gear ranges. Pump
whine varies with pressure ranges.
3. Depress the accelerator to approximately
1200 RPM for no more than six seconds.
A torque converter noise increases under
this load.
. 4. The torque converter should be replaced under
any of the following conditions:
External leaks in the hub weld area
The converter hub is scored or damaged.
The converter pillar is broken or damaged or
fits poorly into the crankshaft.

The threads in one or more of the converter

bqlt holes are damaged. Correct with thread
insert.
Transmis.slon failure. did not display evidence
of damage or worn internal parts, steel. . ..
particles or the cl.utch plate lining material in
th~ tJnit and inside the .fluid filter.

Torque Converter Clutch Shudder

The key to dtagnosing the Torque Converter Clutch
(TCC) shudder is to note when the shudder happens
and under what conditions:
The TCC shudder should 'only occur during the apply
and/or release of the converter clutch, and SELDOM
after the. TCC plate is fully applied.

While the TCC is Applying or Releasing

If the shudder occurs while the TCC is applying, the
problem can be within the transmission or the ,
torque converter. Somethirig is not allowing tlie clutch
to release, or the TCC is trying to release and
apply the clutch at the same time. This could be
caused by leaking turbine shaft seals, a restricted
release orifice, a distorted clutch or a housing surface
due to long converter bolts, or defective friction
material on the TCC plate.

7-228 Automatic Transmission .. 4L60-E

Transmission!Transaxle

Shudder Occurs after the TCC has Applied

Fuel injector-Filter may be plugged;

Important: Once the TCC is applied there is no torque

converter (fluid coupling) assistance. Engine or
driveline vibrations could be unnoticeable before the
TCC engagement.
When the shudder occurs after the TCC has applied,
most of the time there is nothing wrong with the
transmission. As mentioned above, once the TCC has
been applied, it is very unlikely that it will slip.
Engine problems may go unnoticed under light throttle
and load, but engine problems may become
noticeable after TCC apply when going up a hill or
accelerating, di.Je to the mechanical coupling between
the engine and the transmission.
Inspect the following components in order to avoid
misdiagnosis of the TCC shudder and possibly
disassembling a transmission and/or replacing a torque
converter unnecessarily:
Spark plugs-Inspect for cracks, high resistance
or broken insulator.
Plug wires-Look in each end. If there is a red
dust (ozone) or a black substance (carbon)
present, then the wires are bad. Also look for a
white discoloration of the wire indicating arcing
during hard acceleration.
Distributor cap and rotor - Look for broken or
uncrimped parts.
Coil-Look for black on bottom indication arching
while engine is misfiring.

Vacuum leak-Engine won't get correct amount of

fuel and may run rick or lean, depending on
where the leak is located.
EGA valve-Valve may let in too much unburnable
exhaust has causes engine to run lean.
MAP/MAF sensor-Like the vacuum leak, the
engine won't get the correct amount of fuel
for proper engine operation.
Carbon on intake valves-Restricts proper flow or
air/fuel mixture into cylinders.
Flat cam-Valves don't open enough to let proper
fuel/air mixture into cylinders.
Oxygen sensor-May command engine too rich or
too lean for too long.
Fuel pressure-May be too low.
Engine mounts-Vibration of mounts can be
multiplied by TCC engagement.
Axle joints-Check for vibration.
TPS-TCC apply and release depends on TPS in
many engines. IF TPS is out of specification,
TCC may remain applied during the initial
engine crowd.
Cylinder balance-Bad piston rings or valves that
seal poorly can cause low power in a cylinder.
Fuel contamination-Causes poor engine
performance.

AT Wiring Harness Check

Step

Action

Value(s)

Yes

No

Important: This procedure cahnot be used for checking the Automatic Transmission Fluid Pressure Manual Valve Position
Switch (TFP Val. Position Sw.) circuit, or the Automatic Transmission Fluid Temperature (TFT) Sensor circuit. Refer to the
TFP Manual Valve Position Switch Resistance Check, for those circuits.
1. Install the J 39775 Jumper Harness on the
transmission side of the 20-way connector.

2. Using a J 39200 Digital Multimeter (DMM) and a

J 35616-A Connector Test Adapter Kit, measure the
resistance between terminals A and E
(1-2 Shift Solenoid Valve).
Is the resistance within the specified range?
1. Disconnect the 1-2 Shift Solenoid Valve
(1s2 SS Valve) from the Automatic Transmission
Wiring Harness Assembly (A!T Wiring Harness
Assembly).

2. Using the J 39200 DMM, measure the resistance of

the 1-2 SS Valve.,
Is the resistance within the specified range?

Measure the resistance between terminals B and E

(2-3 Shift Solenoid Valve).
.
Is the resistance within the specified range?
1. Disconnect the 2-3 Shift Solenoid Valve
(2-3 SS Valve) from the Afr Wiring Harness
Assembly.

2. Using the J 39200 DMM, measure the resistance of

the 2-3 SS Valve.
Is the resistance within the specified range?

19-24 n@
20C (68F)
24-31 n@
100C (212F)

Go to Step 3

Go to Step 2

Go to Step 14

Go to Step 16

Go to Step 5

Go to Step 4

Go to Step 14

Go to Step 16

19-24 n@
20C (68F)
24-31 n@
100C (212F)

19-24 n@
20C (68F)
24-31 n@
100C (212F)
19-24 n@
20C (68F)
24-31 n@
100C (212F)

Transmission/Transaxle

Automatic Transmission - 4L60-E

7-'229

AT Wiring Harness Check (cont'd)

Step

10

11

12

13

Value(s)

Yes

~o

21-26 n@
20C (68F)
26-330@
100C (212F}

Go to Step 6

Go to Step 14

Measure the resistance between terminals U and E

(Torque Converter Clutch Pulse Width Modulatjon
Solenoid Valve).
Is the resistance within the specified range?

10-110@
20C (68F)
13-15 n@
100C (212F)

Go to Step B

Go to Step 7

1. Disconnect the TCC PWM Sol. Valve from the A/T

Wiring Harness Assembly.
2. Using the J 39200 DMM, measure the resistance of
the TCC PWM Sol. Valve.
Is the resistance within the specified range?

10-11 n@
20C (68F)
13-15 n @
100C (212F)
Go to Step 14

Go to Step 16

Go to Step 10

Go to Step 9

Go to Step 14

Go to Step 16

Go to Step 12

Go to Step 11

Go to Step 14

Go to Step 16

System OK

Go to Step 13

Go to Step 14

Go to Step 16

Action

Measure the resistance between terminals T and E

(Torque Converter Clutch Solenoid Valve).
Is the resistance within the specified range?

Measure the resistance between terminals S and E

(3-2 Shift Solenoid Valve Assembly).
Is the resistance within the specified range?
1. Disconnect the 3-2 Shift Solenoid Valve Assembly
(3-2 SS Valve Assy.) from the A/T Wiring Harness
Assembly.
2. Using the J 39200 DMM, measure the resistance of
the 3-2 SS Valve A'$sy.
Is the resistance within the specified range?
Measure the resistance between terminals C and D
(Pressure Control Solenoid Valve).
Is the resistance within the specified rang!;)?.,

20-24 n@
20C (68F)
29-32 n@
100C (212F}
20-24 n@
20C (68F)
29-320@
100C (212F}
3-5 Q@ 20C
(68F}
4-7 Q@ 100c
(212F)

1. Disconnect the Pressure Control Solenoid Valve (PC.

Sol. Valve) from the A/T Wiring Harness Assembly.
2. Using the J 39200 DMM, measure the resistance of
the PC Sol. Valve.
Is the resistance within the specified range?

3-50@ 20c
(68F)
4-7 Q@ 100C
(212F)

Using the J 39200 DMM and the J 35616-A Connector

Test Adapter Kit, measure the resistance from terminals A,
B, C, D, E, S, T and U of the A/T Wiring Harness
Assembly at the transmission 20-way connector to the
transmission case.
Is the resistance more than the specified value?

250 Kn

1. Disconnect the A/T Wiring Harness Assembly from all

the components.
2. Measure the resistance from all the component
terminals to the transmission case.
Is the resistance more than the specified value?

250 Kn

7-230

Transmission/Transaxle

Automatic Transmission - 4L60-E

AT Wiring Harness Check (cont'd)
Action

Step

14

Value(s)

Inspect for high resistance or a short.

Inspect the A.IT Wiring Harness Assembly at the
transmission 20-way connector, and the component
connectors for the following conditions:
- Poor electrical connections
- A backed out terminal
- A damaged terminal
- A bent terminal
- Poor terminal tension
- A chafed wire that could short to bare metal or
other wiring
- A broken wire inside the insulation

- Moisture intrusion
- Corrosion
If diagnosing for a possible intermittent condition,
move or massage the A.IT Wiring Harness Assembly
while observing the test equipment for a change.
Did you find high resistance or a short?

15

16

No

Yes

Go to Step 1

Replace the Automatic Transmission Wiring Harness

Assembly (A.IT Wiring Harness Assembly).
Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring
Harness Replacement.
Is the replacement complete?

Replace the faulty component.

Is the replacement complete?

Go to Step 15

Go to Step 1
Go to Step 1

Component Resistance
Pass Thru
Pins

Resistance at 20C

Resistance at 100C

Resistance to Ground (Case)

1-2 Shift
Solenoid Valve

A, E

19-24 Q

24-31 Q

Greater than 250 K n

2-3 Shift
Solenoid Valve

8, E

19-24 Q

24-31 Q

Greater than 250 Kn

TCC
Solenoid Valve

T, E

21-26 Q

26-33 Q

Greater than 250 K Q

TCC PWM
Solenoid Valve

U, E

10-11 Q

13-15 Q

Greater than 250 Kn

3-2 Shift Solenoid

Valve Assy.

S, E

20-24 n

29-32 Q

Greater than 250 K n

Pressure Control
Solenoid Valve

C,D

3-5Q

4-7n

Greater than 250 Kn

Component

Transmission
Fluid Pressure
(TFP) Manual
Valve Position
Switch

Refer to TFP Manual Valve Position Switch Resistance Check.

*Transmission
Fluid Temperature
(TFT) Sensor

M, L

3088-3942 n

159.3-198.0 Q

Greater than 1O M Q

Vehicle Speed
Sensor

A, B
VSS CONN

1470-2220 Q

1800-2820 Q

Greater than 1O M n

Important: The resistance of this device is necessarily temperature dependent and will therefore vary far more than any
other device. Refer to the Transmission Fluid Temperature Sensor portion of Electronic Component Description.

Transmission!Transaxle

Automatic Transmission - 4L60-E

7-231

TFP Manual Valve Position Switch Resistance Check

Step

Action

Value(s)

Yes

No

Important: Whenever the transmission 20-way connector is disconnected and the engine is running, multiple DTCs will set.
Be sure to clear these codes when you are finished with this procedure.
Important: This procedure tests the Automatic Transmission Fluid Pressure Manual Valve Position Switch (TFP Val. Position
Sw.) circuits and the Automatic Transmission Fluid Temperature (TFT) Sensor circuit. Do not use this procedure to test other
Automatic Transmission circuits. Refer to the AT Wiring Harness Check.

1. Install the J 39775 Jumper Harness on the

transmission side of the 20-way connector.
2. Using the J 39200 Digital Multimeter (DMM) and the
J 35616-A Connector Test Adapter Kit, measure the
resistance from terminal N to the transmission case.
Is the resistance greater than the specified valLJe?

50KQ

1. Disconnect the TFP Val. Position Sw. from the

Automatic Transmission Wiring Harness Assembly
(A!T Wiring Harness Assembly).
2. Measure the resistance from terminal C of the TFP
Val. Position Sw. to the switch housing.
Is the resistance greater than the specified value?

50KQ

Measure the resistance from terminal R to the

transmission case.
Is the resistance less than the specified value?

200Q

1. Disconnect the TFP Val. Position Sw. from the A!T

Wiring Harness Assembly.
2. Measure the resistance from terminal E of the TFP
Val. Position Sw. to the switch housing.
Is the resistance less than the specified value?

200Q

Measure the resistance from terminal P to the

transmission case.
Is the resistance greater than the specified value?

50KQ

1. Disconnect the TFP Val. Position Sw. from the A!T

Wiring Harness Assembly.
2. Measure the resistance from terminal D of the TFP
Val. Position Sw. to the switch housing.
Is the res.istance greater than the specified value?

50KQ

10

1.
2.
3.
4.
5.

Start the engine.

Allow the engine to idle.
Set the parking brake.
Place the gear selector in Reverse.
Measure the resistance from terminal N to the
transmission case.
Is the resistance less than the specified value?

200Q

1. Place the gear selector in Low (01 ).

2. Measure the resistance from terminal N to the
transmission case.
Is the resistance less than the specified value?

200Q

1. Place the gear selector in Manual Third (03).

2. Measure the resistance from terminal R to the
transmission case.
Is the resistance greater than the specified value?

50KQ

1. Place the gear selector in Drive (04).

2. Measure the resistance from terminal P to the
transmission case.
Is the resistance less than the specified value?

200Q

Go to Step 3

Go to Step 2

G.o to Step 16

Go to Step 19

Go to Step 5

Go to Step 4

Go to Step 16

Go to Step 19

Go to Step 7

Go to Step 6

Go to Step 16

Go to Step 19

Go to Step B

Go to Step 16

Go to Step 9

Go to Step 16

Go to Step 10

Go to Step 16

Go to Step 11

Go to Step 16

7-232

Automatic Transmission - 4L60-E

Transmission!Transaxle

TFP Manual .Valve Position Switch Resistance Check (cont'd)

Action ..

Step

Value(s)

No

Yes

).

1. Place the gear selector in Manual Second (02).

11

2. Measure the resistance from terminal P to the

transmission case.

50KO

Is the resistance greater than the specified value?

Go to Step 12

Go to Step 16

Go to Step 1.3

Go to S.tep 14

System OK

Go to Step 14

Go to Step 15

Go to Step 19

Go to Step 16

Go to Step 19

1. Turn the ignition OFF.

Important: The resistance of the TFT Sensor is

12

temperature dependent, and therefore varies far more than

any other device. Refer to Transmission Fluid Temperature
Sensor in Electronic Component Description.
2. Measure the resistance from terminal L to.terminal M
(TFT_ Sensor) of th~ J 39775 Jumper Harness.

30$8-3942 n
@ 20C (68F)
15~-HJ8 Q@
100C (212F)

Is the resistance within the specified range?

1. Measure the resistance from terminal L to the
transmission case.
13

2. Measure the resistance from terminal M to the

transmission case.

10MO

Are both resistances greater than the specified value?

1. Disconnect the TFP Val. Position Sw. from the A/T
Wiring Harness Assembly.

14

Important: The resistance of the TFT Sensor is

temperature dependent, and therefore varies far more than
any other device. Refer to Transmission Fluid Temperature
Sensor in Electronic Component Description.
2. Using the J 39200 DMM, measure the resistance
between terminal A and terminal B of the TFP Val.
Position Sw. (TFT Sensor).
Is the resistance within the specified range?

3088-3942 n
@ 20C (68F)
159-1980@
100C (212F)

1. Measure the resistance from TFP Val. Position Sw.

terminal A to the transmission case. .
.
15

2. Measure the resistance from TFP Val. Position Sw.

terminal B to the transmission case.

10MQ

Are both resistances greater than the specified value?

Inspect for high resistance or a short:

'

, .

Inspect the A/T Wiring Harness Assembly. for poor

electrical connections at the automatic
transmission 20-way connector, and at the TFP Val.
Position Sw. Look for thE\ following conditions:
- A backed out terminal
- A damaged terminal
- A bent terminal
16

- Poor terminal tension

- A chafed wire
- A broken wire inside the insulation
- Moisture intrusion
-:- Corrosion
If diagnosing for an intermittent condition, massage
the wiring harness while watching the test equipment
for a change.
Did you find high resistance or a short?

Go

to Step

Go to Step 17
\

Transmission/Transaxle

7233

Automatic Transmission - 4L60E

TFP Manual Valve Position Switch Resistance Check (cont'd)

Step

17

Action

Value(s)

1. Disconnect the TFP Val. Position Sw. from the AfT

Wiring Harness Assembly.
2. Inspect the following circuits for an open or short:
Circuit 1224
Circuit 1225
Circuit 1226
Circuit 1227
Did you find an open or shorted condition?

Yes

No

Go to Step 18

Go to Step 19

18

Replace the AfT Wiring Harness Assembly.

Refer to TCC PWM Solenoid, TCC Solenoid, and Wiring
Harness Replacement.
Is the replacement complete? .

19

Replace the TFP Val. Position Sw.

Refer to Valve Body and Pressure Switch Replacement.
Is the replacement complete?

Go to Step 1

Go to Step 1

Electronic Component Malfunctions

Component/System
Can Effect
This table gives some general information about electronic component malfunctions. Use this information to become familiar
with possible conditions caused by transmission/vehicle electrical components. Refer to the Diagnosis Tables for more
specific information.
Throttle Position (TP) Sensor

Automatic Transmission. Output Shaft Speed {AT OSS)

Sensor

Shift Pattern (erratic)

Shift quality (firm or soft)
Engine (rough)
Shift Pattern (erratic)
TCC solenoid valve apply (at wrong time)
Shift quality (harsh or soft)
T9C solenoid valve apply (no apply if diagnostic code is set)
Shift pattern (no fourth gear in hot mode)
Shift quality (harsh)
Line pressure (high)
Manual downshift (erratic)

Transmission Fluid Pressure (TFP) Manual Valve

Position Switch

Automatic Transmission Fluid Temperature (TFT)

Sensor

TCC so.lenoid valve control (On or Off)

Shift quality (harsh or soft)

Engine Coolant Temperature (ECT) Sensor

Shift Solenoid valves
Brake Switch

System Voltage

3-2 Control Shift Solenoid Valve Assembly

Pressure Control Solenoid
TCC Sol Valve
Cruise Control
Acceleration Slip Regulation (ASR)

TCC solenoid valve control (no apply)

Shift quality (harsh)
Gear application (wrong gear, only two gears, no shift)
TCC apply (no apply)
No 4th gear if in hot mode

Line pressure (high)

Gear application (third gear only)
TCC control (no apply)
No 4th gear it in hot mode)

Gear application (third gear only)

3-2 Downshifts (flare or tie-up)
Line pressure (high or low)
Shift quality (harsh or soft)
TCC solenoid valve apply (no apply)
No 4th gear if in hot mode
Delays 3-4 upshift and TCC apply during heavy throttle
Downshifts

7-234

Transmissionrrransaxle

Automatic Transmission - 4L60-E

Oil Pressure High or Low
Cause,

Checks

..

Oil Pump Assembly

Pressure regulator Yi:ilve stuck

Pressure regulator valve spring
Rotor guide :omitted or misassembled,
Rotor cracked or broken
Reverse boost valve or sleeve stuck, damaged or incorrectly assembled
Orifice hole .in pressure regulator valve plugged
Sticking slide or excessive rotor clearance
Pressure relief ball not seated or damaged
Porosity in pump cover or body
Wrong pump cover
Pump faces. not flat
Excessive rotor clearance

Oil Filter

Intake pipe restricted by casting flash

Cracks in fil~er body or intake pipe
0-ring seal missing, cut or damaged
Wrong grease used on rebuild

Control Valve Body

Miir,11,Jal valve scored or damaged

Spacer plate or gas~ets incorrect, misasser'Abled ordainaged
Face not flat
2-3 Shift valve stuck
'
Checkbaltsomitted or misassembled

"'"

'

Pressure Control Solenoid

Transmission Fluid Pressure Manual
Valve Position Switch
Case
System Voltage

'

,./

,'

'

Damage to pins
Contamin~tion
Damaged seals
Case 'to control valve body face not flat

..

12 volts notsupplied to transmission

Electrical short (Pi.nched solenoid wire)
Solenoid not grounded

Checks

Causes

Throttle Position Sensor

Open or shorted circuit

Vehicle Speed Sensor

Open or shorted circuit

,,

Contamination .,
Damaged seals

Trans Fluid Temperature Sensor

Opeh or shorted circuit

Engine Coolant Temperature Sensor

Open or shorted circuit

Pressure Control Solenoid

Damage to pins
Contamination

)
'

Harsh Shifts

Pressure Switch Assembly

'.

Automatic Transmission 4L60-E

Transmission/Transaxle

7-235

Inaccurate Shift Points

Checks
Oil Pump Assembly
Valve Body Assembly

Causes
Stuck pressure regulator valve
Sticking pump slide
Spacer plate or gaskets misassembled, damaged or incorrect

Case

Porous or damaged valve body pad

2-4 Servo Assembly
- 2-4 accumulator porosity
- Damaged servo piston seals
- Apply pin damaged or improper length
2-4 Band Assembly
- Burned
- Anchor pin not engaged

Throttle Position Sensor

Disconnected
Damage

Vehicle Speed Sensor

Disconnected
Damaged
Bolt not tightened

4WD Low Switch

Disconnected
Damaged

1st Gear Range Only No Upshift

Checks
Control Valve Body

Causes
The 1-2 Shift valve is sticking
The spacer plate or gaskets are mispositioned or damaged
The case to valve body face is damaged or is not flat

Case
Shift Solenoid Valves

Stuck or damaged
Faulty electrical connection

2-4 Servo Assembly

The apply passage case is restricted or blocked

Nicks or burrs on the servo pin or on the pin bore in the case
Fourth servo piston is installed backwards

2-4 Band Assembly

The 2-4 band is worn or damaged

The band anchor pin is not engaged

Slips in 1st Gear

Checks

Causes

Forward Clutch Assembly

Clutch plates worn

Porosity or damage in forward clutch piston
Forward clutch piston inner and outer seals missing, cut or damaged
Damaged forward clutch housing
Forward clutch housing retainer and ball assembly not sealing or damaged

Forward Clutch Accumulator

Piston seal missing, cut or damaged

Piston out of its bore
Porosity in the piston or valve body
Stuck abuse valve

Input Housing and Shaft Assembly

Valve Body

Turbine shaft seals missing, cut or damaged

1-2 Accumulator valve stuck
Face not flat, damaged lands or interconnected passages
Spacer plate or gaskets incorrect, mispositioned or damaged

7-236

Automatic Transmission - 4L60-E

Slips in 1st Gear (cont'd)
Causes

Checks
Low Roller Clutch

Torque Converter
1-2 Accumulator Assembly

Lin.e Pressure
2-4 Servo Assembly

Transmission/Transaxle

Damage to lugs to inner ramps

Rollers not free moving
Inadequate spring tension
Damage to inner splines
Lube passage plugged
Stator roller clutch not holding
Porosity in piston or 1-2 Accumulator cover and pin assembly
Damaged ring grooves on piston
Piston seal missing, cut or damaged
Valve body to spacer plate gasket at 1-2 Accumulator cover, missing or
damaged
Leak between piston and pin
Broken 1-2 Accumulator spring
Refer to Oil P,ressure High or Low
4th Servo piston in backwards

Slipping or Rough 1-2 Shift

Causes

Checks
Valve Body Assembly

1-2 Shift valve train stuck

Gaskets or spacer plate incorrect, mispositioned or damaged
1-2 Accumulator.valve l!ltuck
Face not flat

2-4 Servo Assembly

Apply pin too long or too short

2nd servo apply piston seal missing, cut or damaged
Restricted or missing oil passages
Servo bore in case damaged

2nd Accumulator

2-4 Band
Oil Pump Assembly or Case

Checks

Porosity in 1-2 accumulator housing or piston

Piston seal or groove damaged
Nicks or burrs in 1-2 accumulator housing
Missing or restricted oil passage
Worn or mispositioned
Faces not flat

No 2;.3 Shift or 2-3 Shift Slips, Rough or Hunting

Causes

Converter
Oil Pump
Valve Body Assembly

Internal damage
Stator shaft sleeve scored or off location

Input Housing Assembly

3-4 clutch or forward clutch plates worn

Excessive clutch plate travel
Cut or damaged 3-4 clutch or forward clutch piston seals
Porosity in input clutch housing or piston
3-4 clutch piston checkball stuck, damaged or not sealing
Restricted apply passages
Forward clutch piston retainer and ball assembly not seating
Sealing balls loose or missing
3rd accumulator retainer and ball assembly not seating
2nd apply piston seals missing, cut or damaged

Case
2-4 Servo Assembly

2-3 Shift valve train stuck

Gaskets or spacer plate incorrect, mispositioned or damaged
2-3 Accumulator valve stuck
Face not flat

Transmissionrrransaxle
Checks
Shift Solenoid Valves (379)

Automatic Transmission - 4L60~E 7-237

2nd/3rd Gear Only or 1st/4th Gears Only
Causes
Sediment is in the valves
The electrical connection is faulty
.Damaged seal
..

Third Gear Only

Checks

Causes

System Voltage

12 volts not supplied to transmission

Electrical short (pinched solenoid wire)
Solenoid not grounded

3-2 Control Solenoid (394)

Shorted or damaged
Contamination
Damaged Seal

3-2 Flare or Tie-Up

Checks
3-2 Control Solenoid

Checks

Causes
Shorted or damaged
Contamination
Damaged Seal

No 3-4 Shift, Slips or Rough 3-4 Shift

Causes

Oil Pump Assembly

Pump cover retainer and ball assembly omitted or damaged

Faces not flat

Valve Body Assembly

Valves stuck '

-

2-3 Shift valve train

Accumulator valve
1-2 Shift valve train
3-2 Control. valve

Spacer plate or gaskets incorrect, mispositioned or damaged

2-4 Servo Assembly

Incorrect band apply pin

Missing or damaged servo seals
Porosity in piston, cover or case
Damaged piston seal grooves
Plugged or missing orifice cup plug

Case

3rd Accumulator retainer and ball assembly leaking

Porosity in 3-4 accumulator piston or bore
3-4 Accumulator piston seal or seal grooves damaged
Plugged or missing orifice cup plug
Restricted oil passage

Input Housing Assembly

Refer to Slipping 2-3 Shift

2-4 Band Assembly

Warn or misassembled

7-238 Automatic Transmission - 4L60-E

Transmission/Transaxle

No Reverse or Slips in Reverse

Checks
Input Housing Assembly

Manual Valve Link

Valve Body Assembly

Causes
3-4 Apply ring stuck in applied position
Forward clutch not releasing
Turbine shaft seals missing, cut or damaged
Disconnected

2-3 Shift valve stuck

Manual linkage not adjusted
Spacer plate and gaskets incorrect, mispositioned or damaged
Lo overrun valve stuck
Orificed cup plug restricted, missing or damaged

Reverse Input Clutch Assembly

Clutch plate worn

Reverse input housing and drum assembly cracked at weld
Clutch plate retaining ring out of groove
Return spring assembly retaining ring out of groove
Seals cut or damaged
Restricted apply passage
Porosity in piston
Belleville plate installed incorrectly
Excessive clutch plate travel
Oversized housing

Lo and Reverse Clutch

Clutch plates worn

Porosity in piston
Seals damaged
Return spring assembly retaining ring mispositioned
Restricted apply passage

No Part Throttle or Delayed Downshifts

Checks
Input Housing Assembly

Manual Valve Link

Valve Body Assembly

Causes
3-4 Apply ring stuck in applied position
Forward clutch not releasing
Turbine shaft seals missing, cut or damaged
Disconnected

2-3 Shift valve stuck

Manual linkage not adjusted
Spacer plate and gaskets incorrect, mispositioned or damaged
Lo overrun valve stuck
Orificed cup plug restricted, missing or damaged

Reverse Input Clutch Assembly

Clutch plate worn

Reverse input housing and drum assembly cracked at weld
Clutch plate retaining ring out of groove
Return spring assembly retaining ring out of groove
Seals cut or damaged
Restricted apply passage
Porosity in piston
Belleville plate installed incorrectly
Excessive clutch plate travel
Oversized housing

Lo and Reverse Clutch

Clutch plates worn

Porosity in piston
Seals damaged
Return spring assembly retaining ring mispositioned
Restricted apply passage

Transmission/Transaxle

Automatic Transmission - 4L60-E

Harsh Garage Shift

Checks
Valve Body Assembly

Causes
Orifice cup plug missing
Checkball missing

No Overrun Braking - Manual 3-2-1

Checks
External Linkage

Causes
Not adjusted properly

Valve Body Assembly

4-3 Sequence valve stuck

Checkball mispositioned
Spacer plate and gaskets incorrect, damaged or mispositioned

Input Clutch Assembly

Turbine shaft oil passages plugged or not drilled

Turbine shaft seal rings damaged

Turbine shaft sealing balls loose or missing

Turbine shaft sealing balls loose or missing
Porosity in forward or overrun clutch piston
Overrun piston seals cut or damaged
Overrun piston checkball not sealing

No TCC Apply
Checks
Electrical

Torque Converter Clutch

Oil Pump Assembly

Causes

Internal damage
Converter clutch valve stuck or assembled backwards

12 volts not supplied to transmission

Outside electrical connector damaged
Inside electrical connector, wiring harness or solenoid damaged
Electrical short (pinched solenoid wire)
Solenoid not grounded

Converter clutch valve retaining ring mispositioned

Pump to case gasket mispositioned
Orifice cup plug restricted or damaged
Solenoid 0-ring seal cut or damaged
High or uneven bolt torque (pump body to cover)

Input Housing and Shaft

Turbine shaft 0-ring seal cut or damaged

Turbine shaft retainer and ball assembly restricted or damaged

Transmission Fluid Pressure Manual

Valve Position Switch

Contamination
Damaged seals

Control Valve Body Assembly

TCC signal valve stuck

Solenoid 0-ring leaking

Solenoid Screen

Blocked

rec Solenoid Valve

Internal damage

Engine Speed Sensor

Internal damage

Engine Coolant Temperature Sensor

Internal damage

Automatic Transmission Fluid

Temperature Sensor

Internal damage

Brake Switch

Internal damage

7-239

7-240

Automatic Transmission - 4L60-E

Transmission/Transaxle

Torque Converter Clutch Shudder

Checks
Electrical

Causes

12 volts not supplied to transmission

Outside electrical connector damaged
Inside electrical connector, wiring harness or solenoid damaged
Electrical short (pinched solenoid wire)

Solenoid not grounded

Internal damage

Converter
Oil Pump Assembly

Input Housing and Shaft

Turbine shaft 0-ring seal cut or damaged

Turbine shaft retainer and ball assembly restricted or damaged

Pressure Switch Assembly

Contamination
Damaged seals

Valve Body Assembly

TCC signal valve stuck

Solenoid 0-ring leaking

Solenoid Screen

Converter clutch valve stuck or assembled backwards

Converter clutch valve retaining ring mispositioned
Pump to case gasket mispositioned
Orifice cup plug restricted or damaged
Solenoid 0-ring seal cut or damaged
High or uneven bolt torque (pump body to cover)

Blocked

No TCC Release
Checks
TCC Solenoid Valve

Causes
External ground
Clogged exhaust orifice

Converter

Internal damage

Valve Body Assembly

The converter clutch apply valve is stuck in the apply position

Oil Pump Assembly

The converter clutch valve is stuck

PCM

External ground

Drives in Neutral
Checks

Causes

Forward Clutch

The clutch does not release

Manual Valve Link

Disconnected

Case

The face is not flat

Internal leakage exists

2nd Gear Start

Checks
For.yard Clutch Sprag Assembly

Causes
The sprag assembly is installed backwards

No Park
Checks
Parking Linkage

Causes

Actuator rod assembly bent or damaged

Actuator rod spring binding or improperly crimped
Actuator rod not attached to inside detent lever
Parking lock bracket damaged or not torqued properly
Inside detent lever not torqued properly
Parking pawl binding or damaged

-r:ransmissionfTransaxle

Automatic Transmission - 4L60-E

7-241

Oil Out the Vent

Checks

Causes

Oil Pump

Chamber in pump body rotor pocket

Miscellaneous

Fluid level-overfilled

Vibration in Reverse and Whining Noise in Park

Checks

Causes

Oil Pump

Chamber in pump body rotor pocket

Miscellaneous

Fluid level-overfilled

Ratcheting Noise
Checks

Parking Pawl

Causes

The parking pawl return spring is weak, damaged, or misassembled

No Drive in All Ranges

Checks

Torque Converter

Causes

The converter to flex plate bolts are missing

No Drive in Drive Range

Checks

Torque Converter

Causes

The stator roller clutch is not holding

The converter is not bolted to the flex plate

Front Oil Leak

Checks

-,

Causes

Torque Converter

The welded seam is leaking

The converter hub is damaged

Torque Converter Seal

The seal assembly is damaged

The garter spring is missing

Delay in Drive and Reverse

Checks

Torque Converter

(
I

Causes

Converter drainback

7-242

Transmission!Transaxle

Automatic Transmission - 4L60-E

Fluid Leak Diagnosis and Repair

General Method
1. Verify that the leak is transmission fluid.
2. Thoroughly clean the suspected leak area.
3. Operate the vehicle for 24 km (15 mi), or until
normal operating temperatures are reached.
4. Park the vehicle over clean paper or cardboard.
5. Shut OFF the engine.
6. Look for fluid spots on the paper.
7. Make the necessary repairs.

Powder Method
1. Thoroughly clean the suspected leak area with
solvent.
2. Apply an aerosol type powder, such as foot
powder, to the suspected leak area.
3. Operate the vehicle for 24 km (15 mi), or until
normal operating temperatures are reached.
4. Shut OFF the engine.
5. Inspect the suspected leak area.
6. Trace the leak path through the powder in order
to find the source of the leak.
7. Make the necessary repairs.

Dye and Black Light Method

A fluid dye and black light kit is available from various
tool manufacturers.
1. Follow the manufacturer's instructions in order to
determine the amount of dye to use.
2. Detect the leak with the black light.
3. Make the necessary repairs.

Find the Cause of the Leak

Pinpoint the leak and trace the leak back to the
source. You must determine the cause of the leak in
order to repair the leak properly. For example, if
you replace a gasket, but the sealing flange is bent,
the new gasket will not repair the leak. You must also
repair the bent flange. Before you attempt to repair
a leak, check for the following conditions, and
make repairs as necessary:
Gaskets
Fluid level/pressure is too high
Plugged vent or drain-back holes
Improperly tightened fasteners
Dirty or damaged threads
Warped flanges or sealing surface
Scratches, burrs, or other damage to the sealing
surface
Damaged or worn gasket
Cracking or porosity of the component
Improper sealant used, where applicable
Incorrect gasket

Seals
Fluid level/pressure is too high
Plugged vent or drain-back holes
Damaged seal bore

Damaged or worn seal

Improper installation
Cracks in component
Manual or output shaft surface is scratched,
nicked, or damaged
Loose or worn bearing causing excess seal wear

Possible Points of Fluid Leaks

Transmission Oil Pan
Incorrectly tightened oil pan bolts
Improperly installed or damaged- oil pan gasket
Damaged oil pan or mounting face
Incorrect oil pan gasket
Case Leak
Damaged or missing fill tube seal
Mislocated fill tube bracket
Damaged vehicle speed sensor seal
Damaged manual shift seal
Loose or damaged oil cooler connector fittings
Worn or damaged propeller shaft oil seal
Loose line pressure pipe plug
Porous casting
Leak at the Torque Converter End
Converter leak in the weld area
Converter seal lip cut (check the converter hub for
damage)
Converter seal bushing moved forward and
damaged
Converter seal garter spring missing from the seal
Porous casting of the transmission case or the
oil pump
Leak at the Vent Pipe or the Fluid Fill Tube
Overfilled system
Water or coolant in the fluid (the fluid will appear
milky)
Transmission case porous
Incorrect fluid level indicator
Plugged vent
Drain-back holes plugged
Mispositioned oil pump to case gasket (if
equipped)

Transmission!Transaxle

Automatic Transmission - 4L60-E

7-243

Leak Inspection Points

208613

Legend

(1) Wiring Harness Pass-Through Connector

0-Ring Seal
(2) Transmission Vent Assembly
(3) Converter Housing to Case Joint (Pump to
Case Oil Seal)
(4) Line Pressure Plug
(5) Case Extension to Case Seal
(6) Manual Shaft Seal
(7) Case Extension Oil Seal Assembly
(8) Torque Converter Assembly

(9) Pump to Case Oil Seal

(10) Pump Oil Seal Assembly
(11) Internal Transmission Speed Sensor to Case
0-Ring Seal
(12) 2-4 Servo Cover 0-Ring Seal
(13) Oil Fill Tube Seal
(14) Oil Cooler Pipe Connectors
(15) Transmission Case
(16) Transmission Oil Pan Gasket

7-244

Automatic Transmission - 4L60-E

Case Porosity Repair

1. Clean the leak area with solvent.
2. Allow the area to air dry.
Caution: Epoxy adhesive may cause skin irritations
and eye damage. Read and follow all information
on the container label as provided by the
manufacturer.

3. Mix a sufficient amount of epoxy adhesive,

P/N 1052533, or equivalent.
Follow the manufacturer's recommendations.
4. While the transmission case is hot, apply the
epoxy adhesive with a clean, dry soldering
acid brush.
5. Allow the epoxy adhesive to cure for three hours
before starting the engine.
6. Repeat the fluid leak diagnosis procedures in
order to determine if the leak is fixed.

Repair Instructions

Transmission/Transaxle
Notice: The assembly of some components will
require the use of an assembly lube. Always use
J 36850 Transjel or petroleum jelly during assembly.
Greases other than the recommended assembly
lube will change the transmission fluid characteristics
and cause undesirable shift 'conditions and/or filter
clogging.
When installing screws, bolts or studs into
aluminum, always dip the threads into
transmission fluid.
Lubricate all of the internal parts with transmission
fluid during assembly.
Always use a torque wrench for the proper torque.
Recondition damaged or stripped aluminum
threads with thread inserts.
Replace all of the gaskets and 0-ring seals. Do
not use gasket cement or sealers.
Replace the Teflon and the rubber lip seals only
when necessary. Always use the appropriate
seal installers.

Inspection Procedure

Parts Cleaning and Inspection

Service Precautions
Use the following safety equipment as appropriate:
- Safety glasses
- Safety shoes
- Gloves
Keep the work area clean.
Keep the tools clean.
Clean the exterior of the transmission before
removing parts.
Do not use wipe cloths or rags.
Do not use solvents on:
- Rubber seals
- Plastic/Teflon thrust washers or seals
Blow out all of the passages with compressed air.
Clean out the small passages with a fine wire.
Handle the parts carefully in order to prevent
damage.

Inspect the manual linkage for the following:

- Wear at the pivoting points
- Shift cable binding
- Proper shift cable attachment
Inspect the seals, gaskets, 0-ring seals and
mating surfaces for the following:
- Nicks
- Cuts
- Damage
Inspect the snap rings for the following:
- Expansion or compression
- Distortion
- Nicks
- Proper ring to groove fit.
Inspect the bearings and thrusts surfaces for the
following:
- Wear
- Scoring
- Pitting

Transmission/Transaxle

Automatic Transmission - 4L60-E

7-245

BTSI Solenoid Replacement

Removal Procedure
Important: The automatic transmission control lever
solenoid is a part of the brake transmission shift
interlock (BTSI) system. The solenoid prevents the
operator from shifting the automatic transmission
control out of the PARK position unless the brake
pedal is depressed.
1. Remove the front floor console trim plate. Refer to
Trim Plate Replacement - Console (Automatic) in
Instrument Panel, Gauges, and Console.
2. Disconnect the electrical connector from the shift
interlock solenoid.

208247

3. Remove the shift interlock solenoid by unsnapping

the retainers.

38110

Installation Procedure
1. Install the shift interlock solenoid. Snap the
retainers into place.

38110

7-246

Transmission/Transaxle

Automatic Transmission - 4L60-E

2. Connect the electrical connector to the shift

interlock solenoid.
3. Install the front floor console trim plate. Refer to
Trim Plate Replacement - Console (Automatic) in
Instrument Panel, Gauges, and Console.

208247

Park Lock Cable Replacement

Removal Procedure
1. Disable the SIR system. Refer to Disabling the
SIR System in SIR. Refer to SIR Handling
Caution
2. Place the automatic transmission control in PARK.

165282

Important: Do not proceed to the next step with the

ignition key in any other position.
3. Turn the ignition key to the RUN position.
4. Remove the LH instrument panel insulator. Refer
to Insulator Replacement - IP (Left Side) in
Instrument Panel, Gauges, and Console.
5. Remove the instrument panel driver knee bolster.
Refer to Knee Bolster Replacement in Instrument
Panel, Gauges, and Console.
6. Remove the instrument panel driver knee bolster
deflector. Refer to Instrument Panel, Gauges, and
Console.
7. Remove the front floor console. Refer to Console
Replacement - Front Floor in Instrument Panel,
Gauges, and Console.
8. Remove the park/lock cable clip from the stud on
the front of dash.
9. Move the park/lock cable button to the UP
position.

Transmissionrrransaxle

Automatic Transmission - 4L60E

7-247

10. Remove the park/lock cable from the bracket.

11. Lower the steering column. Refer to Steering
Wheel and Column.

165285

12. Unsnap the park/lock cable from the steering

column.
13. Reposition the carpet until retaining clip is
reached.
14. Open retaining clip on drivers side of tunnel and
remove cable.

208257

Installation Procedure
1. Place the automatic transmission control in the
(P) PARK position.
Important: Do not proceed to the next step with the
ignition key in any other position.
2. Turn the ignition key to the RUN position.
3. Snap the cable terminal to the park/lock lever pin.
4. Push the park/lock cable connector forward in
order to remove slack.
5. With no load applied to the connector, press the
park/lock cable lock button down.

38136

7;.248

Automatic Transmission - 4L60-E

Transmission/Transaxle
6. Install the park/lock cable to the bracket. Complete
the following steps:
6.1 . Push the bracket housing against the
adjusting spring.
6.2. Drop the park/lock cable through the slot in
the bracket and seat the cable to the
automatic transmission control.
6.3. Push the park/lock cable button down.

')

165285

7. Snap the park/lock cable into the steering column.

8. Raise the steering column.

208257

9. Install the park/lock clip to the stud on the front

of dash.
10. Close the retainer and repostion the carpet.
11. Install the front floor console. Refer to Console
Replacement - Front Floor in Instrument Panel,
Gauges, and Console.
12. Install the instrument panel driver knee bolster
deflector.
13. Install the instrument panel driver knee bolster.
Refer to Knee Bolster Replacement in Instrument
Panel, Gauges, and Console.
14. Install the LH instrument panel insulator. Refer to
Insulator Replacement - IP (Left Side) in
Instrument Panel, Gauges, and Console.
15. Turn the ignition key to the OFF position.
16. Enable the SIR system. Refer to Enabling the SIR
System in SIR.

!
165282

Transmission/Transaxle

Automatic Transmission - 4L60-E

7-249

Inspection Procedure
Inspect the cable for functional operation. Complete
the following procedure:
1. Place the shift lever in Park. Place the key in the
LOCK position. Ensure that you cannot move the
shifter lever to another position. The ignition
key should be removable from the column.
2. Place the key in the RUN position. Place the shift
lever in Neutral. Ensure that you cannot turn the
key to the LOCK position.
3. If the above conditions are met, the system is
properly adjusted. Go to step 5.
4. If the above conditions are not met, move the
button to the UP position, and readjust the
cable. Then, push the button down and recheck
operation.
5. If you cannot remove the key in the Park position,
move the button to the UP position. Then, move
the cable connector nose rearward until the
ignition key can be removed.
6. Snap the button down.
7. Reinstall the cable into the park/lock clip in order
to ensure correct routing.

Shift Cable Replacement

Removal Procedure
1. Remove the front floor console trim plate.
2. Remove the range selector lever cable from the
automatic transmission control.

208301

7-250

Automatic Transmission - 4L60-E

Transmission/Transaxle
3. Remove the retainer and the cable grommet from
the base of the automatic transmission control.

208303

4. Raise the vehicle. Suitably support the vehicle.

Refer to Lifting and Jacking the Vehicle in
General Information.
5. Unsnap the range selector lever cable from the
range selector lever on the transmission.

208264

6. Remove the retainer and the range selector lever

cable from the cable bracket.

208276

Transmission!Transaxle

Automatic Transmission - 4L60-E

7-251

7. Pull the cable through the hole in the front

compartment floor pan.
8. Remove the cable from the vehicle.

Installation Procedure
1. Feed the cable through the hole in the front
compartment floor pan.
2. Install the cable grommet to the base of the
automatic transmission control.
3. Install the range selector lever cable to the cable
bracket.

208276

4. Place the range selector lever in the (N) Neutral

position. Rotate the lever counterclockwise from
(P) Park through (R) Reverse and into Neutral.
5. Install the range selector lever cable to the range
selector lever on the transmission.
6. Lower the vehicle.
Important: The automatic transmission control must
remain in the (N) Neutral po~ition until the cable
installation is complete.
7. Place the automatic transmission control in
(N) Neutral.

208264

8. Install the range selector lever cable to the

automatic transmission control.

208301

7-252

Automatic Transmi.s.sion .. 4L60-E

TransmissionfTransaxle
9. Install the lock adjustment button on the cable to
the range selector bracket Tum the lock
adjustment button counterclockwise.
10. Install the front floor console trim plate.

208303

Floor Shift Control Replacement

Removal Procedure
1. Remove the range selector lever cable from the
automatic transmission control.
2. Remove the park/neutral position switch. Refer to
Park/Neutral Position Switch Replacement

208301

3. Remove the automatic transmission control bolts.

4. Remove the automatic transmission control.

208310

TransmissionfTransaxle

Automatic Transmission - 4L60-E

7-253

Installation Procedure
1. Install the automatic transmission control.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the automatic transmission bolts.

Tighten
Tighten the bolts to 8 N-m (71 lb in).
3. Install the park/neutral position switch. Refer to
Park/Neutral Position Switch Replacement

208310

4. Install the automatic transmission range select

lever cable.

208310

Park/Neutral Position Switch Replacement

Removal Procedure
Important: The park/neutral position switch prevents
starter motor operation when the automatic
transmission control is in any gear by breaking the
starter motor circuit. When the automatic transmission
control is in Reverse with the engine running, the
park/neutral position switch completes the backup
lamp circuit, lighting the backup lamps.
1. Remove the front floor console. Refer to Console
Replacement - Front Floor in Instrument Panel,
Gauges, and Console.
2. Disconnect the park/neutral position switch
electrical connector.

208312

7-254

Automatic Transmission - 4L60-E

Transmission/Transaxle
3. Remove the park/neutral position switch bolts.

4. Remove the park/neutral position switch from the

shift control.

208314

Installation Procedure
Using The Old Switch
1. Place the automatic transmission control in the
Neutral position.
2. Install the tang on the switch, into the slot on the
automatic transmission control.
3. Loosely, install the automatic transmission
control bolts.

208314

4. lnse.rt a 2.34 mm (0.094 in) gage pin into the

service adjustment hole. Rotate the switch until
the gage pin drops to 15 mm (0.59 in) depth.
Notice: Refer to Fastener Notice in Cautions and
Notices.
5. Tighten the automatic transmission control bolts.

Tighten
Tighten the automatic transmission control bolts
to 2.2 N-m (19 lb in).
6. Install the front floor console. Refer to Console
Replacement - Front Floor in Instrument Panel,
Gauges, and Console.
Important: Ensure that the engine will only start in the
Park or the Neutral position. Readjust the switch, if
the engine will start in any other position.

208319

Transmission!Transaxle

Automatic Transmission - 4L60-E

7-255

Using A New Switch

1 . Place the automatic transmission control in
Neutral.
2. Install the tang on the switch, into the slot on the
automatic transmission control.
Important: Align the holes with the shift control. Place
the shift control lever in Neutral. Do not rotate the
switch. The switch is pinned in the Neutral position. If
the switch has been rotated and the pin is broken,
adjust the switch. Refer to Old Switch Installation.
3. Install the bolts to the automatic transmission
control.
Tighten
tighten the automatic transmission control bolts to
2.2 Nm (19 lb in).
4. Install the front floor console. Refer to Console
Replacement - Front Floor in Instrument Panel,
Gauges, and Console.

208314

Important: Ensure that the engine will only start in the

Park or the Neutral position. Readjust the switch if
the engine will start in any other position. Refer to Old
Switch Installation.

AT Fluid/Filter Changing
Removal Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Place a drain pan under the transmission oil pan.
3. Remove the oil pan bolts from the front and
sides only.
4. Loosen the rear oil pan bolts approximately
4 turns.
5. Lightly tap the oil pan with a rubber mallet or pry
gently in order to allow the fluid to drain.

23578

7-256

Automatic Transmission - 4L60-E

Transmission!Transaxle
6. Remove the remaining oil pan bolts.

13952

7. Remove the oil pan and the gasket.

13955

8. Remove the fluid filter and the seal. The seal may
stick in the transmission case.
9. Inspect the fluid color.
10. Inspect the filter. Pry the metal crimping away
from the top of the filter and pull apart. The
filter may contain the following evidence for root
cause diagnosis:
Clutch material
Bronze slivers indicating bushing wear
Steel particles
11 . Clean the transmission case and the oil pan
gasket surfaces with solvent, and air dry. You
must remove all traces of the old gasket material.

13958

Automatic Transmission

Transmissionrrransaxle

4L60-E

7-257

Installation Procedure
Tools Required
J 36850 Transmission Ass~mbly L.ube
1 . Coat the new filter neck seal with a small amount
of J 36850, or equivalent.
2. Install the new filter neck seal into the
transmission case. Tap the seal intC> place using
suitable size socket.
3. Install the new filter into the case.

13958

4. Install the oil pan and a new gasket.

13955

Notice: Do not reuse automatic trar1smission bolts

and washers if the conical washer is reversed. Failure
to replace the oil pan bolts and washers .may result
in improper fastening of the system components.
Notice: Refer to Fastener Notice in Cautions
and Notices.

5. Install the oil pan bolts.

Tighten
Alternately, and evenly, tighten the oil pan bolts to
11 N-m (97 lb in).
6. Lower the vehicle.
Notice: Do not overfill the transmission. Overfilling will
result in foaming, loss of fluid, and possible damage
to the transmission.
7. Fill the transmission to the proper level. Use
DEXRON Ill, or if unavailable, DEXRON IIE.
13952

7-258

Automatic Transmission - 4L60-E

Transmission/Transaxle
8. Check the COLD fluid level reading for initial fill
only. Refer to Transmission Fluid Checking
Procedure.
9. Inspect the oil pan gasket for leaks.

Oil Cooler Line Replacement

Removal Procedure
1. Disconnect the upper oil cooler line fitting at the
radiator.
2. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

208376

3. Remove the upper hose clamp from the upper

hose and pipe.
4. Remove the propeller shaft. Refer to Propeller
Shaft Replacement - One Piece or Propeller
Shaft Replacement - Two Piece in Propeller Shaft.
5. Remove the rear axle torque arm. Refer to Torque
Arm Replacement in Rear Suspension.
6. Remove the catalytic converter hanger. Refer to

208396

Converter Hanger Assembly Replacement

(3.BL Automatic), Converter Hanger Assembly
Replacement (5. 7L Auto/Man) or Converter
Hanger Assembly Replacement (3.BL Man) in
Engine Exhaust.
7. Support the automatic transmission with a
transmission stand.
8. Remove the transmission support member. Refer
to Transmission Support Replacement in Frame
and Underbody.
9. Lower the transmission stand slightly. This will
allow access to the oil cooler fittings at the
transmission.

TransmissionfTransaxle

Automatic Transmission - 4L60-E

7-259

1O. Disconnect the fittings on the transmission end of

the upper and lower oil cooler pipes.

208329

11 . For the 3800 V6 remove the oil cooler pipes from

the clip at the engine mount.

46662

12. For the 5.7L VB remove the oil cooler pipes from
the clip at the oil pan.
Important: Perform the following procedures when
removing the retaining ring and cooler line from
the quick connect fitting on the transmission.
13. Pull the plastic cap back from the quick connect
fitting and down along the cooler line about
two inches.

208334

7-260

Automatic Transmission'- 4L60-E

Transmission/Transaxle
14. Using a bent-tip screwdriver, pull on one of the
open ends of the retaining ring in order to rotate
the retaining ring around the quick connect
fitting until the retaining ring is out of position and
can be completely removed.

uu

104737

15. Remove the retaining ring from the quick connect

fitting.
16. Discard the retaining ring.

104739

17. Pull the cooler line straight out from the quick
connect fitting.
18. Remove the retciining ring (E-clips) securing the
cooler line to. the quick connect in .order to
remove th~ remaining cooler lines from the
remainin~ quick connect fittings.
19. Remove the cooler lines from the vehicle.

104740

Transmission/Transaxle

Automatic Transmission - 4L60-E

7261

Installation Procedure
1. Install the transmission oil cooler line to the
vehicle.
Important: Do not reuse any of the existing retaining
rings that were removed from the existing quick
connect fittings. All retaining rings being installed must
be new. Ensure the following procedures are
performed when installing the new retaining rings onto
the fittings. Install a new retaining ring (E-clip) into
the quick connect fitting using the following procedure:
2. Hook one of the open ends of the retaining ring
in one of the slots in the quick connect fitting.

104743

3. Rotate the retaining ring around the fitting until the

retaining ring is positioned with all thre.e ears
through the three slots on the fitting.

104746

4. Do not install the new retaining ring onto the

fitting by pushing the retaining ring.

104741

7-262

Automatic Transmission - 4L60-E

Transmission/Transaxle
5. Ensure that the three retaining ring ears are seen
from inside the fitting and that the retaining ring
moves freely in the fitting slots.
6. Install the new retaining ring (E-clip) into the
remaining quick connect fittings.

104664

Notice: Ensure that the cooler line being installed has

a plastic cap on each end that connects to a quick
connect fitting. If no plastic cap exists, or the plastic
cap is damaged, obtain a new plastic cap and position
on to the cooler line prior to the cooler line installation.

7. On the 5.7L V8 install the oil cooler pipes to

the clip at the oil pan.

208334

8. On the 3800 V6 install the oil cooler pipes to the

clip at the engine mount.

46662

Transmission/Transaxle

Automatic Transmission - 4L60-E

7-263

9. Install the cooler lines into the quick connect

fittings.
10. Insert the cooler line end into the quick connect
fitting until a click is either heard or felt.

208329

11. Do not use the plastic cap on the cooler line in

order to install the cooler line into the fitting,
12. Pull back sharply on the cooler line in order to
ensure that the cooler line is fastened into the
quick connect fitting.

0
104750

13. Position (snap) the plastic cap onto the fitting. Do

not manually depress the retaining ring when
installing the plastic cap onto the quick connect
fitting.
14. Ensure that the plastic cap is fully seated against
the fitting.

104753

7;.254

Automatic Transmission - 4L60-E

Transmission!Transaxle
15. Ensure that no gap is present between the cap
and the fitting.

104754

16. Ensure that the yellow identification band on the

tube is hidden within the quick connect fitting. A
hidden yellow identification band indicates
proper joint seating.

104753

17. Do not install the cooler line end into the fitting
incorrectly.
18. If you cannot position the plastic cap against the
fitting, remove the retaining ring from the quick
connect fitting per Step 5 of the cooler line
removal procedure. Check the retaining ring and
the tube end in order to ensure neither is bent.
Replace the cooler line or the retaining ring
if necessary, and reinstall per Step 2 of the cooler
line installation procedure.
19. Install the cooler line into the quick connect fitting
again in order to install the remaining cooler lines
into the remaining quick connect fittings.
20. Install the engine or transmission cooler lines to
the engine and transmission clips and brackets
as applicable.
21. Raise the transmission stand slightly.

104755

Transmisslon!Transaxle

Automatic Transmission - 4L60-E

7-265

22. Install the transmission support member. Refer' to

Transmission Support Rep/ace,:nent in F.rame and
Underbody.
23. Remove the transmission stand.
24. Install the catalytic converter hanger. Refer to
Converter Hanger Assembly. Replacement
(3.BL Automatic), Converter Hanger Assembly
Replacement (5.7L Auto/Man) or Converter
Hanger Assembly Replacement (3.BL Man) in

Engine Exhaust.
25. Install the rear axle torque arm. Refer to Torque
Arm Replacement in Rear Suspension.
26. Install the propeller shaft. Refer to Propeller Shaft
Replacement - .One Piece or Propeller Shaft
Replacement - Two Piece in Propeller Shaft.
27. Install the upper hose clamp to the upper hose
and pipe.

28. Lower the vehicle.

208396

29. Install the oil cooler pipe fittings to the radiator.

Tighten
Tighten the flair nuts to 45 N,m (33 lb ft).
30. Check the transmission fluid. Add if needed.

208376

7-266

Automatic Transmission - 4L60-E

Transmission/Transaxle
2-4 Servo
Removal Procedure

542e

5427

Tools Required
J 29714-A Servo Cover Depressor
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. On the 3.8L remove the 3-way catalytic converter.
Refer to Catalytic Converter Replacement iri
Engine Exhaust.
3. On the 5.7L remove the oxidation catalytic
converter. Refer to Oxidation Catalytic Converter
Replacement (Right) in Engine Exhaust.
4. Remove the propeller shaft. Refer to Propeller
Shaft Replacement - One Piece or Propeller
Shaft Replacement - Two Piece in Propeller Shaft.
5. Remove the torque arm. Refer to Torque
Arm Replacement in Rear Suspension.
6. Support the transmission with a transmission jack.
7. Remove the transmission support. Refer to
Transmission Support Replacement in Frame and
Underbody.
8. Remove the catalytic converter heat shield. Refer
to Converter Heat Shield Replacement in Engine
Exhaust.
9. Lower the transmission.
10. Remove the two oil pan bolts below the
2-4 servo cover.
11. Install the J 29714-A to the oil pan rail.
12. Tighten the bolt on J 29714-A to compress the
servo cover.

TransmissionfTtansaxle
13. Remove the servo covet retaining ring.
14. Loosen the bolt on the J 29714-A to release
tension on the servo cover.

15. Remove the servo cover and 0-ring seal. If the

cover seems to be hung up on tt)..e seal, cut arid
remove the 0-ring seal before. removing the. cover.
16. Remove the 2-4 servo from the transmission.
17. Inspect the 4th apply piston, 2-4 servo converter,
2nd apply piston, and the servo piston inner
housing for the following defects:
Cracks
Scoring
Burrs and nicks

Installation Procedure
Tools Required
J 29714-A Servo Cover Depressor
1. Install new seals on the servo pistons and the
servo cover.
2. Install the 2-4 servo to the transmission.
3. Install the servo cover and 0-ring seal:

Automatic Transmission - 4L60-E

7-267

7-268

Automatic Transmission - 4L60-E

TransmissionfTransaxle
4. Tighten the bolt on the J 29714-A to compress the
servo cover.

5427

5. Install the servo cover retaining ring.

6. Loosen the bolt on the J 29714-A to release
tension on the servo cover.

7. Remove the J 29714-A from the. oil pan rail.

Notice: Refer to Fastener Notice in Cautions and
Notices.
8. Install the two oil pan bolts below the
2-4 servo cover.

9.
10.

11.

12.
13.
5426

Tighten
Tighten the oil pan bolts to 11 N-m (97 lb in).
Raise the transmission.
Install the catalytic converter heat shield. Refer to
Converter Heat Shield Replacement in Engine
Exhaust.
Install the transmission support. Refer to
Transmission Support Replacement in Frame and
Underbody.
Remove the support from the transmission.
Install the torque arm. Refer to Torque Arm
Replacement in Rear Suspension.

Transmission/Transaxle

Automatic Transmission - 4L60-E

7-269

14. lnstal.1 the propeller shaft. Refer to Propeller Shaft

or

Replacemer;it - Or:,e. Piece

Pr.opeller Shaft
Replacement - Two Piece in Propeller Shaft.

15. On the 5. 7L install the oxidation catalytic

converter. Refer to Oxidation Catalytic Converter
Replacement (Right) in Engine Exhaust.
16. On the 3.BL install the 3-way catalytic converter.
Refer to Catalytic Converter Replacement in
Engine Exhaust.
17. Lower the vehicle.

Pressure Regulator Replacement

Removal Procedure
1. Remove the transmission oil pan. Refer to AT
Fluid/Filter Changing

2. Compress the reverse boost valve sleeve and the

related components with a small screwdriver.
3. Remove the reverse boost valve retaining ring.
4. Slowly release the spring pressure.

14433

5. Remove the reverse boost valve sleeve.

6. Remove the reverse boost valve.

14438

7-270

Automatic Transmission - 4L60-E

Transmission/Transaxle
7. Remove the pressure regulator isolator spring.
8. Remove the pressure regulator valve spring.
9. Remove the pressure regulator valve.

14456

Installation Procedure
Tools Required
J 36850 Transjel
1. Install the pressure regulator valve into the oil
pump cover bore.
2. Install the pressure regulator valve spring.
3. Install the pressure regulator isolator spring.

14456

4. Install the reverse boost valve and reverse boost

valve sleeve and other related components.Retain
with J 36850, or equivalent.

14438

Transmission/Transaxle

Automatic Transmission - 4L60-E

7-271

5. Compress the reverse boost valve sleeve and the

related components. Using a small screwdriver.
6. Install the reverse boost valve retaining ring into
the oil pump cover bore.
7. Install the automatic transmission oil pan. Refer to
AT Fluid/Filter Changing

14433

Filler Tube Replacement (VS)

Removal Procedure
1. Remove the fluid level indicator.

208423

2. Remove the transmission bolt attaching the fill .

tube to the transmission.
3. Remove the transmission. Refer to Transmission
Replacement (5. 7L).

208459

7-272

Automatic Transmission - 4L60-E

TransmissionfTransaxle
4. Remove the fill tube and seal from the
transmission.

165576

Installation Procedure
1. Insert the seal into the automatic transmission
case hole.
2. Install the fill tube to the transmission.
3. Install the transmission. Refer to Transmission
Replacement (5. 7L).

165576

Notice: Refer to Fastener Notice in Cautions and

Notices.

4. Install the transmission bolt attaching the fill tube

to the transmission.
Tighten
Tighten the transmission bolt to 47 Nm (35 lb ft).

208459

Transmission/Transaxle

Automatic Transmission - 4L60-E

7-273

5. Install the fluid level indicator.

6. Check the transmission fluid. Refer to
Transmission Fluid Checking Procedure.

208423

Filler Tube Replacement {V6)

Removal Procedure
1. Remove the transmission fluid level indicator.
2. Raise .and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

165298

3. Remove the fill tube nut attaching the tube to the

transmission.
4. Loosen the fill tube from the transmission.
5. Place a drain pan under the transmission to catch
any dripping fluid.
6. Lower the vehicle.

(
\

165305

7-274

Transmission/Transaxle

Automatic Transmission - 4L60-E

7. Remove the fill tube and seal from the

transmission through the engine compartment.

165303

Installation Procedure
1. Place the fill tube to the transmission through the
engine compartment.
2. Raise the vehicle.
3. install the s~al and the fill tube to the transmission.

165303

Notice: Refer to Fastener Notice in Cautions and

Notices.
4. Install the fill tube nut attaching the tube to the
transmission.

Tighten
Tighten the fill tube nut to 25 N-m (18 lb in).
5. Lower the vehicle.

165305

TransmissionfTransaxle

Automatic Transmission~ 4L60E

7-275

6. Install the transmission fluid level indicator.

165298

Torque Converter Cover Replacement (VS)

Removal Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General

Information.
2. If servicing the right side cover, remove the starter
motor. Refer to Starter Motor Replacement
(5.7L VB) in Engine Electrical.
3. Remove the right side converter cover bolt.
4. Remove the right side converter cover.

208464

5. Remove the left side converter cover bolt.

6. Remove the left side converter cover.

208478

7-276

Transmission!Transaxle

Automatic Transmission - 4L60-E

Installation Procedure
1. Install the left side converter cover.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the left side converter cover bolt.
Tighten
Tighten the left side converter cover bolt to
12 Nm (106 lb in).

208478

3. Install the right side converter cover.

4. Install the right side converter cover bolt.
Tighten
Tighten the right side converter cover bolt to
12 N-m (106 lb in).
5. Install the starter motor, if removed. Refer to
Starter Motor Replacement (5. 7L VB) in Engine
Electrical.
6. Lower the vehicle.

208464

Torque Converter Cover Replacement (VG)

1

Removal Procedure
1. Raise and suitably support the vehicle. Refer to
Key and Lock Cylinder Coding in General
Information.
2. Remove the starter motor. Refer to Starter Motor
Replacement (3.8L V6) in Engine Electrical.
3. Remove the transmission brace bolts (5) attaching
the left brace (4) to the engine block.
4. Remove the transmission brace nut (1) attaching
the left brace (4) to the transmission.
5. Remove the transmission brace (4).
6. Remove the transmission converter cover bolt (3).

4
208577

Ttansmissionrrransaxle

Automatic Transmission - 4L60E

7. Remove the transmission brace bolts (2, 3)

attaching the right brace (4) to the engine block.
8. Remove the transmission brace nut (6) attaching
the right brace (4) to the transmission.
9. Remove the right side transmission brace (4)'.
10. Remove the transmission converter cover bolt (1).
11 . Remove the transmission converter cover (5)
from the vehicle.

7-277

4
208574

Installation Procedure
1. Install the transmission converter cover (5) to the
vehicle.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the transmission converter cover bolt (1 ).

Tighten
Tighten the transmission converter cover bolt (1)
to 8.5 N-m (75 lb in).
3. Install the right side transmission brace (4).
4. Install the transmission brace nut (6) attaching the
right brace (4) to the transmission.
Tighten
Tighten the transmission brace nut (6) to
80 N-m (59 lb ft).
5. Install the transmission brace bolts (2, 3) attaching
the right brace (4) to the engine block.
Tighten
Tighten the engine transmission brace bolts (2, 3)
to 50 N-m (37 lb ft).

208574

7-278

Automatic Transmission - 4L60-E

Transmission/Transaxle
6. install the transmission converter cover bolt (3).

Tighten
Tighten the transmission converter cover bolt (3)
to 8.5 N-m (75 lb in).
7. Install the transmission brace (4).
8. Install the transmission brace nut (1) attaching the
left brace (4) to the trans.mission.

Tighten
Tighten the transmission brace nut (1) to
80 N-m (59 lb ft).
9. Install the transmission brace bolts (5) attaching
the left brace (4) to the engine block.
Tighten
Tighten the engine transmission brace bolts (5) to
28 N-m (21 lb ft).
10. Install the starter motor. Refer to Starter Motor
Replacement (3.BL V6) in Engine Electrical.
11 . Lower the vehicle.
208577

Valve Body and Pressure Switch

Replacement
Removal Procedure
1. Remove the transmission oil pan and filter. Refer
to AT Fluid/Filter Changing.
2. Disconnect the internal wiring harness electrical
connectors from the following components:
Transmission pressure switch (1)
1-2 shift control solenoid (2)
2-3 shift control solenoid (3)
Pressure control solenoid (4)
TCC PWM solenoid (5)
3-2 control solenoid (6)

4
181573

3. Remove the TCC PWM solenoid retainer.

4. Remove the TCC PWM solenoid in order to
access one of the TCC solenoid retaining bolts.

298154

Transmission/Transaxle

Automatic Transmission - 4L60-E

7-279

5. Remove the TCC solenoid retaining bolts and the

valve body bolts which retain the internal wiring
harness.

!
298139

6. Remove the TCC solenoid (with 0-ring seal) and

wiring harness from the control valve body.
Reposition the harness to the side of the
transmission case.

71463

7. Remove the control valve body bolts which retain

the transmission fluid pressure switch to the
control valve body.
8. Remove the transmission fluid pressure switch.

29454

7-280

Automatic Transmission - 4L60-E

Transmissi,on!Transaxle
9. Inspect the transmission fluid pressure switch for
damage or debris.

8889

10. Remove the manual detent spring retaining bolt.

11. Remove the hlan'ual detent sprlng.
12. Inspect the manual'detent spring for cracks
damage.

or

71461

13. Remove the' remaining control valvebody bolts.

14. Carefully begin to lower the confrol valve body
down from the transmission case, disconnect
the manual valve link, then remove the control
valve body from the transmission case.
15. Inspect the control valve body. Refer to the
Transmission!Transaxle!Transfer Case Unit Repair
Manual for the control valve body cleaning,
inspection and repair procedures.

29460

Transmission/Transaxle

Automatic Transmission - 4L60-E

7-281

Installation Procedure
1. Install the control valve body to the transmission
case and connect the manual valve link to the
inside detent lever.

29460

2. Verify that the manual valve link (3) is installed

properly to the inside detent lever (1) and the
manual valve (2).

2
72883

Important: When installing bolts throughout this

procedure, be sure to use the correct size bolt and
length in the correct location as specified.
3. Install but do not tighten the control valve body
bolts which retain only the valve body directly.
Each numbered bolt location corresponds to
a specific bolt size and length, as indicated by the
following:
M6 X 1.0 X 65.0 (1)
M6 X 1.0 X 54.4 (2)
M6 X 1.0 X 47.5 (3)
M6 X 1.0 X 35.0 (4)
M6 X 1.0 X 20.0 (5)
M6 X 1.0 X 12.0 (6)
M6 X 1.0 X 18.0 (7)

13370

7-282

Automatic Transmission 4L60E

Transmission!Transaxle
4. Install the manual detent .spring ..
5., Install but do not tighten the manual detent spring
retaining bolt

71461

6. Install the transmission fluid pressure. switch.

7. Install but do'not tighten the control valve body
bolts which retain the transmission fluid pressure
switch to the control valve body.

29454

8. Install the wiring harness and TCC solenbid with a

new 0-ring seal to the valve body.

71463

Transmissionrrransaxle

Automatic Transmission - 4L60-E

7-283

9. Install but do not tighten the valve body bolts

which retain the internal wiring harness.

Notice: Refer to Fastener Notice in Cautions and

Notices.
10. Install the TCC solenoid retaining bolts.

Tighten
Tighten the TCC solenoid retaining bolts to
11 N-m (97 lb in).

i
298139

11 . Install the TCC PWM solenoid to the control .

valve body.
12. Install the TCC PWM solenoid retainer.

298154

Notice: Torque valve body bolts in a spiral pattern

starting from the center. If the bolts are torqued at
random, valve bores may be distorted and inhibit valve
operation.

13. Tighten the control valve body bolts in a spiral

pattern starting from the center, as indicated by
the arrows.

Tighten
Tighten the control valve body bolts (in sequence)
to 11 N-m (97 lb in).

\,

7748

7-284

Automatic Transmission - 4L60-E

Transmission/Transaxle
14. Connect the internal wiring harness electrical
connectors to the following components:
Transmission pressure switch (1)
1-2 shift control solenoid (2)
2-3 shift control solenoid (3)
Pressure control solenoid (4)
TCC PWM solenoid (5)
3-2 control solenoid (6)
15. Install the transmission oil pan and the filter. Refer
to AT Fluid/Filter Changing

4
181573

Control and Shift Solenoids Replacement

Removal Procedure
1. Remove the transmission oil pan and the filter.
Refer to AT Fluid/Filter Changing.
2. Remove the 1-2 accumulator. Refer to
Accumulator Assembly.
3. Disconnect the internal wiring harness electrical
connectors from the following components:
Transmission pressure switch (1)
1-2 shift control solenoid (2)
2-3 shift control solenoid (3)
Pressure control solenoid (4)
TCC PWM solenoid (5)
3-2 control solenoid (6)

4
181573

4. Remove the pressure control solenoid retainer.

5. Remove the pressure control solenoid.

298162

Transmissionffransaxle

Automatic Transmission - 4L60-E

7-285

6. Remove the 1-2 and 2-3 shift solenoid retainers.

7. Remove the 1-2 and 2-3 shift solenoids.

298169

8. Remove the 3-2 control solenoid retainer.

9-' Remove the 3-2 control solenoid.

298167

Installation Procedure
1. Install the 3-2 control solenoid.
2. Install the 3-2 control solenoid retainer.

298167

7-286

Transmission/Transaxle

Automatic Transmission - 4L60-E

3. Install the 1-2 and 2-3 shift solenoids.

4. Install the 1-2 and 2-3 shift solenoid retainers.

298169

5. Install the pressure control solenoid.

Ensure that the electrical tabs are facing outboard.

Notice: Refer to Fastener Notice in Cautions and

Notices.
6. Install the pressure control solenoid retainer and
retaining bolts.

Tighten
Tighten the pressure control solenoid retaining
bolt to 11 N-m (97 lb in).

298162

7. Connect the internal wiring harness electrical

connectors to the following components:
Transmission press,ure switch (1)
1-2 shift control solenoid (2)
2-3 shift control solenoid (3)
Pressure control solenoid (4)
TCC PWM solenoid (5)
3-2 control solenoid (6)

8. Install the 1-2 accumulator. Refer to Accumulator

Assembly.

9. Install the transmission oil pan and the filter. Refer

to AT Fluid/Filter Changing.

4
181573

Transmission!Transaxle

Automatic Transmission - 4L60-E

7-287

TCC PWM Solenoid, TCC Solenoid, and

Wiring Harness
Removal Procedure
Tools Required
J 28458 Power Piston Seal Protector and Diaphragm
Retainer Installer
1 . For the 3.8L remove the 3-way catalytic converter.
Refer to Catalytic Converter Replacement in
Engine Exhaust.
2. For the 5.7L remove the oxidation catalytic
converter. Refer to Oxidation Catalytic Converter
Replacement (Right) in Engine Exhaust.
3. Remove the transmission oil pan and the filter.
Refer to AT Fluid/Filter Changing
4. Disconnect the transmission harness 20-way
connector from the transmission internal
harness pass-through connector.
Depress both tabs on the connector and pull
straight up; do not pry the connector.
5. Disconnect the internal wiring harness electrical
connectors from the following components:
Transmission pressure switch (1)
1-2 shift control solenoid (2)
2-3 shift control solenoid (3)
Pressure control solenoid (4)
TCC PWM solenoid (5)
3-2 control solenoid (6)

173659

181573

I
\

7288

Automatic Transmission 4L60E

Transmission!Transaxle
6. Remove the TCC PWM solenoid retainer.
7. Remove the TCC PWM solenoid in order to
access one of the TCC solenoid retaining bolts.

298154

8. Remove the pressure control solenoid retainer.

9. Remove the pressure control solenoid.

2~8162

10. Remove the TCC solenoid retaining bolts and the

valve body bolts which retain the internal wiring
harness.

!
298139

TransmissionfTransaxle

Automatic Transmission - 4L60-E

7-289

11. Using J 28458, releasethe pass-throughelectrical

connector from the transmission case.
11 .1 . Use the small end of the J 28458 over the
top of the connector.
11.2. Twist in order to release the four tabs
retaining the connector.
11.3. Pull the harness connector down through

the transmission case.

12. Remove. the TCC ~olenoid (with 0-ring seal) and
wiring harness from the transmission case.

71463

13. Inspect the TCC solenoid andwiring harness for

the following defects:
Damage
Cracked connectors
Exposed wires
Loose pins

155017

Installation Procedure
1. Install the wiring harness and TCC solenoid with a
new 0-ring seal to the valve body.
2. Install the pass-through electrical connector to the
transmission case.

71463

7-290

Automatic Transmission - 4L60-E

Transmission/Transaxle
Notice: Refer to Fasten.er Notice in Cautions and
Notices.
-3. Install the valve body bolts which retain the
internal wiring harness and install the TCC
solenoid retaining bolts.
Tighten
'Tighten the control valve body retaining bolts
to 11 Nm (97 lb in).
Tighten the TCC. solenoid retaining bolts
to 11 Nm (97 lb in).

n
298139

4. Install the pressure control solenoid.

Ensure that the electrical tabs are facing outboard.
5. Install the pressure control solenoid retainer and
retaining bolt.
Tighten
Tighten the pressure control solenoid retaining
bolt to 11 N-m (97 lb in).

298162

6. Install the TCC PWM solenoid to,the control

valve body.
7. Install the TCC PWM solepoid retainer.

298154

Transmission/Transaxle
8. Connect the internal wiring harness electrical
connectors to the following components:
Transmissiofl pressure swi.tch (1)
1-2 shift control solenoid (2)
2-3 shift control solenoid (3)
Pressure control solenoid (4)
TCC PWM solenoid (5)
3-2 control solenoid (6)

Automatic Transmission - 4L60-E

7-291

4
181573

9. Connect the transmission harness 20-Way

connector to the transmission internal harness
pass-through connector.
Align the arrows 'on each half of the connector
and insert straight down.
1O. Install the transmission oil pan and the filter. Refer
to AT Fluid/Filter Changing
11. For the 3.8L instal.1 the 3-way catalytic converter.
Refer to Catalytic Converter Replacement in
Engine Exhaust.
12. For the 5.7L install the oxidation catalytic
converter. Refer to Oxidation Catalytic Converter
Replacement (Right) in Engine Exhaust.

173659

Extension Housing Rear Oil Seal

Removal Procedure
1. Remove the propeller shaft. For the 3.8L equipped
vehicle, refer to Propeller Shaft Replacement Two Piece or for the 5.7L equipped vehicle, refer
to Propeller Shaft Replacement - One Piece in
Propeller Shaft.
2. Remove the case extension oil seal (1 ).
Use a flat bladed tool to pry the seal (1) from the
housing.

481930

7-292

Automatic Transmission - 4L60-E

Transmission/Transaxle
Installation Procedure
Tools Required
J 21426 Extension Housing Seal Installer
1. Use the J 21426 and a soft face hammer, install
the case extension oil seal (1).

2. Install the propeller shaft. For the 3.8L equipped

vehicle, refer to Propeller Shaft Replacement Two Piece or for the 5.7L equipped vehicle, .refer
to Propeller Shaft Replacement - One Piece in
Propeller Shaft.
3. Check the automatic transmission fluid level.
Refer to Transmission Fluid Checking Procedure.

J 21426

481931

Case Extension Assembly

Removal Procedure

1 . Rai.se and suitably support the vehicle. Refer to

Lifting and Jacking the Vehicle in General
Information.
2. Remove the propeller shaft. Refer to Propeller
.Shaft Replacement - Two Piece or Propeller
Shaft Replacement - One Piece in Propeller Shaft.
3. Remove the rear axle torque arm. Refer to Torque
Arm Replacement in Rear Suspension.
4. Remove the catalytic converter hanger; Ref~r to
Converter Hanger ,4ssembly Replacement
(3.BL Automatic), Converter Hanger Assembly
Replacement (5. 7L Auto/Man) or Converter
Hanger Assembly Replacement (3.BL Man) in
Engine Exhaust.
5. Remove the case extension bolts (1 ).

481933

6. Remove the case extension (2).

7. Remove the case extension seal (1 ).

481930

Transmissionrrransaxle

Automatic Transmission - 4L60-E

7.;293

8. Remove the output shaft sleeve (1 ), if necessary.

9. Remove the output shaft seal (2), if necessary.

481935

Installation Procedure
Tools Required
J 21426 Case Extension Oil Seal Installer
1. Install a new output shaft seal (2), if necessary.
2. Install a new output shaft sleeve (1) using
J 21426, if necessary.

481935

3. Install a new case extension seal (1) using a soft

face hammer and J 21426.

J 21426
481931

7-294

Automatic Transmission - 4L60-E

Transmission!Transaxle
4. Install a new case extension seal (3).
5. Install the case extension (2).
Notice: Refer to Fastener Notice in Cautions and
Notices.
6. Install the case extension bolts (1 ).

7.

8.

9.
481933

10.

Tighten
Tighten the case extension bolts (1) to
35 N,m (26 lb ft).
Install the catalytic converter hanger. Refer to
Converter Hanger Assembly Replacement
(3.BL Automatic), Converter Hanger Assembly
Replacement (5. 7L Auto/Man) or Converter
Hanger Assembly Replacement (3.BL Man) in
Engine Exhaust.
Install the rear axle torque arm. Refer to Torque
Arm Replacement in Rear Suspension.
Install the propeller shaft. For the 3.8L equipped
vehicle, refer to Propeller Shaft Replacement Two Piece or for the 5.7L equipped vehicle, refer
to Propeller Shaft Replacement - One Piece in
Propeller Shaft.
Lower the vehicle.

Accumulator Assembly
Removal Procedure
1. Remove the transmission oil pan and the filter.
Refer to AT Fluid/Filter Changing.
2. Remove the control valve body. Refer to Valve
Body and Pressure Switch Replacement.
3. Remove the accumulator cover retaining bolts.
4. Remove the 1-2 accumulator cover and pin.

14464

Transmission/Transaxle

Automatic Transmission - 4L60-E

7-295

5. Disassemble the 1-2 accumulator.

5.1. Blow compressd air into the
1-2 accumulator cover, as shown, to
remove the 1-2 accumulator piston.
5.2. Remove the 1-2 accumulator inner and
outer springs.
6. Inspect the 1-2 accumulator inner and outer
springs for cracks.

298151

7. Remove the 1-2 accumulator piston seat (1) from

the 1-2 accumulator piston.
8. Inspect the 1-2 accumulator piston for the
following defects:
Porosity
Cracks
Scoring
Nicks and scratches
(
\

298143

9. Inspect the 1-2 accumulator cover for the following

defects:
Porosity
Cracks
Scoring
Nicks and scratches

7734

7~296

Automatic Transmission - 4L60-E

Trall$missio.n!Transa.xte
10. Remove the spacer plate support retaining bolts.
11. Remove the spacer plate spport.

14468

12. Remove the spacer plate to valve body gasket,

the spacer plate and the spacer, plate to
transmission case gask,et.

14469

13.. Remove the 3-4 accumulator spring and tt,e

3-4 accumulator piston.
14. Inspect the 3-4 accumulator spring for cracks.

29443

Transmission!Transaxle

Automatic Transmission - 4L60-E

7-297

15. Remove the 3-4 accumulator piston seal (1) from

the 3-4 accumulator piston.
16. Inspect the 3-4 accumulator piston for the
following defects:
Porosity
Cracks
Scoring
Nicks and scratches

298143

Installation Procedure
Tools Required
J 25025-B Guide Pin Set
J 36850 Transmission Assembly Lube
1. Install a new 3-4 accumulator piston seal (1) to
the 3-4 accumulator piston.

298143

2. Install the 3-4 accumulator piston onto the pin in

the transmission case.
Ensure that the 3-4 accumulator piston legs face
away from the transmission case.
3. Install the 3-4 accumulator piston spring.

29443

7~298 Automatic Transmission

4L60-E

Transmission/Transaxle
4. Install the J 25025:-B to the transmission case.
5. Install the spacer plate to the transmission case
gasket and the spacer plate to valve body gasket
to the spacer plate; use the J25025-B in order
to retain the gaskets to the spacer plate.
The case gasket is identified by a C.
Be sure to place the case gaskelon the
transmission case side of the spacer plat~.
The valve body gasket is identified by a V.
Be sure to place the valve body gasket on the
valve body side of the spacer plate.
6. Install the spacer plate to transmission case
gasket, the spacer plate and the spacer plate
to valve body gasket to the transmission case.

14469

Notice: Refer to Fastener Notice in Cautions and

Notices.

7. Install the spacer plate support and the spacer

plate support retainiqg bolts.

Tigl:lten
Tighten the spacer plate support retaining bolts to
11 N-m (97 lb in).

'\
)

14468

8. Install a new 12 accumulator piston seal (1) to

the 1-2 accumulator piston.

298143

Trans.mission/Transaxle

Auto.matic Transmission - 4L60-E 7-299

9. Install the ;1 s2 accumulator ir:mer and outer springs

to the 1-2 accumt1lator 9over.
10. Install the 1-2 accumulator piston onto the pin in
the 1-2. accumulator co.var. ,
Ensure that the piston legs faoe'the
accumulator cover.

71462

11. Install. the 1-2 aGCumulator cover and the

accumulator cover retaining bolts
Tighten
Tighten the accumulator cover retaining bblts to
11 N-m (97 lb in).
12. Remove the J 25025-B from the
transmission case.
13. Install the control valve body. Refer to Valve Body
and Pressure Switch Replacement.
14. Install the transmission oil pan and filter. Refer to
AT Fluid/Filter Changing.

14464

Vehicle Speed Sensor Replacement

Removal Procedure
1. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
"
Intormation.
2. Disconnect the vehicle speed sensor electrical
connector.

208480

7-300

Automatic Transmission - 4L60-E

Transmission!Transaxle
3. Remove the vehicle speed sensor bolt (1 ).
4. Remove the vehicle speed sensor (2) and the
0-ring seal (3).
Use a suitable container in order to catch any
transmission fluid that may spill.

481937

5. Inspect the transmission speed sensor for the

following defects:
Cracks
Nicks
Damage

181582

Installation Procedure
1. Install the vehicle speed sensor (2) with a new
0-ring seal (3).
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the vehicle speed sensor bolt (1 ).

Tighten
Tighten the vehicle speed sensor
bolt to (1) 11 Nm (97 lb in).

481937

Jransmission/Transaxl.e

Automatic Transmission- 4L60-E .7-301

3. Connect the vehicle speed sensor electrical

connector.
4. Lower the vehicle.
5. Check transmission fluid, add as required. Refer
to Transmission Fluid Checking Procedure ..

208480

Transmission Replacement (5. 7L)

Removal Procedure
Tools Required
J 21366 Converter Holding Strap
Perform a pressure test before removing the automatic
transmission. This will help to aid in the diagnosis of
the transmission.
1. Disconnect the intake air temperature (IAT) and
mass airflow (MAF) sensors electrical connectors.

208553

2. Remove the air intake duct.

/
I.

208569

7-302

Automatic Transmission - 4L60-E

Transmission/Transaxle
3. Remove the transmission fluid level indicator.
4. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
5. Remove the oxidation catalytic converter, for the
left side, refer to Oxidation Catalytic Converter
Replacement (Left) in Engine Exhaust.
6. Remove the oxidation catalytic converter, for the
right side, refer to Oxidation Catalytic Converter
Replacement (Right) in Engine Exhaust.

208423

7. Unsnap the range selector lever cable from the

transmission.
8. Remove the propeller shaft. Refer to Propeller
Shaft Replacement - One Piece in Propeller Shaft.
9. Support the rear axle with a suitable jack.
10. Remove the rear axle torque arm. Refer to Torque
Arm Replacement in Rear Suspension.
11. Remove the transmission covers. Refer to Torque
Converter Cover Replacement (VB).

208264

12. Remove the transmission torque converter bolts.

13. Remove the transmission oil cooler pipes. Refer
to Oil Cooler Line Replacement.

208580

Transmission!Transaxle

14. Remove the wiring harness clamp bolt (1)

attaching the clamp to the transmission.
15. Disconnect the transmission 20-way electrical
connector (2).
Depress both tabs on the connector and pull
straight up; do not pry the connector.
16. Disconnect the vehicle speed sensor electrical
connector (3).
17. Support the transmission using a
transmission jack.

Automatic Transmission - 4L60-E

7-303

481327

18. Remove the transmission mount nut.

208583

19. Remove the support bolts and the support from

the rail.
20. Lower the tail section of the transmission slightly.

208587

7-304

Automatic Transmission - 4L60-E

Transmission!Transaxle
21. Remove the transmission bolts.
22. Separate the transmission from the engine. Attach
the J 21366 to the transmission.
23. Lower the transmission from the vehicle.
24. Remove the transmission fluid fill tube from the
transmission, if necessary.

208590

Installation Procedure
1.
2.
3.
4.

Install the transmission fluid fill tube, if removed.

Raise the transmission up to the vehicle.
Remove J 21366 from the transmission.
Align and install the transmission to the engine.

Notice: Refer to Fastener Notice in Cautions and

Notices.
5. Install the transmission bolts.
Tighten
Tighten the transmission bolts to 50 Nm (37 lb ft).

208590

6. Install the transmission support and bolts to

the rail.
Tighten
Tighten the transmission support bolts to
90 N-m (66 lb ft).

208587

Transmissionffransaxle

Automatic Transmission - 4L60-E

7-305

7. Install the transmission mount nut.

Tighten
Tighten the transmission mouht nut to
105 Nm (77 lb ft).
8. Remove the transmission support.

208583

9. Connect the vehicle speed sensor electrical

connector (3).
1O. Connect the 20-way electrical connector (2).
11. Install the wiring harness clamp bolt (1) attaching
the clamp to the transmission.

Tighten
Tighten the wiring harness clamp bolt (1) to
2.5 N-m (22 lb in).
12. Install the transmission oil cooler lines. Refer to
Oil Cooler Line Replacement.

481327

13. Install the transmission torque converter bolts.

14.
15.
16.
17.

Tighten
Tighten the transmission torque converter bolts to
60 Nm (44 lb ft).
Install the transmission covers. Refer to Torque
Converter Cover Replacement (VB).
Install the rear axle torque arm. Refer to Torque
Arm Replacement in Rear Suspension.
Remove the rear axle support.
Install the propeller shaft. Refer to Propeller Shaft
Replacement - One Piece in Propeller Shaft.

208580

7~306

Automatic Tra'nsmission - 4L60-E

Transmission/Transaxle
18. Connect the range selector lever cable to the
transmission.
19. Install the oxidation catalytic converter, for,the
right side, refer to Oxidation, Catalytic Converter
Replacement (Right),in Engine Ex~aust. ,
20. Install the oxidation catalytic converter, for the left
side, refer to Oxidation Catalytic Converter
Replacement (Left) in Engine Exhaust.
21. Lower the vehicle.

208264

22. lnstalt the transmission fluid level indicator;

208423

23. Install the air intake duct.

208569

Transmission/Transa:xle

Automatic Transmission .~,4L60~E

7-307

24. Connect the intake air temperature (IAT} and

mass airflow (MAF) se.nsors el~qtri~al connectors;
25. Adjustthe automatic transmission shift control
lever cable. Refer to Shift Cable Replacemeht
Notice: Whenever you remove the transmission for
service, you must perform the autbmatie transmission
oil cooler flushing procedure in order to remove the
existing fluid which may be contaminated. This
will prevent contamination of the new fluid. You must
perform the flushing procedure after the installation
of the overhauled or replacement transmission.
26. Flush the transmission oil cooler, oil cooler pipes,
and the hoses. Refer to AT Oil Cooler Flushing.
27. Check the transmission fluid level. Refer to
Transmission Fluid Checking Procedure.

208553

Transmission Replacement (3;8L) .

Remov,al Procedure
Tools Required
J 21366 Converter Holding Strap
Perform a pressure test before servicing the automatic
transmission. This will help to aiditi the aiagnosis of
the transmission.
1. Disconnect the intake air temperature (IAT)
sensor electrical connector.

208554

2. Remove the air intake duct.

208572

7-308

Automatic Transmission - 4L60-E

Transmission/Transaxle
3. Remove the transmission fluid level indicator;
4. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
5. Remove the 3 way catalytic converter. Refer to
Catalytic Converter Replacement in Engine
Exhaust.

165298

6. Unsnap the range selector lever cable from the

transmission.
7. Remove the propeller shaft. Refer to Propeller
Shaft Replacement - Two Piece in Prope.ller Shaft.
8. Support the rear axle with a. suitable jack.
9. Remove the rear axle torque arm. Refer to Torque
Arm Replacement in Rear Suspension.
10. Remove the torque converter cover. Refer to
Torque Converter Cover Replacement (V6).

208264

11. Remove the transmission torque converter bolts.

12. Remove the transmission oil cooler pipes. Refer
to Oil Cooler Line Replacement.

)
208580

Transmission!Transaxle

13. Remove the wiring harness clamp bolt (1)

attaching the clamp to the transmission.
14. Disconnect the transmission 20-way electrical
connector (2).
Depress both tabs on the connector and pull
straight up; do not pry the connector.

Automatic Transmission - 4L60E

7-309

481414

15. Disconnect the vehicle speed sensor electrical

connector (1 ).
16. Support the transmission using a
transmission jack.

481415

17. Remove the transmission mount nut.

208583

7-310

Automatic Transmission - 4L60-E

TransmissionfTransaxle
18. Remove the support bolts and the support to
the rail.

19. Lower the tail section of the transmission slightly.

208587

20.
21.
22.
23.
24.

Remove the transmission bolts and nuts.

Remove the transmission fill tube.
Separate the transmission from the engine.
Attach the J 21366 to the transmission.
Lower the transmission from the vehicle.

208594

Installation Procedure
1. Raise the transmission into the vehicle.
2. Remove the J 21366 from the transmission.
3. Align and install the transmission to the engine.
4. Install the transmission fluid fill tube.
Notice: Refer to Fastener Notice in Cautions and
Notices.

5. Install the transmission bolts.

Tighten
Tighten the transmission bolts and nuts to
95 N-m (70 lb ft).

208594

Transmission/Transaxle

Automatic Transmission - 4L60-E

7-311

6. Install the transmission support and support bolts

to the rail.
Tighten
Tighten the transmission support bolts to
90 Nm (66 lb ft).

208587

7. Install the transmission mount nut.

Tighten
Tighten the transmission mount nut to
57 N,m (42 lb ft).
8. Remove the transmission support.

208583

9. Connect the vehicle speed sensor electrical

connector ( 1).

481415

7-312

Transmission/Transaxle

Automatic Transmission - 4L60-E

10. Connect the 20-way electrical connector (2).

11. Install the wiring harness clamp bolt (1) attaching
the clamp to the transmission.
Tighten
Tighten the wiring harness clamp bolt (1) to
2.5 Nm (22 lb in).
12. Install the transmission oil cooler lines. Refer to
Oil Cooler Line Replacement.

481414

13. Install the torque converter bolts.

14.
15.
16.
17.

Tighten
Tighten the torque converter bolts to
63 Nm (47 lb ft).
Install the torque converter cover. Refer to Torque
Converter Cover Replacement (V6).
Install the rear axle torque arm. Refer to Torque
Arm Replacement in Rear Suspension.
Remove the support from the rear axle.
Install the propeller shaft. Refer to Propeller Shaft
Replacement - Two Piece in Propeller Shaft.

208580

18. Connect the range selector lever cable to the

transmission.
19. Install the 3 way catalytic converter. Refer to
Catalytic Converter Replacement in Engine
Exhaust.
20. Lower the vehicle.

208264

Transmission/Transaxle

Automatic Transmission .. 4L60E

7-313

21 . Install the transmission fluid level indicator.

165298

22. Install the air intake duct.

208572

23. Connect the intake air temperature (IAT) sensor

electrical connector.
24. Adjust the automatic transmission shift control
lever cable. Refer to Shift Cable Replacement.
Notice: Whenever you remove the transmission for
service, you must perform the automatic transmission
oil cooler flushing procedure in order to remove the
existing fluid which may be contaminated. This
will prevent contamination of the new fluid. You must
perform the flushing procedure after the installation
of the overhauled or replacement transmission.
25. Flush the transmission oil cooler, oil cooler pipes,
and the hoses. Refer to AT Oil Cooler Flushing
26. Check the transmission fluid level. Refer to
Transmission Fluid Checking Procedure.

208554

7-314

Transmission/Transaxle

Automatic Transmission - 4L60-E

AT OH Cooler Flushing
Oil Cooler Flushing
Tools Required
J 35944-A Oil Cooler and Line Flusher
J 35944-20 Cooler Flushing Fluid
Notice: Whenever you remove the transmission for
service, you must perform .the automatic transmission
oil cooler flushing procedure in order to remove the
existing fluid whicti may be contaminated. This
will prevent contamination of the new fluid. You must
perform the flushing procedure after the installation
of the overhauled or replacement transmission.
Notice: Only use J 35944-20 Cooler Flushing Fluid
with the J 35944-A Oil Cooler and Line Flusher. Use of
any other fluid can result i.n damage to the tool,
damage to the automatic transmission oil cooler
components, or improper flushing of the cooler. Do not
reconnect the oil cooler pipes after you reinstall the
overhauled or service replacement transmission in the
vehicle.
Prepara.tion
1. Remove'the fill '.cap on J 35944-A.
2. Fiff'the .tar with 0.6 liter ( 20-:-21 OLmces) of
J't35944.;20, or equivalent, coolet flushing fluid. Do
not overfill, If you overfill, the tool will need
recharging with air before the baekflUsh. Follow
the manufacturer's suggested procedures for
proper handling of the solut.i.on.
Notice: Shop air supply must be equipped with a
water/oil filter, and pressure should not exceed
825 kPa (120 psi). Failure to use a water/oil filtet can
allow residual moisture to cause corrosion of
components. Excessive air pressure can cause
damage to components.
3. Secure the fill cap, and pressurize the flusher with
shop air 10 550-700 kPa (80-100 psi).
4. Connect the discharge hose to the transmission
end of the oil cooler pipe ttiat goes to the bottom
. fitting at the radiator.

5. Clip the discharge hose to the oil drain container.

6. Mount the flushing tool to the undercarriage of
the vehicle with the hook provided.
7. Connect the hose from the flushing tool to the
remaining oil cooler pipe.
8. With the water valve on the tool in the OFF
position, connect the water hose from the
water supply to the tool.
9. Turn ON the water supply at the faucet.

Initial Flushing
Notice: If water does not flow through the oil cooler
(system is completely plugged), do not continue
the flushing procedure, or damage to the tool or
components could result. Turn the water OFF
immediately. Inspect the pipes and the cooler for
restrictions. Replace the oil pipe(s) and/or the
oil cooler.
1. Switch the water valve on the tool to the ON
position. Allow the water to flow through the
oil cooler for 1O seconds in order to remove the
transmission fluid in the system.
2. Switch the water valve on the tool to the OFF
position. Clip the discharge hose onto a
5-gallon pail with a lid. If there is no lid, place a
shop towel over the end of the hose in order
to prevent splash. The discharge will foam
vigorously when you introduce solution into the
water stream.
3. Switch the water valve on the tool to the ON
position. Depress the trigger that mixes the
flushing solution into the water flow. Use the bale
clip on the handle in order to hold down the
trigger.
4. Flush the oil cooler with water and solution for
2 minutes. During the flush, attach the air supply
to the air valve on the tool for 3 to 5 seconds
after every 15 to 20 second interval in order to
create a surging action.
5. Release the trigger. Switch the water valve on the
tool to the OFF position.
6. Disconnect both hoses from the oil cooler pipes .

Transmission/Transaxle

Automatic Transmission - 4L60-E

Backflush

After filling the transmission with DEXRON-111 or,

if unavailable, DEXRON-IIE automatic
transmission fluid, or equivalent, start the engine.
Run the engine for 30 seconds. This removes
any residual moisture from the oil cooler and the
cooler pipes.
You should get a minimum of 1.8 liters (2 quarts)
of transmission fluid during this 30 second run.
If the flow of fluid is insufficient, disconnect the oil
cooler feed line at the radiator and restart the
engine.
Depending on the flow rate, do the following
inspections:
Insufficient Feed Flow - Inspect the
transmission for the cause.
Sufficient Feed Flow - Inspect the oil cooler
pipes anp the fittings for restrictions or
leaks. Repeat the oil cooler flushing procedure.
Repeat the check of fluid flow out of the
return line.
Remove the discharge hose.
Reconnect the cooler return pipe to the
transmission.
Refill the unit to the proper fluid level. Refer to
Transmission Fluid Checking Procedure.

Connect the hoses to the oil cooler pipes opposite

from the initial flush in order to perform a
backflush.
Switch water valve on the tool to the ON position.
Depress the trigger in order to mix the flushing
solution with the water flow. Use the bale clip on
the handle to hold down the trigger.
Flush the oil cooler with water and solution for
2 minutes. During this flush, attach the air
supply to the air valve on the tool for
3 to 5 seconds after each 15 to 20 second interval
in order to create a surging action.
Release the trigger. Allow water only to rinse the
oil cooler for 1 minute.
Switch the water valve on the tool to the OFF
position.
Turn the water supply OFF at the faucet.
Attach the air supply to the air valve on thetool.
Dry out the system with air for at least 2 minutes.
Dry out the system longer than 2 minutes, if
moisture from the oil cooler line discharge hose is
visible. If available, use an air chuck clip to
secure the air chuck onto the air valve for ease of
operation.

Important: The top fitting at the transmission is the

cooler return. The pottom fitting at the transmission is
the cooler feed.
Connect the cooler feed pipe to the transmission.
If not already connected, attach the discharge
hose to the cooler return pipe. Place the hose into
an appropriate drain container.

7-315

Do Not Use Air Tools

Notice: Do not use air powered tools in order to
assemble or disassemble transmissions. Use hand
tools in order to properly determine bolt tightness.
Improper bolt torque can contribute to transmission
repair conditions, and this information, which is vital to
diagnosis, can only be detected when using
hand tools.

7-316

Automatic Transmission - 4L60-E

Transmission!Transaxle

Description and Operation

Transmission ID Information

>--

II

/
11

8CAD187A 16588320
0

165T20

174260

Legend

(1)
(2)
(3)
(4)
(5)

(8::1998)
Model
Hydra-Matic 4L60-E
Julian Date (or Day of the Year)
Shift Built (A, B, J = First Shift; C, H,
W == Second Shift)

(6) Serial No.

(7) Transmission ID Location
(8) Optional Transmission ID Location

Automatic Transmission - 4l60~E

Transmission!Transaxle
Transmission General Information
The HYDRA-MATIC 4L60-E transmission has the
identification information stamped into the case pan
rail. Refer to Transmission ID Information.
This information helps the service technician order the
correct replacement parts from a GM parts catalog.
Additional transmission identification information
is provided o.n the Service Parts Identification label.
This label shows the Regular Production Options
(RPO) as well as the standard and mandatory options.
This label is affixed to the inside of each vehicle at
the assembly plant. For more information, refer
to General Information.

7-317

for repair procedures. If the faulty component is not

serviceable without removing the transmission from the
vehicle, refer to Unit Repair for repair information.

Basic Knowledge
Notice: Do not, under any circumstances, attempt to
diagnose a powertrain condition without basic
knowledge of this powertrain. If you perform diagnostic
procedures without this basic knowledge, you may
incorrectly diagnose .the condition or damage the
powertrain components.
You must be familiar with some basic electronics in
order to use this section of the service manual.
You should also be able to use the following
special tools:
A Digital Multimeter (DMM)

A circuit tester
Jumper wires or leads
A line pressure gageset
The Functional Test Procedures verify the correct
operation of electronic components in the transmission.
These procedures eliminate the unnecessary removal
of transmission components.

Diagnosis

5
6480

Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)

Vehicle Identification Number

Wheel Base
Part Number Location
Model Designation
Order Number
Exterior Color
Paint Technology

How to Use This Section

This section provides the following information:
Genera.I diagnosis information on transmissions
A detailed description of the Hydra-matic
transmission operation
Procedures for diagnosing the Hydra-matic
transmission
When you diagnose any condition of the Hydra-matic
transmission, begin with the Functional Test
Procedure. This procedure indicates the proper path
of diagnosing the transmission by describing the basic
checks. This procedure will then refer you to the
locations of specific checks. After you. have determined
the cause of a condition, refer to Repair Instructions

Notice: If you probe a wire with a sharp instrument

and do. not properly seal the wire afte.rward, the
wire corrodes and an open circuit results.
Diagnostic test probes are now available that allow
you to probe individual wires without leaving the wire
open to the environment. These probe devices are
inexpensive and easy to install, and they permanently
seal the wire from corrosion.

Preliminary Checking Procedure

Transmission performance may be influenced by one,
or more of the following items:
Fluid level high/low.
Engine performance.
Manual linkage adjustment.
Internal fluid leaks.
Electrical system.
Transmission or other mechanical component.
Vacuum Modulator System
These items should be checked and corrected, if
necessary, before attempting transmission dia~nosis.

Transmission Fluid Checking Procedure

Checking fluid level, color, and condition at regular
intervals will provide early diagnostic information about
the transmission. This information may then be
used to correct a condition that, if not detected early,
could result in major transmission repair.
Refer to General Information for maintenance
information and servicing intervals.

Transmissionrrransaxle

7-318 Automatic Transmission - 4L60-E

Important: New automatic transmission fluid is red.
Red dye is added in order to help the assembly plant
distinguish this fluid from engine oil and antifreeze.
The red dye is not permanent. After some driving, the
transmission fluid will look darker. Eventually, the
fluid may appear light brown.
Wait at least 30 minutes before checking the
transmission fluid, if the vehicle has been
driven under the following conditions:
- Outside temperature is above 32C (90F)
- At high speed for more than 15 minutes
- In heavy traffic during hot weather
- While pulling a trailer
In order to get the correct reading, the fluid should
be at a normal operating temperature, which is
82C-94C (180F-200F).
Do the following for a hot check:
Warm up the vehicle by driving about 24 km
(15 miles), when the outside temperature is
above 10C (50F).
If the temperature is colder than 10C (50F), you
may have to drive the vehicle longer.
Do the following for a cold check:
Do a cold check when the transmission
temperature is 24C-29C (75F-85F).
Let the engine run at slow idle for 5 minutes, if
the outside temperature is 10c (50F) or higher.
If the outside temperature is colder than 10C
(50F), you may have to idle the engine longer
than 5 minutes.
Do the following for a hot or a cold transmission
fluid check:
1. Idle the engine.
2. Park the vehicle on a level surface.
3. Place the shift lever in the P (Park) position.
4. Apply the parking brake.
5. With you foot on the brake pedal, move the
shift lever through each gear, pausing for
about 3 seconds in each range. Then, put the
shift lever in P (Park).
6. Idle the engine for 3 minutes or more.
Now, do the following in order to check the
fluid level:
1. Pull out the dipstick. Wipe the dipstick well
with a clean rag or a paper towel.
2. Push the dipstick in all the way. Wait
3 seconds. Then, pull the dipstick back
out again.
3. Check bolt sides of the dipstick, reading the
lower level.
For a cold check, the fluid level must be
in the COLD area.
For a hot check, the fluid level must be
in the HOT or crosshatched area.
4. If the fluid level is OK, push the dipstick back
in all the way.

Notice: Do not overfill the transmission. Overfilling will

result in foaming, loss of fluid, and possible damage
to the transmission.
5. If the fluid level is low, add only enough
DEXRON-111 (or, if unavailable,
DEXRON-IIE) to bring the fluid level up to the
COLD area for a cold check or the HOT
area for a hot check.
Generally, this will require less than a pint
of fluid. Do not overfill.
6. After adding the fluid, recheck the fluid level as
described above. When the fluid level is
correct, push the dipstick in all the way.
Transmission fluid should be red in color when the
fluid is new.

Automatic Transmission Diagnosis

Throttle Positions
Minimum Throttle: The least amount of throttle
opening required for upshift.
Light Throttle:
pedal.

Approximately % of the accelerator

Medium Throttle: Approximately

accelerator pedal travel.
Heavy Throttle:
pedal travel.

1/2

of the

Approximately % of the accelerator

Wide Open Throttle (WOT):

accelerator pedal.

Full travel of the

Full Throttle Detent Densified: A quick application

of the accelerator pedal to its full travel in order to
force a downshift.
Engine Braking: A condition in which you use the
engine in order to slow the car by downshifting
manually during a zero-throttle coastdown.
Zero Throttle Coastdown: A full release of the
accelerator pedal while the car is in motion and in drive
range.

Shift Conditions
Bump: A sudden and forceful engagement of a
clutch or band.
Chuggle: A bucking or jerking that is most noticeable
when the converter clutch is engaged. A Chuggle is
similar to the feel of towing a trailer.
Delayed: A condition in which a shift is expected but
does not occur for a period of time. Delayed is also
defined as late or Extended.
Double Bump (Double Feel): Two sudden and
forceful engagements of a clutch or a band.
Early: A condition in which the shift occurs before
the car has reached the proper speed. The early
condition tends to labor the engine after the upshift.
End Bump: A firmer feel at the end of a shift
as compared to the feel at the start of the shift. End
bump also is define as END FEEL or SLIP BUMP.

Transmission/Transaxle

Firm: A noticeably quick engagement of a clutch or

band that is considered normal with a medium to
heavy throttle. This should not be confused with
HARSH or ROUGH.

Automatic Transmission - 4L60-E

7-319

Electronic Component Description

1-2 and 2-3 Shift Solenoid Valves

Flare: A quick increase in engine rpm along with a

momentary loss of ,torque. This generally occurs during
a shift. Flare is also defined as SLIPPING.
Harsh (Rough): A more noticeable engagement of a
clutch or a band as compared with FIRM. This
condition is considered undesirable at any throttle
position.
Hunting: A repeating quick series of upshifts and
downshifts that causes a noticeable change in engine
rpm. An example is a 4-3-4 shift pattern. Hunting
also is defined as BUSYNESS.
Initial Feel: A distinct sturdy feel at the start of a
shift as compared to the end of the shift.
Late: A shift occurs when the. engine is at a higher
than normal rpm for a given amount of throttle.
Shudder: A continuous jerking condition similar to
CHUGGLE but more severe and rapid. This condition
is most noticeable during certain car speed ranges.
Slipping: A noticeable increase in engine rpm
without a car speed increase. A slip usually occurs
during or after the initial clutch or band engagement.
Soft: A slow, almost unnoticeable clutch or band
engagement with very little shift feel.

Surge: A repeating acceleration and deceleration

that is engine-related. This condition is less intense
than CHUGGLE.
Tie Up: A condition in which two opposing clutches
and/or bands are attempting to engage at the
same time, causing the engine to labor with a
noticeable loss of engine rpm.

Noise Conditions
Planetary Gear Noise: A whine related to the car
speed that is most noticeable in the first gear or
reverse. Planetary Gear Noise is less noticeable after
an upshift.
Pump Noise: A high pitch whine that increases with
engine rpm.

Abbreviations

PCM-Powertrain Control Module

TCC--Torque Converter Clutch
TP Sensor-Throttle Position Sensor
ECT Sensor-Engine Coolant Temperature
Sensor
VSS Sensor-Vehicle Speed Sensor
RWD-Rear Wheel Drive
2WD-2 Wheel Drive
4WD-4 Wheel Drive
TFP Manual Valve Position Switch-Automatic
Transmission Fluid Pressure Manual Valve
Position Switch
TFT Sensor-Automatic Transmission Fluid
Temperature Sensor

8885

Important: The shift solenoid valve resistance should.

measure 19-24 ohms minimum when measured at
20C (68F). The shift solenoid current flow should not
exceed 0.75 amps. The shift solenoid should
energize at a voltage of 7.5 volts or more (measured
across the terminals). The shift solenoid should
de-energize when the voltage is one volt or less.

If both solenoids lose power, third gear only results.

The 1-2 and 2-3 shift solenoid valves (also called
A and B solenoids) are identical devices that control
the movement of the 1-2 and 2-3 shift valves
(the 3-4 shift valve is not directly controlled by a shift
solenoid). The solenoids are normally open exhaust
valves that work in four combinations to shift the
transmission into different gears.
The PCM energizes each solenoid by grounding the
solenoid through an internal quad driver. This
sends.current through the coil winding in the solenoid
and moves the internal plunger out of the exhaust
position. When ON, the solenoid redirects fluid to move
a shift valve.
Important: The manual valve hydraulically can
override the shift solenoids. Only in 04 do the shift
solenoid states totally determine what gear the
transmission is in. In the other manual valve positions,
the transmission shifts hydraulically and the shift
solenoid states CATCH UP when the throttle position
and the vehicle speed fall into the correct ranges.
Diagnostic trouble codes P0753 and P0758 indicate
shift solenoid circuit voltage faults.

The PCM-controlled shift solenoids eliminate the need

for TV and governor pressures to control shift valve
operation.

7-320 Automatic Transmission - 4L60-E

3-2 Shift Solenoid Valve Assembly

Transmission/Transaxle
The PCM controls the pressure control solenoid by
commanding current between 0.1 and 1.1 amps. This
changes the duty cycle of the solenoid, which can
range between 5 percent and 95 percent (typically less
than 60 percent). 1.1 amps corresponds to minimum
line pressure, and 0.1 amps corresponds to maximum
line pressure (if the solenoid loses power, the
transmission defaults to maximum line pressure).
The PCM commands the line pressure values, using
inputs such as the throttle position sensor.
The pressure control solenoid takes the place of the
throttle valve or the vacuum modulator that was
used on the past model transmissions.
If the duty cycle drops below 5 percent or rises above
95 percent, DTC P0748 will set.

Torque Converter Clutch Solenoid Valve

325350

Important: The 3-2 shift solenoid valve assembly

resistance should be a minimum of
20-24 ohms at 20C (68F).
The 3-2 shift solenoid valve assembly is an ON/OFF
solenoid that is used in order to improve the
3-2 downshift. The solenoid regulates the release of
the 3-4 clutch and the 2-4 band apply.
If a voltage fault is detected in the 3-2 shift solenoid
circuit, diagnostic trouble code P0785 will set.

Transmission Pressure Control Solenoid

8882

Important: The TCC solenoid resistance should be

21-'-26 ohms minimum when measured at 20c (68F).

If a fault is detected in the TCC solenoid circuit,

code P0740 will set.
The torque converter clutch solenoid valve is a
normally open exhaust valve that is used to control
torque converter clutch apply and release. When
grounded (energized) by the PCM, the TCC solenoid
valve stops converter signal oil from exhausting.
This causes converter signal oil pressure to increase
and shifts the TCC solenoid valve into the apply
position.
325352

Important: Transmission pressure control solenoid

resistance should measure 3-5 ohms when measured
at 20C (68F).
The transmission pressure control solenoid is an
electronic pressure regulator that controls pressure
based on the current flow through its coil winding. The
magnetic field produced by the coil moves the
solenoid's internal valve which varies pressure to the
pressure regulator valve.

The brake switch is an input to the PCM, and the

PCM directly controls the TCC apply based on
the brake switch status.

Transmission/Transaxle

Automatic Transmission - 4L60E

Torque Converter Clutch PWM Solenoid Valve

7:..321

Transmission Fluid Pressure (TFP) Manual

Valve Position Switch

,,325355

8889

Important: TCC PWM solenoid valve resistance'

should be 10-11 ohms when measured at 20C
(68F), and 13-15 ohms when measured at
100C (212F).

The torque converter clutch PWM solenoid valve

controls the fluid acting on the converter clutch vaive,
which then controls the T,CC apply and release.
This solenoiq ls attached to the control valve bdc;ly
assembly within the transmission. The TCC PWM'
solenoid valve provides smooth engagement .of the
torque converter clutch by operating on a negative duty
cycle a variable percent of ON time.
If a fault is detected in the TCC PWM circuit, code
P1860 will set.

Important: Seven valid c.ombinatio~s and two inva,lid

combinations are available from the TFP manual valve
position switch. Refer to the TFP Manual Valve Position
Switch Logic table for valid/invalid combinations for ,
range signal circuits A, Band C.
The transmission fluid pressure (TFP) manual valve
position switch is a set of five pressure switches on the
control valve body that sense whether fluid pressure .
is present in five different valve body passages.
The combination of which switches are open and
closed is used by the PCM in order to determine actual
manual valve position. The TFP manual valve
position switch, however, cannot distinguish between
PARK and NEUTRAL because the monitored valve
body pressures are. identical in both cases.
The switches are wired to provide three signal lines
that are monitored by the PCM. These inputs are used
to help control line pressure, torque converter clutch.
apply andshift solenoid valve operation. Voltage at
ea~h of the signal lines is either zero or twelve volts.
In order to monitor the TFP manual valve position
switch operation, the PGM compares the actual voltage
combination of the switches to a TFP combination table
stored in its memory. If.the PCM sees one of two illegal
voltage combinations, a OTC P1810 will result. A
OTC P181 Oindicates a short circuit condition in either
the range signa(Aor the range signal C circuits.
The TFP manual v~lye position switch signal voltage
can be measured from ea,ch pin-to-ground and
compared to the combination table. On the automatic
transmission (A/T) wiring harness assembly, pin N is
range signal A, pin R is range signal B, and pin P is
range signal C. With the A/T wiring harness assembly
connected and the engine running, a voltage
measurement of these three lines will indicate a high
reading (near 12 volts) when a circuit is open, and a low
reading (zero volts) when the circuit is switched to
ground.
The transmission fluid temperature (TFT) sensor is
part of the TFP manual valve position switch assembly.

7-322

Automatic Transmission - 4L60-E

Transmission!Transaxle
If the TFT sensor circuit has a fault, DTC P0712 or
P0713 is set. A OTC P0712 indicates a short
circuit condition, while a DTC P0713 indicates an open
circuit condition. DTC P0218 is set if the transmission
is operating at a high temperature for a period
of time.

Vehicle Speed Sensor

Torque Converter Clutch Electrical

Controls

62801

Important: The sensor resistance is model dependent

and varies with speed from a minimum of 0.5 volts
AC at 100 RPM to more than 100 volts AC at
8000 RPM.

The vehicle speed sensor (or transmission output

speed sensor) controls shift points and calculates the
TCC slip.
The speed sensor contains a coil that gives off a
continuous magnetic field. A rotor rotates past
the sensor and the rotor teeth break the magnetic
field. Each break in the field sends a pulse to
the VSSB (Vehicle Speed Sensor Buffer). The VSSB
sends two signals to the PCM. The first is a 2002
pulse per mile (PPM) signal that is used by the engine.
The second is the transmission/transfer case 40
pulse per revolution (PPR) signal that is used in order
to control the transmission.
In two wheel drive (2WD) applications, the vehicle
speed sensor is located on the transmission extension
housing. Trans Output Speed =Transfer Case Speed.
DTC P0502 will set if a fault exists in the vehicle
speed sensor circuit 40 PPR line.

Automatic Transmission Fluid Temperature

Sensor
The automatic transmission fluid temperature (TFT)
sensor is part of the automatic transmission fluid
pressure (TFP) manual valve posjtion switch assembly.
This sensor helps control torque converter clutch
apply and shift quality.
The TFT sensor is a resistor, or thermistor, which
changes value based on temperature. At low
temperatures the resistance is high, and at high
temperatures the resistance is low.
The PCM sends a 5 volt signal to the TFT sensor and
the PCM measures the voltage drop in the circuit.
You will measure a high voltage when the transmission
is cold and a low voltage when the transmission is
hot. Refer to the Temperature vs Resistance table.

The Torque Converter Clutch (TCC) system uses

controls that are internal as well as external to
the transmission.
The TCC system includes the following external
control components:
Cruise Control Release Switch - In order to
avoid stalling the engine when braking, the
converter clutch releases anytime the brake pedal
is applied.
Powertrain Control Module (PCM) - The PCM
receives input signals and grounds TCC
solenoid to apply clutch when the proper operating
conditions are met.
Throttle Position (TP) Sensor - The TP Sensor
sends throttle position information to the
Powertrain Control Module (PCM).
Vehicle Speed Sensor (VSS) - The VSS sends
vehicle speed information to the Powertrain
Control Module (PCM).
Manifold Absolute Pressure (MAP) Sensor - The
MAP Sensor sends engine vacuum (load)
information to the Powertrain Control
Module (PCM).
Engine Coolant Temperature (ECT) Sensor The ECT Sensor sends engine coolant
temperature information to the Powertrain Control
Module (PCM).

Transmission!Transaxle

Automatic Transmission - 4L60-E

Electrical Connector

13265

The transmission electrical connector is an important .

part of the transmission operating system. Any '.

interference with the electrical connection can cause

the transmission to set Diagnostic Trouble Codes
(DTCs) or,affect proper operation.

The following items can affect the electrical connection:'

Bent pins in the connector from rough hahdling
during connection and disconnection
Wires backing away from the pins or coming
uncrimped (in either the internal or the external
wiring harness)
Dirt contamination entering the connector when
disconnected
Pins in the internal wiring connector backing out
of the connector or pushed out of the connector
during reconnection
Excessive transmission fluid leaking into the
connector, wicking up into the external wiring
harness and degrading the wire insulation
Moisture intrusion in the connector
Low pin retention in the external connector from
excessive connection and disconnection of the
wiring connector assembly
Pin corrosion from contamination
Damaged connector assembly

7-323

Remember the following points:

In order to remove the connector, squeeze the
two tabs toward each other and pull straight
up without pulling by the wires.
Limit twisting or wiggling the connector during
removal. Bent pins can occur.
Do not pry the connector off with a screwdriver or
other tool.
Visually inspect the seals to ensure that they are
not damaged during handling.
In order to reinstall the external wiring connector,
first orient the pins by lining up the arrows on
each half of the connector. Push the connector
straight down into the transmission without twisting
or angling the mating parts.
The connector should click into place with a
positive feel and/or noise.
Whenever the transmission external wiring
~onnector is disconnected from the internal
harness and the engine is operating, DTCs will
set: Clear these DTCs after reconnecting the
external connector.

7-324

Transmission/Transaxle

Automatic Transmission - 4L60-E

Component Locator
Transmission Component Location

Component Locator View

25

24

23

22

21

20

19

18

10

17

11

16

12

15

13

14
220457

Legend

(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)

Converter Housing
Reverse Input Clutch
Input Clutch Housing
Overrun Clutch
Forward Clutch
Forward Sprag Clutch Assembly
3-4 Clutch
Input Planetary Gear Set
Lo and Reverse Clutch
Lo Roller Clutch Assembly
Reaction Planetary Gear Set
Speed Sensor

(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)

Output Shaft
Case Extension
Case, Main Section
Parking Pawl
Parking Lock Actuator Assembly
Control Valve Assembly
Manual Shaft
Inside Detent Lever
2-4 Band Assembly
Pump Assembly
Stator Roller Clutch
Torque Converter Assembly
Turbine Shaft

Automatic Transmission - 4L60-E 7-325

Transmission/Transaxle

Electronic Component Locations

326657

Legend

(36) Vehicle Speed Sensor (VSS)

(66) Torque Converter Clutch (TCC) Solenoid
Valve
(69) Automatic Transmission Fluid Pressure
(TFP) Manual Valve Position Switch
(367a) 1-2 Shift Solenoid (SS) Valve

(367b)
(377)
(394)
(396)

2-3 Shift Solenoid (SS) Valve

Pressure Control (PC) Solenoid Valve
3-2 Shift Solenoid (SS) Valve Assembly
Torque Converter Clutch Pulse Width
Modulation (TCC PWM) Solenoid Valve

7-326

Automatic Transmission - 4L60-E

Transmission/Transaxle

Case and Associated Parts (1 of 2)

!~

_5_____ _

L.:--3------

11-J
7

~75
r----------------------,
102
103
100
106

-~

l-3
76
73

181603

Legend

(1) Torque. Converter Assembly (Model

Dependent)
(2) Bolt, Pump to Case
(3) 0-Ring, Pump to Case Bolt
(4) Pump Assembly, Oil
(5) Seal, Oil (Pump to Case)
(6) Gasket, Pump Cover to Case
(7) Bushing, Case
(9) Vent Assembly, Transmission
(10) Connector, Oil Cooler Pipe (Model
Dependent)
(11) Plug, Case Servo
(12) Spring, Servo Return
(13) Pin, 2nd Apply Piston
(14) Ring, Retainer (2nd Apply Piston)
(15) Retainer, Servo Cushion Spring

(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)

Spring, Servo Cushion (Outer)

Piston, 2nd Apply
Ring, Oil Seal (2nd Apply Piston - Outer)
Ring, Oil Seal (2nd Apply Piston - Inner)
Housing, Servo Piston (Inner)
Seal, 0-Ring
Spring, Servo Apply Pin
Washer, Servo Apply Pin
Ring, Retainer (Apply Pin)
Piston, 4th Apply
Ring, Oil Seal (4th Apply Piston - Outer)
Seal, 0-Ring (2-4 Servo Cover)
Cover, 2-4 Servo
Ring, Servo Cover Retaining
Seal, Case Extension to Case
Extension, Case (Model Dependent)

Transmission!Transaxle
(32) Bolt, Case Extension to Case
(33) Bushing, Case Extension
(34) Seal Assembly, Case Extension Oil (Model
Dependent)
(35) Bolt, Speed Sensor Retaining
(36) Speed Sensor, Internal Transmission
(37) Seal, 0-Ring (ITSS to Case Extension)
(71) Seal, Filter
(72) Filter Assembly, Transmission Oil (Model
Dependent)
(73) Gasket, Transmission Oil Pan
(74) Magnet, Chip Collector
(75) Pan, Transmission Oil (Model Dependent)
(76) Screw, Transmission Oil Pan
(94) Bolt, Converter Housing to Case
(95) Connector, Oil Cooler Quick (Model
Dependent)

,Automatic Transmission - 4L60-E

7-327

(96) Clip, Oil Cooler Quick Connect (Model

Dependent)
(97) Plug, Converter Housing Access Hole
(Model Dependent)
(98) Plate, Converter Bolt Inspection (Model
Dependent)
(99) Plug, Cup 04 Orifice
(100) Stud, A/Trans. Case (Y-Car Only)
(101) Plug Asm., A/Trans. Oil Pan
(102) Housing, Converter (Model Dependent)
(103) Case, Main Section (Model Dependent)
(105) Spring, Servo Cushion (Inner) (Model
Dependent)
(106) Seal Assembly, Case Oil (Y-Car Only)

7-328

Transmission/Transaxle

Automatic Transmission - 4L60-E

Case and Associated Parts (2 of 2)

(53)
(54)
(55)
(56)
(57)
(58)
(59)
(60)
(61)
(62)
(63)
(64)
(65)

103

(66)
(67)
(68)
(69)

47
49

(70)
(77)
(91)
(93)
(103)
(104)

48

60

Plate, Spacer Plate Support

Spring, 1-2 Accumulator (Outer)
Ring, Oil Seal (1-2 Accumulator)
Piston, 1-2 Accumulator
Cover and Pin Assembly, 1-2 Accumulator
Bolt, Accumulator Cover
Bolt, Accumulator Cover
Valve Assembly, Control Body
Checkball (#2, 3, 4, 5, 6, 8, 12)
Bolt, Valve Body
Spring Assembly, Manual Detent
Bolt, Manual Detent Spring
Seal, Wiring Harness Pass-through
Connector 0-Ring
Solenoid Assembly, Wiring Harness
Seal, 0-Ring (Solenoid)
Bolt, Hex Washer Head (Solenoid)
Switch Assembly, Transmission Fluid
Pressure Manual Valve Position
Bolt, Pressure Switch Assembly
Bolt, Spacer Plate Support
Number 1 Checkball
Bracket, Dipstick Stop (Model Dependent)
Case, Main Section (Model Dependent)
Spring, 1-2 Accumulator (Inner)

68
283778

Legend
(38) Plug, Transmission Case (Accumulator
Bleed)
(39) Plug, Pressure
(40) Retainer and Ball Assembly, Third
Accumulator (#7)
(41) Pin, Band Anchor
(42) Retainer and Ball Assembly (Double
Orifice) (#10)
(43) Pin, Accumulator Piston
(44) Piston, 3-4 Accumulator
(45) Ring, Oil Seal (3-4 Accumulator Piston)
(46) Spring, 3-4 Accumulator (Model Dependent)
(47) Gasket, Spacer Plate to Case
(48) Plate, Valve Body Spacer
(49) Screen, Shift Solenoids
(50) Screen, Pressure Control Solenoid
(52) Gasket, Spacer Plate to Valve Body

Automatic Transmission - 4L60-E

Transmission/Transaxle

7-329

Oil Pump Assembly

203

204
236

~~~~:e~?o c___,,.._.- 236

'
~
----.Y,
~~ CD-202
207

208
~209

206

213
224

~~1

ct,---210

223

i222

L __
405105

Legend
(200) Body, Pump
(201) Ring, Oil Seal (Slide to Wear Plate)
(202) Seal, 0-Ring (Slide Seal Back-Up)
(203) Slide, Pump
(204) Spring, Pivot Pin
(205) Pin, Pivot Slide
(206) Spring, Pump Slide (Outer)
(207) Spring, Pump Slide (Inner)
(208) Support, Pump Slide Seal
(209) Seal, Pump Slide
(210) Ring, Pump Vane
(211) Guide, Rotor
(212) Rotor, Oil Pump
(213) Vane, Pump
(214) Shaft, Stator
(215) Cover, Pump

(216)
(217)
(218)
(219)
(220)
(221)
(222)
(223)
(224)
(225)
(226)
(227)
(228)
(229)

Valve, Pressure Regu!ator

Spring, Pressure Regulator Valve
Spring, Pressure Regulator Isolator
Valve, Reverse Boost
Sleeve, Reverse Boost Valve
Ring, Oil Pump Reverse Boost Valve
Retaining
Ring, Oil Pump Converter Clutch Valve
Retaining
Valve, Stop
Valve, Converter Clutch
Spring, Converter Clutch Valve (Inner)
Spring, Converter Clutch Valve (Outer)
Rivet, Pressure Relief Bolt
Ball, Pressure Relief
Spring Pressure Relief

7-330
(230)
(231)
(232)
(233)
(234)
(235)
(236)

Automatic Transmission - 4L60-E

Ring, Oil Seal (Stator Shaft)
Seal, Oil Pump Cover Screen
Screen, Oil Pump Cover
Bolt, MB X 1.25 X 40 (Cover to Body)
Bushing, Stator Shaft (Front)
Plug, Oil Pump Cover (FWD Clutch Feed)
Plug, Oil Pump Cover

Transmission/Transaxle
(237)
(238)
(240)
(241)
(242)
(243)
(244)

Retainer and Ball Assembly, Check Valve

Orifice, Converter Clutch Signal (Cup Plug)
Plug, Cup Orifice
Bushing, Stator Shaft (Rear)
Bushing, Pump Body
Seal Assembly, Oil
Retainer, FrontHelix

Control Valve Body Assembly (1 of 2)

405111

Legend

(350)
(353)
(354)
(355)
(356)
(357)
(358)
(359)
(360)
(361)
(362)
(363)
(364)
(365)

Control Valve Body Assembly

Seal, Forward Accumulator Oil
Piston, Forward Accumulator
Pin, Forward Accumulator
Spring, Forward Accumulator
Valve, Forward Abuse
Spring, Forward Abuse Valve
Plug, Bore
Pin, Coiled Spring
Valve, Low Overrun
Spring, Low Overrun Valve
Cover, Forward Accumulator
Bolt, Forward Accumulator Cover
Spring, 1-2 Shift Valve

(366)
(367a)
(367b)
(368)
(369)
(370)
(371)
(372)
(374)
(375)
(376)
(377)
(378)
(395)

Valve, 1-2 Shift

1-2 Shift Solenoid Valve
2-3 Shift Solenoid Valve
Valve, 2-3 Shift
Valve, 2-3 Shuttle
Spring, 1-2 Accumulator Valve
Valve, 1-2 Accumulator
Sleeve, 1-2 Accumulator Valve
Valve, Actuator Feed Limit
Spring, Actuator Feed Limit Valve
Plug, Bore
Pressure Control Solenoid Valve
Retainer, Pressure Control Solenoid
Retainer, Bore Plug and Solenoid

Transmission/Transaxle

Automatic Transmission - 4L60E

7-331

Control Valve Body Assembly (2 of 2)

405114

Legend

(340)
(350)
(359)
(360)
(380)
(381)
(382)
(383)
(384)
(385)
(386)

Manual Valve
Control Valve Body Assembly
Bore Plug
Pin, Coiled Spring
Valve, Regulator Apply
Bore Plug
Spring, 4-3 Sequence Valve
Valve, 4-3 Sequence
Valve, 3-4 Relay
Valve, 3-4 Shift
Spring, 3-4 Shift Valve

(387)
(388)
(389)
(390)
(391)
(392)
(394)
(395)
(396)
(397)
(398)

Valve, Reverse Abuse

Spring, Reverse Abuse Valve
Valve, 3-2 Downshift
Spring, 3-2 Downshift Valve
Valve, 3-2 Control
Spring, 3-2 Control Valve
3-2 Control Solenoid Valve
Retainer, Bore Plug and Solenoid
TCC PWM Solenoid Valve
Spring, Regulator Apply
Valve, Isolator

7-332

Automatic Transmission - 4L60-E

Transmissionrrransaxle

Internal Parts (1 of 2)
602

612B

613 614

213098

Legend
(600)
(601)
(602)
(603)
(605)
(606)
(607)
(608a)
(608b)
(609)
(610)
(611)
(612a)

Spring Assembly, 3-4 Clutch Boost (5)

Washer, Thrust (Pump to Drum)
Band Assembly, 2-4
Bushing, Reverse Input Clutch (Front)
Housing and Drum Assembly, Reverse
Input Clutch
Bushing, Reverse Input Clutch (Rear)
Piston Assembly, Reverse Input Clutch
Seal, Reverse Input Clutch (Inner)
Seal, Reverse Input Clutch (Outer)
Spring Assembly, Reverse Input Clutch
Ring, Reverse Input Clutch Spring Retainer
Plate, Reverse Input Clutch (Belleville)
Plate, Reverse Input Clutch Turbulator
(Steel)

(612b) Plate Assembly, Reverse Input Clutch

(Fiber)
(613) Plate, Reverse Input Clutch Backing
(Selective)
(614) Ring, Reverse Input Clutch Retaining
(615) Bearing Assembly, Stator ShafVSelective
Washer
(616) Washer, Thrust (Selective)
(617) Retainer and Ball Assembly, Check Valve
(618) Seal, 0-Ring (Turbine ShafVSelective
Washer) (Model Dependent)
(619) Ring, Oil Seal (Solid)
(620) Retainer and Checkball Assembly

Transmission!Transaxle
(621) Housing and Shaft Assembly, Input (Model
Dependent)
(622) Seal, 0-Ring lnput to Forward Clutch
Housing
(623}. Piston, 3rd and .4th Clutch
(625} Ring, 3rd and 4th Clutch (Apply)
(626) Spring Assembly, .3rd and 4th Clutch
(627) Retainer and Ball Assembly, 'l:=orward Clutch
Housing
(628) Housing, Forward CIL!tc.h
(630} Piston, Forward Clutch
(632) Piston, Overrun Clutch
(633} Ball, Overrun Clutch
(634) Spring Assembly, Overrun Clutch
(635) Snap. Ring, Overrun Clutch Spring Retainer
(636} Seal., Input Housing to output Shaft
(63J') Bearing Assembly; Input Sun Gear
(638) Snap Hing, Overrun Clutch Hub Retaining
(639) Huo, Overrun Clutcti
(640) Forward Sprag Clutch Inner Race and Input
Sun Gear Assembly
(642) Forward Sprag Assembly
(643) Retainer Ring, Sprag Assembly
(644) Race, Forward Cl~tch (Outer)

'

'

'

Automatic Transmission - 4L60-E 7-333

(645a)
(645b)
(646)
(648)
(649a)
(649b}
(650)
(651)
(652)
(653)
(654a)
(654b)
(655)
(656)
(657)
(659)
(688)
(698)

Plate, Overrun Clutch (Steel)

Plate Assembly, Overrun Clutch (Fiber)
Plate, Forward Clutch (Apply)
Plate, Forward Clutch (Waved)
Plate, Forward Clutch (Steel)
Plate Assembly, Forward Clutch (Fiber)
Plate, Forward Clutch Backing (Selective)
Ring, Forward Clutch Backing Plate Retainer
Plate, 3rd and 4th Clutch (Steel)
(2.2L Engine Only)
Plate, 3rd and 4th Clutch Apply (Stepped)
Plate Assembly, 3rd and 4th Clutch (Fiber)
(Quantity Model Dependent)
Plate, 3rd and 4th Clutch (Steel) (Quantity
Model Dependent)
Plate, 3rd and 4th Clutch Backing (Selective)
(Model Dependent)
Ring, 3rd and 4th Clutch Backing Plate
Retainer
Bushing, Input Sun Gear Front
Bushing, Input Sun Gear Rear
Plug, Cup
Plug, Orificed Cup

7-334

TransmissionJTransaxle

Automatic Transmission - 4L60-E

Internal Parts (2 of 2)

687

r1-:0-e-:~S-
)~-1?Tt)~~
4

L------J

213103

Legend

(661)
(662)
(662a)
(662b)
(662c)
(662d)
(662e)
(662f)
(663)
(664)
(665)
(666)
(667)
(668)
(669)

Retainer, Output Shaft to Input Carrier

Carrier Assembly, Input
Pin, Input Carrier Pinion Gear
Gear, Input Carrier Pinion
Washer, Input Carrier Pinion
Washer, Input Carrier Pinion
Spacer, Input Carrier
Roller, Input Carrier Pinion/Gear Bearing
Bearing Assembly, Thrust (Input Carrier to
Reaction Shaft)
Gear, Input Internal
Bushing, Reaction Carrier Shaft Front
Shaft, Reaction Carrier
Bushing, Reaction Carrier Shaft Rear
Retainer Ring, Reaction Shaft/Internal Gear
Washer, Thrust (Reaction Shaft Shell)

(670)
(671)
(672)
(673)
(674)
(675)
(676)
(677)
(678)
(679)
(680)
(681)
(681a)

Shell, Reaction Sun

Retainer Ring, Reaction Sun Gear
Bushing, Reaction Sun
Gear, Reaction Sun
Washer, Thrust (Race/Reaction Shell)
Race, Low and Reverse Roller Clutch
Retainer Ring, Low and Reverse Support
to Case
Retainer Ring, Low and Reverse Roller
Assembly (Cam)
Clutch Assembly, Low and Reverse Roller
Support Assembly, Low and Reverse Clutch
Spring, Low and Reverse Clutch Support
Retainer
Carrier Assembly, Reaction
Pin, Reaction Carrier Pinion Gear

Transmission/Transaxle
(681 b)
(681c)
(681d)
(681e)
(682a)
(682b)
(682c)
(682d)
(683)
(684)
(685)

Automatic. Transmission - 4L60E

Gear, Reaction Carrier Pinion

Washer, Reaction Carrier Pinion Bat Winged
Washer, Reaction Carrier Pinion
Roller, Reaction Carrier Pinion/GearNeedle
Plate; Low and Reverse Clutch (Waved)
Plate, Spacer Low and Reverse Clutch
(Selective)
Plate Assembly, Low and Reverse Clutch
(Fiber)
Plate, Low and Reverse Clutch Turbulator
(Steel)
Bearing Assembly, Thrust (Reaction
Catrier/Support)
Gear, Internal Reaction
Support, Internal Reaction Gear

(86)
(87)
(88)
(89)
(90)

Parking Lock and Manual Shift Shaft

Assembly

65111

Legend
(78)
(79)
(80)
(81)
(82)
(83)
(84)
(85)

Plug, Steel Cup

Shaft, Parking Brake Pawl
Spring, Parking Pawl Return
Pawl, Parking Brake
Seal, Manual Shaft
Retainer, Manual Shaft
Shaft, Manual (Model Dependent)
Actuator Assembly, Parking Lock

(686)
(687)
(690)
(691)
(692)
(693)
(694)
(695)
(696a)
(696b)
(696c)
(697)
(699)

7-335

Retainer Ring, Reaction Gear/Support

Shaft, Output
Sleeve, Output Shaft (Model Dependent)
Seal, Output Shaft (Model Dependent)
Bearing, Reaction Gear Support to Case
Retainer Ring, Low and Reverse Clutch
Spring Assembly, Low and Reverse Clutch
Piston, Low and Reverse Clutch
Seal, Low and Reverse Clutch (Outer)
Seal, Low and Reverse Clutch (Center)
Seal, Low and Reverse Clutch (Inner)
Deflector, Oil (High Output Models Only)
Rotor, Internal Transmission Speed Sensor

Bracket, Parking Lock

Bolt, Parking Lock Bracket (2)
Lever, Inside Detent
Link, ManualValve
Nut, Hex Head

7-336

Automatic Transmission - 4L60-E

Transmission/Transaxle

Seal Locations
6088

608A

243

~
623

636

34

338497

Legend

(3)
(5)
(18)
(19)
(21)
(26)
(27)
(30)
(34)
(37)
(106)
(230)
(243)
(608a)

0-Ring, Pump to Case Bolt

Seal, Oil (Pump to Case)
Ring, Oil Seal (2nd Apply Piston-Outer)
Ring, Oil Seal (2nd Apply Piston-Inner)
Seal, 0-Ring
Ring, Oil Seal (4th Apply Piston-Outer)
Seal, 0-Ring (2-4 Servo Cover)
Seal, Case Extension to Case
Seal Assembly, Case Extension Oil
Seal, 0-Ring (ITSS to Case Extension)
Seal Assembly, Case Oil (Y-Car Only)
Ring, Oil Seal (Stator Shaft)
Seal Assembly, Oil
Seal, Reverse Input Clutch (Inner)

(608b) Seal, Reverse Input Clutch (Outer)

(618) Seal, 0-Ring (Turbine Shaft/Selective
Washer)
(619) Ring, Oil Seal (Solid)
(622) Seal, 0-Ring Input to Forward Housing
(623). Piston, 3rd and 4th Clutch
(630) Piston, Forward Clutch
(632) Piston, Overrun Clutch
(636) Seal, Input Housing to Output Shaft
(691) Seal, Output Shaft (Model Dependent)
(696a) Seal, Low and Reverse Clutch (Outer)
(696b) Seal, Low and Reverse Clutch (Center)
(696c) Seal, Low and Reverse Clutch (Inner)

Transmissionrrransaxle

Automatic Transmission - 4L60E

7-337

Bearings and Bushings

603

606 241 657 659 665

(O)@@mm

601

615

616

663

669

674

667

683

692

33

13165

Legend

(7) Bushing, Case

(33) Bushing, Case Extension
(234) Bushing, Stator Shaft (Front)
(241) Bushing, Stator Shaft (Rear)
(242) Bushing, Oil Pump Body
(601) Washer, Thrust (Pump to Drum)
(603) Bushing, Reverse Input Cl. (Front)
(606) Bushing, Reverse Input Clutch (Rear)
(615) Bearing Assembly, Stator Shaft/Selective
Washer
(616) Washer, Thrust (Selective)
(637) Bearing Assembly, Input Sun Gear

l.

(657) Bushing, Input Sun Gear (Front)

(659) Bushing, Input Sun Gear (Rear)
(663) Bearing Assembly, Thrust (Input Carrier to
Reaction Shaft)
(665) Bushing, Reaction Carrier Shaft [Front)
(667) Bushing, Reaction Carrier Shaft (Rear)
(669} Washer, Thrust (Reaction Shaft/Shell)
(672) Bushing, Reaction Gear
(674) Washer, Thrust (Race/Reaction Shell}
(683) Bearing Assembly, Thrust (Reactio.n
Carrier/Support)
(692) Bearing, Reaction Gear Support to Case

7-338

Automatic Transmission - 4L60-E

Transmission/Transaxle

Torque Converter Housing Identification

213108

Legend

(1) Domestic Large Bell V-8 (Y-Car)

(2) Domestic Gen Ill Large Bell V-8 (300 mm)
(3) Domestic Gen 1/11 Large Bell V-8N-6

(4) Holden Small Bell V-6

(5) Holden Gen Ill Large Bell V-8
(6) Domestic Small Bell V-6

Automatic Transmission - 4L60-E 7-339

TransmissionfTransaxle

Case Extension Identification

307265

Legend
(1) Case Extension (used on C-Truck, G-Van,
M-Van, S-Truck)

(2) Case Extension (used on F-Car)

7-340

Automatic Transmission - 4L60-E

Transmission/Transaxle

Valve Trains
374

375

395 376

364

378

377

395

380
395

381-384
381
395
385
386
395
381
389
390

395

367A

381
362

395

363
394
364

0
395
392
391

353 354 355 356

340

405117

Legend
(340)
(353)
(354)
(355)
(356)
(357)
(358)
(359)
(360)
(361)
(362)
(363)
(364)
(365)
(366)
(367a)

Valve, Manual
Seal, Forward Accumulator Oil
Piston, Forward Accumulator
Pin, Forward Accumulator
Spring, Forward Accumulator
Valve, Forward Abuse
Spring, Forward Abuse Valve
Plug, Bore
Pin, Coiled Spring
Valve, Low Overrun
Spring, Low Overrun Valve
Cover, Forward Accumulator
Bolt, Forward Accumulator Cover
Spring, 1-2 Shift Valve
Valve, 1-2 Shift
1-2 Shift Solenoid Valve

(367b)
(368)
(369)
(370)
(371)
(372)
(374)
(375)
(376)
(377)
(378)
(380)
(381)
(382)
(383)
(384)

2-3 Shift Solenoid Valve

Valve, 2-3 Shift
Valve, 2-3 Shuttle
Spring, 1-2 Accumulator Valve
Valve, 1-2 Accumulator
Sleeve, 1-2 Accumulator Valve
Valve, Actuator Feed Limit
Spring, Actuator Feed Limit Valve
Plug, Bore
Pressure Control Solenoid Valve
Retainer, Pressure Control Solenoid
Valve, Regulator Apply
Plug, Bore
Spring, 4-3 Sequence Valve
Valve, 4-3 Sequence
Valve, 3-4 Relay

Transmission!Transaxle
(385)
(386)
(387)
(388)
(389)
(390)
(391)

Valve, 3-4 Shift

Spring, 3-4 Shift Valve
Valve, Reverse Abuse
Spring, Reverse Abuse Valve
Valve, 3-2 Downshift
Spring, 3-2 Downshift Valve
Valve, 3-2 Control

Automatic Transmission - 4L60E

(392)
(394)
(395)
(396),
(397)
(398)

7-341

Spring, 3-2 Control Valve

3-2 Control Solenoid Valve
Retainer, Bore Plug and Solenoid
TCC PWM Solenoid Valve
Spring, Regulator Apply
Valve, Isolator

Pump Body Fluid Passages (Pump Cover Side)

338502

Legend
(1)
(2)
(3)
(4)
(5)
(7)
(8)
(11)

Suction (intake)
Decrease
Line
Converter Feed
Release
To Cooler
Lube from Cooler
Torque Signal

(16)
(29)
(37)
(43)
(45)
(46)
(47)
(48)

Reverse Input
3-4 Clutch
Overrun Clutch
Exhaust
Vent
Seal Drain
Void
Regulated Apply

7-342

Automatic Transmission - 4L60-E

Transmissionrrransaxle

48
(238)

338512

Legend
(1)
(2)
(3)
(4)
(5)
(7)
(8)
(11)
(16)
(18)
(29)

Suction (intake)
Decrease
Line
Converter Feed
Release
To Cooler
Lube from Cooler
Torque Signal
Reverse Input
Forward Clutch Feed
3-4 Clutch

(37)
(43)
(45)
(46)
(47)
(48)
(232)
(237)
(238)
(240)

Overrun Clutch
Exhaust
Vent
Seal Drain
Void
Regulated Apply
Oil Pump Cover Screen
Check Valve Retainer and Ball Assembly
Converter Clutch Signal Orificed Cup Plug
Orificed Cup Plug

Transmission/Transaxle

Automatic Transmission - 4L60E

7-343

Pump Cover Fluid Passages (Case Side)

16
(237)

37
(237)

29

11

18
338521

Legend

(1) Suction (Intake)

(2) Decrease
(3) Line
(5) Release
(7) To Cooler
(8) Lube from Cooler
(11) Torque Signal
(16) Reverse Input (Rev. Clutch
(18) Forward Clutch Feed
(29) 3-4 Clutch

(37) Overrun Clutch

(43) Exhaust
(45) Vent
(46) Seal Drain
(47) Void
(48) Regulated Apply
(232) Oil Pump Cover Screen
(237) Check Valve Retainer and Ball Assembly
(240) Orificed Cup Plug

7.;344

Transmission/Transaxle

Automatic Transmission - 4L60-E

Case Fluid Passages (Pump Cover Side)

(10)

48

37

18

16

213848

Legend
(3)
(7)
(8)
(10)
(11)
(16)

Line
To Cooler
Lube from Cooler
Connector, Oil Cooler Pipe
Torque Signal
Reverse Input

(18)
(29)
(37)
(39)
(45)
(48)

Forward Clutch Feed

3-4 Clutch
Overrun Clutch
Plug, Pressure
Vent
Regulated Apply

Transmission!Transaxle

Automatic Transmission - 4L60":"E

7-345

Case Fluid Passages (Control Valve Body Side)

(4j<
3
16

19

29
11

18

37

48

#10(42)
#1 (91)

4g
!.

I
J

b
~

I
l

#7(40)

338530

Legend

(#1) Checkball (91)

(#7) 3rd Accumulator Retainer and Ball
Assembly (40)
(#10) Checkball (42)
(3) Line
(9) Actuator Feed Limit
(10) Filtered Actuator Feed
(11) Torque Signal
(12) PR
(13) 04-3-2
(14) Lo/Reverse
(15) Reverse
(16) Reverse Input (Rev. Clutch
(17) 04
(18) Forward Clutch Feed
(19) Rear Lube

(20)
(21)
(22}
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)

Accumulator
Orificed Accumulator
Signal A
2nd
2nd Clutch
C.C. Signal
3-4 Signal
3rd Accumulator
3-4 Clutch
4th Signal
Servo Feed
4th
3-4 Accumulator
03
Overrun
Overrun Clutch Feed

7-346 Automatic Transmission - 4L60-E

(37)
(38)
(39)
(41)
(42)

Overrun Clutch
02
Orificed 02
Lo
Lo/1st

Transmission/Transaxle
(43)
(44)
(47)
(48)

Exhaust
Orificed Exhaust
Void
Regulated Apply

Transmission/Transaxle

Automatic Transmission - 4L60-E 7-347

Spacer Plate to Case Gasket

12
29

o~ 0

16

0
0

0
29

c:::)

290

30

15

C)29

0 021
Q34 25 ~
Q25 ou D
30

Q24
031

Oo
~

022

0 00
9o

260

0012

ouJ

D c:::J Q24
24
24 0 39
0 24
CJ Q39

330 3sG Oa5

0 33 06 020

Q2s

013

0
0

0
10

0 010

o~
l.....:_J

020
9

oO

20()0
25

09

03

14
0

18

(ill

036
32
28
260 025
0

41

ov17

00353400027
D

Q48

0 0 011

31

34

r:17 A2 D
14
(// )
12
38
(/044
012 042
44
41 041
01a
22
Q14
13
Q24
Q24
010

34

4343

410

Q34

18

O34

Do

26

27

24
33 CJ

25

~9

110

<::]38

0 Q12

29

02~0 038
016

47
0 29

47

c=]38

o~

110

0021

21

o 6QJ
338537

Legend
(3)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(20)
(21)

Line
Actuator Feed Limit
Filtered Actuator Feed
Torque Signal
PR
04-3-2
Lo/Reverse
Reverse
Reverse Input (Rev. Cl.)
04
Forward Clutch Feed
Accumulator
Orificed Accumulator

(22)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)

Signal A
2nd
2nd Clutch
C.C. Signal
3-4 Signal
3rd Accumulator
3-4 Clutch
4th Signal
Servo Feed
4th
3-4 Accumulator
03
Overrun

74348
(36)
(37)
(38)
(39)
(41)

Automatic Transmission - 4L60-E

Overrun Clutch Feed
Overrun Clutch
D2
Orificed D2
Lo

Transmissiori/Transaxle
(42)
(43)
(44)
(47)
(48)

Lo/1st
Exhaust
Orificed Exhaust
Void
Regulated Apply

Transmission/Transaxle

Automatic Transmission - 4L60-E

7-349

Spacer Plate Fluid Passages

'0 ~ 3
. 12
00

(17) 15/16

29/2~ } 290
O g9/28
38
. 016
. 0 29

15/16"-o O

10

~ ~

- - 3g)D

48

34

0
11

0
25

25

27 24

24

35136

CJ

0 14

>--0

012 14 (@)

012

~~9
0

43144

24

{28) ,, 4D CJ
~

24

?r

22

~oo

0 Q14
0

10

<110/23

os 110

90

0
l
I

ii

35/36

17 ~17

<w

@'10/22

Q13

Q24
38 9

~
35139
9;10(49)
@;
0 330 qfi 020 ~

33

36

2~09

026 0

o41

41

000

34
31

~ 0 0 0 017

13

0 Q32
28
(g) 0025

~9

oCLJ

D
35a

17M

0
3800011

18

27/29

300 Q27 CJ
34 0 24/25
22
.- 2 s o ~ o 024
02424/25~
5
31 ~ 3 CJ 33
Q
D
~ 7 43/44 ()
48
0
37
,.-./

@)

29 ~ 0

38"J
34 0
41

~ 18
012 17/18 (),17 42

18

OCJ9
1s
029
11
9
(13)
~ 0 27/29 d ~

12
Q34

041

200
@)

25

O d20/21

20/21

0021

09/10(50) 0

6-

338553

Legend
(49)
(50)
(3)
(9)
(9/10)
(10)
(10/22)
(10/23)
(11)
(12)
(13)
(14)
(15)
(15/16)
(16)
(17)

Shift Solenoids Screen

Pressure Control Solenoid Screen
Line
Actuator Feed Limit
Actuator Feed Limit/Filtered Actuator Feed
Filtered Actuator Feed
Filtered Actuator Feed/Signal A
Filtered Actuator Feed/Signal B
Torque Signal
PR
04-3-2
Lo/Reverse
Reverse
Reverse/Reverse Input (Rev. Clutch
Reverse Input (Rev. Clutch
04

(17/18)
(18)
(20)
(20/21)
(21)
(22)
(24)
(24/25)
(25)
(26)
(27)
(27/29)
(28)
(29/28)
(29)
(30)

04
Forward Clutch Feed
Accumulator
Accumulator/Orificed Accumulator
Orificed Accumulator
Signal A
2nd
2nd/2nd Clutch
2nd Clutch
C.C. Signal
3-4 Signal
3-4 Signal
3rd Accumulator
3-4 Clutch/3rd Accumulator
3-4 Clutch
4th Signal

7-350
(31)
(32)
(33)
(34)
(35a)
(35)
(35/36)
(35/39)
(36)
(37)

TransmissionfTransaxle

Automatic Transmission - 4L60-E

SeNo Feed
4th
3-4 Accumulator
D3
Overrun
Overrun
Overrun/Overrun Clutch Feed
Overrun/Orificed D2
Overrun Clutch Feed
Overrun Clutch

(38)
(38/39)
(41)
(42)
(43)
(43/44)
(44)
(47)
(48)

D2
D2/0rificed D2
Lo
Lo/1st
Exhaust
ExhausVOrificed Exhaust
Orificed Exhaust
Void
Regulated Apply

Transmission/Transaxle

Automatic Transmission - 4L6.0E

7-351

Spacer Plate to Control Valve Body Gasket

@ ~

029 0160

40
0

040

29

15

CJ
Q2s fg\\]9
\V
29

0
30

30

D..

34

22

0 021 D

D
35

~024
'-.__)
24 24
33

25

00

o 31
o
QoDo
25

43 44

31

37

ij36 O

Q4a

9o

28

0
(;;\

32

25 C)

0260

26
0

wJ

250

oc=J

..___0_1_d___

ov17

o 14 O
0012 ll V/)42
/) 17
12
0
18 0 0017 G044
012
42
15
308 41 Q41
4~ 9 0 0Q14
18 024
0 220
34 13
24

OOO

27

034

(1?)

41

'

Q34

34 0

c0 o @O 038 o 034

3800

@] Q12

29

48

22

013

24

D D

38024
0

CJU

204 24

31
D \
Q33 '-...J
OQ35
33

O 1a1

35/39

OoD

17 17 20

10

l:J ~

0
23

LJ

20

~
~

oO

025

09

25

11

Os

~TI

250
o
o 60

20

338563

Legend
(3)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
(20)
(21)
(22)
(23)
(24)

Line
Actuator Feed Limit
Filtered Actuator Feed
Torque Signal
PR
04-3-2
Lo/Reverse
Reverse
Reverse Input (Rev. Cl.)
04
Forward Clutch Feed
Accumulator
Orificed Accumulator
Signal A
Signal B
2nd

(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(35/39)
(36)
(37)
(38)

2nd Clutch
C.C. Signal
3-4 Signal
3rd Accumulator
3-4 Clutch
4th Signal
Servo Feed
4th
3-4 Accumulator
03
Overrun
Overrun/Orificed 02
Overrun Clutch Feed
Overrun Clutch
02

7-352
(40)
(41)
(42)
(43)

Automatic Transmission- 4L60-E

3-2 Signal
Lo
Lo/1st
Exhaust

Transmissionlrransaxle
(44) orificed Exhaust
(47) Void
(48) Regulated Apply

Transmission/Transaxle

Automatic Transmission - 4L60-E

7-353

Control Valve Body Fluid Passages (Case Side)

#8

#4

338570

Legend
(#2)
(#3)
(#4)
(#5)
(#6)
(#8)
(#12)
(3)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)

Checkball (61)
Checkball (61)
Checkball (61)
Checkb.all (61)
Checkball (61)
Checkball (61)
Checkball (61)
Line
Actuator Feed Limit
Filtered Actuator Feed
Torque Signal
PR
04-3-2
Lo/Reverse
Reverse
Reverse Input (Rev. Clutch

(17)
(18)
(20)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30}
(31)
(32)
(33)
(34)

D4
Forward Clutch Feed
Accumulator
Signal A
Signal B
2nd
2nd Clutch
C.C. Signal
3-4 Signal
3rd Accumulator
3-4 Clutch
4th Signal
Servo Feed
4th
3-4 Accumulator
D3

7-354
(35)
(36)
(37)
(38)
(40)

Transmission/Transaxle

Automatic Transmission - 4L60-E

(41)
(42)
(43)
(47)
(48)

Overrun
Overrun Clutch Feed
Overrun Clutch
D2
3-2 Signal

Lo
Lo/1st
Exhaust
Void
Regulated Apply

2-4 Servo Fluid Passages

10130

Legend

(#7) 3rd Accumulator Retainer and Ball

Assembly (40)
(11) Case Servo Orificed Plug
(25) 2nd Clutch
(28) 3rd Accumulator

(32) 4th
(43) Exhaust
(44) Orificed Exhaust

Transmission!Transaxle

Automatic Transmission - 4L60E 7-355

1-2 Accumulator Cover Fluid Passages

---25

25

20

213852

Legend
(20) Accumulator
(21) Orificed Accumulator

(25) 2nd Clutch

7-356

Automatic Transmission- 4L60-E

Transmission/Transaxle

Special Tools and Equipment

Illustration

Tool Number/Description

Illustration

Tool Number/Description

)
J 21426
J 21366

Case Extension Oil Seal

Installer

Converter. Holding Strap

1338

9353

J 36850
Scan Tool

Transmission
Assembly Lube

24825

59260

J 29714-A

J 21366

Servo Cover Depressor

Converter Holding Strap

9202

9353

J 21426

J 35944

Extension Housing Oil Seal

Installer

Oil Cooler and Line Flusher

9210

1338

J 21867
Universal Pressure
Gauge Set

J 35944-20
Cooler Flushing Fluid

)
15015

29339

Transmissionrrransaxle

Automatic Transmission ,. 4L60E

Tool Number;/Description

Illustration

Illustration

Tool Number/Description :

J 22269-01
Piston Compressor

2023

7,.357

J 33037
Band Apply Pin Tool

9206

J 33095
Control Module Connector
Terminal Remover

J 25025-8
Guide Pin Set

19110

5397

J 28458
Power Piston Seal Protector
and Diaphragm Retainer
Installer

1010

J 34142-B
Unpowered Test Lamp

5382

J 28742-A

J 35616
Conneqtor Test Adapter Kit

Weather Pack Terminal

Remover

8917

5396

D
J 35689-A
Metri-pack Terminal
Remover

J 29714-A
Servo Cover Compressor

9202

5395

7-358 Automatic Transmission - 4L60-E

Illustration

Tool Number/Description

J 35944-A
Transmission Oil Cooler and
Line Flushing Tool

Transmission/Transaxle
Illustration

Tool Number/Description

J 38417
Plastic Speed $ensor
Removal and
Installation Tool

9210

J 39200
Digital Multimeter (DMM)

J 35944-20
Cooler Flushing Fluid

3430

15015

J 39775
Jumper Harness

J 36169-A
Fused Jumper Wire

13538

20896

J 41364-A
Neutral Position
Adjustment Tool

J 36850
Transmission Assembly
Lubricant

102613

24825

J 38125-4
Terminal Repair Kit

9081

Clutch

TransmissionfTransaxle

7-359

Clutch
Specifications
Fastener Tightening Specifications
N,m

Application

Lbs Ft

Lbs In

1.3

12

Brake Pedal Pivot Nut

50

37

Clutch Actuator Cylinder Bleed Fitting

20

15

71

Body Hinge Pillar Trim Panel Screw

,.,

Clutch Actuator Cylinder Bolt

Clutch Pressure Plate Bolt (5-Speed)

20 plus
45 degrees

15 plus 45 degrees

Clutch Pressure Plate Bolt (6-Speed)

70

52

Clutch Master Cylinder Nut

20

15

1/P Knee Bolster Bolt

18

Transmission Bolt (5-Speed)

75

55

Transmission Bolt (6-Speed)

50

37

Sealers and Lubricants

Description

Application

Clutch Hydraulic Fluid

Clutch Pedal Bushing Lubricant

GM P/N 12345347
GM P/N 1052497

Diagnostic Information and Procedures

Preliminary Checking Procedure
1 . Before attempting to repair the following
components for any reasons other than an obvious
failure, identify the problem and probable cause:
The clutch
The transmission
Any related hydraulic components
2. Shifting difficulties such as the following conditions
indicate a large percentage of clutch and manual
transmission problems:
When any of these conditions occur, perform a
careful analysis of the difficulty before removing
the clutch or manual transmission for repairs.
A high shift effort
Gear clash
Gear grinding
Transmission blackout
3. Before removing the clutch hydraulic system,
remove the flywheel housing cover and measure
the travel of the clutch actuator pushrod in order to
verify the malfunction (6-Speed Only).
4. Ensure that the clutch actuator pushrod extends a
minimum of 11 mm (0.43 in) against the clutch
fork with the clutch pedal pushed fully to the floor.
(

Do not replace the hydraulic system if the

pushrod travel exceeds 11 mm (0.43 in).

Notice: Before opening the clutch master cylinder,

thoroughly clean .the top and sides. This is in order to
prevent contamination of the system with dirt,
water, or other foreign material. Before adding fluid,
remove the clutch master cylinder reservoir diaphragm.
Carefully replace the diaphragm, cover gasket and
cover after filling the clutch master cylinder.
5. If the clutch actuator pushrod does not meet the
travel requirements, check the clutch master
cylinder reservoir fluid level.
Ensure that the clutch actuator cylinder is in
place when checking the fluid level.
When you add fluid to or refill the system after
service operations, the use of hydraulic clutch
fluid GM P/N 12345347 or the equivalent is
preferred over the standard DOT 3 brake fluid.
Do not over fill the reservoir. The upper portion
of the clutch master cylinder must accept fluid
that is displaced from the clutch actuator
cylinder as the clutch wears.
6. If the clutch master cylinder reservoir requires any
fluid, check the clutch hydraulic system
components for leakage.
Remove the rubber boots from the clutch
master cylinder.
Check for leakage past the pistons. A slight
wetting of the surfaces is acceptable.
Replace the hydraulic system if excessive
leakage is evident.

7-360

Clutch

TransmissionfTransaxle

Clutch Spin Down Time

1. Apply the park brake.
2. Block the vehicle wheels.
3. Shift the transmission into NEUTRAL.
4. Start the engine and allow the engine to idle.
5. Engage the clutch (release the clutch pedal).,

6. Disengage the clutch (depress the clutch pedal):

maintain the clutch in the disengaged position for
9 seconds.
7. While still maintaining the clutch in the disengaged
position, shift the transmission into REVERSE.
a. If any grinding noise is produced, refer to Clutch
Does Not Disengage for further diagnosis.

Clutch Does Not Disengage

Probable Cause

Action
DEFINITION: With the clutch pedal pressed to the floor; the shift control doesnot move freely in and out of REVERSE.
The clutch pedal travel is incorrect.
1. Check for a clutch pedal restriction or a bent clutch pedal.
2. Remove any restrictions from the clutch pedal, or replace the clutch pedal if
necessary.
For the clutch pedal replacement procedure, refer to Clutch Pedal Replacement.
Air is in the clutch hydraulic system.
Bieed the air from the clutch hydraulic system.
Refer to Hydraulic Clutch Bleeding.
The clutch hydraulic system is
1. Inspect the clutch hydraulic system components for the following:
leaking.
Master cylinder leakage: primarily from the rear seal
Actuator cylinder leakage
Hydraulic hose leakage
Hydraulic hose connection leakage
2. Repair or replace components as necessary.
Bleed the air from the clutch hydraulic system.
Refer to Hydraulic Clutch Bleeding.
The clutch pressure plate to engine
1. Inspect the clutch pressure plate to engine flywheel bolts for looseness.
flywheel bolts are loose.
2. If loose bolts are suspected, loosen all the bolts evenly, then tighten the bolts to
specifications.
Refer to Clutch Pressure Plate and Clutch Driven Plate (3.BL) for the 3.8L or Clutch
Pressure Plate and Clutch Driven Plate (5.7L) for the 5.7L.
The release bearing is binding on the
1. Inspect the release bearing and the quill of the actuator cylinder for scoring or a
actuator cylinder quill.
lack of lubrication.
2. Replace or lubricate components as necessary.
For the release bearing replacement procedure, refer to Release Bearing
Replacement.
For the actuator cylinder replacement procedure, refer to Clutch Actuator
Cylinder Replacement.
The clutch driven plate.hub is binding
1. Inspect the propeller shaft splines for wear or damage.
on the propeller shaft input splines.
2. Inspect the clutch driven plate hub for wear or damage.
3. Replace components as necessary.
F6r the propeller shaft replacement procedure, refer to Propeller Shaft
Replacement - One Piece or Propeller Shaft Replacement - Two Piece in
Propeller Shaft.
For the clutch driven plate replacement procedure, refer to Clutch Pressure
Plate and Clutch Driven Plate (3.BL) for the 3.8L or Clutch Pressure Plate
and Clutch Driven Plate (5. 7L) for the 5. 7L.
,
The clutch driven plate is warped.
1, Measure the runout of the clutch driven plate.

2. The clutch driven plate runout should not exceed:

Specification
0.5 mm (0.020 in)
3. Replace the clutch driven plate, if necessary.
Refer to Clutch Pressure Plate and Clutch Driven Plate (3.BL) for the 3.8L or Clutch
Pressure Plate and Clutch Driven Plate (5.7L) for the 5.7L.
The clutch pilot bearing is faulty.

1. Inspect the clutch pilot bearing.

2. Replace the clutch pilot bearing, if necessary.
Refer to Pilot Bearing Replacement.

Clutch 7-361

Transmission/Transaxle
Clutch Slipping
Probable Cause

Action

The clutch driven plate is qi! soaked.

...

The clutch driven plate has been

overheated.
j",

1. Replace the clutch driven plate.

2. Correct the oil leak.
For the clutch driven plate replacement procedure, refer to Clutch Pressure
Plate and Clutch Driven Plate (3.BL) for 3.BL or Clutch Pressure Plate and
Clutch Driven Plate (5. 7L) for the 5. 7L.
For oil leak diagnosis information, refer to Oil Leak Diagnosis in Engine
Mechanical.
1. Allow the system to cool, if necessary.
2. Inspect the clutch driven plate for damage.
3. Replace the clutch driven plate, if necessary.
Refer to Clutch Pressure Plate and Clutch Driven Plate (3.BL) for the 3.8L or Clutch
Pressure Plate and Clutch Driven Plate (5.7L) for the 5.7L.

The clutch driven plate is not seated.

.

Attempt to seat the clutch driven plate:

Make 30 to 40 normal starts. DO NOT overheat.

The facing is worn br torn from the

clutch driven plate.

Replace the clutch driven plate.

Refer to Clutch Pressure Plate and Clutch Driven Plate (3.BL) for the 3.8L or Clutch
Pressure Plate and Clutch Driven Plate (5.7L) for the 5.7L.

The clutch pressure plate diaphragm

spring is weak.

1. Inspect the condition of the clutch pressure plate diaphragm spring.

2. Replace the clutch pressure plate, if necessary.
Refer to Clutch Pressure Plate and Clutch Driven Plate (3.BL) for the 3.8L or Clutch
Pressure Plate and Clutch Driven Plate (5.7L) for the 5.7L.

<.

The clutch pressure plate and or the

engine flywheel are warped.

1. Measure the runout of the clutch pressure plate and the engine flywheel.
2. The runout of the clutch pressure plate or the engine flywheel should not
exceed:
..Specification
1.25 mm (0.050 in)
3. Replace the clutch pressure plate and or the engine flywheel, if necessary.
For the clutch pressure plate replacement procedure, refer to Clutch
Pressure Plate and Clutch Driven Plate (3.BL) for the 3.BL or Clutch
Pressure Plate and Clutch Driven Plate (5.7L) for the 5.7L.
For the engine flywheel replacement procedure, refer to Engine Flywheel
Removal (Manual Transmission) in Engine Mechanical - 3.BL or Engine
Flywheel Removal in Engine Mechanical - 5.7L.

Clutch Grabbing
Probable Cause

Action

There is oil on the clutch driven plate

facings, or the facings are burned or
glazed.

1. Replace the clutch driven plate.

2. Correct the oil leak.
For the clutch driven plate replacement procedure, refer to Clutch Pressure
Plate and Clutch Driven Plate (3.BL) for the 3.BL or Clutch Pressure Plate
and Clutch Driven Plate (5.7L) for the 5.7L.
For oil leak diagnosis information, refer to Oil Leak Diagnosis in Engine
Mechanical.

An improper bolt tightening sequence

was used when installing the clutch
pressure plate to engine
flywheel bolts.

Loosen all bolts evenly, then tighten the bolts evenly using the proper sequence, to
specifications.
Refer to Clutch Pressure Plate and Clutch Driven Plate (3.BL) for the 3.BL or Clutch
Pressure Plate and Clutch Driven Plate (5.7L) for the 5.7L.

The release bearing is binding on the

actuator cylinder quill.

1. Inspect the release bearing and the quill of the actuator cylinder for scoring or a
lack of lubrication.
2. Replace ot lubricate components as necessary.
For the release bearing replacement procedure, refer to Release Bearing
Replacement.
For the actuator cylinder replacement procedure, refer to Clutch Actuator
Cylinder Replacement.

7362

Transmission/Transaxle

Clutch
Clutch Grabbing (cont'd)
Probable Cause

Action

The clutch driven plate hub is binding

on the propeller input shaft splines.

1. Inspect the propeller shaft splines for wear or damage.

2. Inspect the clutch driven plate hub for wear or damage.
3. Replace components as necessary.
For the propeller shaft replacement procedure, refer to Propeller Shaft
Replacement - One Piece or Propeller Shaft Replacement - Two Piece in
Propeller Shaft.
For the clutch driven plate replacement procedure, refer to Clutch Pressure
Plate and Clutch Driven Plate (3.BL) for the 3.8L or Clutch Pressure Plate
and Clutch Driven Plate (5.7L) for the 5.7L.

There is burned or smeared resin on

the engine flywheel or the clutch
pressure plate.

1. Sand off the burned or smeared resin if it is only superficial.

2. Inspect the engine flywheel and the clutch pressure plate surfaces for burn or
heat check marks.
3. Replace the engine flywheel and or the clutch pressure plate if such damage
is noted.
For the engine flywheel replacement procedure, refer to Engine Flywheel
Replacement in Engine Mechanical - 3.8L or Engine Flywheel Replacement
in Engine Mechanical - 5. 7L.
For the clutch pressure plate replacement procedure, refer to Clutch
Pressure Plate and Clutch Driven Plate (3.BL) for the 3.BL or Clutch
Pressure Plate and Clutch Driven Plate (5. 7L) for the 5. 7L.

The clutch pressure plate and/or the

engine flywheel are warped.

1. Measure the runoutof the clutch pressure plate and the engine flywheel.

2. The runout of the clutch pressure plate or the engine flywheel should not
exceed:

Specification
1.25 mm (0.050 in)
3. Replace the clutch pressure plate and or the engine flywheel, if necessary.
For the clutch pressure plate replacement procedure, refer to Clutch
Pressure Plate and Clutch Driven Plate (3.BL) for the 3.BL or Clutch
Pressure Plate and Clutch Driven Plate (5. 7L) for the 5. 7L.
For the engine flywheel replacement procedure, refer to Engine Flywheel
Replacement in Engine Mechanical - 3.8L or Engine Flywheel Replacement
in Engine Mechanical - 5.7L.
The clutch pilot bearing is faulty.

1. Inspect the clutch pilot bearing.

2. Replace the clutch pilot bearing, if necessary.
Refer to Pilot Bearing Replacement.

Clutch Rattle (Trans Click)

Probable Cause

Action

The damper springs in the clutch

driven plate are failing.
The retractor springs in the clutch .
pressure plate are weak.

Replace the clutch driven plate.

Refer to Clutch Pressure Plate and Clutch Driven Plate (3.BL) for the 3.8L or Clutch
Pressure Plate and Clutch Driven Plate (5.7L) for the 5.7L.
Replace the clutch pressure plate.
Refer to Clutch Pressure Plate and Clutch Driven Plate (3.BL) for the 3.BL or Clutch
Pressure Plate and Clutch Driven Plate (5.7L) for the 5.7L.

Release Bearing Noisy with Clutch Engaged

Action

Probable Cause
The release bearing is binding on the
actuator cylinder quill.

1. Inspect the release bearing and the quill of the actuator cylinder for scoring or a
lack of lubrication.

2. Replace or lubricate components as necessary.

The release bearing is worn.

.For the release bearing replacement procedure, refer to Release Bearing

Replacement.
For the actuator cylinder replacement procedure, refer to Clutch Actuator
Cylinder Replacement.
Replace the release bearing.
Refer to Release Bearing Replacement.

Clutch

Transmission/Transaxle

7-363

Clutch Noisy During Engagement

Probable Cause

Action

DEFINITION: The clutch is noisy during engagement or disengagement.

Replace the release bearing.

The release bearing is worn.

Refer to Release Bearing Replacement.

The clutch pilot bearing is loose in
the engine crankshaft.

Replace the pilot bearing.

Refer to Pilot Bearing Replacement.

Pedal Stays on Floor {Clutch Disengaged)

Probable Cause

Action

DEFINITION: The clutch pedal stays on the floor (clutch disengaged), or extremely low pedal effort.
There is a failure in the clutch
hydraulic system.

1. Inspect the clutch hydraulic system components for the following:

2.
3.
4.
5.

6.
The release bearing is binding on the
actuator cylinder quill..

Master cylinder leakage: primarily from the rear seal

Actuator cylinder leakage
Hydraulic hose leakage
Hydraulic hose connections leakage
Repair or replace components as necessary.
Bleed the air from the clutch hydraulic system.
Refer to Hydraulic Clutch Bleeding.
If no leakage is found, depress the clutch pedal while observing the fluid level
in the reservoir.
If the fluid level in the reservoir rose while depressing the clutch pedal, the
master cylinder is faulty.
replace the faulty clutch master cylinder.
Refer to Clutch Master Cylinder Replacement.

1. Inspect the release bearing and the quill of the actuator cylinder for scoring or a
lack of lubrication.

2. Replace or lubricate components as necessary.

For the release bearing replacement procedure, refer to Release Bearing
Replacement.
For the actuator cylinder replacement procedure, refer to Clutch Actuator
Cylinder Replacement.
The clutch pressure plate diaphragm
spring is weak or broken.

1. Inspect the condition of the clutch pressure plate diaphragm spring.

2. Replace the clutch pressure plate, if necessary.

Refer to Clutch Pressure Plate and Clutch Driven Plate (3.BL) for the 3.BL or Clutch
Pressure Plate and Clutch Driven Plate (5.7L} for the 5.7L.

Clutch Pedal Hard to Push

Probable Cause
One or both of the clutch master
cylinder hoses are blocked or
crimped.

Action

1. Inspect the clutch master cylinder hoses for blockage, crimps or damage.

2. Replace the clutch master cylinder as necessary.

Refer to Clutch Master Cylinder Replacement.

The clutch master cylinder or actuator

cylinder is binding.

1. Inspect the operation of the clutch master cylinder and actuator cylinder.

2. Replace the master cylinder or actuator cylinder, if necessary.

For the clutch master cylinder replacement procedure, refer to Clutch Master
Cylinder Replacement.
For the actuator cylinder replacement procedure, refer to Clutch Actuator
Cylinder Replacement.

There is dirt on the inside diameter of

the release bearing.

1. Clean the inside diameter of the release bearing and inspect for scoring.

2. Lubricate or replace the release bearing as necessary.

Refer to Release Bearing Replacement.

7-364

Clutch

Transmission/Transaxle
Clutch Pedal Hard to Push (cont'd)

Probable Cause
The release bearing is binding on the
actuator cylinder quill.

Action

1. Inspect the release bearing and the quill of the actuator cylinder for scoring or a
lack of lubrication.

2. Replace or lubricate components as necessary.

For the release bearing replacement procedure, refer to Release Bearing
Replacement.
For the actuator cylinder replacement procedure, refer to Clutch Actuator
Cylinder Replacement.
The clutch pressure plate is worn or
damaged.

1. Inspect the operation and condition of the clutch pressure plate.

2. Replace the clutch pressure plate, if necessary.
Refer to Clutch Pressure Plate and Clutch Driven Plate (3.BL) for the 3.8L or. Clutch
Pressure Plate and Clutch Driven Plate (5. 7L) for the 5. 7L.

Clutch Pedal Spongy

Probable Cause

Air is in the clutch hydraulic system.

The clutch hydraulic system fluid has
been contaminated causing master
cylinder and or actuator cylinder
internal seal damage.

Action
Bleed the air from the clutch hydraulic system.
Refer to Hydraulic Clutch Bleeding.

1. Inspect the fluid in the clutch hydraulic system for proper condition and type
of fluid.
2. If the fluid is found to be contaminated, flush the clutch hydraulic system to
expel all the contaminated fluid, then replace the hydraulic system components.
For the clutch master cylinder replacement procedure, refer to Clutch Master
Cylinder Replacement.
For the clutch actuator cylinder replacement procedure, refer to Clutch
Actuator Cylinder Replacement.
3. Fill the clutch hydraulic system with new fluid of the correct type, then bleed the
air from the clutch hydraulic system.
Refer to Hydraulic Clutch Bleeding.

Squeaky Clutch Pedal

Probable Cause
DOT 3 brake fluid is affecting the
clutch hydraulic system.

Action
Drain the clutch hydraulic system, refill the system with clutch hydraulic fluid
(GM P/N 12345347 or equivalent), then bleed the air from the system.
Refer to Hydraulic Clutch Bleeding.

The clutch pedal bushings are worn

or dry.

1. Inspect the clutch pedal bushings for proper condition.

2. If the clutch pedal bushings are found to be dry, then lubricate the bushings
using GM P/N 1052497 or equivalent.
3. If the clutch pedal bushings are found to be worn, then replace the bushings.
Refer to Clutch Pedal Replacement.

Clutch 7-365

Transmission/Transaxle
Rapid Driven Plate Wear
Probable Cause
The clutch pressure plate diaphragm
spring is weak.

Action

1. Inspect the condition of the clutch pressure plate diaphragm spring.

2. Replace the clutch pressure plate, if necessary.
Refer to Clutch Pressure Plate and Clutch Driven Plate (3.BL) for the 3.8L or Clutch
Pressure Plate and Clutch Driven Plate (5.ll) for the 5.7L.

The engine flywheel and or the clutch

pressure plate are scored.

1. Grind the engine flywheel and or the clutch pressure plate if the scoring is only
superficial.

2. Replace the engine flywheel and or the clutch pressure plate if the damage is

Improper driving habits.

more severe.
For the engine flywheel replacement procedure, refer to Engine Flywheel
Replacement in Engine Mechanical - 3.8L or Engine Flywheel Replacement
in Engine Mechanical - 5.7L.
For the clutch pressure plate replacement procedure, refer to Clutch
Pressure Plate and Clutch Driven Plate (3.BL) for the 3.8L or Clutch
Pressure Plate and Clutch Driven Plate (5.lL) for the 5.7L.
Attempt (through instruction) to curtail the possibility of the following conditions
occurring:
Riding the clutch
Racing the engine and slipping the clutch excessively during hard starting
Holding the vehicle in position on inclines by slipping the clutch.

7-366

Clutch

Transmission/Transaxle

Repair Instructions
Clutch Pedal Replacement
Removal Procedure
1.
2.
3.
4.

Remove
Remove
Remove
Remove

the
the
the
the

1/P
1/P
1/P
1/P

insulator retainers (2).

insulator panel.
knee bolster bolts.
knee bolster.

296111

5. Disconnect the accel/cruise servo cable adjuster

electrical connectors (1 ).

407641

Clutch

Transmission/Transaxle
6. Remove the servo cable adjuster bracket push-in
retainer (2), if equipped with the 5.7L and traction
control.
7. Remove the servo cable adjuster bracket nut (1),
if equipped with the 5. 7L and traction control.

7-367

----

li;t_J___. ---

479826

8. Remove the clutch pedal lever pin retainer (1 ).

9. Remove the clutch master cylinder rod (3) from
the clutch pedal pin (2).

350159

(
I

7-368

Clutch

Transmission/Transaxle
10. Remove the brake pedal pivot nut (2) and bolt (7).
11. Remove the clutch pedal (5).
12. Remove the clutch pedal pivot bushings, if
necessary from the bracket (1 ).

441779

Installation Procedure
1. Install the clutch pedal pivot bushings, if necessary
to the bracket (1 ).
2. Install the clutch pedal (5).
Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Install the brake pedal pivot bolt (7) and nut (2).

Tighten
Tighten the brake pedal pivot nut (2) to
50 N-m (37 lb ft).

441779

Transmission/Transaxle

Clutch

7-369

4. Install the clutch master cylinder rod (3) to the

clutch pedal pin (2).
5. Install the clutch pedal lever pin retainer (1).

350159

6. Install the servo cable adjuster bracket nut (1), if

equipped with the 5.7L and traction control.
7. Install the servo cable adjuster bracket push-in
retainer (2), if equipped with the 5.7L and
traction control.

479826

7-370

Clutch

Transmission/Transaxle
8. Connect the accel/cruise servo cable adjuster
electrical connectors (1 ).

407641

9. Install the 1/P knee bolster.

10. Install the 1/P knee bolster bolts.
Tighten
Tighten the 1/P knee bolster bolts to
2 N-m (18 lb in).
11. Install the 1/P insulator panel.
12. Install the 1/P insulator retainers (2).

296111

Transmission!Transaxle

Clutch

7-371

Clutch Master Cylinder Replacement

Removal Procedure
Tools Required
J 36221 Hydraulic Clutch Line Separator
1. Remove the driver side instrument panel insulator.
Refer to Insulator Replacement - IP (Left Side) in
Instrument Panel, Gauges and Console.
2. Remove the drive side knee bolster. Refer to
Knee Bolster Replacement in Instrument Panel,
Gauges and Console.
3. Remove the clutch pedal pin retainer (1 ).
4. Remove the clutch master cylinder push rod (3)
from the clutch pedal pin (2).
5. Remove the clutch master cylinder nuts (7).
6. Remove the clutch master cylinder push on
nuts (6).
7. Remove the clutch master cylinder U-bolt (4).
8. Remove the clutch master cylinder (5) from the
front of dash.
9. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.

350159

10. Lower the vehicle.

11 . Using the J 36221, depress the white circular
release ring on the actuator hose and
simultaneously pull lightly on the master cylinder
hose to disconnect.
12. Protect both hose coupling ends from dirt and
damage.
13. Lower the vehicle.

43255

7-372

Clutch

Transmission/Transaxle
14. Remove the clutch master cylinder reservoir
push-in retainer.
15. Slide the clutch master cylinder reservoir out from
the hood strut bracket.
16. Remove the clutch master cylinder (and
reservoir) from the vehicle.

350147

Installation Procedure
1. Install the clutch master cylinder into the opening
in the front of dash.
2. Slide the clutch master cylinder reservoir into the
opening on the hood strut bracket.
3. Install the clutch master cylinder reservoir push-in
retainer.

350147

4. Raise the vehicle.

Important: DO NOT rely on an audible click or a
visual verification of the clutch hydraulic hose quick
connect fitting connection.
5. Connect the clutch master cylinder hose to the
clutch actuator.
Push together the clutch hydraulic quick connect
fittings, then pull back on the fittings to verify
engagement.
6. Check the clutch hydraulic hoses tor twists
or kinks.
7. Lower the vehicle.

)
43255

Transmission/Transaxle

Clutch

7-373

8. Install the clutch master cylinder U-bolt (4).

9. Install the clutch master cylinder push on nuts (6).
Notice: Refer to Fastener Notice in Cautions and
Notices.
10. Install the clutch master cylinder nuts (7).

11 .
12.
13.

14.

15.

Tighten
Tighten the clutch master cylinder nuts (7) to
20 Nm (15 lb ft).
Install the clutch master cylinder push rod (3) onto
the clutch pedal pin (2).
Install the clutch pedal pin retainer (1 ).
Remove the drive side knee bolster. Refer to
Knee Bolster Replacement in Instrument Panel,
Gauges and Console.
Remove the driver side instrument panel insulator.
Refer to Insulator Replacement - IP (Left Side) in
Instrument Panel, Gauges and Console.
Bleed the clutch hydraulic system. Refer to
Hydraulic Clutch Bleeding.

350159

Clutch Actuator Cylinder Replacement

Removal Procedure
1 . Remove the manual transmission. Refer to
Transmission Replacement (Removal) in Manual
Transmission - M49 or Transmission Replacement
(Removal) in Manual Transmission - MM6.
2. Remove the clutch bleeder fitting from the
actuator cylinder.
3. Using a small drift or punch, remove the roll-pin
retaining the hydraulic fitting to the actuator
cylinder.
4. Remove the clutch actuator cylinder bleed fitting.
5. Remove the clutch actuator cylinder bolts (1 ).
6. Remove the clutch actuator cylinder (2).

2
43256

7-374 Clutch

Transmission/Transaxle
Installation Procedure
1. Install the clutch actuator cylinder (2).

Notice: Refer to Fastener Notice in Cautions and

Notices.
2. Install the clutch actuator cylinder bolts (1 ).

Tighten
Tighten the clutch actuator cylinder bolts (1) to
8 N-m (71 lb in).
3. Install the hydraulic titting to the actuator cylinder.
4. Install the actuator cylinder titting roll-pin retainer
using a small drift or punch.
5. Install the clutch actuator cylinder bleed fitting.

2
43256

Tighten
Tighten the clutch actuator cylinder bleed titting to
20 N-m (15 lb ft).
6. Install the manual transmission. Refer to
Transmission Replacement (Installation) in Manual
Transmission - M49 or Transmission Replacement
(Installation) in Manual Transmission - MM6.

Hydraulic Clutch Bleeding

43252

Notice: DO NOT use fluid which has been bled from

a hydraulic clutch system, in order to till the clutch
master cylinder reservoir; due to the possibility that the
fluid may be aerated, have too much moisture
content or be contaminated and may cause system or
vehicle damage.
Bleeding the hydraulic clutch system is necessary
whenever the level of fluid in the clutch master cylinder
reservoir has been allowed to tall so low that air has
been drawn into the master cylinder.
1 . Clean all dirt and debris from the clutch master
cylinder cap to ensure that no foreign substances
will enter the system.
2. Remove the clutch master cylinder reservoir cap
with diaphragm.
3. Fill the clutch master cylinder reservoir with clutch
hydraulic fluid GM P/N 12345347, or equivalent, it
necessary.
4. Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle in General
Information.
5. Having an assistant depress the clutch pedal fully
and hold.
6. Loosen the bleeder on the clutch actuator cylinder
to purge air.
7. Tighten the bleeder.
8. Release the clutch pedal.
9. Repeat steps 5 through 8 until all air is completely
evacuated.
Check and refill the clutch master cylinder
reservoir with clutch hydraulic fluid GM
P/N 12345347, or equivalent, as necessary in
order to prevent air from being drawn through the
clutch master cylinder.

Transmission/Transaxle

Clutch

7-375

1O. Fill the clutch master cylinder reservoir with clutch

hydraulic fluid GM P/N 12345347, or equivalent, if

necessary.
11. Lower the vehicle.

Clutch Anticipate Switch Replacement

Removal Procedure
1.
2.
3.
4.

Remove
Remove
Remove
Remove

the
the
the
the

1/P
1/P
1/P
1/P

retainers (2).
insulator panel.
knee bolster bolts.
knee bolster.

296111

5. Disconnect the clutch anticipate switch electrical

connector from the clutch anticipate switch (2).
6. Remove the clutch anticipate switch (2) from the
pedal bracket assembly.

296589

7-376 Clutch

Transmission/Transaxle
Installation Procedure
1. Install the clutch anticipate switch (2) to the pedal
bracket assembly until fully seated.
With the clutch pedal maintained in its fully
rearward position, push the switch through its
retainer until the switch barrel is touching the pedal
target and the switch plunger is fully depressed.
2. Connect the clutch anticipate switch electrical
connector to the clutch anticipate switch (2).

296589

3. Install the 1/P knee bolster.

Notice: Refer to Fastener Notice in Cautions and
Notices.
4. Install the 1/P knee bolster bolts.
Tighten
Tighten the 1/P knee bolster bolts to
2 Nm {18 lb in).
5. Install the 1/P insulator panel.
6. Install the 1/P retainers (2).

296111

Clutch Pedal Position Switch Replacement

Removal Procedure
1.
2.
3.
4.

Remove
Remove
Remove
Remove

the
the
the
the

1/P
1/P
1/P
1/P

retainers (2).
insulator.
knee bolster bolts.
knee bolster.

)
296111

Transmission/Transaxle

Clutch

7-377

5. Disconnect the clutch pedal position switch

electrical connector (2).
6. Pull up to disengage the clutch pedal position
switch (3) from the pedal bracket (1 ).
7. Remove the clutch pedal position switch (3).

350142

Installation Procedure
1. Install the clutch pedal position switch (3).
2. Align the buttons on the clutch pedal position
switch (3) to the slotted holes on the bracket (1 ).
3. Press the clutch pedal position switch (3) down
until secure.
4. Connect the clutch pedal position switch electrical
connector (2).

350142

5. Install the 1/P knee bolster.

Notice: Refer to Fastener Notice in Cautions and
Notices.
6. Install the 1/P knee bolster bolts.

Tighten
Tighten the 1/P knee bolster bolts to
2 N-m (18 lb in).
7. Install the 1/P insulator.
8. Install the 1/P retainers (2).

296111

7-378

Clutch

Transmission!Transaxle
Clutch Housing Replacement
Removal Procedure
1. Remove the manual transmission. Refer to
Transmission Replacement (Removal) in Manual
Transmission - M49 or Transmission Replacement
(Removal) in Manual Transmission - MM6.
2. Remove the clutch actuator cylinder. Refer to
Clutch Actuator Cylinder Replacement.
3. Remove the transmission bolts (3).
4. Separate the flywheel/clutch housing (1) from the
transmission (2).
5-speed transmission shown, 6-speed
transmission similar.

472967

Installation Procedure
1. Install the flywheel/clutch housing (1) to the
transmission (2).

Notice: Refer to Fastener Notice in Cautions and

Notices.
2. Install the transmission bolts (2).
Tighten
Tighten the 5-speed transmission bolts to
75 Nm (55 lb ft).
Tighten the 6-speed transmission bolts to
50 Nm (37 lb ft).
3. Install the clutch actuator cylinder. Refer to Clutch
Actuator Cylinder Replacement.
4. Install the manual transmission. Refer to
Transmission Replacement (Installation) in Manual
Transmission - M49 or Transmission Replacement
(Installation) in Manual Transmission - MM6.
472967

Pilot Bearing Replacement

Removal Procedure
Tools Required
J 23907 Clutch Pilot Bearing Remover
1. Remove the clutch pressure plate and clutch
driven plate. Refer to Clutch Pressure Plate
and Clutch Driven Plate (3.BL) for the 3.8L or
Clutch Pressure Plate and Clutch Driven
Plate (5.7L) for the 5.7L
2. Using the J 23907, remove the clutch pilot
bearing.

71486

Clutch

TransmissionfTransaxle

7-379

Installation Procedure
1. Using a suitable size socket, install the clutch pilot
bearing.
2. Install the clutch pressure plate and clutch driven
plate. Refer to Clutch Pressure Plate and Clutch
Driven Plate (3.BL) for the 3.8L or Clutch
Pressure Plate and Clutch Driven Plate (5. 7L) for
the 5.7L

71487

Clutch Pressure Plate and Clutch Driven

Plate (3.8L)
Removal Procedure
1. Remove the manual transmission. Refer to
Transmission Replacement (Removal) in Manual
Transmission - M49.
2. Remove the clutch pressure plate bolts (1 ).
3. Remove the clutch pressure plate (2) and driven
disc (4) from the dowel pins on the flywheel (3).

479575

Installation Procedure
Tools Required
J 33169 Clutch Alignment Arbor
J 36660 Torque Angle Meter
Important: When the clutch driven plate requires
replacement, the engine flywheel must also be
replaced along with the clutch pressure plate as an
assembly.
1. Install the clutch pressure plate (2) and driven
plate (6) to the dowel pins on the flywheel (5).
2. Match the gray paint spot (7) on the pressure
plate (2) to the X (4) on the flywheel (5).
3. Install the clutch pressure plate bolts (1)
finger tight.
4. Install the J 33169 in order to align the clutch
driven plate to the clutch pilot bearing.

6
441865

7-380

Clutch

Transmission/Transaxle
Notice: Refer to Fastener Notice in Cautions and
Notices.
5. Tighten the clutch pressure plate bolts (1 ).
Tighten
Tighten the clutch pressure plate bolts (1) to
20 Nm (15 lb ft). Use J 36660 in order to tighten
the bolts an additional 45 degrees.
6. Install the manual transmission. Refer to
Transmission Replacement (Installation) in Manual
Transmission - M49.

Clutch Pressure Plate and Clutch Driven

Plate (5. 7L)

Removal Procedure
1. Remove the manual transmission. Refer to
Transmission Replacement (Removal) in Manual
Transmission - MM6.
2. Remove the pressure plate bolts (4).
3. Remove the pressure plate (3) and driven
plate (2) from the dowel pins on the flywheel (1).

441863

Installation Procedure
Tools Required
J 38836 Pilot Bushing Installer/Clutch Alignment Arbor
Important: When the clutch driven plate requires
replacement, the engine flywheel must also be
replaced along with the clutch pressure plate as an
assembly.
1. Install the clutch pressure and driven plate to the
dowel pins on the flywheel.
2. Install the pressure plate bolts finger tight.
3. Install the J 38836 in order to align the clutch
driven plate to the clutch pilot bearing.

J 38836
71488

Transmission/Transaxle

Clutch

Notice: Refer to Fastener Notice in Cautions and

Notices.

7-381

4. Tighten the clutch pressure plate bolts.

Tighten
Tighten the clutch pressure plate bolts (in
sequence shown) to 70 N-m (52 lb ft).
5. Install the manual transmission. Refer to
Transmission Replacement (Installation) in Manual
Transmission - MM6.

5
71490

Clutch Pressure Plate Adjustment

(Off Vehicle (5.7L Only))
Important: Clutch pressure plate adjustment is dnly
necessary when the driven (clutch) disc is worn
and the pressure plate has compensated for the
worn disc.
1. Place the clutch pressure plate, flat surface down,
on a press.
2. Compress the pressure plate diaphragm spring
fingers until tension is released from the stepped
adjusting ring.
3. Hold 2 screwdrivers or other suitable tools, and
place them against 2 of the 3 stepped adjusting
ring tension spring stops (1 ), just ahead of
the adjusting ring tension springs.

173634

4. Using the screwdrivers, rotate the stepped

adjusting ring counterclockwise (compressing the
tension springs) until the adjusting ring steps
are fully adjusted out, then continue to hold
in position.
5. Release the press pressure from the pressure
plate diaphragm spring fingers.
6. Release the adjusting ring tension spring stops.
7. Remove the pressure plate from the press.

174781

7-382

Clutch

Transmission/Transaxle
Release Bearing Replacement
Removal Procedure
1. Remove the manual transmission. Refer to
Transmission Replacement (Removal) in Manual
Transmission - M49 or Transmission Replacement
(Removal) in Manual Transmission - MM6.
2. Remove the clutch release bearing.
Rotate the bearing in either direction.
The compression spring load will push the release
bearing off the end of the clutch actuator
cylinder.

479580

Installation Procedure
Important: DO NOT use cleaners or chemicals to
clean the quill and DO NOT grease the quill.
1. Using a clean dry cloth, clean the exposed area
of the actuator cylinder quill.

479581

Important: DO NOT grease the new clutch release

bearing. The new clutch release bearing to be installed
is pre-greased.
2. Install the new clutch release bearing to the clutch
actuator cylinder.
Firmly push the clutch release bearing into place.
The release bearing will snap over the retainer
tab and will be self-retained to the actuator
cylinder.
3. Install the manual transmission. Refer to
Transmission Replacement (Installation) in Manual
Transmission - M49 or Transmission Replacement
(Installation) in Manual Transmission - MM6.

Transmission/Transaxle

Clutch

7-383

Description and Operation

Principal Components
The following are the principal components of the
clutch system:
The driving members; attached to the engine and
turning with the engine.
The driven members; attached to the engine
driveline and tran!:lmission and turning with
the driveline and transmission.
The operating members; including the spring, the
clutch hydraulic system, and the clutch pedal
linkage, required to apply and release the
pressure, which hold the driving and driven
members in contact with each other.

Clutch Driving Members

The clutch driving members consist of two, flat
surfaced, iron plates, machined to a smooth finish.
One of these surfaces is the rear face of the engine
flywheel and. the other is a comparatively heavy
flat ring, with one side machined, known as the clutch
pressure plate.

Clutch Driven Members

The driven member (friction or clutch disc) consists of
a hub and a plate, with facings attached to the
plate. The clutch disc has cushion springs and
dampening springs. The cushion springs are slightly
waved, or curled. The cushion springs are attached to
the plate, and the clutch facings are attached to the
springs. When the clutch is engaged, the cushion
springs compress slightly to take up the shock
of engagement. The dampening springs are heavy coil
springs set in a circle around the hub. The hub is
driven through these springs. They help to smooth out
the torsional vibration so that the power flow to the
transmission is smooth.
There are grooves in both sides of the clutch disc
facings. These grooves prevent the facings from
sticking to the flywheel face and pressure plate when
the clutch is disengaged. The grooves break any
vacuum that might form and cause the facings to stick
to the flywheel or pressure plate.

Clutch Operating Members

The driving member and the driven member are held
in contact by spring pressure. This pressure is
exerted by a one-piece conical or diaphragm spring.
A diaphragm spring is a conical piece of spring
steel that has been specially stamped to give it greater
flexibility. The diaphragm is positioned between the
cover and the pressure plate so that the diaphragm

spring is nearly flat when the clutch is in the engaged

position. The action of this type of spring is similar
to that of an ordinary oil can.
The pressure of the inner rim of the spring on the
pressure plate decreases as the flat position is passed.
The inner rim of the diaphragm bears on the edge
of the pressure plate and is pivoted on a ring on the
outer edge of the pressure plate. The application
of a pulling load on the inner section of the pressure
plate will cause the inner rim to move away from
the flywheel and allow the pressure plate to move
away from the clutch disc, thereby releasing or
disengaging the clutch. When the pressure is released
from the inner section, the OIL CAN action of the
diaphragm causes the inner section to move in, and
the movement of the inner rim forces the pressure
plate against the clutch disc, thus engaging the clutch.
The clutch release bearing is moved by the actuator
assembly to move the release levers which move
the pressure plate to the rear, thus separating
the clutch disc from the flywheel when the clutch
pedal is depressed by the driver. A piston return spring
in the actuator cylinder preloads the clutch linkage
and assures a small load on the release bearing with
the actuator assembly at all times. As the clutch
disc wears, the diaphragm spring fingers move forward
forcing the release bearing, actuator assembly, and
push rod to move. This movement forces the actuator
cylinder piston to move forward in its bore, consuming
hydraulic fluid from the master cylinder reservoir,
thereby providing the SELF-ADJUSTING feature of
the hydraulic clutch linkage system.

Hydraulic Clutch Description

The clutch hydraulic system consists of a master
cylinder and an actuator cylinder. When pressure is
applied to the clutch pedal (pedal depressed), the
pushrod contacts the plunger and pushes it down the
bore of the master cylinder. In the first 0.8 mm
(0.031 in) of movement, the recuperation seal closes
the port to the fluid reservoir tank, and as the
plunger continues to move down the bore of the
cylinder, the fluid is forced through the outlet line to
the actuator cylinder. As fluid is pushed down the pipe
from the master cylinder, this in turn forces the
piston in the actuator cylinder outward. As the actuator
cylinder piston moves forward, it forces the release
bearing to disengage the clutch pressure plate
from the clutch disc. On the return stroke (pedal
released), the plunger moves back as a result of the
return pressure of the clutch. Fluid returns to the
master cylinder and the final movement of the plunger
opens the port to the fluid reservoir, allowing an
unrestricted flow of fluid between system and reservoir.

7-384 Clutch

Transmission!Transaxle

Special Tools and Equipment

Illustration

Tool Number/ Description

Illustration

Tool Number/ Description

mJ

J 23907
Clutch Pilot Bearing
Remover

J 33169
Clutch Alignment Arbor

995

43268

J 36221

J 38836

Hydraulic Clutch Line

Separator

Pilot Bushing Installer/Clutch

Alignment Arbor

105916

18093

J 36660
Torque Angle Meter

3413

INDEX

A
Abbreviations and Their Meanings ..................... 0-20
Accelerator and Servo Control Module
(ASM) Replacement ........................ 5-250
Accelerator Controls
Cable Replacement (3.8L) .......................... 6-1169
Cable Replacement (5.7L) .......................... 6-1802
Pedal Replacement (3.8L) .......................... 6-1170
Pedal Replacement (5.7L) .......................... 6-1804
Acid Rain ...................................................... 8-1020
Actuator
Air Inlet Replacement (A/C - Manual) ........... 1-106
Defroster Replacement (A/C - Manual) ......... 1-107
Heater/Bi-Level Vacuum Replacement
(A/C - Manual) ............................... 1-108
Vent Replacement (A/C - Manual) ................ 1-106
Actuator Replacement
Liftgate Lock . .. .. .. .. .. .. . . .. .. .. .. ... .. .. . .... .. .. ... . .. .. . 8-980
Release .. .. .. .. .. .. .. .. . .. ... .. .. .. .. .. .. ... . .. ... . ... ... . .. . . 8-981
Adjustment
Rack Bearing Preload - Power Steering ......... 2-42
Adjustments
Backlash Adjustment
Rear Drive Axle .......................................... 4-50
Clutch Pressure Plate .................................. 7-381
Pinion Depth Adjustment
Rear Drive Axle .......................................... 4-29
Side Bearing Preload Adjustment
Rear Drive Axle .......................................... 4-48
AIR
Check Valve/Pipe Replacement
Bank1 (5.7L) ........................................... 6-1853
Bank2 (5.7L) ........................................... 6-1852
Air Baffle Assemblies and Deflectors
(Engine Cooling) .................. 6-652, 6-653
Air Cleaner
Assembly Replacement (5.7L) .................... 6-1859
Element Replacement (3.8L) ...................... 6-1219
Element Replacement (5.7L) ...................... 6-1858
Intake Duct Replacement (3.8L) ................. 6-1220
Air Conditioning
Diagnosis
Request Circuit (5.7L) ............................. 6-1750
Air Deflector Replacement
Radiator ........................................................8-761
Air Inlet Actuator Replacement
(A/C - Manual) ... . .. .. .. .. .. .. ... .. .. .. . .. . .. 1-106
Air Inlet Grille Panel Replacement ................... 8-762
Air Outlet Replacement - Right Defogger
(A/C - Manual) ............................... 1-110
Air Wind/Noise
Diagnosis
Air Pressure Test ..................................... 8-665
Air/Wind Noise
Diagnosis
Air/Wind Noise .......................................... 8-665
Soap Suds or Bubble Test ....................... 8-665
Tracing Powder or Chalk Test .................. 8-665
Alignment
Checking Frame to Body Alignment ........... 8-1041
Alignment Checking
Frame and Underbody ............................... 8-1041

Aluminum Wheel
Hub Cap Replacement ................................... 3-60
Porosity Repair .. .. .. .. .. .. .. .. ... .. ... .. ... ... .. .. .. .. .. .. .. 3-60
Refinishing ..................................................... 3-60
Amplifier Replacement .. .. .. .. ... .. ... .. .. .. .. .. 8-244, 8-245
Antenna
Schematic
Power .. .. ... .. .. .. .. .. .. . ... .. .. .. .. .. . .. ... .. .. .. .. .. .. .. .. 8-205
Antenna Mast Cleaning .. .. .. .. .. .. . ... ... .. .. .. . .. .. .. .. . 8-256
Antenna Mast Replacement
Fixed ........................................................... 8-253
Power .......................................................... 8-254
Antenna Motor Replacement .. .. .. .. ... .. .. .. .. ... .. .. . 8-255
Antenna Replacement
Fixed .. .. . . .. ... .. .. .. .. ... .. .. ... .. .... ... ... .. .. ... .. .. . .. . ... 8-254
Antenna System Check
Power .......................................................... 8-218
Antilock Brake System
ABS!TCS Schematics .. .. ... .. ... ... .. . .. .. . .. .. .. .. . .. . 5-112
Adjuster Assembly Replacement ................... 5-253
BPMV Hydraulic Flow Chart .............. 5-109, 5-110
Brake Pressure Modulator Valve
Replacement .................................. 5-251
Cable Adjustment Procedure ........................ 5-255
Component Locations ................................... 5-120
Component Views ........................................ 5-123
Connector End Views .. .. . . .. . ... .. .. .. .. .. .. .. .. ... .. .. 5-128
Diagnostic
TCS Off Indicator On with No DTC Set ..... 5-229
Description
Abbreviations and Definitions .. .. . .. . .. .. .. .. .. .. 5-260
ABS!TCS System ..................................... 5-261
ABS!TCS System Operation .. .. . ... .. .. .. ... ... . 5-262
Basic Knowledge Required ....................... 5-260
General . ... . ... .. .. .. ... .. .. .. . .. . .. . ... . .. .. ... . .. ... . .. .. 5-260
Service Precautions .................................. 5-260
Diagnosis
ABS Indicator Inoperative with
No DTC Set .................................... 5-241
ABS Indicator On No DTC Set .................. 5-239
ASR Indicator Inoperative with
No DTC Set .. ... .. .. .. .. .. .. .. .. .. .. ... .. .. .. .. 5-235
ASR Indicator On with No OTC Set .......... 5-233
Clearing Diagnostic Trouble Codes ........... 5-133
Diagnostic System Check .. .. .. ... .. ... .. .. .. .. .. . 5-136
Displaying Diagnostic Trouble Codes ........ 5-133
Electromagnetic Interference .. .. .. .. .. ... .. .. .. .. 5-135
Initialization Sequence .............................. 5-133
lntermittents and Poor Connections .......... 5-133
Low Traction Indicator Inoperative ............. 5-245
Low Traction Indicator On
All of the Time .. . . .. .. .. . .. .. .. .. .. .. .. .. .. .. 5-243
No Communication with EBCM/EBTCM .... 5-237
Scan Tool Diagnostics ... .. . .. .. .. .. .. ... .. .. .. ... .. 5-133
Self-Diagnostics ........................................ 5-133
TCS Indicator Inoperative with
No DTC Set .................................... 5-231
Electronic Brake Control Module
Replacement .. .. ... .. .. . ... . . ... ... . .. ... . .. .. 5-247
GM SPO Group Numbers ............................ 5-108
Schematic
ABS Schematic Icons .. .. ... . .. ... .. .. .. .. . .. .. .. .. . 5-111
ABS Schematic References ...................... 5-111

2
Antilock Brake System (cont.)
Special Tools ............................................... 5-264
Specifications
Fastener Tightening .................................. 5-108
Wheel Speed Sensor
Jumper Harness Replacement ...... 5-257, 5-258,
5-259
Ring Replacement .................................... 5-260
Wheel Speed Sensor Replacement .... 5-255, 5-256,
5-257
Anti-Theft Labeling ............................................ 0-11
Arm Blade Replacement .. .. .. . .. .. .. .. .. .. .. .. .. .. ... . ... 8-180
Arrows and Symbols, Description ........................ 0-4
Ashtray Lamp Bulb Replacement ..................... 8-130
Ashtray Replacement . .. .. .. .. ... .. .. .. . ... .. .. .. . .. ... .. .. 8-506
Assist Rod Ball Stud Replacement
Hood ........................................................... 8-756
Assist Rod Replacement
Hood ........................................................... 8-755
Audible Warnings
Diagnosis
Diagnostic System Check ......................... 8-496
Fasten Safety Belt Chime Always On ....... 8-497
Fasten Safety Belt Chime Inoperative ....... 8-497
Key-in Ignition Chime On with LF Door
Closed ............................................ 8-499
Key-in-Ignition Chime Always On .............. 8-498
Key-In-Ignition Chime Inoperative .............. 8-498
Lights On Chime Inoperative .................... 8-499
Lights On Chime On with Ignition in Run ..... 8-499
Auto Trans Shift Lock Control
Description
Circuit (Tilt Column) .................................. 2-110
Diagnosis
Always On With Ignition in RUN ................. 2-60
Inoperative ................................................. 2-59
System Check ............................................ 2-58
Diagnosis (Tilt Column) .................................. 2-62
Auto Trans Shift Lock Control Schematics
Steering Wheel/Column - lilt ......................... 2-55
Automatic Transmission - 4L60-E
2-4 Servo ..................................................... 7-266
Accumulator Assembly ................................. 7-294
Brake Transmission Shift Interlock
Solenoid Replacement .................... 7-245
Case Extension Assembly Installation ........... 7-292
Component Location .................................... 7-324
Component Location Table .................... 7-79, 7-81
Control and Shift Solenoids Replacement ..... 7-284
Description
Diagnosis ................................................. 7-318
Electrical Connector Description ................ 7-323
Electronic Component ............................... 7-319
Preliminary Checking Procedure ............... 7-317
Torque Converter Clutch Electrical
Controls .. .. .. .. . .. .. ... .. .. .. . .. .. ... .. .. . .. . .. .. 7-322
Transmission ID Information ..................... 7-316
Diagnosis
1st Gear Range Only-No Upshift .............. 7-235
2nd Gear Start . .. . .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. . 7-240
2nd Gear Start Switch and Indicator
Lamp Circuit Check ........................ 7-220
2nd/3rd Gears Only or 1st/4th
Gears Only ..................................... 7-237

INDEX
Automatic Transmission - 4L60-E (cont.)
Diagnosis (cont.)
3-2 Flare or Tie-Up ................................... 7-237
Component Resistance .. .. .. .. .. .. .. . .. . .. .. .. ... .. 7-230
Delay in Drive and Reverse ...................... 7-241
Drives in Neutral ....................................... 7-240
Electrical/Garage Shift Procedure .............. 7-224
Electronic Component Malfunctions ........... 7-233
Fluid Leak . .. .. .. .. .. ... . .. ... .. . ... .. .. .. .. .. .. .. .. .. .. .. 7-242
Flywheel/Torque Converter
Vibration Test ................................. 7-226
Functional Test Procedure .......................... 7-72
Harsh Garage Shift ................................... 7-239
Harsh Shifts ............................................. 7-234
Inaccurate Shift Points .............................. 7-235
Line Pressure Check Procedure ............... 7-223
No 2-3 Shift or 2-3 Shift Slips,
Rough or Hunting ........................... 7-236
No 3-4 Shift, Slips or Rough 3-4 Shift ...... 7-237
No Drive in All Ranges ............................. 7-241
No Overrun Braking - Manual 3-2-1 .......... 7-239
No Park . .. .. .. .. .. ... . ... .. .. .. .. . .. ... .. .. .. .. .. .. .. .. .. .. 7-240
No Part Throttle or Delayed Downshifts .... 7-238
No Reverse or Slips in Reverse ............... 7-238
No Torque Converter Clutch Apply ........... 7-239
No Torque Converter Clutch Release ....... 7-240
Noise and Vibration Analysis .................... 7-226
Oil Out the Vent ....................................... 7-241
Oil Pressure High or Low ......................... 7-234
Ratcheting Noise . .. .. .. .. .. .. .. ... .. . ... .. . .. .. .. ... .. 7-241
Road Test Procedure ............................... 7-224
Slipping or Rough 1-2 Shift ...................... 7-236
Slips in 1st Gear ....................................... 7-235
Third Gear Only ....................................... 7-237
Torque Converter Clutch ........................... 7-226
Torque Converter Clutch Shudder .... 7-227, 7-240
Transmission Fluid Checking Procedure .... 7-222
Transmission Fluid Pressure Valve Position
Switch Resistance Check ................ 7-231
Vibration in Reverse and Whining
Noise in Park ................................. 7-241
Wiring Harness Check .............................. 7-228
Do Not Use Air Tools ................................... 7-315
Electronic Component Views .......................... 7-83
Extension Housing Rear Oil Seal ................. 7-291
Filler Tube Replacement .................... 7-271, 7-273
Floor Shift Control Replacement ................... 7-252
Fluid/Filter Changing .................................... 7-255
lnline Harness Connector End View ............... 7-84
Internal Connector End Views ........................ 7-85
Oil Cooler Flushing ...................................... 7-314
Oil Cooler Line Replacement ....................... 7-258
Park Lock Cable Replacement ..................... 7-246
Park/Neutral Position Switch Replacement . .. 7-253
Parts Cleaning and Inspection ...................... 7-244
Pressure Regulator Replacement ................. 7-269
Replacement ..................................... 7-301, 7-307
Schematic
Controls Schematic Diagrams ..................... 7-74
Schematic Icon Table ................................. 7-73
Schematic Reference Table ........................ 7-73
Shift Cable Replacement .............................. 7-249
Special Tools ............................................... 7-356

INDEX

Automatic Transmission - 4L60-E (cont.)

Specifications
Diagnostic Trouble Code (OTC)
Identification ............................ 7-64, 7-67
Fastener Tightening .................................... 7-56
Fluid Capacity ............................................ 7-69
Line Pressure ............................................. 7-71
Range Reference Table .............................. 7-70
Scan Tool Data Definitions ................ 7-60, 7-62
Scan Tool Data Value Examples ....... 7-57, 7-58
Shift Solenoid Valve State and
Gear Ratio ....................................... 7-70
Shift Speed Table ....................................... 7-70
Temperature vs Resistance ........................ 7-56
TFP Manual Valve Position Switch Logic ....... 7-71
Torque Converter Clutch PWM Solenoid, TCC
Solenoid, and Wiring Harness .......... 7-287
Torque Converter Cover Replacement ......... 7-275,
7-276
Valve Body and Pressure Switch
Replacement . .. .. .. .. .. .. .. . ... .. .. .. .. .. .. .. . 7-278
Vehicle Speed Sensor Replacement ............. 7-299
Automatic Transmission- 4L60-E
Diagnosis
Front Oil Leak .......................................... 7-241
No Drive in Drive Range .......................... 7-241
Automatic Transmission 4- L60-E
General Information ...................................... 7-317
Automatic Transmission 4L60-E
Description
Fluid Checking Procedure ......................... 7-317
Axle Replacement
Rear Drive Axle ............................................. 4-54

8
Balancing Tires and Wheels .............................. 0-66
Ball Joint Replacement, Lower Front
Suspension ....................................... 3-19
Ball Joint Replacement, Upper Front
Suspension ....................................... 3-17
Basecoat/Clearcoat Paint Systems ................. 8-1016
Battery
Cable Replacement ........................... 6-695, 6-700
Charging ...................................................... 6-691
Common Causes of Failure ......................... 6-675
Description . . ... .. . .. .. .. ... .. .. .. .. . ... .. .. . ... .. .. .. .. .. . .. . 6-720
Hydrometer Displays Dark or Yellow Dot ...... 6-676
Is Undercharged or Overcharge ................... 6-679
Jump Starting in Case of Emergency ........... 6-692
Load Test - Parasitic .................................... 6-676
Negative Cable Disconnect .......................... 6-693
Replacement . .. . .. .. .. ... .. .. .. .. . . .. .. . .. ... .. .. .. .. .. .. . .. 6-689
Battery Temperature vs Minimum Voltage ........ 6-666
Battery Usage Specifications ........................... 6-665
Belt, Drive, Diagnosis ...................................... 6-258
Belt, Drive, Diagnosis (3.8L) .............................. 6-28
Belt, Drive, Replacement (3.8L) ......................... 6-34
Belt, Drive, Replacement (5.7L) ............ 6-267, 6-269
Belt Reveal Molding Replacement ........ 8-950, 8-951
Bezel Replacement
IP Cluster .......................................... 8-502, 8-503

Blade Element Cleaning .................................. 8-193

Blower
Diagnosis
High Speed Inoperative (A/C - Manual) ...... 1-20
Inoperative at Any Speed (A/C - Manual) ...... 1-17
Low Speed Inoperative (A/C - Manual) ....... 1-18
Operates at High Speed Only
(A/C - Manual) ................................. 1-19
Operates Continuously (A/C - Manual) ........ 1-20
Operates in One Speed Only
(A/C - Manual) ................................. 1-19
Motor and Fan Assembly Replacement
(A/C - Manual) ................................. 1-92
Resistor Replacement (A/C - Manual) ............ 1-92
Blower Motor
Description
Controls Circuit (A/C - Manual) ................. 1-127
Relay Replacement (A/C - Manual) ................ 1-91
Body Control Module Programming/RPO
Configuration .................................. 8-465
Body Control Module Replacement .................. 8-463
Body Control System
Body Control Module Component Views ....... 8-439
Body Control Module Components .. .. .. .. .. ... .. 8-436
Body Control Module Connector
End Views . .. .. ... . .. .. .. .. .. .. .. .. ... .. . .. ... .. 8-440
Description
Circuit ....................................................... 8-465
Diagnosis
Clearing DTCs .. .. .. .. . ... .. ... . ... . .. ... .. .. . ... . ... .. . 8-443
Displaying DTCs ... . ... ... .. . .. .. .. .. .. ... ... .. .. .. .. .. 8-442
DTC List .. .. .. .. .. . ... . .. .. ... .. .. ... .. .. . . .. .... .. .. . .. .. . 8-443
lntenninents and Poor Connections .......... 8-442
Schematics
Body Control Module ..................... 8-426, 8-431
Body Control Module Schematic Icons ...... 8-425
Body Control Module Schematic
References .. .. ... .. .. .. .. . .. .. ... .. .. .. . ... .. .. 8-425
Body Dimensions ........................................... 8-1023
Body Front End
Description
General .................................................... 8-770
Specifications
Fastener Tightening .................................. 8-734
Body Measurements ............. 8-1042, 8-1050, 8-1059
Body Rear End
Component Views . .. .. .. .. .. .. .. .. .. .. .. . .... . .. .. .. .. .. . 8-960
Components ................................................. 8-958
Connector End Views ................................... 8-962
Description .. .. .. .. .. .. .. .. .. ... . ... .. .. . ... . .. ... . ... .. .. .. . . 8-986
Rear Compartment Lid Release Circuit ..... 8-986
Schematic
Schematic Icons ....................................... 8-955
Schematic References .............................. 8-955
Special Tools ............................................... 8-986
Body Side
Door Molding Replacement .......................... 8-653
Brake Booster
Hose Replacement . . .. ... . . .. .. .. . ... . .. .. ... .. .. .. .. .. . .. 5-59
Brake Caliper
Bracket Replacement ..................................... 5-84
Inspection ...................................................... 5-78

INDEX

4
Brake Caliper (cont.)
Overhaul ............................................... 5-78, 5-81
Replacement .. .. .. ... .. .. . .. .. .. ... .. .. .. .. .. .. .. . ... 5-73, 5-76
Brake Pad Inspection ........................................ 5-70
Brake Pads Replacement ......................... 5-70, 5-72
Brake Pedal Bracket Replacement .. .. . .. .. .. .. .. ... .. 5-34
Brake Pedal Replacement . ... .. . ... .. .. ... .. .. .. . .. .. ... . . 5-30
Brake Pedal Travel
Hydraulic Brakes ............................................ 5-25
Brake Rotor
Refinishing ............................................ 5-87, 5-89
Brake Rotor Replacement ........................ 5-85, 5-86
Brake System Diagnosis
Hydraulic Brakes ............................................ 5-15
Brake System Testing
Hydraulic Brakes ............................................ 5-15
Brake Vacuum Brake Booster
Description . . .. .. ... .. .. .. .. .. .. .. .. ... .. .. .. ... . .. .. .. .. .. ... . . 5-65
Brake Warning System
Schematics . .. .. .. . .. .. .. .. .. .. .. ... .. . .. . .. .. .. . .. . .. . .. .. .. .. .. 5-7
Bumper Replacement
Rear Suspension ........................................... 3-45
Bumpers
Air Deflector Replacement
Front Fascia ............................................. 8-713
Description
Bumper and Fascia .................................. 8-733
Energy Absorber Replacement
Front ............................................. 8-721, 8-722
Rear .............................................. 8-730, 8-731
Fascia Grille Replacement
Front Lower .............................................. 8-720
Fascia Replacement
Front ............................................. 8-714, 8-716
Rear .. .. .. .. .. . .. ... .. .. .. ... . ... . .. .. .. . .. .. .. .. . 8-723, 8-726
Impact Bar Replacement
Front ........................................................ 8-720
Rear ......................................................... 8-732
License Bracket Replacement
Rear ......................................................... 8-723
License Pocket Cover Replacement
Front ........................................................ 8-719
Specifications
Fastener Tightening .................................. 8-712

c
Cable Replacement
Accelerator Controls (3.8L) ......................... 6-1169
Accelerator Controls (5. 7L) ......................... 6-1802
Hood Latch Release .................................... 8-751
Cage Nut Service, Damaged ......................... 8-1077
Camshaft Position Sensor
Replacement (3.8L) ....................... 6-1214
Camshaft Position Sensor
Replacement (5.7L) ....................... 6-1848
Cargo Area Trim Front Panel
Replacement ........................ 8-940, 8-941
Cargo Area Trim Side Panel Replacement . .. ... . 8-942
Carper Replacement
Rear Center Trim Panel Carpet .. ... .. . . 8-945, 8-946
Carpet Replacement .. .. .. .. .. ... . ... . .. .. ... .. .. .. .. .. .. ... 8-944
Cassette Player
Cleaning Tape Head and Capstan ................ 8-246

Caster and Camber Adjustment, Front ................ 3-8

Catalytic Converter Replacement . .. .. .. .. .. . .. .. .. . 6-1902
CD Changer Replacement
Remote ............................................. 8-247, 8-249
Charging System
Circuit Description ........................................ 6-722
Charging System Check .................................. 6-672
Charging System Description ........................... 6-721
Cigarette Lighter Replacement IP .................... 8-511
Cleaning
Fabric Trim .................................................. 8-954
Glass Surfaces ............................................ 8-954
Removal of Specific Stains .......................... 8-954
Cleaning Agents . ... .. .... .. ... . . .. .. ... .. .. .. .. ... .. .. . .. . ... 8-954
Cleaning Leather Trim ..................................... 8-953
Cleaning The Headliner ................................... 8-954
Cleaning Vinyl Trim ......................................... 8-953
Clearcoat Repair without Repainting .............. 8-1019
Clearcoat Thickness ...................................... 8-1021
Clutch
Actuator Cylinder Replacement .................... 7-373
Anticipate Switch Replacement ..................... 7-375
Clutch Pressure Plate Adjustment ................ 7-381
Clutch Pressure Plate and Clutch Driven
Plate Replacement ............... 7-379, 7-380
Description
Clutch Driven Members ............................ 7-383
Clutch Driving Members ............................ 7-383
Clutch Operating Members ....................... 7-383
Principal Components ............................... 7-383
Diagnosis
Does Not Disengage ................................ 7-360
Grabbing (Chattering) ............................... 7-361
Noisy During Engagement ........................ 7-363
Pedal Hard to Push .. .. .. .. . .. .. .. . ... .. .. . .. ... .. ... 7-363
Pedal Spongy .. .. .. .. .. . .. .. .. .. .. .. . .. .. ... . .. . ... .. ... 7-364
Pedal Squeaky . .. . .. .. .. .. .. .. .. .. .. .. .. .. ... . .. .. ... .. 7-364
Pedal Stays on Floor (Clutch
Disengaged) ................................... 7-363
Preliminary Checking Procedure ............... 7-359
Rapid Driven Plate Wear ... . .. .. .. . ... .. . ... . .. . .. 7-365
Rattle (Trans Click) ................................... 7-362
Release Bearing Noisy w/Clutch
Engaged .. .. .. ... .. . .. ... . .. .. .. .. ... .. . .. .. ... .. 7-362
Slipping .................................................... 7-361
Spin Down Time ....................................... 7-360
Housing Replacement . .. .. . .. .. .. .. .. . .. ... . .. . .. . .. . .. 7-378
Hydraulic Clutch Bleeding ............................ 7-374
Master Cylinder Replacement ....................... 7-371
Pedal Position Switch Replacement ............. 7-376
Pedal Replacement .. .. .. .. .. .. .. . .. .. .. .. . .. .. . ... . ... .. 7-366
Pilot Bearing Replacement ........................... 7-378
Release Bearing Replacement ..................... 7-382
Special Tools ............................................... 7-384
Specifications
Fastener Tightening .................................. 7-359
Sealers, Adhesives and Lubricants ........... 7-359
Clutch Anticipate Switch Replacement (3.8L) .... 6-1218
Coding Keys and Lock Cylinders ....................... 0-25
Coil Spring Insulators Replacement, Rear ......... 3-53

INDEX
Coil Spring Replacement
Rear Suspension . .. .. ... . ... .. .. .. .. . ... ... .. . .. ... . .. .. .. . 3-52
Coin Holder Replacement
Front Floor Console ..................................... 8-526
Collision Repair
Radiator Support
Description . .. .. ... . .. ... .. .. .. .. .. .. . ... .. .. .. .. ... .. .. . 8-1112
Compact Disc Care and Cleaning ................... 8-251
Compressor
Clutch Coil Removal (A/C - Manual) . .. .. 1-50, 1-52
Clutch Plate and Hub Assembly Removal
(A/C - Manual) .. .. .. ... . .. ... .. .. .. . .. 1-46, 1-47
Clutch Plate/Hub Assembly Install
(A/C - Manual) ........................ 1-59, 1-60
Clutch Rotor and/or Bearing Install
(A/C - Manual) ........................ 1-61, 1-64
Clutch Rotor and/or Bearing Removal
(A/C - Manual) .. .. .. . ... ... . .. .. ... . .. 1-48, 1-49
Compressor Clutch Coil Install
(A/C - Manual) . .. .. .. ... .. .. .. . ... .. .. 1-65, 1-67
Control Switches Install (A/C - Manual) .......... 1-71
Control Switches Removal (A/C - Manual) ..... 1-58
Control Valve Assembly Install
(A/C - Manual) . . .. .. . ... .. ... . .. .. ... . .. .. .. .. . 1-58
Control Valve Assembly Removal
(A/C - Manual) ................................. 1-53
Hose Assembly Replacement
(A/C - Manual) ........................ 1-77, 1-79
Leak Testing (A/C - Manual) . .. . .... . ... .. .. . ... . .. .. . 1-72
Mounting Bracket Replacement
(A/C - Manual) .. . .. . ... ... . .. .. .. .. .. . 1-73, 1-76
Pressure Relief Valve Install
(A/C - Manual) ................................. 1-71
Pressure Relief Valve Removal
(A/C - Manual) .. . .. .. ... .. . ... .. . .. . .. .. .. .. .. . 1-57
Replacement (A/C - Manual) ................. 1-40. 1-43
Shaft Seal Install (A/C - Manual) .......... 1-67. 1-69
Shaft Seal Removal (A/C - Manual) ...... 1-54. 1-56
Condenser Replacement (A/C - Manual) ... ... . ... . 1-85
Console
Armrest Replacement
Front Floor ............................................... 8-523
Coin Holder Replacement
Front Floor ............................................... 8-526
Cup Holder Replacement
Front Floor ............................................... 8-525
Power Accessory Port Replacement
Front Floor ............................................... 8-524
Replacement
Front Floor ............................................... 8-521
Trim Plate Replacement .................... 8-517, 8-520
Control Arm Bushings Replacement
Rear Suspension . ... .. .. ... . .. .. .. .. . .... .. .. . .. .. .. .. ... . . 3-46
Control Arm Bushings Replacement, Upper ....... 3-26
Control Arm, Lower, Bushings
Replacement ........................... 3-29, 3-30
Control Arm Replacement
Rear Axle Lower ............................................ 3-46
Control Arm Replacement, Lower ...................... 3-28
Control Arm Replacement, Upper ...................... 3-24
Control Assembly
Replacement (A/C - Manual) ........................ 1-101

5
Conversion Table
English/Metric .................................................. 0-3
Coolant
Description .. .. .. .. .. .. .. . ... .. .. .. .. .. .. .. . .. .. ... .. .. .. .. .. . 6-664
Heater Description ....................................... 6-660
Level Sensor Replacement
(Engine Cooling) ............................. 6-644
Recovery Pipe Replacement
(Engine Cooling) ............................. 6-602
Recovery Reservoir Replacement
(Engine Cooling) ............................. 6-598
Recovery System Description . .. .. .. .. .. .. .. ... .. . .. 6-660
Coolant Heater
Cord Replacement (Engine Cooling) ... 6-657, 6-658
Coolant Heater Replacement
(Engine Cooling) ................. : 6-654, 6-655
Cooling System Draining and Filling ..... 6-592, 6-595
Courtesy Lamp Replacement
Rear Quarter .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. .. . 8-142
Cover Replacement
Trim Panel Opening ..................................... 8-966
Crankcase Ventilation System ........................ 6-1893
Crankcase Ventilation System
Inspection (3.8L) ........................... 6-1219
Crankshaft Position Sensor
Replacement (3.8L) ....................... 6-1213
Crankshaft Position Sensor
Replacement (5.7L) ....................... 6-1846
Crankshaft Position System Variation Learn
Procedure (3.8L) ........................... 6-1157
Crankshaft Position System Variation Learn
Procedure (5. 7L) ........................... 6-1789
Crossmember Brace Replacement
Front .......................................................... 8-1068
Crossmember Replacement ........................... 8-1070
Cruise Control
Cable Adjustment . .. .. .. ... . .. ... . .. .. .. .. .. ... .. .. .. . ... . 8-632
Cable Replacement ........................... 8-617, 8-621
Component Locations .. ... .. .. .. .. . .. .. ... .. .. .. .. . ... .. 8-604
Component Views . .. .. .. .. .. .. .. .. .. .. .. .. ... .. .. . .. .. .. . 8-605
Connector End Views . ... .. .. .. .. .. . .. ... .. .. .. .. .. .. .. . 8-608
Description
System Circuit ............................... 8-638, 8-639
System Description ................................... 8-636
System Operation .. .. .. .. ... . .. .. .. .. .. ... .. . .. .. .. .. . 8-636
Diagnosis
Does Not Resume, Accelerate, or
Tap Up or Down ............................ 8-613
Inoperative ................................................ 8-609
System Check .. ... . ... .. .. .. .. .. .. .. . .. ... .. .. .. .. .. .. . 8-609
Module Replacement ................................... 8-614
Multifunction Lever Replacement .................. 8-632
Release Switch Adjustment .. .. . ... .. .. .. .. .. .. .. .. .. 8-635
Release Switch Replacement .. ... . .. ... .. .. .. .. .. . . 8-634
Schematic
Icons ........................................................ 8-601
References ............................................... 8-601
Schematics . .. .. .. .. .. .. .. .. .. .. .. .. ... . .. .. .. ... .. .. . .. .. .. . 8-602
Specifications
Fastener Tightening .................................. 8-601
Cup Holder Replacement
Front Floor Console ..................................... 8-525

INDEX

D
Daytime Running Lamps
Ambient Light Sensor Replacement ... .. .. .. .. .. . 8-137
Control Module Replacement ....................... 8-135
Decimal and Metric Equivalents .......................... 0-3
Definition of Caution, Notice and Important ............ 3
Defogger
Right Air Outlet Replacement
(A/C - Manual) ............................... 1-110
Defroster Actuator Replacement
(A/C - Manual} .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 1-107
Description of Arrows and Symbols . .. .. .. ... .. .. .. . ... . 0-4
Diagnosis
Ball Stud Check .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 3-14
Low or Uneven Trim Height ............................. 3-6
Strategy Based Diagnosis .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 0-31
Tire Wear, Abnormal or Excessive ................... 3-4
Vehicle Leads/Pulls .......................................... 3-3
Diagnostic Work Sheets .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. . 0-5
Disc Brakes
Brake Caliper
Inspection ................................................... 5-78
Overhaul ........................................... 5-78, 5-81
Replacement ..................................... 5-73, 5-76
Brake Rotor Replacement ..................... 5-85, 5-86
Burnishing Pads and Rotors .......................... 5-73
Description .. .. .. .. .. .. .. .. .. .. .. .. ... .. . .. .. .. .. .. ... . ... .. .. .. 5-90
Diagnosis
Brake Rotor Lateral Runout Check ............. 5-69
Brake Rotor Thickness Variation Check ...... 5-69
Brake Rotor Tolerance ............................... 5-69
Refinishing Brake Rotors ....................... 5-87, 5-89
Special Tools ................................................. 5-91
Specifications
Component . .. ... .. .. .. .. .. . ... . ... .. .. . ... .. .. .. .. .. .. .. .. . 5-68
Fastener Tightening .................................... 5-68
Dome and Reading Lamp Bulb
Replacement .................................. 8-130
Dome Lamp Replacement ............................... 8-143
Door Lamp Replacement ...................... 8-139, 8-140
Door Lock Switch Replacement ............ 8-799, 8-800
Door Locks
Diagnosis
Power Door Locks .................................... 8-790
Inoperative ............................................ 8-790
Lock Inoperative, Lock Operates ........... 8-790
Unlock Inoperative, Lock Operates ........ 8-790
Power Door Locks Switch Lock
Function Inoperative ....................... 8-791
One ...................................................... 8-791
Power Door Locks Switch Unlock
Function Inoperative ....................... 8-791
One ...................................................... 8-791
Door Opening Frame Replacement Side ....... 8-1097,
8-1098, 8-1100
Door Replacement
Fuel Filler .................................................... 8-970
Door Service ................................................. 8-1103
Door Sill Plate Replacement .. .. .. .. .. .. .. . .. .. . .. .. . .. . 8-943
Doors
Description
Power Door Locks Circuit ......................... 8-823
Power Mirrors Circuit ................................ 8-824

Doors (cont.)
Description (cont.)
Power Windows Circuit ............................. 8-823
Diagnosis
One Mirror Inoperative in Up/Down
Direction .............................. 8-794, 8-795
Outside Mirrors System Check .................. 8-785
Power Door Locks System Check . ... .. . .. ... . 8-784
Power Windows System Check ................ 8-784
Door Handle Replacement
Inside ....................................................... 8-81 O
Outside .. .. .. .. .. .. .. . . .. ... . .. .... . . ... . . .. .. .. .. .. .. . ... .. 8-809
Door Hinge Replacement .................. 8-807, 8-808
Door Replacement .. .. .. .. . .. .. .. ... .. .. .. .. .. .. .. . .. ... . 8-806
Door Seal Replacement ............................... 8-819
Lock Actuator Replacement .. .. .. .. . .. .. .. .. .. .. . .. .. 8-813
Lock Replacement ....................................... 8-812
Lock Striker Adjustment ............................... 8-814
Mirror Face Replacement .................. 8-822, 8-823
Mirrors Replacement .................................... 8-821
Power Door Systems Component Views ... ... 8-779
Power Door Systems Components ............... 8-777
Power Door Systems Connector
End Views .. ... .. .. .... .. ... .. .. .. .. ... .. .. ... .. 8-783
Pull Handle Replacement ............................. 8-802
Schematic
Door Locks . .. . ... ... .. .. .. ... .. .. .. .. .. . .. .. .. .. .. ... ... . 8-774
Outside Mirrors ......................................... 8-775
Power Door Systems Schematic Icons .. .. .. 8-772
Power Door Systems Schematic
References ..................................... 8-772
Power Windows ........................................ 8-773
Special Tools .. .. .. .. .. ... .. .. .. ... . .. .. .. .. .. .. .. . ... .. . .. . 8-824
Specifications
Fastener Tightening .................................. 8-771
Striker Replacement ..................................... 8-814
Trim Panel Replacement
Door ......................................................... 8-804
Water Deflector Replacement
Door ......................................................... 8-805
Weatherstrip Replacement
Door ......................................................... 8-820
Window Regulator Motor Replacement ......... 8-816
Window Regulator Replacement ................... 8-815
Window Replacement ................................... 8-817
Drain Channel Replacement ............................ 8-879
Drain Cock
Replacement (Engine Cooling) ..................... 6-646
Draining and Filling Cooling System
(Engine Cooling) .................. 6-592, 6-595
Drive Belt
Replacement (5.7l) ........................... 6-267, 6-269
Tensioner Replacement (5.7L) ........... 6-272, 6-273
Drive Belt Diagnosis .. .. .. .. . .. .. .. ... .. .. .. .. .. .. .. .. . . .... 6-258
Drive Belt Diagnosis - 3.8L ............................... 6-28
Drive Belt Replacement - 3.8L .......................... 6-34
Drive Tension Specifications ............ 0-33, 5-33, 5-76
DTC 12 .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. . .. .. .. . .. .. .. .. .. . . 8-444
DTC 21/31 ....................................................... 8-446
DTC 22/32 ............................................ 8-448, 8-450
DTC 23/33 .. .. .. .. .. .. .. .. .. .. ... . .. .. .. .. .. ... .. .. .. . ... .. .. . .. . 8-452
DTC 24/34 . . .. ... .. .. . .. ... .. .. .. .. .. .. .. .. .. . .. . .. .. .. .. .. .. .. . . 8-454
DTC 25/35 ....................................................... 8-456
DTC 41 ... .. .. .. .. .. .. .. .. ... . ... .. .. .. .. . .. ... ... . .. .. .. .. .. .. .. . 8-458

INDEX
DTC 42 .. .. ... . .. .. .. .. .. .. .. .. .. .. .. .. .. . .. ... . ... .. .. . ... . .. .. .. 8-459
DTC 43 .. .. ... . .. .. ... . .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. . ... .. . .. .. 8-460
DTC 44 ... . ... .. .. . ... . .. .. .. ... .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. 8-461
DTC 45 . .. .. .. .. .. .. . ... .. . .. ... .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. . .. 8-462
DTC 55 . .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. .. . .. .. .. ... . ... .. . .. .. .. . 8-463
DTC 81015 ....................................................... 9-40
DTC81016 ....................................................... 9-44
DTC81017 ....................................................... 9-47
DTC 81018 ....................................................... 9-51
DTC 81019 ....................................................... 9-54
DTC 81021 ....................................................... 9-56
DTC 81022 . .. .. .. .. . .. .. .. .. ... . .. ... . .. .. .. .. .. .. .. .. .. . .. .. .. .. 9-60
DTC 81024 .. . .. .. .. .. . ... . .. ... . .. ... . .. .. .. .. ... .. . .. .. .. . ... . .. 9-64
DTC 81025 .. .. . .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. ... .. .. . .. .. .. .. .. . 9-67
DTC 81026 ....................................................... 9-70
DTC 81051 ....................................................... 9-74
DTC 81053 ....................................................... 9-75
DTC 81061 ....................................................... 9-76
DTC 81071 ....................................................... 9-77
DTC C0035 . .. .. .. .. .. .. . .. ... .. . ... . .. .. .. .. .. .. .. .. .. .. .. .. . .. 5-139
DTC C0036 . .. .. .. .. .. .. .. . .... . .. .. . .. .. .. .. .. .. .. .. .. .. .. .. . .. 5-142
DTC C0040 .. .. . ... . .. .. .. .. ... . .. .. .. . ... . .. .. ... . ... . .. .. .. . .. 5-145
DTC C0041 ..................................................... 5-148
DTC C0045 ..................................................... 5-151
DTC C0046 .. .. .. .. .. .. .. .. . ... .. .. . .. .. .. .. .. ... . .. .. .. .. .. .. . . 5-154
DTC C0050 ..................................................... 5-157
DTC C0051 ..................................................... 5-160
DTC C0055 . .. .. .. .. .. . .. .. .. .. ... . .. .. .. .. .. .. .. .. .. .. .. . .. .. .. 5-163
DTC C0056 . .. .. .. .. .. .. . .. .. ... .. . .. .. .. .. .. .. .. .. .. .. .. . ... . .. 5-166
DTC C0060 . .. .. .. .. .. .. . ... .. .. .. . .. .. .. .. .. .. ... . .. .. .. .. .. .. . 5-169
DTC C0065 ..................................................... 5-171
DTC C0070 .. .. .. .. .. .. . .. .. ... . ... . .. .. .. .. . .. ... .. .. .. .. .. . .. . 5-173
DTC C0075 ..................................................... 5-175
DTC C0080 .. .. .. .. .. . .. .. .. ... .. .. . .. .. .. .. .. ... .. . ... . .. .. .. . . 5- 177
DTC C0085 . . .. ... .. . .. .. .. . ... .. .. .. .. . .. .. .. ... .. .. .. .. . .. .. . . 5- 179
DTC C0090 ..................................................... 5-181
DTC C0095 . .. .. .. .. .. . .. .. .. ... .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. 5-183
DTC C0100 ..................................................... 5-185
DTC C0105 ..................................................... 5-187
DTC C0110 ..................................................... 5-189
DTC C0121 ..................................................... 5-192
DTC C0161 ..................................................... 5-195
DTC C0166 ..................................................... 5-198
DTC C0171 ..................................................... 5-200
DTC C0181 ..................................................... 5-202
DTC C0182 ..................................................... 5-205
DTC C0236 ..................................................... 5-207
DTC C0237 ..................................................... 5-210
DTC C0238 ..................................................... 5-212
DTC C0239 ..................................................... 5-214
DTC C0245 ..................................................... 5-216
DTC C0266 ..................................................... 5-219
DTC C0550 ..................................................... 5-222
DTC C0901 ..................................................... 5-225
DTC C0896 . .. .. .. .. .. .. . .. ... .. .. .. .. . ... .. . .. ... .. .. .. . .. .. .. 5-223
DTC P0101 ..................................................... 6-795
DTC P0101 ................................................... 6-1334
DTC P0102 ..................................................... 6-799
DTC P0102 ................................................... 6-1339
DTC P0103 ......................................... 6-802, 6-1344
DTC P0107 ......................................... 6-805, 6-1348
DTC P0108 ......................................... 6-808, 6-1352
DTC P0112 ...................................................... 6-811
DTC P0112 .................................................... 6-1356

DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
OTC
DTC
OTC
DTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
DTC
OTC
OTC
OTC
OTC
OTC
DTC
OTC
OTC
OTC
OTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
OTC
OTC
OTC
DTC

P0113
P0117
P0118
P0121
P0122
P0123
P0125
P0131
P0132
P0133
P0134
P0135
P0137
P0138
P0140
P0141
P0143
P0144
P0146
P0147
P0151
P0152
P0152
P0153
P0154
P0154
P0155
P0157
P0158
P0160
P0161
P0171
P0172
P0174
P0175
P0175
P0201
P0202
P0203
P0204
P0205
P0206
P0218
P0230
P0300
P0325
P0327
P0327
P0332
P0332
P0335
P0336
P0341
P0342
P0343
P0351
P0352
P0353
P0354
P0355
P0356
P0357
P0358
P0401

......................................... 6-813, 6-1359

......................................... 6-816, 6-1363
......................................... 6-818, 6-1366
......................................... 6-821, 6-1370
......................................... 6-824, 6-1374
......................................... 6-827, 6-1378
......................................... 6-830, 6-1382
......................................... 6-833, 6-1385
......................................... 6-836, 6-1389
......................................... 6-839, 6-1393
......................................... 6-842, 6-1397
......................................... 6-845, 6-1401
................................................... 6-1405
................................................... 6-1409
................................................... 6-1413
................................................... 6-1417
..................................................... 6-848
..................................................... 6-851
..................................................... 6-854
..................................................... 6-857
......................................... 6-860, 6-1421
..................................................... 6-863
................................................... 6-1425
......................................... 6-866, 6-1429
..................................................... 6-869
................................................. 6-1433
........................................ 6-872, 6-1437
.. .. ................................ 6-1440
.................................... 6-1444
.........
.. ................................ 6-1448
. . .................................. 6-1452
.
. ........................... 6-876, 6-1456
......................... 6-880, 6-1459
........................................ 6-884, 6-1462
..................................................... 6-887
................................................... 6-1465
..................................................... 6-890
..................................................... 6-893
..................................................... 6-896
..................................................... 6-899
. . ... .. .. .. .. .. .. . ... .. .. .. .. . ... .. .. .. .. . . .. .. .. . .. . 6-902
. .. ... .. . .. .. .. .. .. .. ... .. .. . .. .. .. .. . .. ... .. .. .. .. . . 6-905
.............................................. 7-87, 7-89
......................................... 6-908, 6-1468
......................................... 6-911, 6-1472
......................................... 6-916, 6-1478
..................................................... 6-918
................................................... 6-1479
..................................................... 6-921
. .. .. .. .. .. .. .. .. .. .. ... .. . .. .. . ... .. .. . ... .. .. .. .. 6-1483
. .. .. ... . ... . .. .. .. .. ... .. . .. .. .. .. .. .. ... . .. .. .. .. 6-1487
......................................... 6-924, 6-1491
.. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 6-927, 6-1494
................................................... 6-1497
................................................... 6-1503
................................................... 6-1509
................................................... 6-1513
................................................... 6-1517
................................................... 6-1521
... .. .. .. .. .. .. .. .. .. ... .. .. . .. .. .. .. .. . ... .. .. .. . . 6-1525
. .. ... . .. ... .. . .. .. .. ... .. .. . .. .. .. .. .. .. .. .. .. .. .. 6-1529
................................................... 6-1533
.. . ... .. .. .. .. .. .. . .. ... .. .. .. . .. .. .. .. ... . .. .. .. .. 6-1537
..................................................... 6-932

INDEX

8
OTC P0401
OTC P0403
OTC P0404
OTC P0404
OTC P0405
OTC P0410
OTC P0412
OTC P0418
OTC P0420
OTC P0430
OTC P0440
OTC P0442
OTC P0443
OTC P0446
OTC P0449
OTC P0452
OTC P0452
OTC P0453
OTC P0453
OTC P0461
OTC P0462
OTC P0463
OTC P0480
OTC P0481
OTC P0500
OTC P0502
OTC P0503
OTC P0506
OTC P0506
OTC P0507
OTC P0507
OTC P0530
OTC P0560
OTC P0562
OTC P0563
OTC P0601
OTC P0602
OTC P0604
OTC P0608
OTC P0650
OTC P0654
OTC P0656
OTC P0704
OTC P0705
OTC P0706
OTC P0711
OTC P0712
OTC P0713
OTC P0719
OTC P0724
OTC P0740
OTC P0742
OTC P0748
OTC P0751
OTC P0753
OTC P0756
OTC P0758
OTC P0785
OTC P0801
OTC P0803
OTC P0804
OTC P1106
OTC P1107
OTC P1111

................................................... 6-1541
. .. .. .. ... .. . .. .. .. .. .. .. .. .. .. .. .. .. .. . ... . ... .. . .. . 6-934
.. . .. .. ... .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. . .. ... .. .. 6-1543
. .. .. .. .. .. .. .. .. .. .. .. . .. ... .. .. .. . .. .. .. .. ... .. . .. . 6-938
......................................... 6-942, 6-1547
................................................... 6-1551
................................................... 6-1557
................................................... 6-1561
......................................... 6-946, 6-1565
. . .. .. .. ... .. . .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. ... .. . 6-1567
......................................... 6-949, 6-1569
.. .. .. .. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 6-954, 6-157 4
.. . .. .. ... .. .. .. .. . .. .. .. ... .. . .. .. .. .. .. . .. ... ... . 6-1579
......................................... 6-958, 6-1583
. .. .. .. .. ... .. . .. .. .. .. .. .. .. .. .. . ... .. . .. .. ... .. .. 6-1587
.. .. .. ... .. .. .. .. .. .. . .. .. ... .. .. . .. .. .. .. .. .. .. .. .. . 6-962
................................................... 6-1591
.. .. .. .. ... . .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. ... .. .. . .. 6-965
................................................... 6-1596
.. .. .. . .... . .. .. .. .. .. .. .. .. .. .. . ... .. . .. .. .. ... .. . 6-1600
.. . .. ... .. .. .. .. .. .. . ... . ... .. . ... .. .. . .. .. .. .. ... . 6-1603
. .. .. .. .. ... .. .. . .. .. .. .. ... . .. .. .. .. .. .. .. . ... .. .. 6-1606
................................................... 6-1610
................................................... 6-1613
......................................... 6-968, 6-1616
.............................................. 7-92, 7-95
............................................ 7-98, 7-101
. .. .. ... .. .. .. .. . ... . .. .. ... .. .. .. . .. .. .. .. .. ... . .. .. 6-970
................................................... 6-1619
. .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. .. . .. ... .. .. .. . . 6-973
. .. .. .. .. ... .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. 6-1622
......................................... 6-976, 6-1625
. . .. .. .. ... .. . .. .. .. .. .. .. .. ... . .. .. .. .. .. .. ... . .. .. . 6-979
.. .. .. ... .. . ... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 6-1628
................................................... 6-1631
......................................... 6-982, 6-1633
......................................... 6-983, 6-1634
. .. .. .. .. ... .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. . .... . .. 6-1635
. .. .. .. .. ... .. . .. .. .. .. .. .. .. .. .. . ... . ... . .. .... . .. 6-1636
. .. .. .. .. .. .. .. .. .. . ... . .. ... .. .. . .. .. .. .. .. ... .. .. 6-1639
. .. . .. ... .. .. .. .. . .. ... . .. .. .. .. .. .. .. .. .. .. .. ... .. 6-1642
.. .. .. .. ... .. . .. .. .. .. .. .. .. .. .. .. .. .. .. . .. ... ... . . 6-1645
.. .. . .... .. . .. .. .. .. .. .. . ... . ... .. . .. .. .. .. .. .. .. .. .. 6-984
..................................................... 6-987
..................................................... 6-991
........................................... 7-104, 7-108
........................................... 7-112, 7-116
........................................... 7-120, 7-124
........................................... 7-128, 7-131
........................................... 7-134, 7-136
........................................... 7-138, 7-141
........................................... 7-144, 7-147
........................................... 7-150, 7-154
........................................... 7-158, 7-161
........................................... 7-164, 7-168
........................................... 7-172, 7-175
........................................... 7-178, 7-182
........................................... 7-186, 7-190
................................................... 6-1649
.. .. .. .. ... .. . .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. ... .. . 6-1653
. ... . .. ... .. .. .. .. . .. .. ... .. .. .. .. .. . .. .. .. .. ... . .. 6-1656
...................................................... 6-994
...................................................... 6-996
...................................................... 6-998

OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC

P1111 .................................................... 6-1659

P1112 .................................................... 6-1662
P1112 .................................................... 6-1000
P1114 .................................................... 6-1665
P1114 .................................................... 6-1002
P1115 ....................................... 6-1004, 6-1668
P1121 .................................................... 6-1671
P1121 .................................................... 6-1006
P1122 ....................................... 6-1008, 6-1674
P1133 ....................................... 6-1010, 6-1677
P1134 ....................................... 6-1013, 6-1681
P1153 .................................................... 6-1685
P1153 .................................................... 6-1016
P1154 .................................................... 6-1689
P1154 .................................................... 6-1019
P1258 ................................................... 6-1693
P1336 ....................................... 6-1022, 6-1695
P1351 ................................................... 6-1024
P1352 ................................................... 6-1026
P1361 ................................................... 6-1028
P1362 ................................................... 6-1031
P1374 ................................................... 6-1034
P1380 ....................................... 6-1037, 6-1698
P1381 ................................................... 6-1038
P1404 ....................................... 6-1040, 6-1699
P1415 ................................................... 6-1703
P1416 ................................................... 6-1706
P1441 ....................................... 6-1043, 6-1709
P1539 ................................................... 6-1711
P1545 ................................................... 6-1714
P1546 ................................................... 6-1718
P1554 ................................................... 6-1047
P1626 ....................................... 6-1049, 6-1721
P1629 ................................................... 6-1052
P1635 ....................................... 6-1054, 6-1724
P1639 ................................................... 6-1727
P1639 ................................................... 6-1058
P1641 ................................................... 6-1060
P1651 ................................................... 6-1066
P1652 ................................................... 6-1070
P1653 ................................................... 6-1074
P1662 ................................................... 6-1077
P1663 ................................................... 6-1080
P1665 ................................................... 6-1083
P1671 ................................................... 6-1086
P1672 ................................................... 6-1089
P1676 ................................................... 6-1092
P1810 ........................................... 7-194, 7-198
P1860 ........................................... 7-202, 7-206
P1870 ........................................... 7-210, 7-215
U 1304 .. .. .. .. .. ... .. .. .. .. .. .. .. .. .. . .. .. .. . .. .. .. .. ... .. . 5-227

E
Emblem Replacement
Front Bumper Fascia ................................... 8-652
End gate Latch Replacement .. .. .. .. .. .. .. .. .. .. . .. . .. .. 8-979
Engine Compression Test ................................ 6-252
Engine Compression Test (3.8L) ........................ 6-20
Engine Controls - 3.8L
Component Views ........................................ 6-763
Components . .. .. .. ... .. .. .. .. .. .. .. .. ... .. . .. .. ... .. .. . .. . .. 6-758
Connector End Views ................................... 6-771

INDEX

Engine Controls - 3.8L (cont.)

Description
Air Intake System ................................... 6-1243
Crankcase Ventilation System (3.8L) ....... 6-1243
Electric Engine Cooling Fan .................... 6-1227
Electronic Ignition System .. .. .. .. .. .. .. .. .. .. .. . 6-1236
EVAP Control System (3.8L) ................... 6-1234
Exhaust Gas Recirculation
System (3.8L) ............................... 6-1242
Fuel Metering Modes of Operation .......... 6-1231
Fuel Metering System
Component (3.8L) ......................... 6-1232
Fuel Supply Component .......................... 6-1227
Information Sensors/Switches .................. 6-1221
Diagnosis
Alcohol/Contaminants-in-Fuel ................... 6-1148
Backfire .................................................. 6-1110
Cranks but Does Not Run ........................ 6-784
Cuts Out, Misses .................................... 6-1104
Data Link Connector ................................. 6-782
Detonation/Spark Knock .......................... 6-1101
Dieseling, Run-On ................................... 6-1110
Electric Cooling Fan ............................... 6-1124
Engine Oil Level Sensor/Switch .. .. .. .. .. .. .. 6-1133
EV AP Control System .. .. .. . .. .. .. .. .. .. .. ... .. .. . 6-1149
Fuel Injector Balance Test ...................... 6-1141
Fuel Injector Coil Test ............................ 6-1144
ECT Between 10-35 .. .. .. .. .. .. .. . .. .. .. . .. .. .. 6-1144
ECT Outside 10-35 ............................. 6-1146
Fuel Pump Relay Circuit ........................... 6-791
Fuel System ............................................. 6-794
Fuel System Pressure Test ..................... 6-1135
Fuel Tank Leak Check ............................ 6-1148
Fuel Tank Vent Valve ............................. 6-1148
Hard Start . .. .. .. .. .. ... .. .. . .. .. .. .. ... . .. . .. .. . .. .. .. .. 6-1095
Hesitation, Sag, Stumble ......................... 6-1102
Idle Air Control System ........................... 6-1152
Intermittent Condition .............................. 6-1095
Lack of Power, Sluggishness, or
Sponginess ................................... 6-1099
No Malfunction Indicator Lamp .................. 6-780
Poor Fuel Economy ................................ 6-1106
Powertrain Control Module ...................... 6-1113
Powertrain Control Module Controlled
Air Conditioning ............................ 6-1118
Powertrain Control Module Controlled
Warning Lamps ............................ 6-1114
Powertrain On Board Diagnosis
System Check .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. . 6-778
Restricted Exhaust System Check .. . .. ... .. 6-1112
Rough, Unstable, or Incorrect Idle,
Stalling ......................................... 6-1108
Surges/Chuggles ..................................... 6-1097
Powertrain Control Module Connector
End Views . ... .. .. .. .. .. . .. .. .. .. . .. .. . .. .. .. .. . 6-767
Schematic
Emission Hose Routing Diagram ............... 6-741
Icons ........................................................ 6-742
References . .. . .. .. ... .. .. .. .. .. .. .. .. .. . ... .. .. .. .. . .. .. . 6-742
Schematics .. .. .. . ... . .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. . 6-743
Special Tools .............................................. 6-1244
Specifications
DTC List . .. . .. . .. .. .. .. .. . . .. .. .. .. . . .. .. .. .. .. .. .. .. .. .. . . 6-736
Fastener Tightening .................................. 6-725

9
Engine Controls - 3.8L (cont.)
Specifications (cont.)
Fuel System ............................................. 6-739
GM SPO Group Numbers ......................... 6-740
Scan Tool Data Definitions ....................... 6-731
Scan Tool Data List .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 6-726
Temperature vs Resistance ...................... 6-725
Engine Controls - 5.7L
Component Views .. .. ... .. .. .. . .. ... . .. .. .. .. . .. .. .. . .. 6-1286
Components . .. .. .. .. ... . .. .. . .. .. .. . ... . .. .. .. ... .. . ... .. . 6-1281
Connector End Views ................................. 6-1304
Description .. .. .. . ... .. .. .. . ... .. .. .. .. .. . ... . .. ... .. .. .. .. . 6-1893
Air Intake System ................................... 6-1895
Electric Engine Cooling Fan .................... 6-1876
Electronic Ignition System ....................... 6-1886
EVAP Control System .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 6-1884
Exhaust Gas Recirculation System .......... 6-1892
Fuel Metering Modes of Operation .......... 6-1879
Fuel Metering System Component .......... 6-1880
Fuel Supply Component .......................... 6-1877
Information Sensors/Switches .. .. .. .. .. .. .. .. .. 6-1869
Knock Sensor System .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 6-1889
Long Term Fuel Trim .............................. 6-1883
Powertrain Control Module Controlled
Air Conditioning ............................ 6-1876
Secondary Air Injection System ............... 6-1890
Short Term Fuel Trim ............................. 6-1883
Speed Density System .. .. .. .. ... .. .. .. . ... .. . ... . 6-1883
Diagnosis
Air Conditioning ...................................... 6-1750
Request Circuit .................................... 6-1750
Air Conditioning Refrigerant Pressure
Sensor .......................................... 6-1753
Alcohol/Contaminants-in-Fuel ................... 61781
Backfire .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 6-17 46
Cuts Out, Misses .................................... 6-1740
Data Link Connector ............................... 6-1315
Detonation/Spark Knock . .. .. .. .. . .. .. .. . .. .. .. .. . 6-1738
Dieseling, Run-On ................................... 6-1746
Electric Cooling Fan ............................... 6-1756
Electronic Ignition System ....................... 6-1782
Engine Cranks but Does Not Run ........... 6-1318
Engine Oil Level Sensor/Switch .............. 6-1766
Fuel Injector Balance Test ...................... 6-1771
Fuel Injector Circuit ................................. 6-1778
Fuel Injector Coil Test ............................ 6-1774
ECT Between 10-35 ............................ 6-1774
ECT Outside 10-35 ............................. 6-1776
Fuel Pump Relay Circuit ......................... 6-1324
Fuel System ........................................... 6-1329
Fuel Tank Leak Check ............................ 6-1781
Fuel Tank Vent Valve ............................. 6-1781
Hard Start . .. .. .. .. .. .. .. .. ... .. . .. .. .. .. .. .. ... . .. ... .. . 6-1734
Hesitation, Sag, Stumble ......................... 6-1739
Ignition Relay .......................................... 6-1321
Inspection/Maintenance Status Reset
Procedure ..................................... 6-1785
Lack of Power, Sluggishness, or
Sponginess . ... .. .. .. .. ... .. . .. . .. .. .. . .. .. .. . 6-1737
Low Engine Oil Level Indicator ............... 6-1769
Park/Neutral Position Switch ................... 6-1763
Poor Fuel Economy ................................ 6-1742
Powertrain On Board Diagnostic
System Check .............................. 6-1312

10
Engine Controls - 5.7L (cont.)
Diagnosis (cont.)
Restricted Exhaust System Check .......... 6-1749
Rough, Unstable, or Incorrect Idle,
Stalling ......................................... 6-1744
Surges/Chuggles ..................................... 6-1735
Symptoms .............................................. 6-1733
Emission Hose Routing Diagram ................ 6-1261
Powertrain Control Module Connector
End Views .................................... 6-1300
Schematic
Icons ...................................................... 6-1262
References . ... .. .. .. .. ... . .. .. ... .. . ... .. .. .. .. . ... .. .. 6-1262
Schematics .. .. ... .. .. .. .. .. .. .. .. .. .. .. ... . ... . .. .. ... . . .. 6-1263
Special Tools .............................................. 6-1897
Specifications
OTC List ................................................. 6-1256
Fastener Tightening ................................ 6-1247
Fuel System ........................................... 6-1259
GM SPO Group Numbers ....................... 6-1260
Scan Tool Data Definitions ..................... 6-1251
Scan Tool Data List . ... .. .. . ... .. . ... .. ... .. . ... .. . 6-1248
Temperature vs Resistance ..................... 6-1247
Engine Coolant Temperature Sensor
Replacement (3.8L) ....................... 6-1158
Engine Coolant Temperature Sensor
Replacement (5.7L) ....................... 6-1790
Engine Coolant Temperature Sensor Replacement
(Engine Cooling) .................. 6-645, 6-646
Engine Cooling
Components .. .. ... . ... . ... .. . .. .. .. .... . .. .. .. . ... .. .. . . .. .. 6-584
Connector End Views ................................... 6-585
Description
Air Baffles and Seals ................................ 6-663
Coolant .. .. ... .. .. .. .. .. .. ... . .. ... . ... .. . .. .. .. .. ... .. .. ... 6-664
Coolant Heater . .. .. .. .. .. .. ... .. .. . .. .. .. .. .. .. ... .. .. . 6-660
Coolant Recovery System .. .. .. .. . .. .. .. .. ... .. .. . 6-660
Cooling Fan Relay .................................... 6-663
Cooling System ........................................ 6-660
Electric Engine Cooling Fan ...................... 6-663
Engine Coolant Temperature Sensor ........ 6-663
Low Coolant Sensor . ... . ... .. .. . ... . ... . ... . .. .... . . 6-664
Radiator Assembly .................................... 6-661
Radiator Filler/Pressure Cap Assembly ..... 6-662
Thermostat .. .. .. .. .. .. .. .. .. . .... . .. .. .. .. .. .. .. ... . .. ... 6-663
Throttle Body Coolant System .................. 6-660
Water Pump ............................................. 6-663
Diagnosis
Coolant Concentration Testing .. ... . ... .. .. .. .. . 6-589
Cooling System Leak Testing ................... 6-590
Engine Fails To Reach Normal
Operating Temperature ................... 6-588
Loss of Coolant .. .. .. .. .. .. ... .. . .. .. .. .. .. ... . .. . .. .. . 6-587
Overheating .............................................. 6-586
Pressure Cap Testing ............................... 6-591
Thermostat . ... .. .. .. .. .. .. .. . ... . . .. .. ... . .. .. .. .. ... .. .. 6-588
Schematic
Cooling Fan .............................................. 6-582
Cooling System Icons ............................... 6-581
Cooling System References ...................... 6-581
Special Tools ............................................... 6-664
Specifications
Fastener Tightening .................................. 6-580
GM SPO Group Numbers ......................... 6-580

INDEX
Engine Cooling (cont.)
Specifications Engine Cooling System .......... 6-580
Engine Diagnosis
Exhaust Leakage ....................................... 6-1901
Engine Electric
Specifications
Fastener Tightening .................................. 6-665
Engine Electrical
Component Locations . .. .. .. .. .. ... .. . ... . .. .. .. .. .. ... . 6-670
Description
Battery ...................................................... 6-720
Charging System ...................................... 6-721
Charging System Circuit ........................... 6-722
Charging System Operation Charging
System .. ... .. .. .. .. .. . ... ... . .. .. .. .. .. .. .. .. .. .. 6-722
Operation .............................................. 6-722
Ignition System .............................. 6-722, 6-723
Starting System Circuit ............................. 6-720
Diagnosis
Battery Hydrometer Displays Dark or
Yellow Dot . .. . .. .. ... . .. .. ... . .. .. .. .. .. .. .. ... . 6-676
Battery Is Undercharged or
Overcharged . . .. .. ... .. .. .. .. .. .. .. .. . ... .. .. .. 6-679
Charging System Check ........................... 6-672
Common Causes of Battery Failure .......... 6-675
Engine Cranks/Cranks Slowly, but
Does Not Start . ... . .. ... .. .. .. .. . .. .. .. .. ... . 6-674
Generator Assembly Check ...................... 6-681
Parasitic Load Test - Parasitic .. .. .. ... . .. . .... . 6-676
Spark Plug Visual ..................................... 6-682
Spark Plug Wire Harness ......................... 6-684
Starter No Load Test .............. ; ................. 6-675
Starter Solenoid Does Not Click .. . ... .. .. . ... . 6-672
Starting System Check ............................. 6-671
Generator Brace Replacement ..................... 6-706
Generator Bracket Replacement ................... 6-705
Generator Replacement . . ... .. .. .. .. .. .. .. .. 6-707, 6-709
Ignition Coil and Ignition Control Module
Replacement .................................. 6-718
Ignition Coil Replacement ............................. 6-716
Schematic
Starting and Charging ............................... 6-668
Starting and Charging Icons . .. . .. .. .. .. .. .. ... . . 6-667
Starting and Charging References ............ 6-667
Spark Plug Replacement .............................. 6-715
Spark Plug Wire Ha mess Replacement ....... 6-711,
6-714
Special Tools ............................................... 6-724
Specifications
Battery Temperature vs Voltage Drop ....... 6-666
Battery Usage Table ................................. 6-665
Generator Usage Table ............................ 6-666
GM SPO Group Numbers ......................... 6-666
Starter Motor Usage Table ....................... 6-666
Starting and Charging Connector
End Views ...................................... 6-671
Engine Exhaust
Catalytic Converter Replacement ................ 6-1902
Converter Hanger Assembly
Replacement ....... 6-1917, 6-1919, 6-1920
Converter Heat Shield Replacement ........... 6-1924
Description
Exhaust System .. .. . ... .. .. .. . .... .. . .. .. .. ... .. . ... . 6-1929

INDEX

Engine Exhaust (cont.)

Diagnosis
Exhaust Noise ........................................ 6-1901
Internal Muffler Rattles/Loss of Power ..... 6-1900
Exhaust Pipe and Muffler Heat Shields
Replacement . .. . .. .. .. ... . .. ... . ... . ... . .. .. . 6-1926
Heat Shield Replacement ........................... 6-1925
Muffler Hangers Replacement ........ 6-1921, 6-1923
Muffler Replacement .................................. 6-1913
Oxidation Catalytic Converter
Replacement .................... 6-1905, 6-1908
Specifications
Fastener Tightening ................................ 6-1900
GM SPO Group Numbers ....................... 6-1900
Engine Flywheel
Replacement (5.7L) ...................................... 6-374
Engine ID and Partial VIN Location ..................... 0-8
Engine Mechanical - 3.8L
Balance Shaft
Bearing and/or Bushing Installation ........... 6-198
Bearing and/or Bushing Removal .............. 6-197
Clean and Inspect .................................... 6-197
Installation (Off-Vehicle) ............................ 6-203
Balance Shaft Removal (Off-Vehicle) ............ 6-165
Camshaft
Bearing Installation (Off-Vehicle) ............... 6-185
Bearing Removal (Off-Vehicle) .................. 6-183
Camshaft and Bearings Clean and
Inspect (Off-Vehicle) ....................... 6-184
Installation (Off-Vehicle) ............................ 6-203
Removal (Off-Vehicle) ............................... 6-165
Replacement ... . .. .. .. . .. . .. .. .. .. .. .. .. ... .. . .. .. .. . ... 6-1 O1
Crankshaft
Balancer Clean and Inspect ...................... 6-176
Balancer Installation (Off-Vehicle) ... 6-210, 6-211
Balancer Removal (Off-Vehicle) ................ 6-161
Balancer Replacement ................................ 6-83
Cranksahft and Bearings Removal
(Off-Vehicle) ................................... 6-169
Crankshaft and Bearings Clean and
Inspect (Off-Vehicle) ....................... 6-173
Crankshaft and Bearings Installation
(Off-Vehicle) ................................... 6-199
Front Oil Seal Installation (Off-Vehicle) ..... 6-210
Front Oil Seal Removal (Off-Vehicle) ........ 6-162
Front Oil Seal Replacement ........................ 6-86
Rear Oil Seal and Housing Installation
(Off-Vehicle) ................................... 6-205
Rear Oil Seal and Housing Removal
(Off-Vehicle) ................................... 6-167
Rear Oil Seal and Housing
Replacement . .. ... .. . .. .. . ... ... . ... . ... . .. .. . 6-116
Rear Oil Seal Installation (Off-Vehicle) ...... 6-206
Rear Oil Seal Removal (Off-Vehicle) ......... 6-166
Rear Oil Seal Replacement ...................... 6-116
Cylinder Boring and Honing ......................... 6-172
Cylinder Head
Assemble .. .. .. .. . .. .. ... . .. .. .. .. .. .. .. .. .. ... .. . .. .. .. .. 6-192
Clean and Inspect .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . 6-187
Disassemble .. .. .. .. ... .. . .. .. .. .. .. .. .. .. ... . .. .. .. .. . .. 6-186
Installation (Off-Vehicle) ............................ 6-212
Removal (Off-Vehicle) ............................... 6-160
Replacement . .. .. .. . ... .. .. .. .. .. . ... .. . ... .. . 6-103, 6-105

11
Engine Mechanical - 3.8L (cont.)
Description
Cleanliness and Care ............................... 6-223
Components ............................................. 6-221
Installation Precautions ............................. 6-225
Lubrication ................................................ 6-222
Replacing Engine Gaskets ........................ 6-224
Separating Parts ....................................... 6-225
Thread Repair .......................................... 6-223
Tools and Equipment ................................ 6-225
Use of ATV and Anaerobic Sealer ............ 6-224
Diagnosis
Base Engine Misfire ................................... 6-18
Cylinder Leakage Test ................................ 6-28
Drive Belt ................................................... 6-28
Engine Compression Test ........................... 6-20
Engine Noise ..................................... 6-20, 6-23
Oil Consumption ......................................... 6-25
Oil Leak ..................................................... 6-26
Oil Pressure Diagnosis and Testing ............ 6-25
Disassembled Views .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . 6-29
Draining Fluids and Oil Filter Removal
(Off-Vehicle) .................................... 6-152
Drive Belt
Replacement - 3.8L .................................... 6-34
Tensioner Installation (Off-Vehicle) ............ 6-219
Tensioner Removal (Off-Vehicle) ............... 6-154
Tensioner Replacement .. .. .. .. .. ... . .... .. . .. .. .. . .. 6-35
Engine Block
Clean and Inspect (Off-Vehicle) ................ 6-170
Plug Installation (Off-Vehicle) .................... 6-199
Plug Removal (Off-Vehicle) ....................... 6-170
Engine Flywheel
Installation (Off-Vehicle) ............................ 6-220
Engine Front Cover Clean and Inspect ........ 6-197
Engine Front Cover Installation
(Off-Vehicle) .................................... 6-209
Engine Front Cover Removal (Off-Vehicle) ... 6-162
Engine Front Cover Replacement .................. 6-86
Engine Mount
Inspection ................................................... 6-36
Replacement .. .. .. .. .. . ... .. .. .. .. . .. .. .. ... .. .. .. .. . ... .. 6-37
Engine Oil and Oil Filter Replacement ......... 6-151
Engine Replacement .................................... 6-118
Exhaust Manifold
Clean and Inspect .................................... 6-196
Installation (Off-Vehicle) ................. 6-213, 6-215
Removal (Off-Vehicle) .................... 6-157, 6-158
Replacement .. .. .. .. .. . .. .. .. .. .. .. .. ... .. . .. .. .. 6-57, 6-64
Flywheel
Replacement ............................................ 6-114
Flywheel Clean and Inspect ......................... 6-177
Flywheel Removal (Off-Vehicle) .................... 6-153
Intake Manifold
Clean and Inspect .................................... 6-195
Installation (Off-Vehicle) ................. 6-216, 6-217
Removal (Off-Vehicle) .................... 6-155, 6-157
Replacement ..................................... 6-46, 6-56
Oil Filter
Adapter and Valve Assembly
Installation (Off-Vehicle) .................. 6-208

12
Engine Mechanical - 3.8L (cont.)
Oil Filter (cont.)
Adapter and Valve Assembly
Replacement . .. .. . .. ... .. .. .. . .. .. ... .. .. .. .. .. . 6-96
Oil Filter Adapter and Valve Assembly
Removal (Off-Vehicle) ..................... 6-163
Oil Level Indicator and Tube Installation
(Off-Vehicle) .................................... 6-219
Oil Level Indicator and Tube Removal
(Off-Vehicle) .................................... 6-154
Oil Level Indicator and Tube Replacement ..... 6-45
Oil Pan
Clean and Inspect .................................... 6-195
Installation (Off-Vehicle) ............................ 6-202
Oil Pan Removal (Off-Vehicle) ...................... 6-167
Oil Pan Replacement .. .. . ... .. ... . .. .. .. .. .. .. . .... . .. . 6-107
Oil Pump
Clean and Inspect .................................... 6-193
Cover and Gear Set Installation
(Off-Vehicle) ................................... 6-208
Cover and Gear Set Replacement . . .. .... . .. ... 6-96
Pipe and Screen Assembly Installation ..... 6-202
Pipe and Screen Assembly Removal
(Off-Vehicle) ................................... 6-168
Pipe and Screen Assembly
Replacement . .. .. .. ... .. . .. .. .. .. .. .. .. ... . .. . 6-113
Oil Pump Cover and Gear Set Removal
(Off-Vehicle) .................................... 6-163
Piston and Connecting Rod Assemble .......... 6-182
Piston and Connecting Rod Disassemble ..... 6-177
Piston, Connecting Rod, and Bearing
Installation ...................................... 6-201
Piston, Connecting Rod, and Bearing
Removal (Off-Vehicle) ..................... 6-168
Piston, Connecting Rod and Bearings
Clean/Inspect .................................. 6-178
Piston Selection .. .. .. .. .. .. .. . .... . .. .. .. .. .. .. .. . ... .. .. . 6-180
Rear Oil Seal Replacement .. . .. .. .. .. .. . .. ... .. ... . . 6-116
Service Prior to Assembly ............................ 6-198
Special Tools ............................................... 6-226
Specifications
GM SPO Group Numbers ........................... 6-17
Specifications . ... .. .. .. . .. .. .. .. .. ... . .. .. .. .. .. .. .. ... .. .. .. . 6-14
Fastener Tightening .................................... 6-13
Sealers, Adhesives, and Lubricants ............ 6-18
Timing Chain
Timing Chain and Sprockets Clean and
Inspect .. .. .. .. .. .. .. . ... .. .. ... .. .. . .. .. . . .. ... .. 6-185
Timing Chain and Sprockets Installation
(Off-Vehicle) ................................... 6-207
Timing Chain and Sprockets Removal
(Off-Vehicle) ................................... 6-164
Timing Chain and Sprockets
Replacement .................................. 6-100
Valve
Rocker Arm and Push Rod Removal
(Off-Vehicle) ................................... 6-160
Valve Guide ReamingNalve and Seat
Grinding ......................................... 6-189
Valve Lifter Installation (Off-Vehicle) ............. 6-211
Valve Lifter Removal (Off-Vehicle) ................ 6-161
Valve Lifter Replacement .. .. ... ... .. .. .. ... . ... .. .. .. .. 6-82
Valve Lifters and Guides Clean and
Inspect .. .. .. .. .. .. . .. ... .. .. .. . .. ... .. . .. ... .. .. . 6-186

INDEX
Engine Mechanical - 3.8L (cont.)
Valve Rocker Arm and Push Rod
Installation (Off-Vehicle) .................. 6-212
Valve Rocker Arm and Push Rod
Replacement .. .. . ... .. . .... . .. .. .. . ... .. .. . ... .. 6-77
Valve Rocker Arm and Push Rods Clean
and Inspect .................................... 6-186
Valve Rocker Arm Cover Clean and
Inspect . ... .... . . .. .. .. . .. .. ... . ... . .. ... . .. .. .. .. 6-194
Valve Rocker Arm Cover Installation
(Off-Vehicle) .................................... 6-213
Valve Rocker Arm Cover Removal
(Off-Vehicle) ......................... 6-159, 6-160
Valve Rocker Arm Cover Replacement .... 6-70, 6-74
Valve Stem Oil Seal and Valve Spring
Replacement .................................... 6-79
Water Outlet
Installation (Off-Vehicle) ............................ 6-219
Water Outlet Removal (Off-Vehicle) .............. 6-154
Water Pump
Clean and Inspect .................................... 6-196
Installation (Off-Vehicle) ............................ 6-218
Removal (Off-Vehicle) ....... , ....................... 6-155
Engine Mechanical - 5. 7L
Balancer, Crankshaft, Replacement . .. .. .. .. .. .. . 6-339
Camshaft
Bearing Installation ................................... 6-481
Bearing Removal ........................... 6-474, 6-476
Camshaft and Bearings Clean and
Inspect ........................................... 6-478
Installation (Off-Vehicle) ............................ 6-523
Removal (Off-Vehicle) ............................... 6-434
Replacement ............................................ 6-371
Crankshaft
Balancer Clean and Inspect ...................... 6-462
Balancer Installation (Off-Vehicle) .............. 6-557
Balancer Removal (Off-Vehicle) ................ 6-411
Balancer Replacement .. .. .. .. ... .. .. .. .. . ... . .. .. .. 6-339
Crankshaft and Bearings Clean
and Inspect ............... 6-446, 6-456, 6-460
Crankshaft and Bearings Installation
(Off-Vehicle) ................................... 6-518
Crankshaft and Bearings Removal
(Off-Vehicle) ................................... 6-437
Front Oil Seal Installation (Off-Vehicle) ..... 6-533
Front Oil Seal Replacement ...................... 6-346
Rear Oil Seal Installation (Off-Vehicle) ...... 6-530
Rear Oil Seal Replacement ... . ... .. .. . . .. .. .. .. . 6-357
Cylinder Boring and Honing (Off-Vehicle) ..... 6-444
Cylinder Head
Assemble .. . .. .. . .. . .. .. .. .. . .. .. .. .. .. .. ... .. .. . . .. .. .. .. 6-493
Clean and Inspect .. . .. .. .. . ... .. . .. ... .. . .. .. . .. ... .. 6-487
Disassemble . . .. . .. .. . . .. .. .. . ... .. .. .. .. .. . ... .. . .. ... .. 6-485
Installation (Off-Vehicle) ................. 6-538, 6-539
Removal (Off-Vehicle) .................... 6-425, 6-426
Replacement .................................. 6-328, 6-331
Description
Cleanliness and Care ............................... 6-572
Engine Components . .. .. .. .. .. .. .. .. .. .. .. .. . .. .... . 6-560
Identification ............................................. 6-562
Lubrication ................................................ 6-563
New Product Information .......................... 6-561

13

INDEX
Engine Mechanical - 5.7L (cont.)
Description (cont.)
Replacing Engine Gaskets ........................
Separating Parts .......................................
Thread Repair ..........................................
Tools and Equipment ................................
Use of RTV and Anaerobic Sealer ............
Diagnosis
Base Engine Misfire ..................................
Drive Belt .................................................
Engine Compression Test .........................
Engine Noise ............................................
Oil Consumption .......................................
Oil Leak ...................................................
Oil Pressure Diagnosis and Testing ..........
Valve Train ...............................................
Disassembled Views .. .. .. .. .. .. . ... .. ... . .. .. ... . .. .. . .
Draining Fluids and Oil Filter Removal
(Off-Vehicle) ....................................
Drive Belt
Idler Pulley Replacement ............... 6-270,
Replacement .................................. 6-267,
Tensioner Replacement ................. 6-272,
Engine Block
Clean and Inspect (Off-Vehicle) ................
Engine Block Plug Installation ......................
Engine Block Plug Removal (Off-Vehicle) .....
Engine Mount
Replacement .................................. 6-274,
Engine Set-Up and Testing ..........................
Exhaust Manifold
Clean and Inspect ....................................
Installation (Off-Vehicle) ................. 6-553,
Removal (Off-Vehicle) .................... 6-413,
Replacement .................................. 6-315,
Flywheel
Clean and Inspect ....................................
Installation (Off-Vehicle) ............................
Removal (Off-Vehicle) ...............................
Front Cover
Clean and Inspect ....................................
Installation (Off-Vehicle) ............................
Replacement ............................................
Front Cover Removal (Off-Vehicle) ...............
Fuel Rail and Injectors Installation
(Off-Vehicle) ....................................
Fuel Rail and Injectors Removal
(Off-Vehicle) ....................................
Intake Manifold
Clean and Inspect ....................................
Installation (Off-Vehicle) ............................
Removal (Off-Vehicle) ...............................
Replacement ............................................
Oil and Oil Filter Change .............................
Oil Filter
Oil Filter, Adapter, Pan Cover
Installation (Off-Vehicle) ..................
Oil Filter, Adapter and Pan Cover
Removal (Off-Vehicle) .....................
Oil Level Indicator and Tube
Installation (Off-Vehicle) ............................
Removal (Off-Vehicle) ...............................
Replacement . . .. ... . ... .. . ... .. .. .. ... ... .. .. . ... .. . ... .

6-573
6-57 4
6-564
6-574
6-573
6-250
6-258
6-252
6-252
6-255
6-256
6-256
6-254
6-259
6-409
6-271
6-269
6-273
6-443
6-515
6-440
6-277
6-559
6-512
6-554
6-414
6-321
6-462
6-556
6-412
6-502
6-530
6-348
6-431
6-551
6-417
6-509
6-547
6-418
6-281
6-408
6-536
6-428
6-556
6-413
6-311

Engine Mechanical - 5.7L (cont.)

Oil Pan
Clean and Inspect ....................................
Installation (Off-Vehicle) ............................
Removal (Off-Vehicle) ...............................
Replacement ... . .. .. .. .. ... . .. .. .. .. .. .. .. ... .. . .. .. .. ..
Oil Pump
Assemble .................................................
Clean and Inspect ....................................
Disassemble . .. .. .. ... . .. .. .. .. ... .. . .. .. .. .. . .. .. . .. .. ..
Oil Pump, Pump Screen and Deflector
Installation (Off-Vehicle) ..................
Oil Pump, Pump Screen and Deflector
Removal (Off-Vehicle) .....................
Oil Pump, Pump Screen and Deflector
Replacement . .. .. ... .. .. . .. .. .. .. . . ... . .. .. . . .
Piston and Connecting Rod Assemble ..........
Piston and Connecting Rod Disassemble .. .. .
Piston, Connecting Rod, and Bearing
Installation (Off-Vehicle) ..................
Piston, Connecting Rod, and Bearing
Removal (Off-Vehicle) .....................
Piston, Connecting Rod and Bearings
Clean/Inspect ............ 6-465, 6-467,
Piston Selection ...........................................
Rear Cover
Clean and Inspect .. .. .. .. .. . .. .. . .. ... .. .. .. .. .. . .. ..
Installation (Off-Vehicle) ............................
Removal (Off-Vehicle) ...............................
Replacement . .. .. ... . .. .. .. .. ... .. . .. .. .. .. .. ... . .. .. .. .
Replacement .. .. .. .. . .. ... . ... .. .. .. .. .. .. . .. .. ... .. .. .. . .. .
Service Prior to Assembly ............................
Special Tools ...............................................
Specifications
Engine Mechanical ...................................
Fastener Tightening ..................................
GM SPO Group Numbers .........................
Sealers, Adhesives, and Lubricants ..........
Thread Repair ..........................................
Throttle Body Installation (Off-Vehicle) ..........
Throttle Body Removal (Off-Vehicle) .............
Timing Chain
Timing Chain and Sprockets Clean
and Inspect ....................................
Timing Chain and Sprockets Installation
(Off-Vehicle) ...................................
Timing Chain and Sprockets Removal
(Off-Vehicle) ...................................
Timing Chain and Sprockets
Replacement .. .. .. .. .. .. .. .. ... . .. .. .. .. .. .. ..
Valley Cover
Clean and Inspect ....................................
Installation (Off-Vehicle) ............................
Valley Cover Removal (Off-Vehicle) ..............
Valley Cover Replacement .. .. .. .. .. .. . ... .. . ... .. .. .
Valve Guide Reaming/Valve and Seat
Grinding .........................................
Valve Lifter
Installation (Off-Vehicle) ............................
Removal (Off-Vehicle) ...............................
Replacement .. .. .. .. .. .. ... . .. ... .. . .. .. .. ... . .. .. .. .. ..

6-506
6-533
6-429
6-360
6-500
6-498
6-496
6-526
6-432
6-369
6-471
6-463
6-521
6-435
6-470
6-470
6-503
6-527
6-431
6-358
6-376
6-515
6-575
6-231
6-229
6-234
6-236
6-237
6-551
6-416

6-482
6-524
6-433
6-370
6-503
6-545
6-421
6-297
6-488
6-537
6-427
6-339

14
Engine Mechanical - 5.7L (cont.)
Valve Lifters and Guides Clean
and Inspect .................................... 6-484
Valve Rocker Arm and Push Rod
Installation (Off-Vehicle) .. .. .. .. .. .. .. .. .. .. ... .. .. . 6-541
Removal ................................................... 6-424
Replacement . .. .. .. .. .. .. .. . ... .. .. .. .. .. .. .. .. .. .. .. .. . 6-307
Engine Mechanical - 57L
Valve Rocker Arm and Push Rods
Clean and Inspect .. .. .. .. .. .. .. .. .. .. .. .. .. . .. . .. .. .. 6-483
Engine Mechanical - 5. 7L
Valve Rocker Arm Cover
Clean and Inspect .................................... 6-504
Installation (Off-Vehicle) ................. 6-543, 6-544
Removal (Off-Vehicle) .................... 6-422, 6-423
Replacement .................................. 6-299, 6-302
Valve Stem Oil Seal and Valve Spring
Replacement . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 6-308
Vapor Vent Pipe
Installation (Off-Vehicle) ............................ 6-546
Vapor Vent Pipe Clean and Inspect ............. 6-514
Vapor Vent Pipe Removal (Off-Vehicle) ........ 6-421
Vapor Vent Pipe Replacement ...................... 6-296
Water Pump
Clean and Inspect .. .. .. .. ... .. .. .. .. .. . .. .. .. .. .. .. .. 6-514
Installation (Off-Vehicle) .. .. .. .. .. .. .. .. .. .. .. . .. .. . 6-552
Removal (Off-Vehicle) ............................... 6-416
Engine Mount
Replacement (3.8L) ........................................ 6-37
Replacement (5.7L) ........................... 6-27 4, 6-277
Engine Oil and Oil Filter Change (5.7L) ........... 6-408
Engine Oil and Oil Filter
Replacement (3.8L) ........................ 6-151
Engine Oil Life Monitor Reset
Procedure (5.7L) ........................... 6-1861
Engine Oil Pressure Sensor/Switch
Replacement (3.8L) ....................... 6-1209
Engine Replacement (3.8L) ............................. 6-118
Engine Replacement (5.7L) ............................. 6-376
English/Metric Conversion Table .......................... 0-3
Entertainment
Amplifier Replacement ....................... 8-244. 8-245
Antenna Mast Cleaning ................................ 8-256
Antenna Mast Replacement
Fixed ........................................................ 8-253
Power ....................................................... 8-254
Antenna Module Replacement
Fixed ........................................................ 8-254
Antenna Motor Replacement ........................ 8-255
Cassette Player
Cleaning Tape Head and Capstan ............ 8-246
CD Changer Replacement
Remote .......................................... 8-247, 8-249
Compact Disc Care and Cleaning ................ 8-251
Component Locations . .. .. .. ... .. .. . .. ... . .. .. .. .. ... .. . 8-206
Component Views .. .. .. .. .. .. ... .. . .. .. .. .. .. .. .. .. .. .. .. 8-209
Connector End Views ................................... 8-214
Description
Compact Disc Player Operation ................ 8-277
Power Antenna System ............................ 8-281
Power Antenna System Circuit .................. 8-281
Radio Controls Operation ... 8-267, 8-268, 8-271,
8-274, 8-276
Radio/Audio System ....................... 8-265, 8-266

INDEX
Entertainment (cont.)
Description (cont.)
Radio/Audio System Circuit ....................... 8-280
Steering Wheel Controls System Circuit .... 8-281
Steering Wheel Controls System
Operation ....................................... 8-280
Theftlock Operation ................................... 8-279
Diagnosis
Antenna Inoperative .................................. 8-227
Antenna Poor Reception ........................... 8-223
Compact Disc Inoperative ......................... 8-221
General Radio Noise . .. .. .. .. .. .. .. . .. .. .. .. . .. .. . .. 8-222
Power Antenna System Check .................. 8-218
Radio Display Inoperative, No Sound
from Speakers .. .. .. ... .. .. .. .. . .. ... . .. .. .. .. 8-219
Radio Display Inoperative, Speakers
Operative ........................................ 8-218
Radio Illuminate Inoperative with Park
Lamps On ...................................... 8-219
Radio Memory Inoperative ........................ 8-218
Radio/Audio System Check ....................... 8-217
Speaker General ...................................... 8-228
Speakers Inoperative ................................ 8-229
One or More ........ 8-229, 8-230, 8-231, 8-232,
8-233, 8-234, 8-235,
8-236, 8-237, 8-238
Subwoofer ............................................. 8-239
Steering Wheel Control System Check ..... 8-218
Steering Wheel Controls Illumination
Inoperative ...................................... 8-226
Steering Wheel Controls Inoperative ......... 8-225
Tape Player Inoperative ............................ 8-220
Radio Replacement ........................... 8-240, 8-242
Schematic
Icons ........................................................ 8-195
Power Antenna ......................................... 8-205
Radio/Audio System ................................. 8-196
References ............................................... 8-195
Steering Wheel Controls ........................... 8-204
Speaker Grille Replacement
Rear .............................................. 8-263, 8-264
Speaker Replacement ....................... 8-257, 8-258
Rear ......................................................... 8-259
Special Tools ............................................... 8-281
Specifications
Fastener Tightening .................................. 8-195
Steering Wheel Control Switches
Replacement .................................. 8-251
EVAP
Canister Purge Solenoid Valve
Replacement (3.8L) ....................... 6-1209
Canister Purge Solenoid Valve
Replacement (5.7L) ....................... 6-1842
Canister Replacement (3.8L) ...................... 6-1211
Canister Replacement (5.7L) ...................... 6-1844
System Cleaning (5.7L) .............................. 6-1845
Vent Valve Replacement (3.8L) .................. 6-1210
Vent Valve Replacement (5. 7L) .................. 6-1843
Evaporator Core Replacement
(A/C - Manual) .. .. .. .. .. . .. .. . .. .. .. . . .. ... . .. . 1-93
Evaporator Tube Replacement
(A/C - Manual) ................................. 1-81
Exhaust Gas Recirculation
Pipe Replacement (5. 7L) ............................ 6-1857

INDEX

15

Exhaust Gas Recirculation (cont.)

System Cleaning (5. 7L) .............................. 6-1858
Valve Replacement (3.8L) .......................... 6-1217
Valve Replacement (5.7L) ................ ,......... 6-1856
Exhaust Manifold
Replacement (3.8L) ............................... 6-57, 6-64
Exhaust Manifold Replacement (5. 7L) ... 6-315, 6-321
Exterior Lamps
Diagnosis ................................................... 8-80
Lamps Inoperative .......................... 8-80, 8-81
Exterior Trim
Description
Adhesive Retained Molding and
Emblem .......................................... 8-657
Molding/Nameplates Replacement .... 8-647, 8-648,
8-649, 8-650, 8-651
Washing and Waxing ................................... 8-656
Weld Stud Replacement .. . .. .. .. .. ... .. .. .. .. . .. .. .. . . 8-656

F
Fan
Cooling Fan Relay Description ..................... 6-663
Cooling Fan Relay Replacement
(Engine Cooling) ............................. 6-622
Electric Cooling Fan Motor Replacement
(Engine Cooling) ............................. 6-621
Electric Cooling Fan Replacement
(Engine Cooling) ............................. 6-616
Electric Engine Cooling Fan Description ....... 6-663
Shroud Replacement (Engine Cooling) ......... 6-647
Fasteners .......................................................... 0-14
Filter Replacement
In-Line Fuel (3.8L) ..................................... 6-1181
In-Line Fuel (5.7L) ..................................... 6-1813
Finish Panel Replacement
Upper Rear Trim .......................................... 8-949
Floor Panel Reinforcement Replacement ....... 8-1067
Fluid Capacities, Approximate ............................ 0-33
Fluids and Lubricants, Recommended ............... 0-33
Flushing (Engine Cooling) ............................... 6-598
Flywheel Replacement (3.8L) .......................... 6-114
Fog Lamp
Aiming Procedure ........................................ 8-124
Replacement
Front ................................... 8-118, 8-120, 8-121
Rear .............................................. 8-122. 8-123
Switch Replacement .......................... 8-133. 8-134
Fog Lamp Bulb Replacement .......................... 8-124
Folding Top
Arm Replacement ........................................ 8-87 4
Bow Link Replacement ................................ 8-844
Front Side Rail Link Replacement ................ 8-865
Pivot Bracket Replacement .......................... 8-861
Side Front Weatherstrip Replacement .......... 8-888
Side Rail Assembly Replacement ................. 8-873
Side Rail Link Replacement ......................... 8-853
Side Rail Replacement ................................. 8-846
Stowage Compartment Lid Latch Replace .... 8-883
Weatherstrip Retainer Replacement .............. 8-887
Folding Top Adjustment ................................... 8-864
Folding Top Bow Replacement ........................ 8-837
Folding Top Hose Replacement
Power . .. ... .. .. .. .. .. .. .. . .. ... .. .. .. .. . ... .. .. .. .. .. .. .. . .. .. . 8-836

Folding Top Pump with Motor Replacement ..... 8-835

Frame
Floor Panel Reinforcement Replacement .... 8-1067
Frame and Underbody
Description
Centerline ............................................... 8-1078
Datum .................................................... 8-1078
General .................................................. 8-1079
Diagnosis
Alignment Checking ................................ 8-1041
Checking Frame to Body Alignment ........ 8-1041
Special Tools .. .. .. .. .. .. .. .. ... .. . .. .. .. ... . .. ... . .. ... .. . 8-1079
Specifications
Asymmetrical Reference Points ............... 8-1040
Body Dimensions .................................... 8-1023
Fastener Tightening ................................ 8-1022
Symmetrical Reference Points ................ 8-1040
Frame Dimensions ........................................ 8-1032
Front .................................................... 8-133, 8-134
Front Bumper Fascia Emblem Replacement .... 8-652
Front Fender
Rear Side Molding Replacement .................. 8-653
Front Oil Seal Replacement (5.7L) .................. 6-346
Front Suspension
Component Locations .................................... 3-13
Description
General ...................................................... 3-39
Diagnosis
Ball Stud Check .. .. .. . ... .. . .. .. .. .. .. .. ... .. . .. .. . .. . .. 3-14
Special Tools ................................................. 3-40
Specifications
Fastener Tightening .................................... 3-12
Front Weatherstrip Replacement ...................... 8-890
Fuel Filler Door Replacement .......................... 8-970
Fuel Filler Pocket Replacement ....................... 8-970
Fuel Filter Replacement, In-Line (3.8L) .......... 6-1181
Fuel Filter Replacement, In-Line (5.7L) .......... 6-1813
Fuel Hose/Pipe
Replacement
Filter to Tank (3.8L) ................................ 6-1200
Fuel Hose/Pipes
Assembly Replacement (5.7L) .................... 6-1833
Replacement
Engine Compartment (3.8L) .................... 6-1201
Filter to Engine (3.8L) ............................. 6-1194
Fuel Hose/Pipes Replacement
Chassis (5.7L) ............................................ 6-1826
Engine Compartment (5. 7L) ........................ 6-1832
Fuel Injector Replacement (3.8L) ................... 6-1207
Fuel Injector Replacement (5.7L) ................... 6-1839
Fuel Level Sensor Replacement (3.8L) .......... 6-1193
Fuel Pressure Connection Valve
Replacement (5.7L) ....................... 6-1836
Fuel Pressure Regulator Replacement (3.8L) ... 6-1206
Fuel Pressure Relief Procedure (3.8L) ........... 6-1175
Fuel Pressure Relief Procedure (5. 7L) ........... 6-1807
Fuel Pulse Dampener Replacement (5.7L) ..... 6-1826
Fuel Pump Relay Replacement (3.8L) ........... 6-1208
Fuel Pump Relay Replacement (5. 7L) ........... 6-1841
Fuel Pump Strainer Replacement (3.8L) ........ 6-1192
Fuel Rail Assembly Replacement (3.8L) ......... 6-1204
Fuel Rail Assembly Replacement (5. 7L) ......... 6-1836
Fuel Sender Assembly
Replacement (5.7L) ............................... .... 6 1823

16

INDEX

Fuel Sender Assembly (cont.)

Service (5.7L) ............................................
Fuel Sender Assembly Replacement (3.8L) ....
Fuel Sender Assembly Service (3.8L) ............
Fuel System Cleaning (3.8L) .........................
Fuel System Cleaning (5.7L) .........................
Fuel Tank
Draining Procedure (3.8L) ..........................
Draining Procedure (5.7L) ..........................
Pressure Sensor Replacement (3.8L) .........
Pressure Sensor Replacement (5.7L) .........
Replacement (3.8L) ....................................
Replacement (5.7L) ....................................
Vent Valve Replacement (3.8L) ..................
Vent Valve Replacement (5.7L) ..................

6-1824
6-1190
6-1191
6-1203
6-1835
6-1182
6-1814
6-1189
6-1822
6-1183
6-1815
6-1188
6-1821

G
Garnish Molding Replacement
Liftgate . .. .. .. .. .. ... .. .. .. .. .. .. .. .. .. ... .. . .. .. .. ... . ... .. .. . 8-984
Upper Pillar .................................................. 8-948
Windshield Pillar .......................................... 8-947
General Description
Suspension Diagnosis ...................................... 3-6
Generator
Assembly Check .......................................... 6-681
Brace Replacement .. .. .. .. .. . . ... .. . .. ... . .. .. ... .. .. .. . 6-706
Bracket Replacement . .. .. .. .. ... . .. .. .. .. .. .. .. .. . .. .. . 6-705
Replacement ..................................... 6-707, 6-709
Generator Usage .. .. .. .. .. .. .. .. .. .. . .. .. . .. .. ... . .. ... .. . ... 6-666
Glass Surface Cleaning ................................... 8-954
GM SPO Group Numbers
Anti lock Brake System ................................. 5-108

H
Hard Top Headliner Replacement .................... 8-833
Hazard Lamp
Flasher Replacement ................................... 8-139
Headlamp
Aiming .............................................. 8-114, 8-118
Bezel Replacement ...................................... 8-112
Bracket Replacement ........................ 8-759, 8-760
Bulb Replacement . .. . .. .. ... . ... .. .. . ... .. .. . .. .. ... .. ... 8-109
Door Module Replacement ........................... 8-113
Housing Panel Replacement ........................ 8-757
Opening Door Adjustment ............................ 8-111
Opening Door Replacement ......................... 8-109
Replacement ..................................... 8-104, 8-106
Switch Replacement ..................................... 8-131
Headlight
Leveling Schematic ........................................ 8-29
Headlights
Door Schematics .. .. .. . .. .. . .. .. .. .. .. ... . .. .. .. . .. .. .. .. . . 8-28
Schematics ........................................... 8-18, 8-19
Headlights - DRL Schematics ................... 8-20, 8-24
Headliner Cleaning .......................................... 8-954
Headliner Replacement
Hard Top ..................................................... 8-833
Headrest Replacement
Front Seat ................................................... 8-930
Heat Excessive (A/C - Manual) .. .. .. .. . .. .. . .. .. .. .. .. . 1-33
Heat Shield Replacement
Converter ................................................... 6-1924

Heat Shield Replacement (cont.)

Exhaust Pipe and Muffler ........................... 6-1926
Heater
Pipes Replacement (A/C - Manual) .. .. .. . 1-97, 1-99
Heater Core Replacement .. .. .. .. .. .. .. .. . .. .. .. ... . .. .. .. 1-96
Heater Replacement-Engine (Block)
Coolant .. .. .. .. .. . .. .. . .. .. .. .. .. ... . .. 6-654, 6-655
Heater/Bi-Level Vacuum Actuator
Replacement (A/C - Manual) .......... 1-108
Heating Insufficient (A/C - Manual) .. .. .. .. . .. .. .. .. .. . 1-30
High Mounted Stop Lamp
Replacement ........................ 8-143, 8-145
Hinge Cover Replacement
Hood ........................................................... 8-739
Hinge Pillar Trim Replacement ........................ 8-939
Hinge Replacement
Hood ........................................................... 8-743
Rear Compartment Lid .. .. . .. .. .. .. .. .. .. .. . 8-977, 8-978
Rear Lift Window .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. . 8-976
Hood
Adjustment ................................................... 8-735
Air Extractor Replacement ................. 8-740, 8-742
Assist Rod Ball Stud Replacement .. .. .. .. . .. .. .. 8-756
Assist Rod Replacement .............................. 8-755
Bumper Replacement .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. 8-736
Close Out Filler Replacement .. .. .. . .. .. .. .. .. .. .. .. 8-739
Hinge Cover Replacement ........................... 8-739
Hinge Replacement ...................................... 8-743
Insulator Replacement .................................. 8-754
Latch Release Cable Replacement ............... 8-751
Latch Replacement
Primary ..................................................... 8-746
Secondary .. . .. .. ... .. ... . .. .. .. .. ... .. .. .. .. . ... .. .. . ... . 8-750
Replacement . .. .. .. ... .. .. .. .. . .. ... .. .. .. .. .. .. .. .. .. .. .. .. 8-736
Hood Rear Seal Replacement .. . .. .. .. .. .. .. .. .. .. .. .. 8-763
Hook Replacement, Tow ................... 8-1074, 8-1076
Horn Replacement ........................................... 8-566
Horns
Component Locations .. .. ... .. . .. .. ... . .. .. .. .. ... .. .. .. 8-562
Connector End Views .. .. .. .. .. . .. .. ... ... . .. .. .. .. .. .. . 8-563
Description
Circuit ....................................................... 8-568
Operation ................................................. 8-568
Diagnosis
Homs Always on .. .. ... .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. 8-565
Homs Inoperative ..................................... 8-563
System Check .. . ... .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . . 8-563
Relay Replacement .. . .. ... .. . .. .. .. . ... .. . ... . .. ... .. . .. 8-567
Schematic
Icons ........................................................ 8-560
References .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . 8-560
Schematics . .. .. .. ... .. . ... .. .. . ... . ... ... . ... . .. .. .. . ... .. .. 8-561
Specifications
Fastener Tightening .. . .. .. .. .. . .. .. . .. . .. .. .. .. . .. .. . 8-560
Hose Routing Diagram
Emission (5.7L) .......................................... 6-1261
Hose Routing Diagram, Emission (3.8L) .......... 6-741
Hose-Inlet, Replacement, Radiator ........ 6-603, 6-606
Hose-Outlet, Replacement, Radiator ..... 6-609, 6-612
How to Obtain Replacement Labels .................. 0-14
How to Use Diagnostic Tables .. .. .. .. .. .. . .. .. . .. .. . .. 8-289
Hub Cap
Aluminum Wheel Hub Cap Replacement ........ 3-60
Hub/Wheel Bearing Replacement, Front ............ 3-21

INDEX

HVAC - Manual
Description .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... .. . .. . .. .. .. . .. 1-119
Handling of Refrigerant Lines and
Fittings . .. .. .. . . .. .. .. .. .. .. . .. ... ... . .. .. .. .. .. .. 1-119
Accumulator Replacement .............................. 1-90
Air Distributor Duct Replacement .................. 1-109
Air Inlet Actuator Replacement ..................... 1-106
Air Outlet Replacement - Floor .. .. .. .. . ... .. . ... . .. 1-110
Air Outlet Replacement - Right Defogger ..... 1-11 O
Air Outlet Replacement - Side Window .. .. .. .. 1-111
Blower Control Schematic .. .. ... .. .. .. .. .. . .. .. .. .. . ... . 1-5
Blower Motor and Fan Assembly
Replacement .. .. . ... . .. .. .. ... .. .. . ... .. . .. .. .. . 1-92
Blower Motor Relay Replacement .................. 1-91
Blower Motor Resistor Replacement ............... 1-92
Component Locations .. .. .. . .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. . 1-8
Component Views . .. .. .. .. .. .. .. . .. ... .. . . .. .. .. .. .. .. . .. .. 1-10
Compressor Control Module Replacement ...... 1-83
Compressor Control Schematic .. .. .. ... .. .. .. . .. .. .. .. 1-6
Compressor Hose Assembly
Replacement ........................... 1-77, 1-79
Compressor Mounting Bracket
Replacement .. .. .. .. .. .. .. .. .. .. . .. .. .. 1-73, 1-76
Compressor Replacement .. .. .. .. .. .. .. .. .. .. . 1-40, 1-43
Condenser Replacement . . .. .. .. .. .. .. . . ... . ... . .. .. .. .. 1-85
Connector End Views .................................... 1-14
Control Assembly Replacement .. .. .. .. .. .. .. .. .. .. 1-101
Defroster Actuator Replacement ................... 1-107
Description
A/C System .. .. .. . ... ... . .. .. .. .. .. .. .. .. . . .. . . .. .. .. .. .. 1-115
Accumulator . . .. .. .. .. ... . .. .. .. .. .. .. .. ... . .. . .. . .. .. .. .. 1-120
Air Distribution System ............................. 1-116
Blower Controls Circuit ............................. 1-127
Blower Motor . ... . .. ... .. .. . .. .. ... . .. .. .. ... .. .. . .. .. .. . 1-125
Compressor . .. .. .. .. ... . ... . .. ... . .. .. .. ... .. .. .. .. .. . .. . 1-122
Condenser . . ... . .. .. .. ... . ... . .. .. .. .. .. . ... .. . . .. .. . .. . . . 1-120
Control Assembly . .. .. .. .. .. . ... . .. ... .. .. .. .. .. .. .. .. . 1-123
Evaporator .. .. . .. .. ... . ... .. . .. ... . .. .. .. .. ... . .. .. .. . . . .. 1-120
Expansion (Orifice) Tube .......................... 1-120
Handling A/C Compressor ........................ 1-119
Handling Compressor Oil .. .. .. .. .. .. .. .. ... .. .. .. . 1-118
Handling R-134a ....................................... 1-118
Heater Core ............................................. 1-121
High Pressure Relief Valve ....................... 1-123
Maintaining Chemical Stability .. .... .. .. ... .. .. .. 1-119
0-Ring ...................................................... 1-127
Refrigerant Oil Distribution ........................ 1-125
Refrigerant Pressure Sensor ..................... 1-127
Refrigerant R-134a . ... .. . ... .. . .. . .. ... .. .. . .. .. .. . . . 1-118
Refrigeration System .. ... . .. .. .. .. .. ... .. .. . .. .. .. .. . 1-117
Relays and Switches .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 1-127
Vacuum Hose Harness ............................. 1-126
Diagnosis
Air Delivery Improper .................................. 1-34
Blower Control System Check .................... 1-16
Cooling Insufficient - A/C Inoperative .......... 1-33
Functional Check .. .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. . .. . 1-14
Heat Excessive . . .. .. .. ... .. .. . .. .. .. .. ... .. .. .. ... .. . .. .. 1-33
Heating Insufficient . .. .. .. .. . ... .. .. .. .. .. .. .. .. .. . . .. . . 1-30
Leak Testing .............................................. 1-23
Noise ......................................................... 1-36
Odor ........................................................... 1-38
Refrigerant System Checks .. .. .. .. .. .. .. .. .. .. .. .. 1-23
System Performance Test .......................... 1-21

17
HVAC - Manual (cont.)
Diagnosis (cont.)
Temperature Control Inoperative ................. 1-37
VDOT A/C System .. .. .. .. .. .. . .. . .. . .. .. .. .. . .. .. .. .. . 1-25
Evaporator Core Replacement .. .. . .. .. .. .. .. .. .. . .. . 1-93
Evaporator Tube Replacement ....................... 1-81
Expansion (Orifice) Tube ................................ 1-83
Heater Core Replacement .. .. .. .. . .. . .. .. .. .. .. .. .. .. .. 1-96
Heater Pipes Replacement .................... 1-97, 1-99
Heater/Bi-Level Vacuum Actuator
Replacement . .. . . ... .. . .. .. .. .. .. . . .. .. .. .. .. . 1-108
IP Air Outlet Ducts Replacement .................. 1-108
Odor Correction . .. .. .. . .. .. . .. .. .. . ... .. .. .. .. .. . ... .. .. .. . . 1-38
0-Ring Replacement ...................................... 1-72
Refrigerant Pressure Sensor Replacement ..... 1-84
Refrigerant Recovery ..................................... 1-39
Schematic Icons .............................................. 1-4
Service Ports Replacement .. .. .. .. .. .. .. .. .. .. .. . .. .. . 1-82
Special Tools ............................................... 1-128
Specifications
Fastener Tightening .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. ... .. .. . 1-3
Refrigerant Oil Distribution ............................ 1-4
System Capacities . .. .. .. .. .. .. .. .. .. . .. ... . .. . .. .. .. .. .. . 1-3
Temperature Control Cable .. .. .. .. .. .. .. .. .. .. .. .. .. 1-104
Temperature Control Cable Replacement ..... 1-103
Vacuum Hose Harness Replacement
(A/C - Manual) ..................... 1-113, 1-114
Vacuum Tank Replacement
(A/C - Manual) ............................... 1-112
Vent Actuator Replacement . .. .. .. .. .. . .. . .. . .. .. . .. . 1-106
HVAC Control Lamp Replacement .. .. . .. .. .. .. .. .. .. 8-141
Hydraulic Brake System
Component . .. .. .. .. .. .. . .. .. ... .. .. . .. ... . .. .. ... .. .. .. . ... . ... . 5-8
Schematic
References ................................................... 5-6
Hydraulic Brakes
Description
Brake Fluid and Brake Fluid Handling .. .. .. . . 5-65
Brake Warning System ............................... 5-66
Brake Warning System Circuit .................... 5-67
Master Cylinder .......................................... 5-64
Vacuum Brake Booster ............................... 5-65
Diagnosis
Brake Fluid Leaks .. . .. .. . .. .. .. .. .. . .. .... . .. .. .. .. .. .. 5-25
Brake Pedal Travel ..................................... 5-25
Brake System .. .. .. . .. .. .. ... .. .. .. . .. . .. .. .. .. .. ... .. .. .. 5-15
Brake System Testing ................................ 5-15
Brake Warning Indicator Always On ........... 5-12
Brake Warning Indicator Inoperative .... 5-13, 5-14
Brake Warning System Check .................... 5-12
Master Cylinder Diagnosis .......................... 5-26
Front Brake Hose Replacement ..................... 5-39
ISO Flares Replacement ................................ 5-38
Pipe Replacement . .. .. .. .. . .. .. .. . .. .. .. .. .. .. .. .. .. .. .. ... 5-38
Rear Brake Hose Replacement .... 5-41, 5-42, 5-44
Special Tools .. . .. . .. ... . .. .. .. .. . .. . .. .. .. .. .. .. ... . .. .. .. .. . 5-67
Specifications
Brake System ............................................... 5-5
Fastener Tightening ...................................... 5-5
System Bleeding ................................... 5-46, 5-49
System Flushing ................................... 5-53, 5-55
Vacuum Brake Booster Check Valve
Replacement .. .. . . .. .. .. .. .. .. . .. ... .. .. .. .. .. .. 5-60

INDEX

18
Hydraulic Brakes (cont.)
Vacuum Brake Booster Hose
Replacement .. .. . .. .. ... .. .. .. .. . ... .. .. .. .. .. . . 5-59
Vacuum Brake Booster Replacement ............. 5-57
Hydraulic Brakes System
Schematic
Icons ............................................................ 5-6
Hydraulic Brake System
Component Views ............................................ 5-9

I
Identification, Vehicle ........................................... 0-5
Idle Air Control Valve Replacement (3.8L) ...... 6-1166
Idle Air Control Valve Replacement (5.7L) ...... 6-1801
Idle Learn Procedure (5. 7L} ........................... 6-1789
Ignition Coil
Replacement ................................................ 6-716
Ignition Coil and Ignition Control Module
Replacement .................................. 6-718
Ignition Coil(s) Replacement (3.8L} ................ 6-1212
Ignition Control Module Replacement (3.8L) ..... 6-1212
Ignition System
Description ........................................ 6-722, 6-723
Important, Caution and Notice, Definition of ........... 3
Instrument Cluster
Description
Circuit ....................................................... 8-540
Gauge Operation ...................................... 8-537
General .................................................... 8-536
Indicator Operation ................................... 8-538
Instrument Panel
Carrier ......................................................... 8-527
Cigarette Lighter Replacement ..................... 8-511
Cluster Replacement .................................... 8-504
Compartment Lamp Replacement ................ 8-141
Compartment Latch Replacement ................. 8-514
Compartment Lock Cylinder Replacement .... 8-516
Description
Odometer Repair Label ............................. 8-536
Insulator Replacement .................................. 8-534
Storage Compartment Door Replacement ..... 8-513
Upper Trim Pad Replacement ...................... 8-500
Instrument Panel Compartment Lamp
Inoperative ..................................................... 8-97
Instrument Panel, Gauges and Console
Audible Warnings Component Locations ....... 8-495
Audible Warnings Connector End Views ....... 8-496
Description
Audible Warnings ...................................... 8-542
Audible Warnings Circuit ........................... 8-542
Console ... . .. ... . .. ... .. .. .. . .. ... . .. ... .. .. . .. .. ... . . .. . .. 8-543
Diagnosis
CHECK GAGES Indicator Always On ....... 8-485
CHECK GAGES Indicator Inoperative ....... 8-485
Engine Coolant Temperature Gauge
Always Cold .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. 8-482
Engine Coolant Temperature Gauge
Always Hot ..................................... 8-482
Engine Coolant Temperature Gauge
Inaccurate or Inoperative ................ 8-483
Engine Oil Pressure Gauge
Always High ................................... 8-483

Instrument Panel, Gauges and Console (cont.)

Diagnosis (cont.)
Engine Oil Pressure Gauge

G~~g~.. j~~~~~~~t~

8 484
Engin/~ti~e~~:r~ ..
....... or Inoperative ................................. 8-484
Fasten Safety Belt Indicator Always On .... 8-486
Fasten Safety Belt Indicator Inoperative .... 8-486
Fuel Gauge Inaccurate or Inoperative ., ..... 8-484
Instrument Cluster .................................... 8-480
System Check . .. .. . .. ... . .. .. ... .. . ... .. .. .. .. . .. ... 8-480
Low Engine Coolant Indicator
Always On . .. .. . .. .. ... . .. ... .. .. .. .. .. . .. .. .. . . 8-487
Low Engine Coolant Indicator
Inoperative ...................................... 8-488
Low Engine Oil Level Indicator
Always On .. . .. .. . ... .. .. . ... .. .. .. .. . .. .. .. .. . . 8-488
Low Engine Oil Level Indicator
Inoperative ...................................... 8-489
Speedometer and/or Odometer
Inoperative ...................................... 8-490
Speedometer Inaccurate (J 38522
Available) ....................................... 8-489
Tachometer Inaccurate or Inoperative ....... 8-491
Instrument Cluster Component Locations ..... 8-473
Instrument Cluster Component Views ........... 8-475
Instrument Cluster Connector End Views ..... 8-479
Schematic
Audible Warnings Schematic Icons ........... 8-492
Audible Warnings Schematic
References ..................................... 8-492
Instrument Cluster Schematic Icons .......... 8-468
Instrument Cluster Schematic
References .. .. .. .. .. ... .. .. .. .. .. .. .. ... .. .. .. . 8-468
Schematics
Audible Warnings ...................................... 8-493
Instrument Cluster .................................... 8-469
Analog .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. .. .. . .. . .. .. . ... .. 8-469
Special Tools ............................................... 8-544
Specifications
Fastener Tightening .................................. 8-467
Instrument Panel Service Precautions .............. 8-500
Intake Air Temperature Sensor
Replacement (3.8L) ....................... 6-1165
Intake Air Temperature Sensor
Replacement (5.7L} ....................... 6-1800
Interior Trim
Specifications
Fastener Tightening .................................. 8-939

J
Jacking and Lifting ............................................ 0-28

K
Key Coding and Lock Cylinders ........................ 0-25
Keyless Entry
Component Location .................................... 8-549
Description
Remote Keyless Entry General . . .. .. ... . .. .. .. . 8-559
Remote Key less Entry System Circuit ....... 8-557
Remote Keyless Entry System
Operation .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. ... .. 8-556

19

INDEX
Keyless Entry (cont.)
Diagnosis
Courtesy Lamps Inoperative With
Transmitter ..................................... 8-554
Door Lock/Unlock Inoperative ................... 8-554
Right Front ............................................ 8-554
Door Unlock Inoperative with
Transmitter ..................................... 8-553
All ......................................................... 8-553
Doors Lock Inoperative with Transmitter ... 8-553
All ......................................................... 8-553
Doors Lock/Unlock Inoperative .................. 8-554
Left Front .............................................. 8-554
Rear Release Inoperative with
Transmitter ..................................... 8-553
Remote Keyless Entry System Does Not
Change Customization Modes ......... 8-552
Remote Keyless Entry System
Inoperative ...................................... 8-551
System Check .......................................... 8-551
Transmitter Test ....................................... 8-552
Schematic
Icons ........................................................ 8-545
References ............................................... 8-545
Schematics . ... . .. .. .. .. ... . .. .. .. .. .. .. . .. ... .. .. .. .. .. .. . .. 8-546
Knee Bolster
Bracket Replacement ................................... 8-532
Knee Bolster Replacement .............................. 8-509
Knock Sensor Replacement (3.8L) ................. 6-1215
Knock Sensor Replacement (5.7L) ................. 6-1849
Knock Sensor System Description (3.8L) ....... 6-1240

L
Label
Anti-Theft Labeling ......................................... 0-11
Service Parts ID ............................................ 0-12
Label, Vehicle Certification .................................. 0-6
Labels
Replacement, How to Obtain ......................... 0-14
Latch Replacement
Endgate ....................................................... 8-979
Hood Primary ............................................... 8-746
Hood Secondary .......................................... 8-750
License Lamp Replacement ............................. 8-14 7
Lift Off Panel
Adjustment ................................................... 8-886
Weatherstrip Replacement ............................ 8-893
Weatherstrip Retainer Replacement .............. 8-894
Lift Off Panel Replacement .............................. 8-881
Lift Window Panel Adjustment
Rear ............................................................ 8-971
Lift Window Panel Hinge Replacement
Rear ............................................................ 8-976
Lift Window Panel Opening Weatherstrip
Replacement
Rear ............................................................ 8-985
Lift Window Panel Replacement
Rear ............................................................ 8-972
Liftgate Garnish Molding Replacement ............. 8-984

Lift gate Lock Actuator Replacement .. ... .. .. .. .. . .. . 8-980

Liftgate Lock Cylinder Replacement ................. 8-978
Liftgate Trim Panel Replacement ..................... 8-965
Lifting and Jacking ............................................ 0-28
Lift-Out Panel
Mounting Hardware Replacement ................. 8-882
Replacement .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. ... .. .. .. .. .. .. 8-882
Lighting Systems
Component Locations . ... .. . .. .. . ... .. . .. ... .. .. .. .. .. . .. 8-49
Component Views .......................................... 8-57
Connector End Views .................................... 8-63
Description ................................................... 8-154
Backup Lights Circuit ................................ 8-159
Daytime Running Lamps Circuit ................ 8-157
Exterior Lights Circuit ............................... 8-158
Fog Lights Circuit .......................... 8-157, 8-158
Headlight Doors Circuit ............................. 8-158
Headlight Leveling Circuit ......................... 8-158
Headlights Circuit ...................................... 8-156
Interior Lights Circuit ................................. 8-159
Interior Lights Dimming Circuit .................. 8-160
Diagnosis
Backup Lamp Inoperative - One ................. 8-73
Backup Lamps Always On .......................... 8-73
Backup Lamps Inoperative .......................... 8-71
Backup Lights System Check ..................... 8-69
Courtesy Lamps Always On ....................... 8-74
Courtesy Lamps Inoperative ....................... 8-75
Courtesy Lamps Inoperative IP
Dimmer Switch ................................. 8-75
Courtesy Lamps Inoperative with
Doors Ajar ............................... 8-76, 8-77
Courtesy Lamps Inoperative with
Rear Compartment Lid Open ............ 8-78
Courtesy/Reading Lamps Always On .......... 8-79
Courtesy/Reading Lamps Inoperative .......... 8-79
Courtesy/Reading Lamps Inoperative
with Lamp Switch ............................. 8-75
Daytime Running Lamps Inoperative,
Headlamp Switch Operates
Normally ........................................... 8-79
Daytime Running Lamps On With Park
Brake Applied ................................... 8-92
Daytime Running Lamps System Check ..... 8-67
Daytime Running Lamps Turn Off. with
Ignition On (Park Brake Applied) ...... 8-92
Exterior Lights System Check ..................... 8-68
Fog Lamp Indicator Inoperative ......... 8-85, 8-86
Fog Lamps Always On ...................... 8-81, 8-82
Fog Lamps Inoperative - All .............. 8-82, 8-83
Fog Lamps Inoperative - One ..................... 8-85
Fog Lights System Check ........................... 8-68
Hazard Lamps Inoperative .......................... 8-86
Headlamps Do Not Switch Intensity ............ 8-91
Headlamps Inoperative ............................... 8-88
High Beams ............................................ 8-88
Low Beams .................................... 8-87, 8-88
One Lamp ............................................... 8-89
Headlamps Inoperative In Low Light
Conditions ........................................ 8-90
Headlamps On in Day Light Conditions ...... 8-90

20
Lighting Systems (cont.)
Diagnosis (cont.)
Headlight Do Not Close .............................. 8-93
Headlight Doors Inoperative - One Door ..... 8-93
Headlight Doors System Check .................. 8-68
Headlight Leveling Inoperative .................... 8-95
Headlight Leveling Inoperative Actuator Switch Illumination .............. 8-96
Headlight Leveling Inoperative One Actuator .................................... 8-94
Headlight Leveling System Check ............... 8-68
Headlight System Check ............................. 8-67
High Beam Indicator Inoperative ................. 8-96
Instrument Panel Compartment Lamp
Inoperative ....................................... 8-97
Instrument Panel Lamps Do Not Dim ......... 8-97
Instrument Panel Lamps Inoperative ........... 8-98
Instrument Panel Lamps
Inoperative - One ............................. 8-98
Interior Lights Dimming System Check ....... 8-71
Interior Lights System Check ...................... 8-69
Stop Lamps Always On .. ... .. .. . .. . .. .. .. .. . .. .. . ... 8-99
Stop Lamps Inoperative .............................. 8-99
All ........................................................... 8-99
Center High Mounted ............................ 8-100
CHMSL Operative ................................. 8-100
Turn Signal and Hazard Lamps
Inoperative ...................................... 8-101
Turn Signal Indicators Inoperative ............. 8-102
Left ....................................................... 8-103
Turn Signal Lamp Always On ................... 8-102
One Side . .. .. .. ... . .. .. . .. ... . . .. .. .. .. .. .. .. .. .. .. .. . 8-102
Turn Signal Lamps Inoperative ................. 8-101
Schematic
Backup Lights ............................................. 8-41
Exterior Lights .......................... 8-30, 8-35, 8-38
Fog Lights .. .. .. ... . .. .. ... . .. ... .. . .. .. .. .. .. .. .. .. .. ... . .. 8-25
Headlight Doors .......................................... 8-28
Headlight Leveling ...................................... 8-29
Headlights ......................................... 8-18, 8-19
Headlights - Daytime Running
Lamps ..................................... 8-20, 8-24
Icons .......................................................... 8-17
Interior Lights .................................... 8-42, 8-44
Interior Lights Dimming ............................... 8-46
References . .. ... . .. .. .. .. .. .. ... . .. .. .. .. .. .. .. .. .. .. .. .. .. 8-17
Special Tools ............................................... 8-160
Specifications
Bulb Usage ................................................ 8-16
Fastener Tightening .................................... 8-15
Lock Actuator Replacement
Liftgate . .. .. .. .. .. . .. .. .. . .. ... . ... . ... . ... . ... . ... .. .. ... .. ... 8-980
Lock Cylinder Replacement
Liftgate . . .. .. .. .. ... .. .. .. . ... . .. .. ... .. .. . ... . .. ... .. . .... .. .. 8-978
Lock Cylinders and Key Coding ........................ 0-25
Lock Striker Replacement
Rear Compartment Lid ................................. 8-982
Long Trip/Highway Maintenance Schedule ......... 0-37
Lubricants and Fluids Recommended ................ 0-33
Luggage Screen Support Replacement ............ 8-947
Lumbar Bladder Replacement .......................... 8-924
Lumbar Motor Replacement ............................. 8-922

INDEX

M
Maintenance Schedule Long Trip/Highway ......... 0-37
Maintenance and Lubrication
Inspections and Other Services ...................... 0-41
Maintenance Items ......................................... 0-34
Maintenance Schedule ................................... 0-34
Periodic Maintenance Inspections .......... 0-43, 0-44
Maintenance Items ... .. .. .. . .. ... . ... . ... .. .. .. .. . .. ... . ... .. . 0-34
Maintenance Lubrication
Explanation of Scheduled Services .. .. .. .. .. ... . .. 0-39
Maintenance Schedule, Short Trip/City .............. 0-35
Manifold Absolute Pressure Sensor
Replacement (3.8L) ....................... 6-1160
Manifold Absolute Pressure Sensor
Replacement (5.7L) ....................... 6-1792
Maintenance Schedule .. .. .. .. .. .. . .. .. . .. .. .. . .. ... . ... . .. . 0-34
Manual Transmission - MM6
Control Lever Handle Assembly ..................... 7-39
Manual Transmission - M49
Backup Lamp Switch .......................................7-15
Control Assembly ... .. . .. ... . .. .. .. .. .. ... .. . .. .. .. .. .. .. . . . 7-11
Control Lever Boot Assembly ... . .. .. .. .. .. .. .. .. .. .. . 7-12
Diagnosis
Gear Clash When Shifting Gears ................. 7-6
Transmission Does Not Shift into
One Gear ........................................... 7-7
Transmission Jumps Out Of Gear ................ 7-6
Transmission Locked in One Gear ............... 7-7
Transmission Noisy ...................................... 7-6
Transmission Shifts Hard .............................. 7-5
Fluid Level Check ............................................ 7-8
Mains haft Rear Oil Seal .. . ... .. .. .. .. .. .. . ... .. . .. ... .. . 7-14
Oil Drain and Fill ........................................... 7-18
Replacement . .. . .. . .. .. .. .. .. .. . . .. .. .. .. .. .. .. . . .. .. 7-19, 7-22
Shift Control Closeout Boot Replacement ....... 7-13
Shift Control Knob Replacement .. . ... .. .. . .. ... .. .. 7-14
Special Tools
Special Tools ............................................. 7-27
Specifications
Fastener Tightening ...................................... 7-5
Lubrication . .. .. ... .. . .. .. .. .. .. .. ... .. .. . .. .. .. .. .. .. .. .. .. .. 7-5
Support and Mount Assembly . .. .. .. .. .. .. . .. .. ... .. .. . 7-9
Vehicle Speed Sensor ... .. . .. .. .. ... .. .. . ... . .. .. .. ... . .. 7-17
Manual Transmission - MM6
Backup Lamp Switch Replacement .. . .. .. .. ... .. .. 7-41
Control Assembly .. .. .. .. .. .. .. . ... .. .. .. .. .. . .. .. ... . ... .. . 7-36
Control Lever Boot Assembly .. .. .. .. .. .. .. . .. .. .. ... . 7-37
Diagnosis
Clunk on Acceleration or Deceleration ........ 7-31
Gear Clash When Shifting Gears ................ 7-29
Oil Leak . .. .. .. .. .. ... .. . .. .. .. ... . ... .. .. . .. . . .. .. .. .. ... .. . 7-32
Transmission Does Not Shift into
One Gear . .. . .. ... .. .. .. . ... .. .. .. .. . .. ... . ... .. .. 7-30
Transmission Jumps Out of Gear ............... 7-30
Transmission Locked in One Gear .............. 7-31
Transmission Noisy .................................... 7-30
Transmission Shifts Hard ............................ 7-28
Transmission Shifts Hard into Reverse ....... 7-29
1
7 33
~
Replacement .. .. .. .. .. .. ... .. . .. .. .. .. .. ... . ... . 7-45
Mainshaft Rear Oil Seal . .. .. . .. .. .. . .. .. .. .. .. .. ... .. .. . 7-41
Oil Drain and Fill ........................................... 7-46

~! ~~~=~v~~~iks"i~itts~i~~~id

INDEX

21

Manual Transmission - MM6 (cont.)

Replacement ......................................... 7-47, 7-51
Reverse Lockout Solenoid
Replacement (MM6) ......................... 7-44
Shift Control Closeout Boot Replacement . .. . .. . 7-38
Shift Control Knob Replacement .. ... . .. .. .. .. .. .. .. 7-40
Special Tools
Special Tools ............................................. 7-55
Specifications
Fastener Tightening Specifications .............. 7-28
Lubrication .................................................. 7-28
Vehicle Speed Sensor Replacement ............... 7-43
Vent Tube Replacement ................................. 7-47
Manual Transmission (M49)
Description .. .. .. .. . ... .. .. .. .. .. .. .. .. .. .. . ... .. .. .. . .. .. .. .. .. 7-26
Manual Transmission (MM6)
Description ............. ,. .. .. .. .. .. .. .. . .. .... . .. .. . .. .. .. .. .. . 7-54
Marker Lamp
Bulb Replacement
Side ......................................................... 8-126
Replacement
Side ......................................................... 8-125
Mass Air Flow Sensor Replacement (3.8L) .... 6-1159
Mass Air Flow Sensor Replacement (5.7L) .... 6-1791
Master Cylinder
Bench Bleeding ............................................. 5-29
Replacement . .. .. .. .. .. .. .. .. .. .. .. .. .. . .. ... .. .. .. .. . ... . .. .. 5-28
Reservoir Filling ............................................. 5-26
Reservoir Replacement .................................. 5-27
Meanings of Abbreviations ................................. 0-20
Mirror Face Replacement ..................... 8-822, 8-823
Mirror Replacement
Door ............................................................ 8-821
Mirrors
Diagnosis
Power Mirrors Inoperative ......................... 8-791
One ............................................ 8-792, 8-793
Power Mirrors Inoperative in Left
and Right Direction ......................... 8-796
One ............................................ 8-796, 8-797
Power Mirror Switch Replacement ................ 8-801
Molding Replacement
Belt Reveal ....................................... 8-950, 8-951
Body Side Door .. . ... .. .. .. .. .. .. . .. .. .. .. ... .. .. . .. .. .. .. 8-653
Liftgate Garnish .. .. .. .. ... . ... . .. .. .. .. .. . ... .. .. .. .. .. .. . 8-984
Rear Quarter ................................................ 8-654
Rocker Panel .. . .. .. .. .. ... .. . .. .. .. .. .. .. .. .. .. .. .. .. ... ... 8-655
Upper Pillar Garnish .................................... 8-948
Windshield Pillar Garnish ............................. 8-947
Mount, Engine, Replacement (5.7L) ...... 6-274, 6-277

N
Noise Diagnosis
Instrument Panel .................... 8-668,
Noise Diagnosis
Door .................................................
Front of Vehicle .................................
Rear of Vehicle ........... 8-677, 8-678,
Roof ....................................... 8-674,
Seat ..................................................
Under Vehicle ...................................
Notice, Caution and Important, Definition

8-669, 8-670
8-673, 8-674
8-667, 8-668
8-679, 8-680
8-675, 8-676
8-671, 8-672
8-680, 8-681
of ........... 3

0
Oil Consumption Diagnosis (3.8L) ..................... 6-25
Ordering Information, Special Tools ..................... 0-5
Oxygen Sensor Replacement,
Heated Bank .. .. .. .. .. .. .. .. . .. . 6-1794, 6-1797
Oxygen Sensor Replacement,
Heated (3.8L) ............................... 6-1161

p
Paint Coatings
Environmental Fallout
Acid Rain ................................................ 8-1020
Paint Gauges ................................................ 8-1021
Paint/Coatings
Anti-Corrosion Treatment and Repair .......... 8-1016
Basecoat/Clearcoat Paint Systems ............. 8-1016
Clearcoat Repair without Repainting ........... 8-1019
Paint Identification ...................................... 8-1019
Specifications
Clearcoat Repair - 3M Products .............. 8-1014
Clearcoat Repair - Meguiar Products ...... 8-1015
Painting
Clearcoat Thickness ................................... 8-1021
Rail Dust Damage Repair .......................... 8-1021
Panel Information and Repair
Specifications
Repair Materials ....................................... 8-987
Flexible Plastic Part ............................... 8-987
Rigid Plastic Part .................................. 8-987
Panel Repair
Backing Patch Fabrication ............................ 8-998
Gouge or Puncture ...................................... 8-989
Partial . .. .. .. .. ... .. . .. .. .. .. .. ... .. .. .. . .. .. ... . .. .. .. ... . .. .. . 8-993
Plastic Structure ......................................... 8-1004
Panel Replacement
Air Inlet Grille .............................................. 8-762
Complete .. ... .. .. .. .. . .. .. .. ... .. .. .. .. ... . .. . .. ... .. . .. .. .. . 8-997
Front Side ......................................... 8-764, 8-767
Quarter .. .. .. .. .. .. .. ... . .. . .. . ... ... .. .. . .. ... .. 8-1105, 8-1108
Rear End . ... ... . .. .. .. .. .. .. ... .. .. .. .. . .. .. . .. . .. 8-983, 8-984
Rocker . . .. .. .... .. . .. ... . .. .. . .... ... . .. . .. . .. ... .. . .. . . .. .. . 8-1094
Upper Rear Trim Finish ................................ 8-949
Wheelhouse . .. .. . .. .. .. ... .. .... .. . ... . .. . .. .. .. ... . .. .. .. . . 8-769
Panels, Plastic ................................................ 8-988
Park Brake
Actuator Replacement . . ... .. .. .. . .. .. ... .. .. . .. .. .. .. . . 5-105
Backing Plate Replacement . .. .. .. ... . .. .. . ... .. .. . .. 5-104
Brake Drum Inspection ................................. 5-104
Cable Replacement ............................. 5-97, 5-100
Description
System .. .. .. .. ... . .. . ... .. .. .. .. . ... .. . ... . .. ... .. .. . . ... . . 5-106
Disabling the Park Brake Automatic
Adjuster .......................................... 5-103
Enabling the Park Brake Automatic
Adjuster .. ... .. .. . ... . ... .. ... ... . . .... .. .. . . .. ... 5-104
Lever Replacement ........................................ 5-94
Shoe Adjustment .. . .. .. .. .. ... . ... .. . .. .. .. . .. ... .. .. .. .. . .. 5-93
Shoe Replacement .. . .. .. .. .. . .. . .. ... . ... . .. .. .. .. .. .. .. . 5-92
Special Tools .. . .. .. .. .. .. .. ... .. . .. .. .. .. .. . .. ... .. .. .. . .. . 5-107
Specifications
Fastener Tightening .................................... 5-92
Park/Turn Signal Lamp Bulb Replacement ....... 8-129

22
Park!Turn Signal Lamps Replacement .... 8-126, 8-128
Pedal Replacement
Accelerator Controls (3.8L) ......................... 6-1170
Accelerator Controls (5.7L) ......................... 6-1804
Plastic Panel Information and Repair
Description
Handling Precautions For Plastic ............. 8-1013
How to Identify Plastic Parts ................... 8-1011
Plastic Identification and Refinishing
Systems ....................................... 8-1011
Plastic Repair Precautions ...................... 8-1013
Plastic Panels .. .. ... .. . .. ... .. . .. .. .. ... .. . .. .. .. .. .. .. .. .. .. . 8-988
Plastic Repair Instructions ............................... 8-988
Plate Replacement
Door Sill ...................................................... 8-943
Power Door Lock Switch
Replacement ........................ 8-799, 8-800
Power Folding Top Bow Replacement ............. 8-837
Power Folding Top Cylinder Replacement ........ 8-836
Power Folding Top Pump with Motor
Replacement . .. . ... .. .. .. .. . ... . .. .. .. ... .. .. . 8-835
Power Folding Top System Check ................... 8-829
Power Mirror Switch Replacement ................... 8-801
Power Mirrors
Diagnosis
Inoperative ................................................ 8-791
One ............................................ 8-792, 8-793
Inoperative in Left and Right Direction ...... 8-796
One ............................................ 8-796, 8-797
Power Steering
Bleeding the System ...................................... 2-25
Checking and Adding Fluid ............................ 2-25
Control Valve Replacement ................... 2-21, 2-22
Cooler Replacement . .. .. . .. ... .. . .. . .. . .. ... ... . ... .... .. 2-36
Cylinder Line Assemblies/0-Ring Seals .......... 2-44
Description
Gear ........................................................... 2-49
Pump ......................................................... 2-49
Seal Replacement Recommendations ......... 2-49
Diagnosis
Excessive Wheel Kickback or
Loose Steering ................................. 2-12
Foaming, Milky-Appearing PS Fluid.
Low in Level .................................... 2-14
Gear and Pump Leaks .. .. .. . .. .. .. . .. .. .. .. .. .. .. . .. .. 2-7
Groan Noise in Steering Pump ................... 2-14
Growl Noise in Steering Pump ................... 2-14
Hissing Noise in Steering Gear .................... 2-6
Increase in Effort While Turning .................. 2-12
Low Oil Pressure Due to
Steering Gear ................................... 2-14
Low Oil Pressure Due to
Steering Pump ................................. 2-14
Poor Return of Steering Wheel ................... 2-12
Rattle Noise in Rack and Pinion ................... 2-7
Rattle or Chuckle Noise In
Steering Gear ................................... 2-11
Seal Replacement Recommendations . .. .. . ... . . 2-9
Steering Effort Hard in Both Directions ....... 2-13
Steering Wheel Kickback ............................ 2-13
System Inspection ........................................ 2-6
System Test ... .. .. .. .. .. . ... .. .. .. .. . ... .. .. . .. .. . .. .. .. . . 2-11
System Test Procedure .............................. 2-10
Too Much Play in Steering ......................... 2-13

INDEX
Power Steering (cont.)
Diagnosis (cont.)
Vehicle Leads to One Side
or the Other ..................................... 2-13
Wander or Poor Steering Stability ............... 2-13
Wheel Surges or Jerks While Turning ........ 2-12
Whine Noise in Steering Pump ................... 2-15
Drive Shaft Seal Replacement ....................... 2-23
Flushing the System ...................................... 2-27
Gear Disassembled View ................................. 2-5
Gear Replacement ................................ 2-37, 2-40
Hoses Replacement ....................................... 2-28
Inner Tie Rod Replacement ........................... 2-42
Pinion Seals and Bearing Annulus
Replacement . .. .. .. .. .. ... .. .. .. .. . ... .. .. .. .. .. 2-46
Pulley Replacement ....................................... 2-17
Pump Front Bracket Replacement .................. 2-24
Pump Rear Bracket Replacement .................. 2-24
Pump Replacement ............................... 2-18, 2-19
Rack and Pinion Boot Replacement ............... 2-33
Rack Bearing Pre load .................................... 2-42
Remote Fluid Reservoir Bracket
Replacement .................................... 2-16
Remote Fluid Reservoir Replacement ............ 2-15
Reservoir Replacement .................................. 2-20
Special Tools ................................................. 2-50
Specifications
Fastener Tightening ...................................... 2-3
Fluid Specifications ....................................... 2-3
Tie Rod End Replacement - Outer ................. 2-30
Unit Repair
Pump Assemble ......................................... 2-23
Power Steering Pump
Disassembled View .. .. .. . .. . .. .. . .. .. .. .. .. ... .. .. .. .. .. .. .. 2-4
Unit Repair
Pump Disassemble ..................................... 2-23
Power Window
Switch Replacement .. .. .. .. .. .. . .. .. .. .. .. .. . 8-798, 8-799
Power Windows
Diagnosis
Inoperative ................................................ 8-786
Express Function ................................... 8-786
From LF Switch .................................... 8-789
From RF Switch .................................... 8-789
Left Front .............................................. 8-787
RF from LF Switch .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. 8-788
Right Front ............................................ 8-788
Power Windows Inoperative ...................... 8-786
All ......................................................... 8-786
Powertrain Control Module
Air Conditioning Control Diagnosis (3.8L) ...... 6-1118
Connector End Views (3.8L) ........................ 6-767
Connector End Views (5.7L) ....................... 6-1300
Controlled Air Conditioning
Description (3.8L) ......................... 6-1226
Controlled Warning Lamps
Description (3.8L) ......................... 6-1226
Description (3.8L) ....................................... 6-1221
Description (5.7L) ....................................... 6-1862
Diagnosis (3.8L) ......................................... 6-1113
Replacement/Programming (3.8L) ............... 6-1155
Replacement/Programming (5.7L) ............... 6-1786
Warning Lamps Control Diagnosis (3.8L) .... 6-1114

23

INDEX

PoWertrain Control Module Idle Learn

Procedure (5. 7L) ........................... 6-1789
Programming Additional Keys-Theft
Deterrent .. .. ... .. .. . ... .. .. . .. .. ... .. .. .. . .. ... . 8-593
Programming/Replacement
Powertrain Control Module (3.8L) ............... 6-1155
Powertrain Control Module (5.7L) ............... 6-1786
Programming/Synchronization .......................... 8-556
Keyless Entry Transmitter ............................. 8-556
Propeller Shaft
Description ........... ,. . ... .. .. . ... .. .. .. . .. .. . .. .. .. .. .. .. . .. . 4-20
Center Bearing ........................................... 421
Phasing ...................................................... A-21
Universal Joint ............................................ 4-21
Diagnosis .. ... . ... . .. .. .. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 4-4, 4-5
Leak at Front Slip Yoke ............................... 4-5
Noise ........................................................... 4-8
Knock or Clunk Noise ............................... 4-8
Noise ........................................................... 4-8
Ping, Snap, or Click Noise ........................ 4-8
Noise ........................................................... 4-8
Scraping Noise ......................................... 4-8
Roughness or Vibration .. .. .. ... . .. . . .. ... . .. ... . .. ... . 4-6
Shudder on Acceleration at Low Speed ........ 4-9
Propeller Shaft Replacement, On~-Piece ........ 4-10
Propeller Shaft Replacement, Two-Piece ........ 4-12
Special Tools ................................................. 4-22
Specifications
Fastener Tightening ...................................... 4-3
Run out Specifications ................................... 4-3
Universal Joints Replacement ........................ 4-16
Propeller Shaft Balancing Weight Amounts ........ 0-45
Propeller Shaft Runout Specifications ................ 0-45
Proper Use of Torque Wrenches ....................... 0-18

Q
Quarter Panel Replacement .............. 8-1105,
Quick Connect Fitting Service
Metal Collar (3.8L) .....................................
Metal Collar (5.7L) .....................................
Plastic Collar (3.8L) ....................................
Plastic Collar (5.7L) ....................................

81108
6-1175
6-1808
6-1178
6-1811

Radiator
Air Baffle Assemblies and Deflectors
(Engine Cooling) ................. , 6-652, 6-653
Air Deflector Replacement ............................ 8-761
Assembly Description ................................... 6-661
Cleaning (Engine Cooling) ............................ 6-598
Filler/Pressure Cap Assembly Description ..... 6-662
Inlet Hose Replacement
(Engine Cooling) .................. 6-603, 6-606
Outlet Hose Replacement
(Engine Cooling) .................. 6-609, 6-612
Replacement (Engine Cooling) ..................... 6-648
Support Replacement (Engine Cooling) ........ 6-631
Radiator Support Description .............. : .......... 8-1112

Radio Replacement .............................. 8-240, 8-242

Radio/Audio
System Check ............................................. 8-217
System Schematic .. . .. .. ... .. .. .. .. .. .. . ... ... . .. ... . .. . 8-196
Rail Replacement
Side ........................................................... 8-1093
Upper ........................................................ 8-1080
Rail Sectioning
Lower ........................................................ 8-1088
Rail Sub-Assembly Replacement Front Lower .................................. 8-1091
Rear Compartment Lamp Replacement . .. ... . . ... 8-153
Rear Compartment Lid Applique
Replacement .. .. ... .. . ... .. . .. .. ... .. .. .. .. .. . 8-967
Rear Compartment Lid Hinge
Replacement ........................ 8-977, 8-978
Rear Compartment Lid Lock Striker
Replacement .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . 8-982
Rear Compartment Lid Release Inoperative ..... 8-962
Rear Compartment Lid Release
System Check .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . 8-962
Rear Compartment Lid Replacement .... 8-974, 8-975
Rear Compartment Lid Switch Replacement . ... 8-965
Rear Crankshaft Oil Seal
Replacement (5.7L) ........................ 6-357
Rear Drive Axle
Axle Replacement .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 4-54
Axle Shaft Replacement ................................. 4-32
Description
Rear Axle .. ... . .. .. .. .. .. ... .. .. .. .. .. .. .. .. .... .. . . .. .. .. .. 4-60
Diagnosis
General Information .................................... 4-26
Noise Diagnosis ......................................... 4-25
Drive Pinion Installation .................................. 4-55
Lubricant Level Check ................................... 4-28
Oil Deal and/or Bearing Replacement ............ 4-34
Pinion Oil Seal Replacement ......................... 4-36
Rear Cover and Gasket Replacement .. . .. .. .. .. . 4-28
Special Tools .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... . 4-63
Specifications
Fastener Tightening .................................... 4-23
Pinion Bearing and Differential Bearing
Preload ............................................ 4-24
Rear Axle .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. . .. .. . .. .. .. .. .. .. .. . 4-23
Rear Axle Usage .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 4-24
Unit Repair
Backlash Adjustment .. .. .. . .. .. .. .. .. .. ... .. . .. .. .. .. . 4-50
Bearings Inspection .................................... 4-43
Differential Case Assembly .. .. .. .. .. .. .. .. .. .. .. .. . 4-44
Gear Tooth Contact Pattern Check ............. 4-51
Inspection Before Disassembly .. .. .. .. .. .. .. .. .. . 4-39
Pinion and Ring Gear Inspection ................ 4-40
Pinion Depth Adjustment ............................ 4-29
Rear Axle Disassemble .. .. .. .. .. .. .. . .. .. . .. .. .. .. .. 4-28
Side Bearing Preload Adjustment .. .. ... .. .. . .. . 4-48
Rear Drive Axle
Unit Repair
Rear Axle Assemble .. .. .. .. .. .. .. .. .. ... .. .. .. .. .. .. .. 4-32
Rear End Panel Replacement .............. 8-983, 8-984
Rear Lift Window
Replacement ................................................ 8-701

24
Rear Quarter
Molding Replacement .. .. .. .. ... .. .. . ... .. .. . ... .. ... .. . 8-654
Rear Suspension .. .. .. .. .. . ... . .. .. ... .. .. .. .. .. .. .. .. ... .. .. .. 3-54
Rear Suspension
Component Locations .. .. .. .. .. ... .. .. .. .. .. .. .. ... .. . .. . 3-44
Special Tools .. .. ... .. .. .. . .. .. ... .. .. .. .. .. .. .. .. .. ... .. .. .. . 3-57
Specifications
Fastener Tightening .................................... 3-43
Rear Window
Defogger Braided Lead Wire .. .. ... . .. .. .. . .. .. . ... . 8-709
Rearview Mirror
Replacement .. ... . .. .. ... . .. .. .. .. ... ... . .. .. ... .. .. . ... .. .. 8-694
Support Replacement . .. .. .... ... .. .. .. .. ... . .. .. ... .. .. 8-695
Relay
Blower Motor Relay Replacement
(A/C - Manual) ................................. 1-91
Compressor Relay Replacement
(A/C - Manual) . .. .... ... . . ... .. ... .. . .. .. .. .. . . 1-83
Cooling Fan Relay Description ..................... 6-663
Fuel Pump Relay Replacement (5.7L) ........ 6-1841
Horn Relay Replacement .. ... . .. .. .. ... . .. .. . .. . ... . . 8-567
Theft Deterrent Relay Replacement .............. 8-590
Release Actuator Replacement ........................ 8-981
Release Systems
Diagnosis
Rear Compartment Lid Release
System Check ... . .. ... .. .. .. ... . .. .. ... .. .. . . 8-962
Schematics . ... . ... .. .. .. .. .. .. .. ... .... .. . .. .. ... . .... .. . .. . 8-956
Replacement ........................................ 6-684, 6-686
Retained Accessory Power
Component Locations .. .. .. .. ... .. . .. ... .. .. . .. .... . .. .. 8-643
Description
Circuit ....................................................... 8-646
Diagnosis
RAP Inoperative ....................................... 8-645
RAP On After Timeout .... .. .. ... .. .. .. .. . .. ... .. .. . 8-645
System Check .. .. ... . .. . .. ... ... .. . .. ... .. .. .. ..... .. .. 8-644
Schematic
Icons ........................................................ 8-640
References ............................................... 8-640
Schematics . .. ... .. .. .. .. .. .. .. .. .. .... .. .. ... . .. . 8-641. 8-642
Rocker Panel
Molding Replacement ................................... 8-655
Rocker Panel Replacement .... . .. .. .. . ... .. ... ... . .. . 8-1094
Roof
Description
Power Folding Top Circuit ........................ 8-895
Diagnosis
Power Folding Top Does Not Close .......... 8-831
Power Folding Top Does Not Open .......... 8-830
Power Folding Top System Check ............ 8-829
Lift Off Panel Replacement .......................... 8-881
Power Roof Systems Component
Locations . .. .. .. ... . .. ... .. ... . ... . .. .. ..... ... . . 8-827
Power Roof Systems Component Views ... .. .. 8-828
Power Roof Systems Connector
End Views ... .. . .. .. ... .. .. .. .. .. .. .. ... .. .. .. .. 8-829
Schematic
Power Folding Top ................................... 8-826
Power Roof Systems Schematic Icons . .. ... 8-826
Power Roof Systems Schematic
References .. . .. .. ... .. .. .. .. .. .. ... . .. ... .. .. .. 8-825
Specifications
Fastener Tightening .................................. 8-825

INDEX
Roof Outer Replacement ............................... 8-1105
RPO Code List ................................................. 0-12

s
Scan Tool
Does Not Communicate with Class 2
Data Line ....................................... 8-381
Does Not Communicate with
UART Data Line ............................. 8-379
Inoperative ................................................... 8-379
Schematic
Backup Lights .. .. ... .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. ... .. .. 8-41
Exterior Lights .............................. 8-30, 8-35, 8-38
Fog Lights ..................................................... 8-25
Headlight Doors ............................................. 8-28
Headlight Leveling ......................................... 8-29
Headlights - Daytime Running Lamps ... 8-20, 8-24
Instrument Cluster
Analog . .. . .. ... . .. ... .. .. .. .. .. .. .. .. ... .. . .. .. .. .. .. .. ... .. 8-469
Interior Lights ........................................ 8-42, 8-44
Interior Lights Dimming .................................. 8-46
Power Folding Top ....................................... 8-826
Schematics
Audible Warnings .. ... .. .. . .. .. .. .. .. . .. .. .. .. .. .. .. . ... .. 8-493
Auto Trans Shift Lock Control
Steering Wheel/Column - Tilt ...................... 2-55
Body Control Module ......................... 8-426, 8-431
Cruise Control .............................................. 8-602
Defogger .. .. . .. ... . .. ... .. .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. .. .. .. 8-684
Door Locks . ... . .. .. ... .. .. .. .. .. . .. ... . . .. .. .. .. .. .. .. .. .. .. 8-77 4
Engine Controls (3.8L) . .. .. .. . .. ... .. .. .. .. .. .. . .. .... . 6-743
Engine Controls (5.7L) ............................... 6-1263
Fuse Block Details ....................................... 8-318
schematics
Ground Distribution ...................................... 8-330
Schematics
Headlights ... . ... . .. ... .. .. .. .. .. .. .. .. ... ... .. .... .. .. 8-18, 8-19
Horns ........................................................... 8-561
Keyless Entry .. . ..... .. ... .. . .. .. ... .. . ... . ... .. .. .. . .. .. .. . 8-546
Lumbar Support . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... . ... . 8-898
Outside Mirrors .. .... .. . .. .. . . . ... . ... .. .. . .. ... .. . .. .. ... . 8-775
Power Distribution ........................................ 8-314
Power Seats . .. .. .. . . .. ... . .. .. .. .. ... .. .. .. .. . .. ... . .. ... .. 8-897
Power Windows ... . ... .. ... .. .. .. .. ... . .. .. ... . .. .. .. ... .. 8-773
Release Systems .. .. .. .. .. .. .. .. .. .. ... . .. .. .. .. .. .. . .... 8-956
Retained Accessory Power .. .. .. .. . ... .. .. 8-641, 8-642
SIR ................................................................ 9-23
Theft Deterrent . .. .. .. .. .. .. .. ... . .. .. ... . .. .. .. .. .. .. .. .. .. 8-570
Seal Replacement
Hood Rear .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... . .. .. .. ... . .. .. ... . . 8-763
Seat Adjuster Mechanism Replacement
Power .. .. ... . .. .. .. .. ... . ... .. . .. .... .. ... .. .. . .. .. .. ... . .. ... . 8-928
Seat Back Latch Replacement
Rear Folding .. . .. ... .. . ... .. .. .. . .. ... .. .. .. .. .. .. .. .. . ... .. 8-936
Seat Back Latch Striker Replacement
Rear Folding ................................................ 8-936
Seat Back Replacement
Rear Split Folding ........................................ 8-934
Seat Belt
Child Seat Restraint System Belt Kit ..... 9-17, 9-18
Seat Belt Buckle Replacement
Left Front ........................................................ 9-5
Right Front ...................................................... 9-8

INDEX

Seat Belt Retractor Replacement

Left Front ................................................. 9-5, 9-7
Rear ..................................................... 9-12, 9-13
Right Front ............................................. 9-9, 9-1 O
Seat Belt Side Buckle Replacement
Rear .............................................................. 9-11
Seat Belts
Description
System Operation . .. .. .. .. .. .. .. ... . ... .. ... ... .. .. . .. .. 9-19
Diagnosis
Seat Belt Service Precautions . .... . .. .. .. .. .. . .. ... 9-4
Emergency Locking Retractor Checks .............. 9-4
Seat Belt Checks .. .. ... .. .. .. .. .. .. .. .. ... .. .. .. .. . .. .. .. .. .. 9-3
Specifications
Fastener Tightening ...................................... 9-3
Seats
Description
Front Seats .............................................. 8-937
Power Lumbar Circuit ............................... 8-938
Power Seat .. .. .. . ... .. .. .. .. .. ... .. . .. ... ... . .. .. .. .. ... 8-938
Systems Circuit Description ................... 8-938
Rear Seats .. .. .. .. .. ... .. .. . .. ... . .. .. .... . ... .. .. .. . .. .. 8-938
Diagnosis
Lumbar Support Does Not Move
Up or Down . .. .. .. .. .. .. .. .. .. ... .. .. . .. .. ... .. 8-906
Lumbar Support Inoperative ...................... 8-906
Lumbar Support Inoperative
in One Direction ............................. 8-907
Lumbar Support System Check .. .. .. ... . .. .. .. 8-902
Power Seat Adjuster Does Not Move
Vertically ......................................... 8-902
Power Seat Does Not Move Forward/
Rearward .. .. ... . .. .. .. .. .. .. .. ... ... . .. .. ... ... . 8-903
Power Seat Does Not Tilt Forward . .. ... .. ... 8-904
Power Seat Does Not Tilt Rearward ......... 8-905
Power Seat Inoperative ............................. 8-903
Power Seat Systems Check .. .. ... . .. ... ... . .. .. 8-902
Headrest Replacement
Front Seat ................................................ 8-930
Lumbar Bladder Replacement ...................... 8-924
Lumbar Motor Replacement ......................... 8-922
Power Recliner Replacement
Front Seat ................................................ 8-917
Power Seat Systems Component Views ....... 8-900
Power Seat Systems Components ............... 8-899
Schematic
Power Seat Systems Schematic Icons ... .. . 8-896
Power Seat Systems Schematic
References ..................................... 8-896
Schematics
Lumbar Support ........................................ 8-898
Power Seats ... . . ... .. .. .. .. .. ... . .. ... . .. ... .. . . ... .. .. . 8-897
Seat Back Hinge/Recliner Mechanism
Replacement
Front ........................................................ 8-916
Seat Back Recliner Mechanism
Replacement
Front ........................................................ 8-921
Seat Back Replacement
Front ........................................................ 8-914
Seat Cushion Cover Replacement
Front ........................................................ 8-913
Seat Cushion Trim Cover and Pad
Replacement .................................. 8-913

25
Seats (cont.)
Seat Replacement
Bucket ........................................... 8-908, 8-909
Front Bucket .................................. 8-910, 8-911
Power with Adjuster ....................... 8-925, 8-926
Shoulder Restraint Guide Replacement
Rear Seat .. .. .. .. . .. .. .. . ... .. .. .. ... .. .. . . ... . 8-934, 8-935
Specifications
Fastener Tightening .................................. 8-896
Secondary Air Injection
Pump Relay Replacement (5.7L) ................ 6-1854
Pump Replacement (5. 7L) .......................... 6-1850
Solenoid Relay Replacement (5.7L) ............ 6-1854
Secondary Air Injection Bleed Valve
Solenoid Replacement (5.7L) ........ 6-1855
Service Parts ID Label ...................................... 0-12
Shelf Trim Panel Replacement
Rear ............................................................ 8-952
Shock Absorber Replacement
Rear Suspension . . ... .. . ... .. .. .. . .. .. .. . . .. ... .. .. .. . .. .. . 3-51
Shock Absorber Replacement, Front .................. 3-32
Short Trip/City Maintenance Schedule ............... 0-35
Shoulder Belt Replacement
Rear .............................................................. 9-15
Side Marker Lamp Replacement .. ... .. . ... .. .. .. .. .. . 8-151
Side Weatherstrip Retainer Protector
and Seal . ... . .. ... .. .. . ... . .. .. . .. . ... .. . .. . . .. . 8-894
SIR
AIR BAG Warning Lamp Replacement ........... 9-89
Component Views . . . . . . . . .. . . . . . . .. .. .. .. .. . . . . .. . . .. .. . . . . 9-25
Components . .. .. .. .. .. . ... .. .. .. ... .. .. .. ... .. .. ... . .. .. . .. .. 9-24
Connector End Views .. .. .. .. .. .. .. . ... .. .. .. .. .. .. .. . .. . 9-26
Description
Special Tools . . ... . .. .. .. .. .. .. .. .. .. .. ... . .... . .. . .. ... . 9-110
System Component Description and
Definitions . .. . .. ... .. .. . .. .. .. .. .. . .. . . . ... .. .. .. 9-107
System Operation . .. .. .. .. .. . . .. .. .. .. .. .. .. .. .. .. .. .. 9-106
Description (Tilt Column) .............................. 2-11 O
Diagnosis
AIR BAG Warning Lamp Comes
On Steady . ... .. ... . .. .. .. .. .. .. .. ... . .. ... . .. .. .. 9-32
AIR BAG Warning Lamp
Does Not Come On .. .. .. .. .. .. .. .. .. .. .. .. . 9-36
Diagnostic System Check .. .. . .. .. .. .. . .. ... . ... .. . . 9-28
General Diagnosis .. .. .. . . .. .. .. . .. ... .. . .. ... .. .. .. .. .. 9-27
lntennittents and Poor Connections . . .. .. . .. . .. 9-27
SOM Integrity Check .. . . .. . .. .. .. .. .. .. .. .. . . .. . .. . .. . 9-30
Disabling the SIR System .............................. 9-79
Enabling the SIR System ............................... 9-81
General Service Instructions .......................... 9-83
Inflatable Restraint Instrument Panel
lnflator Module Replacement ............ 9-86
Inflatable Restraint Sensing and
Diagnostic Module Replacement . .. . .. . 9-84
Inflatable Restraint Steering Wheel
Module Coil Replacement . .. ... .. . .. .. ... . 9-89
Inflatable Restraint Steering Wheel
Module Replacement . .. .. ... .. .. .. .. .. . .. .. . 9-89
lnflator Module Handling, Shipping, and
Scrapping ......................................... 9-94
Repairs and Inspections Required After
an Accident . . ... .. .. .. .. .. .. .. .. . .. ... .. .. .. .. .. . 9-93
Schematics ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... ... . .. .. .. .. .. . 9-23
Icons .......................................................... 9-22

26
SIR (cont.)
Schematics (cont.)
References .. .. ... . .. .. .. .. ... . ... .. .. . ... .. . .. .. ... .. .. .. .. 9-22
Service Precautions .. .. .. .. .. .. .. ... .. . ... . .. .. ... .. .. .. .. 9-79
Special Tools ............................................... 9-111
Specifications
Fastener Tightening .................................... 9-20
GM SPO Group Numbers ........................... 9-21
Scan Tool Data Definitions ......................... 9-21
Scan Tool Data List ................................... 9-20
Wiring Repair ................................................. 9-89
Solenoid
Brake Transmission Shift Interlock
Solenoid Replacement
Automatic Transmission (4L60-E) .............. 7-245
Control and Shift Solenoids Replacement
Automatic Transmission (4L60-E) .............. 7-284
Torque Converter Clutch PWM Solenoid, TCC
Solenoid, and Wiring Harness
Automatic Transmission (4L60-E) ............. 7-287
Spare Tire Replacement
Compact . ... . .. ... .. .. .. .. .. . .. .. ... .. .. .. .. .. .. .. .. .. .. ... . .. .. 3-63
Spark Plug
Replacement ................................................ 6-715
Visual Diagnosis .......................................... 6-682
Wire Harness Diagnosis ............................... 6-684
Speaker Grille Replacement
Rear ................................................. 8-263, 8-264
Speaker Replacement .......................... 8-257, 8-258
Front
Entertainment ........................................... 8-258
Rear ............................................................. 8-259
Special Tools
Anti lock Brake System ................................. 5-264
Automatic Transmission (4L60-E} . . .. ... . ... ... .. . 7-356
Body Rear End . ... .. .. .. .. .. .. ... .. ... .. .. .. . .. .. .. .. ... .. 8-986
Clutch .......................................................... 7-384
Disc Brakes ................................................... 5-91
Doors ........................................................... 8-824
Engine Controls (3.8L) ............................... 6-1244
Engine Controls (5.7L) ............................... 6-1897
Engine Cooling ............................................ 6-664
Engine Electrical .......................................... 6-724
Engine Mechanical (3.8L) ............................. 6-226
Engine Mechanical (5.7L) ............................. 6-575
Entertainment ............................................... 8-281
Frame and Underbody ............................... 8-1079
Front Suspension ........... .; .............................. 3-40
General Information ....................................... 0-32
HVAC - Manual ............................................ 1-128
Hydraulic Brakes ............................................ 5-67
Instrument Panel, Gauges and Console ....... 8-544
Lighting Systems .......................................... 8-160
Park Brake .................................................. 5-107
Power Steering .............................................. 2-50
Propeller Shaft .. .. .. .. .. .. .. .. .. .. .. .. .. ... . .. .. .. .. ... .. . .. . 4-22
Rear Drive Axle . . ... .. . . .. ... . ... ... . . .... . .. .. . ... ... . .. .. . 4-63
Hear Suspension ........................................... 3-57
SIR .............................................................. 9-111
Stationary Windows ...................................... 8-711
Steering Wheel/Column - Tilt ........................ 2-111
Theft Deterrent . . .. .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. ... . .. ... 8-600
Vibration Diagnosis . . .. .. .. .. ... .. .. .. . .. .. .. .. ... .. .. .. .. . 0-98
Wipers/Washer Systems ............................... 8-194

INDEX
Special Tools Ordering Information ...................... 0-5
Specifications
Scan Tool Data Definitions
Engine Controls (5. 7L) ............................ 6-1251
Specifications
Approximate Fluid Capacities ......................... 0-33
Battery Temperature vs Voltage Drop ........... 6-666
Battery Usage . .. ... .. . ... . ... . ... . ... .. .. .. .. .. .. .. .. .. .. .. 6665
Body Dimensions ....................................... 8-1023
Brake System
Hydraulic Brakes ........................... ,. . ... . ... .. .. . 5-5
Components
Disc Brakes ................................................ 568
Diagnostic Trouble Code (DTC) Identification
Automatic Transmission (4L60-E) ....... 7-64, 7-67
Drive Belt Tension .......................................... o;.33
DTC List
Engine Controls (3.8L) .............................. 6-736
Engine Controls (5. 7L) ............................ 6-1256
Engine Cooling System
Engine Cooling .............. : ...................... ,... 6-580
Engine Mechanical (3.8L) ............................... 6-14
Engine Mechanical (5.7L) ............................. 6-231
Fastener Tightening
3.8L ........................................................... 6-13
Anti lock Brake System .............................. 5-108
Automatic Transmission .............................. 7-56
4L60-E . .. .. .. ... .. .. . .. ... . ... .. .. .. .. .. .... .. .. .. .. ... .. . 7-56
Bumpers ................................................... 8-712
Clutch . .. .. ... .. ... ... .. .. ... . .. .. .. .. ... .... .. .. . ... . ... .. .. 7-359
Cruise Control .......................................... 8-601
Disc Brakes ................................................ 5-68
Doors ................................... :. . .. .. .. . ... .. .. .. . 8-771
Engine Control (3.8L) . ... .. .. .. .. .. .. .. .. .. . ... ... . . 6-725
Engine Controls (5.7L) ............................ 6-1247
Engine Cooling . .... .. .. .. .. .. .. ... . .. .. .. .. .. .. .. ... .. . 6-580
Engine Electrical . ... . .. .. .. .. .. .. .. .. ... . ... . .. .. .... .. 6-665
Engine Exhaust .. .. .. .. .. .. .. . ... .. .. .. .. .. . ... . .. ... 6-1900
Entertainment . ... ... .. . .. .. .. .. .. ... . .. .. .. ... .. .. .. .. .. . 8-195
Frame and Underbody ............................ 8-1022
Front Suspension . .. .. .. .. . . .... .. .. .. .. .. .. .... ... ... .. 3-12
Homs ....................................................... 8-560
HVAC - Manual .. .. .. .. .. .. .. .. .. .. ... .. .. .. .. .. .. .. . .. .. .. 1-3
Hydraulic Brakes .. .... .. .. .. .. .. .. .. .. .. . .... . .. . ... ... . .. 5-5
Instrument Panel, Gauges and Console ... . 8-467
Interior Trim .............................................. 8-939
Lighting Systems .. ... .. ... .. .. .... .. .. . ... .. .. .... .. .. . . 8-15
Manual Transmission .................................... 7-5
M49 .......................................................... 7-5
MM6 ....................................................... 7-28
Park Brake . .. .. ... .. .. . .. .. ... .. ... .. .. . ... ... .. ... .. .. .. .. 5-92
Power Steering . .. .. .. .. .. .. .. .. ... .. .. .. .. . .. ... . ... .. .. .. . 2-3
Propeller Shaft ............................................. 4-3
Rear Drive Axle .......................................... 4-23
Rear Suspension . .. .. .. .. .. ... . .... . .. .. .. .. .. ... ... .. .. 3-43
Roof ......................................................... 8-825
Seat Belts . .. .. ... .. .. .. .. .. .. .. .. .. ... .. .. . ... . ... .. .. .. .. .. . 9-3
Seats .. .. . .. .. .. ... .. .. .. .. .. .. .. .. .. ... .. .. .. . ... . .. . .. .. .. . 8-896
SIR ............................................................. 9-20
Stationary Windows .................................. 8-683
Steering Wheel/Column - Tilt ...................... 2-51
Theft Deterrent ......................................... 8-569
Ti res and Wheels .. .. .. .. .. . .. ... ... . .. .. .. .. ... . ... . ... 3-58
Wheel Alignment .......................................... 3-7

INDEX
Specifications (cont.)
Fastener Tightening (cont.)
Wipers/Washer System ............................. 8-161
Fastener Tightening (5.7L) ........................... 6-229
Fastener Tightening Specifications
Body Front End ........................................ 8-734
Fluid Capacity
Automatic Transmission .............................. 7-69
4L60-E .................................................... 7-69
Fluid Specifications
Power Steering ............................................. 2-3
Frame Dimensions ..................................... 8-1032
Fuel System
Engine Controls (3.8L) .............................. 6-739
Engine Controls (5.7L) ............................ 6-1259
Generator Usage ... . ... .. .. .. .. .. .. . .. ... .. .. .. .. .. . .. .. 6-666
GM SPO Group Numbers
Engine Controls (3.8L) .............................. 6-740
Engine Controls (5.7L) ............................ 6-1260
Engine Cooling ......................................... 6-580
Engine Electrical ....................................... 6-666
Engine Exhaust ...................................... 6-1900
Engine Mechanical (3.8L) ........................... 6-17
Engine Mechanical (5.7L) ......................... 6-234
SIR ............................................................ 9-21
Lubrication
Manual Transmission (M49) .......................... 7-5
Manual Transmission (MM6) ....................... 7-28
Pinion Bearing and Differential Bearing Preload
Rear Drive Axle .......................................... 4-24
Propeller Shaft Balancing Weight Amounts ..... 0-45
Propeller Shaft Runout ................................... 0-45
Range Reference Table
Automatic Transmission (4L60-E) ................ 7-70
Rear Axle Usage .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 4-24
Recommend Fluids and Lubricants ................ 0-33
Refrigerant Oil Distribution
HV AC - Manual .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 1-4
Runout Specifications
Propeller Shaft ............................................. 4-3
Scan Tool Data Definitions
Automatic Transmission (4L60-E) ....... 7-60, 7-62
Engine Controls (3.8L) .............................. 6-731
SIR ............................................................ 9-21
Scan Tool Data List
Engine Controls (3.8L) .............................. 6-726
Engine Controls (5.7L) ............................ 6-1248
SIR ............................................................ 9-20
Scan Tool Data Value Examples
Automatic Transmission (4L60-E) ....... 7-57, 7-58
Sealers, Adhesives and Lubricants
Clutch ....................................................... 7-359
Sealers, Adhesives, and Lubricants
Engine Mechanical (3.8L) ........................... 6-18
Engine Mechanical (5.7L) ......................... 6-236
Shift Solenoid Valve State and Gear Ratio
Automatic Transmission (4L60-E) ................ 7-70
Shift Speed Table
Automatic Transmission (4L60-E) ................ 7-70
Starter Motor Usage .................................... 6-666
System Capacities
HVAC - Manual .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 1-3
Temperature vs Resistance
Automatic Transmission (4L60-E) ................ 7-56

27
Specifications (cont.)
Temperature vs Resistance (cont.)
Engine Control (5.7L) .............................. 6-1247
Engine Controls (3.8L) .............................. 6-725
Thread Repair
Engine Mechanical (5.7L) ......................... 6-237
Tire Inflation Pressure .................................... 0-34
Tires and Wheels ........................................... 3-58
Trim Height
Trim Height Specifications ............................ 3-3
Wheel Alignment .............................................. 3-7
Spoiler Replacement
Rear ................................................. 8-968, 8-969
Spring Insulators Replacement, Rear Coil ......... 3-53
Spring Replacement
Coil
Rear Suspension ........................................ 3-52
Squeaks and Rattles
Description
Noise . .. .. ... .. .. .. .. .. .. .. .. . .. .. . .. .. ... . .. .. ... .. ... .. .. . . 8-682
Diagnosis .. ... .. .. .. .. .. .. .. ... . ... .. .. .. .. . .. .. .. . .. .. .. ... .. 8-667
Stabilizer Shaft
Link Replacement .......................................... 3-16
Stabilizer Shaft Link Replacement ..................... 3-17
Rear Suspension . .. .. . .. ... .. .. .. .. .. .. .. .. .. . . .. ... .. . .. .. 3-50
Stabilizer Shaft Replacement
Rear Suspension ... .. .. .. .. .. .. .. .. ... .. . ... . ... .. .. .. .. .. . 3-49
Stains Removal ............................................... 8-954
Starter
Diagnosis
No Load Test ........................................... 6-675
Solenoid Does Not Click .. .. .. .. .. . ... .. .. . .. . . .. .. 6-672
Starter Motor ........................................ 6-684, 6-686
Shield Replacement ..................................... 6-688
Starter Motor Usage ........................................ 6-666
Starting System
Circuit Description ........................................ 6-720
Starting System Check .................................... 6-671
Stationary Windows
Bus Bar Lead Terminal Repair ..................... 8-709
Component Locations ................................... 8-685
Component Views ........................................ 8-686
Connector End Views ................................... 8-687
Description
Adhesive Service Kit Description ............... 8-71 O
Extended Method Description ................... 8-710
General .................................................... 8-710
Rear Window Defogger ............................. 8-710
Rear Window Defogger Circuit .................. 8-711
Rear Window Defogger Operation ............. 8-711
Reveal Molding ......................................... 8-71 O
Short Method Description .......................... 8-710
Diagnosis
Defogger Always On - Rear .. .. .. .. .. .. .. .. .. .. . 8-688
Defogger Grid Lines ................................. 8-690
Defogger Indicator Always On . .. .. .. ... .. . .. .. . 8-690
Defogger Indicator Inoperative .................. 8-690
Defogger Inoperative - Rear ..................... 8-689
Defogger System Check . .. . .. .. .. .. .. .. .. .. .. . .. .. 8-688
Grid Line Repair .......................................... 8-707
Schematic
Icons ........................................................ 8-683
References . .. .. .. . ... .. .. .. .. ... .. . .. .. .. .. .. . ... .. .. .. .. 8-683

28
Stationary Windows (cont.)
Schematics
Defogger .................................................. 8-684
Special Tools ............................................... 8-711
Specifications
Fastener Tightening .................................. 8-683
Window Cleaning ......................................... 8-707
Window Polishing ......................................... 8-706
Steering Column
Overhaul
Turn Signal Cancel Cam, Upper
Bearing Inner Race Assemble .......... 2-96
Steering Knuckle Replacement .......................... 3-22
Steering Wheel Control Schematic .. .. ... . ... .. .. .. . 8-204
Steering Wheel Control Switches
Replacement .. .. .. .. .. .. .. .. ... . .. .. .. .. ... .. . 8-251
Steering Wheel Control System Check ............ 8-218
Steering Wheel/Column - Tilt
Component Locations .. .. .. . ... .. .. .. .. .. . .. ... .. .. .. ... . 2-56
Component Views .. . .. .. ... . ... .. .. .. .. .. .. .. . ... .. ... .. .. . 2-57
Connector End Views .................................... 2-58
Description
Auto Trans Shift Lock Control ................... 2-110
Auto Trans Shift Lock Control Circuit ........ 2-110
Ignition Lock System ................................ 2-110
Steering Wheel and Column ..................... 2-109
Supplemental Inflatable Restraint .............. 2-110
Diagnosis
Auto Trans Shift Lock Control Always
On With Ignition in RUN ................... 2-60
Auto Trans Shift Lock Control
Inoperative ....................................... 2-59
Auto Trans Shift Lock Control System ........ 2-62
Auto Trans Shift Lock Control System
Check .............................................. 2-58
Hazard Switch Does Not Stay On
Wheel/Column .................................. 2-65
Hazard Warning Cannot Be Turned Off ...... 2-64
High Lock Effort ......................................... 2-61
High Lock Effort Between the Off Lock
Positions .......................................... 2-61
High Steering Shaft Effort ........................... 2-62
Housing Scraping Bowl ............................... 2-62
Ignition Switch Cannot Be Set Correctly ..... 2-65
Ignition Switch Does Not Tum .................... 2-65
Ignition Switch Electrical System Does
Not Operate . .. .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. .. . 2-65
Key Cannot Be Removed in the Off
Lock Position .................................... 2-61
Lash In Steering Column ............................ 2-62
Lock Cylinder Can Be Removed
Without Depressing Retainer ............ 2-61
Lock System Does Not Lock .. .. .. .. .. .. ... .. .. .. . 2-60
Lock System Does Not Unlock ................... 2-60
Loose Steering Wheel ................................ 2-63
Loose Steering Wheel (Every Other Tilt
Position) ........................................... 2-63
Noise in Steering Column ........................... 2-62
Noise When Tilting Steering Column .......... 2-63
Steering Wheel Does Not Lock in Any
Tilt Position ...................................... 2-63
Steering Wheel Not Returning to Top
Tilt Position ...................................... 2-63
Turn Signal Difficult to Operate ................... 2-64

INDEX
Steering Wheel/Column - Tilt (cont.)
Diagnosis (cont.)
Turn Signal Does Not Cancel ..................... 2-64
Turn Signal Does Not Indicate Lane
Change ... .. .. .. . ... .. .. .. .. .. ... . .. ... . .. .. ... .. .. 2-63
Turn Signal Does Not Stay in Turn
Position ... .. .. . .. ... .. .. .. .. .. ... .. . ... . .. ... . ... .. 2-64
Flexible Coupling Replacement ...................... 2-75
Hazard Warning Switch Replacement ............. 2-69
Horn Switch Replacement . .. .. ... .. . ... .. .. .. .. .. .. .. .. 2-72
Ignition Switch Replacement . ... .. .. .. .. .. .. . .. .. ... .. 2-66
lnflator Module Replacement .......................... 2-70
Replacement .. .. .. ... .. .. .. . .. ... .. .. .. .. .. ... . ... . ... . .. ... .. 2-77
Schematic
Icons .......................................................... 2-54
References . .. .. ... .. .. .. . .. ... .. .. .. .. .... . .. .. . .. ... .. .. .. 2-54
Special Tools .. . .. ... .. .. .. .. ... .. . ... .. .. .. .. .. ... . .. .. .. .. 2-111
Specifications
Fastener Tightening .................................... 2-51
Steering Wheel Control Switch Assembly
Replacement .. . .. ... .. . .... .. .. .. .. .. . ... .. .. . .. 2-73
Steering Wheel Replacement . ... . .. .. ... .. . .. .. . .. .. . 2-74
Tilt Lever Replacement .. . ... . .. ... ... .. .. .. . .. ... . ... . .. 2-69
Turn Signal and Multifunction Switch
Assembly - Disassemble ................... 2-88
Turn Signal Multifunction Signal Lever
Replacement . .. .. .. .. .. ... .. .. .. .. .. .. .. ... . ... . 2-68
Unit Repair
Dimmer Switch Assembly - Assemble ... . .. .. . 2-92
Dimmer Switch Assembly Disassemble .. ... . .. .. .. .... .. . .. .. .. .. .. ... .. .. . 2-92
Disassembly/Assembly ................................ 2-79
Housing - Assemble ................................... 2-98
Ignition and Key Alarm Switch
Assembly ......................................... 2-81
Ignition Switch Assembly - Assemble .......... 2-91
Ignition Switch Assembly - Disassemble ..... 2-91
Lock Cylinder Set - Assemble .. . ... .. . .. . .. . .. .. . 2-95
Lock Cylinder Set - Disassemble . .. .. .. .. . ... .. . 2-95
Lock Housing Assembly - Assemble ......... 2-101
Lock Housing Assembly - Disassemble ... .. 2-100
Pivot and Pulse Switch Assembly Assemble .. .. .. .. ... .. .. . .... .. . ... . .. .. ... . ... .. . 2-94
Pivot and Pulse Switch Assembly Disassemble .. .. .. .. .. ... .. .. ... . .. ... .. . .. ... .. . 2-93
Steering Column Accident Damage .. .. .. .. . .. 2-107
Steering Shaft, Lower Bearing, JacketAssemble . . ... . ... . ... .. .. .. .. .. ... . .. .. .. .. ... . 2-105
Steering Shaft, Lower Bearing, JacketDisassemble . . .. .. ... .. .. .. ... .. .. .. . .. .. ... .. . 2-103
Tilt Spring - Assemble . .. .. .. ... .. .. .. .. .. .. .. .. .. ... . 2-87
Tilt Spring - Disassemble . .. .. . .. .. .. .. .. .. .. .. .. .. .. 2-85
Turn Signal and Multifun'ction Switch
Assembly - Assemble . .. .. .. .. .. .. .. .. ... .. . 2-89
Turn Signal Cancel Cam, Upper
Bearing Inner Race Disassemble ...... 2-95
Visual Identification
Disassembled View ... .. .. .. .. ... .. .. .. .. .. .. .. .. ... . .. 2-52
Steering Wheel/Column Tilt
Unit Repair
Housing - Disassemble .. .. .. ... .. .. .. .. .. .. .. .. .. ... . 2-97
Stop Lamp Bulb Replacement
High Mounted ................................... 8-143, 8-145

29

INDEX
Stoplamp Switch
Adjustment . .. .. .. .. .. .. .. ... . .. ... .. .. . .. .. ... .. .. .. . .. ... . .. .. 5-63
Replacement .................................................. 5-61
Strategy Based Diagnosis ................................. 0-31
Striker Replacement
Rear Compartment Lid Lock . .. .. .. . . ... .. . .. .. .. .. . 8-982
Struts or Shock Absorbers
Diagnosis
Leak ............................................................. 3-5
Noisy ........................................................... 3-5
Weak ........................................................... 3-5
Sunshade Panel Replacement ......................... 8-880
Suspension
Description
General ........................................................ 3-6
Diagnosis
Abnormal or Excessive Tire Wear ................ 3-4
Low or Uneven Trim Height ......................... 3-6
Struts or Shack Absorbers Weak .................. 3-5
Struts or Shock Absorbers Leak ................... 3-5
Struts or Shock Absorbers Noisy .................. 3-5
Vehicle Leads/Pulls ...................................... 3-3
Front
Description . .. .. .. .. .. ... . .. ... .. .. . .. .. ... .. .. .. . .. .. .. .. .. 3-39
General . .. .. .. .. .. .. .. ... .. .. .. .. . .. .. ... .. .. .. . .. ... . .. .. 3-39
Rear
Component Locations .. .. .. . ... .. .. .. .. ... . .. .. .. . .. .. 3-44
Description . .. .. .. .. .. .. ... . ... .. . .. ... . .. . .. ... .. .. .. .. .. .. 3-56
General . .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. . .. .. .. . .. ... . .. .. 3-56
Switch
Clutch Anticipate Switch Replacement .......... 7-375
Clutch Pedal Position Switch
Replacement .................................. 7-376
Cruise Release Switch Adjustment ............... 8-635
Cruise Release Switch Replacement ............ 8-634
Fog Lamp Switch Replacement ......... 8-133, 8-134
Hazard Warning Switch Replacement
(Tilt Column) ..................................... 2-69
Headlamp Switch Replacement .................... 8-131
Horn Switch Replacement (Tilt Column) ......... 2-72
Ignition and Key Alarm Switch Assembly
(Tilt Column) ..................................... 2-81
Ignition Switch Replacement (Tilt Column) ...... 2-66
IP Compartment Lamp Switch
Replacement . . .. ... . .. .. .. ... . . .. ... . .. .. .. .. . 8-526
Park/Neutral Position Switch Replacement
Automatic Transmission - 4L60-E ............. 7-253
Power Door Lock Switch
Replacement ........................ 8-799, 8-800
Power Mirror Switch Replacement ................ 8-801
Power Window Switch Replacement ... 8-798, 8-799
Rear Compartment Lid Switch
Replacement .. .. ... . .. .. .. .. ... .. .. . ... . .. .. .. 8-965
Steering Wheel Control Switch Assembly
Replacement (Tilt Column) ................ 2-73
Steering Wheel Control Switches
Replacement .. .. .. .. .. .. .. .. ... . .. ... .. . ... . .. 8-251
Stoplamp Switch Adjustment .......................... 5-63
Stoplamp Switch Replacement . .. ... ... . .. . .. .... ... . 5-61
Valve Body and Pressure Switch
Replacement
Automatic Transmission - 4L60-E ............. 7-278
Switches
Traction Control Switch Replacement ........... 5-260

T
Tail Lamp Replacement ........................ 8-149,
Temperature Control Cable Adjustment
(A/C - Manual) ... ... ... . .. .. .. ... . .. ... .. . .. .
Temperature Sensor Description-Engine
Coolant .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. . .. .. ...
Tensioner, Drive Belt,
Replacement (5.7L) .............. 6-272,
Theft Deterrent
Diagnosis
System Feature Customization
Inoperative ......................................
Theft Deterrent
Component Locations .. .. .. ... .. . .. .. .. .. ... .. . .. .. .. ...
Component Views ... .. .. .. .. .. .. .. .. .. .. .. ... .. ... .. .. .. .
Connector End Views ...................................
Description
Content Theft Deterrent . .. .. .. .. ... . ... . .. .. ... .. . .
Content Theft Deterrent Circuit .................
Content Theft Deterrent Operation .. .. .. .. .. ..
Vehicle Theft Deterrent .............................
Vehicle Theft Deterrent Circuit ..................
Vehicle Theft Deterrent Operation .............
Diagnosis
Content Theft Deterrent Alarm Mode
Always On ... . ... .. .. .. .. .. .. .. . ... .. .. .. .. ... ..
Content Theft Deterrent Alarm Mode
Inoperative ......................................
Horn Inoperative in CDT Alarm Mode .......
Ignition Lock Cylinder Test .......................
lntermittents and Poor Connections ..........
Lights Inoperative in CDT Alarm Mode .....
SECURITY Indicator Inoperative ...............
SECURITY Indicator Off,
Engine Cranks ................................
SECURITY Indicator Off, Engine Does
Not Crank .. . .. .. .... .. ... . .. .... .. ... .. .. .. .. .. .
SECURITY Indicator On Engine Starts .....
Shock Sensor Inoperative .........................
System Check ..........................................
Content ... .. . .. .. .. ... .. .. .. .. .. .. .. .. ... ... ... .. ... .. ..
Vehicle ..................................................
Feature Customization .................................
Ignition Lock Cylinder Replacement ..............
Pass Key Programming ...............................
Programming Additional Keys .......................
Programming Replacement Keys, Ignition
Cylinder, or Powertrain Control
Module .. .. .. . .. .. ... .. . .. .. .. .. .. . .. .. .. .. ... .. ..
Relay Replacement .. .. .. .. . ... .. ... .. .. ... .. .. .. .. .. .. ..
Schematic
Icons ........................................................
References ...............................................
Schematics .. . .. .. .. .. .. ... . .. .. .. ... .. . .. .. .. ... .. .. .. ... . ..
Shock Sensor Replacement . ... .... .. .. .. . .. .. ... . ..
Special Tools ...............................................
Specifications
Fastener Tightening ..................................
Thermostat
Description .. .. .. .. . .. .. .. .. ... .. .. .. .. .. .. .. . ... .. ... . .. .. .. .
Housing Replacement
(Engine Cooling) .................. 6-623,
Replacement (Engine Cooling) .......... 6-627,

8-150
1-104
6-663
6-273

8-587
8-57 4
8-576
8-577
8-596
8-598
8-596
8-598
8-600
8-598
8-585
8-585
8-586
8-581
8-577
8-586
8-584
8-582
8-582
8-584
8-587
8-578
8-578
8-580
8-594
8-591
8-587
8-593
8-594
8-590
8-569
8-569
8-570
8-592
8-600
8-569
6-663
6-625
6-629

IND.EX

30
Thread Inserts ................................................... 0-17
Throttle Body
Assembly Replacement (5.7L} .................... 6-1804
Coolant System Description .. .. .. . . .. .. .. .. .. .. . .. .. 6,-660
Throttle Body Air Inlet Screen
Replacement (3.8L} ....................... 6-1174
Throttle Body Assembly Replacement (3.8L) .... 6-1171
Throttle Body Heater
Inlet Hose Replacement (Engine Cooling) .... 6-614
Outlet Hose Replacement
(Engine Cooling) ............................. 6-615
Throttle Position Sensor
Replacement (3.8L) ....................... 6-1163
Throttle Position Sensor
Replacement (5. 7L) ....................... 6-1800
Thrust Angle Adjustment, Rear ............................ 3-9
Tire
Chain Usage Description ............................... 3-67
Description .. .. .. .. .. ... . ... . ... . ... ... .. .. . .. .. .. .. .. ... .. .. .. . 3-66
Mounting and Dismounting ............................. 3-64
Placard Description ........................................ 3-68
Replacement
Compact Spare .......................... , .. .. .. .. . . .. . . . 3-63
Rotation ,......... :.. ............................................ 3-65
Tire and Wheel Balancing ................................. 0-66
Tire Inflation Pressure Specifications ................. 0-34
Tire Placard ........................................................ 0-7
Tire Repair ........................................................ 3-63
TiteWear
Abnormal or Excessive . .. .. . .. .. .. .. .. .. .. .. . .. .. .. . .. .. .. 3-4
Tires and Wheels
Description ..................................................... 3-66
Chain Usage .............................................. 3-67
P-Metric Sized Tires ................................... 3-67
Tire Placard ................................................ 3-68
Wheels .. .. . .. .. ... .. .. .. .. .. .. ... .. .. .. . .. ... .. . . .. .. . . .. .. .. 3-68
Diagnosis
Wheel Mounting Surface Checl< . .. . .. .. ... ... . .. . 3-59
Specifications .. . .... . . .. . .. .. ... .. .. .. .. .. .. .. .. .. .. .. . .. .. . .. 3-58
Fastener Tightening .................................... 3-58
Wheel Installation ........................................... 3-62
Wheel Removal . .. .. .. . .. ... .. .. .. .. .. ... . .. .. .. .. ... .. .. . .. 3-61
Toe Adjustment, Front . .. .. .. . .. .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . 3-9
Torque Arm Replacement
Rear Suspension . .. .. . .. ... .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. . 3-47
Torque Wrenches
Proper Use . .. .. .. ... .. .. .. . .. .. ... .. .. .. .. .. .. ... . .. ... .. .. .. . 0-18
Tow Hook Replacement .................... 8-1074, 8-1076
Track Bar Replacement ......... ,........................... 3-54
Traction Control Switch Replacement .............. 5-260
Transmission Floor Shift Control Indicator '
Lamp Replacement ......................... 8-142
Transmission ID and Partial VIN Location ......... 0-10
Transmission (MM6)
Support and Mount Assembly (MM6} ............. 7-34
Transmission Support Replacement .....'.......... 8-1065
Transmission Usage .......................................... 0-11
Transmitter
Battery Replacement
Keyless Entry .. . ... .. .. .. . .. ... . . .. .. .. .. .. .. .. .. ... ... . 8-555
Trim Cleaning
Fabric .......................................................... 8-954

trim Cleaning
. Vinyl .. ... .. . .. .. .. ... . ... .. .. .. .. .. .. .. .. .. ... .. .. .. .. .. .. .. .. ..
Trim Panel Carper Replacement
Rear Center ...................................... 8-945,
Trim Panel Opening Cover Replacement .........
Trim Panel Replacement
Cargo Area Side .........................................
IP Accessory ..................................... 8-506,
Liftgate . .. .. .. .. .. .. .. ... .. . ... .. .. .. . .. .... . .. .. .. .. .. .. .. ... .
Shelf
Rear . . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . . .. .. ... . .. .. ... .. .
Trim Panel Replacement
Cargo Area Front .............................. 8-940,
Trim Replacement
Hinge Pillar ..................................................
Turn Signal
. Flasher Replacement .. .. .. .. .. .. ... . ... . ... . .. .. ... .. ..

8-953
8-946
&966
8-942
8-508
8-965

8-952
8-941
8-939
8-138

u
Underbody Inspection ........................'. ........... 8-1077
Upper Garnish Molding Replacement ............... 8-948
Upper Rear Trim Finish Panel Replacement ....... 8-949

v
Vacuum Brake Booster
Check Valve Replacement .. ... ... . .. .. ... .. . .. .... . . .. 5-60
Replacement . .. .. .. ... .. .. . .. .. ... . ... .. .. .. .. .. .. .. .. .. ... .. . 5-57
Vacuum Hose Harness Replacement
(A/C - Manual) ...... : .............. 1-113, 1-114
Vacuum Tank Replacement (A/C - Manual) ..... 1-112
Vapor Vent Pipe
Clean and Inspect (5.7L) , ............................. 6-514
Replacement (Engine Cooling) ..................... 6-602
Vapor Vent Pipe Replacement (5.7L) ............... 6-296
Vehicle Certification Label ................................... 0-6
Vehicle Identification ............................................ 0-5
Vehicle Speed Sensor
Manual Transmission - M49 ........................... 7-17
Vehicle Speed Sensor Replacement
Automatic Transmission - 4L60-E ................. 7-299
Manual Transmission (MM6) .......................... 7-43
Vent Actuator Replacement (A/C - Manual) ..... 1-106
Vibration Diagnosis
Balancing Tires and Wheels .......... ,................ Q-66
Classifying the Vibration . .. .. .. . .... .. . . .. .. .. . .. .. .... . . 0-49
Correcting Driveline Vibration RWD and 4WD ................................ 0-71
Correcting Non-Uniform Tires ........................ 0-70
Correcting Tire and Wheel Vibration . .. .. .. . .... .. . 0-62
Driveline Vibration Analysis .......... , ................. 0-53
Engine Related Vibration .... ,. . ... .. .. .. .. . .. ... . .. ... .. 0-58
General Description ..................................... 0-87
General Service Precautions ........ ,................. 0-62
Road Test .......................................... , ........... 0-47
Special Tools .......................... :...................... 0-98
Tire and Wheel Vibration ............................... 0-52
Vibration Diagnosis . .. .. .. ... .. .. . .. ... ... . . .. .. ... . .. .. . .. 0-45
Wheel Runout Measurement . ... .. .. .. .. .. .. .. . .. .... . 0-52
VIN Derivative ..................................................... 0-6
VIN, Partial, Location and Engine ID ................... 0-8

31

INDEX

w
Washer
Pump Replacement ...................................... 8-178
Solvent Container Replacement .. .. . ... .. . .. .. .. .. 8-176
Water Pump
Clean and Inspect ........................................ 6-514
Description . .. .. .. .. .. .. ... . .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. . . 6-663
Replacement (Engine Cooling) .......... 6-634, 6-636
Waterleaks
Body Waterleak Repair ................................ 8-662
Diagnosis
Air Hose Test ........................................... 8-660
Body Waterleak Repair ............................. 8-658
Dust Leaks ............................................... 8-661
Generalized Testing .................................. 8-659
Localized Testing (Spot Testing) ............... 8-659
Test Preparation .. ... .. .. . ... . ... . .. ... .. .. .. .. .. . ... . . 8-658
Water Hose Test : 8-660
Specifications
Recommended Materials ........................... 8-658
Stationary Window Waterleak Repair ............ 8-664
Weatherstrip Waterleak Repair ..................... 8-663
Weatherstrip Replacement
Door ............................................................ 8-820
Folding Top Side Rear ................................. 8-888
Front ............................................................ 8-890
Lift Off Panel . .. .. .. .. ... .. .. .. . .. ... .. . .. ... . .. . .. .. .. . .. .. 8-893
Rear Lift Window Panel Opening ................. 8-985
Weatherstrip Retainer Protector and Seal
Side ............................................................. 8-894
Weatherstrip Retainer Replacement
Folding Top .................................................. 8-887
Lift Off Panel .. ... . .. ... .. . .. .. .. .. ... . .. .. .. . ... .. .. . .. .. .. 8-894
Wheel
Installation
Tires and Wheels ....................................... 3-62
Removal
Tires and Wheels ....................................... 3-61
Wheel Alignment
Description
Camber . . .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. ... .. .. .. . .. .. ... .. . 3-10
Caster ........................................................ 3-10
Toe ............................................................ 3-11
Diagnosis
Preliminary Alignment Inspection .................. 3-7
Front Caster and Camber Adjustment .............. 3-8
Front Toe Adjustment ....................................... 3-9
Measuring ........................................................ 3-8
Rear Thrust Angle Adjustment .......................... 3-9
Specifications . .. ... . .. ... .. .. .. .. . ... .. .. .. .. .. .. ... .. . .. . ... ... 3-7
Fastener Tightening ...................................... 3-7
Wheel Bearing/Hub Replacement - Front ........... 3-21
Wheel Hub Bolt Replacement ............................ 3-15
Wheelhouse
Panel Replacement . ... .. .. . ... .. . .. .. .. . .. .. .. .. .. .. .. .. 8-769
Wheelhouse Replacement
Front . .. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... .. 8-1083, 8-1086
Rear .. .. .. .. .. .. .. .. .. . .. . .. .. .. .. .. .. .. .. . ... ... .. .. .. . .. ... . 8-1110
Wheels
Description . .. .. .. .. . ... . ... .. . ... .. .. .. . .. .... . .. .. .. .. .. .. .. .. 3-68
Wind noise
Exterior ... . .. .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. ... .. . ... .. . .. .. .. 8-666
Interior ......................................................... 8-666

Window Regulator Motor Replacement

Door ............................................................
Window Regulator Replacement ......................
Window Replacement
Door ............................................................
Windows
Diagnosis
Power Windows Inoperative ......................
All .........................................................
Express Function ...................................
From LF Switch ....................................
From RF Switch ....................................
Left Front ..............................................
RF from LF Switch ................................
Right Front ............................................
Power Window Switch
Replacement ........................ 8-798,
Windshield
Reveal Molding Replacement .......................
Side Garnish Molding
Replacement . .. . ... . .. ... . ... . .. ... . 8-692,
Windshield Glass Cleaning ..............................
Windshield Pillar Garnish Molding
Replacement ..................................
Windshield Replacement .................................
Wiper .. . .. ... .. .. .. .. .. .. . ... .. .. .. .. .. .. ... . .. . ... . .. .. . .. .. . ... ..
Arm Replacement ... . .. .. .. .. ... . ... . . .. . . .. .. .. . .. . .... .
Blade Element Replacement ........................
Chatter Repair .............................................
Motor Cover Replacement ............................
Motor Replacement ......................................
Transmission Replacement ...........................
Wiper Blade Element Cleaning . .. ... ... ... .. . .... .. ...
Wipers/Washer Systems
Component Locations . . .. .. .. ... .. .. . ... ... . .. .. .. .. .. ..
Component Views .. .. .. . .. . .. .. .. .. ... .. .. ... .. .. . ... . .. .
Connector End Views . ... . .. ... .. .. .. . .. .. .. .. ... . ... .. .
Description
System Operation . .. ... . .. ... .. .. .. . ... ... ... .. .. .. .. .
Windshield Wipers/Washer System . .. .. . .. .. .
Diagnosis
System Check .. ... . .. ... .. . ... .. . .. .. .. ... .. .. . ... . .. ..
Washer Always On . ... .. .. .. . ... . .. .. ... .. .. .. .. .. .. .
Washer Pump Inoperative .........................
Wiper Always On ......................................
Wiper Arm Tip Pressure Check, Blade
Element Check . .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .
Wiper Blades Do Not Park with
Switch Off . . .. .. ... .. . .. .. .. .. .. . ... .. .. .. .. . ... .
Wipers Delay Mode Inoperative ................
Wipers High Mode Inoperative,
Low Mode Operates .. .. ... .. . .. .. .. ... . ...
Wipers Inoperative ....................................
All Modes .. .. . .. .. .. .. ... . .. .. .. .. ... . . ... .. ... . .. .. . ..
Wipers Mist, Delay, and Low Modes
Inoperative ......................................
Schematic
Icons ........................................................
References . .. .. . ... . .. .. ... .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .
Schematics Pulse .. .. . .. ... .. .. .. . .. .. .. .. ... .. . .. .. .. .. .
Special Tools ...............................................
Specifications
Fastener Tightening ..................................

8-816
8-815
8-817
8-786
8-786
8-786
8-789
8-789
8-787
8-788
8-788
8-799
8-691
8-693
8-193
8-947
8-697
8-180
8-179
8-181
8-193
8-182
8-183
8-188
8-193
8-163
8-164
8-166
8-194
8-193
8-167
8-174
8-173
8-171
8-175
8-172
8-168
8-169
8-167
8-167
8-170
8-161
8-161
8-162
8-194
8-161

INDEX

32
Wiring System
Electrical Center Identification ......................
Wiring Systems
Description
Data Link Connector Circuit ......................
Harness Routing Views .............................
lnline Harness Connector End Views ........
Diagnosis .....................................................
Checking Aftermarket Accessories ............
Circuit Protection ......................................
Circuit Breakers .....................................
Fuses ....................................................
Fusible Links .........................................
Connector Position Assurance Locks ........
Connector Repairs ....................................
Data Link Connector (DLC) System
Check . ... .. .. .. .. .. . .. .. ... .. . ... . .. ... . .. .. .. .. ..
Electrical Symbols ....................................
Flat Wire Repairs .....................................
General Electrical Diagnosis Procedures .....
H02S Wiring Repairs ...............................
How to Use Circuit Descriptions ...............
How to Use Component Location
Tables ............................................
How to Use Component Location Views ......
How to Use Connector End Views ............
How to Use Diagnostic System Checks ....
How to Use Electrical Diagnosis . .. .. .. .. .. .. ..
How to Use Electrical Schematics .. ... . ... .. .
How to Use Schematic Icon Tables ..........
How to Use Schematic Reference
Tables ............................................
lntermittents and Poor Connections ..........
Passenger Car Zoning ..............................
Probing Electrical Connectors ...................
Pull to Seat Connectors ............................
Push to Seat Connectors ..........................
Repairing Connector Terminals .................
Repairing Damaged Wire Insulation ..........
Scan Tool Does Not Communicate with
Class 2 Data Line ..........................

8-369
8-382
8-401
8-383
8-289
8-298
8-302
8-302
8-301
8-302
8-310
8-310
8-378
8-291
8-309
8-296
8-307
8-290
8-287
8-288
8-289
8-289
8-285
8-286
8-287
8-287
8-297
8-291
8-299
8-311
8-310
8-312
8-302
8-381

Wiring Systems (cont.)

Diagnosis (cont.)
Scan Tool Does Not Communicate with
UART Data Line ............................. 8-379
Scan Tool Inoperative ............................... 8-379
SIR Wiring Repairs ................................... 8-307
Splicing Copper Wire Using Splice Clips ..... 8-302
Splicing Copper Wire Using Splice
Sleeves .. ... .. .. .. .. . ... .. . ... .. .. . ... .. .. .. . ... . 8-304
Splicing lnline Harness Diodes .................. 8-306
Splicing Twisted or Shielded Cable .. .. .. .. ... 8-305
Symptom Diagnostic Example .. .. .. .. . ... .. .. .. . 8-296
Terminal Position Assurance Locks ........... 8-310
Testing for Continuity ................................ 8-300
Testing for Electrical lntermittents ............. 8-301
Testing for Short to Ground ...................... 8-300
Testing for Voltage ................................... 8-299
Testing for Voltage Drop ........................... 8-300
Troubleshooting with a Digital
Multimeter ....................................... 8-298
Troubleshooting with a Short Finder ......... 8-299
Troubleshooting with a Test Light ............. 8-298
Using Connector Test Adapters ................ 8-299
Using Fused Jumper Wires ....................... 8-299
Weather Pack Connectors ........................ 8-311
Where to Find Electrical Schematics ......... 8-282
Wiring Repairs .......................................... 8-301
Power and Grounding Component Views ..... 8-367
Power and Grounding Components .............. 8-344
Power and Grounding Connector
End Views ...................................... 8-375
Schematics
Data Link Connector (DLC) Schematics ...... 8-376
Fuse Block Details .................................... 8-318
Ground Distribution ................................... 8-330
Power and Grounding Schematic Icons .... 8-313
Power and Grounding Schematic
References ..................................... 8-313
Power Distribution ..................................... 8-314
Work Sheets, Diagnostic .. .. .. ... .. . ... .. . ... . .. ... . .. .. ... .. 0-5