TRUCKS

Covering Natural Gas Models

ST 375-92NGS
 CAUTION

To reduce the chance of personal injury and/or property damage, the

following instructions must be carefully observed:

Proper service and repair are important to the safety of the service
technician and the safe, reliable operation of all motor vehicles. If part
replacement is necessary, the part must be replaced with one of the
same part number or with an equivalent part. Oo not use a replacement
part of lesser quality.

The service procedures recommended and described in this service

manual are effective methods of performing service and repair. Some of
these procedures require the use of tools specifically designed for the
purpose.

Accordingly, anyone who intends to use a replacement part, service

procedure, or tool which is not recom m ended by the vehicle
manufacturer, must first determine that neither his safety nor the safe
operation of the vehicle will be jeopardized by the replacement part,
service procedure, or tool selected.

It is important to note that this manual contains various Cautions and

Notices that must be carefully observed in order to reduce the risk of
personal injury during service or repair, or the possibility that improper
service or repair may damage the vehicle or render it unsafe. It is also
important to understand that these ‘Cautions’ and ‘Notices’ are not
exhaustive, because it is impossible to warn of all the possible
hazardous consequences that might result from failure to follow these
instructions.
Special service tools that are shown in this service manual that have tool product numbers beginning with “J ’
“ BT” are available for worldwide distribution from:

Kent-Moore
SPX Corporation
29784 Little Mack
Roseville, Ml 48066-2298
1-800-345-2233
Mon.-Fri. 8:00 p.m. EST
Telex: 244040 KMTR VR
FAX: 313-578-7375

General Motors dealers can purchase TECH 1 scan tools and accessories through Kent-Moore at the above
address and phone number. Non-General Motors dealer repair facilities can purchase TECH 1 scan tools and
accessories from Kent-Moore at the above address or:

Sun Electric Corporation

One Sun Parkway
Crystal Lake, IL 60014
1-800-CALLSUN (225-5786)
6:45 a.m. - 7:00 p.m. CST
 1992
NATURAL GAS
POWERED TRUCK
SERVICE MANUAL
SUPPLEMENT
This service manual supplement contains service, fuel and emissions, and electrical diagrams and
diagnosis information specific to the Natural Gas Powered Chevrolet truck.
Service manual information not specific to the Natural Gas Powered Chevrolet truck is covered in the
1992 Service Manual for Models.
Fuel and emissions information not specific to the Natural Gas Powered Chevrolet truck is covered in
the 1992 Light Duty Truck Fuel and Emissions Manual.
Unit repair information not specific to the Natural Gas Powered Chevrolet truck is covered in the 1992
Light Duty Truck Unit Repair Manual.
Wiring diagrams and electrical diagnosis information not specific to the Natural Gas Powered
Chevrolet truck is covered in the 1992 Electrical Diagrams and Diagnosis Manual.
This manual should be kept in a handy place for ready reference. If properly used, it will meet the
needs of technicians and vehicle owners.
When reference is made in this manual to a brand name, number, or specific tool, an equivalent
product may be used in place of the recommended item.
All information, illustrations, and specifications contained in this manual are based on the latest
product information available at the time of publication approval. The right is reserved to make changes
at any time without notice.

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a
fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number
fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not
reused, and those requiring thread locking compound will be called out. The correct torque value must be used when
installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

CHEVRO LET MOTOR DIVISION

General M otors Corporation
ST-375-92 NGS W arren, Michigan
©1992 General Motors Corporation April 1992
Printed in U.S.A. All rights reserved

No part of this publication may be reproduced, stored in any retrieval system or transmit­
ted, in any form or by any means, including but not limited to electronic, mechanical, photo­
copying, recording or otherwide, without the prior written permission of the Chevrolet
Division of General Motors Corp. This includes all text, illustrations, tables and charts.
 TABLE OF CONTENTS
The table of contents on this page indicates the sections covered in this manual supplement. At the beginning of each
individual section is a table of contents which gives the page number on which each major subject begins.

PART I SERVICE MANUAL SUPPLEMENT

SECTION SUBJECT CONTENTS

GENERAL OA GENERAL INFORMATION OB MAINTENANCE AND
0
INFORMATION LUBRICATION
3 SUSPENSION 3D REAR SUSPENSION
6A ENGINE, DRIVEABILITY, AND 6D7 ENGINE WIRING
DIAGNOSIS 6F EXHAUST
6 ENGINE
6A4 5.7LV 8
6B1 ENGINE COOLING
7A1 4L60 AUTOMATIC
7 TRANSMISSION
TRANSMISSION

PART II FUEL AND EMISSIONS MANUAL SUPPLEMENT

SECTION SUBJECT
1 GENERAL INFORMATION
2 DRIVEABILITY SYMPTOMS
3 COMPUTER COMMAND CONTROL
4 FUEL CONTROL
5 EVAPORATIVE EMISSION CONTROL
6 IGNITION SYSTEM/EST
7 ELECTRONIC SPARK CONTROL
8 AIR MANAGEMENT
9 EXHAUST GAS RECIRCULATION
10 TRANSMISSION CONTROLS
11 POSITIVE CRANKCASE VENTILATION
12 THERMOSTATIC AIR CLEANER
13 SPECIAL TOOLS
14 ABBREVIATIONS

PART III ELECTRICAL DIAGRAMS AND DIAGNOSIS MANUAL SUPPLEMENT

 1992 SERVICE MANUAL COMMENT FORM

Use this form to advise us of any errors you might find in this manual. We also welcome suggestions for
improving the Chevrolet Service Manual.
Service Manual(s) that have the error________________________________________________________________
Page number(s) that have the error__________________________________________________________________
Figure numbers that have the error__________________________________________________________________
VIN (if available) or model and applicable options_______________ _____________________________________
Describe in detail, the error found or the suggestion(s). Attach additional pages if necessary.

From: Dealer Firm Name________________________________________ Dealer Code_

City/Town________________________________________________ State________

Name of Person Submitting This Comment Form__________________________

Signature________________________________________________ Date.

Mail To: Service Technology Group ‘ Additional comment

Service Information Production forms can be found at
(C30-5) the rear of this manual.
C. C. O. Building
30007 Van Dyke Ave.
Warren, Ml 48090
 SECTION 0

GENERAL INFORMATION
CONTENTS

SUBJECT PAGE
General Information........................................................................................................................................................ OA-1
Maintenance and Lubrication.......................................................................................................................................OB-1
Vibration Diagnosis........................................................................................................................................................ OC-1

SECTION OA

GENERAL INFORMATION
CONTENTS

SUBJECT PAGE
Handling Electrostatic Discharge (ESD) Sensitive Parts.................................................................................OA- 1
Vehicle Certification Label......................................................................................................................................OA- 2
Vehicle Identification Number................................................................................................................... ............OA- 2
Model Identification..................................................................................................................................................OA- 2
Engine Identification Number............................................................................................................................... OAr 2
Transmission Identification Number..................................................................................................................... OA- 4
General Vehicle Lifting and Jacking.................................................................................................................... OA- 4
Lock Cylinder Coding.............................................................................................................................................. OA- 5
Metric Fasteners....................................... ................................................................................................................ OA- 7
Fastener Strength Identification........................................................................................................................... OA- 7
Prevailing Torque Fasteners...................................................................................................................................OA- 7
Metric-English Conversion......................................................................................................................................0A-10
Decimal and Metric Equivalents........................................................................................................................... OA-11
Common Automotive Abbreviations..................................................................................................................... OA-12
Replacement Labels................................................................................................................................................ OA-13
Service Parts Identification Label......................................................................................................................... OA-13
RPO Code Listing (Regular Production Option)................................................................................................... OA-14

HANDLING ELECTROSTATIC
DISCHARGE NOTICE
(ESD) SENSITIVE PARTS
Many solid state electrical components can be dam­
aged by Electrostatic Discharge (ESD). Some will dis­
play a label, but many will not (figure 1).
A
NOTICE: In order to avoid possibly damaging
A
any components, observe the following:
CONTENTS SENSITVE
1. Body movement produces an electrostatic charge. TO
To discharge personal static electricity, touch a STATIC ELECTRICITY
ground point (metal) on the vehicle. This should be
done any time you: Figure 1—Electrostatic Discharge Symbol
 • Slide across the vehicle seat.
• Sit down or get up.
• Do any walking.
2. Do not touch exposed electric terminals on compo­
nents with your finger or any tools. Remember, the
connector that you are checking might be tied into
a circuit that could be damaged by electrostatic
discharge.
3. When using a screwdriver or similar tool to discon­
nect a connector, never let the tool come in con­
tact with or come between the exposed terminals.
4. Never jumper, ground, or use test equipment
probes on any components or connectors unless
specified in diagnosis. When using test equipment,
always connect the ground lead first.
5. Do not remove the solid state component from its
protective packaging until you are ready to install
the part.
6. Always touch the solid state components package
to a ground before opening. Solid state compo­
nents can also be damaged if:
• They are bumped or dropped.
• They are laid on any metal work benches or
components that operate electrically, such as a
TV, radio, or oscilloscope.
VEHICLE CERTIFICATION LABEL
The vehicle certification label indicates the GVWR
(Gross Vehicle Weight Rating), front and rear GAWR
(Gross Axle Weight Rating), and the payload rating for
the vehicle (figures 2 and 3).
n MFD BY G D E R A L MOTORS COfP F
GVWR GAWR FHT GAWR RR
I::::::;::;— T1 f?T?Trr:":T:::':l 3 LB/KG
S K O M C R S MANUAL FOP AOOITIONAL INFORMATION
F9710
Figure 2—Complete Vehicle Certification Label
INC VEH W*D BY GENERAL MOTORS CORP
DETROIT, MICHIGAN 48202
GVWR GAWR FRT GAWR
F9825
Figure 3— Incomplete Vehicle Certification Label
The gross vehicle weight (GVW) is the weight of the
originally equipped vehicle and all items added to it
after it has left the factory. This would include bodies,
winches, booms, etc., the driver and all occupants, and
the load the vehicle is carrying. The gross vehicle
weight (GVW) must not exceed the gross vehicle
weight rating (GVWR). Also, the front and rear gross
axle weights (GAW) must not exceed the front and rear
GAWR (Gross Axle Weight Rating).
The payload rating shown on the label is the maxi­
mum allowable cargo load (including the weight of the
driver and all occupants) that the vehicle can carry
based on all factory installed equipment on the vehicle.
The payload rating is reduced if any accessories or
other equipment are added to the vehicle after final
date of manufacture. The weight of these items should
be determined and deducted from the payload rating.
The vehicle may also have a GCWR (Gross Combi­
nation Weight Rating). The GCWR (Gross Combination
Weight Rating) is the total weight of the loaded tow
vehicle (including passengers) and a loaded trailer.
The tires on the vehicle must be the proper size and
properly inflated for the load which you are carrying. The
vehicle certification label shows the originally equipped
tire size and recommended inflation pressures. For more
information on tires, refer to SECTION 3E.
VEHICLE IDENTIFICATION
NUMBER
The vehicle identification number (VIN) is the seven­
teen digit legal identifier of the vehicle. It is located on
a plate which is attached to the left top of the instru­
ment panel and can be seen through the windshield
from the outside of the vehicle. To find the manufactur­
er, model and chassis type, engine type, GVW (Gross
Vehicle Weight) range, model year, plant code, and
sequential number, refer to figure 4.
MODEL IDENTIFICATION
Models and body styles are shown in figure 5.
ENGINE IDENTIFICATION
NUMBER
The vehicle identification number provides detailed
VIN code information by liter and by the engine code
letter located on the vehicle identification plate.
Stick-on labels attached to the engine, or laser etch­
ing or stampings on the engine block, indicate the
engine unit number or date code.
All engines are stamped with an engine identification
number. The stam ping contains eight positions
(figure 6).
 VEHICLE IDENTIFICATION NUMBER (VIN)
1 G D F P 3 7 K 8 N 3 1 3 2 1 6 6

V2637

Figure 4—Vehicle Identification Chart

A. PICKUP, EXTENDED CAB - FLEETSIDE/WIDESIDE

1. Engine I.D.
2. Engine I.D. (Optional Location)

V2638-CNG V7553-CNG

Figure 5— Model Identification Figure 6 — 5.7L Engine I.D. Location

 TR A N SM ISSIO N
ID E N TIF IC A TIO N NUM BER
Manual and automatic transmission model identifica­
tion is located on a label or tag applied to the transmis­
sion case. If the label or tag is missing or unreadable,
use the Service Parts Identification label to determine
w hich transm ission was installed in the ve hicle
(figure 7).
GENERAL V EH IC LE LIFTIN G
AND JA C K IN G
NOTICE: When jacking or lifting a vehicle, be
certain that the lift pads do not contact the cat­
alytic converter, brake lines, brake cables,
CNG fuel cylinders, or fuel lines. Such contact
may result in damage or unsatisfactory vehicle
performance.
CAUTION: When a vehicle is on a hoist, sup­
port the vehicle at the opposite end from
which components are being removed in
order to reduce the possibility of the vehicle
falling off the hoist and causing personal
injury.
When removing major components of the vehicle
while the vehicle is on a hoist, the vehicle frame should
be chained to the hoist pads at the same end as the
removed components in order to prevent tip-off and
personal injury.
VEHICLES WITH A MAXIMUM GVWR OF
11,000 LBS:
NOTICE: Do not attempt to use a hoist to lift
a vehicle equipped with a camper body. The
HYDRA-MATIC 4L60 TRANSMISSION
IDENTIFICATION INFORMATION
1. Transmission I.D. Location
Figure 7 — Hydra-Matic 4L60 Transmission I.D. Location
weight distribution of the body may make the
vehicle unstable during hoisting and cause
damage to the frame.
The only lift points for this vehicle is shown in figure 8,
and are described in the following paragraphs.
When lifting a C or K model vehicle with a hoist, the
front pads should be positioned under the frame rails,
just forward of the second crossmember. The rear
pads should be positioned under the rear spring front
brackets.
When lifting a C model vehicle front end with a floor
jack, position the jack pad under the lower control arm
and inboard from the ball joint. Also the C model vehi­
cle front end can be lifted by positioning the floor jack
pad under the center of the front crossmember.
When lifting a C model vehicle front end with a vehi­
cle jack, position the jack under the lower control arm
and inboard from the ball joint.
When lifting a C or K model vehicle rear end with a
floor jack, position the jack pad either between the
spring pad and the shock absorber hanger or under
the axle differential case.
When lifting a C or K model vehicle rear end with a
vehicle jack, position the jack pad between the spring
pad and the shock absorber hanger.
When lifting a K model vehicle front end with a floor
jack, position the jack pad either under the middle of
the front crossmember or under the lower control arm
at the lowest point of the control arm.
Any time a vehicle is lifted with a vehicle jack or a
floor jack, the wheels at the opposite end of the lifted
end should be chocked. Also, jack stands should be
used to provide support. When supporting the vehicle
with jack stands, the jack stands should be placed
under the frame, the front suspension crossmember or
the axle.
When removing major components of the vehicle
while the vehicle is on a hoist, the vehicle frame should
be chained to the hoist pads in order to prevent tip-off.
V1378
 A. Lower control arm; inboard of the lower ball joint.
B. Center of front suspension crossmember.
C. Frame at forward edge of crossmember.
D. Rear spring at front bracket.
E. Rear axle just inboard of the spring.
F. Rear axle at the center of the differential case.

F2916

Figure 8 — Chassis Lift Points — C Model (6,000 to 11,000 Lb. GVWR)

LOCK CYLINDER CODING

KEY IDENTIFICATION AND USAGE
The lock cylinder keyway is designed so that other
model keys will not enter a current model lock cylinder.
Two non-interchangeable keys are used. The square
headed key is used in the ignition lock cylinder. The
oval headed key is used in all other lock cylinders.
Key identification is obtained from the four-character
key code stamped on the knockout portion of the key
head and an identification letter stamped on the key
POSITION LEVELS
shank. After the code number has been recorded by
the owner, the plugs should be knocked out of the key F6625
head. From these numbers, the lock combination can
be determined by use of a code list. This list is avail­ Figure 9 — Key Code Diagram
able to owners of key cutting equipment from equip­
ment suppliers. If the key code numbers are not REPLACEMENT LOCK CYLINDERS
available from records or from the knockout plug, the Lock cylinders are available from service parts ware­
lock combination (tumbler numbers and position) can houses. The new cylinder has a locking bar staked in
be determined by laying the key on the diagram in place. Tumblers are also available and must be assem­
figure 16. bled into the cylinder.

CUTTING KEYS ASSEMBLING AND CODING LOCK CYLINDERS

1. Determine the code from the code list or the key
code diagram (figure 9).
2. Cut a blank key to the proper level for each of six
tumbler positions.
3. Check the key operation in the lock cylinder.
All Lock Cylinders Except Instrument Panel
Compartment
Tumblers for all locks are shaped exactly alike with
the exception of the notch position on one side. As the
key is inserted in the lock cylinder, tumblers are
lowered to the correct heights so that notches on each
tumbler are at the same level. When the notches on all
tumblers line up, the side bar is pushed into the
notches by two small springs. This allows the cylinder
to turn in its bore. Five types of tumblers are used to
make the various lock combinations. Each tumbler is
coded according to a number, 1 through 5, stamped on
its side.
❖ Assemble (Figures 10 and 11)
1. Determine the tumbler numbers and arrangement.
• With the numerical key code, use the code list
provided by a key cutting equipment supplier.
• Without the numerical key code or without a
code list, refer to figure 9.
A. Lay the key on the key code diagram. Be
sure the key is outlined by the diagram.
B. Start with position number one. Find and
record the lowest level (tumbler number) that
is visible. Repeat for each of the remaining
five positions.
2. Starting with position one (the open end or head of
the cylinder), insert tumblers in their proper slots in
the order called for by the code (figure 10).
3. Pull the side bar out so that the tumblers will drop
completely into place.
4. Insert one tumbler spring above each tumbler.
5. Insert the spring retainer so that the end prongs
slide into the slots at each end of the cylinder. Press
the retainer down (figure 11).
1. TUMBLER
2. BAR, SIDE
3. HEAD, LOCK CYLINDER
4. CYLINDER, LOCK
F9487
Figure 11— Installing Spring Retainer
6. Insert the key into the lock cylinder to check for
proper installation. If the tumblers are installed
properly, the side bar will drop down. If it doesn’t,
take the cylinder apart and reassemble it.
NOTICE: Use leather or wood at each vise Jaw
to prevent damage to the cylinder.
7. Remove the key, and secure the cylinder in a vise
with the spring retainer exposed.
8. Stake the spring retainer securely in place at each
end. Use a suitable staking tool, and stake the
cylinder metal over the retainer.
9. Lock cylinders should be lubricated with GM multi­
purpose lubricant PN 12345120 or with a light oil
(5W30).
Instrument Panel Compartment Lock Cylinder
A lock cylinder with span-in tumblers is used for the
instrument panel compartment lock (figures 12 and 13).
The lock cylinder has four or five tumbler positions. The
number 1 or 2 position (closest to the cylinder head) is a
brass retainer tumbler. The 2 through 5 positions or 3
1. TUMBLER
6. RETAINING TUMBLER
7. HEAD OF CYLINDER
8. TUMBLER SPRING
9. SNAP-IN LOCK CYLINDER
F9489
Figure 12— Installing Tumblers
10
A. AFTER INSTALLLATION, TAP TUMBLERS
FLUSH WITH THE CYLINDER
10. WOODEN BLOCK
F9490
Figure 13— Locking the Tumblers in Place
through 5 positions are standard tumbler positions de­
pending on cylinder type. Therefore, only the last 4 or 5
tumbler combinations are required. To assemble the
lock cylinder, determine the tumbler numbers and
arrangement as previously described and install the
tumblers.
METRIC FASTENERS
Current model GM vehicles are primarily dimen­
sioned in the metric system. Many fasteners are metric
and are very close in dimension to well-known custom­
ary fasteners in the inch system. It is most important
that replacement fasteners be of the correct nominal
diameter, thread pitch, and strength.
Original equipment metric fasteners (except "beauty"
bolts, such as exposed bumper bolts and cross recess
head screws) are identified by a number of markings
indicating the strength of the material in the fastener as
outlined later. Metric cross recess screws are identified
by a Posidriv or Type 1A. Either a Phillips head or Type
1A cross recess screwdriver can be used in Posidriv
recess screw heads, but Type 1A cross recess screw­
drivers will perform better.
NOTICE: Most metric fasteners have a blue
color coating. However, this should not be
used as positive identification, as some fas­
teners are not color coated.
General Motors Engineering Standards, along with
other North American Industries, has adopted a portion
of the standard metric fastener sizes defined by ISO
(International Standards Organization). This was done
to reduce the number of fastener sizes used and yet
retain the best strength qualities in each thread size.
For example, the customary 1/4-20 and 1/4-28 screws
are replaced by the metric M6.0X1 screw which has
nearly the same diameter and has 25.4 threads per
inch. The thread pitch is in between the customary
coarse and fine thread pitches.
CUSTOMARY
1/4 — 20
THREAD MAJOR NUMBER OF THREADS
DIAMETER IN INCHES PER INCH
~ i —
THREAD PITCH
Metric and customary thread notation differ slightly.
The difference is described in figure 14.
FASTENER STRENGTH
IDENTIFICATION
Most commonly used metric fastener strength prop­
erty classes are 9.8 and 10.9 with the class identification
embossed on the head of each bolt. Customary (inch
strength classes range from grade 2 to 8 with radial line
identification embossed on each bolt head. Markings
correspond to two lines less than the actual grade (i.e.
grade 7 bolt will exhibit 5 embossed radial lines on the
bolt head). Some metric nuts will be marked with single
digit strength identification numbers on the nut face. To
review the different strength markings available, refer to
figure 15.
When replacing metric fasteners, be careful to use
bolts and nuts of the same strength or stronger than
the original fasteners (the same number marking or
higher). Likewise, it is important to select replacement
fasteners of the correct size. Correct replacement bolts
metric fasteners available in the aftermarket parts
channels were designed to metric standards of coun­
tries other than the United States, and may be of a
lower strength, may not have the numbered head mark­
ing system, and may be of a different thread pitch. The
metric fasteners used on GM products are designed to
new, international standards that may not yet be manu­
factured by some non-domestic bolt and nut suppliers.
PREVAILING TORQUE
FASTENERS
A prevailing torque nut is designed to develop an inter­
ference between the nut and bolt threads. This is most
often accomplished by distortion of the top of an all-
metal nut by using a nylon patch on the threads in the
middle of the hex flat. A nylon insert may also be used
as a method of interference between nut and bolt
threads (figure 16).
METRIC
M6.0 X 1
THREAD MAJOR DIAMETER DISTANCE BETWEEN
IN MILLIMETERS THREADS IN MILLIMETERS
V1262
 RECOMMENDATIONS FOR REUSE:
1. Clean, unrusted, prevailing torque nuts and bolts
may be reused as follows:
A Clean dirt and other foreign material off the nut
or bolt.
B. Inspect the nut or bolt to ensure there are no
cracks, elongation, or other signs of abuse or
overtightening. (If there is any doubt, replace
with a new prevailing torque fastener of equal
or stronger strength.)
C. Assemble the parts, and hand start the nut or
bolt.
D. Observe that, before faste n e r seats, it
develops torque per the chart in figure 16. (If
there is any doubt, replace with a new
pre vailin g to rq u e fa s te n e r o f equal or
stronger strength).
E. Tighten the fastener to the torque specified in
the appropriate section of this manual.
1. Grade 2 (GM 260-M) 2. Bolts and nuts which are rusty or damaged should
2. Grade 5 (GM 280-M) be replaced with new parts of equal or stronger
3. Grade 7 (GM 290-M) strength.
4. Grade 8 (GM 300-M)
5. Manufacturer’s Identification METRIC-ENGLISH
6. Nut Strength Identification CONVERSION
7. Identification Marks (Posidriv Screw Head) For determining metric and english conversions, refer
to figure 17.
V1263

Figure 15 — Fastener Strength Markings DECIMAL AND METRIC

(Identification) EQUIVALENTS
For determining decimal and metric equivalents, refer
A prevailing torque bolt is designed to develop an to figure 18.
interference between bolt and nut threads, or the
threads of a tapped hole. This is accomplished by dis­
torting some of the threads or by using a nylon patch
or adhesive.
 GSD

S> cud

9 Pt
m

A
6 & 6.3 8 10 12 14 16 20
4 ,5 N-m 0.4 0.8 1.4 2.2 3.0 4.2 7.0
In. Lbs. 4.0 7.0 12 18 25 35 57
1, 2, 3, 6, N-m 0.4 0.6 1.2 1.6 2.4 3.4 5.6
7, 8, 9 In. Lbs. 4.0 5.0 10 14 20 28 46
B
.250 .312 .375 .437 .500 .562 .625 .750
4 ,5 N-m 0.4 0.6 1.4 1.8 2.4 3.2 4.2 6.2
In. Lbs. 4.0 5.0 12 15 20 27 35 51
1,2, 3, 6, N-m 0.4 0.6 1.0 1.4 1.8 2.6 3.4 5.2
...... 8 , 9 . . In. Lbs. 4.0 5.0 9.0 12 15 22 28 43
A. Metric Sizes 1. Top Lock Type 6. Nylon Strip Or Patch
B. Inch Sizes 2. Center Lock 7. Nylon Washer Insert
3. Dry Adhesive Coating 8. Nylon Patch
4. Out Of Round Thread 9. Nylon Insert
5. Deformed Thread Profile
B2406

Figure 16— Prevailing Torque Nuts and Bolts

 0A-10
CONVERSION TABLE

GENERAL INFO RM ATIO N

to get equivalent to get equivalent
Multiply by number of: Multiply by number of:
LENGTH ACCELERATION
Inch 25.4 millimeters (mm) Foot/sec2 0.304 8 meter/sec2(m/s2)
Foot 0.304 8 meters (m) lnch/secJ 0.025 4 meter/sec2
Yard 0.9144 meters TORQUE
Mile 1.609 kilometers (km)
Figure 17— Metric-English Conversion Table

Pound-inch 0.112 98 newton-meters (Nm)

AREA Pound-foot 1.355 8 newton-meters
Inch2 645.2 millimeters2(mm2) POWER
6.45 centimeters* (cm2)
Horsepower 0.746 kilowatts (kW)
Foot2 0.092 9 meters" (m2)
PRESSURE OR STRESS
Yard2 0.836 1 meters2
VOLUME Inches of water 0.249 1 kilopascals (kPa)
Pounds/sq. in. 6 895 kilopascals
Inch3 16.387 mm3
16.387 ENERGY OR WORK
cm3
0.016 4 liters (I) BTU 1 055 joules (J)
Quart 0.946 4 liters Foot-pound 1.355 8 joules
Gallon 3.785 4 liters Kilowatt-hour 3 600 000 joules (J * one W)
Yard3 0.764 6 meters3(m3) or 3.6 x 106
MASS LIGHT
Pound 0.453 6 kilograms (kg) Foot candle 1.076 4 lumens/meter2(lm/m2)
Ton 907.18 kilograms (kg) FUEL PERFORMANCE
Ton 0.907 tonne (t) Miles/gal 0.425 1 kilometers/liter (km/l)
FORCE Gal/mile 2.352 7 liter/kilometer (l/km)
Kilogram 9.807 newtons (N) VELOCITY
Ounce 0.278 0 newtons Miles/hour 1.609 3 kilometers/hr. (km/h)
Pound 4.448 newtons
TEMPERATURE
Degree
Fahrenheit (t°F-32) 4- 1.8 degree Celsius (C)

-t-
CO
■'J
 DECIMAL AND METRIC EQUIVALENTS
Fractions Decimal In. Metric mm Fractions Decimal In. Metric mm

1/64 0.015625 0.39688 33/64 0.515625 13.09687

1/32 0.03125 0.79375 17/32 0.53125 13.49375
3/64 0.046875 1.19062 35/64 0.546875 13.89062
1/16 0.0625 1.58750 9/16 0.5625 14.28750
5/64 0.078125 1.98437 37/64 0.578125 14.68437
3/32 0.09375 2.38125 19/32 0.59375 15.08125
7/64 0.109375 2.77812 39/64 0.609375 15.47812
Figure 18— Decimal and Metric Equivalents

1/8 0.125 3.1750 5/8 0.625 15.87500

9/64 0.140625 3.57187 41/64 0.640625 16.27187
5/32 0.15625 3.96875 21/32 0.65625 16.66875
11/64 0.171875 4.36562 43/64 0.671875 17.06562
3/16 - 0.1875 4.76250 11/16 0.6875 17.46250
13/64 0.203125 5.15937 45/64 0.703125 17.85937
7/32 0.21875 5.55625 23/32 0.71875 18.25625
15/64 0.234375 5.95312 47/64 0.734375 18.65312
1/4 0.250 6.3500 3/4 0.750 19.05000
17/64 0.265625 6.74687 49/64 0.765625 19.44687

GENERAL
9/32 0.28125 7.14375 25/32 0.78125 19.84375
19/64 0.296875 7.54062 51/64 0.796875 20.24062
5/16 0.3125 7.93750 13/16 0.8125 20.63750
21/64 0.328125 8.33437 53/64 0.828125 21.03437
11/32 0.34375 8.73125 27/32 0.84375 21.43125
23/64 0.359375 9.12812 55/64 0.859375 21.82812
3/8 0.375 9.52500 7/8 0.875 22.22500

INFORMATION
25/64 0.390625 9.92187 57/64 0.890625 22.62187
13/32 0.40625 10.31875 29/32 0.90625 23.01875
27/64 0.421875 10.71562 59/64 0.921875 23.41562
7/16 0.4375 11.11250 15/16 0.9375 23.81250
29/64 0.453125 11.50937 61/64 0.953125 24.20937
15/32 0.46875 11.90625 31/32 0.96875 24.60625
31/64 0.484375 12.30312 63/64 0.984375 25.00312
1/2 0.500 12.7000 1 1.00 25.40000

OA-11
 COMMON AUTOMOTIVE Gov—Governor
g—gram
ABBREVIATIONS Ham— Harness
AC— Alternating Current HO—Hydrocarbons
A/C— Air Conditioning HD— Heavy Duty
ACCEL— Accelerator HE!—High Energy Ignition
ADJ—Adjust Hg— Mercury
A/F— Air Fuel Ratio IAC— Idle Air Control
AIR—Air Injection Reaction System IC— Integrated Circuit
ALDL—Assembly Line Diagnostic Link ID— Identification or Inside Diameter
Alt— Altitude IGN— Ignition
AMP—Ampere (s) ILC— Idle Load Compensator
ANT—Antenna INJ— Injection
APS—Absolute Pressure Sensor IP— Instrument Panel
ASM— Assembly IPC— Instrument Panel Cluster
AT— Automatic Transmission INT— Intake
ATDC— After Top Dead Center km— Kilometer
Auto—Automatic km/h—Kilometer Per Hour
BARO— Barometric kPa— KiloPascals
Bat— Battery kV— Kilovolts (thousands of volts)
Bat +— Battery Positive Terminal L— Liter
BP— Back Pressure L4— Four Cylinder In-Line engine
BTDC— Before Top Dead Center MAF—Mass Air Flow
°C— Degrees Celsius MAN—Manual
Calif—California MAP— Manifold Absolute Pressure
Cat. Conv.— Catalytic Converter MAT—Manifold Air Temperature
CCC— Computer Command Control Max— Maximum
CCOT— Cycling Clutch Orifice Tube M/C— Mixture Control
CID—Cubic Inch Displacement Min— Minimum
CL—Closed Loop mL—Milliliter
CO— Carbon Monoxide mm—Millimeter
Coax—Coaxial MPG—Miles Per Gallon
Conn— Connector MPH—Miles Per Hour
Conv— Converter mV—Millivolt
CP—Canister Purge NC— Normally Closed
CPS— Central Power Supply N.m—Newton Meters
Crank—Crankshaft NO—Normally Open
CTS— Coolant Temperature Sensor NOx—Nitrogen, Oxides of
CV— Constant Velocity OD— Outside Diameter
Cyl— Cylinder(s) OL—Open Loop
C3I— Computer Controlled Ignition 0/2—Oxygen
DBM— Dual Bed Monolith PAIR— Pulse Air Injection Reaction System
DC— Direct Current P/B— Power Brakes
Diff— Differential PCV— Positive Crankcase Ventilation
DIS— Direct Ignition System PRESS— Pressure
Dist— Distributor PROM—Programmable Read Only Memory
DVM— Digital Voltmeter (10 meg.) P/S— Power Steering
EAC— Electric Air Control psi—Pounds Per Square Inch
EAS— Electric Air Switching Pt—Pint
ECM— Electronic Control Module PTO— Power Takeoff
ECU— Engine Calibration Unit (PROM) Qt—Quart
EECS— Evaporative Emission Control System REF— Reference
EFE— Early Fuel Evaporation RFI— Radio Frequency Interference
EFI— Electronic Fuel Injection RPM—Revolutions Per Minute
EGR— Exhaust Gas Recirculation RPO— Regular Production Option
EGR/TVS— Exhaust Gas Recirculation/Thermostatic RTV— Room Temperature Vulcanizing
ESC— Electronic Spark Control RVB— Rear Vacuum Break
EST— Electronic Spark Timing RVR— Response Vacuum Reducer
ETR— Electronically Tuned Receiver SAE—Society of Automotive Engineers
EVRV— Electronic Vacuum Regulator Valve(EGR) Sec—Secondary
EXH— Exhaust SES—Service Engine Soon
T — Degrees Fahrenheit SI—System International
FED— Federal (All States Except Calif.) Sol—Solenoid
GAL— Gallon SPEC— Specification
Gen— Generator
Speedo-Speedometer REPLACEMENT LABELS
Tach—Tachometer
TBI—Throttle Body Injection Replacement labels are available through GM Ser­
TCC— Transmission Converter Clutch vice Parts Operations (SPO) for the following:
TDC— Top Dead Center • Vehicle Emission Control Information (Exhaust
Term—Terminal Emission Tune-Up)
THERMAC— Thermostatic Air Cleaner • Spare Wheel Caution
TEMP—Temperature • Jacking
TPS—Throttle Position Sensor • Spare Tire Storage
TRANS— Transmission • Serpentine Belt Routing
TV—Throttle Valve • Engine Fan Caution
TVRS— Television & Radio Suppression These and other labels will be found in the Standard
TVS—Thermal Vacuum Switch Parts Catalog.
U-Joint— Universal Joint The Vehicle Certification Label, Tire Pressure Plac­
V—Volt(s) ard, and Service Parts identification Label are NOT
VAC—Vacuum available as service parts.
VDOT—Variable Displacement Orifice Tube
VIN— Vehicle Identification Number SERVICE PARTS
VIR— Valve In Receiver IDENTIFICATION LABEL
VRV— Vacuum Reducer Valve
The Service Parts Identification Label has been devel­
VSS— Vehicle Speed Sensor
oped and placed on the vehicle to aid service and parts
w/—With
personnel in identifying parts and options originally in­
W/B—Wheel Base
stalled on the vehicle (figure 19).
w/o—Without
WOT—Wide Open Throttle

irtn wa ran K?g gga E23 CZS

ww w n
EZ3 E33 E23 ESI CHI E 3
r o i m g C S S ( S 3 CES9 U B S E B 3 B S 8 C P E l P 3
essa tsa (sa Eza o b era is d cza e3 ess ebd cm e a 1. Vehicle Identification Num ber (VIN)
C3S3 CS.3 G 30 CS53 1209
2. Wheel Base
3. Model Designation
4. RPO and/or SEO O ptions
5. Order Number
6. Exterior Color
7. Paint Technology
LV-

c - '• ''y •->- «■■' l WCil •!.v.-w ■

F2911

Figure 19— Service Parts Identification Label

 RPO CODE LISTING (REGULAR PRODUCTION OPTION)
AE7 Seating: 40/60 Split Front Bench FF5 Torsion Bar Spr ng Adjust Arm, Right
AG9 Seat Adjuster: Power, 6 Way FF6 Torsion Bar Spr ng Adjust Arm, Left
AJ1 Window: Deep Tint, All Except Windshield and FF7 Torsion Bar Spr ng Adjust Arm, Right
Door Glass FF8 Torsion Bar Spr ng Adjust Arm, Left
AK9 Restraint System: Rear Seat Shoulder FF9 Torsion Bar Spr ng Adjust Arm, Right
AM7 Seat: Rear Folding Bench FK2 Torsion Bar Spr ng Adjust Arm, Left
AS3 Rear Seat: Suburban FK3 Torsion Bar Spr ng Adjust Arm, Right
AT5 Rear Seat: Center, Folding F44 Chassis Equipment, Heavy Duty
AU3 Lock: Side Door, Electric F51 Shock Absorbers: Front & Rear, Heavy Duty
AU6 Lock: Tailgate, Elect. Release F60 Springs, Front: Heavy Duty
A20 Window: Rear Quarter Vent, Swing Out F61 Rear Stabilizer Shaft
A28 Window: Rear Full Width, Sliding GK9 Axle: Rear, 4.63 Ratio
A31 Window: Side, Power GQ1 Axle: Rear, Standard Ratio
A50 Seat: Front Bucket GTY Rear Axle, Wide Track
A52 Seat: Front Folding Bench GT4 Axle: Rear, 3.73 Ratio
A82 Head Restraint System GT5 Axle: Rear, 4.10 Ratio
A95 Front Bucket Seats, High Back and Reclining GU4 Axle: Rear, 3.08 Ratio
BG9 Covering: Floor, Rubber GU6 Axle: Rear, 3.42 Ratio
B3J Diesel Equipment G80 Axle, Rear: Limited Slip Differential
B32 Floor Mats: Front Removable, Color Keyed HC4 Axle: Rear, 4.56 Ratio
B33 Floor Mats: Rear Removable, Color Keyed HC7 Axle: Rear, 5.13 Ratio
B37 Covering: Floor Mats, Frt. & Rear, Aug JAN Plant Code: Janesville, Wl.
B71 Moldings: Wheel Opening, Colored JB5 Power Brake, Disc/Drum, 6400 Lbs.
B74 Moldings: Wheel Opening, Black JB6 Power Brakes, Disc/Drum, 7200 Lbs.
B84 Moldings: Black Body Side JB7 Power Brakes, Disc/Drum, 8400 Lbs.
B85 Moldings: Bright Body Side JB8 Power Brakes, Disc/Drum, 10,000 Lbs.
B96 Moldings: Chrome Wheel Opening JD5 Dual Power Brakes, Disc/Drum, 6400 Lbs.
C25 Wiper System: Rear Window JD6 Hydraulic Power Brakes, Disc/Drum, 7200 Lbs.
C36 Heater: Auxiliary JD7 Hydraulic Power Brakes, Disc/Drum, 8400 Lbs.
C49 Defogger: Rear Window, Electric JF9 Hydraulic Power Brakes, 4 Wheel Discs
C5B 15,000 Lbs. GVW KC4 Engine Oil Cooling System
C5G 5600 Lbs. GVW KL5 Natural Gas Power
C5M 6100 Lbs. GVW K05 Engine Block Heater
C5P 6250 Lbs. GVW K19 Air Injection Reactor System
C5S 6600 Lbs. GVW K34 Cruise Control: Electric
C5U 6800 Lbs. GVW K60 Generator: 100 Ampere
C5Z 7200 Lbs. GVW K68 Generator: 105 Ampere
C6P 8600 Lbs. GVW K99 Generator: 85 Ampere
C6U 9000 Lbs. GVW LB4 Engine: 4.3 Liter V6 EFI
C6W 8600 Lbs. GVW LH6 Engine: 6.2 Liter V8, Light Duty
C6Y 9600 Lbs. GVW LL4 Engine: 6.2 Liter V8, Heavy Duty
C60 Air Conditioning: Front, Manual L03 Engine: 5.0 Liter V8 EFI
C69 Air Conditioning: Rear, Roof Mounted L05 Engine: 5.7 Liter V8 EFI
C7A 10,000 Lbs. GVW L19 Engine: 7.4 Liter V8 EFI
C7E 11,000 Lbs. GVW L65 Engine: 6.5 Liter V8 Diesel Turbo
C7L 12,000 Lbs. GVW MD8 Transmission: Hydra-Matic 4L60, 4-Speed
C95 Roof Lamp: Courtesy, Dual Reading Automatic
DF2 Mirrors Exterior: Camper Type, Stainless Steel MG5 Transmission: New Venture Gear 5LM60,
DG5 Mirrors Exterior: West Coast Type, Stainless 5-Speed Manual
Steel MM5 Transmission: Manual, 5-Speed w/Overdrive
DK6 Console: Instrument, Roof MT1 Transmission: Hydra-Matic 4L80-E, 4-Speed
DR1 Mirrors, Exterior: LH & RH Man. Cont., Painted Automatic
D44 Mirrors, Exterior: Below-Eye-Line Type, Black MT8 Transmission: New Venture Gear 4500,
D45 Mirrors, Exterior: Below Eyeline, Bright 5-Speed Manual
D48 Mirrors, Exterior: Electric, Painted MXO Transmission: Automatic w/Overdrive
D55 Console: Frt. Compt., Floor NA1 Emission System (Less than 8500 Lbs.)
D85 Decal: Solid Color Stripe NA4 Emission System (Above 8500 Lbs.)
E55 Endgate: Suburban NA5 Emission System: Federal
E62 Pickup Box: Sportside/Stepside NA6 Emission System: High Altitude
E63 Pickup Box: Fleetside NB2 Emission System: California
FF4 Torsion Bar Spring Adjust Arm, Left ND3 Vehicle Label: Emission Control
NK3 Steering Wheel: Sport Z62 CS SLX Equipment
NK7 Fuel Tank, 117 L, 31 Gal. Z71 Off-Road Chassis Package
NM8 Emission System: Leaded Fuel Z81 Chassis: Basic Camper Equipment
NN5 Emission Override, California System Z82 Trailering Equipment: Heavy Duty
NY1 Shield: Fuel Tank Steel 12A Stripe Color: Accent, Silver Metallic
NZZ Skid Plate: Off Road 12U Primary Color: Exterior, Yellow White
N33 Steering Column: Tilt 13C Trim Combination: Cloth, Light Gray
N90 Wheels: Aluminum, Cast 13D Trim Combination: Cloth, Light Gray
PF4 Wheel: 16 x 7, Aluminum, Forged 131 Interior Trim: Light Smoke Gray
P01 Wheel Trim: Wheel Covers 13V Trim Combination: Vinyl, Light Gray
P06 Wheel Trim: Trim Rings 13W Trim Combination: Vinyl, Light Gray
P13 Carrier, Spare Wheel, Side Mounted 19U Primary Color: Exterior, Lamp Black
P18 Carrier, Spare Tire with Hoist 21A Stripe Color Accent: Two-Tone, Light Blue/Slate
Q4B 6200 Lbs. GVW. 22L Secondary Color: Exterior, Bahama Blue
R04 Wheels, Rear: Single Metallic
R05 Wheels, Rear: Dual 22U Primary Color: Exterior, Bahama Blue Metallic
TP2 Battery: Auxiliary, Camper 23A Stripe Color Accent: Light Blue
TR9 Lighting, Auxiliary 23U Primary Color: Exterior, Ocean Blue
T61 Daytime Running Lights 24C Trim Combination: Cloth, Dark Blue
UD4 Speed Alarm: 120 km/hr. 24D Trim Combination: Cloth, Dark Blue
UF2 Lamp: Cargo Area 241 Interior Trim, Dark Blue
UM6 Radio Equipment: ETR AM/FM Stereo Cas- 24U Primary Color: Exterior, Medium Blue Metallic
sette, Clock w/Seek & Scan 24V Trim Combination: Vinyl, Dark Blue
UM7 Radio Equipment: ETR AM/FM Stereo, Clock 24W Trim Combination: Vinyl, Dark Blue
w/Seek & Scan 27A Stripe Color Accent: Two-Tone, Light Blue/Dark
UP4 Radio Equipment: AM ETR Blue
UWO Speaker System: Dual Frt. I/P Mounted, Dual 27L Secondary Color: Exterior, Lt. French Blue
Roof Mounted Metallic
UX1 Radio Equipment: ETR AM/FM Stereo, Seek & 27U Primary Color: Exterior, Lt. French Blue
Scan, Cassette w/ Search and Repeat, Graphic Metallic
Equalizer, Digital Clock 29U Primary Color: Exterior, Dark Blue
UY1 Camper Wiring Harness 30L Secondary Color: Exterior, Gray Blue Metallic
UY7 Harness, Wiring: Trailer Heavy Duty (7 Wire) 30U Primary Color: Exterior, Gray Blue Metallic
U01 Lamps, Roof Marker 32A
U16 Tachometer, Engine 32A Stripe Color Accent: Light Teal Metallic
U18 Speedometer (Kilo.). 33A Stripe Accent: Two-Tone, Vermillion/Garnet
U66 Radio Equipment: Four Speakers (avail. w/UM6 36L Secondary Color: Exterior, Medium Dark Teal
& UM7) Metallic
U88 Radio Equipment: Six Speakers (Dual l/P 36U Primary Color: Exterior, Medium Dark Teal
Mounted, Dual Rear Side Door, Dual Roof Metallic
Mounted) 39A Stripe Color Accent: Two-Tone, Light Teal
VB3 Bumper: Chromed Rear Step Metallic/Silver
VG3 Bumper: Deluxe Front Bumper 41L Secondary Color: Exterior, Black
VK3 Bracket, License Plate: Front 41U Primary Color: Exterior, Black
VLA Work Truck Trim Package 46U Primary Color: Exterior, Dark Green
VR4 Trailering Equipment: Weight Distributing Plat- 47A Stripe Color Accent: Two-Tone, Vermillion/Beige
form Hitch Metallic
VT5 Bumper: Rear Step with Rub Strip and Step 47C Trim Combination: Cloth, Dark Red
Pad 47D Trim Combination: Cloth, Dark Red
V01 Cooling System: Radiator, Heavy Duty 47I Interior Trim: Dark Red
V02 Cooling System: Transmission Oil Cooler, 47V Trim Combination: Vinyl, Dark Red
Heavy Duty 47W Trim Combination: Vinyl, Dark Red
V10 Cold Climate Package 50L Secondary Color: Exterior, Blue White
V22 Appearance: Deluxe Front 50U Primary Color: Exterior, Blue White
V27 Bumper Guards, Front 57L Secondary Color: Exterior, Beige Metallic
V43 Bumper: Painted Rear Step 57U Primary Color: Exterior, Beige Metallic
V54 Luggage Carrier: Roof, Painted 6Y4 Wheel and Tire: Spare, Delete
V76 Towing Device: Front 60C Trim Combination: Cloth, Dark Cognac
YE9 CL/SLE Equipment 601 Interior Trim, Dark Cognac
ZY1 Color Combination: Solid 60V Trim Combination: Vinyl, Dark Cognac
ZY2 Color Combination: Two-Tone 60W Trim Combination: Vinyl, Dark Cognac
ZY3 Color Combination: Special Two-Tone 61A Stripe Color Accent: Beige Metallic
ZY4 Color Combination: Deluxe Two-Tone 61U Primary Color: Exterior, Tan
Z49 Daytime Running Lights 64C Trim Combination: Cloth, Light Beige
64D Trim Combination: Cloth, Light Beige 79A Stripe Color Accent: Two-Tone, Vermillion/Silver
64I Interior Trim, Light Beige Metallic
64V Trim Combination: Vinyl, Light Beige 82C Trim Combination: Cloth, Dark Medium Gray
64W Trim Combination: Vinyl, Light Beige 82I Interior Trim: Dark Medium Gray
68A Stripe Color Accent: Cinnamon 82V Trim Combination: Vinyl, Dark Medium Gray
71U Primary Color: Exterior, Red Orange 82W Trim Combination: Vinyl, Dark Medium Gray
72U Primary Color: Exterior, Standard Red 88A Stripe Color Accent: Two-Tone, Gold/Black
74L Secondary Color: Exterior, Victory Red 90U Primary Color: Exterior, Gray Metallic
74U Primary Color: Exterior, Victory Red 91L Secondary Color: Exterior, Dark Argent
94L Secondary Color: Exterior, Blue Red Metallic
76L Secondary Color: Exterior, Dark Garnet Red
94U Primary Color: Exterior, Blue Red Metallic
Metallic
96L Secondary Color: Exterior, Ultra Silver Metallic
76U Primary Color: Exterior, Dark Garnet Red 96U Primary Color: Exterior, Ultra Silver Metallic
Metallic 97L Secondary Color: Exterior, Dark Gray Metallic
77A Stripe Color Accent: Victory Red 97U Primary Color: Exterior, Dark Gray Metallic
 SECTION OB

MAINTENANCE AND LUBRICATION

CONTENTS

SUBJECT PAGE
Scheduled Maintenance Services ................................................................................. ........................... ..............OB- 1
Normal Vehicle Use ........................................................................................................ ........................................OB- 1
Maintenance Schedule 1 ....................................................................................................................................... OB- 1
Maintenance Schedule 2 ................................................................................................. .....................................OB- 1
Explanation of Scheduled Maintenance Services ...........................................................................................OB- 1
Engine Oil and Filter Change ......................................................... .................................................................... OB- 1
Chassis Lubrication ....................................................................... ...................... .................................................. OB- 2
EGR System Service .............................................................................................................................................. OB- 2
Approximate Fluid Capacities ...............................................................................................................................OB- 6
Maintenance Items ...................................................................................................... ...........................................OB- 6

SCHEDULED MAINTENANCE SERVICES

NORMAL VEHICLE USE
The maintenance instructions contained in the Main­
tenance Schedule are based on the assumption that
the vehicle will be used as designed:
• To carry passengers and cargo within the limi­
tation indicated on the vehicle certification label
located on the edge of the driver's door.
• On reasonable road surfaces within legal oper­
ating limits.
• On unleaded gasoline.
MAINTENANCE SCHEDULE 1
Follow Maintenance Schedule 1 if the vehicle is oper­
ated under one or more of the following conditions:
• When most trips are less than 4 miles (6 km).
• Operating when outside temperatures remain
below freezing and when most trips are less
than 10 miles (16 km).
• When most trips include extended idling and/or
frequent low-speed operation as in stop-and-go
traffic.
• Towing a trailer.
• Operating in dusty areas.
Maintenance Schedule 1 should also be followed if
the vehicle is used in delivery service or other commer­
cial applications.
MAINTENANCE SCHEDULE 2
Follow Maintenance Schedule 2 only if none of the
driving conditions specified in Maintenance Schedule 1
apply.
EXPLANATION OF SCHEDULED
MAINTENANCE SERVICES
Refer to “ Scheduled Maintenance Services” charts
for the schedules of time and/or mileage intervals.
ENGINE OIL AND FILTER CHANGE
ALWAYS USE “ SG” QUALITY ENERGY CONSERV­
ING II OILS OF PROPER VISCOSITY.
The “ SG" designation may be shown alone or in
combination with other designations such as SG/CC,
SG/CD, SF, SG, CC, etc.
Oil Filter
NOTICE: To prevent leakage of all oil filters
such as PF-35, PF-51, etc., it is very important
that the installation instructions listed below
are closely followed.
Remove the old filter by turning counterclockwise.
Clean the gasket sealing area on the engine oil filter
mounting surface. (If the engine has an adapter base,
make sure threaded njpple or bolt is properly torqued.).
Lightly oil gasket with clean oil, and install filter. After
the oil filter gasket contacts the oil filter mounting sur­
face, tighten 3/4 to 1 full turn. When necessary, use a
cap-type wrench, strap-type wrench with handle, or
equivalent to ensure proper installation.
With engine oil at proper level, run engine three min­
utes and thoroughly check filter area for leaks.
Engine Oil Viscosity
Engine oil viscosity (thickness) has an effect on fuel
economy and cold-weather operation (starting and oil
flow). Lower viscosity engine oils can provide better
fuel economy and cold weather performance; however,
higher temperature weather conditions require higher
viscosity engine oils for satisfactory lubrication.
NOTICE: Using oils of any viscosity other than
those viscosities recommended could result
in engine damage.
 CHASSIS LU B R IC A TIO N
Lubricate transmission shift linkage, parking brake ca­
HOT WEATHER
S ' r -1 "S ble guides, underbody contact points, and linkage
F UC (figures 2, 3 and 4).
f 100- - +30

NOTICE: Do not lubricate the parking brake

+ 60 - ■+16 cables. Lubrication destroys the plastic coat­
+ 40 ■. +4 ing on the cables.
+ 32 ■■ 0 SAE 30

0 ■■ -10 Wipe off all dirt from the grease fitting before lubri­
SAE 10W-30 cating the joint. Ball joints should not be lubricated
-20 ■■ -29 PREFERRED
unless their temperature is -12°C (10°F) or higher. Dur­
SAE 5W-30 ing cold weather, the ball joint should be allowed to
u warm-up as necessary before being lubricated. Use a
COLD WEATHER low-pressure grease gun on all joints to prevent seal
V1903
damage.
Figure 1— Engine Oil Viscosity Recommendation
(5.7L Engines) EGR SYSTEM SERVICE
When choosing an oil, consider the range of tempera­ Perform “ EGR System Check.” Refer to the 1992
tures the vehicle will be operated in before the next oil Light Duty Fuel and Emissions Manual if you are using
change. Then select the recommended oil viscosity X-9231 and to the Fuel and Emissions section at rear
(figure 1). of this manual if you are using ST-375-92.

9 8 7

1. Steering Linkage 7. Clutch Actuator

2. Wheel Bearings 8. Master Cylinder
3. Air Cleaner 9. Oil Filter
4. Transmission 10. Steering Gear
5. Propeller Shaft-Slip Joint 11. Engine
6. Rear Axle-Differential

F3533

Figure 2 — Lubrication Points (Two-Wheel Drive Models)

 F6209

Figure 3 — Lubrication Fittings (Driver Side)

F6210

Figure 4 — Lubrication Fittings (Passenger Side)

 OB-4 MAINTENANCE
Scheduled Maintenance Services
GASOLINE ENGINES WITH LIGHT DUTY EMISSION— MAINTENANCE SCHEDULE If

If your driving conditions meet those specified on page OB-1, use If your driving conditions do NOT meet those specified on page OB-1, use
Maintenance Schedule I (+). Maintenance Schedule I! (•).

Item M iles (000) 3 6 7.5 9 12 15 18 21 22.5 24 27 30 33 36 37.5 39 42 45 48 51 52.5 54 57 60

No. Service Kilometers (000) 5 10 12.5 15 20 25 30 35 37.5 40 45 50 55 60 62.5 65 70 75 80 85 87.5 90 95 100
1 Engine Oil C h a n g e *— Every 3 M o nth s, or +■ + + + + + + + + + + + + + + + + + + +
Oil Filter C h a n g e *— Every 3 M o n th s, or + + + + + + + + + + + + + + + + + + +

AND LUBRICATION
2 C hassis L u b ric a tio n — Every 12 M o n th s,
+ + + + + + + + + + + + + + + + + + +
or +
5 C ooling S yste m S e rv ic e *— Every 24
+ +
M o n th s or
6 A ir C leaner E lem ent R ep la cem e n t* + +
7 Front W heel B earing R epack (2W D
+ + + +
Only)
8 Transmission Service — See page 7-19
of Owners Manual
11 Spark P lugs R ep la ce m e n t* + +
12 S park Plug W ire In sp e ctio n * +
14 E lectron ic V acuum R eg u lator Valve
+
(EVRV) In s p e c tio n *
15 Engine T im in g C heck* +
16 Fuel Tank. Cap and Lines In sp e ctio n * +
18 Engine A cce sso ry D rive Belt(s)
+
In s p e c tio n *
24 Tire and Wheel Rotation — See page 7-21
of Owners Manual
25 D rive A xle S ervice + • + + + + + + + + + + + + + + + + + + +
Brake Systems Inspection — See page
26
7-21 of Owners Manual
FOOTNOTES: THE SERVICES SHOW N ON TH IS C HART UP TO 6 0 .0 0 0 M ILE S (1 0 0 0 0 0 km ) ARE
*A n E m issio n C ontrol S e rvice TO BE DONE AFTER 6 0 ,0 0 0 M ILES AT THE SAM E INTERVALS.
tTo determine the emissions classification of your engine refer to page 7-4 of
Owners Manual.
T0337-CNG T0338-CNG
Scheduled Maintenance Services
GASOLINE ENGINES WITH LIGHT DUTY EMISSION- MAINTENANCE SCHEDULE Ilf

If your driving conditions meet those specified on page OB-1, use If your driving conditions do NOT meet those specified on page 0B-1, use
Maintenance Schedule I (+). Maintenance Schedule II (•).

Item M iles (000) 3 6 7.5 9 12 15 18 21 22.5 24 27 30 33 36 37.5 39 42 45 48 51 52.5 54 57 60

No. Service Kilometers (000) 5 10 12.5 15 20 25 30 35 37.5 40 45 50 55 60 62.5 65 70 75 80 85 87.5 90 95 100
1 Engine Oil C h a n g e *— Every 12 M onths, or • • • • • • • •
Oil Filter C h a n g e *— Every 12 M o nth s, or • • • •
2 C hassis L u b ric a tio n — Every 12 M o nth s, • • • • • • • •
or
5 C ooling S yste m S e rv ic e * — Every 24 • •

MAINTENANCE
M o n th s or
6 A ir C leaner E lem ent R e p la ce m e n t* • •

7 Front W heel B earing R epack (2W D O nly) • •

8 Transmission Service— See page 7-19
of Owners Manual
11 S p a rk Plugs R e p la ce m e n t* • •

12 S park Plug W ire In s p e c tio n * •

14 E le ctro n ic V a cu um R e g u la to r Valve •
(EVRV) In s p e c tio n *
15 Engine T im in g C heck* •

AND LUBRICATION
16 Fuel Tank. Cap and Lines In s p e c tio n * •

18 Engine A cce s so ry D rive B elt(s) •

In s p e c tio n *
24 Tire and Wheel Rotation— See page 7-21
of Owners Manual
25 D rive A xle S ervice • • • • • • • •

26 Brake Systems Inspection — See page 7-21

of Owners Manual
FOOTNOTES: THE SERVICES SHOW N ON THIS CHART UP TO 6 0 ,0 0 0 M ILE S (1 00 0 00 km ) ARE
*A n E m issio n C ontrol S ervice TO BE DONE AFTER 6 0 ,0 0 0 M ILES AT THE SAME INTERVALS,
tTo determine the emissions classification of your engine refer to page 7-4 of
Owners Manual.
T0332-CNG T0333-CNG

OB-5
 APPROXIMATE FLUID CAPACITIES
Engine Cooling System
5.7L (VIN K)
With Air Conditioning.................................................................................................................................. 17.0 L (18 qts.)
Without Air Conditioning..........................................................................................................................16.5 L (17.5 qts.)
With Air Conditioning — C3500 H.D.......................................................................................................... 25.5 L (27 qts.)
Without Air Conditioning — C3500 H.D................................................................................................. 25.0 L (26.5 qts.)

Engine Crankcase
5.7L (VIN K)*
With Filter.......................................................................................................................................................4.8 L (5.0 qts.)
Without Filter..................................................................................................................................................3.8 L (4.0 qts.)
* Add one additional quart for C3500 H.D. models

Fuel Tank
Standard (Side Tank)............................................................................................................................................... 150 lbs.

Transmission
4L60 Automatic— Drain and Refill................................................................................................................4.7 L (5 qts.)
After Complete O verhaul............................................................................................................................10.6 L (11 qts.)

MAINTENANCE ITEMS
Air Cleaner Element
5.7L (VIN K ).............................................................................................................................................. AC Type A-348C

Engine Oil Filter

5.7L (VIN K )................................................................................................................................................ AC Type PF-35

PCV Valve
5.7L (K ).................................................................................................................................................. AC Type CV-774C

Spark Plugs and Gap

5.7L (VIN K )............ AC Type CR43TS (90 mm, .035")
 SECTION 3D

REAR SUSPENSION
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS

SUBJECT PAGE
General Description ..................................................................................................................................................... 3D-1
On-Vehicle Service ....................................................................................................................................................... 3D-1
Shock Absorber Replacement ............................................................................................................................... 3D-1
Leaf Spring Replacement ........................................................................................................................................3D-2
Shackle Replacement ...............................................................................................................................................3D-4
Bushing Replacement ..............................................................................................................................................3D-5
Specifications ................................................................................................................................................................ 3D-5

GENERAL DESCRIPTION
All CK series vehicles use a leaf spring and solid
rear axle suspension system. The rear axle assembly is
attached to multi-leaf springs by U-bolts. The front ends
of the springs are attached to the frame at the front
hangers, through rubber bushings. The rear ends of
the springs are attached to the frame with shackles that
allow the springs to "change their length" while the
vehicle is in motion.
Ride control is provided by two identical direct double
acting shock absorbers angle-mounted between the
frame and brackets attached to the axle tubes.

ON-VEHICLE SERVICE
SHOCK ABSORBER 3. Shock absorber (6) from the vehicle.

REPLACEMENT Install or Connect (Figure 1)

NOTICE: Original equipment shock absorbers
serve additionally as suspension drop cutoffs.
Replacement shock absorbers must have a NOTICE: For steps 2, and 3, see "NOTICE” on
built in suspension cutoff feature and must page 3D-7.
not be longer than original shocks when they
are fully extended or serious vehicle or com­ 1. Shock absorber (6) to the vehicle.
ponent damage could result 2. Lower shock bolt (5), washer (4), and nut (3).
3. Upper shock bolt (2) and nut (1).
Remove or Disconnect (Figure 1)

£ Tighten
• Raise the vehicle on a hoist.
1. Upper shock nut (1) and bolt (2) from the frame • The lower nut to 110 N.m (81 ft. lbs.).
bracket. • The upper nut to 25 N.m (18 ft. lbs.).
2. Lower shock nut (3), washer (4), and bolt (5) from
the axle bracket.
 4. Washer
5. Bolt
6. Shock Absorber

F3445
Figure 1—Shock Absorber Components

LEAF SPRING REPLACEMENT 1. Spring assembly (24) to the vehicle.

2. Spring to front bracket bolt (22), washers (21), and
RIGHT nut (20).
• Do not tighten.
Remove or Disconnect (Figures 2 and 3)
3. Shackle (18) to rear bracket bolt (17), nut (15), and
• Raise the vehicle on a hoist and support the washers (16).
rear axle independently to relieve the tension • Do not tighten.
on the leaf springs. 4. Spacer (11) and new U-bolts (10) to the top of the
spring.
1. U-bolt nuts (7) and washers (8).
5. Anchor plate (9).
2. Anchor plate (9).
6. Washers (8) and nuts (7).
3. U-bolts (10) and spacer (11).
• Loosen the shackle to spring nut (12). Q Tighten (Figure 4)
4. Shackle (18) to rear bracket nut (15). washers (16)
and bolt (17). A The nuts (7) in sequence to the torque listed in
5. Spring to front bracket (23) nut (20), washers (21), "Specifications".
and bolt (22).
6. Spring assembly (24) from the vehicle. 0 Adjust (Figure 5)

Install or Connect (Figures 2 and 3) The spring height to obtain a measurement of

182 mm (7 11/64 inches) between the top
NOTICE: For steps 2, 3, 4, and 6, refer to surface of the axle jounce pad and the bottom
“Notice” on page 3D-1. surface of the frame jounce bracket (figure 5).
 0 Install or Connect
Notice: For steps 2 ,3 , 4, 6, 8, 9, 13, and 15, refer
to “Notice” on page 3D-1.
1. Spring assembly (24) to the vehicle.
2. Spring to front bracket bolt (22), washers (21), and
nut (20).
• Do not tighten.
3. Shackle (18) to rear bracket bolt (17), nut (15), and
washers (16).
• Do not tighten.
4. Spacer (11) and new U-bolts (10) to the top of the
spring.
5. Anchor plate (9).
6. Washers (8) and nuts (7).

Tighten (Figure 4)
Figure 2 — Single and Dual Wheel Leaf Springs A. The nuts (7) in sequence to the torque listed
in “Specifications.”
NOTICE: See"Notice" on page 3D-1.
Adjust (Figure 5)
B. The front (20) and rear (12) spring and shackle • The spring height to obtain a measurement of
(15) nuts to 110 N-m (81 ft. lbs.). 182 mm (7 11/64 inches) between the top
surface of the axle jounce pad and the bottom
• Lower the vehicle. surface of the frame jounce bracket (figure 5).
B. The front (20) and rear (12) spring and
LEFT shackle (15) nuts to 110 N«m (81 ft. lbs.)
7. Raise CNG cylinders & straps into position using
B Remove or Disconnect (Figures 2 and 3) trans jack and special holding fixture PAS-56074.
• Raise the vehicle on a hoist and support the rear 8. Cylinder strap nuts and bolts.
axle indepently to relieve the tension on the leaf • R em ove tra n s ja c k and h o ld in g fix tu r e
springs. PAS-56074.
1. Negative battery cable.
2. Turn 1/4 turn shut-off valve to “closed” position. Tighten
3. Drive shaft bolts and shaft. • Nuts to 50 N*m (37 ft. lb.)
4. Solenoid electrical connectors at left cylinders. • Bolts to 50 N*m (37 ft. lb.)
• Remove holding fixture PAS-56074.
• Loosen fuel lines at left cylinders and allow fuel
pressure to bleed off. 9. Nuts at cylinder support straps between left
cylinders.
5. Fuel lines at left cylinders.
6. Nuts at cylinder support straps between left £ Tighten
cylinders. • Nuts to 50 N*m (37 ft. lb.
• Support cylinders with transmission jack and 10. Fuel lines to left cylinders.
special holding fixture PAS-56074.
7. Cylinder strap nuts, & bolts. £ Tighten
8. Lower cylinders and straps. • Line nuts to 20 N-m (15 ft. lb.)
11. Solenoid electrical connectors to left cylinders.
• Move cylinders out of work area.
12. Drive shaft.
9. Leaf spring U-bolt nuts (7) and washers (8).
13. Drive shaft bolts.
10. Anchor plate (9)
11. U-bolts (10) and spacer (11). aTighten
• Loosen the shackle to spring nut (12). • Bolt to 20 Nvn (15 ft. lb.)
12. Shackle (18) to rear bracket nut (15), washers (16) 14. Turn 1/4 turn shut-off valve to “open” position.
and bolt (17). 15. Negative battery cable.
13. Spring to front bracket (23), nut (20), washers (21)
and bolt (22). Tighten
14. Spring assembly (24) from the vehicle. Bolt to 15 N*m (11 ft. lb.)
 A. CK1, 2, 3 17. Bolt
7. Nut 18. Shackle
8. Washer 19. Rear Bracket
9. Anchor Plate 20. Nut
10. U-bolt 21. Washer
11. Spacer 22. Bolt
12. Nut 23. Front Bracket
13. Washer 24. Spring Assembly
14. Bolt
15. Nut
16. Washer

F3448-CNG

Figure 3 — Axle Attaching Components

15. Negative battery cable. 1. Shackle (18) to rear bracket bolt (17), nut (15), and
washers (16).
H x l Tighten 2. Shackle to spring nut (12), washers (13), and bolt
(14).
• Bolt to 15 N-m (11 ft. lb.)
3. Shackle (18) from the vehicle.
IL«1 Inspect
Install or Connect (Figures 2 and 3)
• For gas leaks at fittings with soap & water
solution.
• Lower the vehicle. NOTICE: For steps 2, and 3, refer to “Notice”
on page 3D-1.

SHACKLE REPLACEMENT 1. Shackle (18) to the vehicle.

2. Shackle to spring bolt (14), washers (13), and nut
0 Remove or Disconnect (Figures 2 and 3) ( 12).

• Do not tighten.
• Raise the vehicle on a hoist and support the
3. Shackle to rear bracket bolt (17), nut (15), and
rear axle independently to relieve the tension
washers (16).
on the leaf springs.
• Loosen the shackle to spring nut (12). • Do not tighten.
£ Adjust (Figure 5) BUSHING REPLACEMENT
The spring height to obtain a measurement of +-► Remove or Disconnect (Figure 3)
182 mm (7 11/64 inches) between the top sur­
face of the axle jounce pad and the bottom 1. Spring assembly. Refer to “ Leaf Spring Replace­
surface of the frame jounce bracket (figure 4). ment.”
Tighten 2. Bushing from the leaf spring.
• Place the leaf spring in a press and press the
• The front (20) and rear (12) spring nuts and the bushing out.
shackle nut (15) to 110 N m (81 ft. lbs.). • Clean the spring bushing bore of bits of old
bushing, and burrs or corrosion.

Install or Connect (Figure 3)

1. Bushing to the leaf spring.

• Place the leaf spring in a press and press the
bushing in.
2. Spring assembly. Refer to “ Leaf Spring Replace­
ment.”

B
A. AXLE JOUNCE PAD
B. BUMPER
A
C. FRAME JOUNCE BRACKET
D. 182 MM (7 11/64 INCHES)
F3450

Figure 5—Rear Axle Trim Height

Figure 4— U-Bolt Tightening Sequence

SPECIFICATIONS
FASTENER TIG H TE N IN G S P EC IFIC A TIO N S
FASTENER
Drive Shaft Bolts..................................... ..................................... ......................................................... 20 N*m 15 Ft. Lbs.
Fuel Cylinder Strap Bolts............................................................. ......................................................... 50 N*m 37 Ft. Lbs.
Fuel Cylinder Strap Nuts............................................................. ......................................................... 50 N*m 37 Ft. Lbs.
Leaf Spring to Bracket Nuts............................ ........................... ....................................................... 120 N*m 89 Ft. Lbs.
Leaf Spring to Shackle Nuts....................................................... ....................................................... 120 N*m 89 Ft. Lbs.
Shackle to Bracket Nuts.............................................................. ....................................................... 120 N*m 89 Ft. Lbs.
Shock Absorber Upper Nuts....................................................... ......................................................... 25 N*m 17 Ft. Lbs.
Shock Absorber Lower Nuts....................................................... ....................................................... 110 N*m 81 Ft. Lbs.
U-Bolt Nuts.................................................................................... ....................................................... 110 N«m 81 Ft. Lbs.

T2104-CNG
3D -6 REAR SUSPENSIO N
 SECTION 6A

ENGINE, DRIVEABILITY, AND

DIAGNOSIS
CONTENTS

SUBJECT PAGE
General Information .................................................................................................................................................... 6A- 1
Statement on Cleanliness and Care ................................................................................................................... 6A- 1
Tune-up Information ................................................................................................................................................6A- 1
Use of RTV Sealant and Anaerobic Gasket Eliminator .................................................................................. 6Ar 2
Replacing Engine Gaskets .......................................................................................................................... ......... 6A* 2
Gasoline Engine Mechanical Diagnosis ................................................................................................................. 6A- 2
Gasoline Engine Compression Check ................................................................................................................ 6A> 5
Diagnosis of Hydraulic Lifters .................................................................................................................................. 6A- 5
Oil Leak Diagnosis.........................................................................................................................................................6A- 7
Finding the Leak.........................................................................................................................................................6A- 7
Repairing the Leak..................................................................................................................................................... 6A- 7
Special T o o ls.................................................................................................................................................................. 6A- 7

GENERAL INFORMATION
STATEMENT ON
CLEANLINESS AND CARE
• An engine is a combination of many machined,
honed, polished, and lapped surfaces with very
fine tolerances.
• Whenever valve train components, cylinder head,
cylinder, crankshaft, or connecting rod components
are removed for service, they should be retained in
order. At the time of installation, they should be
installed in the same locations and with the same
mating surfaces as when removed.
• Any time the air cleaner or TBI unit is removed,
the intake opening must be covered. If a diesel
engine is being serviced, the recommended cover
set (J 29664) should be used. This will protect
against the entrance of foreign material which
could follow the intake passage into the cylinder
and cause extensive damage when the engine is
started.
• When any internal engine parts are serviced, care
and cleanliness are important. A liberal coating of
engine oil should be applied to friction areas dur­
ing assembly to protect and lubricate the surfaces
on initial operation. 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 stat­
ed.
• On diesel engines, whenever the fuel injection
pump or lines are removed or disconnected, care
must be taken to prevent the entry of dirt into the
pump, lines, and injectors. The entry of even a
small amount of dirt or other foreign material into
the fuel injection system may cause serious dam­
age.
• It should be kept in mind, while working on the
engine, that the 12-volt electrical system is capa­
ble of violent and damaging short circuits. When
performing any work where electrical term inals
could possibly be grounded, the ground cable of
the battery should be disconnected at the battery.
• Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.
• Cover or otherwise protect exposed electrical con­
nections to prevent damage from oil and fuel.
• When raising or supporting the engine for any rea­
son, 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 it to be bent against the pump screen result­
ing in a damaged oil pickup unit.
TUNE-UP INFORMATION
All information required to tune up the ve h icle ’s
engine is given in the Engine Emission Control Label.
This label is located in the engine compartment.
 Information that can be found on the label includes:
• Spark plug type and gap.
• Ignition timing.
• Valve lash (if applicable).
• Idle, fast idle, and solenoid screw speeds, as
applicable.
• The proper sequence for making the adjust­
ments.
• Emission hose routing diagram (sometimes on
a separate label).
USE OF RTV SEALER
AND ANAEROBIC
GASKET ELIMINATOR
Two types of sealer are commonly used in engines
covered by this manual. These are RTV sealer and
anaerobic “ gasket eliminator” sealer.
It is important that these sealers be applied properly
and in the proper place to prevent oil leaks. THE TWO
TYPES OF SEALER ARE NOT INTERCHANGEABLE.
Use the sealer recommended in the procedure.
USING ANAEROBIC GASKET ELIMINATOR
• RTV (room temperature vulcanizing) sealer is
used where a non-rigid part is assembled to a
rigid part. Common examples are oil pans and
rocker arm covers.
• Anaerobic gasket eliminator hardens in the
absence of air. This sealer is used where two
rigid parts (such as castings) are assembled
together. When two rigid parts are disassem­
bled and no sealer or gasket is readily notice­
able, the parts were probably assembled using
gasket eliminator.
USING RTV SEALER
1. Don’t use RTV when extreme temperatures are
expected, such as exhaust manifold, head gasket,
or where gasket eliminator is specified.
2. When separating components sealed with RTV,
use a rubber mallet and “ bump” the part sideways
to shear the RTV sealer. “ Bumping” should be
done at bends or reinforced areas to prevent dis­
GASOLINE ENGINE MECHANICAL DIAGNOSIS
The following information pertains to the basic
assembly only. For more diagnosis information, refer to
the following:
• Overheating or other cooling system problems:
Refer to SECTION 6B1.
• Cranking and ignition system problems: Refer
tortion of parts. RTV is weaker in shear (lateral)
strength than in tensile (vertical) strength.
NOTICE: Attempting to pry or p u ll compo­
nents apart may result in damage to the part.
3. Surfaces to be resealed must be clean and dry.
Remove all traces of oil and RTV Clean with a
chlorinated solvent (GM part number 1050454 or
equivalent). Don't use petroleum cleaners such as
mineral spirits; they leave a film to which RTV
won’t stick.
4. Apply RTV to one of the clean surfaces. Use a
bead size as specified in the procedure. Run the
bead to the inside of any bolt holes. Do not allow
the sealer in any blind threaded holes, as it may
prevent the bolt from seating properly or cause
damage when the bolt is tightened.
5. Assemble while RTV is still wet (within 3 minutes).
Don't wait for RTV to skin over.
6. Torque bolts to specifications. Don’t over-torque.
1. Clean surfaces to be resealed with a chlorinat­
ed solvent to remove all oil, grease and old
material.
2. Apply a continuous bead of gasket eliminator to
one flange.
3. Spread bead evenly with your finger to get a
uniform coating on the complete flange.
4. Assemble parts in the normal manner and
torque to specifications.
REPLACING ENGINE GASKETS
CAUTION: Composite type gaskets are used
in some areas of the engine assembly. These
gaskets have a thin metal core. Use caution
when removing or handling composite gas­
kets to help avoid personal injury.
to SECTION 6D.
• Starting, d rive a b ility, fuel econom y, etc.
problems: Refer to Fuel and Emissions, Part 2
of this supplement.
 GASOLINE ENGINE MECHANICAL DIAGNOSIS
PROBLEM POSSIBLE CAUSE
Engine Will Not Turn 1. Battery, cranking system, or other elec­
Over trical problem.
2. Liquid in combustion chamber.
3. Seized engine.
Engine Cranks Nor­ 1. Fuel or ignition system problem.
mally But Does Not
Start 2. Restricted exhaust system.
3. Low compression due to stuck or
burned valves, stuck rings, blown head
gasket, etc.
Rough Idle 1. Fuel, ignition system, or emissions sys­
tem problem.
2. Uneven cylinder compression.
3. Bent pushrod or broken valve spring.
4. Faulty engine mount.
White Smoke Usually caused by water vapor, which is a None required.
normal byproduct of combustion. Usually
seen on cold days.
Black Smoke Usually caused by rich fuel mixture.
Blue Smoke Usually caused by oil burning in the com­ Refer to “ Excessive Oil Loss” diagnosis in
bustion chambers. this section..
Excessive Oil Loss 1. External oil leaks.
2. Improper reading of dipstick.
3. Improper oil viscosity.
4. Continuous high speed driving and/or
severe usage.
5. Crankcase ventilation or PCV system
malfunctioning.
6. Valve guides and/or valve stem seals
worn, or seals missing.
7. Piston rings not seated.
8. Broken or worn piston rings.
9. Piston improperly installed.
CORRECTION
1. Refer to ENGINE ELECTRICAL (SEC­
TION 6D).
2. Remove with suction gun.
3. Repair.
1. Refer to Fuel and Emissions, Part 2 of this
supplement.
2. Repair.
3. Perform a compression test, as outlined
in this section. Repair engine as neces­
sary.
1. Refer to Fuel and Emissions, Part 2 of this
supplement.
2. Perform a compression test, as outlined
in this section. Repair engine as neces­
sary.
3. Repair.
4. Repair or replace.
Refer to Fuel and Emissions, Part 2 of this
supplement.
1. Tighten bolts and/or replace gaskets
and seals as necessary.
2. Check oil with vehicle on a level sur­
face and allow adequate drain-down
time.
3. Use recommended viscosity for prevail­
ing temperatures.
4. C ontinuous high speed operation
and/or severe usage w ill normally
cause decreased oil mileage.
5. Service as necessary.
6. Ream guides and install oversize ser­
vice valves and/or new valve stem
seals.
7. Allow adequate time for rings to seat.
8. Replace broken or worn rings as nec­
essary.
9. Replace piston or repair as necessary.
 GASOLINE ENGINE MECHANICAL DIAGNOSIS (cont’d)
PROBLEM POSSIBLE CAUSE CORRECTION

Low Oil Pressure 1. Slow idle speed. 1. Set idle speed to specifications.
2. Incorrect or faulty oil pressure switch or 2. Replace with proper switch or sensor.
sensor.
3. Incorrect or faulty oil pressure gage. 3. Replace with proper gage.
4. Improper oil viscosity. 4. Replace with proper oil.
5. Diluted engine oil 5. Change engine oil and filter. Repair
cause of dilution (rich mixture, etc.)
6. Oil pump worn or dirty. 6. Clean pump and replace worn parts as
necessary.
7. Plugged oil filter 7. Replace filter and oil.
8. Oil pickup screen loose or plugged. 8. Clean or replace screen as necessary.
9. Hole in oil pickup tube. 9. Replace tube.
10. Excessive bearing clearance. 10. Replace as necessary.
11. Cracked, porous or plugged oil galleys. 11. Repair or replace block.
12. Galley plugs missing or mis-installed. 12. Install plugs or repair as necessary.

Valve Train Noise 1. Low oil pressure. 1. Repair as necessary. (See diagnosis
for low oil pressure).
2. Loose rocker arm attachments. 2. Inspect and repair as necessary.
3. Worn rocker arm and/or pushrod. 3. Replace as necessary.
4. Broken valve spring. 4. Replace spring.
5. Sticking valves. 5. Free valves.
6. Lifters worn, dirty, or faulty. 6. Refer to “ Diagnosis of Hydraulic Lift­
ers."
7. Camshaft worn or faulty. 7. Replace camshaft.
8. Worn valve guides. 8. Repair as necessary.

Engine Knocks Cold 1. Flywheel contacting splash shield. 1. Reposition splash shield.
And Continues For 2. Loose or broken torsional damper or 2. Tighten or replace as necessary.
Two To Three Min­ drive pulleys.
utes. Knock 3. Excessive piston to bore clearance. 3. Replace piston.
Increases With 4. Bent connecting rod. 4. Replace connecting rod.
Torque.
Engine Has Heavy 1. Broken balancer or pulley hub. 1. Replace parts as necessary.
Knock Hot With 2. Loose torque converter bolts. 2. Tighten bolts.
Torque Applied. 3. Accessory belts too tight or nicked. 3. Replace and/or tension to specifica­
tions as necessary.
4. Exhaust system grounded. 4. Reposition as necessary.
5. Flywheel cracked or loose rivets on fly­ 5. Replace flywheel.
wheel.
6. Excessive main bearing clearance. 6. Repair as necessary.
7. Excessive rod bearing clearance. 7. Repair as necessary.

Engine Has Light 1. Faulty EST or ESC system. 1. Refer to Fuel and Emissions, Part 2 of this
Knock Hot In Light supplement.
Load Conditions. 2. Improper timing. 2. Adjust to specifications.
3. Poor quality fuel. 3. Use fuel of recommended grade.
4. Loose torque converter bolts. 4. Tighten bolts.
5. Exhaust leak at manifold. 5. Tighten bolts and/or replace gaskets.
6. Excessive rod bearing clearance. 6. Replace bearings as necessary.

Engine Knocks On 1. Improper oil viscosity. 1. Install proper oil viscosity for expected
Initial Start Up But temperatures.
Only Lasts A Few 2. Hydraulic lifter bleed down. 2. Refer to “ Diagnosis of Hydraulic Lift­
Seconds. ers.”

Injector Noise This condition is normal. CNG fuel injectors are None needed
louder than gasoline injectors because of higher
operating pressures.
 GASOLINE ENGINE MECHANICAL DIAGNOSIS (cont’d)
PROBLEM POSSIBLE CAUSE
Engine Knocks At 1. Loose or worn drive belts.
Idle Hot 2. Compressor generator bearing.
3. Valve train.
4. Improper oil viscosity.
5. Excessive piston pin clearance.
6. Connecting rod alignment.
7. Insufficient piston to bore clearance.
(Cold engine piston knock usually dis­
appears when the cylinder’s spark plug
is grounded out. Cold engine piston
knock which disappears in 1.5 minutes
should be considered acceptable.)
8. Loose torsional damper.
CORRECTION
1. Tension and/or replace as necessary.
2. Replace as necessary.
3. Refer to ‘‘Valve Train Noise.”
4. Install proper viscosity oil for expected
temperature.
5. Install new piston, pin and/or connect­
ing rod as needed.
6. Check and replace rods as necessary.
7. Hone and fit new piston, if required.
8. Torque any or replace worn parts.
D0272

GASOLINE ENGINE
COMPRESSION CHECK
1. Disconnect the primary lead from the distributor or
ignition coil. Refer to SECTION 6D.
2. Remove all spark plugs.
3. Block the throttle plate wide open.
4. Make sure the battery is fully charged.
5. Starting with the compression gage at zero, crank
the engine through four compression strokes (four
“ puffs” ).
6. Make the compression check at each cylinder and
record each reading.
7. If some cylinders have low compression, inject
about 15 ml. (one tablespoon or about 3 squirts
from a pump type oil can) of engine oil into the
combustion chamber through the spark plug hole.
8. Minimum compression recorded in any one cylin­
der should not be less than 70 per cent of highest
cylinder, and 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 low­
est allowable pressure for any other cylinder would
be725 kPa (105 psi). (1035 x 70% = 725) (150 x
70% = 105).
• Normal— Compression builds up quickly and
evenly to specified compression on each cylin­
der.
• Piston Rings Leaking— compression low on first
stroke tends to build up on following strokes
but does not reach normal. Improves consider­
ably with addition of oil.
• Valves Leaking— Low on first stroke. Does not
tend to build up on following strokes. Does not
improve much with addition of oil.
• If two adjacent cylinders have lower than nor­
mal compression, and injecting oil into cylin­
ders does not increase the compression, the
cause may be a head gasket leak between the
cylinders.

DIAGNOSIS OF HYDRAULIC LIFTERS

PROBLEM POSSIBLE CAUSE CORRECTION
Momentarily Noisy This condition is normal. Oil drains from the None needed.
When Engine Is lifters which are holding the valves open
Started when the engine is not running. It will take
a few seconds for the lifter to fill after the
engine is started.
Intermittently Noisy 1. Dirt in hydraulic lifter. 1. Disassemble and clean.
On Idle Only, Disap­ 2. Pitted or damaged check ball. 2. Replace the hydraulic lifter.
pearing When
Engine Speed Is
Increased

Noisy At Slow Idle High leak down rate. Replace the hydraulic lifter.
Or With Hot Oil;
Quiet At Higher
Engine Speeds Or
With Cold Oil
 DIAGNOSIS OF HYDRAULIC LIFTERS (cont’d)
PROBLEM POSSIBLE CAUSE CORRECTION

Noisy At High Vehi­ 1. Oil level above the “ Full” mark allows 1. Drain oil to proper level.
cle Speeds, Quiet At crankshaft counterweights to churn the
Low Speeds oil into foam. When foam is pumped
into the lifters, they will become noisy
since a solid column of oil is required
for proper operation.
2. Oil level below the “ Add” mark allows 2. Add oil as needed.
the oil pump to pump air at high
speeds which results in noisy lifters.
3. Oil pan bent against oil pump pickup 3. Repair.
screen.
4. Oil pump screen bent or loose. 4. Repair.

Noisy At idle, 1. This noise is not connected with lifter 1. Repair as necessary.
Becoming Louder As malfunction. It becomes most notice­
Engine Speed Is able in the vehicle at 10 to 15 mph “ L”
Increased To 1500 (Low) range, or 30 to 35 mph “ D”
RPM (Drive) range and is best described as
a “ hashy” sound. At slow idle, it may
be entirely gone or appear as a light
ticking noise in one or more valves. It
is caused by one or more of the follow­
ing:
• Badly worn or scuffed valve tip and
rocker arm pad.
• Excessive valve stem to guide clear­
ance.
• Excessive valve seat runout.
• Off square valve spring.
• Excessive valve face runout.
• Valve spring damper clicking on rotator.
2. Off-square valve spring. Occasionally 2. If 1.6 mm (1/16 inch) off-square, it
this noise can be eliminated by rotating should be replaced.
the valve spring and valve. Crank
engine until noisy valve is off its seat.
Rotate spring. This will also rotate
valve. Repeat until valve becomes qui­
et. If correction is obtained, check for
an off-square valve spring.
Noisy Regardless Of 1. Incorrect valve adjustment (excessive 1. Adjust as specified.
Engine Speed lash) (engines with adjustable valve
lash).
2. Excessive valve lash. Check for valve 2. Repair engine as needed.
lash by turning the engine so the piston
in that cylinder is on TDC of the firing
sroke. If valve lash is present, the
pushrod can be freely moved up and
down a certain amount with rocker arm
held against valve. Excessive lash can
be caused by:
a. Worn pushrod upper end ball. a Replace pushrod and rocker arm.
b. Bent pushrod. b. Replace pushrod.
c. Improper lubrication of the pushrod. c. Replace pushrod and rocker arm.
Check lubrication system feed to the
pushrod.
d. Loose or damaged rocker arm. d. Replace rocker arm.
e. If pushrod and rocker arm are OK, trou­ e. Replace hydraulic lifter.
ble in the hydraulic lifter is indicated.
D0017
 OIL LEAK DIAGNOSIS
Most oil leaks are located easily and repaired by
visually finding the leak and replacing or repairing the
necessary parts. On some occasions, a fluid leak may
be difficult to locate or repair. The following procedure
may help in locating and repairing most.
FINDING THE LEAK
1. Identify the fluid, determine whether it is engine
oil, automatic transmission fluid, power steering
fluid, etc.
2. From what area is the fluid leaking? After running
the vehicle at normal operating temperature, park
the vehicle over a large sheet of paper. After a few
minutes, you should be able to find the approxi­
mate location of the leak by the dripping on the
paper.
3. Visually check around the suspected component.
Check around all gasket mating surfaces for leaks.
A mirror is useful for finding leaks in areas that are
hard to reach.
4. If the leak still can not be found, it may be neces­
sary to clean the suspected area with a degreaser,
steam or spray solvent. Clean the area, then dry
the area. Operate the vehicle for several miles at
normal operating temperature and varying speed.
After operating the vehicle, visually check the sus­
pected component. If you still cannot locate the
leak, try using the powder or black light and dye
method.
POWDER METHOD
1. Clean the suspected area.
2. Apply an aerosol-type powder (such as foot
powder) to the suspected area.
3. Operate the vehicle under normal operating
conditions.
4. Visually inspect the suspected component. You
should be able to trace the leak path over the
white powder surface to the source.
BLACK LIGHT METHOD
1. Pour specified amount of dye into leaking com­
ponent.
2. Operate the vehicle under normal conditions as
directed by the directions in the kit.
3. Direct the light toward the suspected area. The
dyed fluid will appear as a yellow path leading
to the source.
REPAIRING THE LEAK
Once the leak has been pinpointed back to its
source, the cause of the leak must be determined in
order for it to be repaired properly. If a gasket is
replaced, but the sealing flange is bent, the new gasket
will not repair the leak. The bent flange must be
repaired also. Before attempting to repair a leak, check
to be sure that the following conditions are corrected as
they may cause a leak.
GASKET LEAKS
Check for:
• High fluid levei or high oil pressure.
• Plugged ventilation filter or valve.
• Improperly tightened fasteners or dirty/dam ­
aged threads.
• Warped flanges or sealing surfaces.
• Scratches, burrs or other damage to the sealing
surface.
• Damaged or worn gasket.
• Cracked or porosity of the component.
• Improper sealant used, or no sealant where
required.
SEAL LEAKS
Check for:
• High fluid level or high oil pressure.
• Plugged ventilation filters, or valve.
• Damaged or worn seal.
• Improper installation.
• Cracks in component.
• Shaft surface scratched, nicked, or damaged.
• Loose or worn bearing causing excessive seal
wear.
6A -8 EN G IN E, P R IV E A B IL ITY , AND DIAGNOSIS
 SECTION 6A4

5.7L V 8 RPO L 0 5 , V IN K
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) m ay be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result

CONTENTS

SUBJECT PAGE
General Description ..................................................................................................................................................6A4- 1
Engine Lubrication ................... ............................................................................................................................6A4- 5
On-Vehicle Service ....................................................................................................................................................6A4- 7
Rocker Arm Cover Replacement ...................................................... .............. ................................................. 6A4- 7
Rocker Arm and Pushrod Replacement ...........................................................................................................6A4- 8
Valve Adjustment .................................................................................................................................................. 6A4- 8
Valve Stem Seal and Valve Spring Replacement ......................................................................................... 6A4- 9
Intake Manifold Replacement ......... ................................................................................................................... 6A4-10
Hydraulic Lifter Replacement ............................................................................................................................ 6A4-11
Rocker Arm Stud Replacement ...................... ..................... ............................................................................. 6A4-12
Exhaust Manifold Replacement ......................................................................................................................... 6A4-13
Cylinder Head Replacement .............................................................................................................................. 6A4-13
Torsional Damper and Crankshaft Front Seal Replacement ...................................................................... 6A4-14
Front Cover Replacement .................................................................................................................................. 6A4-15
Oil Pan Replacement ........................................................................................................................................... 6A4-16
Oil Pump Replacement ........................................................................................................................................6A4-16
Crankshaft Rear Oil Seal Replacement ........................................................................................................... 6A4-17
Crankshaft Rear Oil Seal Retainer Replacement .......................................................................................... 6A4-17
Measuring Camshaft Lobe Lift .......................................................................................................................... 6A4-18
Camshaft Replacement ........................................................................................................................................6A4-18
Connecting Rod and Piston Replacement ...................................................................................................... 6A4-20
Oil Filter Bypass Valve ........................................................................................................................................6A4-22
Main Bearing Replacement ............................................................... ................................................................ 6A4-22
Crankshaft Replacement ....................... .............................................................................................................. 6A4-23
Flywheel Replacement (Automatic and Manual Transmission) .................................................................6A4-23
Engine Mountings ................................................................................................................................................. 6A4-24
Engine Replacement ............................................................................................................................................ 6A4-25
Thread Repair ............................................................................................................................................................ 6A4-27
Specifications ............................................................................................................................................................ 6A4-28
Special Tools ........................................ ..................................................................................................................... 6A4-31

GENERAL DESCRIPTION
The small block engine covered in this section is the For engine identification, refer to SECTION OA. For
7L (350 CID). engine component identification, refer to figures 1
through 4.
 10. Coolant Pump 149. Connecting Rod Bearing Cap
11. Coolant Pump Gasket 150. Connecting Rod Bearing
12. Coolant Pump Bolt 151. Piston Pin
13. Plug 152. Connecting Rod
71. Oil Pan 153. Piston
72. Bolt 154. Piston Rings
73. Nut 155. Connecting Rod Bolt
74. Oil Pan Gasket 156. Expansion Cup Plug
75. Reinforcement 157. Plug
76. Oil Pan Baffle Nut 158. Drain Plug
77. Oil Pump Bolt 159. Dowel Pin
79. Oil Pan Baffle 160. Lock Washer
89. Crankshaft Front Oil Seal 161. Clutch Cover and Pressure Plate Bolt
90. Front Cover Gasket 162. Straight Fitting
91. Front Cover 163. Bolt
93. Front Cover Bolt 164. Clutch Fork Ball Stud
99. Pin 165. Clutch Housing
100. Camshaft Sprocket Bolt 166. Clutch Pressure Plate Cover
101. Camshaft Sprocket 167. Clutch Pilot Bearing
102. Timing Chain 168. Flywheel Dowel Pin
110. Flywheel 169. Oil Pan Drain Plug
111. Flywheel Bolt 170. Gasket
118. Groove Pin 171. Oil Pan Stud
119. Torsional Damper 172. Clamp
120. Rear Seal Retainer Gasket 173. Spring Pin
121. Crankshaft Rear Seal Retainer 174. Clutch Driven Plate
122. Rear Seal Retainer Screw 175. Plug
123. Rear Seal Retainer Nut 176. Expansion Cup Plug
124. Rear Seal Retainer Stud 177. Dowel Pin
130. Crankshaft 178. Oil Pump Drive Shaft
132. Rear Main Bearing Cap 179. Retainer
133. Main Bearing Cap 180. Oil Pump
134. Main Bearing Cap Bolt 182. Oil Pump Cover
135. Lower Main Bearing Insert 183. Oil Pressure Regulator Valve
136. Upper Main Bearing Insert 184. Regulator Valve Spring
137. Main Bearing Cap Stud 185. Spring Stop Retaining Pin
138. Oil Level Indicator 187. Pick-Up Screen and Pipe
139. Bolt 190. Pin
140. Oil Level Indicator Tube 191. Regulator Valve Spring Stop Plug
141. Bolt 192. Bolt
142. Fuel Pump Opening Cover 214. Crankshaft Sprocket
143. Fuel Pump Opening Cover Gasket 215. Woodruff Key
144. Engine Block 216. Camshaft
145. Fitting 217. Pin
146. Oil Pressure and Fuel Pump Switch Sensor 218. Camshaft Bearings
147. Plug 219. Oil Pressure Plug
148. Nut 220. Groove Pin

V1203
 300

301 20 20
36
20 21\ 302
^ \.5 0
21

250
& * 2S4 1& * ----251
4 2 ^ ^ $u<-----39
<&*- 252 ^ ---- 252
<SU~255 — 255
210 $ * -2 5 6 — 256

201 203
/2 0 2 / /

2 0 5 -^
206

209

V1196
 1. Exhaust Manifold 203. Spark Plug Shield Bracket
2. Washer 204. Bolt
3. Exhaust Manifold Lock 205. Plug
4. Bolt/Stud 206. Spark Plug Wire Support
6. Heat Shield 207. Air Injection Pipe Extension
7. Outer Heat Stove 208. Dowel Pin
8. Inner Heat Stove 209. Valve Lifter
20. Bolt/Stud 210. Pushrod
21. Intake Manifold 211. Spark Plug Wire Retainer Support
22. Intake Manifold Gasket 212. Drain Plug
32. Rocker Arm Cover 213. Coolant Temperature Sensor
34. Rocker Arm Cover Gasket 250. Rocker Arm Stud
36. Rocker Arm Cover Bolt 251. Valve Stem Key
39. Inlet Valve Spring Cap 252. Valve Stem Oil Seal (O-Ring)
40. Rocker Arm Nut 254. Exhaust Valve Rotator
41. Rocker Arm Ball 255. Valve Stem Oil Shield
42. Rocker Arm 256. Valve Spring with Damper
46. Cylinder Head 257. Valve Stem Oil Seal
47. Cylinder Head Gasket 258. Exhaust Valve
50. Plug 259. Inlet Valve
51. Cylinder Head Bolts 300. Bo!t/Stud
200. Oil Filler Cap 301. Coolant Outlet
201. Spark Plug Wire Retainer Support 302. Gasket
202. Spark Plug 303. Thermostat

V1197

Figure 4—Cylinder Head, Manifolds, and Components

Small block engines are 90-degree V8 type, over­ ENGINE LUBRICATION

head valve, liquid cooled, with cast iron block and
heads.
The crankshaft is supported by five precision insert
main bearings, with crankshaft thrust taken at the num­
ber five (rear) bearing.
The camshaft is supported by five plain type bear­
ings and is chain driven. Motion from the camshaft is
transmitted to the valves by hydraulic lifters, pushrods,
and ball type rocker arms. The valve guides are inte­
gral in the cylinder head.
The pistons are cast aluminum alloy and the con­
necting rods are forged steel with precision insert type
crankpin bearings. The piston pins are a press fit in the
connecting rods and a floating fit in the piston.
Lubrication schematics are shown in figures 5 and 6.
The gear type oil pump is driven from the distributor
shaft, which is gear driven from the camshaft. Oil is
drawn into the oil pump through a pickup screen and
pipe.
Pressurized oil is routed to the oil filter. In case of
excessive oil pressure, a bypass valve is provided. Fil­
tered oil flows into the main gallery and then to the
camshaft and crankshaft bearings. The valve lifter oil
gallery supplies oil to the valve lifters. Oil flows from
the hydraulic lifters through the hollow pushrods to the
rocker arms. Oil from the overhead drains back to the
crankcase through oil drain holes.
The timing chain is drip fed from the front camshaft
bearing. The pistons and piston pins are lubricated by
oil splash.
Figure 5— Engine Lubrication Diagram
 Figure 6—Engine Lubrication Diagram

ON-VEHICLE SERVICE
ROCKER ARM COVER 7. Rocker arm cover bolts (5).
8. Rocker arm cover (7) and gasket (8).
REPLACEMENT
Clean
Remove or Disconnect (Figure 7)
• All traces of old gasket from the rocker arm cover
1. Negative battery cable. and cylinder head.
2. Air cleaner.
3. Crankcase ventilation hoses at the rocker arm cov­ Inspect
ers.
4. Wiring harnesses from the clips, and move aside.
• Rocker arm cover sealing surface for distortion.
5. Components as follows for right rocker arm cover:
Replace if necessary.
• PCV valve.
• Upper dipstick bracket. Install or Connect (Figure 7)
• Heat stove pipe.
• Emissions sensors with bracket, and move
Rocker arm cover (7) and new gasket (8).
aside.
6. Components as follows for left rocker arm cover:
• Generator rear brace. NOTICE: See “NOTICE” on page 6A4-1.
• Crankcase ventilation pipe.
• Power brake vacuum pipe and move aside. 2. Rocker arm cover bolts (5).
 Important

• Store used components in order so they can be

reassembled in the same location.

Bolt L* Inspect
Washer
Rocker Arm Cover Rocker arms and balls at their mating surfaces.
Gasket These surfaces should be smooth and free from
scoring or other damage.
Rocker arm areas that contact the valve stems and
the sockets that contact the pushrods. These areas
should be smooth and free of damage and wear.
Pushrods for bending. Roll the pushrod on a flat
surface to determine if it is bent. Replace if neces­
sary.
Ends of the pushrods for scoring or roughness.

+4- Install or Connect

1. Pushrod. Make sure the pushrod seats properly in

the hydraulic lifter.
2. Rocker arm with ball.

9 Important

• When new rocker arms and/or balls are

installed, coat their bearing surfaces with high
F3043
viscosity oil with zinc (GM part number
12345501) or equivalent.
Figure 7—Rocker Arm Cover 3. Rocker arm nut.
Tighten

• Bolts (5) to 11 N-m (100 in. lbs.). • Valves as outlined later in this section.
3. Components as follows for left rocker arm cover: 4. Rocker arm cover, as outlined previously in this
• Power brake vacuum pipe. section.
• Crankcase ventilation pipe.
• Generator rear brace. VALVE ADJUSTMENT
4. Components as follows for right rocker arm cover: 1. Remove the rocker arm cover as outlined previous­
• Emissions sensors with bracket. ly-
• Heat stove pipe. 2. Crank the engine until the mark on the vibration
• Upper dipstick bracket. damper lines up with the “0” mark on the timing
• PCV valve.
5. Wiring harnesses to the rocker arm clips.
6. Crankcase ventilation hoses.
7. Air cleaner.
8. Negative battery cable.

ROCKER ARM AND PUSHROD

REPLACEMENT
++ Remove or Disconnect

1. Rocker arm cover, as outlined previously.

2. Rocker arm nut.
• If only the pushrod is to be replaced, back the
rocker arm nut off until the rocker arm can be
swung away from the pushrod. Then pull the
pushrod out.
3. Rocker arm with ball.
4. Pushrod. Figure 8—-Adjusting the Valves
 tab and the engine in the number one firing posi­
tion. This may be determined by placing fingers on
the number one valve as the mark on the damper
comes near the “ 0” mark on the timing tab. If the
rocker arms are not moving, the engine is in the
number one firing position. If the rocker arms
move as the mark comes up to the timing tab, the
engine is in the number six firing position and
should be turned over one more time to reach the
number one position.
3. With the engine in the number one firing position
as determined above, the following valves may be
adjusted:
• Exhaust: 1, 3, 4, 8
• Intake: 1, 2, 5, 7
(Even numbered cylinders are in the right bank;
odd numbered cylinders are in the left bank, when
viewed from the rear of the engine).
4. Back out the adjusting nut until lash is felt at the
pushrod then turn in the adjusting nut until all lash
is removed. This can be determined by rotating the
pushrod while turning the adjusting nut (figure 8). 2. Rocker arms, as outlined previously in this section.
When the play has been removed, turn the adjust­ 3. Spark plugs.
ing nut in one full additional turn (to center the 4. Valve keepers (20).
lifter plunger). A. Install J 23590 into the spark plug hole.
5. Crank the engine one revolution until the timing B. Apply compressed air to hold the valves in
tab “ 0” mark and vibration damper mark are again place.
in alignment. This is the number six firing position C. Install a rocker arm nut (figure 10).
the following valves may be adjusted: D. Use J 5892-C to compress the valve spring (fig­
• Exhaust: 2, 5, 6, 7 ure 10).
• Intake: 3, 4, 6, 8 E. Remove the valve keepers.
6. Install the rocker arm cover as outlined previously F Carefully relieve the spring tension. Remove
in this section. J 5892-C.
5. Cap (21) and/or rotator (28), shield (22), and spring
VALVE STEM SEAL AND (26) with damper (25).
6. O-ring seal (23).
VALVE SPRING REPLACEMENT 7. Seal (24).
Remove or Disconnect (Figures 9 and 10) + 4- Install or Connect (Figures 9, 10, and 11)
Tools Required:
J 23590 Air Adapter. Tools Required:
J 5892-C Spring Compressor. J 23590 Air Adapter
1. Rocker arm cover, as outlined previously in this J 5892-C Spring Compressor
section. J 23738-A Vacuum Pump
1. New seal (24). Install the seal over the valve stem
and seat it against the head.
20. Valve Keeper 26. Spring 2. Spring (26) with damper (25), shield (22), and cap
21. Cap 27. Intake Valve (21) and/or rotator (28).
22. Shield 28. Rotator 3. New O-ring seal (23) and valve keepers (20).
23. O-Ring Seal 29. Exhaust Valve A. With air pressure applied to the cylinder with
24. Seal J 23590, compress the spring with J 5892-C
25. Damper (figure 10).
B. Lubricate the O-ring seal with engine oil. Install
the seal on the valve stem. Make sure the seal
is not twisted.
C. Install the valve keepers. Use grease to hold
I 1 22 23 24 _ them in place.
D. Carefully release spring pressure. Make sure
the valve keepers stay in place.
E. Remove J 5892-C and J 23590.
F. Check each O-ring seal for leakage (figure 11).
a. Place the suction cup furnished with
B7609 J 23738-A over the shield.
b. Connect J 23738-A to the suction cup and
apply a vacuum. Watch the vacuum pump
 gage. No air should be able to leak past the
seal. If the seal will not hold a vacuum, it
may have been damaged or improperly
installed.
4. Spark plugs.
5. Rocker arms, as outlined previously in this section.
Adjust
Zl
• Valves, as outlined previously in this section.
6. Rocker arm cover, as outlined previously in this
section.
19. Intake manifold.
20. Gaskets and clips.
Old gasket and RTV from the block, heads, and
intake manifold. Remove all RTV that is loose or
will cause interference at assembly.
Excessive carbon deposits from the exhaust and
EGR passages.
Excessive scale and deposits from the coolant
passages.

INTAKE MANIFOLD I* Inspect

Manifold for cracks and gasket surface damage.
REPLACEMENT
+«- Install or Connect (Figures 12 and 13)
Remove or Disconnect (Figure 12) 1. Gaskets to the cylinder head. Install the clips over
the gaskets, to the rib between the intake ports.
1. Negative battery cable. Then apply a dot of RTV to the upper side of the
2. Air cleaner. clip.
• Drain the cooling system. 2. RTV to the front and rear sealing surfaces on the
3. Heater pipe and upper radiator hose at the intake block (figure 12). Apply a 5 mm (3/16-inch) bead of
manifold.
RTV (part number 1052366 or equivalent) to the
4. Generator rear brace at the manifold.
front and rear of the block as shown. Extend the
5. Vacuum hoses at the manifold, TBI unit, and EGR
valve. bead 13 mm (1/2-inch) up each cylinder head to
6. Electrical connections at the manifold and TBI unit. seal and retain the gaskets.
• Raise the vehicle. Support with suitable safety 3. Intake manifold to the engine.
stands.
NOTICE: See “NOTICE” on page 6A4-1.
7. Turn 1/4-turn shutoff valve to closed position.
• Lower the vehicle.
4. Intake manifold bolts.
8. Fuel line(s) at the TBI unit.
9. Accelerator, cruise control, and TV cables, as Tighten
equipped.
&
Distributor. Refer to SECTION 6D. • Intake manifold bolts to 48 N-m (35 ft. lbs.).
10.
11. Air conditioning compressor rear bracket. Use the tightening sequence shown in figure
12. Brake booster vacuum pipe. 13.
13. Coil wires. 5. TBI unit (if removed).
14. Emission control sensors and bracket on right side. 6. Bracket at rear of belt idler.
15. Fuel line bracket at rear of manifold. Move the fuel 7. Fuel line bracket at rear of manifold.
line aside. 8. Emission control sensors and bracket.
16. Bracket at rear of belt idler.
9. Coil wires.
17. TBI unit (if necessary).
18. Intake manifold bolts. 10. Brake booster vacuum pipe.
11. Air conditioning compressor rear bracket.
12. Distributor. Refer to SECTION 6D.
13. Accelerator, cruise control, and TV cables, as
equipped.
14. Fuel line at the TBI unit.
15. Electrical connections.
16. Vacuum hoses.
17. Generator brace.
18. Heater pipe and upper radiator hose.
19. Air cleaner.
• Raise the vehicle. Support with suitable safety
stands.
20. Turn 1/4 turn shut-off valve to open position.
• Lower the vehicle.

L* Inspect
Fuel line for leaks with soap and water solution.
21 Negative battery cable.
• Fill the cooling system with the proper quantity
Figure 11—Testing the \falve Seals and grade of coolant.
 C. Forward
D. RTV Sealant

B7915

Figure 12—Intake Manifold

HYDRAULIC LIFTER
REPLACEMENT

<--► Remove or Disconnect (Figures 14 and 15)

Tools Required:
J 3049-A Hydraulic Lifter Remover (Plier Type)
or
J 9290-01 Hydraulic Lifter Remover (Slide Ham­
mer Type)
1. Rocker arm cover, intake manifold, and pushrod,
as outlined previously in this section. Figure 14—Removing the Hydraulic lifter
2. Hydraulic lifters.
• Remove the hydraulic lifters one at a time and
place them in an organizer rack. The lifters
must be installed in the same bore from which
they were removed.
0 0 • A stuck hydraulic lifter can be removed using
J 3049-A (figure 14) or J 9290-01 (figure 15).
0
o L* Inspect

9)® O O O Of • Hydraulic lifter body for scuffing and scoring. If

i v— w —y _ the lifter body wall is worn or damaged, the
mating bore in the block should also be
FRONT _
B9569 checked.
• Check the fit of each hydraulic lifter in its mat­
Figure 13— Intake Manifold Bolt Tightening ing bore in the block. If the clearance is exces­
Sequence sive, try a new lifter.
 Figure 16— Removing the Rocker Arm Stud

• The hydraulic lifter foot must be smooth and

slightly convex. If worn, pitted, or damaged, the
mating camshaft lobe should also be checked.
Hydraulic Lifter Repair
• Refer to Section 6A of the Light Duty Truck Unit
Repair Manual.

-►4- Install or Connect

1. Hydraulic lifters to the block. Lubricate the lifter

foot and body with High Viscosity Oil with Zinc
(GM part number 12345501) or equivalent.

Important

• When any new hydraulic lifters or a new cam­

shaft is installed, change the engine oil and
filter. High viscosity oil with zinc (GM part num­
ber 12345501) or equivalent should be added
to the crankcase oil.
• Replace all hydraulic lifters when a new cam­
shaft is installed.
2. Intake Manifold, as outlined previously in this sec­
tion.
3. Pushrod, as outlined previously in this section.
\j^ \ Adjust
• Valves, as outlined previously in this section.
4. Rocker arm cover, as outlined previously in this
section.
ROCKER ARM STUD
REPLACEMENT
Remove or Disconnect (Figure 16)
Tool Required:
J 5802-01 Rocker Arm Stud Remover
1. Rocker arm cover and rocker arm, as outlined pre­
viously in this section.
2. Rocker arm stud.
A. Place J 5802-01 over the rocker arm stud.
B. Install a nut and flat washer.
C. Turn the nut to remove the stud (figure 16).
-►«- Install or Connect (Figures 17 and 18)
Tools Required:
J 5715 Reamer (0.003-inch oversize) or
J 6036 Reamer (0.013-inch oversize)
J 6880 Rocker Arm Stud Installer
NOTICE: Do not attempt to install an oversize
rocker arm stud without reaming stud hole as
this could damage the cylinder head.
• Ream the hole to the proper size for the replace­
ment oversize rocker arm stud. Use J 5715 for
0.003-inch oversize studs; J 6036 for 0.013-inch
oversize studs (figure 17).
• Coat lower end (press-fit area) of rocker arm stud
with hypoid axle lubricant.
1. Rocker arm stud. Use J 6880 (figure 18). Stud is
installed to proper depth when the tool bottoms on
the cylinder head.
 +«- Install or Connect

1. Exhaust manifold to the cylinder head.

NOTICE: See “NOTICE" on page 6A4-1.

2. Exhaust manifold fasteners. Install the flat washers

against the manifold, then the tab washers and
bolts.

• Two center bolts to 36 N.m (26 ft. lbs.).

• Outside bolts to 28 N.m (20 ft. lbs.).
• Bend the tab washers against the bolt heads.
3. Power steering pump rear bracket at the manifold
(left side manifold).
4. Dipstick tube bracket (right side manifold).
5. Heat stove pipe (right side manifold).
6. Oxygen sensor wire.
• Raise the vehicle. Support with suitable safety
stands.
7. Exhaust pipe.
• Lower the vehicle.
8. Negative battery cable.

CYLINDER HEAD
2. Rocker arm, as outlined previously in this section. REPLACEMENT
^ Adjust Remove or Disconnect
• Valves, as outlined previously in this section.
1. Negative battery cable.
3. Rocker arm cover, as outlined previously in this
section. • Drain the cooling system.
2. Intake manifold, as outlined previously in this sec­
tion.
EXHAUST MANIFOLD 3. Exhaust manifold, as outlined previously in this
section.
REPLACEMENT 4. Ground strap at rear of cylinder head (right side
Remove or Disconnect cylinder head).
5. Components as follows for right side cylinder
1. Negative battery cable. head.
• Raise the vehicle. Support with suitable safety • Nut and stud attaching air conditioning com­
stands. pressor to cylinder head.
2. Exhaust pipe at the manifold.
• Lower the vehicle.
3. Oxygen sensor wire (left side manifold). Do not
remove the oxygen sensor unless replacement is
required.
4. Heat stove pipe (right side manifold).
5. Power steering pump rear bracket at the manifold © 0 0 0 ©
(left side manifold).
6. Dipstick tube bracket (right side manifold).
7. Exhaust manifold bolts, washers, and tab washers.
8. Exhaust manifold. ©©0 0000 ©.
y | Clean
B9572
• Mating surfaces on the manifold and head.
• Threads on the exhaust manifold bolts.
 • Fuel pipe, plug wire, and wiring harness brack­
ets at the rear of the cylinder head.
6. Components as follows for left side cylinder head.
• Nut and stud attaching main accessory bracket
to the cylinder head. It may be necessary to
loosen the remaining bolts and studs and move
the bracket forward slightly for clearance to
remove the cylinder head.
• Coolant sensor wire.
• Spark plug wire brackets at the rear of the cyl­
inder head.
7. Rocker arm cover, as outlined previously in this
section.
8. Spark plugs.
9. Pushrods, as outlined previously in this section.
10. Cylinder head bolts.
11. Cylinder head.
12. Head gasket.
Clean
• Carbon deposits from combustion chambers.
• All traces of old head gasket from cylinder head
and block.
• C ylinder head bolt threads and threads in the
block.
Inspect
• Sealing surfaces of the block and cylinder head for
nicks, heavy scratches, or other damage.
Cylinder Head Repair
• Refer to Section 6A of the Light Duty Truck Unit
Repair Manual.
Install or Connect (Figure 19)
1. Head gasket.
• Do not use sealer on composition steel-asbes-
tos gaskets.
• Place the gasket over the block dowel pins with
the bead up.
2. Cylinder head. Carefully guide the cylinder head
into place over the dowel pins and gasket.
NOTICE: Ssee “NOTICE” on page 6A4-1.
3. Cylinder head bolts. Coat threads of the cylinder
head bolts with sealing compound (GM part num­
ber 1052080 or equivalent) and install finger-tight.
• Bolts in three steps using the sequence shown
in figure 19 until the proper torque is reached:
• The first sequence to 35 N.m (25 ft. lbs.).
• The second sequence to 60 N-m (45 ft. lbs).
• The final torque sequence to 90 N.m (65 ft.
lbs.).
4. Pushrods, as outlined previously in this section.
• Valves, as outlined previously in this section.
5. Rocker arm cover, as outlined previously in this
section.
6. Spark plugs.
7. Components as follows for right side cylinder
head:
• AIR pump bolt and spacer at the cylinder head.
• Nut and stud attaching the air conditioning
compressor to the cylinder head.
• Fuel pipe, plug wire and wiring harness brack­
ets at the rear of the cylinder head.
8. Components as follows for left side cylinder head:
• Nut and stud attaching main accessory bracket
to the cylinder head.
• Remaining main accessory bracket bolts and
nuts, if necessary.
• Coolant sensor wire.
• Spark plug wire brackets at the rear of the cyl­
inder head.
9. Ground strap at the rear of the cylinder head (right
side cylinder head).
10. Exhaust manifold, as outlined previously in this
section.
11. Intake manifold, as outlined previously in this sec­
tion.
12. Negative battery cable.
• Fill the cooling system with the proper quantity
and grade of coolant.
TORSIONAL DAMPER AND
CRANKSHAFT FRONT SEAL
REPLACEMENT
Remove or Disconnect (Figure 20)
Tool Required:
J 23523-E Torsional Damper Puller and Installer
1. Multiple ribbed belt, fan, and pulley.
2. Fan shroud assembly.
Figure 20—Removing the Torsional Damper

Figure 21— installing the Crankshaft Front Oil Seal
A. Installation Stud
B. Nut
C. Washer and Bearing L0707
Figure 22—Installing the Torsional Damper
3. Accessory drive pulley.
4. Torsional damper bolt.
5. Torsional damper. Use J 23523-E (figure 20).
6. Crankshaft front seal. Pry out with a large screw­
driver. Take care not to distort the timing cover.
7. Crankshaft key, if necessary.
I* Inspect
Oil seal contact area on the torsional damper shaft
for grooving and roughness. Replace if necessary.
Install or Connect (Figures 21 and 22)
Tools Required:
J 35468 Seal Installer
J 23523-E Torsional Damper Puller and
Installer
1. Crankshaft key, if removed.
2. Crankshaft front seal. Use J 35468 (figure 21). The
open end of the seal faces inside the engine. Coat
the seal lips with engine oil.
NOTICE: The inertia weight section of the tor­
sional damper is assembled to the hub with a
rubber type material. The correct installation
procedures (with the proper tool) must be fol­
lowed or movement of the inertia weight sec­
tion of the hub will destroy the tuning of the
torsional damper.
3. Stud (item A, figure 22) to the crankshaft. Thread
the stud fully into the tapped hole in the crank­
shaft.
4. Torsional damper over the end of the stud. Align
the keyway in the torsional damper shaft with the
crankshaft key.
• Use a small amount of RTV sealant to seal the
torsional damper key to crankshaft joint.
5. Bearing, washer and nut (figure 22).
• Turn the nut to pull the vibration damper into
place.
• Remove the tool.
NOTICE: See “NOTICE” on page 6A4-1.
6. Torsional damper bolt and washer.
& Tighten
• Bolt to 95 N.m (70 ft. lbs.).
7. Accessory drive pulley.
8. Fan shroud assembly.
9. Fan pulley, fan, and multiple ribbed belt.
FRONT COVER REPLACEMENT
Remove or Disconnect
1. Torsional damper, as outlined previously in this
section.
2. Coolant pump.
3. Oil pan, as outlined later in this section.
4. Front cover bolts.
5. Front cover.
6. Front cover to block gasket.
7. Crankshaft front seal from the front cover. Pry out
with a screwdriver. Take care not to distort the front
cover.
5 H C|ean
Old gasket from the front cover and block.
*
L1 Inspect
• Front cover for distortion and damage. Replace if
necessary.
Install or Connect (Figure 21)
Tools Required:
J 35468 Seal Installer
1. Crankshaft front seal. Use J 35468 (figure 21). The
open end of the seal faces inside the engine. Coat
the seal lips with engine oil.
 2. Front cover gasket to the front cover. Use gasket
cement to hold it in place.
NOTICE: See "NOTICE” on page 6A4-1.
3. Front cover and bolts to the engine.
Tighten
• Front cover to block bolts to 11 N-m (100 in.
lbs.).
4. Oil pan, as outlined later in this section.
5. Coolant pump. Refer to SECTION 6B1.
6. Torsional damper, as outlined previously in this
section.
OIL PAN REPLACEMENT
A one-piece type oil pan gasket is used.
C-MODELS
3. Flywheel/torque converter cover.
4. Strut rods at the engine mountings (if used).
5. Oil pan bolts, nuts, and reinforcements.
6. Oil pan and gasket.
Clean
Gasket surfaces on the engine and oil pan.
I* Inspect
Oil pan gasket for damage. Replace if necessary.
♦4- Install or Connect (Figure 23)
• Apply sealant (GM part number 1052080 or equiv­
alent) to the front cover to block joint and to the
rear crankshaft seal to block joint. Apply the seal­
ant for about 25 mm (1 inch) in both directions
from each of the four corners.
1. Oil pan gasket to the oil pan.
2. Oil pan to the engine.

Remove or Disconnect (Figure 23) NOTICE: See “NOTICE” on page 6A4-1.

1. Negative battery cable. 3. Oil pan bolts, nuts, and reinforcements.

• Raise the vehicle. Support with suitable safety Tighten

stands.
$
* Drain the engine oil. • Oil pan bolts to 11 N m (100 in. lbs.).
• Oil pan nuts to 22 N-m (16 ft. lbs.).
2. Exhaust crossover pipe.
4. Strut rods at the engine mount (if used).
5. Flywheel/torque converter cover.
6. Exhaust crossover pipe.
• Lower the vehicle.
7. Proper quantity and grade of engine oil. Refer to
SECTION 0B.
8. Negative battery cable.

OIL PUMP REPLACEMENT

♦ Remove or Disconnect

1. Oil pan, as outlined previously in this section.

2. Oil pump bolt.
3. Oil pump.
• Oil pump pickup tube for looseness. If the tube
is loose in the oil pump body, replace it, as
outlined in Section 6A5 of the Light Duty Truck
Unit Repair Manual. A loose pickup tube can
result in an air leak and loss of oil pressure.
Oil Pump Repair
• Refer to Section 6A5 of the Light Duty Truck Unit
Repair Manual.
74. Gasket
75. Reinforcement Install or Connect

1. Oil pump to the engine. Align the slot in the oil

B7989
pump shaft with the tang on the distributor shaft.
The oil pump should slide easily into place. No
gasket is used.
 NOTICE: See “NOTICE’’ on page 6A4-1. Inspect

2. Oil pump bolt. Chamfer on crankshaft for grit, loose rust, and
burrs. Correct as necessary.
$ Tighten
IJUjl Clean
• Bolt to 90 N m (65 ft. lbs.).
Seal running surface on the crankshaft with a
3. Oil pan, as outlined previously in this section. non-abrasive cleaner.

CRANKSHAFT REAR OIL SEAL -►«- Install or Connect (Figure 25)

REPLACEMENT
«■+ Remove or Disconnect (Figure 24)
1. Transmission.
2. Clutch and flywheel or flexplate, as equipped.
NOTICE: Care should be taken when remov­
ing the rear crankshaft oil seal so as not to
nick the crankshaft sealing surface.
3. Crankshaft rear oil seal. Insert a screwdriver into
the notches provided in the seal retainer and pry
the seal out (figure 24). Take care not to damage
the crankshaft seal surface.
Tool Required:
J 35621 Seal Installer
1. Crankshaft rear oil seal (figure 25).
A. Lubricate the inner and outer diameter of the
seal with engine oil.
B. Install the seal on J 35621.
C. Position J 35621 against the crankshaft. Thread
the attaching screws into the tapped holes in
the crankshaft.
D. Tighten the screws securely with a screwdriver.
This will ensure that the seal is installed
squarely over the crankshaft.
E. Turn the handle until it bottoms.
F. Remove J 35621.
2. Clutch and flywheel or flexplate, as equipped.
3. Transmission.

CRANKSHAFT REAR OIL SEAL

RETAINER REPLACEMENT
Remove or Disconnect (Figures 24 and 26)

1. Transmission.
2. Clutch and flywheel or flexplate, as equipped.
3. Oil pan, as outlined previously in this section.
4. Screws (80) and nuts (81).
5. Seal retainer (82).
6. Gasket (84).
7. Crankshaft rear oil seal. Insert a screwdriver into
the notches provided in the seal retainer and pry
the seal out (figure 24).

jjj| Clean

• Gasket surfaces on block and seal retainer.

Install or Connect (Figure 26)

• Whenever the seal retainer is removed, a new

retainer gasket and crankshaft rear oil seal must
be installed.
1. Gasket (84) to the block. It is not necessary to
use sealant to hold the gasket in place.
2. Seal retainer (82).
NOTICE: See “NOTICE” on page 6A4-1.
3. Screws (80) and nuts (81).

Tighten

Screws (80) and nuts (81) to 15 N-m (135 in.

lbs.).
 A. Rear of Block
80. Screw
81. Nut
82. Retainer
83. Stud
84. Gasket

B7614

Figure 26— Crankshaft Rear Oil Seal Retainer

4. Oil pan, as outlined previously in this section.
5. Crankshaft rear oil seal as outlined previously
in this section.
6. Clutch and flywheel or flexplate, as equipped.
7. Transmission.
MEASURING CAMSHAFT
LOBE LIFT
Tool Required:
J 8520 Camshaft Lobe Lift Indicator
1. Remove the rocker arm as outlined previously in
this section.
2. Refer to figure 27. Position the dial indicator (part
of J 8520) so the plunger rests on the pushrod
end, as shown. Make sure the pushrod is in the
lifter socket.
3. Rotate the crankshaft slowly in the direction of nor­
mal rotation until the lifter is on the heel of the
cam lobe. At this point, the pushrod will be in its
lowest position.
4. Set dial indicator on zero, then rotate the crank­
shaft slowly, or attach an auxiliary starter switch
and “bump” the engine over, until the pushrod is
in fully raised position.
[ V | Important
• Whenever the engine is cranked remotely at
the starter, with a special jumper cable or other
means, the distributor primary lead or coil pri­
mary leads should be disconnected.
5. Compare the total lift recorded from the dial indica­
tor with specifications.
6. If camshaft readings for all lobes are within specifi­
cations, remove dial indicator assembly.
7. Install the rocker arm and adjust the valves as
previously outlined in this section.
CAMSHAFT REPLACEMENT
Remove or Disconnect (Figures 28, 29, and
30)
Tool Required:
J 5825-A Crankshaft Sprocket Puller

Figure 27— Measuring Camshaft Lobe Lift Figure 28—Timing Marks

 Figure 30—Replacing the Camshaft
NOTICE: When raising or supporting the
engine for any reason, do no t use a ja c k
under the oil pan, any sheet metal or crank-
shaft pulley. Due to the sm all clearance
between the oil pan and the oil pump screen,
jacking against the oil pany may cause it to
be bent against the pump screen, resulting in
a damaged oil pickup unit.
Figure 29— Replacing the Crankshaft Sprocket
• Raise the engine.
1. Negative battery cable. 15. Camshaft
2. Air cleaner. • Install two or three 5/16-18 bolts 100-125 mm
3. Fan, shroud, and radiator. (4-5 inches) long into the camshaft threaded
4. Rocker arm covers, as outlined previously in this holes. Use these bolts to handle the camshaft
section. (figure 30).
5. Coolant pump. • Pull the camshaft from the block. Use care to
6. Torsional damper, as outlined previously in this prevent damage to the camshaft bearings.
section.
7. Front cover, as outlined previously in this section. Cleaning, Inspection, and Repair
8. Distributor. Refer to SECTION 6D4. Clean, inspect, and repair or replace the camshaft
9. Intake manifold, as outlined previously in this sec­ and related components, as outlined in Section 6A5 of
tion. the Light Duty Truck Unit Repair Manual.
10. Pushrods and hydraulic lifters, as outlined previ­ The Light Duty Truck Unit Repair Manual also
ously in this section. describes camshaft bearing replacement.

• Align the timing marks (figure 28). Install or Connect (Figures 28 through 30 and
11. Camshaft sprocket bolts. 38)
12. Camshaft sprocket and timing chain. The sprocket
is a light interference fit on the camshaft. Tap the NOTICE: For steps 3 and 6, see “NOTICE” on
sprocket on its lower edge to loosen it. page 6A4-1.
13. Crankshaft sprocket (if required). Use J 5825-A
(figure 29). Tool Required:
14. Front engine mounting through bolts. J 5590 Crankshaft Sprocket Installer
 • Coat the camshaft lobes and journals with a high CONNECTING ROD AND
viscosity oil with zinc (GM part number 12345501)
or equivalent. PISTON REPLACEMENT
1. Two or three 5/16-18 bolts 100-125 mm (4-5 ♦ Remove or Disconnect (Figure 31)
inches) long into the camshaft threaded holes. Use
these bolts to handle the camshaft. Tool Required:
2. Camshaft to the engine (figure 30). Handle the J 5239 Guide Set
camshaft carefully to prevent damage to the cam­ 1. Cylinder head, as outlined previously in this sec­
shaft bearings. tion.
• Lower the engine. 2. Oil pan, as outlined previously in this section.

3. Engine mount through-bolts.

Tighten

• Through-bolts to specifications. Refer to figure

38.
4. Crankshaft sprocket (if removed). Use J 5590 (fig­
ure 29). Make sure the timing mark faces outside.
5. Camshaft sprocket and timing chain.

important

• Line up the timing marks on the camshaft

sprocket and crankshaft sprocket (figure 28).
6. Camshaft sprocket bolts.

Tighten

• Bolts to 24 N.m (18 ft. lbs.).

7. Hydraulic lifters and pushrods, as outlined previ­
ously in this section.

important

Replace all hydraulic lifters, change the engine

oil and filter, and add High Viscosity Oil with
Zinc (GM part number 12345501) or equivalent Figure 31—Replacing the Piston and
whenever a new camshaft is installed. Connecting Rod

^ Adjust O
ENGINE UEFT ENGINE FRONT ENGINE RIGHT
• Valves, as outlined previously in this section.
8. Intake manifold, as outlined previously in this sec­
tion.
9. Distributor. Refer to SECTION 6D4.
10. Front cover, as outlined previously in this section.
11. Torsional damper, as outlined previously in this
section.
12. Coolant pump.
13. Rocker arm covers, as outlined previously in this
B. 2nd Compression Ring Gap
section.
C. Notch In Piston
14. Fan, shroud, and radiator.
15. Air cleaner. D. Oil Ring Spacer Gap
16. Negative battery cable. (Tang In Hole Or Slot With Arc)
E. Top Compression Ring Gap B7895
• Fill the cooling system with the proper quantity and
grade of coolant.
 3. Oil pump, as outlined previously in this section (if
necessary).
4. Ridge or deposits from the upper end of the cylin­
der bores.
A. Turn the crankshaft until the piston is at BDC.
B. Place a cloth on top of the piston.
C. Perform the cutting operation with a ridge
reamer.
D. Turn the crankshaft until the piston is at TDC.
E Remove the cloth and cuttings.
5. Connecting rod cap. Check the connecting rod
and cap for identification marks. Mark the parts if
required. The connecting rod and cap must be
kept together as mating parts.
6. Connecting rod and piston.
• Attach J 5239 to the connecting rod bolts (fig­
ure 31).
• Use the long guide rod of J 5239 to push the
connecting rod and piston out of the bore.
7. Connecting rod bearing.
Cleaning, Inspection, and Repair
Clean, inspect, and repair or replace the components
as necessary. Measure connecting rod bearing clear­
ance, piston clearance, ring clearances, etc. Refer to
Section 6A of the Light Duty Truck Unit Repair Manual.
The Light Duty Truck Unit Repair Manual contains
information on:
• Connecting rod and piston.
• Piston rings.
• Connecting rod and crankpin.
• Cylinder bores.
Install or Connect (Figures 31 through 34)
the crankpin with J 5239 (figure 31). Hold the
ring compressor against the block until all rings
have entered the cylinder bore.
F Remove J 5239 from the connecting rod bolts.
important
Each connecting rod and bearing cap should
be marked, beginning at the front of the
engine. Cylinders 1, 3, 5, and 7 are the left
bank and, 2, 4, 6, and 8 are the right bank.
The numbers on the connecting rod and bear­
ing cap must be on the same side when
installed in the cylinder bore. If a connecting
rod is ever transposed from one block or cylin­
der to another, new connecting rod bearings
should be fitted and the connecting rod should
be numbered to correspond with the new cylin­
der number.
% Measure
• Connecting rod bearing clearance. Refer to
Section 6A of the Light Duty Truck Unit Repair
Manual.
3. Connecting rod cap and bearing.
NOTICE: See “NOTICE” on page 6A4-1.
4. Connecting rod cap nuts.
Q Tighten
• Connecting rod cap nuts to 60 N-m (45 ft. lbs.).

Tools Required:
J 5239 Connecting Rod Guide Set
J 8037 Ring Compressor
• Make sure the cylinder walls are clean. Lubricate
the cylinder wall lightly with engine oil.
• Make sure the piston is installed in the matching
cylinder.
1. Connecting rod bearings.
• Be certain that the bearings are of the proper
size.
• Install the bearings in the connecting rod and
connecting rod cap.
• Lubricate the bearings with engine oil.
2. Piston and connecting rod to the proper bore.
A. With the connecting rod cap removed, install
J 5239 onto the connecting rod studs.
B. Locate the piston ring end gaps as shown in
figure 32. Lubricate the piston and rings.
C. Without disturbing the ring end gap location,
install J 8037 over the piston (figure 33).
D. The piston must be installed so that the notch
in the piston faces the front of the engine (fig­
ure 32).
E. Place the piston in its matching bore. The con­
necting rod bearing tang slots must be on the
side opposite the camshaft. Using light blows
with a hammer handle, tap the piston down B7902
into its bore (figure 33). At the same time, from
beneath the vehicle guide the connecting rod to
 fj| Measure Py| Clean

• Connecting rod side clearance. Use a feeler • Valve chamber in the block.
gage between the connecting rods (figure
34). The correct clearance is 0.006-0.014 |-n-| Install or Connect (Figure 35)
inch.
1. Oil filter bypass valve (93).
5. Oil pump (if removed), as outlined previously in
this section. NOTICE: See “NOTICE” on page 6A4-1.
6. Oil pan and cylinder head, as outlined previously
2. Bolts (94).
in this section.

OIL FILTER BYPASS VALVE

• Bolts (94) to 26 N-m (20 ft. lbs.).
++ Remove or Disconnect (Figure 35) 3. Oil filter.
4. Engine oil, as needed.
1. Oil filter.
MAIN BEARING REPLACEMENT
1? Inspect
Remove or Disconnect (Figure 36)
• Bypass valve spring and valve disc for proper
operation, cracks, and damage. If replacement Tool Required:
is needed, the oil filter bypass valve (93) must J 8080 Main Bearing Remover/Installer
be replaced, as follows:
2. Bolts (94).
3. Oil filter bypass valve (93).

Figure 34— Measuring Connecting Rod Side

Clearance

A. Valve Disc
93. Oil Filter Bypass Valve
94. Bolt B5286
 1. Spark plugs.
2. Oil pan, as outlined previously in this section.
3. Oil pump, as outlined previously in this section.
4. Main bearing caps.
• Check the main bearing caps for location mark­
ings. Mark the caps if necessary. The caps
must be returned to their original locations dur­
ing assembly.
5. Lower main bearing inserts from the main bearing
caps.
6. Upper main bearing inserts.
• Insert J 8080 into the crankshaft oil hole (figure
36).
• Rotate the crankshaft to “ turn” the bearing
insert out of the block.
Cleaning, Inspection, and Repair
Clean, inspect, and repair or replace the components
as required. Refer to Section 6A of the Light Duty Truck
Unit Repair Manual. The Unit Repair Manual contains
information on
• Crankshaft.
• Main and connecting rod bearings.
Install or Connect (Figures 36 and 37)
NOTICE: For steps 3 and 4, see “NOTICE” on
page 6A4-1.
Tool Required:
J 8080 Main Bearing Remover/Installer
1. Upper main bearing inserts.
A Insert tool J 8080 into a crankshaft main bear­
ing oil hole (figure 36).
B. Apply engine oil to inserts of the proper size.
C. Insert the plain end (without the bearing tang)
of the insert between the crankshaft and the
notched side of the block.
D. Rotate the crankshaft to “ roll” the insert into
the block.
E. Remove the tool.
2. Lower main bearing inserts to the main bearing
caps.
• Make sure the inserts are of the proper size.
• Apply engine oil to the inserts.
Measure
• Main bearing clearance. Refer to Section 6A of
the Light Duty Truck Unit Repair Manual. If the
engine is in the vehicle, the crankshaft must be
supported upward to remove any clearance
from the upper bearing. The total clearance
can then be measured between the lower bear­
ing and journal.
3. Main bearing caps (except rear cap) and bolts to
the block.
& Tighten
• Main bearing cap bolts to specifications.
• Outer bolts on #2, #3, and #4 main bearing
caps: 95 N-m (70 ft. lbs.).
• All others: 110 N m (80 ft. lbs.).
4. Rear main bearing cap and bolts.
Tighten
Rear main bearing cap bolts temporarily to 14
N-m (124 in. lbs.).
Measure
• Crankshaft end play, as follows:
A. Tap the end of the crankshaft first rearward
then forward with a lead hammer. This will
line up the rear main bearing and crank­
shaft thrust surfaces.
B. Tighten the rear main bearing cap bolts to
110 N-m (80 ft. lbs.).
C. With the crankshaft forced forward, mea­
sure at the front end of the rear main bear­
ing with a feeler gage (figure 37). The
proper clearance is 0.002-0.006-inch.
• If correct end play cannot be obtained, be
certain that the correct size rear main bear­
ing has been installed. Production engines
may have rear main bearings that are
0.008-inch wider across the thrust faces
than standard. Refer to Section 6A5 of the
Light Duty Truck Unit Repair Manual for
more information.
5. Oil pump, as outlined previously in this section.
6. Oil pan, as outlined previously in this section.
7. Spark plugs.
CRANKSHAFT REPLACEMENT
1. Remove the engine, as outlined later in this sec­
tion.
2. Refer to Section 6A5 of the Light Duty Truck Unit
Repair Manual for crankshaft replacement proce­
dures.
FLYWHEEL REPLACEMENT
(AUTOMATIC AND MANUAL
TRANSMISSIONS)
Remove or Disconnect
1. Transmission, flywheel housing, and clutch.
2. Flywheel bolts.
3. Flywheel.
jy | Clean
• Mating surfaces of crankshaft and flyw heel.
Remove any burrs.
Inspect
• Flywheel for burning, scoring, warping, and wear.
Replace the flywheel if necessary. Do not machine
the flywheel.
• Flywheel ring gear for worn or broken teeth.
Flywheel Ring Gear Replacement
1. Use a torch to heat the gear around the entire
circumference, then drive the gear off the flywheel,
using care not to damage the flywheel.
 NOTICE; Never heat starter gear to red heat
as this will change metal structure.
2. Uniformly heat the flywheel gear to temperature
which will expand the gear to permit installation.
Temperature must not exceed 204’C (400“F).
3. As soon as the gear has been heated, install on
the flywheel.
Install or Connect
1. Flywheel.
NOTICE: See “NOTICE" on page 6A4-1.
2. Replace the mounting if the following condi­
tions exist:
• Rubber cushion separated from the metal
plate of the mounting.
• Mounting bottomed out (tailshaft can be
moved up but not down).
3. If there is relative movement between a metal
plate of the mounting and its attaching point,
tighten the bolts or nuts attaching the mounting
to the transmission or crossmember.
FRONT MOUNTING REPLACEMENT
4* + Remove or Disconnect (Figures 38 and 39)

2. Flywheel bolts.

NOTICE: When raising or supporting the

• Flywheel bolts to 100 N-m (75 ft. lbs.).
3. Clutch, flywheel housing, and transmission.
ENGINE MOUNTINGS
NOTICE: Broken or deteriorated mountings
c an cause m is a lig n m e n t a n d e v e n tu a l
destruction of certain drive train components.
When a single mounting breakage occurs, the
remaining mountings are subjected to abnor­
mally high stresses.
INSPECTING ENGINE MOUNTINGS
Front Engine Mountings
NOTICE: When raising or supporting the
engine for any reason, do not use a ja c k
under the oil pan, any sheet metal, or crank­
shaft pulley. Due to the sm all clearance
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.
engine for any reason, do not use a ja c k
under the oil pan, any sheet metal, or crank­
shaft pulley. Due to the sm all clearance
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.
• Support the engine with a suitable jack. Do not
load the engine mounting.
1. Engine mounting through-bolt and nut.
NOTICE: Raise the engine only enough for
sufficient clearance. Check for interference
between the rear of the engine and the dash
panel which could cause distributor housing
damage.
• Raise the engine only enough to permit removal of
the engine mounting.
2. Mounting assembly bolts, nuts, and washers.
3. Mounting assembly.

1. Raise the engine to remove weight from the

mountings and to place a slight tension on the
rubber cushion. Observe both mountings while
raising the engine.
2. Replace the mounting if the following conditions
exist:
• Hard rubber surface covered with heat check
cracks.
• Rubber cushion separated from the metal plate
of the mounting.
• Rubber cushion split through the center.
3. If there is movement between a metal plate of the
mounting and its attaching points, lower the
engine and tighten the bolts or nuts attaching the
mounting to the engine, frame, or bracket.
Rear Mountings
1. Push up and pull down on the transmission Figure 38— Front Engine Mounting Brackets to
tailshaft. Observe the transmission mounting. Frame (C-Models)
 REAR MOUNTING REPLACEMENT

4- + Remove or Disconnect (Figure 40)

NOTICE: When raising or supporting the

engine for any reason, do no t use a ja c k
under the oil pan, any sheet metal, or crank­
shaft pulley. Due to the sm all clearance
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.

• Support the rear of the engine to relieve the weight

on the rear mountings.
1. Mounting to crossmember nut(s) and washer(s).
2. Mounting to transmission bolts and washers.
• Raise the rear of the engine only enough to permit
removal of the mounting.
3. Mounting.
Install or Connect (Figure 40)

NOTICE: For steps 2 and 3, see “NOTICE” on

page 6A4-1.
1. Mounting.
• Lower the rear of the engine.
2. Mounting to transmission bolts and washers.
D. SPACER, ENGINE MOUNT BRACKET 3. Mounting to crossmember nut(s) and washer(s).
E. BRACKET, ENGINE MOUNT
F. WASHER, ENGINE MOUNT BRACKET & Tighten
G. BOLT, 51 N m (38 Ft. Lbs.)
H. NUT, 68 N m (50 Ft. Lbs.) Fasteners to specifications. Refer to figures 41
I. MOUNT, ENGINE and 42.
J. BOLT, 95 N m (70 Ft. Lbs.)
K. BRACKET, TRANSMISSION STRUT ENGINE REPLACEMENT
Remove or Disconnect
V2759

1. Negative battery cable.

Figure 39— Front Engine Mounts to Brackets
2. Hood.
• Drain the cooling system.
Install or Connect (Figures 38 and 39) • Raise the vehicle. Support with suitable safety
stands.
NOTICE: For steps 2 and 3, see “NOTICE” on 3. Turn 1/4 turn shut-off valve to closed position.
page 6A4-1.
• Lower the vehicle.
1. Mounting assembly. 4. Air cleaner.
2. Mounting assembly bolts, nuts, and washers.
5. Accessory drive belt.
$ Tighten 6. Fan and coolant pump pulley.
7. Radiator and shroud.
• Fasteners to specifications. Refer to figures 38
and 39. 8. Heater hoses at the engine.
3. Engine mount through-bolt and nut lower the 9. Accelerator, cruise control, and detent linkage (if
engine until the bolt can be inserted. Install the used) from TBI unit.
nut.
10. Air conditioning compressor (if used) and lay aside.
11. Power steering pump (if used) and lay aside.
12. Engine wiring harness from the engine.
Through-bolt nut to specifications. Refer to fig­
ure 40. 13. Fuel line.

Figure 40— Rear Engine Mounting (C-Models)
14. Vacuum lines from the intake manifold.
• Raise the vehicle. Support with suitable safety
stands.
• Drain the crankcase oil.
15. Exhaust pipes from the manifolds.
16. Strut rods at the engine mountings (if used).
17. Flywheel or torque converter underpan.
18. Wiring along oil pan rail (if used).
19. Starter.
20. Wiring, as necessary.
21. Converter to flex plate bolts.
• Lower the vehicle.
• Support the transmission.
• Attach a suitable lifting fixture.
22. Bell housing to engine bolts.
23. Front engine mounting to frame bolts.
24. Engine.
V2761
-n - Install or Connect (Figure 38, 39, and 40)
1. Engine to the vehicle.
• Raise the vehicle. Support with suitable safety
stands.
NOTICE: See “NOTICE” on page 6A4-1.
2. Front engine mounting to frame bolts.
Q Tighten
• Fasteners to specifications. Refer to figures 38,
39, and 40.
3. Bell housing to engine bolts. Remove the transmis­
sion support.
4. Converter to flex plate bolts.
5. Wiring, as required.
6. Starter.
7. Wiring along oil pan rail (if used).
8. Flywheel or torque converter underpan.
9. Strut rods at the engine mountings (if used).
10. Exhaust pipes to the manifolds.
• Lower the vehicle.
11. Vacuum lines to the intake manifold. • Raise the vehicle. Support with suitable safety
12. Fuel line. stands.
13. Engine wiring harness.
14. Power steering pump (if used). 23. Turn 1/4 turn shut-off valve to open position.
15. Air conditioning compressor (if used). • Lower the vehicle.
16. Accelerator, cruise control, and detent linkages.
17. Heater hoses.
18. Radiator and shroud. Inspect
19. Accessory drive belt. • Fuel line for leaks with soap and water solution.
20. Air cleaner.
21. Hood. 24. Negative battery cable.
22. Proper quantity and grade of coolant and crank­
case oil, Refer to SECTION OB.

THREAD REPAIR
Damaged threads may be reconditioned by drilling
out, rethreading and installing a suitable thread insert.
Tools Required:
General purpose thread repair kits are available
commercially.
CAUTION: Wear safety glasses to avoid eye
damage.
1. Determine size, pitch, and depth of damaged
thread. If necessary, adjust stop collars on cutting
tool and tap to required depth.
3. Tap hole. Lubricate tap with light engine oil. Clean
the thread.
Important
• Avoid build-up of chips. Back out the tap every
few turns and remove chips.
4. Thread the thread insert onto the mandrel of the
installer (figure 41). Engage the tang of the insert
onto the end of the mandrel.
5. Lubricate the insert with light engine oil (except
when installing in aluminum) and install.
Important

9 Important • When correctly installed, the insert should be

flush to one turn below the surface.
6. If the tang of the insert does not break off when
• Refer to the kit manufacturer’s instructions backing out the installer, break the tang off with a
regarding the size of drill and tap to be used. drift.
2. Drill out damaged thread. Clean out chips.

B
DRILL HOLE TO TAP HOLE TO INSTALL INSERT INSTALL INSERT INTO
PROPER SIZE PROPER SIZE ON MANDREL NEWLY THREADED
HOLE
V1195
 SPECIFICATIONS
ENGINE SPECIFICATIONS (5.7L)
All Specifications are in INCHES iwtess otherw ise noted.
GENERAL DATA:
Type V8
Displacement 5.7L (350 CID)
RPO (VIN Code) L05 (K)
Bore 4.00
Stroke 3.480
Compression Ratio 8.3:1
Firing Order 1-8-4-3-6-5-7-2
Oil Pressure (Minimum) 6 PSI @ 1000 RPM; 18 PSI @ 2000 RPM;
24 PSI min. @ 4000 RPM
CYLINDER BORE:
Diameter 3.9995-4.0025
Out Of Production 0.001 (Maximum)
Round Service 0.002 (Maximum)
Thrust Side 0.0005 (Maximum)
Production
Taper Relief Side 0.001 (Maximum)
Service 0.001 (Maximum)
PISTON:
Production 0.0007-0.0021
Clearance
Service Limit 0.0027 (Maximum)
PISTON RING:
C Top
0 Production 0.0012-0.0032
M Groove 2nd
P Clearance
R Service Limit Hi Limit Production ± 0.001
E Top 0.010-0.020
S Production
S 2nd 0.018-0.026
1 Gap
O Service Limit Hi Limit Production ± 0.010
N
Groove Production 0.002-0.007
0 Clearance Service Limit Hi Limit Production ± 0.001
1
L Production 0.010-0.030
Gap
Service Limit Hi Limit Production ± 0.010
PIS'PON PIN:
Diameter 0.9269-0.09271
Clearance Production 0.0002-0.0007
In Piston Service Lmit 0.001 (Maximum)
Fit In Rod 0.0008-0.0016 Interference
T2368-CNG
 SPECIFICATIONS
ENGINE SPECIFICATIONS (5.7L) (Cont.)
All specifications are in INCHES unless otherwise noted.
DISPLACEMENT: 5.7L (350 Cu. In.)
CRANKSHAFT
#1 2.4484-2.4493
Diameter #2. #3, #4 2.4481-2.4490
#5 2.4479-2.4488
Main
Production 0.0002 (Maximum)
Journal Taper
Service Limit 0.001 (Maximum)
Out Of Production 0.0002 (Maximum)
Round Service Limit 0.001 (Maximum)
#1 0.0008-0.0020
Production #2, #3, #4 0.0011-0.0023
Main
#5 0.0017-0.0032
Bearing
#1 0.0010-0.0015
Clearance
Service Limit #2, #3, #4 0.0010-0.0025
#5 0.0025-0.0035
Crankshaft End Play 0.002-0.006
Diameter 2.0988-2.0998
Production 0.0005 (Maximum)
Taper
Crankpin Service Limit 0.001 (Maximum)
Out Of Production 0.0005 (Maximum)
Round Service Limit 0.001 (Maximum)
Rod Bearing Production 0.0013-0.0035
Clearance Service Limit 0.003 (Maximum)
Rod Side Clearance 0.006-0.014
CAMSHAFT:
Lobe Intake 0.2565
Lift ±0.002 Exhaust 0.2690
Journal Diameter 1.8682-1.8692
Camshaft End Play 0.004-0.012
VALVE SYSTEM:
Lifter Hydraulic
Rocker Arm Ratio 1.50:1
Intake
Valve Lash One Turn Down From Zero Lash
Exhaust
Face Angle (Intake & Exhaust) 45'
Seat Angle (Intake & Exhaust) 46°
Seat Runout (Intake & Exhaust) 0.002 (Maximum)
Intake 1/32-1/16
Seat Width
Exhaust 1/16-3/32
Intake 0.0010-0.0027
Stem Production
Exhaust 0.0010-0.0027
Clearance Intake High Limit Production +0.001
Service
Exhaust High Limit Production +0.002
Free Length 2.03
Valve
Pressure Closed 76-84 lbs. @ 1.70”
Spring
lbs. @ in. Open 194-206 lbs. @ 1.25”
(Outer)
Installed Heiaht ±1/32” 1 23/32
Valve Spring Free Length 1.86
Damper Approx. # of Coils 4
T2369-CNG
 SPECIFICATIONS (CONT.)
FASTENER TIGHTENING SPECIFICATIONS
ITEM Nm FT. LBS. IN. LBS.
Rocker Arm Cover Bolts...................................................................... ............. 10 — 90
Intake Manifold B olts........................................................................... ............. 48 35
Exhaust Manifold Bolts
Two Center Bolts........................................................................... ............. 36 26 —
All O thers....................................................................................... ............. 28 20 —
Cylinder Head Bolts............................................................................. ............. 90 65 —
Torsional Damper B o lt......................................................................... ............. 95 70 —
Front Cover Bolts................................................................................. ............. 11 — 100
Oil Pan Nuts at Corners...................................................................... ............. 22 — 200
Oil Pan B olts......................................................................................... ............. 11 — 100
Oil Pump Bolt........................................................................................ ............. 90 65 —
Oil Pan Baffle Nuts (Some 5.7L Engines)........................................ ............. 36 26 —
Rear Crankshaft Oil Seal Retainer Screws and Nuts...................... ............. 15 — 135
Camshaft Sprocket Bolts..................................................................... ............. 28 21 —
Connecting Rod Cap N uts.................................................................. ............. 60 45 —
Oil Filter Bypass Valve Bolts............................................................... ............. 26 20
Main Bearing Cap Bolts
Outer Bolts on #2, #3, and #4 Caps.......................................... ............. 95 70 —
All O thers....................................................................................... ............. 110 80 —
Oil Pump Cover Bolts.......................................................................... ............. 9 — 80
Flywheel Bolts....................................................................................... ............. 100 75 —
Spark Plugs........................................................................................... ............. 20 15 —
Coolant Outlet Bolts............................................................................. ............. 28 21 —
Coolant Pump Bolts............................................................................. ............. 40 30 —
Flywheel Housing Bolts....................................................................... ............. 44 32 —
Oil Pan Drain Plug............................................................................... ............. 28 20 —
Oil Pan Studs to Back or Rear Oil Seal Retainer........................... ............. 2 — 15
Block Drain Plug................................................................................... ............. 22 16
T21
 SPECIAL TOOLS

1. ■>©©
O
©no
wf
f
J 23523* E 10. J 3049-A

2. J 5892-C 11.
J 5802*01

3. J 23590
12. J 5715
13. J 6036
4. J 35468

14.
J 6880

5. J 8080
15. J 5825-A

6. J 8037 16.
J 5590

7. J 5239 17. J 8520

8. J 23738-A
o n
18. J 35621

9.

1. Torsional Damper Remover and Installer 10. Hydraulic Lifter Remover (Plier Type)
2. Valve Spring Compressor 11. Stud Remover
3. Air Adapter 12. Reamer (0.003-inch oversize)
4. Crankshaft Seal Installer and Centering Tool 13. Reamer (0.013-inch oversize)
5. Main Bearing Replacer 14. Stud Installer
6. Piston Ring Compressor 15. Crankshaft Gear Puller
7. Guide Set 16. Crankshaft Gear Installer
8. Vacuum Pump 17. Dial Indicator Adapter
9. Hydraulic Lifter Remover (Slide Hammer Type) 18. Rear Crankshaft Seal Installer

F2562
 SECTION 6B1

ENGINE COOLING
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.

CONTENTS

SUBJECT PAGE
General Description ................................................................................................................................................. 6B1- 1
Cooling System ...................................................................................................................................................... 6B1- 1
Coolant Recovery Tank ........................................................................................................................................ 6B1- 2
Coolant Pump ......................................................................................................................................................... 6B1- 2
Thermostat ...............................................................................................................................................................6B1- 2
Diagnosis of Engine Cooling ..................................................................................................................................6B1- 2
System Checks ......................................................................................................................................................6B1- 2
Fan Clutch Diagnosis ........................................................................................................................................... 6B1- 3
Thermostat Diagnosis .......................................................................................................................................... 6B1- 3
Coolant Diagnosis ................................................................................................................................................ 6B1- 3
Cooling System Diagnosis ..................................................................................................................................6B1- 5
Uncommon Cooling System Problems .............................................................................................................6B1- 7
Coolant Level Indicator Diagnosis ....................................................................................................................6B1- 8
Diagnosis of Drive Belt System ..... .......................................................................................................................6B1- 9
On-Vehicle Service ....................................................................................................................................................6B1-10
Draining and Filling the Cooling System .........................................................................................................6B1-10
Flushing the Cooling System ............................................................................................................................ 6 B1-10
Coolant Recovery Tank Replacement ...............................................................................................................6B1-10
Radiator Hose Replacement .............................................................................................................................. 6B1-11
Fan And Fan Clutch Replacement ....................................................................................................................6B1-12
Auxiliary Cooling Fan Replacement .................................................. ............................................................... 6B1-13
Thermostat Replacement .....................................................................................................................................6B1-16
Coolant Pump Replacement .............................................................................................................................. 6B1-16
Belt Tensioner Inspection ................................................................................................................................... 6B1-17
Belt Tensioner Replacement .............................................................................................................................. 6B1-17
Drive Belt Replacement ...................... ................................................................................................................ 6B1-18
Engine Oil Cooler Line Replacement .............................................................................................................. 6B1-19
Fuel Pressure Regulator Coolant Hose.............................................................................................................6B1-23
Specifications ............................................................................................................................................................ 6B1-24
Special Tools .............................................................................................................................................................. 6B1-24

GENERAL DESCRIPTION
COOLING SYSTEM
All C/K-Model vehicles have pressure type engine
cooling systems with thermostatic control of the coolant
circulation. The cooling system is sealed by a pressure
type radiator cap that allows the system to operate at
higher than atmospheric pressure. The high pressure
operation raises the boiling point of the coolant, which
increases the cooling efficiency of the radiator. The
105kPa (15 psi) pressure cap raises the boiling point of
the coolant to about 125°C (257°F) at sea level.
The radiator cap has an integral pressure-vacuum
valve. This valve releases the expanding coolant when
it reaches approximately 15 psi and routes it to the
coolant recovery reservoir. The vent function allows the
coolant to return to the radiator. As the system cools,
the extra coolant in the reservoir is drawn into the radi­
ator through the vent valve. The nominal 105kPa (15
psi) pressure will not be reached until the system is
working at maximum capacity. Any air or vapor in the
cooling system will be forced to the coolant reservoir
and out through the vent tube at the top of the reser­
voir. In this manner, the radiator keeps itself full at all
times.
COOLANT RECOVERY TANK
A coolant recovery tank is a plastic reservoir, con­
nected to the radiator by a hose. As the vehicle is driven,
the coolant is heated and expands. The portion of the
fluid displaced by this expansion flows from the radiator
into the recovery bottle. When the vehicle is stopped
and the coolant cools and contracts, vacuum draws the
displaced coolant back into the radiator. This keeps the
radiator full at all times, resulting in maximum cooling
efficiency. Keep the coolant level between the “ADD”
and “FULL” marks on the recovery bottle. These marks
are about one liter (one quart) apart. Use a 44/56
(50/50) in Canada) mixture of ethylene glycol anti-freeze
and water and keep the system at the “FULL” mark
when hot.
COOLANT PUMP
The die cast pump is of the centrifugal vane impeller
type. The impeller turns on a steel shaft that rotates in
a permanently lubricated ball bearing.
DIAGNOSIS OF ENGINE COOLING
SYSTEM CHECKS
DRIVE BELT - MULTIPLE RIBBED BELT
Check the drive belt for looseness, damage, or fabric
delamination. If the belt is loose, check the belt ten-
sioner for proper operation. The belt tensioner is not
adjustable. If it is not working properly, it must be
replaced. If the belt is delaminated or damaged,
replace it.
Important
• Cracks across the rib material are a normal part of
the belt aging process. Cracks do not affect belt
operation, and do not indicate a need to replace it.
Check the belt length scale on the tensioner. If it
reads outside the “ acceptable” range, check for proper
routing as shown on the belt routing label and in this
section. Also check for proper tracking of belt ribs in
the pulley grooves, correct pulley sizes (including
idlers), and correct belt length.
Important
• Multiple rib belts stretch and wear very little. Nor­
mal stretch and wear rarely exceeds 10 mm (3/8
inch) on the belt length scale.
EXHAUST LEAKS
To check for exhaust leaking into the cooling system,
drain the system until the coolant level stands just
above the top of the cylinder heads, then disconnect
the upper radiator hose and remove the thermostat and
The pump inlet is connected to the bottom of the
radiator by a rubber hose. From the pump, coolant
passes through the engine front cover into the coolant
passages in the block to pick up excess engine heat.
THERMOSTAT
A pellet-type thermostat in the coolant outlet passage
controls the flow of engine coolant to provide fast
engine warm-up and regulate coolant temperatures. A
wax pellet element in the thermostat expands when
heated and contracts when cooled. The pellet is con­
nected through a piston to a valve. When the pellet is
heated, pressure is exerted against a rubber dia­
phragm to force the valve open. As the pellet cools, the
contraction allows a spring to close the valve. This
allows the valve to remain closed while the coolant is
cold, preventing circulation of coolant through the radi­
ator. At this point, coolant circulates throughout the
engine to warm it quickly and evenly.
As the engine warms, the pellet expands and the
thermostat valve opens. The coolant then flows through
the radiator where heat is passed through the radiator
walls. This opening and closing of the thermostat
allows the cooling system to keep the engine in the
correct operating temperature range.
belt. Start the engine and accelerate several times. At
the same time, note any appreciable coolant rise or the
appearance of bubbles that may indicate that exhaust
gases are leaking into the cooling system.
NOTICE: A worn head gasket may allow
exhaust gases to leak into the cooling sys­
tem. This can damage the cooling system as
the gases combine with the water to form
acids that are harm ful to the rad iato r and
engine.
COOLANT PUMP
Check coolant pump operation by running the engine
while squeezing the upper radiator hose. When the
engine warms, a pressure surge should be felt. Check
for a plugged vent hole in the pump.
RADIATOR
Test for restrictions in the radiator by warming the
engine up, turning the engine off, and feeling the radia­
tor. The radiator should be hot along the left side and
warm along the right side, with an even temperature
rise from right to left. Cold spots in the radiator indicate
clogged sections.
THERMOSTAT
Make an operational check of the therm ostat by
hanging the thermostat on a hook in a 33 percent gly­
col solution, -12°C (10°F) below the temperature indi­
cated on the valve. With the valve submerged and the
coolant agitated, the valve should close.
OVERHEAT AND/OR NOISE
Restrictions in the cooling system can cause engine
overheating and/or cooling system noise.
Components prone to this condition are the cylinder
head, coolant pump, block, thermostat housing, and
inlet manifold. Symptoms are:
• Engine may make snapping/cracking noises.
• Heater core may gurgle or surge.
• Radiator hoses may collapse and expand.
• Heater hoses may vibrate and thump.
• Overheat light may or may not come on.
Symptoms are caused by coolant boiling at some
localized area and may be noticed after extended idling
and/or while driving. Determine which side of the
engine is involved and whether it is at the front or rear
of the engine.
Diagnosis/Inspection
1. Isolate the area by probing the engine with a
sounding bar (large screwdriver).
C A U TIO N : The ra d ia to r cap should be
removed from a cool engine only. If the radi­
ator cap is removed from a hot cooling sys­
tem, serious personal injury may result.
2. With the radiator cap removed, observe the coolant
being circulated in the radiator. Feel the front area
of the radiator for cold spots which indicate block­
age. Blocked radiators generally occur on units
that have accrued miles and not on new vehicles.
3. Inspect the thermostat to see if it opens.
4. Inspect the thermostat housing to make sure it is
free of obstructions.
5. Remove the coolant pump from the vehicle and
remove the back cover on the pump. Inspect all
internal passages using a flashlight.
6. Inspect the crossover at the front of the inlet mani­
fold. This entire passage can be seen only with the
thermostat removed.
7. Remove the heads and check the block with a pen
light flashlight. Never replace a block unless the
restricted area can be seen.
8. Inspect the heads if the problem is not found.
Heads with blocked coolant passages generally
have more than one area that is blocked. Look for
signs of overheat discoloration (a dark blue or
black area). If none are found, look in the coolant
passages for blockage and probe all accessible
passages. The head is intricate, and all the pas­
sages cannot be reached. Use a substantial wire
to go through or around a partially blocked area. If
nothing is found by visual inspection and probing,
inspect the passages for a rough, ragged appear­
ance. The roughest internal passages are probably
the ones that are blocked. Replace a blocked or
suspect head and inspect the replacement head
before installation.
FAN CLUTCH DIAGNOSIS
NOISE
Fan noise is sometimes evident under the following
normal conditions.
• When the clutch is engaged for maximum cooling.
• During the first few minutes after start-up until the
clutch can redistribute the silicone fluid back to the
normal disengaged operating condition (after over­
night setting).
Fan noise or an excessive roar will generally occur
continuously under high engine speed conditions (2500
rpm and up) if the clutch assembly is locked up due to
an internal failure. If the fan cannot be rotated by hand
or there is a rough grating feel as the fan is turned,
replace the clutch. Refer to “ Fan and Fan Clutch
Replacement” in this section.
LOOSENESS
Check a loose fan assembly for wear and replace as
necessary. Under various temperature conditions, there
is a visible lateral movement at the tip of the fan blade.
Approximately 6.5 mm (1/4 in.) maximum lateral move­
ment measured at the fan tip is allowable. This is not
cause for replacement.
SILICONE FLUID LEAKS
The fan clutch operation is generally not affected by
small fluid leaks that may occur in the area around the
bearing assembly. If leakage appears excessive,
replace the fan clutch. Refer to “ Fan and Fan Clutch
Replacement” in this section.
ENGINE OVERHEATING
If the fan and clutch assembly free-wheel with no
drag (revolves more than five times when spun by
hand), replace the clutch. Refer to “ Fan and Fan
Clutch Replacement” in this section.
THERMOSTAT DIAGNOSIS
Refer to the thermostat diagnostic chart for thermo­
stat diagnosis procedures (figure 1).
COOLANT DIAGNOSIS
HYDROMETER
Due to changes in commercially available antifreeze,
the use of a hydrometer may give an incorrect reading.
The hydrometer should be used to test ethylene glycol
base antifreeze only. Ethylene glycol base antifreeze is
recommended for year round use.
COOLANT TESTER
Coolant testers J 26568 (Centigrade Scale) and
J 23688 (Fahrenheit Scale) can be used to check the
anti-freeze protection of the coolant. Make sure the
hydrometer readings are correct. Unless J 26568 or
J 23688 has a provision for temperature correction, test
the temperature at which J 26568 or J 23688 is cali­
brated. If the coolant is warmer or cooler, the reading
may be incorrect. Follow the manufacturer’s directions
for using J 26568 or J 23688.
Cleaning
• Before each use, swing the plastic cover back at
the slanted end of J 26568 or J 23688, exposing
the measuring window and the bottom of the
plastic cover (figure 2).
 ‘ NOTE: THE TEMPERATURE STICK IS A PENCIL LIKE DEVICE WHICH HAS A WAX MATERIAL CONTAINING
CERTAIN CHEMICALS WHICH MELT AT A GIVEN TEMPERATURE. TEMPERATURE STICKS CAN BE USED TO
DETERMINE A THERMOSTAT'S OPERATING TEMPERATURE BY RUBBING 86.6°C (188°F) AND 96.6°C
(206°F) STICKS ON THE THERMOSTAT HOUSING. THE M A R K S MADE BY THE STICKS SHOULD MELT WHEN
COOLANT TEMPERATURES OF 86.6°C (188°F) AND 96 6°C (206°F) ARE REACHED, RESPECTIVELY. THESE
TEM PERATURES ARE THE NORMAL OPERATING RANGE OF THE THERMOSTAT, THEREFORE, IF THE
COOLANT FLOWS AS INDICATED ON THE DIAGNOSIS CHART, THE THERMOSTAT MAY BE WORN.
B7540

Figure 1—Thermostat Diagnosis Chart

• Wipe dry with tissue or clean soft cloth. • Do not remove the clear plastic pump from the
• Close the plastic cover. tester.
1. Release the tip of the pump from J 26568 or
Testing J 23688.
2. Insert the tip of the pump into the radiator filler
Tools Required: neck (figure 3).
J 26568 or J 23688 Coolant Tester 3. Make sure the tip of the pump is below the level of
the coolant.

Figure 2—Cleaning the Coolant Tester Figure 3—Collecting the Coolant

 4. Press and release the bulb to draw a sample.
5. Insert the tip of the pump into the cover plate
opening.
6. Press the bulb and inject a few drops of coolant J 23688 or .* )
mmm -40
onto the measuring surface. 0 1 xx>™ mm -30
0 •

i J-i
o :
• Do not open the plastic cover when taking read­
4

r
* - T E —
ings because water evaporation can change the «p»i
= n mmm * 5
reading. C 1140 A mmm * K>
A 2 N ^ * 15
* V10Q —
Reading G
C
mmm, JO

B A T T fR Y — * w
CHARGE
• Point J 26568 or J 23688 toward any light source — * w

and look into the eyepiece (figure 4). n ff M A N C N T

A N T IF R E E Z E
> « O T E t TlO N *F
• Coolant protection reading is at the point where
the dividing line between light and dark crosses
the scale (antifreeze protection is the scale on
the right). M1197
• Temperature scale is reversed from a standard
thermometer scale. Figure 4— Reading the Coolant Tester
• Below zero readings are on upper half of the
scale. COOLING SYSTEM DIAGNOSIS
• Readings on the lower half of the scale indicate Refer to the cooling system diagnosis charts for
solutions without enough antifreeze concentra­ detailed cooling system diagnostic procedures (figures
tion to provide adequate rust protection. 5 and 6).
• If the readings are not clear, the measuring sur­
faces were not cleaned and dried properly.
Wipe dry and make a new test.
COOLING SYSTEM DIAGNOSIS - CHART A

L0770
 UNCOMMON COOLING SYSTEM
PROBLEMS
PROBLEMS NOT REQUIRING DISASSEMBLY OF
THE COOLING SYSTEM
1. Remove large obstructions blocking the radiator or
COOLING SYSTEM DIAGNOSIS - CHART B condenser.
• Auxiliary oil cooler.
COOLANT LOSS • License plates.
X • Spare tires.
CHECK PRESSURE CAP BAD • Ice, mud, or snow obstructing the grille.
X 2. Engine oil is overfilled.
OK REPLACE 3. Incorrect radiator for the application.
ZC • Check the part number.
VISUAL SYSTEM CHECK 4. Loose, damaged, or missing air seals.
I 5. Missing or damaged lower air baffle.
6. Incorrect ignition timing.
1. LEAKS - CHECK HOSES. RADIATOR.
CLAMPS, COOLANT PUMP, THERMOSTAT PROBLEMS REQUIRING DISASSEMBLY OF THE
HOUSING. RADIATOR DRAIN. SOFT OR
CORE PLUGS. HEATER COOLANT VALVES,
COOLING SYSTEM
HEATER CORE 1. Incorrect or damaged fan.
2. FOAMING COOLANT - OBSERVE IN THE 2. Worn or damaged emission system components.
FILLER NECK AFTER ENGINE WARMUP.
3. OVERFLOW SYSTEM - (SEMI-SEALED • Could cause overheating at idle.
SYSTEM) • Damaged positive crankcase ventilation (PCV)
A. CHECK FOR GASKET IN PRESSURE CAP.
valve, thermal vacuum switch (TVS), or coolant
B. CHECK FOR LEAKS ~ HOSES, CLAMPS. temperature switch (CTS).
OVERFLOW BOTTLE, FILLER NECK NIPPLE. 3. Pressure check the cooling system with the pres­
C. CHECK FOR OBSTRUCTIONS OR sure cap installed.
PLUGGING IN THE HOSE BETWEEN THE
RADIATOR AND BOTTLE. • Shows if the pressure cap leaks because of
radiator filler neck damage.
4. Worn or damaged coolant pump.
REPAIR OR • Impeller vanes eroded or broken.
REPLACE DEFECTS • Worn or damaged bearing and/or seal. Check
for shaft or bearing play.
5. Plugged radiator tubes.
PRESSURE CHECK SYSTEM
LEAKS
• Perform a flow check.
INSTALL PRESSURE CAP
6. Internal system leaks.
CHECKER ON THE RADIATOR
FILLER NECK AND PRESSURIZE • Head gasket.
THE SYSTEM TO RATED • Cracked block.
PRESSURE IF THE SYSTEM REPAIR
• Timing chain cover.
DOES NOT HOLD PRESSURE
LOOK FOR THE LEAK LOCATION.
• Intake manifold gasket.
7. Plugged coolant passages in the cylinder heads.
I • Visual check.
OK
X
ANY REPAIRS?

YES

SYSTEM IS OK

V0329

Figure 6—Cooling System Diagnosis Chart

 COOLANT LEVEL INDICATOR
DIAGNOSIS C
The coolant level indicator circuit is shown in figure
7. B m
'
INDICATOR LAMP WILL NOT ILLUMINATE
1
H i'
1. Turn the ignition switch to the “ ON” position. 1 Module
• If the lamp illuminates, the lamp is OK and the
connector is properly installed on the module. Go L— 1 - - - - _ •-! '
to step 2.
• If the lamp does not illuminate, check the bulb,
socket, and wiring between the socket and the A. Coolant Level Probe
module connector, as well as the connector on the B. Module
module. Replace or repair as required. C. "Low Coolant" Indicator Lamp
2. Turn the ignition switch to the “ ON” position and D. Fuse
disconnect the electrical lead at the coolant level
sensor on the radiator. L0700
• If the lamp fails to illuminate, check the wiring
between the coolant level sensor connector and Figure 7—Low Coolant Level Sensor Circuit
the module for a short circuit to ground. If the
circuit is OK, replace the module. • If the lamp does not illuminate, replace the
sensor.
INDICATOR LAMP REMAINS ILLUMINATED • If the lamp remains illuminated, connect the
1. Turn the ignition switch to the “ ON” position. electrical lead and go to step 3.
• Check the coolant level. Add coolant if neces­ 3. Check for an open circuit between the sensor and
sary. the module.
• If the lamp remains illuminated, go to step 2. • If an open circuit is found, repair it.
2. Disconnect the electrical lead at the coolant level • If no open circuit is found, replace the module.
sensor on the radiator (use a jumper wire and “ G”
type electrical connector).
 DIAGNOSIS OF DRIVE BELT SYSTEM
Drive belts and pulleys wear evenly with use. Unusual signs of wear indicate some correction is needed. The
following diagnostic chart will aid in diagnosing multiple ribbed belt system problems.

DEFINITIONS:
Chirping: Chirping is a high pitched noise that is usually heard once per revolution of a pulley or belt. It is also
usually heard at idle and is most common on cold damp mornings. By squirting water onto a chirping
belt, the noise will momentarily go away.
Squeal: Squeal is a loud screeching noise that is usually caused by a slipping belt. The noise usually occurs
when a heavy load is applied to the belt, such as compressor engagement, accelerating the engine,
or the belt slipping on seized pulley.
W hine: Whine is a high pitched continuous noise that may be caused by a failed bearing.
Faint Cyclic
Rumbling: Faint cyclic rumbling is a deep low frequency noise (once per revolution of the belt).
Pilling: Pilling is 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 affected unless
buildup exceeds 1/3 of the belt groove depth.

PROBLEM POSSIBLE CAUSE CORRECTION

Chirp 1. Misalignment of pulleys. 1. Check pulley alignment.

a Power steering pump pulley.
b. Bent or cracked brackets.
c. Loose or missing fasteners.
2. Bent pulley flange.
3. Severe pilling, exceeding 1/3 of belt
groove depth.
a. Refer to SECTION 3B.
b. Replace as necessary.
c. Check and re-torque. Replace as
necessary.
2. Replace as necessary.
3. Replace belt.

Squeal 1. Seized bearings. 1. Replace as necessary.

2. Insufficient tension. 2.
a. Incorrect belt length. a Replace belt.
b. Incorrect pulley size. b. Replace pulley.
c. Malfunctioning tensioner. c. Replace tensioner.
d. Incorrect drive belt routing. d. Refer to drive belt routing.
Whine Worn bearings. Replace as necessary.

Ffeint Cyclic Rum­ Severe pilling. Replace belt.

bling

Belt Falls Off 1. Misalignment of pulleys. 1. Check pulley alignment,

a. Bent or cracked brackets.
b. Loose or missing fasteners.
c. Misaligned power steering pump
pulley.
2. Damaged belt.
3. Malfunctioning tensioner.
4. Worn idler or tensioner pulley bearings.
Vibration 1. Bent or cracked brackets.
2. Loose or missing fasteners.
3. Damaged fan blades.
4. Bent fan clutch or coolant pump shaft.
a Replace as necessary.
b. Check and re-torque, replace as
necessary.
c. Refer to SECTION 3B.
2. Replace as necessary.
3. Replace as necessary.
4. Replace as necessary.
1. Replace as necessary.
2. Check and re-torque, replace as neces­
sary.
3. Replace as necessary.
4. Replace as necessary.

Excessive Wear in Ribs in the drive belt do not match the Replace damaged belt as necessary. Refer
Either Outside grooves in the pulley. to Drive Belt Replacement in this section.
Groove of Drive Belt
D0270
 ON-VEHICLE SERVICE
DRAINING AND FILLING
THE COOLING SYSTEM
DRAINING
1. Place a drain pan under the radiator drain cock.
2. Install a tube on the drain cock.
3. Place the end of the tube in the pail or pan.
4. Make sure the cooling system is cool, then remove
the radiator cap.
5. Open the drain cock completely.
6. Lift the cooling system drain until the flow stops.
7. Place a drain pan under the engine.
8. Remove the drain plug in the engine block.
9. Let the engine block drain until the flow stops.
• There may be more drainage from the radiator
at this time.
10. Replace the engine block drain plug.
11. Close the radiator drain cock.
FILLING
1. Check the radiator drain cock to be sure it is
closed.
2. Check the engine drain plug to be sure it is tight.
3. Premix the antifreeze, with clear water on a 44/56
(50/50 in Canada) ratio.
• If the old coolant is being used, check it for
44/56 glycol/water mix (50/50 in Canada) and
make sure it is clean and clear.
4. Place a large top funnel in the radiator fill hole.
100.
101.
102.
103.
101 104.
105.
106.
107
5. Slowly pour in the coolant. The filling may be
slowed because of the thermostat being closed.
6. After the cooling system is filled to 1/2 inch below
the fill hole, start the engine and let the cooling
system warm up. When the thermostat opens, the
coolant level may drop. If the level drops, add
coolant until the level is up to the fill hole.
7. Replace the radiator cap.
8. Check the coolant level in the recovery tank. Add
coolant if needed.
FLUSHING THE COOLING SYSTEM
Various methods and equipment can be used to flush
the cooling system. If special equipment such as a
back flusher is used, follow the equipment manufactur­
er’s instructions.
Important
Remove the thermostat before flushing the cooling
system.
COOLANT RECOVERY TANK
REPLACEMENT
Remove or Disconnect (Figure 8)
1. Coolant from the recovery tank (100).
RESERVOIR, COOLANT RECOVERY
CAP, COOLANT RECOVERY RESERVOIR
BOLT, COOLANT RECOVERY RESERVOIR
SUPPORT, COOLANT RECOVERY RESERVOIR
CLAMP
HOSE, COOLANT RECOVERY RESERVOIR
CLAMP
BRACKET, COOLANT RECOVERY RESERVOIR SUPPORT
107
V2763
2. Clamps (104 and 106). RADIATOR HOSE
3. Coolant recovery reservoir hose (105) from the
recovery tank (100). REPLACEM ENT
4. Overflow hose (108).
5. Bolts (102). Some C/K-Models use a spring-type clamp at the radi­
6. Coolant recovery tank (100) from the vehicle. ator hose connections. When this type of clamp is used,
the radiator hoses should be installed on dry non­
Install or Connect (Figure 8) painted surfaces to ensure proper sealing.

1. Coolant recovery tank (100) to the vehicle.

5.7L ENGINE
NOTICE: See “Notice” on page 6B1-1.
Remove or Disconnect (Figure 9)
2. Bolts (102).
• Drain the cooling system.
1. Retaining strap (53) from the upper fan shroud.
2. Bolt (55) from the hose support (54).
• Bolts (102) to 10 N-m (89 in. lbs.). 3. Hose support (54).
3. Coolant overflow hose (108) to the recovery tank 4. Hose clamps (52 and 56) from the inlet and outlet
( 100 ). hoses.
4. Coolant recovery reservoir hose (105) to the recov­ 5. Radiator inlet hose (50).
ery tank (100). 6. Radiator outlet hose (51).
5. Clamps (104 and 106).
6. Coolant in the recovery tank (100).

50. HOSE, RADIATOR INLET

51. HOSE, RADIATOR OUTLET
52. CLAMP, RADIATOR HOSE
56. CLAMP, RADIATOR HOSE
57. STRAP, RADIATOR OUTLET HOSE
58. SUPPORT, RADIATOR INLET HOSE
59. BOLT, RADIATOR INLET HOSE SUPPORT

V2634
-►«- Install or Connect (Figure 9) FAN AND FAN CLUTCH
REPLACEMENT
NOTICE: For steps 3 and 5, see “Notice” on Remove or Disconnect (Figure 10)
page 6B1-1.
1. Radiator fan shroud. Refer to SECTION 6B2.
1. Radiator outlet hose (51). 2. Nuts (17).
2. Radiator inlet hose (50). 3. Fan (15) and fan clutch (16) from the coolant pump
3. Clamps (52 and 56) to the radiator inlet and outlet pulley.
hoses (50 and 51). 4. Bolts (14).
5. Fan (15) from the fan clutch (16).
a Tighten
inspect
• Clamps to 3 N-m (27 in. lbs.).
4. Hose support (54) to inlet hose (50). * Inspect the mating surfaces (the coolant pump hub
5. Bolt (55). and the fan clutch hub) for smoothness. Rework as
necessary to eliminate any burrs or other imperfec­
tions.

• Bolt to 3 N-m (27 in. lbs.).
6. Retaining strap (53) to the upper fan shroud.
• Fill the cooling system to the proper level.
|+<-| Install or Connect (Figure 10)
CAUTION: Do not repair and reuse a fan with
a bent or damaged blade. Replace the fan as
an assembly. A damaged blade can change
the balance of a fan. A fan out of balance
could fly apart during use and cause person­
al injury or damage to the vehicle.

F. PULLEY, COOLANT PUMP

13. STUD
14. BOLT, FAN CLUTCH
15. FAN
16. CLUTCH, FAN
17. NUT V2864

Figure 10— Fan and Fan Clutch

 Auxiliary Cooling
Fan Relay

Auxiliary

B
0

j
c
U
A Engine..... ...
12 V.

Harness | B A I
Connector 1
Frame; Sheet 12 V.
Metal Ground 20A
I B 1 A j

Coolant
Temperature
Switch

L0799

Figure 11— Auxiliary Cooling Fan Circuit Diagram

NOTICE: For steps 2 and 4, see “Notice” on AUXILIARY COOLING FAN

page 6B1-1.
REPLACEMENT
1. Fan (15) to the fan clutch (16). The auxiliary cooling fan provides additional cooling
2. Bolts (14). for low speed vehicle operations, extended idle, stop
and go conditions, and running the air conditioning
Tighten system.
The auxiliary cooling fan circuit consists of a coolant
• Bolts (14) to 24 N.m (18 ft. lbs.). temperature sensor, relay, and auxiliary fan. When the
coolant sensor reaches a predetermined temperature, it
3. Fan and clutch assembly to the coolant pump
closes the circuit to the relay coil, this energizes the
pulley. relay, passing 12 volts to the auxiliary fan. When the
4. Nuts (17). coolant temperature decreases below the setpoint of
• Align the yellow reference marks on the coolant the sensor, the circuit to the relay opens and voltage to
pump hub and the fan clutch hub. the auxiliary fan stops. The cooling fan only operates
when the ignition is on and the coolant temperature
£ Tighten sensor is above the set temperature.
Refer to figure 11 for the auxiliary cooling fan circuit
• Nuts (17) to 24 N-m (18 ft. lbs.). diagram, and figure 12 for auxiliary cooling fan system
5. Fan shroud. Refer to SECTION 6B2. diagnosis.
 L1200

Figure 12— Auxiliary Cooling Fan System Diagnosis

FAN RELAY +*• Install or Connect (Figure 13)

Remove or Disconnect (Figure 13)
NOTICE: See “Notice” on page 6B1-1.
1. Negative battery cable.
2. Wiring harness connector. 1. Coolant temperature sensor (145).
3. Fan relay (141) from inner fender panel.
& Tighten
Install or Connect (Figure 13)
• Coolant temperature sensor to 23 N m (17 ft.
1. Fan relay (141) to inner fender panel. lbs.).
2. Wiring harness connector. 2. Wiring harness connector (144).
3. Negative battery cable. 3. Negative battery cable.
COOLANT TEMPERATURE SENSOR

Remove or Disconnect (Figure 13)

1. Negative battery cable.

2. Wiring harness connector (144).
3. Coolant temperature sensor (145).
144 145
5.7L
V2865-CNG
 THERMOSTAT REPLACEMENT
<#•+ Remove or Disconnect (Figure 14)

1. Drain the cooling system until the radiator coolant

level is below the thermostat.
2. Bolts (24) or studs (20).
3. Coolant outlet (21).
4. Thermostat (23) from its housing.
5. Gasket (22).

§ )• Clean

• Thermostat housing and coolant outlet sealing sur­

faces.

0 Install or Connect (Figure 14)

1. Thermostat (23) in its housing.

2. New gasket (22) into position.
3. Coolant outlet (21).

NOTICE: See “Notice” on page 6B1-1.

4. Bolt (24) and studs (20).

$ Tighten

• Bolts (24) and studs (20) to 28 N*m (21 ft. lbs.).

5. Fill the cooling system.
6. Start the engine and run with the radiator cap
removed until the radiator upper hose becomes hot
(thermostat is open).
7. With the engine idling, add coolant to the radiator
until the coolant level reaches the bottom of the
filler neck.
8. Radiator cap to the radiator, making sure the
arrows line up with the overflow tube.
Figure 14— Thermostat and Components
(5.7L Engine)
COOLANT PUMP REPLACEMENT
2. New gaskets (94).
I++I Remove or Disconnect (Figure 15) 3. Bolts (92).
1. Coolant from the radiator.
2. Upper fan shroud. Refer to SECTION 6B2. £ Tighten
3. Drive belt. Refer to “Drive Belt Replacement.”
4. Fan, fan clutch, and pulley from the coolant pump. • Bolts (92) to 41 N-m (30 ft. lbs.).
Refer to “Fan and Fan Clutch Replacement.” 4. Lower radiator (outlet) hose and heater hose to the
5. Lower radiator (outlet) hose and heater hose from coolant pump.
the coolant pump. 5. Coolant pump pulley, fan, and fan clutch to the
6. Bolts (92). coolant pump hub. Refer to “ Fan and Fan Clutch
7. Coolant pump (91) from the engine block. Replacement.”
6. Drive belt. Refer to “ Drive Belt Replacement.”
E93 Clean 7. Upper fan shroud. Refer to SECTION 6B2.
• Mating surfaces on the coolant pump and the engine 8. Start the engine and run, with the radiator cap
block. removed, until the upper radiator hose becomes
hot (thermostat is open).
0 Install or Connect (Figure 15) 9. Add coolant to the radiator until the level reaches
the bottom of the filler neck.
NOTICE: For steps 3 and 6, see “Notice” on • Engine must be running at idle speed.
page 6B1-1.
10. Radiator cap, making sure the arrows line up with
1. Coolant pump (91) to the engine block. the overflow tube.
 • Movement should feel smooth and return freely
without any binding. If any binding is observed,
replace the tensioner.

-►+ Install or Connect

1. Multiple ribbed drive belt. Refer to “ Drive Belt

Replacement” in this section.
2. Negative battery cable.

BELT TENSIONER REPLACEMENT

Remove or Disconnect (Figures 16
90.
91.
Engine Block
Coolant Pump 0 through 19)
92. Bolt 1. Negative battery cable.
94. Gasket 2. Multiple ribbed drive belt. Refer to “Drive Belt
F9548
Replacement” in this section.
Figure 15— Coolant Pump and Components 3. Bolt (111).
(5.7L Engine) 4. Tensioner (110).

BELT TENSIONER INSPECTION Install or Connect (Figures 16 through 19)

1. Negative battery cable.
2. Multiple ribbed drive belt. Refer to “ Drive Belt
Replacement” in this section.
• Position a hex head socket on the belt tensioner
pulley bolt head.
• Move the drive belt tensioner through its full travel.
NOTICE: Do not allow the drive belt tensioner
to snap into the “free” position. This may
result in damage to the tensioner.
1. Tensioner (110) to mounting bracket.
NOTICE: See “Notice” on page 6B1-1.
2. Bolt (111).
a Tighten
• Bolt (111) to 83 N-m (61 ft. lbs.).
3. Multiple ribbed drive belt. Refer to “Drive Belt
Replacement” in this section.
4. Negative battery cable.

111

FRT +

109. BRACKET, DRIVE BELT TENSIONER

110. TENSIONER, DRIVE BELT
111. BOLT, DRIVE BELT TENSIONER
V2765
 123

109

127

WITHOUT A/C
109. BRACKET, DRIVE BELT TENSIONER WITH A/C WITHOUT A.I.R.
121. STUD, DRIVE BELT TENSIONER BRACKET
122. NUT, IDLER PULLEY BRACKET
123. BRACKET IDLER PULLEY
124. NUT, DRIVE BELT TENSIONER BRACKET
125. BOLT, IDLER PULLEY BRACKET
126. BOLT, DRIVE BELT TENSIONER BRACKET
127. PULLEY, IDLER
V2768-CNG

Figure 17— Idler Pulley and Bracket (5.7L Engine)

DRIVE BELT REPLACEMENT

109. BRACKET, DRIVE BELT TENSIONER Maintaining the multiple ribbed drive belt and pulleys
112. NUT
can extend the normal life of a drive belt.
113. NUT
114. BRACE PULLEY INSPECTION
115. NUT
116. BOLT
Examine the pulleys for chips, nicks, tool marks,
117. BRACE
cracks, bent sidewalls, corrosion, or other damage.
1. Place a straightedge or position a cord across the
two pulleys so they touch at all points (figure 20).
2. Turn each pulley one half revolution and recheck
116 with a straightedge or cord. Full contact at all
points must be made. If contact is not made at all
points, the pulley may be warped or its shaft could
be bent. Replace any parts found to be damaged.
3. If the belt becomes loose and squeals or the belt
comes off the engine drive pulleys, refer to “ Diag­
nosis of Drive Belt System” in this section.
117 DRIVE BELT INSPECTION

Important

• Routine inspection of the belt may reveal cracks in

the belt ribs. These cracks will not impair belt per­
formance and are not a basis for belt replacement.
If sections of the belt are missing, the belt should
be replaced.
Do not use drive belt dressings to extend belt life.
V2766-CNG Use of belt dressing will soften the belts and cause
deterioration. Oil or grease contamination on the belt or
Figure 18— Belt Tensioner Braces pulleys will also deteriorate the belt.
(5.7L Engine with A/C)
 VIEW A

1. Used Belt Acceptable Wear Range 6. New Belt Range

2. Arm 7. New Belt Length Range
3. Pulley 8. Used Belt Length Range
4. Belt 9. Spindle
5. Spindle 10. Arm

F8885
Figure 19— Automatic Belt Tensioner and Belt Length Scale

DRIVE BELT REPLACEMENT

Remove or Disconnect (Figure 21)

nrr 1. Use a 1/2-inch breaker bar with a 16-mm (5/8-inch)

socket placed on the tensioner pulley axis bolt and
rotate the tensioner to release belt tension.
2. Belt.

install or Connect (Figure 21)

1. Route belt over all the pulleys except the belt ten­
sioner.
ijJ B | I 2. Use a 1/2-inch breaker bar with a 16-mm (5/8-inch)
A. Correct Alignment socket placed on the tensioner pulley axis bolt and
rotate the tensioner to the released position.
B. Incorrect Alignment
3. Belt over the belt tensioner pulley.
C Cord Or Straight Edge
4. Check the belt for correct “ V ” groove tracking
B8087
around each pulley.
Figure 20— Checking the Pulley Alignment
ENGINE OIL COOLER LINE
REPLACEMENT
BELT INSTALLATION The optional oil cooler is either an integral part of the
Install a multiple ribbed belt following the belt routings radiator or a separate unit placed in front of the radia­
shown in figure 21. The grooves in the belt must match tor. If an integral type cooler needs repair, refer to SEC­
the grooves in the pulleys. The tensioner is spring load­ TION 6B2. Cooler lines and hoses are serviceable.
ed. After removing the belt, the tensioner will return the Refer to figures 22 through 24 for the applicable engine
tension position. being serviced.
 A. PULLEY, A/C COMPRESSOR
B. PULLEY, DRIVE BELT TENSIONER
C. PULLEY, GENERATOR
D. PULLEY, POWER STEERING PUMP
E. PULLEY, CRANKSHAFT
F. PULLEY, COOLANT PUMP WITHOUT A/C WITH A/C
H. PULLEY, IDLER
V2772

Figure 21— Multiple Rib Drive Belt Routing (5.7L Engine)

OIL COOLER SYSTEM SERVICE

XJJJI Clean
If foreign material has entered the oil cooler or if the
engine has been damaged internally, flush the oil cool­
• All components in a suitable solvent and dry with
er, connecting lines, and filter adapter assembly in the
compressed air.
following manner.
Remove or Disconnect (Figures 22
through 26)
L* Inspect

All fittings, connectors, and cooler lines for dam­

• Set the parking brake.
1. Oil cooler lines (148 and 150) from the connector
(149 or 176).
• Using a small pick-type tool and your thumb (A
in figure 25), grasp the connector end (149)
and pull the clip from the connector (B in figure
25). This releases the cooler line (148 or 150)
from the connector (149).
NOTICE: Do not use more than 690 kPa (100
psi) air to clean the cooler and lines. Exceed­
ing 690 kPa (100 psi) could damage the cool-
er or lines.
A. Using clean solvent and compressed air,
back-flush the oil cooler and lines (148 and
150).
B. Using compressed air, remove the cleaning sol­
vent.
C. Flush the system using the same type of oil
normally circulated through the cooler.
2. Bolt (155) or nut (161) from bracket (147) or clamp
(160).
3. Oil filter and discard.
4. Oil cooler lines (148 and 150) from the clip (163 or
152) or strap (159).
5. Oil cooler lines (148 and 150) from the oil cooler at
fitting (146).
age or distortion.
+«- Install or Connect (Figures 22 through 26)
NOTICE: For steps 1, and 3, See “Notice” on
page 6B1-1.
• Using your thumb and forefinger, insert the con­
nector clip into one of the three recesses in the
connector (C in figure 26). With one end of the clip
engaged in the connector slot, use your thumb
and rotate the clip around the connector until it
snaps into place (D and E in figure 26).
NO TICE: M ake sure the c o n n e cto r clip
engages all three slots in the connector. Fail­
ure to properly install the connector clip
could cause the oil cooler line to come loose
and cause damage to the engine.
1. Oil cooler lines (148 and 150) to the oil cooler.
$ Tighten
• Oil cooler line fittings (146) to 23 N-m (17 ft.
lbs.).
2. Oil cooler lines (148 and 150) to the clip (163 or
152) or strap (159).
 Figure 22— Engine Oil Cooler Lines and Components (5.7L Engine without H.D. Cooling)

A. MOUNT, ENGINE
146. FITTING, OIL COOLER HOSE
148. HOSE, OIL COOLER INLET
149. CONNECTOR, OIL FILTER ADAPTER
150. HOSE, OIL COOLER OUTLET
158. BRACKET, OIL COOLER HOSE
160. CLAMP, OIL COOLER HOSE BRACKET
161. NUT, OIL COOLER HOSE BRACKET CLAMP
162. BOLT, OIL COOLER HOSE BRACKET
163. CLIP, OIL COOLER HOSE
164. BOLT, OIL COOLER HOSE CLIP
165. COOLER, ENGINE OIL

165

146

164

161 V2869
 Figure 24— Auxiliary Engine Oil Cooler Assembly

Figure 25—-Removing Oil Cooler Line From Connector

3. Bolt (155) or nut (161) to bracket (147) or clamp • A distinct “ snap” should be heard when
(160). assembling the oil cooler line to the quick
connector (149 or 176). The oil cooler line
a Tighten must be fully inserted into the quick connec­
tor (149 or 176). Check this by applying a
• Bolt (155) to 9 N-m (80 in. lbs.). forceful pull to the fitting.
• Nut (161) to 13 N-m (115 in. lbs.). • If the flow is restricted, replace the radiator.
Refer to SECTION 6B2.
4. New oil filter.
Run the engine and check for leaks.
• Test the flow of oil through the cooler before
connecting the lines (148 and 150).
• If the flow is not restricted, connect the oil lines
(148 and 150) to the connector (149 or 176).
 Figure 26— Installing Oil Cooler Line Clip Into Connector

FUEL PRESSURE REGULATOR

CO O LANT HOSE

0 Remove or Disconnect (Figures 27 and 28)

• Open hood.
• Drain the cooling system.
1. Hose clamp.
2. Regulator coolant hose from heater hose “T.”
• Raise vehicle. Support with suitable jackstands.
3. Hose clamp.
4. R e g u la to r c o o la n t hose from fue l pre ssure
regulator.
5. Hose clamp at transmission.
6. Pressure regulator coolant hose.

R Install or Connect (Figures 27 and 28)

NOTICE: For steps 2, 4 and 6, see “Notice” on
page 6B1-1.
1. Fuel pressure regulator coolant hose.
2. Coolant hose clamp to transmission.
3. Coolant hose to fuel pressure regulator.
4. Mubea hose clamp.
• Lower the vehicle.
5. Regulator coolant hose to heater hose “T.”
6. Mubea hose clamp.
• Fill the cooling system to the proper level.

1. COOLANT HOSE TO REGULATOR

2. HEATER HOSE “T”
3. HEATER HOSE
4. CLAMP

C0001-6B1-CNG

Figure 27— Regulator Coolant Hose at Heater

Hose “T”
 Figure 28— Regulator Coolant Hose at Fuel Pressure Regulator

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Item Nm Ft. Lbs. In. Lbs.
Coolant Recovery Reservoir Bolts (102) ..................... 10 - 89
Radiator Hose Clamps (52 or 56) ..................... 3 - 27
Radiator Inlet Hose Support Bolt (55) ..................... 3 - 27
Fan to Fan Clutch Bolts (14) ................ ..................... 24 18 -
Fan Clutch to Coolant Pump Stud Nuts (17) ........................ ..................... 24 18 -
Fan Clutch to Coolant Pump Stud (13) ..................... 8 - 71
Coolant Temperature Sensor (145) ..................... 23 17 -
Coolant Outlet to Intake Manifold Bolt (24) or Stud (20) .... ..................... 28 21 -
Coolant Pump Bolts (9 2 )....................... ..................... 41 30 -
Drive Belt Tensioner Bolt (111) ..................... 83 61 -
Oil Cooler Line Fittings (146) ............... ..................... 23 17 -
Oil Cooler Line Clip Bolt (167) ............. ..................... 6 — 53
Oil Cooler Line Bracket Bolt (155) ..................... 9 - 80
Oil Cooler Line Clamp Nut (161) ..................... 13 - 115
T2856-CNG

SPECIAL TOOLS

1 /»*==: J 23688 (Farenheit Scale)

J 26568 (Centigrade Scale)

1. Coolant Testers
F9624
 SECTION 6D7

ENGINE W IR IN G

When it is necessary to move any of the wiring,

whether to lift wires away from their harnesses or move
harnesses to reach some component, take care that all
wiring is replaced in its original position and all
harnesses routed correctly. If clips or retainers break,
replace them. Electrical problems can result from wiring
or harnesses becoming loose and moving from their
original positions or from being rerouted. Refer to figures
1 through 5 for the correct routing of engine wiring.

3. INSTRUMENT PANEL HARNESS

4. A/C HARNESS

F9417-CNG

Figure 1 — Engine Wiring to the ECM

 4| F ftf

13 62

6. CONNECTOR, AUXILIARY FAN, 7.4L ONLY 65

7. HARNESS, FORWARD LAMP
8. SENSOR, OXYGEN
9. CONNECTOR, BULKHEAD
10. SWITCH, AUXILIARY FAN, 7.4L ONLY
13. COVER, JUNCTION BLOCK
34. HARNESS, CNG CONTROL
62. MOTOR, WINDSHIELD WASHER
63. VALVE, BRAKE PRESSURE WARNING
64. LEAD, ELECTRIC FUEL PUMP
65. HARNESS, TAIL AND STOPLAMP
67. VALVE, BRAKE SENSOR MODULE

V2926-CNG
11. RELAY, FUEL SUPPLY
12. RELAY, CNG CONTROL
14. COWL
15. HARNESS, ENGINE
16. BYPASS, EST
17. CONNECTOR, A/C
18. BLOCK, JUNCTION
19. WIRE, GROUND
20. FUSE, IN-LINE VIEW A
21. FUSE, IN-LINE CNG
22. HARNESS, CNG
V2927-CNG

Figure 3— Junction Block and Relays

21. COMPRESSOR, A/C
24. SENSOR, MAP
25. SENSOR, KNOCK
30. GENERATOR
32. CABLE, BATTERY
33. SOLENOID, STARTER MOTOR
34. HARNESS, CNG CONTROL
35. MODULE, ESC
36. SENSOR, THROTTLE
38. INJECTOR, CNG FUEL
39. CONTROL, IDLE AIR
40. VALVE, EVR (5.7L ONLY)

V2930-CNG
6 19

6. GENERATOR
8. SENSOR, OXYGEN-HEATED /*.
19. WIRE, GROUND
24. COIL, IGNITION
28. STUD, ENGINE
29. HARNESS, GROUND
34. HARNESS, CNG CONTROL
41. SENSOR, COOLANT TEMPERATURE
42. DISTRIBUTOR
43. SENDER, OIL PRESSURE
44. SWITCH, ENGINE TEMPERATURE
V2931-CNG
6D 7-6 ENG INE W IR IN G
 SECTION 6F

EXHAUST SYSTEM
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed, always reinstall them at the same location from which they were removed. If a fastener needs to
be replaced, use the correct part number for the application. If the correct part number is not available, a
fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused and those
requiring thread locking compound will be called out. The correct torque value must be used when
installing fasteners that require it. I the above conditions are not followed, parts or system damage could
result.

CONTENTS

SUBJECT PAGE
General Description ......................................................................................... ...........................................................6F- 1
Diagnosis of Exhaust System .................................................................... .............................................................. 6F- 2
On-Vehicle Service ....................................................................................................................................................... 6F- 3
Inspection ..................................................................................................................................................................6F- 3
Removing Exhaust Parts ........................................................................................................................................6F- 3
Installing Exhaust Parts ..........................................................................................................................................6F- 3
Catalytic Converter Replacement .........................................................................................................................6F- 3
Intermediate Exhaust Pipe Replacement..............................................................................................................6F- 4
Specifications .............................................................................................................................................................. 6F- 7

GENERAL DESCRIPTION
Exhaust system designs vary according to the engine
designation and intended use of the vehicle.
The exhaust pipe(s), muffler(s), and tailpipe(s) are
standard equipment. The exhaust system uses a ball
joint coupling to secure the exhaust pipe to the engine
manifold. The ball joint allows angular movement for
alignment purposes. The other connections use a slip
joint coupling design with a clamp and U-bolt.
The exhaust system is suspended by hangers
attached to the frame members. These allow some
movement of the exhaust system, but should not allow
the transfer of noise and vibration into the vehicle.
Heat shields are used to protect the vehicle and the
environment from the high temperatures developed
from the exhaust system, especially the catalytic con­
verter.
The catalytic converter is an emission control device
added to the engine exhaust system to reduce hydrocar­
bon and carbon monoxide pollutants from the exhaust
gases. The catalytic converter for the computer com­
mand control emission system will also contain rhodium
to reduce the level of nitrogen oxides. The catalyst in the
converter is not serviceable.
 DIAGNOSIS OF EXHAUST SYSTEM
Exhaust system performance complaints, such as excessive back pressure, are noticeable by their effect on engine
performance. However, other malfunctioning vehicle components have similar effects on engine performance and
are characterized by the same symptoms or complaints. Therefore, it is necessary to refer to the engine diagnosis
procedure when attempting to diagnose this type of problem.
NOTICE: Replacement of exhaust system parts MUST be OEM standard.

PROBLEM POSSIBLE CAUSE CORRECTION

Vibrating or Rattling Loose and/or misaligned components. Align, then tighten connections. Check for
From Exhaust Sys- damaged hanger or mounting brackets and
tem clamps.

Restricted Exhaust 1. “ Kinked” exhaust tubing.
System
2. Restriction within the muffler. Refer
to “ R e s t r i c t e d E x h a u s t Sy s t em
Check” in Part II of this supplement.
3. End of tail pipe obstruction.
4. Plugged catalytic converter (may re­
sult from serious engine malfunction).
Refer to “Restricted Exhaust System
Check” in Part II of this supplement.
1. If possible, repair the damaged condi­
tion, otherwise replace the component.
2. If restriction is suspected, remove the
muffler and visually check it. Replace
muffler if condition is doubtful.
3. Remove the obstruction, or if end is
crimped, straighten outlet.
4. Replace the catalytic converter.

Exhaust Leakage 1. Leakage at exhaust component joints 1. Tighten clamps or couplings to speci­
and/or Noise and couplings. fied torque.
2. Improperly installed or misaligned. 2. Align, then tighten connections.
3. Exhaust manifold cracked or broken. 3. Replace the manifold.
4. Leak between exhaust manifold and 4. Tighten the manifold to cylinder head
cylinder head. nuts and bolts to specifications.
5. Damaged or worn seals or packing. 5. Replace the seals or packing as neces­
sary.
6. Burned or rusted out exhaust pipe heat 6. Replace the heat tube extensions as
tube extension. required.
7. Burned or rusted out exhaust pipe. 7. Replace the exhaust pipe.
8. Burned or blown out muffler. 8. Replace the muffler assembly.
9. Broken or loose clamps and/or brack­ 9. Repair or replace as necessary.
ets. D0020-CNG
 ON-VEHICLE SERVICE
INSPECTION
Inspect exhaust pipes, catalytic converters (if equip­
ped), mufflers, and tailpipes for cracked joints, broken
welds, and corrosion damage that would result in a
leaking exhaust system. Inspect the clamps, brackets,
and insulators for cracks and stripped or corroded bolt
threads.
The exhaust system, including heat shield, must be
free of leaks, binding, grounding, and excessive vibra­
tion. These conditions are usually caused by damaged
or loose flange bolts, heat shields, brackets, or pipes. If
any of these conditions exist, check the exhaust sys­
tem alignment. Align and replace the components as
necessary.

REMOVING EXHAUST PARTS

CAUTION: Always wear protective goggles

and gloves when removing exhaust parts as
falling rust and sharp edges from worn
exhaust components could result in serious
personal injury.
CATALYTIC CONVERTER
REPLACEMENT
When removing exhaust components an accumula­
tion of dirt and corrosion can make work difficult. Using Remove or Disconnect (Figure 2)
a penetrating oil on the threads of U-bolts can assist in
the removal of these components. Raise the vehicle.
1. Clamps at the front and rear of the converter.
INSTALLING EXHAUST PARTS 2. Converter to front exhaust pipe and converter to
intermediate exhaust pipe.
When installing a new exhaust pipe, or muffler, or
3. Catalytic converter.
tailpipe, on any model, check for proper alignment.
Rattles and noise vibrations in the exhaust system are
usually caused by the misalignment of parts. When Install or Connect
aligning the system, leave all bolts and nuts loose until
all parts are properly aligned, then tighten, working 1. New catalytic converter into the exhaust pipe.
from the front to the rear.
Damaged exhaust system hangers, hanger brackets,
NOTICE: See "Notice" on page 6F-1.
and clamps should be replaced to maintain exhaust
system alignment.
2. New U-bolts and clamps at the front and rear of
Important the converter.

• When jacking or lifting the vehicle from the frame

side rails, be certain lift pads do not contact the
catalytic converter as damage to the converter will • Bolts to specifications, refer to "Specifications"
result. at the end of this section.
• Sealer (GM P/N 9985020) or equivalent is to be • Check for clearance and alignment.
applied to all slip joint connections. • Lower the vehicle.
• When installing the exhaust pipe to the engine
manifold, always use new packing and nuts. Clean
the engine manifold stud threads with a wire brush
before installing the new nuts.
Refer to figures 1 through 18 for component replace­
ment of the engine exhaust system.
 4. Catalytic Converter
20. Sealer
21. Clamp
F6790

Figure 2 — Clamp - Method B

IN TER M ED IA TE EXHAUST PIPE 5. Muffler hangers and retaining nuts.

Remove or Disconnect (Figure 4) Tighten

1. Negative battery cable. • Nuts to 45 N«m (33 lb. ft.)
• Raise vehicle. Support with suitable jackstands. Catalytic converter to intermediate exhaust pipe
2. Electrical connector from right fuel cylinder solenoid clamp.
valve.
Tighten
• Loosen lines from right fuel cylinder and allow
fuel pressure to bleed off. • Clamp nuts to 60 N*m (44 lb. ft.)
3. Fuel lines from right fuel cylinder. Muffler to intermediate exhaust pipe clamp.
• Support fuel cylinder with transmission jack and
special holding fixture PAS-56074. Tighten
4. Right fuel cylinder nuts, bolts and retaining straps. • Clamp nuts to 41 N*m (33 lb. ft.)
5. Right fuel cylinder. 8. Right CNG fuel cylinder.
6. Rear catalytic converter clamp. 9. Fuel cylinder strap, nuts and bolts.
7. Intermediate exhaust pipe hanger nuts.
8. Intermediate pipe from catalytic converter. Tighten
9. Muffler hanger nuts. • Nuts to 50 N*m (37 lb. ft.)
10. Intermediate pipe and muffler assembly. • Bolts to 50 N«m (37 lb. ft.)
11. Muffler clamp to intermediate pipe. 10. Fuel lines to right CNG fuel cylinder.
12. Muffler from intermediate pipe.
13. Intermediate exhaust pipe hangers. Tighten
• Fuel line fittings to 20 N*m (15 lb. ft.)
Install or Connect 11. Electrical connector to right fuel cylinder solenoid
NOTICE: For steps 3, 5, 6, 7, 9, 10 and 12, see valve.
“Notice” on page 6F-1. firi Inspect
1. Intermediate exhaust pipe hangers.
For gas leaks at fuel fittings with soap and water
2. Intermediate exhaust pipe to catalytic converter. solution.
3. Intermediate exhaust pipe hangers and retaining Lower vehicle.
nuts. 12. Negative battery cable.

Tighten Tighten
• Nuts to 34 N*m (25 lb. ft.) Bolt to 15 N«m (11 lb. ft.)
4. Muffler to intermediate exhaust pipe.
TYPE AD
TYPEAE TYPE BC

TYPE BD
TYPE CD

F6792
 6F-6 EXHAUST
SYSTEM
Figure 4 — Exhaust System
Natural Gas Powered Truck

7. MUFFLER 32. HANGER EXHAUST

21. CLAMP, EXHAUST 34. ROD, EXHAUST HANGER
 SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
N-m Ft. Lbs. In. Lbs.
Exhaust Pipe to Manifold Bolts..................................................... ................... 20 15 —
Exhaust Pipe Hanger Bracket to Frame Bolts............................ ................... 45 33 —
Muffler Hanger Clamp Nuts.......................................................... ................... 41 30 —
Muffler Hanger to Frame Bolt....................................................... ................... 45 33 —
Tail Pipe Hanger Clamp Nut......................................................... ................... 41 30 —
Tail Pipe Bracket to Frame Bolt.................................................... ................... 45 33 —
Catalytic Converter Hanger Bolt................................................... ................... 45 33 —
Catalytic Converter U-Bolt Nuts.................................................... 60 44 —
Catalytic Converter to Exhaust Pipe Bolts.................................. ................... 60 44 —
Hanger to Frame Bolt (Rod Type)................................................. ................... 35 26 —
Hanger to Frame Nut (Rod Type)................................................. ................... 34 25 —
Exhaust V-Band Clamp................................................................. ................... 8 — 71
T2141
6F-8 EXHAUST SYSTEM
 SECTION 7A1

4L60 AUTOMATIC TRANSM ISSION

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number for the application. If the correct
part number is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners
that are not reused and those requiring thread locking compound will be called out. The correct torque
value must be used when installing fasteners that require it. If the above conditions are not followed, parts
or system damage could result.

CONTENTS

SUBJECT PAGE
On-Vehicle Service.......................................................................................................................................................7A1-1
Transmission Replacement.......................................................................... ..........................................................7A1-1

ON-VEHICLE SERVICE
TRAN SM ISSIO N REPLACEMENT 13. Transmission crossmember.

Important
If the transmission is being lowered for clearance,
perform steps 1-8 only. • Do not stretch or damage any cables, wires or
other c om po n e n ts when l ow er i ng the
transmission.
++ Remove or Disconnect
14. Transmission far enough for clearance to reach
other components.
Tool Required: 15. Dipstick tube (221) and the seal.
J 21366 Converter Holding Strap • Cover the opening in the transmission.
16. Speedometer harness connector.
1. Negative (-) battery cable.
17. Electrical connectors from the transmission.
2. Air cleaner, and the TV cable from the throttle
linkage, if the transmission is being removed. 18. Cooler lines (223).
• Raise the vehicle. • Cap all openings in the transmission and the
3. Turn 1/4 turn shut-off valve to closed position. lines.
• Lower the vehicle. 19. Transmission support braces (222).
4. Fuel line from TBI. • Note the location of the braces, they must be
• Raise the vehicle. installed in the same positions.
5. Transmission fluid. 20. Converter housing cover (228).
6. Shift linkage. • Mark the flywheel and the torque converter
7. Pressure transducer to fuel regulator line. alignment.
8. Fuel line hose from low pressure solenoid. 21. Screws (230).
9. Fuel pressure regulator bracket nuts, bolts and
upper bracket. Important
• Hang regulator from frame rail. • Support the engine with a jack or hoist before
10. Coolant hose retaining strap from transmission. disconnecting the transmission.
11. Propeller shaft, refer to SECTION 4A. 22 . Screws (226).
• Front propeller shaft, if used, from the transfer • Note the location of any brackets or clips and
case. move them aside.
12. The support bracket at the catalytic converter. • Slide the transmission straight back of the
• Any other components as needed for clearance. locating pins (A) and install J 21366.
• Support the transmission, and the transfer case, 23. Fuel line from vehicle.
if used, with a transmission jack. 24. Transmission (225) from the vehicle.

g Clean
• Transmission case using a solvent dampened
cloth. Do not allow solvent to enter the transmis­
sion. Air dry.
• All hardware and flywheel cover using solvent. Air
dry.
1? Inspect
All parts for wear and damage.
All seals and fittings for signs of leakage.
Torque converter for stripped or broken weld nuts
or screw holes.
Transmission case for porosity.
Install or Connect (Figure 82)
* If the transmission was lowered for clearance only,
perform steps 13-20.
Tool Required:
J 21366 Converter Holding Strap
NOTICE: For steps 2, 3, and 11, see "Notice"
on page 7A1-1.
1. Transmission (225).
• Be sure the torque converter is seated properly
and that J 21366 is in place.
• Support the transmission, and the transfer case
if used, with a transmission jack.
• Raise the transmission into place and remove
J 21366.
• Slide the transmission straight onto the locating
pins (A) while lining up the marks on the fly­
wheel and the torque converter.
Important
• The torque converter must be flush onto the
flywheel and rotate freely by hand.
2. Fuel line to vehicle.
3. Screws (226).
• All brackets, clips, and harnesses must be
positioned as they were when removed.
• Do not install the dipstick tube or the
transmission support brace screws.
4. Screws (230).
& Tighten
• Screws finger tight to ensure proper converter
seating.
• Screws (230) to 63 N-m (46 ft. lbs.).
• Remove the engine hoist or jack.
5. Converter housing cover (228).
• Hook the cover under the lip of the engine oil
pan.
6. Transmission support braces (222).
• The braces must be installed in the positions
from which they were removed.
7. Cooler lines (223).
• Uncover the openings.
• Do not twist or bend the lines.
8. Speedometer harness connector.
9. Electrical connectors to the transmission.
10. Dipstick tube (221) with a new seal.
• Uncover the opening and install the seal first.
• Install screw (226).
Tighten
• 32 N-m (23 ft. lbs.).
11. Transmission in place.
Important
• Do not pinch or damage any cables, wires or
ot he r c o m p o n e n t s w h e n r a i si n g t he
transmission.
12. Transmission crossmember and the transmission
mount.
• Any components that were removed for
clearance.
• Remove the transmission jack.
13. Coolant hose retaining strap to transmission.
14. Fuel pressure regulator.
15. Regulator bracket, bolts and nuts.
Tighten
&
• Nuts to 25 N*m (18 ft. lbs.).
16. Fuel line hose to low pressure solenoid.
Tighten
&
Hose fitting to 20 N*m (15 ft. lbs.).
17. Fuel pressure transducer to fuel regulator line.
& Tighten
• Line fittings to 20 N*m (15 ft. lbs.).
18. The support bracket at the catalytic converter.
19. Propeller shaft, refer to SECTION 4A.
• Front propeller shaft to the transfer case, if
used.
20. Fuel lines. Refer to the 1992 Light Duty Fuel and
Emissions Manual if are using X-9231 and to the
Fuel and Emissions section at the rear of this
manual if you are using ST 375-92.
21. Shift linkage.
• Lower the vehicle.
22. New transmission fluid.
23. Air cleaner, and the TV cable, if removed.
24. Negative (-) battery cable.
Inspect
Fuel line fitting for leaks with soap and water
solution.
 220

221

220

224 223

220. Harness
221. Dipstick Tube
222. Support Brace
223. Cooler Lines
224. Seal
225. Transmission
226. Screws, Transmission to Engine 228
228. Converter Housing Cover
229. Flywheel
230. Screw, Flywheel to Torque Converter
231. Washer
232. Screw

F3529
7A1-4 4 L 60 AUTOMATIC TRANSM ISSIO N
... ' ....... ......... .... .........— ................................■1 "J-- .........
 PART II
FU E L A N D E M IS S IO N S
S E R V IC E M A N U A L S U P P L E M E N T
CONTENTS
SECTION PAGE
General Information ........................................................................................................................................................ 1-1
Driveability Symptoms ................................................................................................................................................. 2-1
Computer Command Control ....................................................................................................................................... 3-1
Fuel Control ..................................................................................................................................................................... 4-1
Evaporative Emission Control .................................................................................................................................... 5-1
Ignition System/EST .................................................................................................................................................... 6-1
Electronic Spark Control .............................................................................................................................................. 7-1
Air Management ........................................................................................................................................................... 8-1
Exhaust Gas Recirculation ........................................................................................................................................... 9-1
Transmission Controls .............................................................................................................................................. 10-1
Positive Crankcase Ventilation .................................................................................................................................... 11-1
Thermostatic Air Cleaner .......................................................................................................................................... 12-1
Special Tools .............................................................................................................................................................. 13-1
Abbreviations .............................................................................................................................................................. 14-1

SECTION 1
GENERAL INFORMATION
CONTENTS
General Description ..............................................1-1 Section "6 " Ignition System/Electronic Spark
Visual/Physical Underhood Inspec.................... 1-2 Timing (EST) ............................................1-3
Basic Electric Circuits ....................................1-2 Section "7 " Elect. Spark Control (ESC) . 1-3
Emissions ...........................................................1-2 Section "8 " Air M a n a g e m e n t.................... 1-3
Maintenance Schedule ....................................1-2 Section "9 " Exhaust Gas Recirculation . 1-3
Vehicle Emission Control Information Section "10" Transmission Controls . . . 1-3
Label .............................................................. 1-2 Section "11" Positive Crankcase
General Description of S e c tio n s ................... 1-2 Ventilation (PCV) .....................................1-3
Section "2 " Driveability Symptoms . . . 1-2 Section "12" Thermostatic Air Cleaner
Section "3 " Computer Command (THERMAC) ...............................................1-3
Control .................................................... 1-2 Section "13" Special Tools ........................1-3
Section "4 " Fuel Control .......................... 1-2 Section "14" Abbreviations ........................1-3
Section "5 " Evaporative Emissions Component Locations .....................................1-5
Control .................................................... 1-2 5.7L CNG - "C " Series .............................. 1-5

A L L N E W G E N E R A L M O T O R S V E H IC L E S A R E C E R T IF IE D B Y T H E U N IT E D S T A T E S
E N V IR O N M E N T A L P R O T E C T IO N A G E N C Y A S C O N F O R M IN G T O TH E R E Q U IR E M E N T S O F T H E
R E G U L A T IO N S FO R THE C O N T R O L OF A IR P O L L U T IO N F R O M N E W M O T O R V E H IC L E S. T H IS
C E R T IF IC A T IO N IS C O N T IN G E N T O N C E R T A IN A D J U S T M E N T S B E IN G S E T T O F A C T O R Y
ST A N D A RD S. IN M O S T C A S E S , T H E S E A D J U S T M E N T P O IN T S E IT H E R H A V E B E E N
P E R M A N E N T L Y S E A L E D A N D /O R M A D E IN A C C E S S IB L E T O P R E V E N T IN D IS C R IM IN A T E O R
R O U T IN E A D J U S T M E N T IN THE FIELD. FO R T H IS R E A S O N , THE F A C T O R Y P R O C E D U R E F O R
T E M P O R A R IL Y R E M O V IN G P L U G S , C A P S , ETC., F O R P U R P O S E S O F S E R V IC IN G T H E
P R O D U C T , M U S T BE STRIC TLY F O L L O W E D A N D , W H E R E V E R P R A C T IC A B L E , R E T U R N E D T O
TH E O R IG IN A L IN T E N T OF THE D ESIG N .
1-2 G E N E R A L IN F O R M A T IO N
GENERAL DESCRIPTION
T h e C o m p r e s s e d N a t u r a l G a s ( C N G ) e n g in e
c o v e re d i n t h is m a n u a l h a s a C o m p u t e r C o m m a n d
C o n t r o l c a lle d a n E le c t r o n ic C o n t r o l M o d u l e ( E C M ) .
T h e E C M w i l l v a r y a ir / f u e l r a t io , i g n i t i o n t i m i n g
s y s t e m s , a s w e ll a s o t h e r e m is s io n c o n t r o l s y s t e m s .
I t is im p o r t a n t to r e v ie w th e e m is s io n s e c t io n s
a n d E C M w i r i n g d i a g r a m s to d e t e r m in e w h a t is
c o n t r o lle d b y t h e E C M a n d w h a t s y s t e m s a r e n o n -
E C M c o n tro lle d .
• T h i s s e c t io n h a s a b r i e f d e s c r ip t io n o f s y s t e m s
u s e d to c o n t r o l f u e l a n d e m i s s i o n s a n d
c o m p o n e n t lo c a tio n s.
• A b b r e v i a t io n s t h a t a re u s e d i n d r i v e a b il it y a n d
e m is s io n s a re lis t e d in A B B R E V I A T I O N S
( S E C T I O N 14).
• W i r i n g h a r n e s s s e r v ic e in f o r m a t io n , fo r h a r n e s s e s
u s e d w i t h t h e E C M , a ls o r e f e r to C O M P U T E R
C O M M A N D C O N T R O L ( S E C T I O N 3) fo r f u r t h e r
in fo r m a t io n .
• S p e c i a l t o o ls u s e d to d i a g n o s e a n d r e p a i r a
s y st e m a re illu s t r a t e d in S P E C I A L T O O L S
(S E C T IO N 13).
V IS U A L / P H Y S IC A L U N D E R H O O D
IN S P E C T IO N
T h e v is u a l/ p h y s ic a l u n d e r h o o d in s p e c t io n s h o u ld
a l w a y s b e t h e f i r s t s te p i n a n y e m i s s i o n s r e l a t e d
d ia g n o s t ic p ro c e d u re . T h i s c a n o fte n le a d to f i x i n g
a p r o b l e m w i t h o u t a n y f u r t h e r s te p s. I n s p e c t a l l
v a c u u m h o s e s fo r c o rre c t r o u t in g , p in c h e s , cu ts, o r
d is c o n n e c t s . In s p e c t t h e h o s e s t h a t a r e d i f f i c u l t to
se e b e n e a t h th e a i r c le a n e r, c o m p re s s o r, g e n e ra to r,
etc. I n s p e c t a l l w i r e s i n t h e e n g i n e c o m p a r t m e n t
fo r c o rre c t a n d p r o p e r c o n n e c tio n s, b u r n e d o r c h a fe d
sp o ts, p in c h e d w ire s , a n d c o n ta c t w i t h s h a r p e d g e s
o r h o t e x h a u s t m a n ifo ld s . T h e v is u a l/ p h y s ic a l
in s p e c t io n is v e r y im p o r t a n t a n d m u s t b e d o n e
c a r e f u lly a n d t h o r o u g h ly .
B A S IC E L E C T R IC C IR C U IT S
Y o u s h o u ld u n d e r s t a n d th e b a s ic t h e o r y of
e le c t r ic it y . T h i s w ill in c lu d e th e m e a n in g of
v o lt a g e , a m p s , o h m s , a n d w h a t h a p p e n s i n a c ir c u it
w i t h a n o p e n o r a s h o r t e d w ire . Y o u s h o u ld a ls o be
a b le to r e a d a n d u n d e r s t a n d w i r i n g d i a g r a m s . A
s h o r t to g r o u n d w i l l b e re fe rre d to a s a g r o u n d so
t h a t it c a n b e d i s t i n g u i s h e d f r o m a s h o r t b e t w e e n
w ire s .
E M IS S I O N S
T h e e x h a u s t e m iss io n c o n tro l s y st e m s u s e d on
e n g i n e s p e r f o r m a s p e c if ic f u n c t io n to lo w e r
e x h a u s t e m is s io n s w h ile m a in t a in in g g o o d fu e l
e c o n o m y a n d d r iv e a b ilit y .
M A IN T E N A N C E S C H E D U L E
R e fe r to M A I N T E N A N C E A N D L U B R I C A T I O N
( S E C T I O N O B) o f t h e p r o p e r N a t u r a l G a s P o w e r e d
T r u c k S e r v ic e M a n u a l S u p p le m e n t o r i n th e v e h ic le
g lo v e b o x fo r t h e m a in t e n a n c e s e r v ic e . P r o p e r
s c h e d u le d m a i n t e n a n c e s h o u l d b e p e r f o r m e d to
r e t a in e m is s io n c o n t ro l p e rfo rm a n c e .
V E H IC L E E M IS S IO N C O N T R O L
IN F O R M A T IO N L A B E L
T h e V e h ic le E m i s s i o n C o n t r o l In f o r m a t io n la b e l
c o n t a in s im p o r t a n t e m is s io n s p e c if ic a t io n s a n d
p r o c e d u r e s . O n t h e u p p e r le f t c o r n e r i s e x h a u s t
e m i s s i o n i n f o r m a t i o n . R e f e r to F i g u r e 1-1 f o r
f u r t h e r b r e a k o u t c la r if ic a t io n . A l s o t h e r e is a n
illu s t r a t e d e m is s io n c o m p o n e n t s a n d a v a c u u m h o s e
s c h e m a t ic . T h i s la b e l i s lo c a t e d i n t h e e n g in e
c o m p a rt m e n t o f e v e r y v e h ic le . I f th e la b e l h a s b e e n
re m o ve d , a re p la c e m e n t la b e l c a n b e o rd e r e d fro m
G e n e r a l M o t o r s S e r v ic e P a r t s O p e r a t io n s ( G M S P O ) .
R e fe r to th e S t a n d a r d P a r t s C a t a lo g .
G E N E R A L D E S C R IP T IO N O F S E C T IO N S
Section " 2 "
Driveability S y m p t o m s
T h e fu e l a n d e m is s io n s d r iv e a b ilit y d ia g n o s is
p r o c e d u r e s a p p l y to v a r i o u s s y s t e m s . T h e s e
p r o c e d u r e s a s s u m e t h e p r o b l e m i s d u e to t im e ,
w e a r, d ir t o r o t h e r re la te d c a u se s. A f t e r a c o m p le te
E C M d i a g n o s i s h a s b e e n p e r f o r m e d , t h i s s e c t io n
c a n be u s e d fo r d r i v e a b il it y s y st e m s .
Section " 3 "
C o m p uter C o m m a n d Control
T h is e le c t r o n ic a lly c o n t ro lle d exh aust e m is s io n
s y s t e m h a s a n E le c t r o n ic C o n t r o l M o d u l e ( E C M ) to
c o n tro l fu e l d e liv e r y , ig n it io n t im in g , a ir
m a n a g e m e n t a n d e x h a u s t g a s r e c ir c u la t io n . T h e
E C M c o n tro ls th e e n g a g e m e n t o f t h e t r a n s m is s io n
c o n v e rt e r clu tch . T h i s s e c t io n d ia g n o s e s th e s y s t e m
w it h a T e c h 1 “S c a n ” tool.
Section " 4 "
Fuel Control
T h e E C M c o n t r o ls t h e a ir / fu e l d e l i v e r y to t h e
c o m b u s t io n c h a m b e r b y c o n t r o l l i n g t h e f u e l f lo w
t h r o u g h th e in je cto r(s). T h e E C M a ls o c o n t ro ls id le
speed . T h e fu e l c y lin d e r s h u t - o f f s o le n o id s a re
c o n t r o lle d b y t h e E C M . W h e n i g n i t i o n i s t u r n e d
“O N , ” t h e s o le n o i d s w i l l o p e n fo r 2 s e c o n d s , t h e n
s to p u n le s s t h e e n g in e is c r a n k i n g o r o p e ra tin g . A
fu e l c o n tro l sy st e m is u se d o n th e 5 .7 L C N G
e n g in e . T h e E C M c o n t r o ls th e A / C c lu t c h o f t h e
c o m p r e s s o r a n d m a i n t a i n s id le s p e e d to im p r o v e
id le q u a lit y .
Se c tio n " 5 "
E vaporative E m issio n Control
E v a p o r a t iv e e m is s io n c o n tro l sy ste m s w e re
d e v e lo p e d t o k e e p f r o m r e l e a s i n g g a s o li n e v a p o r s
f r o m t h e f u e l t a n k in t o t h e a t m o s p h e r e . B e c a u s e
c o m p re sse d n a t u r a l g a s is g a se o u s, th e sto ra g e
t a n k s m u s t b e a c lo s e d s y s t e m . B e i n g a c lo s e d
s y s t e m m e a n s n o C N G c a n b e r e le a s e d fro m t h e
g a s c y lin d e r s u n le s s th e t r u c k is r u n n in g .
T h e re fo re , th e N a t u r a l G a s P o w e r e d T r u c k d o es n o t
n e e d a n e v a p o r a t iv e e m is s io n c o n tro l sy ste m .
Se c tio n " 6 "
Ign itio n System /E lectron ic Sp a rk Tim ing
(E ST )
T h e i g n i t i o n s y s t e m fo r th e N a t u r a l G a s
P o w e r e d T r u c k is th e s a m e s y s t e m u s e d o n th e C / K
T r u c k 's 5 . 7 L g a s o l i n e e n g in e . R e f e r to th e 1 9 9 2
L i g h t D u t y T r u c k F u e l a n d E m is s io n s S e r v ic e
M a n u a l for fu r t h e r in fo rm a t io n .
S e c tio n " 7 "
Electronic S p a rk Control (E SC )
W h ile th e N a t u r a l G a s P o w e re d T r u c k is
e q u ip p e d w i t h th e s a m e E S C s y s t e m u s e d o n t h e
C / K T r u c k 's 5 . 7 L g a s o l i n e e n g i n e , i t d o e s n o t
s u p p ly a n y in p u t to th e E C M . B e c a u s e o f th e h i g h
o c t a n e r a t i n g o f C N G , t h e k n o c k s e n s o r a c t u a ll y
r e d u c e s d r i v e a b i l i t y a n d p e r f o r m a n c e w it h t h e
c u r r e n t E S C s y ste m . So, th e k n o c k s e n s o r s ig n a l to
th e E C M h a s b e e n m a sk e d , a n d no k n o c k se n so r
d a t a w i l l b e r e c e iv e d b y y o u r T E C H I o n N a t u r a l
G a s Pow ered T ru cks.
Se ctio n " 8 "
A ir M a n a g e m e n t
A . I . R . m a n a g e m e n t s y s t e m s w e r e d e v e lo p e d to
h e l p r e d u c e v e h i c l e e m i s s i o n le v e ls . C o m p r e s s e d
n a t u r a l g a s b u r n s m u c h c le a n e r t h a n g a s o lin e
e n g i n e s a n d i s a b le to m e e t e m i s s i o n s r e g u l a t i o n s
w it h o u t th e u s e o f a n A . I.R . m a n a g e m e n t sy ste m .
So , t h e N a t u r a l G a s P o w e r e d T r u c k is n o t e q u ip p e d
w it h a n A . I. R . m a n a g e m e n t sy ste m .
Se c tio n " 9 "
E x h au st G a s Recirculation
C o m p re sse d N a t u r a l G a s e n g in e s do p ro d u c e
N O x (o x id e s o f n itro g e n ). T h e N a t u r a l G a s P o w e r e d
T r u c k is e q u ip p e d w it h a n E G R s y s t e m to r e g u la t e
N O x e m is s io n le v e ls . T h e E G R s y s t e m fo r th e
N a t u r a l G a s P o w e r e d T r u c k is th e s a m e o n e
u s e d o n C / K T r u c k ’s u n d e r 8 5 0 0 G V W w i t h 5 . 7 L
g a s o lin e e n g in e s . T h e E G R is a n e g a t iv e
b a c k p r e s s u r e E G R v a l v e s o le n o id c o n t r o l s y s t e m .
R e f e r to t h e 1 9 9 2 L i g h t D u t y T r u c k F u e l a n d
E m i s s i o n s S e r v ic e M a n u a l fo r f u r t h e r in f o r m a t io n .
Se ctio n "1 0 "
T ra n sm issio n C o n tro ls
T h e T o rq u e C o n v e rte r C lu t c h (T C C ) is E C M
c o n t r o lle d . T h i s s y s t e m r e d u c e s s l i p p a g e l o s s e s i n
th e to rq u e c o n v e rt e r b y c o u p lin g th e e n g in e
f ly w h e e l to th e o u t p u t s h a f t o f th e t r a n s m is s io n .
Se ctio n "11"
Positive C rankcase V en tilation (P C V )
T h e P C V s y st e m p a s s e s c r a n k c a s e v a p o r s in to
th e in t a k e m a n ifo ld . T h i s s y s t e m i s n o t c o n t r o lle d
b y th e E C M .
Se ctio n "1 2 "
T h erm ostatic A ir Cleaner (T H E R M A C )
T h e T H E R M A C sy st e m r e g u la t e s h e a te d a ir
t h r o u g h th e a i r c le a n e r to p r o v id e u n if o r m in le t a i r
t e m p e ra t u re a n d a llo w s g o o d d r iv e a b ilit y u n d e r
v a r i o u s c l i m a t i c c o n d it io n s . T h i s s y s t e m i s n o t
c o n tro lle d b y th e E C M .
Se c tio n "1 3 "
Sp ecial T o o ls
S p e c ia l to o ls a n d e q u ip m e n t n e e d e d to d ia g n o s e
th e fu e l c o n tro l a n d e m is s io n s s y s t e m s a re
illu s t r a t e d a n d lis t e d i n t h is sectio n .
Se ctio n "1 4 "
A b b re viatio n s
A l l a b b r e v ia t io n s u s e d i n t h is m a n u a l a r e lis t e d
i n t h is sectio n .
 issa

**§«&«>•

,,fc ^ < 0 s ; s> c 0,

S^ O F ir .^ * n
 'C ' series rpo:L05 eng ine c o d e : K 5.7L C N G V8

□ COMPUTER COMMAND O ECM INFORMATION EMISSION COMPONENTS

CONTROL SENSORS (NOT ECM CONTROLLED)
C1 Electronic Control Module (ECM) A Manifold Absolute Pressure (MAP) Nl Crankcase Vent Valve (PCV)
C2 ALDL diagnostic connector B Exhaust Oxygen Sensor (0 2)
C3 "SERVICE ENGINE SOON" light C Throttle Position Sensor (TPS)
C5 ECM harness ground D Coolant Temperature Sensor (CTS)
C6 Fuse block F Vehicle Speed Sensor (VSS)
C8 Fuel supply test connector J Electronic Spark Control (ESC) Knock

□ ECM CONTROLLED
COMPONENTS
1 Fuel injector
2 Idle Air Control (IAC)
3 Fuel supply relay
5 Transmission converter clutch connector
6 Electronic Spark Timing (EST) Distributor
6a Remote ignition coil
7 Electronic Spark Control (ESC) module
8 Oil pressure switch
12 Exhaust Gas Recirculation (EGR) Vacuum Solenoid
15 Fuel supply fuse
16 CNG control relay

5-18-91
7S3303-6E-CNG
1-6 G E N E R A L IN F O R M A T IO N
 D R IV E A B IL IT Y S Y M P T O M S 2-1

S E C T IO N 2
DRIVEABILITY SYMPTOMS
(NATURAL GAS POWERED TRUCK)

CONTENTS

Im portant Prelim inary C h e c k s ............................................................................................................... Page 2-2

Interm ittents (1 o f 2) ...............................................................................................................................Page 2-3
Hard Start (1 o f 2) ..................................................................................................................................Page 2-5
Surges and/or C h u g g le s ........................................................................................................................ Page 2-7
Lack o f Power, Sluggish, or Spongy (1 of 2) ....................................................................................Page 2-8
Detonation/Spark Knock (1 of 2) ......................................................................................................... Page 2-10
Hesitation, Sag, Stum ble ..................................................................................................................... Page 2-12
Cuts Out, Misses .....................................................................................................................................Page 2-13
Poor Fuel E c o n o m y ..................................................................................................................................Page 2-14
Rough, Unstable or Incorrect Idle, Stalling (1 o f 2) ....................................................................... Page 2-15
Excessive Exhaust Emissions or Odors ............................................................................................. Page 2-17
Dieseling, Run-On ..................................................................................................................................Page 2-18
Backfire .................................................................................................................................................... Page 2-19
IMPORTANT PRELIMINARY CHECKS

B E F O R E U S IN G TH IS SE C T IO N

B e fo re u s i n g t h is s e c tio n y o u s h o u ld h a v e p e r fo rm e d th e " D i a g n o s t i c C i r c u i t C h e c k ” a n d
d e t e rm in e d th at:
1. T h e E C M a n d “S e r v ic e E n g i n e S o o n ” l i g h t a re o p e r a t in g co rre ctly.
2. T h e r e a re n o d ia g n o s t ic co d es sto re d , o r th e re is a d ia g n o s t ic code b u t n o " S e r v ic e E n g i n e S o o n ”
lig h t.
• S e v e r a l o f th e f o llo w in g s y m p t o m p r o c e d u r e s ca ll for a c a re fu l v is u a l/ p h y s ic a l check.
T h e im p o r t a n c e o f v is u a l/ p h y s ic a l c h e c k s c a n n o t be s tre s s e d too s t r o n g ly , t h e y c a n le a d to
c o r r e c t in g a p r o b le m w it h o u t fu r t h e r c h e c k s a n d c a n sa v e v a lu a b le tim e.

B E F O R E ST A R T IN G
T h i s c h e c k s h o u ld in c lu d e :
• E C M g r o u n d s fo r b e i n g c le a n , tig h t , a n d in t h e ir p ro p e r lo c a tio n . R e f e r to “C o m p o n e n t
L o c a t io n s ” i n G E N E R A L I N F O R M A T I O N ( S E C T I O N 1).
• V a c u u m h o s e s fo r s p lits , k i n k s a n d p r o p e r c o n n e c tio n s, a s s h o w n o n " V e h ic l e E m i s s i o n C o n t r o l
In f o r m a t io n ” labe l. C h e c k t h o r o u g h ly fo r a n y type o f le a k o r re s t ric tio n .
• A i r le a k s a t a ll m o u n t in g a r e a s o f th e in t a k e m a n ifo ld s e a lin g s u rfa c e s.
• Ig n it io n w ir e s fo r c r a c k in g , h a r d n e s s , p r o p e r ro u tin g , o r c a rb o n t r a c k in g .
• W i r i n g fo r p r o p e r c o n n e c t io n s , p in c h e s , a n d c u ts . R e f e r to C O M P U T E R C O M M AN D
C O N T R O L ( S E C T I O N 3).
• T h e f o l l o w i n g s y m p t o m c h a r t s c o n t a i n g r o u p s o f p o s s ib le c a u s e s fo r e a c h s y m p t o m a n d
c o v e r s e v e r a l e n g in e s . These procedu res are not necessarily m eant to be done in
consecutive o rd e r. I f T e c h 1 “S c a n ” to o l r e a d in g s do n o t in d ic a t e t h e p r o b le m s , t h e n
p ro c e e d i n a lo g ic a l o rd er, e a s ie s t to c h e c k o r m o st li k e ly c a u s e first. T o d e t e r m in e i f a
p a r t ic u la r s y s t e m o r c o m p o n e n t is u s e d o n a sp e cific ve h icle , re fe r to th e “E C M W i r i n g
D i a g r a m ” fo r a p p lic a t io n .

SYM PTOM
V e r if y th e c u s t o m e r c o m p la in t, a n d lo c a te th e corre ct s y m p t o m in th e ta b le o f c o n te n ts. Check
th e it e m s in d ic a t e d u n d e r th a t sy m p to m .
 INTERMITTENTS
(5.7L CNG ENGINE)
(P a g e 1 o f 2)
Definition: P r o b le m m a y o r m a y n o t t u r n " O N ”
th e " S e r v ic e E n g i n e S o o n ” l i g h t , o r
sto re a code.

P R E L IM IN A R Y C H E C K S
• R e f e r to " Im p o r t a n t P r e l im i n a r y C h e c k s . ”
• D O N O T u s e th e D ia g n o s t ic C o d e C h a r t s i n C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N 3)
fo r in t e r m it t e n t p ro b le m s. T h e fa u lt m u s t be p r e s e n t to lo c a t e th e p r o b le m . I f a f a u l t i s
in t e r m it t e n t , u s e o f d ia g n o s t ic code c h a r t s m a y r e s u lt in re p la c e m e n t o f go o d p a rts.

F A U LT Y ELECT RICA L C O N N E C T IO N S O R W IR IN G
M o s t in t e r m it t e n t p ro b le m s a re c a u se d b y f a u lt y e le c t r ic a l c o n n e c t io n s o r w i r i n g . P e rfo rm
c a r e f u l c h e c k o f s u s p e c t c ir c u it s for:
P o o r m a t in g o f th e co n n e c to r h a lv e s , o r t e r m in a ls , n o t f u lly se a te d in th e c o n n e c t o r b o d y
(b a c k e d out).
Im p r o p e r ly fo rm e d o r d a m a g e d t e r m in a ls . A l l c o n n e c t o r t e r m in a ls in p r o b le m c ir c u it s h o u l d
be c a r e f u lly r e fo rm e d o r re p la c e d to i n s u r e p ro p e r c o n ta c t te n sio n .
P o o r t e r m in a l to w ire co n n e ctio n . T h i s r e q u ir e s r e m o v i n g th e t e r m in a l f r o m th e c o n n e c t o r
b o d y to ch eck. R e fe r to " O n - V e h ic l e S e r v ic e ” i n C O M P U T E R C O M M A N D C O N T R O L
( S E C T I O N 3).

R O A D TEST
I f a v is u a l/ p h y s ic a l c h e c k d o es n o t locate th e c a u se o f th e p ro b le m , th e v e h ic le c a n be d r iv e n w it h
a v o lt m e t e r co n n e c te d to a su sp e c te d c ir c u it o r a T e c h 1 " S c a n ” to o l m a y be u sed . A n a b n o r m a l
v o lt a g e o r " S c a n ” re a d in g , w h e n the p r o b le m o c c u rs, in d ic a t e s th e p r o b le m m a y be in t h a t
c ir c u it . I f th e w i r i n g a n d c o n n e c to rs c h e c k O K , a n d a d ia g n o s t ic code w a s s to re d fo r a c ir c u it
h a v i n g a s e n s o r, e x c e p t fo r C o d e s 4 4 a n d 45, re p la c e th e s e n s o r.
 INTERMITTENTS
(5.7L CNG ENGINE)
(P a g e 2 o f 2)
Definition: P r o b le m m a y o r m a y n o t t u r n " O N ”
th e " S e r v ic e E n g i n e S o o n ” lig h t , o r
s to re a code.

IN T E R M IT T E N T "S E R V IC E E N G IN E S O O N L IG H T "
A n in t e r m it t e n t " S e r v ic e E n g i n e S o o n ” lig h t , a n d N o D ia g n o s t ic C o d e s, m a y b e c a u s e d by:
E l e c t r i c a l s y s t e m in t e r f e r e n c e c a u s e d b y a d e fe c tiv e r e la y , E C M d r i v e n s o le n o id , o r
s w it c h . T h e y c a n c a u s e a s h a r p e le c t r ic a l s u rg e . N o r m a l l y , t h e p r o b le m w i l l o c c u r
w h e n th e f a u lt y c o m p o n e n t is o p e ra te d .
Im p r o p e r in s t a lla t io n o f e le c tric a l d e v ic e s, s u c h a s lig h ts , 2 -w a y ra d io s , e le c tr ic m o to rs , etc.
E S T w ir e s s h o u ld b e ro u t e d a w a y fro m s p a r k p lu g w ire s, i g n i t i o n s y s t e m c o m p o n e n t s
a n d ge n e ra to r. W ir e fo r C K T 4 5 3 fro m ECM to i g n i t i o n syste m s h o u ld be good
g rou n d .
I g n i t i o n s e c o n d a r y s h o r t e d to g ro u n d .
C K T 4 1 9 ( " S e r v ic e E n g i n e S o o n ” lig h t ) o r C K T 4 5 1 ( d ia g n o s t ic " t e s t ” t e r m in a l)
in t e r m it t e n t ly s h o rt e d to g ro u n d .
E C M g r o u n d s . R e f e r to “C o m p o n e n t L o c a t i o n s , ” i n G E N E R A L I N F O R M A T I O N
( S E C T I O N 1).

L O S S OF D IA G N O S T IC C O D E M E M O R Y
• T o ch e ck , d is c o n n e c t T P S a n d id le e n g in e u n t il “S e r v ic e E n g i n e S o o n ” l i g h t c o m e s “O N . ”
C o d e 2 2 s h o u ld be sto re d , a n d k e p t i n m e m o r y w h e n th e ig n i t i o n i s t u r n e d “O F F ” fo r a t
le a s t 10 se co n d s. I f not, th e E C M is fa u lty .
 HARD START
(5.7L CNG ENGINE)
(Page 1 of 2)
Definition : E n g in e c ra n k s O K , b u t d oes not sta rt
fo r a lo n g tim e. D o e s e v e n t u a ll y r u n ,
o r m a y s t a r t b u t im m e d ia t e ly d ie s.

P R E L IM IN A R Y C H E C K S
• R e fe r to " Im p o r t a n t P r e l im i n a r y C h e c k s . ”
• M a k e s u r e th e d r iv e r is u s i n g the co rre ct s t a r t i n g p ro ce d u re .

SEN SO RS
• CHECK: C o o la n t T e m p e r a t u r e S e n s o r ( C T S ) - U s i n g a " S c a n ” tool, c o m p a re c o o la n t t e m p e r a t u r e
w it h a m b ie n t te m p e ra t u re on a c o ld e n g in e .
I f c o o la n t te m p e ra t u re r e a d in g is 5 d e g re e s g r e a t e r t h a n o r le s s t h a n a m b ie n t a i r
te m p e ra t u re o n a cold e n g in e , c h e c k fo r h ig h r e s is t a n c e in c o o la n t s e n s o r c i r c u it o r
s e n s o r itself. R e fe r to "C o d e 1 5 ” in C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N
3) a n d c o m p a re re s is ta n c e v a lu e s .
• CHECK: T h r o t t le P o s it io n S e n s o r ( T P S ) - I f a s t i c k i n g t h ro t t le s h a ft o r b i n d i n g li n k a g e
c a u s e s a h i g h T P S v o lt a g e (o p e n t h ro t t le in d ic a t io n ), th e E C M w i ll n o t c o n tro l
id le . M o n i t o r i n g T P S v o lt a g e . A “S c a n ” to o l a n d / o r v o lt m e t e r s h o u l d r e a d le s s
t h a n 1.25 v o lt s w it h th ro ttle closed. R e f e r to F U E L C O N T R O L ( S E C T I O N 4).

FUEL S Y S T E M
• CHECK: F u e l s u p p l y r e la y o p e ra tion . F u e l s u p p l y s o le n o id v a l v e s a n d lo w p r e s s u r e fu e l
s h u t - o f f s o le n o id s s h o u l d o p e r a t e fo r 2 s e c o n d s w h e n i g n i t i o n i s t u r n e d “O N . ”
R e f e r to “C H A R T A - 5 ” in C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N 3).
• CHECK: F u e l P re ssu re . R e f e r to " C H A R T A - 6 ” in C O M P U T E R CO M M AND CO NTROL
( S E C T I O N 3).
• CHECK: F u e l s u p p ly re la y - C o n n e ct D V O M b e t w e e n f u e l s u p p l y “t e s t ” t e r m i n a l a n d
g r o u n d . V o lt a g e s h o u ld be p r e s e n t fo r 2 se c o n d s f o llo w in g i g n i t i o n “O N . ” I f not,
re fe r to “C H A R T A - 5 ” in C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N 3).
 HARD START
(5.7L CNG ENGINE)
(P a g e 2 o f 2)
Definition: E n g in e c ra n k s O K , but does not sta rt
fo r a lo n g tim e. D o e s e v e n t u a lly ru n ,
o r m a y s t a r t b u t im m e d ia t e ly dies.

IG N IT IO N S Y S T E M
• CHECK: Ig n it io n s y s t e m for:
- P r o p e r i g n it io n v o lt a g e o u t p u t w it h s p a r k te ste r J 2 6 7 9 2 o r e q u iv a le n t ( S T -1 2 5 ) .
- S p a r k p lu g s , w et p lu g s , c ra c k s , w ear, im p ro p e r gap , b u r n e d e le c t r o d e s o r h e a v y
d e p o sits.
- B a r e a n d s h o r t e d w ire s.
- M o i s t u r e in d is t r ib u t o r cap.
- W o r n d is t r ib u t o r sh a ft.
- P ic k u p c o il r e s is t a n c e a n d c o n n e ctio n s.
- L o o s e ig n i t i o n c o il c o n n e c tio n s.
• CHECK: I f e n g in e s t a rt s , b u t th e n im m e d ia t e ly s ta lls, d is c o n n e c t th e se t t i m i n g c o n n e c to r. If
e n g in e th e n s t a rt s , a n d r u n s O K , re p la ce d is t r ib u t o r p ic k u p coil.
• CHECK: C K T 4 2 3 ( E S T ) fo r s h o r t to g r o u n d . R e fe r to I G N I T I O N S Y S T E M / E S T ( S E C T I O N 6).

A D D IT IO N A L C H E C K S
• CHECK: I A C o p e ra t io n - re fe r to " C o d e 3 5 ” in C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N
3), a n d " D i a g n o s i s ” i n F U E L C O N T R O L ( S E C T I O N 4).
• CHECK: N o c r a n k s ig n a l - r e fe r to C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N 3).
• CHECK: E G R o p e ra tio n - re fe r to E X H A U S T G A S R E C I R C U L A T I O N ( S E C T I O N 9).
• CHECK: S e r v ic e B u l l e t i n s fo r P R O M , C A L - P A K u p d a te s.
 SURGES AND/OR CHUGGLES
(5.7L CNG ENGINE)
Definition: E n g i n e p o w e r v a r ia t io n , u n d e r s t e a d y
th ro tt le o r c ru is e . F e e ls li k e th e v e h ic le
s p e e d s u p a n d s lo w s d o w n , w i t h n o
c h a n g e i n th e a c c e le ra t o r p e d a l.

P R E L IM IN A R Y C H E C K S
• R e f e r to " Im p o r t a n t P r e lim i n a r y C h e c k s . ”
• B e s u r e d r i v e r u n d e r s t a n d s T o rq u e C o n v e r t e r C lu t c h ( T C C ) a n d A / C c o m p r e s s o r o p e r a t io n in
o w n e r ’s m a n u a l.
• U s e a “S c a n ” to o l to m a k e s u r e r e a d i n g o f V S S m a t c h e s v e h ic le s p e e d o m e te r. R e f e r to
“C o d e 2 4 D i a g n o s t ic A i d s ” i n C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N 3).

SEN SO RS
• CHECK: O x y g e n ( 0 2) s e n s o r fo r s ilic o n c o n t a m in a t io n fro m im p r o p e r u s e o f s e a la n t ( n e v e r
u s e a n y s e a la n t o n a n y w a t e r p r o o f c o n n e c t o rs ). T h e s e n s o r m a y h a v e a w h it e ,
p o w d e r y c o a t in g a n d r e s u lt i n a h i g h b u t f a ls e s i g n a l v o lt a g e ( r ic h e x h a u s t
in d i c a t io n ) . T h e E C M w i l l t h e n r e d u c e t h e a m o u n t o f f u e l d e l i v e r e d to t h e
e n g in e , c a u s in g a se v e re d r i v e a b il it y p ro b le m .

FUEL S Y S T E M
CHECK: T o d e t e r m in e if th e c o n d itio n is c a u s e d b y a r i c h o r le a n s y s t e m , th e v e h ic le s h o u l d be
d r iv e n a t th e sp e e d o f the c o m p la in t. M o n i t o r i n g b lo c k l e a r n w i l l h e lp i d e n t i f y a
p ro b le m .
L e a n - B l o c k le a r n g r e a t e r t h a n 170. R e f e r to " C o d e 4 4 D ia g n o s t ic A i d s ” in
C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N 3).
R ic h - B lo c k le a rn le s s th a n 9 0 . R e f e r to " C o d e 4 5 D ia g n o s t ic A i d s ” in C O M P U T E R
C O M M A N D C O N T R O L ( S E C T I O N 3).
CHECK: F u e l p r e s s u r e w h i le c o n d it io n e x i s t s , r e f e r to " C H A R T A - 6 ” in C O M PU TER
C O M M A N D C O N T R O L ( S E C T I O N 3).

IG N IT IO N S Y S T E M
• CHECK: F o r p ro p e r ig n it io n vo lta g e o u t p u t v o lt a g e u s i n g s p a r k te ste r J 2 6 7 9 2 o r e q u iv a le n t
(S T -1 2 5 ).
• CHECK: S p a r k p lu g s. R e m o v e s p a r k p lu g s , c h e c k fo r w et p lu g s , c ra c k s , w e a r, im p r o p e r g a p ,
b u r n e d ele ctrod es, o r h e a v y d e p o sits. R e p a ir o r re p la c e a s n e c e s s a ry .
• CHECK: Ig n i t i o n tim in g . R e fe r to I G N I T I O N T I M I N G / E S T ( S E C T I O N 6).

A D D IT IO N A L C H E C K S
• CHECK E C M g r o u n d s fo r b e in g cle a n , tig h t, a n d i n t h e ir p r o p e r lo c a tio n s.
• CHECK G e n e r a t o r o u tp u t vo lta ge. R e p a ir i f le s s t h a n 9 o r m o re t h a n 16 v o lts.
• CHECK V a c u u m lin e s for k i n k s o r le a k s.
• CHECK F o r in t e r m it t e n t E G R . R e fe r to E X H A U S T G A S R E C I R C U L A T I O N ( S E C T I O N 9).
• CHECK TCC o p e r a t io n . R e f e r to T R A N S M I S S I O N CO N TRO LS (S E C T IO N 1 0 ), or
T R A N S M I S S I O N ( S E C T I O N 7) o f th e a p p r o p r ia t e v e h ic le s e r v ic e m a n u a l.
LACK OF POWER, SLUGGISH, OR SPONGY
(5.7L CNG ENGINE)
(Page 1 of 2)
Definition: E n g i n e d e l i v e r s le s s t h a n e x p e c t e d p o w er.
L it t le or no in c r e a s e in sp e e d , w hen
a c c e le ra t o r p e d a l is p u s h e d d o w n p a r t w ay.

PRELIMINARY CHECKS
• R e f e r to " Im p o r t a n t P r e l i m i n a r y C h e c k s . ”
• C o m p a r e c u s t o m e r ’s v e h ic le to s im i la r u n it. M a k e s u r e th e c u s t o m e r h a s a n a c t u a l p ro b le m .
• R e m o v e a i r f ilt e r a n d c h e c k a i r filt e r fo r d irt, o r for b e in g p lu g g e d , re p la c e a s n e c e ssa ry .
• T r a n s m i s s i o n s h if t p a t t e r n a n d d o w n s h if t o p e ra tion .
• T h i s s y m p t o m c a n b e c a u s e d b y o n ly o n e injecto r th a t is o p e r a t in g c o rre c tly . T o c h e c k fo r
a d e f e c t iv e in j e c t o r o r a f a u l t y s i g n a l to th e in j e c t o r , r e f e r to “C H A R T A - 3 ” in th e
C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N 3).

FUEL SYSTEM
• CHECK: F o r im p r o p e r fu e l p re ss u re . R e f e r to “C H A R T A - 6 ” i n C O M P U T E R COM M AND
C O N T R O L ( S E C T I O N 3).

IGNITION SYSTEM
• CHECK: P r o p e r i g n i t i o n v o lt a g e o u t p u t w it h s p a r k te ste r J 2 6 7 9 2 o r e q u iv a le n t (S T -1 2 5 ).
• CHECK: I g n i t i o n t i m i n g a n d p ro p e r o p e r a t io n o f E S T . R e f e r to I G N I T I O N S Y S T E M / E S T
( S E C T I O N 6).

EXHAUST SYSTEM
• CHECK: E x h a u s t S y s t e m fo r p o s s ib le re stric tio n : R e fe r to C O M P U T E R C O M M A N D C O N T R O L
( S E C T I O N 3) o r E X H A U S T ( S E C T I O N 6 F ) o f the a p p r o p ria t e s e rv ic e m a n u a l.
In s p e c t e x h a u s t s y s t e m fo r d a m a g e d o r c o lla p s e d p ip e s. In s p e c t m u f f le r fo r h e a t
d is t r e s s o r p o s s ib le in t e r n a l fa ilu r e .
1. W i t h e n g in e a t n o r m a l o p e r a t in g te m p e ra tu re , c o n n e c t a v a c u u m g a g e to a n y
c o n v e n ie n t v a c u u m p o rt o n in t a k e m a n ifo ld .
2. O p e r a t e e n g in e a t 1 0 0 0 r p m a n d reco rd v a c u u m re a d in g .
3. In c r e a s e r p m s lo w ly to 2 5 0 0 rp m . N o te v a c u u m r e a d in g a t s t e a d y 2 5 0 0 rp m .
4. I f v a c u u m a t 2 5 0 0 rp m d e c re a s e s m o re t h a n 10 k P a (3 ” H g ) fr o m r e a d in g a t 1 0 0 0
rp m , th e e x h a u s t s y s t e m s h o u ld be in sp e c te d fo r re s t ric t io n s .
5. D is c o n n e c t e x h a u s t p ip e fr o m e n g in e a n d re p e a t S t e p s 3 & 4. I f v a c u u m s t ill d r o p s
m o re t h a n 10 k P a (3 ” H g ) w it h e x h a u s t d isc o n n e c te d , c h e c k fo r e x h a u s t m a n if o ld
r e s t r ic t io n a n d v a lv e t im in g .
 LACK OF POWER, SLUGGISH, OR SPONGY
(5.7L CNG ENGINE)
(Page 2 of 2)
Definition: E n g i n e d e l i v e r s le s s t h a n e x p e c t e d p o w e r .
L it t le o r n o in c r e a s e in sp e e d , w h e n
a c c e le ra t o r p e d a l i s p u s h e d d o w n p a r t w a y .

ADDITIONAL CHECKS
• CHECK: E C M g r o u n d s fo r b e i n g c le a n , t i g h t , a n d i n t h e i r p r o p e r lo c a t io n . R e f e r to
“C o m p o n e n t L o c a t io n s ” i n G E N E R A L I N F O R M A T I O N ( S E C T I O N 1).
• CHECK: E G R o p e ra tio n for b e in g o p e n o r p a r t ly o p e n a ll th e tim e. R e f e r to E X H A U S T G A S
R E C I R C U L A T I O N ( S E C T I O N 9).
• CHECK: T o r q u e C o n v e r t e r C lu t c h ( T C C ) o p e ra tio n . R e f e r to T R A N S M I S S I O N C O N T R O L S
( S E C T I O N 10) o r T R A N S M I S S I O N ( S E C T I O N 7) o f th e a p p r o p r ia t e v e h ic le s e r v ic e
m a n u a l.
• CHECK: A / C o p e r a t io n . R e f e r to " A / C C h a r t ” i n C O M P U T E R C O M M A N D C O N T R O L
( S E C T I O N 3).
• CHECK: G e n e r a t o r o u t p u t voltage. R e p a ir i f le s s t h a n 9 o r m o re t h a n 16 vo lts.

ENGINE MECHANICAL
• CHECK: E n g i n e c o m p re ssio n , v a lv e t im in g , a n d fo r p r o p e r o r w o r n c a m s h a ft . R e f e r to E N G I N E
M E C H A N I C A L D I A G N O S I S ( S E C T I O N 6 A ) o f th e a p p r o p r ia t e s e r v ic e m a n u a l.
 DETONATION/SPARK KNOCK
(5.7L CNG ENGINE)
(Page 1 of 2)
Definition: A m ild to s e v e re p in g , u s u a l l y w o r s e u n d e r
a c c e le ra tio n . T h e e n g in e m a k e s s h a r p m e t a llic
k n o c k s th a t c h a n g e w it h th ro tt le o p e n in g .

P R E L IM IN A R Y C H E C K S
• R e f e r to " Im p o r t a n t P r e l i m i n a r y C h e c k s . ”
• M a k e s u r e the c u s t o m e r h a s a n a c t u a l p ro b le m .
• T h i s s y m p t o m c a n b e c a u s e d b y o n ly o n e in je cto r t h a t i s o p e r a t in g c o rre c tly . T o c h e c k fo r
a d e f e c t iv e in j e c t o r o r a f a u l t y s i g n a l to t h e in j e c t o r , r e f e r to “C H A R T A - 3 ” i n t h e
C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N 3).
• P a r k / N e u t r a l (P / N ) S w i t c h o p e r a t io n . R e f e r to “P a r k / N e u t r a l (P / N ) S w itc h C h e c k ” in
C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N 3).

C O O L IN G S Y S T E M
• CHECK: F o r o b v io u s o v e r h e a t in g p ro b le m s. R e fe r to E N G I N E C O O L I N G ( S E C T I O N 6 B 1 ) o f
a p p r o p ria t e s e r v ic e m a n u a l.
• CHECK: L o w e n g in e co o la n t.
• CHECK: L o o se w a t e r p u m p be lt
• CHECK: R e s t ric te d a i r flo w to r a d ia t o r , o r r e s t ric te d c o o la n t flow.
• CHECK: F a u l t y o r in c o r r e c t th e rm o sta t.
• CHECK: C o rre c t c o o la n t so lu tio n .

SEN SO R
• CHECK: C o o la n t T e m p e r a t u r e S e n s o r ( C T S ) , w h ic h h a s sh ifte d in v a lu e . R e f e r to " C o d e 15
D ia g n o s t ic A i d s ” in C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N 3).

FUEL S Y S T E M
• CHECK: T o d e t e r m in e i f th e c o n d it io n is c a u se d b y a le a n sy ste m , th e v e h ic le s h o u l d be d r iv e n a t
the sp e e d o f th e c o m p la in t. M o n it o r i n g b lo c k le a r n w ill h e lp id e n t if y th e p ro b le m .
L e a n - B l o c k le a r n g r e a t e r t h a n 170. R e f e r to " C o d e 4 4 D i a g n o s t i c A i d s ” in
C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N 3).
• CHECK: F u e l p re ssu re . R e f e r to " C H A R T A - 6 ” in C O M P U T E R CO M M AN D CONTROL
( S E C T I O N 3).
• CHECK: F o r p ro p e r fu e l p re ss u re .
• I f “S c a n ” to o l r e a d i n g s a r e n o r m a l a n d t h e r e a r e n o e n g in e m e c h a n i c a l f a u lt s , f i l l f u e l
c y lin d e r s a n d r e - e v a lu a t e v e h ic le p e rfo rm a n c e .
 DETONATION/SPARK KNOCK
(5.7L CNG ENGINE)
(P a g e 2 o f 2)
Definition: A m ild to s e v e re p in g , u s u a l l y w o r s e u n d e r
a c c e le ra tio n . T h e e n g in e m a k e s s h a r p m e t a llic
k n o c k s th a t c h a n g e w it h t h ro tt le o p e n in g .

IG N IT IO N S Y S T E M
• CHECK: S p a r k p lu g s fo r p ro p e r heat r a n g e a n d gap.
• CHECK: E S C s y s t e m e x is t s b u t is n o n - o p e r a t io n a l o n 5 . 7 L C N G E n g in e s .
• CHECK: Ig n i t i o n tim in g . R e fe r to I G N I T I O N S Y S T E M / E S T ( S E C T I O N 6).

E N G IN E M E C H A N IC A L
• CHECK: F o r c a rb o n b u ild u p . R e m o v e c a r b o n w it h top e n g in e c le a n e r. F o llo w i n s t r u c t io n s o n
can.
• CHECK: F o r in c o rr e c t b a s ic e n g in e p a r t s s u c h a s cam , he a d s, p is to n s , etc.
• CHECK: F o r e x c e s siv e o il e n t e r in g c o m b u s t io n c h a m b e r.

A D D IT IO N A L C H E C K S
• CHECK: P r o p e r o p e ra tio n o f E G R va lve .
• CHECK: P r o p e r o p e ra tio n o f T h e rm a e . R e f e r to T H E R M O S T A T I C A I R C L E A N E R ( S E C T I O N
12).
• CHECK: F o r p ro p e r t r a n s m is s io n s h if t p o in ts . R e f e r to T R A N S M I S S I O N ( S E C T IO N 7) o f
a p p r o p ria t e s e rv ic e m a n u a l.
• CHECK: T o r q u e C o n v e r t e r C lu t c h ( T C C ) o p e ra tio n . R e fe r to T R A N S M I S S I O N CO NTROLS
( S E C T I O N 10).
• CHECK: F o r co rre ct P R O M (see S e r v ic e B u lle t in s ) .
2-12 D R IV E A B IL IT Y S Y M P T O M S

HESITATION, SAG, STUMBLE

(5.7L CNG ENGINE)
Definition: M o m e n t a r y la c k o f r e s p o n s e a s th e a c c e le ra to r is
p u s h e d d o w n . C a n o c c u r a t a n y v e h ic le speed.
U s u a l l y m o st s e v e re w h e n f ir s t t r y i n g to m a k e
th e v e h ic le m o ve, a s fr o m a sto p s ig n . M a y c a u se
th e e n g in e to s t a ll i f s e v e re e n o u g h .

P R E L IM IN A R Y C H E C K S
• R e fe r to " Im p o r t a n t P r e l i m i n a r y C h e c k s . ”

FUEL S Y S T E M
• CHECK: F u e l p re ss u re . R e f e r to C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N 3) a n d F U E L
C O N T R O L ( S E C T I O N 4).
• CHECK: T h r o t t le P o s it io n S e n s o r ( T P S ) - C h e c k T P S fo r b i n d i n g o r s t ic k in g . V o lt a g e s h o u ld
in c r e a s e at a s t e a d y ra t e a s t h ro tt le is m o ve d to w a rd W id e O p e n T h r o t t le ( W O T ) .
• CHECK: M A P s e n s o r r e s p o n s e a n d a c c u ra c y . R e fe r to " M a n i f o l d A b s o lu t e P r e s s u r e ( M A P )
O u t p u t C h e c k ” in C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N 3).
• CHECK: C o o l a n t T e m p e r a t u r e S e n s o r r e s p o n s e a n d a c c u ra c y . R e f e r to “( C T S ) C ir c u it
C h e c k ” i n C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N 3).

IG N IT IO N S Y S T E M
• CHECK S p a r k p lu g w ir e s fo r b e in g fa u lty .
• CHECK S p a r k p lu g s fo r b e in g fouled.
• CHECK O p e n ig n it io n s y s t e m g r o u n d C K T 4 5 3 o r ig n it io n t im in g . R e f e r to I G N I T I O N
S Y S T E M / E S T ( S E C T I O N 6).

A D D IT IO N A L C H E C K S
• CHECK: F o r c o rre c t P R O M (see S e r v ic e B u lle t in s ) .
• CHECK: G e n e r a t o r o u t p u t v o lta g e . R e p a ir i f le ss t h a n 9 o r m o re t h a n 16 vo lts.
• CHECK: E G R v a lv e o p e ra tio n . R e f e r to E X H A U S T G A S R E C I R C U L A T I O N ( S E C T I O N 9).
 CUTS OUT, MISSES
(5.7L CNG ENGINE)
Definition: S t e a d y p u ls a t io n o r j e r k i n g th a t f o llo w s e n g in e speed,
u s u a l l y m o re p ro n o u n c e d a s e n g in e lo a d in c re a s e s . T h e
_______________e x h a u s t h a s a s te a d y s p it t in g s o u n d a t id le o r lo w speed.

P R E L IM IN A R Y C H E C K S
• R e fe r to " Im p o r t a n t P r e l im i n a r y C h e c k s . ”
• T h i s s y m p t o m c a n be c a u se d b y o n ly o n e in je c to r t h a t is o p e r a t in g c o rre ctly. T o c h e c k fo r
a d e f e c t iv e in j e c t o r o r a f a u l t y s i g n a l to t h e in j e c t o r , r e f e r to “C H A R T A - 3 ” i n t h e
C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N 3).

IG N IT IO N S Y S T E M
• CHECK: F o r c y lin d e r m is s by:
1. S t a r t e n g in e , a llo w e n g in e to s t a b iliz e t h e n d is c o n n e c t I A C m o to r. R e m o v e o n e s p a r k
p lu g w ire a t a tim e, u s in g in s u la t e d p lie rs .

N O TIC E: D o n o t p e rfo rm t h is test fo r m o re t h a n 2 m in u t e s , a s t h is m a y c a u se d a m a g e to th e

c a t a ly tic c o n v e rte r.

2. I f th e re is a n rp m drop, o n a ll c y lin d e r s , (e q u a l to w i t h in 5 0 rp m ), go to " R o u g h ,

U n s t a b le O r In c o rre c t Idle, S t a l l i n g ” s y m p to m . R e c o n n e c t I A C m o to r w it h ig n i t i o n
"O F F .”
3. I f th e re is n o rp m d ro p on o ne o r m o re c y lin d e r s , o r e x c e s s iv e v a r ia t io n in d ro p , c h e c k
fo r s p a r k , o n th e su sp e c te d c y l i n d e r ( s ) w it h J 2 6 7 9 2 ( S T - 1 2 5 ) S p a r k T e s t e r o r
e q u iv a le n t.
4. I f n o s p a r k , re fe r to I G N I T I O N S Y S T E M / E S T ( S E C T I O N 6).
5. I f th e re is s p a r k , re m o v e s p a r k p lu g ( s ) in th e se c y lin d e r s a n d c h e c k for:
In s u la t io n C r a c k s .
W e a r.
Im p r o p e r G ap.
B u r n e d E le c tro d e s.
H e a v y D e p o sits.
• CHECK: S p a r k p lu g w ire re s is ta n c e ( s h o u ld n o t exc e e d 3 0 ,0 0 0 o h m s), a lso , c h e c k r o t o r a n d
d is t r ib u t o r cap.
• CHECK: I f th e p r e v io u s c h e c k s d id not fin d th e p ro b le m :
-________________ V i s u a l l y in s p e c t ig n it io n s y s t e m fo r m o is t u re , d u st, c ra c k s , b u r n s , etc. W i t h e n g in e
_________________ r u n n in g , s p r a y p lu g w ire s w it h fin e w a t e r m is t to c h e c k fo r s h o rts.

FUEL S Y S T E M
• CHECK: F u e l P re ssu re . R e f e r to " C H A R T A - 6 ” in C O M P U T E R CO M M AND CONTROL
( S E C T I O N 3) o r F U E L C O x N T R O L ( S E C T I O N 4).
N O TIC E: F u e l filt e r s a re n o t u s e d o n 5 . 7 L C N G E n g i n e s w it h 4 L 6 0 T r a n s m is s io n .

EN G IN E M E C H A N IC A L
• CHECK: F o r p ro p e r v a lv e t im in g , low c o m p re s s io n , b e n t p u s h ro d s , w o r n ro c k e r a r m s , b r o k e n o r
w e a k v a l v e s p r i n g s , w o rn c a m s h a f t lo b e s . R e f e r to E N G I N E M E C H A N I C A L
D I A G N O S I S ( S E C T I O N 6 A ) o f a p p r o p r ia t e s e rv ic e m a n u a l.
• CHECK: In t a k e a n d e x h a u s t m a n ifo ld p a s s a g e s fo r c a s t in g fla sh .
 POOR FUEL ECONOMY
(5.7L CNG ENGINE)
Definition: F u e l e c o n o m y , a s m e a s u r e d b y a n a c t u a l r o a d te st, i s
n o t ic e a b ly lo w e r th a n e xp e cte d . A lso , econom y is
n o t ic e a b ly lo w e r t h a n it w a s o n t h i s v e h ic le a t o n e tim e,
a s p r e v i o u s ly s h o w n b y a n a c t u a l r o a d test.

P R E L IM IN A R Y C H E C K S
• R e fe r to " Im p o r t a n t P r e l i m i n a r y C h e c k s . ”
• C h e c k a i r c le a n e r e le m e n t (filte r) fo r d ir t o r b e in g p lu g g e d a n d o p e r a t io n o f T H E R M A C .
• V i s u a l l y ( p h y s ic a lly ) ch eck: V a c u u m h o s e s fo r sp lits, k in k s , a n d p r o p e r c o n n e c t io n s a s s h o w n o n
"V e h ic l e E m i s s i o n C o n t r o l In f o r m a t io n ” label.
• P e r f o r m " D i a g n o s t ic C ir c u i t C h e c k . ”
• C h e c k o w n e r ’s d r i v i n g h a b its.
I s A / C " O N ” f u ll tim e ( D e f r o s t e r m o d e " O N ”)?
A r e t ir e s a t c o rre c t p r e s s u r e ?
A r e e x c e s s iv e ly h e a v y lo a d s b e in g c a r r ie d ?
I s a c c e le ra t io n too m u c h , too o fte n ?
• S u g g e s t o w n e r f ill fu e l t a n k s a n d r e c h e c k fu el econ om y.
• S u g g e s t d r iv e r re a d " Im p o r t a n t F a c t s o n F u e l E c o n o m y ” in O w n e r ’s M a n u a l .

FUEL S Y S T E M
• CHECK: F o r fu e l le a k s , (c y lin d e rs, lin e s, fittin g s, v a lv e s).
• CHECK: F u e l p re ssu re . R e f e r to " C H A R T A - 6 ” in C O M P U T E R CO M M AND CONTROL
( S E C T I O N 3).
• CHECK: T h a t e a c h f u e l c y l i n d e r s o le n o id v a l v e i s f u n c t i o n i n g p r o p e r ly . T u r n v e h ic le
“O F F ”. D is c o n n e c t 2 o f th e 3 s o le n o id v a lv e s . S t a r t v e h ic le a n d m a k e s u r e it w i l l
s t a y r u n n i n g . I f v e h i c le r u n s s o le n o id v a l v e i s O K . R e p e a t f o r e a c h s o le n o id
v a lv e .

IG N IT IO N S Y S T E M
• CHECK: S p a r k p lu g s . R e m o v e s p a r k p lu g s , ch e ck fo r w et p lu g s , c r a c k s , w e a r, im p r o p e r gap ,
b u r n e d e le ctro d e s, o r h e a v y d e p o sits. R e p a ir o r re p la ce a s n e c e s s a ry .
• CHECK: Ig n i t i o n w ir e s fo r c r a c k in g , h a r d n e s s , a n d p ro p e r c o n n e c tio n s.
• CHECK: Ig n i t i o n t im in g . R e fe r to I G N I T I O N S Y S T E M / E S T ( S E C T I O N 6).

.CH EC K : E n g i n e c o o la n t level. C O O L IN G S Y S T E M
• CHECK: E n g i n e t h e r m o s t a t for f a u lt y p a r t (a lw a y s open) o r fo r w r o n g h e a t ra n g e . R e f e r to
E N G I N E C O O L I N G ( S E C T I O N 6 B 1 ) o f a p p r o p ria t e s e rv ic e m a n u a l.

SEN SO RS
• CHECK: C o o l a n t T e m p e r a t u r e S e n s o r ( C T S ) — u s i n g “S c a n ” to o l, c o m p a r e r e s i s t a n c e
v a l u e s . R e f e r to “ C o d e 1 5 ” “D i a g n o s t i c A i d s ” i n C O M P U T E R C O M M A N D
C O N T R O L ( S E C T I O N 3).

A D D IT IO N A L C H E C K S
• CHECK: T r a n s m i s s i o n s h if t p a tte rn .
• CHECK: TCC O p e r a t io n - R e f e r to T R A N S M I S S I O N CO N TRO LS (S E C T IO N 10) or
T R A N S M I S S I O N ( S E C T I O N 7) o f a p p ro p ria te v e h ic le s e r v ic e m a n u a l. A " S c a n ” tool
s h o u ld in d ic a t e a n rp m d ro p w h e n the T C C is c o m m a n d e d " O N . ”
• CHECK: F o r p ro p e r c a lib r a t io n o f sp eed om e ter.
• CHECK: F o r d r a g g i n g b ra k e s . R e fe r to H Y D R A U L I C B R A K E S ( S E C T I O N 5) o f th e a p p r o p r ia t e
s e r v ic e m a n u a l.
 ROUGH, UNSTABLE OR INCORRECT IDLE, STALLING
(5.7L CNG ENGINE)
(P a g e 1 o f 2)
Definition: T h e e n g in e r u n s u n e v e n l y a t id le . I f b a d e n o u g h , th e
v e h ic le m a y s h a k e . A ls o , th e id le m a y v a r y i n r p m (c a lle d
" h u n t i n g ”). E i t h e r c o n d it io n m a y be s e v e re e n o u g h to c a u s e
s t a llin g . E n g i n e id le s a t in c o rr e c t speed.

P R E L IM IN A R Y C H E C K S
• R e f e r to " Im p o r t a n t P r e lim i n a r y C h e c k s . ”

SEN SO RS
• CHECK: O x y g e n ( 0 2) s e n s o r - I n s p e c t s e n s o r fo r s i l i c o n c o n t a m i n a t i o n f r o m u s e o f
im p r o p e r s e a la n t (n e v e r u s e s e a la n t o n a n y w a t e r p r o o f co n n e cto rs). T h e s e n s o r
w i l l h a v e a w h it e , p o w d e r y c o a t in g , a n d w i l l r e s u l t i n a h i g h b u t f a ls e s i g n a l
v o lt a g e (ric h e x h a u s t in d ic a tio n ). T h e E C M w i ll t h e n re d u c e th e a m o u n t o f fu e l
d e liv e r e d to th e e n g in e , c a u s i n g a le a n d r iv e a b il it y p ro b le m .
• CHECK: T h r o t t le P o s it io n S e n s o r ( T P S ) - I f a s t i c k in g t h ro t t le s h a f t o r b i n d i n g l i n k a g e
c a u s e s a h i g h T P S v o lt a g e o p e n t h r o t t le in d ic a t io n , t h e E C M w i l l n o t c o n t r o l
idle. M o n it o r T P S vo lta ge . A “S c a n ” to o l a n d / or v o lt m e t e r s h o u ld re a d le s s t h a n
1.25 v o lt s w it h th ro tt le closed. R e f e r to F U E L C O N T R O L ( S E C T I O N 4).
• CHECK: C o o la n t T e m p e r a t u r e S e n s o r ( C T S ) - U s i n g a " S c a n ” tool, c o m p a re c o o la n t t e m p e r a t u r e
w it h a m b ie n t t e m p e ra t u re o n a c o ld e n g in e .
- I f c o o la n t t e m p e ra t u re r e a d s 5 d e g r e e s g r e a t e r t h a n o r le s s t h a n a m b i e n t a i r
te m p e ra tu re . C h e c k for h i g h r e s is t a n c e in c o o la n t s e n s o r c ir c u it o r s e n s o r itse lf.
R e f e r to " C o d e 15 D i a g n o s t i c A i d s ” i n C O M P U T E R C O M M A N D C O N T R O L
( S E C T I O N 3).
• CHECK: M A P s e n s o r re sp o n se a n d a c c u r a c y - R e f e r to " M a n i f o l d A b s o lu t e P r e s s u r e ( M A P )
O u t p u t C h e c k ” in C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N 3).

FUEL S Y S T E M
• CHECK: T o d e t e rm in e i f the c o n d itio n is c a u s e d b y a r ic h o r le a n sy st e m , th e v e h ic le s h o u l d be
d r i v e n a t th e sp eed o f the c o m p la in t . M o n it o r i n g b lo c k le a r n w ill h e lp id e n t ify p ro b le m .
L e a n - B l o c k le a r n g r e a t e r t h a n 170. R e f e r to " C o d e 4 4 D i a g n o s t i c A i d s ” i n
C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N 3).
R i c h - B lo c k le a rn le s s th a n 90. R e f e r to " C o d e 4 5 D ia g n o s t ic A i d s ” in C O M P U T E R
C O M M A N D C O N T R O L ( S E C T I O N 3).
• CHECK: P e r f o r m a c y lin d e r c o m p re s s io n c h e ck . R e f e r to E N G I N E M E C H A N I C A L D I A G N O S I S
( S E C T I O N 6 A ) o f a p p ro p ria te s e r v ic e m a n u a l.
• CHECK: F o r in je c to r(s) le a k in g . C h e c k fu e l p re ss u re . R e f e r to " C H A R T A - 6 ” in C O M P U T E R
C O M M A N D C O N T R O L ( S E C T I O N 3) a n d F U E L C O N T R O L ( S E C T I O N 4).

IG N IT IO N S Y S T E M
• CHECK: I g n i t i o n s y s t e m a n d ig n it io n t im in g . R e fe r to I G N I T I O N S Y S T E M / E S T ( S E C T I O N 6).
 ROUGH, UNSTABLE OR INCORECT IDLE, STALLING
(5.7L CNG ENGINE)
(Page 2 of 2)
Definition: T h e e n g in e r u n s u n e v e n ly a t id le . I f b a d e n o u g h , th e
v e h ic le m a y s h a k e . A ls o , the id le m a y v a r y in r p m (ca lle d
" h u n t i n g ”). E it h e r c o n d it io n m a y be se v e re e n o u g h to c a u se
s t a llin g . E n g i n e id le s a t in c o rr e c t speed.

ADDITIONAL CHECKS
• CHECK: V a c u u m le a k s c a n c a u se h i g h e r t h a n n o r m a l id le a n d lo w I A C co u n ts.
• CHECK: I A C o p e ra tio n - re fe r to "C o d e 3 5 ” in C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N
3), a n d " D i a g n o s i s ” in F U E L C O N T R O L ( S E C T I O N 4).
• CHECK: ECM g r o u n d s fo r cle an, t ig h t, a n d p ro p e r ro u t in g . R e f e r to “C o m p o n e n t L o c a t io n ”
i n G E N E R A L I N F O R M A T I O N ( S E C T I O N 1).
• CHECK: P a r k / N e u t r a l (P / N ) S w it c h o p e ra tio n . R e fe r to “P a r k / N e u t r a l (P / N ) S w i t c h C h e c k ”
in C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N 3).
• CHECK: U s e " S c a n ” tool to d e t e rm in e i f E C M is r e c e iv in g A / C re q u e s t s ig n a l. W h e n e v e r A / C is
se le cte d re fe r to C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N 3). I f p r o b le m e x is t s
w it h A / C " O N , ” c h e c k A / C s y s t e m o p e r a t io n . R e f e r to A I R C O N D I T I O N I N G
( S E C T IO N IB ).
• CHECK: E G R " O N , ” w h ile id lin g , w ill c a u se r o u g h n e s s , s t a ll in g a n d h a r d s t a r t in g . R e f e r to
E X H A U S T G A S R E C I R C U L A T I O N ( S E C T I O N 9).
• CHECK: B a t t e r y c a b le s a n d g r o u n d s t r a p s s h o u ld be c le a n a n d secu re. E r r a t i c v o lt a g e w ill c a u s e
I A C to c h a n g e it s p o sitio n , r e s u l t i n g in p o o r id le q u a lit y .
• CHECK: I A C v a lv e w ill n o t m o ve if s y s t e m v o lta g e is b e lo w 9 o r g r e a te r t h a n 1 6 vo lts.
• CHECK: A / C r e f r ig e r a n t p r e s s u r e too h i g h o r fa u lt y h ig h p r e s s u r e sw itch .
• CHECK: P C V v a lv e fo r p ro p e r o p e r a t io n b y p la c in g f in g e r o v e r in le t h o le in v a lv e e n d s e v e r a l
tim e s . V a lv e s h o u ld s n a p b ack. I f n o t, r e p la c e v a lv e . R e f e r to P O S I T I V E
C R A N K C A S E V E N T I L A T I O N ( S E C T I O N 11).

ENGINE MECHANICAL
• CHECK: F o r b r o k e n m o to r m o u n t s o r lo w c o m p r e s s io n . R e f e r to E N G I N E M E C H A N IC A L
D I A G N O S I S ( S E C T I O N 6 A ) o f a p p ro p ria t e s e rv ic e m a n u a l.
 EXCESSIVE EXHAUST EMISSIONS OR ODORS
(5.7L CNG ENGINE)
Definition: V e h ic le fa ils a n e m is s io n te st . V e h ic le has
e x c e s s iv e "r o t t e n e g g ” sm e ll. E x c e s s i v e o d o r s do
n o t n e c e s s a r ily in d ic a t e e x c e s s iv e e m is s io n s .

P R E L IM IN A R Y C H E C K S
• R e fe r to " Im p o r t a n t P r e lim i n a r y C h e c k s . ”
• P e r f o r m " D i a g n o s t ic C ir c u i t C h e c k . ”
• M a k e s u r e e n g in e is a t n o r m a l o p e ra tin g t e m p e ra t u re .
• I f E M I S S I O N T E S T s h o w s e x c e ssiv e C O a n d H C c h e c k it e m s w h ic h c a u se v e h ic le to r u n R I C H .
( B lo c k L e a r n M e m o r y ( B L M ) le s s th a n 9 0 ) re fe r to "C o d e 4 5 D ia g n o s t ic A i d s ” in C O M P U T E R
C O M M A N D C O N T R O L ( S E C T I O N 3).
• I f E M I S S I O N T E S T s h o w s e x c e ssiv e N O x c h e c k it e m s w h ic h c a u se e n g in e to o p e ra te L E A N o r too
hot.

SEN SO RS
• CHECK: I f the " S c a n ” tool in d ic a te s a v e r y h i g h c o o la n t t e m p e ra t u re a n d th e s y s t e m i s r u n n i n g
L E A N : c h e c k the c o o lin g s y s t e m a n d c o o li n g f a n fo r p r o p e r o p e r a t io n . R e f e r to
E N G I N E C O O L I N G ( S E C T I O N 6 B 1 ) o f th e a p p r o p r ia t e s e rv ic e m a n u a l.

FUEL S Y S T E M
• CHECK: I f th e s y s t e m is r u n n i n g rich , (b lo c k le a r n le s s t h a n 9 0 ), re fe r to " C o d e 4 5 D i a g n o s t ic
A i d s ” o r i f th e s y s t e m is r u n n i n g le a n , (b lo c k le a r n g r e a t e r t h a n 170), re fe r to " C o d e 4 4
D ia g n o s t ic A i d s ” in C O M P U T E R C O M M A N D C O N T R O L ( S E C T I O N 3).
• CHECK: F o r p r o p e r ly o p e r a t in g fu e l f ill v a lv e , ( o n e -w a y ch eck).
• CHECK: F u e l p r e s s u r e . R e f e r to " C H A R T A - 6 ” in C O M P U T E R CO M M AN D CO NTRO L
( S E C T I O N 3) o r F U E L C O N T R O L ( S E C T I O N 4).
• CHECK: C o m p r e s s e d N a t u r a l G a s fu e l s y s t e m fo r le a k s . ( P r e s s u r iz e s y s t e m a n d u s e s o a p y
w a t e r so lu tio n ).
• CHECK: I f te st s h o w s e x c e s siv e N O x, c h e c k it e m s w h ic h c a u se e n g in e to o p e ra te L E A N o r too
hot.

IG N IT IO N S Y S T E M
• CHECK: I g n i t i o n s y s t e m , in c o r r e c t t i m i n g , o r e x c e s s i v e a d v a n c e . R e f e r to I G N I T I O N
S Y S T E M / E S T ( S E C T I O N 6).
• CHECK: S p a r k p lu g s , p lu g w ire s, a n d ig n i t i o n c o m p o n e n ts. R e fe r to E N G I N E E L E C T R I C A L
( S E C T I O N 6 D ) o f a p p ro p ria te s e r v ic e m a n u a l.

A D D IT IO N A L C H E C K S
• CHECK: F o r v a c u u m le a k s.
• CHECK: F o r le a d c o n t a m in a t io n o f c a t a ly t ic c o n v e r t e r (lo o k fo r th e r e m o v a l o f fu e l f ille r n e c k
re stric to r).
• CHECK: C a r b o n b u ild -u p . R e m o v e c a rb o n w it h to p e n g in e c le a n e r. F o llo w in s t r u c t io n s o n can.
• CHECK: E G R v a lv e fo r no t o p en in g. R e f e r to E X H A U S T G A S R E C I R C U L A T I O N ( S E C T I O N
9).
• CHECK: P C V v a lv e fo r b e in g p lu g g e d , s t u c k , o r b lo c k e d P C V h o se . R e f e r to P O S I T I V E
C R A N K C A S E V E N T I L A T I O N ( S E C T I O N 11).
• CHECK: F o r p re se n c e o f fu e l in c ra n k c a se .
 DIESELING, RUN-ON
(5.7L CNG ENGINE)
Definition: E n g i n e c o n t in u e s to r u n a ft e r k e y is
t u r n e d " O F F , ” b u t r u n s v e r y r o u g h ly .
I f e n g in e r u n s s m o o t h ly , c h e c k
i g n i t i o n s w it c h a n d a d ju s t m e n t.

P R E L IM IN A R Y C H E C K S
• R e fe r to " Im p o r t a n t P r e l i m i n a r y C h e c k s . ”

FUEL S Y S T E M

• CHECK: In je c to r(s) o n T B I u n i t fo r le a k a g e . A p p l y 12 v o lt s to fu e l p u m p “t e s t ” t e r m in a l
to t u r n “O N ” fu e l s u p p l y a n d p r e s s u r iz e fu e l sy ste m . C h e c k in je c to r(s) fo r fu e l
le a k a g e . R e f e r to F U E L C O N T R O L ( S E C T I O N 4).

IG N IT IO N S Y S T E M

• CHECK: S p a r k p lu g s fo r p ro p e r h e a t r a n g e a n d gap .
• CHECK: Ig n i t i o n t im in g . R e f e r to I G N I T I O N S Y S T E M / E S T ( S E C T I O N 6).

C O O L IN G S Y S T E M

• CHECK: E n g i n e c o o la n t level.
• CHECK: E n g i n e t h e r m o s t a t ( n o t o p e n i n g f u lly ) o r fo r i n c o r r e c t h e a t r a n g e . R e f e r to
E N G I N E C O O L I N G ( S E C T I O N 6 B 1 ) o f a p p r o p ria t e s e r v ic e m a n u a l.

A D D IT IO N A L C H E C K S

• CHECK: F o r c a r b o n b u ild u p . R e m o v e c a rb o n w it h to p e n g in e c le a n e r. F o llo w in s t r u c t io n s

o n can.

• CHECK: F o r e x c e s s iv e o il e n t e r in g c o m b u s t io n c h a m b e rs, ( in s p e c t sp a rk p lu g s fo r
d e p o sits).

• CHECK: Id le A i r C o n t r o l m o to r ( IA C ) fo r p r o p e r o p e r a t i o n . R e fe r to “C o d e 3 5 ”
( S E C T I O N 3).

• CHECK: T h r o t t le P la t e s fo r p ro p e r c lo s in g .
 BACKFIRE
(5.7L CNG ENGINE)
Definition: F u e l ig n it e s in in t a k e m a n if o ld , o r
in e x h a u s t s y st e m , m a k i n g a lo u d
p o p p in g n o ise .

P R E L IM IN A R Y C H E C K S
• R e f e r to " Im p o r t a n t P r e l im i n a r y C h e c k s . ”

IG N IT IO N S Y S T E M
• CHECK: P r o p e r ig n it io n c o il o u t p u t v o lt a g e w it h s p a r k te ste r J 2 6 7 9 2 o r e q u iv a le n t ( S T - 125).
• CHECK: S p a r k p lu g s. R e m o v e s p a r k p lu g s , c h e c k fo r w et p lu g s , c ra c k s , w e a r, im p r o p e r g a p ,
b u r n e d e le ctrod es, o r h e a v y d e p o sits. R e p a ir o r re p la c e a s n e c e s s a ry .
• CHECK: Ig n i t i o n s y s t e m a n d ig n it io n t im in g . R e f e r to I G N I T I O N S Y S T E M / E S T ( S E C T I O N 6).
• CHECK: F o r c r o s s fir e b e tw e e n s p a r k p lu g s ( d is t r ib u t o r cap, s p a r k p lu g w ire s , a n d p r o p e r r o u t i n g
o f p l u g w ire s.) R e fe r to E N G I N E E L E C T R I C A L ( S E C T I O N 6 D ) o f a p p r o p r ia t e s e r v ic e
m a n u a l.

E N G IN E M E C H A N IC A L
• CHECK: C o m p r e s s io n , v a lv e tim in g , m a n if o ld g a s k e t s , s t i c k in g o r le a k in g v a lv e s . R e f e r to
E N G I N E M E C H A N I C A L D I A G N O S I S ( S E C T I O N 6 A ).
• CHECK: E G R o p e r a t io n fo r b e in g o p e n a ll th e t im e . R e fe r to E X H A U ST G AS
R E C I R C U L A T I O N ( S E C T I O N 9).
• CHECK: In t a k e a n d e x h a u s t s y s t e m fo r c a s t in g f la s h o r o th e r re s t ric tio n s .
2-20 D R IV E A B IL IT Y S Y M P T O M S
 SECTION 3
COMPUTER COMM AND CONTROL
(USING "SCAN" TOOL DIAGNOSIS)

CONTENTS
General Description .......................................... 3-3 CNG Fuel Control ....................................................3-16
ALDL Connector ....................................... 3-3 CNG Fuel I n j e c t o r s ............................................3-16
W iring Harness and Connectors . . . . 3-4 Fuel Pressure R egu lator ................................ 3-16
Information Sensors ................................ 3-4 Idle A ir Control (IAC) ....................................3-16
Electrostatic Discharge D a m a g e ............. 3-4 CNG Fuel S up p ly Relay C ircuit ................ 3-16
Electronic Control Module (ECM) ............. 3-4 Low Pressure Fuel S h u t-o ff S o len o id . . 3-16
PROM (5.7L CNG Engine Fuel D oor S h u t-o ff S w itch ........................ 3-16
With 4L60 Transmission) .......................3-5 Fuel C ylinder S olen oid V alves ................ 3-16
CAL-PAK (5.7L CNG Engine Fuel Pressure T ra n s d u c e r ............................ 3-17
With 4L60 Transmission) .......................3-5 C o o lan t T e m p e ra tu re S e n s o r ............................ 3-17
Fuel Control .................................................... 3-5 M A P S ensor ........................................................... 3-17
Input Information ...........................................3-6 O xygen ( 0 2) Sensor - H eated ........................ 3-17
Coolant Temperature Sensor (CTS) . . . 3-6 T h ro ttle Position S ensor (TPS) ........................ 3-17
Manifold Absolute Pressure (MAP) TPS O u t p u t ........................................................... 3-17
Sensor .....................................................3-6 V ehicle S peed S enso r (VSS) ............................ 3-17
Oxygen (02) Sensor (Heated) ................ 3-6 EGR S ystem ........................................................... 3-17
Throttle Position Sensor (TPS) ............. 3-7 Idle Speed ............................................................... 3-18
Vehicle Speed Sensor (VSS) ................ 3-7 Electronic S park T im in g (EST) ........................ 3-18
Knock Sensor .......................................... 3-7 Electronic Spark C ontrol ( E S C ) ........................ 3-18
Park/Neutral (P/N) Switch Signal . . . . 3-7 S ystem O ver V o lta g e ............................................3-18
Crank Signal ..............................................3-7 P ark/N eu tral (P/N) S w itch ................................ 3-18
Distributor Reference S ig n a l....................3-7 Crank S ignal ........................................................... 3-18
A/C Request Signal .................................3-7 D istributor R eference Signal ............................ 3-18
Transmission Gear Position Signal . . . 3-7 A/C R equest Signal ................................................3-18
Diagnostic Circuit C h e c k .......................... 3-8 E xhaust S y s t e m ....................................................... 3-18
Field Service Mode .................................3-8 D iagnostic Code Identification ........................ 3-19
Tech 1 ........................................................3-8 N o "S e rv ic e Engine S o o n "
Engine Does Not Start .......................... 3-8 Light C H A R T A-1 ................................................3-20
Diagnostic Code System .......................3-8 No ALDL Data Or W o n 't Flash
Clearing Codes ...........................................3-9 Code 12 "S e rv ic e E ngine S o o n "
D ia g n o s is .............................................................. 3-9 Light " O N " S te a d y - C H A R T A -2 3-22
Bulb Check .....................................................3-9 Engine Cranks But W ill N o t Run
Diagnostic Circuit Check ............................. 3-9 C H A R T A -3 ........................................................... 3-24
Diagnostic Circuit Check .................................3-10 Injector Circuit D iagnosis
Typical Tech 1 "Scan" Data Values . . . . 3-12 C HA RT A -4 ........................................................... 3-28
Tech 1 Tool Data ...........................................3-12 Fuel S up p ly Relay Circuit D iagnosis
Typical Tech 1 Data Definitions ................ 3-13 CHA RT A -5 ........................................................... 3-30
"Scan" Tool Modes .................................... 3-13 Fuel System Diagnosis
"Scan" Tool Positions .................................3-13 CHART A -6 ........................................................... 3-36
Electronic Control Module (ECM) ............. 3-15 Code 13 O xygen ( 0 2) Sensor Circuit
ECM Quad-Driver (QDR) Check ............. 3-15 (O pen Circuit) ................................................... 3-40
PROM (calibrator) .................................... 3-15 Code 14 C oolant T e m p e ra tu re S ensor
CAL-PAK .....................................................3-15 (CTS) Circuit ....................................................... 3-42
Code 15 C oolant T e m p e ratu re Sensor
(CTS) Circuit ....................................................... 3-44
Code 21 Throttle Position Sensor (TPS) ECM Wiring Diagrams
Circuit (Signal Voltage High) .................3-46 5.7L CNG Engine With
Code 22 Throttle Position Sensor (TPS) 4L60 Transmission (1 of 4 ) ................. 3-82
Circuit (Signal Voltage Low) .................3-48 ECM Connector Terminal End View
Code 24 Vehicle Speed Sensor (VSS) 5.7L CNG Engine With
Circuit Fault ...............................................3-50 4L60 Transmission (1 of 2 ) ................. 3-86
Code 33 Manifold Absolute Pressure On-Vehicle Service ............................................3-88
(MAP) Sensor Circuit (Signal Voltage Wire Harness .................................................. 3-88
High - Low Vacuum) .............................. 3-52 Connectors and Terminals ........................... 3-88
Code 34 Manifold Absolute Pressure Micro-Pack .................................................. 3-89
(MAP) Sensor Circuit (Signal Voltage Metri-Pack .................................................. 3-89
Low-High V a c u u m ) .....................................3-54 W eather-Pack...............................................3-89
Code 42 Electronic Spark Timing Compact T h r e e ........................................... 3-90
(EST) ............................................................3-56 Electronic Control Module ...........................3-90
Code 43 Electronic Spark Control ECM Connector Terminal Voltages . . . 3-90
(ESC) Circuit (1 of 3) .............................. 3-58 ECM Replacement - With
Code 44 Oxygen (02) Sensor Circuit PROM & CAL-PAK (5.7L CNG) . . . . 3-91
(Lean Exhaust Indicated) ....................... 3-60 P R O M ............................................................ 3-91
Code 45 Oxygen (0 2) Sensor Circuit CAL-PAK ..................................................... 3-91
(Rich Exhaust Indicated) ...........................3-62 Servicing ECM - With 5.7L CNG
Code 54 Fuel Supply Circuit Engine .........................................................3-92
(Low Voltage) ........................................... 3-64 Coolant Temperature S e n s o r ........................3-93
Code 51 PROM Problem .............................. 3-70 MAP Sensor .................................................. 3-93
Code 52 Fuel CAL-PAK Missing .................3-70 Oxygen (0 2) Sensor .....................................3-93
Code 53 System Over V o lt a g e .................... 3-70 Throttle Position Sensor -
Code 55 Faulty ECM .....................................3-70 Replacement-TBI ........................................ 3-94
Restricted Exhaust System Check ..............3-71 Intake Air Temperature (IAT) Sensor . . . . 3-95
Manifold Absolute Pressure (MAP) Knock Sensor .................................................. 3-95
Output Check ........................................... 3-72 Vehicle Speed Sensor (VSS) ........................3-95
Idle Air Control (IAC) System Vehicle Speed Sensor Buffer (DRAC)
Diagnosis ..................................................... 3-74 Module .........................................................3-95
Park/Neutral (P/N) Switch Diagnosis . . . . 3-76 Park/Neutral (P/N) Switch ...........................3-96
A/C Request Signal Diagnosis .................... 3-78 Parts Information ...............................................3-96
ECM QDR Check Procedure ........................3-80
 GENERAL DESCRIPTION

T h e C o m p u te r C o m m a n d C o n tro l sy ste m h a s a n T h i s c o n n e c t o r h a s t e r m i n a l s t h a t a r e u s e d to
E le c t r o n ic C o n t r o l M o d u l e (c o m p u te r) to c o n tro l t h e d ia g n o s e th e s y s t e m e it h e r w i t h j u m p e r w i r e s o r a
fu e l d e liv e r y , i g n i t i o n t im in g , so m e e m is s io n c o n tro l T e c h 1 “S c a n ” tool.
s y s t e m s a n d e n g a g e m e n t of th e t r a n s m is s io n T h e f o llo w in g t e r m in a ls a re use d :
c o n v e r t e r c lu tc h . A - T h is t e r m in a l p r o v id e s a g r o u n d c ir c u it to
The syste m , th ro u g h th e E le c t ro n ic C o n tro l o t h e r t e r m in a ls .
M o d u l e ( E C M ) , m o n i t o r s a n u m b e r o f e n g in e a n d B - T h i s t e r m in a l is t h e “d ia g n o s t ic t e r m i n a l ” fo r
v e h ic le fu n c t io n s ( F ig u r e 3 -1 ) a n d c o n t r o ls th e th e E C M . W h e n g r o u n d e d to “A ” t e r m in a l, t h e
f o llo w in g o p e ra tio n s : “S e r v ic e E n g i n e S o o n ” l i g h t w i l l f l a s h c o d e s
• F u e l co n tro l. ( k e y “O N ” a n d e n g i n e “O F F ”) e n t e r i n g t h e
• Ig n it io n / e le c t r o n ic s p a r k t im in g . d ia g n o s t ic m o d e o r f la s h e s a fie ld s e r v ic e m o d e
• E le c t r o n ic s p a r k c o n tro l. ( e n g in e r u n n i n g ) to d e t e r m in e i f s y s t e m i s i n
• E x h a u s t g a s r e c ir c u la t io n . a “C lo s e d L o o p ” o r “O p e n L o o p ” o p e ra tio n .
• E C M - T o r q u e C o n v e r t e r C lu t c h . C - T h is t e r m in a l, o n so m e a ir m a n a g e m e n t
T h e d i a g n o s i s i n t h i s s e c tio n i s p ro v id e d w h e n s y s t e m s , i s w i r e d to t h e g r o u n d s i d e o f t h e
a “S c a n ” to o l to in t e r f a c e w it h th e C o m p u te r e le c t r ic a i r c o n t r o l v a l v e . I t c a n b e u s e d to
C o m m a n d C o n t r o l s y s t e m i s a v a ila b le . d ia g n o s e th e a i r m a n a g e m e n t s y s t e m . R e f e r to
“A i r M a n a g e m e n t , ” S e c t io n “8 ”.
E - T his t e r m i n a l is th e s e ria l d a t a lin e on a ll
A L D L C o n n e ctor 5.7L CNG E ngines W ith 4L60 T ra n sm issio n
Figure 3-2 and is used by a Tech 1 “S c a n ” tool to rea d
various system data information.
T h e A s s e m b ly L in e D ia g n o s t ic L in k (A L D L ) F - T h is t e r m in a l is use d on E C M e q u ip p e d
t w e lv e t e r m in a l c o n n e c t o r i s w ir e d to th e E C M and v e h i c le s to d i a g n o s e t h e T C C syste m and is
is lo c a t e d u n d e r th e in s t r u m e n t p a n e l in th e w ir e d to t h e g r o u n d s id e o f th e T C C s o le n o id .
p a s s e n g e r c o m p a rt m e n t . R e f e r to “T r a n s m i s s i o n C o n t r o ls , ” S e c t io n “1 0 ”.

* SYSTEMS CONTROLLED

A/C "O N " or "OFF" • Exhaust Gas Recirculation (EGR)

Engine Coolant Tem perature • Electronic Spark Timing (EST)
Engine Crank Signal • Fuel Control
Exhaust 0 x y g e n (0 2) Sensor - Idle Air Control (IAC)
Distributor Reference - Low Pressure Shut-off Solenoid
- Crankshaft Position • Fuel Cylinder Solenoid Valves
- Engine Speed (RPM) • Transmission Converter Clutch (TCC)
M anifold Absolute Pressure (MAP) • Diagnostics
ELECTRONIC
Park/Neutral (P/N) Switch Position - "Service Engine Soon" Light
CONTROL
System Voltage MODULE (ECM) - Diagnostic Term inal (ALDL)
Throttle Position Sensor (TPS) - Data O utput (ALDL)
Transmission Gear Position • Electronic Spark Control (ESC) -
Vehicle Speed Sensor (VSS) (Masked by PROM)

Fuel Supply Relay Voltage • EGR Valve Solenoid

EGR Vacuum
Engine Knock (ESC) - (Masked by PROM)

5-16-91
*All systems not used on all engines. 7§ 3537-6E-CNG
 ■ ■ ■ T h e r e a re s e v e r a l w a y s fo r a p e r s o n to b e c o m e
F E C B A s t a t ic a l l y c h a r g e d . T h e m o s t c o m m o n m e t h o d s o f
o G H
o c h a r g in g a re b y f r ic t io n a n d b y in d u c t io n . A n
4___
e x a m p le o f c h a r g i n g b y f r ic t io n i s a p e r s o n s l i d i n g
TERMINAL IDENTIFICATION
a c ro s s a c a r seat, i n w h i c h a c h a r g e o f a s m u c h a s
A GROUND
F T.C.C. (IF USED) 2 5 , 0 0 0 v o lt s c a n b u i l d u p . C h a r g i n g b y i n d u c t i o n
B DIAGNOSTIC TERMINAL FUEL SUPPLY CIRCUIT o c c u rs w h e n a p e r so n w it h w e ll in s u la t e d sh o e s
G
TEST TERMINAL (CNG) s ta n d s n e a r a h ig h ly c h a r g e d o b je c t a n d
C A.I.R. (IF USED)
BRAKE SENSE
H m o m e n t a r ily t o u c h e s g r o u n d . C h a r g e s o f t h e s a m e
SERIAL DATA SPEED INPUT (CNG)
E p o la r it y a re d r a in e d off, l e a v i n g th e p e r s o n h i g h l y
(SEE SPECIAL TOOLS)
c h a r g e d w i t h t h e o p p o s it e p o la r it y . S t a t i c c h a r g e s
o f e it h e r t y p e c a n c a u s e d a m a g e , t h e r e fo r e , it i s
____________________ _______________ 6-8-90 *7S 3541-6E-CNG
i m p o r t a n t to u s e c a r e w h e n h a n d l i n g a n d t e s t i n g
Figure 3-2 - ALDL Connector e le c tro n ic c o m p o n e n ts.

G - T h i s t e r m i n a l i s u s e d to d i a g n o s e t h e f u e l
s u p p l y s y s t e m c ir c u it o n N a t u r a l G a s P o w e r e d
T r u c k s . R e f e r to C H A R T A - 5 .
H - T h i s t e r m i n a l i s u s e d to d i a g n o s e t h e b r a k e
syste m on N a t u r a l G a s P o w e re d T ru c k s. R e fe r
to “ C / K L i g h t D u t y ” S e r v ic e M a n u a l fo r
a d d it io n a l in fo r m a t io n .
W irin g H arn e ss and C o n n e cto rs
A w i r i n g h a r n e s s e le c t r ic a lly c o n n e c t s t h e E C M
to v a r i o u s s e n s o r s , s o le n o id a n d r e l a y s w i t h i n t h e
syste m . M an y co n n e cto rs in th e e n g in e
c o m p a r t m e n t a re e n v i r o n m e n t a ll y p ro te c te d b e c a u s e
o f t h e s y s t e m s lo w v o lt a g e s a n d c u r r e n t le v e ls.
In form ation S e n so rs
In a d d it io n to th e EC M , th e C o m p u te r
C o m m a n d C o n t r o l sy st e m h a s th e f o llo w in g
in f o r m a t io n s e n s o rs :
• O x y g e n ( 0 2) s e n s o r (H e a te d ).
• C o o la n t T e m p e r a t u r e S e n s o r ( C T S ) .
• T h r o t t le P o s it i o n S e n s o r ( T P S ) .
• M a n i f o l d A b s o l u t e P r e s s u r e ( M A P ) s e n so r.
• V e h ic le S p e e d S e n s o r ( V S S ) .
• K n o c k se n so r - (M a sk e d b y P R O M ),
a n d t h e f o llo w in g i n p u t s ig n a ls :
• P a r k / N e u t r a l (P / N ) s w it c h s ig n a l.
• C r a n k s ig n a l.
• D i s t r i b u t o r re fe re n c e s ig n a l.
• A / C r e q u e s t s ig n a l.
• T r a n s m i s s i o n g e a r p o s it io n s ig n a l.
E lectrostatic D isch a rge D a m a g e
E le c t r o n ic c o m p o n e n ts u se d in c o n tro l s y s t e m s
a r e o fte n d e s i g n e d to c a r r y v e r y lo w v o lt a g e , a n d
a r e v e r y s u s c e p t ib le to d a m a g e c a u s e d b y
e le c t r o s t a t ic d is c h a r g e . I t i s p o s s ib le fo r le s s t h a n
1 0 0 v o l t s o f s t a t ic e le c t r ic i t y to c a u s e d a m a g e to
s o m e e l e c t r o n ic c o m p o n e n t s . B y c o m p a r i s o n , it
t a k e s a s m u c h a s 4 ,0 0 0 v o lt s fo r a p e r s o n to e v e n
fe e l t h e z a p o f a s t a t ic d is c h a r g e .
N O T IC E : T o p r e v e n t p o s s ib le E le c t r o s t a t ic
D is c h a r g e d a m a g e :
• Do Not to u ch th e E C M con n e cto r p in s or
so ld e re d c o m p o n e n ts o n th e E C M c ir c u it b o a rd .
• W h e n h a n d lin g a P R O M , or C A L - P A K , D o N o t
t o u c h t h e c o m p o n e n t le a d s , a n d D o N o t re m o ve
in t e g r a t e d c ir c u it f r o m c a rr ie r.
• B e s u r e to f o llo w t h e g u i d e l i n e s l i s t e d b e lo w i f
s e r v ic in g a n y o f t h e s e e le c tr o n ic c o m p o n e n ts.
1. D o n o t o p e n th e re p la c e m e n t p a r t p a c k a g e u n t i l
it i s t im e to i n s t a l l t h e p a rt.
2. A v o i d t o u c h in g e le c t r ic a l t e r m in a ls o f t h e p a rt.
3. B e fo re r e m o v in g th e p a rt fro m it s p a c k a g e ,
g r o u n d th e p a c k a g e to a k n o w n g o o d g r o u n d o n
th e v e h ic le .
4. A lw a y s to u c h a k n o w n g o o d g r o u n d b e fore
h a n d l i n g t h e p a rt. T h i s ste p s h o u l d b e re p e a te d
b e fo r e i n s t a l l i n g t h e p a r t i f t h e p a r t h a s b e e n
h a n d le d w h ile s lid in g a c ro ss th e se at, w h ile
s it t i n g d o w n fro m a s t a n d i n g p o s it io n , o r w h ile
w a l k i n g a d ista n c e .
E L E C T R O N IC C O N T R O L M O D U L E (E C M )
Figure 3-3
T h e E le c t r o n ic C o n t r o l M o d u l e ( E C M ) i s lo c a te d
in th e p a s s e n g e r c o m p a rt m e n t a n d is th e c o n tro l
c e n te r o f th e C o m p u t e r C o m m a n d C o n t r o l sy st e m .
T h e E C M c o n s t a n t ly lo o k s a t th e in f o r m a t io n
fro m v a r io u s s e n s o rs , a n d c o n t r o ls t h e s y s t e m s t h a t
affect v e h ic le p e rfo rm a n c e . T h e E C M p e r f o r m s t h e
d ia g n o s t ic f u n c t io n o f t h e s y st e m . I t c a n re c o g n iz e
o p e ra t io n a l p ro b le m s, a le r t th e d r i v e r t h r o u g h th e
“S e r v ic e E n g i n e S o o n ” lig h t , a n d s t o r e a c o d e o r
c o d e s w h i c h i d e n t i f y t h e p r o b le m a r e a s to a i d t h e
te c h n ic ia n i n m a k i n g r e p a ir s . S e e d i a g n o s i s s e c t io n
fo r m o re in fo r m a t io n .
T h e E C M i s d e s i g n e d to p r o c e s s t h e v a r i o u s
i n p u t i n f o r m a t io n ( F i g u r e 3-1 ) a n d t h e n s e n d s t h e
n e c e s s a r y e le c t r ic a l r e s p o n s e s to c o n t r o l fu e l
d e liv e r y , s p a r k t i m i n g a n d o t h e r e m i s s i o n c o n t r o l
s y ste m s. T h e in p u t in f o r m a t io n h a s a n in t e r r e la t io n
to m o r e t h a n o n e o u tp u t, th e re fo re , i f th e one i n p u t
f a ile d it c o u ld a ffe c t m o re t h a n o n e s y s t e m s
o p e ra tio n .
T h e E C M h a s a “l e a r n i n g ” a b ilit y w h ic h a llo w s
it to m a k e c o r r e c t io n s f o r m i n o r v a r i a t i o n s i n t h e
fu e l s y s t e m to im p r o v e d r iv e a b ilit y . I f th e b a t t e r y
i s d i s c o n n e c t e d to c l e a r c o d e s , o r f o r r e p a ir , t h e
“l e a r n i n g ” p r o c e s s h a s to b e g in a ll o v e r a g a in .
A c h a n g e m a y b e n o t e d i n t h e v e h i c l e ’s
p e rfo rm a n c e . T o “t e a c h ” t h e v e h ic le , m a k e s u r e t h e
e n g i n e i s a t o p e r a t i n g t e m p e r a t u r e , a n d d r iv e a t
p a r t t h r o t t le , w i t h m o d e r a t e a c c e le r a t io n a n d i d le
c o n d it io n s , u n t i l n o r m a l p e r fo rm a n c e re t u r n s .
N O T IC E : T h e E C M m u s t b e m a in t a in e d a t a
t e m p e r a t u r e b e lo w 8 5 ° C (1 8 5 ° F ) a t a l l t im e s .
T h i s is m o s t e s s e n t ia l i f th e v e h ic le is p u t
t h r o u g h a p a i n t b a k i n g p ro ce ss. T h e E C M w i l l
b e c o m e in o p e r a t iv e i f it s te m p e ra t u re e xce e d s
8 5 ° C (185°F). T h e re fo re , it i s re c o m m e n d e d t h a t
t e m p o r a r y i n s u l a t i o n b e p la c e d a r o u n d th e E C M
d u r i n g t h e t i m e t h e v e h i c le i s i n a p a i n t o v e n
o r o t h e r h i g h t e m p e r a t u r e p ro ce sse s.
T h e r e i s o n e t y p e o f c o n t r o l m o d u le u s e d i n
5 .7 L N a t u r a l G a s P o w e re d T ru cks.
5 .7 L C N G E n g in e s W it h 4 L 6 0 T r a n s m is s io n s
h a v e a n E C M ( r e f e r r e d to a s G M C M ) w it h t h r e e
p a r t s fo r s e r v ic e . A c o n t r o lle r (a n E C M w it h o u t a
P R O M ) , a P R O M (c a lib ra t o r) w it h sp e cific p r o g r a m
in f o r m a t io n fo r a n e n g in e a n d ve h ic le , a n d a C A L -
P A K w it h s p e c ific b a c k -u p fu e l c a lib r a t io n
in f o r m a t io n o n so m e v e h ic le s . O n 5 .7 L C N G
E n g i n e s th e C A L - P A K is so ld e re d in.
P R O M (5.7L C N G E n gin e W ith
4L60 T ra n sm issio n )
Figure 3-4
I n f o r m a t i o n fo r s p e c if ic e n g i n e a n d v e h i c l e i s
p r o g r a m m e d u s i n g a n i n t e g r a t e d c i r c u i t c a ll e d a
P R O M , (P ro g r a m m a b le R e a d -O n ly M e m o r y ). In th e
p a r t s b o o k , it i s lis t e d a s a c a lib r a t o r . T h i s a llo w s
o n e m o d e l o f c o n t r o lle r to b e u s e d f o r m a n y
d iffe r e n t v e h ic le s . T h e P R O M i s lo c a t e d i n s id e t h e
E C M a n d h a s i n f o r m a t io n o n t h e v e h ic le ’s w e ig h t ,
e n g in e , t r a n s m is s io n , a x le ra t io , a n d s e v e r a l o th e rs .
W h ile o ne E C M p a rt n u m b e r c a n be u se d b y m a n y
v e h i c le lin e s , a P R O M ( c a lib r a t o r ) i s v e r y s p e c if ic
a n d m u s t b e u s e d f o r t h e r i g h t v e h ic le . F o r t h i s
r e a s o n , i t i s v e r y i m p o r t a n t to c h e c k t h e l a t e s t
p a r t s b o o k a n d S e r v ic e B u l l e t i n in f o r m a t io n fo r t h e
c o rre c t p a r t n u m b e r w h e n r e p la c i n g a P R O M .
C A L -P A K (5.7L C N G E n gin e W ith
4L60 T ra n sm issio n )
Figure 3-4
T h e C A L - P A K on th e 5 .7 L C N G e n g in e is n o t
d e s ig n e d to c o n t r o l f u e l d e l i v e r y o p e r a t i o n i n t h e
e v e n t o f a n E C M fa ilu r e , o r w h e n i n t h e “T e c h I ”
F u e l B a c k - u p m ode. I f th e E C M f a ils t h e r e w i l l b e
a “N o R u n / N o S t a r t ” c o n d itio n . P e r f o r m t h e p r o p e r
t e s t p r o c e d u r e to d e t e r m i n e a n E C M f a i l u r e o r
re fe r to C H A R T A - 3 ( E n g i n e C r a n k s B u t W i l l N o t
R u n ) fo r th e c a u s e o f a “N o S t a r t ” c o n d it io n .
1 ECM 3 PROM CARRIER
2 PROM ^ CALPAK
(ENGINE CALIBRATOR) LALrAK
4S 1217-6E
Figure 3-4 - PROM (calibrator) and CAL-PAK
(Natural Gas Powered Truck)
FU E L C O N T R O L
F u e l d e liv e r y is c o n t ro lle d b y th e C o m p u t e r
C o m m a n d C o n t r o l s y s t e m . T h e g e n e r a l d e s c r ip t io n
o f fu e l c o n t r o l i s i n “F u e l C o n t r o l S y s t e m , ” S e c t io n
“4 ” . T h i s i n c l u d e s t h e f u e l i n j e c t o r s , p r e s s u r e
r e g u la t o r , T B I u n it , I d l e A i r C o n t r o l ( I A C ) v a l v e ,
T h r o t t le P o s it i o n S e n s o r ( T P S ) a n d t h e f u e l s u p p l y
e le c t r ic a l c irc u it.
IN P U T IN F O R M A T IO N T h e E C M s e n d s a 5 v o lt re fe re n c e s i g n a l to t h e
M A P se n so r. A s t h e m a n if o ld p r e s s u r e c h a n g e s , t h e
C o o la n t Tem perature S e n s o r (C T S) e le c tric a l r e s is t a n c e o f t h e s e n s o r a ls o c h a n g e s . B y
Figure 3-5 m o n it o r in g th e s e n s o r o u t p u t v o lt a g e , th e E C M
k n o w s th e m a n ifo ld p re ssu re . A h ig h e r p re ss u re ,
The C o o la n t T e m p e ra tu re Se n so r (C T S ) is a lo w v a c u u m ( h i g h v o l t a g e ) r e q u i r e s m o r e f u e l,
t h e r m i s t o r (a r e s i s t o r w h i c h c h a n g e s v a l u e b a s e d w h ile a lo w e r p r e s s u r e , h i g h e r v a c u u m ( lo w
o n t e m p e r a t u r e ) m o u n t e d in th e e n g in e c o o la n t v o lt a g e ) r e q u ir e s le s s fuel.
s t r e a m . L o w c o o la n t t e m p e r a t u r e p r o d u c e s a h i g h T h e E C M u s e s t h e M A P s e n s o r to c o n t r o l f u e l
r e s is t a n c e (1 0 0 ,0 0 0 o h m s a t -40°C /-40°F) w h ile h i g h d e liv e r y a n d i g n i t i o n t im in g .
te m p e ra tu re ca u se s lo w re s is ta n c e (7 0 ohm s at
130°C /266°F).
The E C M s u p p lie s a 5 v o lt s ig n a l to th e
C o o la n t T e m p e ra tu re Se n so r (C T S ) th ro u g h a
r e s is t o r i n t h e E C M a n d m e a s u r e s t h e v o lt a g e . T h e
v o l t a g e w i l l b e h i g h w h e n t h e e n g i n e i s co ld , a n d
lo w w h e n th e e n g in e is hot. B y m e a s u r in g th e
v o lt a g e , th e E C M k n o w s th e e n g in e c o o la n t
t e m p e r a t u r e . E n g i n e c o o la n t t e m p e r a t u r e a ffe c ts
m o st sy ste m s th e E C M c o n tro ls.

O xy ge n ( 0 2) S e n so r (Heated)
Figure 3-7
1 HARNESS CONNECTOR TO ECM

2 LOCKING TAB T h e h e a te d o x y g e n s e n s o r w o r k s in th e sa m e
m a n n e r a s a n o n -h e a te d o x y g e n se n so r. T h e
3 TEMPERATURE SENSOR 5S1640-6E
e x c e p tio n i s t h a t B + i s s u p p lie d to a h e a t i n g u n i t
Figure 3-5 - Coolant Tem perature Sensor t h a t i s p a r t o f t h e s e n s o r it s e lf. T h e h e a t e r h e lp s
th e E C M c o n tro l t h e fu e l in je c t io n s o o n e r fo r b e tte r
fu e l e m is s io n s . T h e r e a r e n o m a l f u n c t i o n c o d e s to
d e te c t i f t h e h e a t e r p a r t o f t h e s e n s o r i s w o r k i n g .
M a n ifo ld A b so lu te Pressure (M A P ) S e n so r
T o c h e c k t h e h e a t e r , r e f e r to “F u n c t i o n C h e c k ” i n
Figure 3-6
C o d e 13 ch a rt.

T h e M a n if o ld A b so lu t e P r e s s u r e ( M A P ) se n so r
m e a s u r e s th e c h a n g e s in th e in t a k e m a n ifo ld
p r e s s u r e , w h ic h r e s u lt fr o m e n g in e lo a d a n d sp e e d
c h a n g e s , a n d c o n v e r t s t h i s to a v o lt a g e o u tp u t.
A c lo s e d t h r o t t le o n e n g in e c o a s t d o w n w i l l
p r o d u c e a r e l a t iv e l y lo w M A P o u t p u t , w h ile a W i d e
O p e n T h r o t t le ( W O T ) w ill p ro d u c e a h ig h o u tp u t.
T h i s h i g h o u t p u t i s p ro d u c e d b e c a u s e th e p r e s s u r e
in s id e th e m a n ifo ld is th e s a m e a s o u t sid e th e
m a n ifo ld , so 1 0 0 % o f th e o u t s id e a ir p r e s s u r e is
m e a su re d .
T h e M A P s e n s o r r e a d in g i s t h e o p p o s it e o f
w h a t y o u w o u ld m e a s u r e o n a v a c u u m g a g e . W h e n
m a n i f o l d p r e s s u r e i s h i g h , v a c u u m i s lo w . T h e
M A P s e n s o r i s a l s o u s e d to m e a s u r e b a r o m e t r i c
p r e s s u r e u n d e r c e r t a in c o n d it io n s, w h ic h a llo w s th e
E C M to a u t o m a t ic a lly a d j u s t fo r d iffe r e n t a lt it u d e s.
Throttle Po sitio n S e n so r (TPS)
Figure 3-8
T h e T h r o t t le P o s it i o n S e n s o r ( T P S ) is c o n n e c te d
to t h e t h r o t t l e s h a f t o n t h e T B I u n i t . I t i s a
p o t e n t io m e t e r w i t h o n e e n d c o n n e c t e d to 5 v o l t s
f r o m t h e E C M a n d t h e o t h e r to g r o u n d . A t h i r d
w i r e i s c o n n e c t e d to t h e E C M to m e a s u r e t h e
v o lt a g e fr o m th e T P S . A s th e th ro tt le v a lv e a n g le
i s c h a n g e d (a c c e le ra t o r p e d a l m o ve d ), th e o u t p u t o f
th e T P S a ls o c h a n g e s . A t a c lo se d t h ro tt le p o s itio n ,
t h e o u t p u t o f t h e T P S i s lo w ( a p p r o x i m a t e l y .5
v o lt ). A s t h e t h r o t t le v a l v e o p e n s, th e o u t p u t
in c r e a s e s s o t h a t , a t W i d e O p e n T h r o t t le ( W O T ) ,
th e o u t p u t v o lt a g e s h o u ld b e a p p r o x im a t e ly 4 .5
vo lts.
B y m o n i t o r i n g t h e o u t p u t v o lt a g e fro m th e T P S ,
th e E C M c a n d e t e r m in e fu e l d e liv e r y b a se d o n
th r o t t le v a l v e a n g le ( d r iv e r d e m a n d ).
K n ock S e n so r
T h e K n o c k S e n s o r i s lo c a t e d o n t h e r i g h t s id e
o f t h e e n g i n e b lo c k . I t s i g n a l s t h e E C M t h r o u g h
t h e E S C s y s t e m to r e t a r d i g n i t i o n t i m i n g d u r i n g
s p a r k k n o c k . T h i s a l l o w s t h e E C M to m a i n t a i n
m a x i m u m t i m i n g a d v a n c e u n d e r m o s t c o n d it io n s .
O n 5 . 7 L C N G e n g in e s w it h 4 L 6 0 t r a n s m is s io n ,
t h e K n o c k S e n s o r i s p r e s e n t o n t h e e n g i n e b lo c k ,
h o w e v e r i t s s i g n a l i s n o t u s e d b y t h e E C M to
r e t a r d t i m i n g b e c a u s e o f th e h i g h o c ta n e r a t i n g o f
C o m p r e s s e d N a t u r a l G a s . T h e s i g n a l is m a s k e d b y
th e P R O M .
Park/Neutral (P IN) S w itc h S ig n a l
T h e P a r k / N e u t r a l (P / N ) s w it c h , lo c a t e d o n t h e
s t e e r in g c o lu m n , is u s e d o n 4 L 6 0 a u t o m a t ic
t r a n s m i s s i o n e q u ip p e d v e h i c l e s to i n d i c a t e to t h e
EC M w hen th e t r a n s m is s io n is in “P a r k ” o r
“N e u t r a l . ” T h i s i n f o r m a t i o n i s u s e d to c o n t r o l t h e
o p e r a t io n o f th e T r a n s m is s io n C o n v e r t e r C lu t c h
( T C C ) a n d Id le A i r C o n t r o l ( I A C ) v a lv e .

Crank S ig n a l

The EC M u s e s t h is s i g n a l to t e l l w h e n th e
v e h ic le is in th e S T A R T IN G m ode. T h is
in f o r m a t io n i s u s e d to a llo w e n r ic h m e n t a n d c a n c e l
d ia g n o s t ic s w h ile e n g in e i s c r a n k in g .
1 SENSOR-THROTTLE POSITION (TPS)

2 SCREW ASSEMBLY - TPS ATTACHING D istribu tor Reference S ig n a l

3 SEAL-THROTTLE POSITION SENSOR
MP 1205-AS T h e d i s t r i b u t o r s e n d s a s i g n a l to t h e E C M to
Figure 3-8 - Throttle Position Sensor (5.7L CNG) in d ic a t e e n g i n e r p m . S e e “I g n i t i o n S y s t e m / E S T , ”
S e c t io n “6 ” fo r f u r t h e r in fo r m a t io n .
V eh icle S p e e d S e n s o r (V S S )
A /C R e q u e st S ig n a l
T h e V e h ic l e S p e e d S e n s o r ( V S S ) is m a d e u p o f
a c o il m o u n t e d o n t h e t r a n s m is s io n a n d a to o t h
T h is s ig n a l in d ic a t e s t h a t th e A / C c o n t r o l
r o t o r m o u n t e d to t h e o u t p u t s h a f t in t h e
s w it c h i s t u r n e d “O N ” a n d t h e p r e s s u r e s w i t c h i s
t r a n s m i s s i o n . A s e a c h r o t o r t o o t h n e a r s th e c o il,
c lo s e d . T h e E C M u s e s t h i s s i g n a l t o a d j u s t a n d
t h e c o il p r o d u c e s a n A C v o lt a g e p u ls e . A s t h e
m a i n t a i n i d le sp e e d , o n 5 . 7 L C N G E n g i n e s W i t h
v e h i c le s p e e d i n c r e a s e s t h e n u m b e r o f A C v o lt a g e
4 L 6 0 T r a n s m is s io n .
p u ls e s p e r se c o n d in c re a s e s . T h e v e h ic le sp e e d
s e n s o r b u ffe r ( D R A C ) m o d u le p ro c e sse s in p u t s fro m
t h e V S S a n d o u t p u t s i g n a l to t h e s p e e d o m e t e r , T ra n sm issio n G e a r Po sitio n S ig n a l
E C M , a n d c r u is e c o n tro l m o d u le . T h e D R A C t a k e s
t h e v o lt a g e p u ls e s fr o m t h e V S S a n d u s e s t h e m to A s w it c h , lo c a t e d i n s id e t h e a u t o m a t ic
o p e n a n d c lo s e f o u r s o l id s t a t e o u t p u t s w it c h e s to t r a n s m is s io n , o p e n s w h e n t h e t r a n s m i s s i o n s h i f t s to
g r o u n d a t a r a t e p r o p o r t io n a l to v e h ic le speed. T h e h ig h ge a r. T h is s ig n a l is u se d fo r d e la y e d
D R A C i s m a t c h e d to t h e v e h i c l e b a s e d o n f i n a l d is e n g a g e m e n t o f th e T o rq u e C o n v e rte r C lu t c h
d r iv e r a t io a n d t ir e size. I t is im p o r t a n t to e n s u r e ( T C C ) . R e f e r to “T r a n s m i s s i o n C o n t r o ls , ” S e c t io n
t h a t t h e c o rre c t D R A C is in s t a lle d i n th e v e h ic le i f “1 0 ” fo r sp e c ific a p p lic a t io n .
r e p la c e m e n t i s n e c e s s a ry .
D ia g o stic Circuit Check
I f t h e d i a g n o s t i c t e r m i n a l “B ” , i n A L D L
c o n n e c to r, i s g r o u n d e d w it h t h e i g n i t i o n “O N ” a n d
th e e n g in e stop p e d , th e syste m w ill e n te r th e
d ia g n o s t ic m ode.
W it h th e k e y “O N ” a n d th e e n g in e “O F F , ”
ju m p e r A L D L t e r m i n a l “B ” to “A . ” T h e “S e r v ic e
E n g i n e S o o n ” l i g h t s h o u ld f la s h C o d e 12 to in d ic a t e
t h a t t h e d i a g n o s t i c s y s t e m i s w o r k i n g . C o d e 12
c o n s i s t s o f “o n e f l a s h ” f o llo w e d b y a p a u se and
t h e n “tw o f la s h e s . ”
T h e code w ill re p e a t fo r a to t a l o f th re e t im e s
a n d w i l l c o n t in u e to r e p e a t i f t h e r e a r e n o o t h e r
co d e s sto re d . T h i s p r o c e d u r e c a n a ls o b e d o n e w i t h
s o m e “S c a n ” t o o ls . I f t h e “S e r v i c e E n g i n e Soon”
l i g h t f l a s h e s C o d e 12 le s s t h a n 3 t im e s , p e r f o r m
E C M Q u a d - D r i v e r c h e c k p ro c e d u re s.
I f C o d e 12 d o e s n o t d i s p l a y , r e f e r to C H A R T
A - 2 . A f l a s h i n g C o d e 12 d o e s n o t m e a n a n e n g i n e
p ro b le m ; it s im p l y m e a n s t h a t th e d ia g n o s t ic c ir c u it
c h e c k i s w o r k in g . A n y o t h e r s t o r e d c o d e s ( F i g u r e
3 -13) w i l l b e g in to f la s h a ft e r C o d e 12.
Field Service M o d e
I f th e d ia g n o s t ic t e r m in a l “B ” i s g r o u n d e d w it h
t h e e n g in e r u n n i n g , th e s y s t e m w i l l e n t e r t h e fie ld
s e r v ic e m o d e . I n t h i s m o d e , t h e “S e r v ic e E n g i n e
S o o n ” lig h t w ill sh o w w h e th e r th e sy st e m is in
“O p e n ” o r “ C l o s e d L o o p ” a n d f u e l s y s t e m i s
o p e r a t in g n o r m a lly .
I n “O p e n L o o p , ” t h e l i g h t f l a s h e s i n e v e r y 2.5
s e c o n d s i n “C lo s e d L o o p ” t h e l i g h t f la s h e s e v e r y
secon d.
Tech 1
T h e d ia g n o s t ic p ro c e d u re s in t h is m a n u a l
a s s u m e t h e u s e o f a T e c h 1 “S c a n ” to o l. S i n c e t h e
T e c h 1, p r o d u c e d b y E x p e r t e c , i s a b le to p e r f o r m
fu n c t io n s , s u c h as, b id ir e c t io n a l c o m m u n ic a t io n t h a t
o t h e r “S c a n ” t o o l s a r e u n a b l e to p e r f o r m , i t h a s
b e e n m a d e a n e s s e n t i a l to o l. A l t h o u g h , t h e t e r m
“S c a n ” to o l w i l l c o n t in u e to b e u s e d fo r s im p l ic i t y ’s
s a k e , w e re c o m m e n d t h e T e c h 1 b e u s e d w h e n e v e r
p o s s ib le . I n fa c t, a n y p r o c e d u r e c a l l in g fo r
b id ir e c t o in a l c o m m u n ic a t io n w it h th e E C M w ill
r e q u ir e t h e u s e o f a T e c h 1. E x p l i c i t in s t r u c t io n s o n
c o n n e c t in g , a n d u s i n g t h e v a r io u s T e c h 1 f u n c t io n s
a r e c o n t a in e d i n t h e T e c h 1 o w n e r ’s m a n u a l.
T e c h 1 i s d e s ig n e d to in t e r f a c e w it h t h e
C o m p u t e r C o m m a n d C o n t r o l sy ste m . I t s u p p lie s a
v is u a l r e a d in g of m o st in p u t s to t h e ECM and
s o m e o u tp u ts.
C o n n e c t a T e c h 1 “S c a n ” to o l to th e A L D L a n d
c ig a r e t t e / c ig a r l i g h t e r c o n n e c t o r o r 12 v o l t s a n d
t h e r e s h o u l d b e a v i s u a l i n s t r u c t i o n d is p la y e d . I f
t h e re i s no d i s p la y o r to o l r e a d s “N o D A T A o r N o
A L D L ” w it h i g n i t i o n “O N , ” r e fe r to C H A R T A - 2 .
W i t h t h e to o l i n t h e c o d e p o s it io n , t h e d i s p l a y
w in d o w w i l l in d ic a t e a n y c o d e s t o r e d i n t h e E C M
m e m o r y ( F i g u r e 3-1 3). R e f e r r i n g to t h e a p p l ic a b le
c o d e c h a r t , t h e t o o l w i l l “S c a n ” a n i n p u t to
d e t e rm in e i f a sp e c ific c ir c u it i s o p e r a t in g p ro p e rly .
I f th e re a re n o co d e s, th e s y s t e m c h e c k is
c o m p le te d . A d d i t i o n a l i n f o r m a t i o n o n “S c a n ” t o o ls
i s i n T y p ic a l T e c h 1 D a t a D e f in it io n s .
I f th e re a re a d d it io n a l d r iv e a b ilit y sy m p to m s,
re fe r to “D r i v e a b i l i t y S y m p t o m s , ” S e c t io n “2 ”.
I f th e re a r e a d d it io n a l codes, r e f e r to a p p lic a b le
code ch a rt.
Engine D o e s N o t S ta rt
I f th e e n g in e c r a n k s b u t w i l l n o t s ta rt, r e fe r to
C H A R T A - 3 t h r o u g h A - 6 to d e t e r m in e i f t h e r e i s a
fu e l o r i g n i t i o n p ro b le m .
D ia gn o stic C o d e S y ste m
Figure 3-9
T h e E C M i s e q u ip p e d w it h a s e l f - d ia g n o s is
sy ste m w h ic h dete cts s y s t e m f a ilu r e a n d a id s th e
t e c h n ic ia n in lo c a t in g t h e c ir c u it a t f a u lt v i a a
code.
T h e E C M i s r e a l l y a c o m p u te r. I t u s e s s e n s o r s
to lo o k a t m a n y e n g in e o p e r a t in g c o n d it io n s . I t h a s
a m e m o ry a n d it k n o w s w h a t a c e r t a in s e n s o r
r e a d i n g s h o u l d b e u n d e r c e r t a i n c o n d it io n s . T h e s e
c o n d it io n s a re d e s c r ib e d o n t h e f a c in g p a g e o f e a c h
code c h a rt. I f a s e n s o r r e a d in g is n o t w h a t th e
ECM t h i n k s it s h o u l d be, t h e E C M w i l l t u r n “O N ”
th e “S e r v ic e E n g i n e S o o n ” l i g h t o n th e i n s t r u m e n t
p a n e l, a n d w i l l s t o r e a c o d e i n t h e m e m o r y . T h e
code t e lls w h ic h c ir c u it t h e t r o u b le i s in . A c ir c u it
c o n s is t s o f a s e n s o r , s u c h a s c o o la n t t e m p e r a t u r e ,
th e w i r i n g a n d c o n n e c t o rs to it, a n d t h e E C M .
A n “i n t e r m i t t e n t ” c o d e i s o n e w h i c h d o e s n o t
re se t a n d is n o t p r e s e n t w h ile y o u a r e w o r k i n g o n
th e v e h ic le . T h i s is o fte n c a u s e d b y a lo o s e
c o n n e c t io n . T h e f a c i n g p a g e o f a co d e c h a r t w i l l
c o n t a in d i a g n o s t ic a i d s to h e lp i n d e t e c t in g
in te rm it te n ts .
A “h a r d ” code i s o n e w h i c h i s p r e s e n t w h e n y o u
a re w o r k in g o n th e v e h ic le a n d s t ill e x is t s d u r in g
d ia g n o s is . T h e c h a r t w i t h t h e s t o r e d c o d e n u m b e r
w i l l le a d y o u to t h e c a u s e o f t h e p ro b le m .
C le arin g C o d e s
W h e n t h e E C M s e t s a c o d e , t h e “S e r v i c e
E n g i n e S o o n ” l i g h t w i l l co m e “O N ” a n d a code w i l l
b e s t o r e d in m e m o ry . I f th e p ro b le m is
in t e r m it t e n t , t h e l i g h t w i l l g o o u t a fte r 10 s e c o n d s
w h e n t h e f a u lt g o e s a w a y . H o w e v e r, th e code w i l l
s t a y i n th e E C M m e m o r y fo r 5 0 s t a r t s o r u n t i l th e
b a t t e r y v o lt a g e to t h e E C M is re m o ve d . R e m o v i n g
b a t t e x y v o lt a g e fo r 3 0 s e c o n d s w i l l c le a r a ll s to re d
codes.
C o d e s s h o u l d b e c le a re d a ft e r r e p a ir s h a v e b e e n
c o m p le t e d . A l s o , s o m e d i a g n o s t i c c h a r t s w i l l t e ll
y o u to c le a r t h e c o d e s b e fo re u s i n g t h e c h a rt. T h i s
a llo w s t h e E C M to se t t h e co d e w h ile g o i n g
t h r o u g h th e c h a rt, w h ic h w ill h e lp to fin d th e
c a u s e o f t h e p r o b le m m o r e q u ic k ly .
N O T IC E : T o p r e v e n t E C M d a m a g e , t h e k e y
m u st be “O F F ” w h e n d is c o n n e c t in g o r
r e c o n n e c t in g p o w e r to E C M (fo r e x a m p le
b a t t e r y c a b le , E C M p i g t a il , E C M fu se , j u m p e r
ca b le s, etc.).

DIAGNOSIS
T h e C o m p u te r C o m m a n d C o n tro l sy ste m h a s a BULB CHECK
d ia g n o s t ic s y s t e m b u i l t in t o th e E C M to in d ic a t e a
f a i l e d c i r c u it . A n a m b e r “S e r v i c e E n g i n e S o o n ” W it h th e ig n it io n “O N ” a n d e n g in e n o t
lig h t o n th e in s t r u m e n t p a n e l w ill illu m in a t e i f a r u n n in g , th e la m p s h o u ld illu m in a t e , w h ic h
p r o b l e m h a s b e e n d e t e c t e d w h e n t h e e n g in e a n d in d i c a t e s t h a t t h e E C M h a s c o m p le t e d t h e c i r c u i t
v e h i c le a r e r u n n i n g . T h i s l i g h t i s a ls o u s e d f o r a to t u r n “O N ” t h e lig h t .
b u lb a n d s y s t e m ch e ck . I f th e “S e r v ic e E n g i n e S o o n ” l i g h t i s n o t “O N , ”
The Diagnostic Circuit Check is the starting r e fe r to C H A R T A - 1 fo r d ia g n o s is .
p o in t for th e d ia g n o stic p roced u res or an W h e n t h e e n g in e i s sta rte d , th e l i g h t w i l l t u r n
em issions test failure. T h e d i a g n o s t ic c h a r t s a r e “ O F F . ” I f t h e l i g h t r e m a i n s “ O N , ” r e f e r to
r e la t e d to t h e E C M a n d w i l l d e t e rm in e i f th e E C M “D i a g n o s t ic C i r c u i t C h e c k . ”
i s w o r k i n g p ro p e rly . T h i s s e c tio n d ia g n o s e s th e fu e l
s y s t e m c o n t r o lle d b y t h e E C M a n d h a s c h a r t s to D IA G N O S T IC C IR C U IT C H E C K
d i a g n o s e a c i r c u i t w h e n t h e E C M h a s d i s p la y e d a
code. S in ce th is is th e sta r tin g p o in t for th e
T h e s y s t e m r e q u ir e s a n A L D L re a d -o u t “S c a n ” diagnostic procedures or finding the cause of
t o o l, t a c h o m e t e r , t e s t l i g h t , o h m m e t e r , d i g i t a l an emissions test failure, always begin here.
v o lt m e t e r w it h 10 m e g o h m s im p e d a n c e (J 3 4 0 2 9 A ) , The c ir c u it check is p e rfo rm e d th ro u g h th e
v a c u u m g a g e a n d j u m p e r w ir e s fo r d ia g n o s is . R e f e r t w e lv e t e r m in a l a s s e m b ly lin e d ia g n o s t ic lin k
to “S p e c ia l T o o l s , ” S e c t io n “1 3 ” fo r a d d i t i o n a l (A L D L ) co n n e cto r ( F ig u r e 3 -2 ) under th e
in f o r m a t io n a b o u t s p e c ia l tools. in s tru m e n t p a n e l in th e p a sse n g e r c o m p a rtm e n t.
 MS 11731-CNG

DIAGNOSTIC CIRCUIT CHECK

(U sin g A Tech 1 " S c a n " Tool)

T h e d ia g n o s t ic c ir c u it c h e c k i s a n o r g a n iz e d a p p r o a c h to i d e n t if y in g a p r o b le m c re a te d b y a n C o m p u t e r
C o m m a n d C o n t r o l S y s t e m m a lf u n c t io n . I t m u s t b e t h e s t a r t i n g p o i n t fo r a n y d r i v e a b i l i t y c o m p l a i n t
d ia g n o s is , b e c a u s e it d ir e c t s th e s e r v ic e t e c h n ic ia n to th e n e x t lo g ic a l ste p i n d i a g n o s i n g t h e c o m p la in t .
U n d e r s t a n d i n g th e c h a r t a n d u s i n g it c o rre c t ly w i l l re d u c e d ia g n o s t ic t im e a n d p r e v e n t t h e u n n e c e s s a r y
r e p la c e m e n t o f g o o d p a rts .

T e s t D e s c r ip t io n : N u m b e r(s) b e lo w r e f e r to
c ir c le d n u m b e r ( s ) o n t h e d ia g n o s t ic c h a rt.
1. T h i s ste p i s a c h e c k fo r t h e p r o p e r o p e r a t io n o f
t h e “S e r v i c e E n g i n e S o o n ” l i g h t . T h e “S E S ”
l i g h t s h o u l d b e “O N ” ste a d y .
2. N o “S E S ” l i g h t a t t h i s p o i n t i n d i c a t e s t h a t
t h e r e i s a p r o b le m w i t h t h e “S E S ” l i g h t c ir c u it
o r t h e E C M c o n t r o l o f t h a t c irc u it.
3. T h i s t e s t c h e c k s t h e a b i l i t y o f t h e E C M to
c o n t r o l t h e “S E S ” l i g h t . W i t h t h e d i a g n o s t i c
t e r m in a l g r o u n d e d , t h e “S E S ” l i g h t s h o u ld f la s h
a C o d e 12 t h r e e tim e s , fo llo w e d b y a n y t r o u b le
code sto re d in m e m o ry . D e p e n d in g u p o n th e
typ e o f E C M , P R O M o r C A L - P A K e rro r m a y
r e s u lt i n t h e i n a b i l i t y to f la s h C o d e 12.
4. T h i s t e s t c h e c k s t h e “Q u a d - D r i v e r ” c ir c u it . I f
t h e “S E S ” l i g h t f l a s h e s le s s t h a n t h r e e t im e s ,
in d ic a t e s t h a t th e re is a p ro b le m w it h th e
“S E S ” l i g h t c ir c u it o r t h e E C M c o n t r o l o f t h a t
c irc u it . R e f e r to “E C M , Q D R C h e c k P r o c e d u r e . ”
5. U s e T e c h 1 to a i d d i a g n o s i s , th e r e fo r e , s e r i a l
d a t a m u s t be a v a ila b le . I f a P R O M o r C A L -
P A K e r r o r i s p re se n t, t h e E C M m a y h a v e b e e n
a b le to f l a s h C o d e 12/51, b u t n o t e n a b le s e r i a l
d a ta .
6. A l t h o u g h t h e E C M i s p o w e r e d u p , a “C r a n k s
B u t W i l l N o t R u n ” s y m p t o m c o u ld e x is t
b e c a u s e o f a n E C M o r s y s t e m p ro b le m .
7. T h i s ste p w i l l is o la t e i f t h e c u s t o m e r c o m p la in t
i s a “S E S ” l i g h t o r a d r i v e a b il it y p r o b le m w it h
n o “S E S ” l i g h t . R e f e r t o “D i a g n o s t i c C o d e
Id e n t if ic a t io n ” i n t h i s s e c t io n fo r a l i s t o f v a l i d
co des. A n i n v a l i d c o d e m a y b e t h e r e s u l t o f a
f a u lt y “S c a n ” tool, P R O M or E C M .
8. C o m p a r is o n o f a c t u a l c o n t r o l s y s t e m d a t a w it h
th e T y p ic a l T e c h 1 D a t a V a lu e s is a q u ic k
c h e c k to d e t e r m i n e i f a n y p a r a m e t e r i s n o t
w i t h in lim it s . K e e p i n m in d t h a t a b a s e e n g in e
p r o b l e m ( i. e . a d v a n c e d c a m t i m i n g ) m a y
s u b s t a n t ia ll y a lt e r s e n s o r v a lu e s .
9. In s t a ll a t io n o f a T e c h 1 “S c a n ” to o l w i l l p r o v id e
a g o o d g r o u n d p a t h fo r t h e E C M a n d m a y h id e
a d r i v e a b il it y c o m p la in t d u e to p o o r E C M
g r o u n d s . R e f e r to “D r i v e a b i l i t y S y m p t o m s , ”
S e c t io n “2 ”.
10. I f t h e a c t u a l d a t a i s n o t w i t h i n t h e t y p i c a l
v a lu e s e s t a b lis h e d , r e f e r to t h e a p p lic a b le
d ia g n o s is s e c t io n to p r o v id e a f u n c t io n a l c h e c k
fo r th e s u s p e c t c o m p o n e n t o r sy st e m .
 DIAGNOSTIC CIRCUIT CHECK
(U sin g A Tech 1 " S c a n " T o o l)

• IGNITION "O N ," ENGINE "OFF."

• NOTE "SERVICE ENGINE SOON" (SES) LIGHT.

© [ STEADY LIGHT
© [ NO LIGHT FLASHING CODE 12
f : r : . : X
USING TECH 1 PERFORM "DIAGNOSTIC USE CHART A-1 CHECK FOR GROUNDED
© CIRCUIT CHECK." DIAGNOSTIC TEST CKT451.
OR
JUMPER ALDL TERMINAL "B" TO "A ".
DOES SES LIGHT FLASH CODE 12?

YES NO

© DOES SES LIGHT FLASH CODE 12

AT LEAST THREE TIMES?
USE CHART A-2

YES NO
= r= r__-----------
XT 1
© [ DOES TECH 1 DISPLAY ENGINE DATA? | USE ECM QDR |
i CHECK PROCEDURE, i
L_______________ I

YES NO
~ T ~ ITT
| USE CHART A-2. \
®[ DOES ENGINE START?

YES NO
~1~
© ARE ANY CODES DISPLAYED?

1
YES NO

X X
REFER TO APPLICABLE CODE CHART. COMPARE TECH 1 DATA WITH TYPICAL TECH 1 DATA VALUES.
START W ITH LOWEST CODE. ARE VALUES NORMAL OR WITHIN TYPICAL RANGES?

YES NO

© REFER TO "DRIVEABILITY
SYMPTOM S," IN SECTION (2).
REFER TO THE APPLICABLE
SYSTEM SECTION.

5-2-91
MS 11729-CNG
 TYPICAL TECH 1 "Scan" DATA VALUES
T h e T e c h 1 " S c a n ” d a t a lis te d in t h is ta b le m a y be u se d fo r c o m p a r is o n a fte r c o m p le t in g th e D i a g n o s t ic
C ir c u i t C h e c k a n d f i n d i n g the o n -b o a rd d ia g n o s t ic s fu n c t io n in g p ro p e rly w it h n o d ia g n o s t ic c o d e s d is p la y e d .
T h e " T y p i c a l T e c h 1 D a t a V a l u e s ” a re a n a v e r a g e o f d is p la y v a lu e s re c o rd e d fro m n o r m a l ly o p e r a t in g v e h ic le s
a n d a re in te n d e d to re p re s e n t w h a t a n o r m a l ly fu n c t io n in g s y s t e m w o u ld d is p la y . T h e v a lu e s y o u g e t m a y
v a r y d u e to lo w b a t te r y c h a r g e o r o th e r r e a so n s, b u t th e y s h o u ld be v e r y close.
A "SC A N " TOOL THAT DISPLAYS FAULTY DATA SHOULD NOT BE USED, AN D THE PROBLEM
SHOULD BE REPORTED TO THE MANUFACTURER. THE USE OF A FAULTY "SC A N " TOOL CAN
RESULT IN M ISDIAGN O SIS AN D UNNECESSARY PARTS REPLACEMENT.
O n l y th e p a r a m e t e r s lis te d b e lo w a re u s e d in t h is m a n u a l fo r d ia g n o s is . I f a ’’S c a n ” to o l re a d s o t h e r
p a ra m e t e rs , th e v a lu e s a re n o t re c o m m e n d e d b y G e n e ra l M o t o r s fo r u se in d ia g n o s is . F o r m o re d e s c r ip t io n o n
th e v a lu e s a n d u se o f th e T e c h 1 tool to d i a g n o s i s E C M in p u ts , re fe r to th e a p p lic a b le " C o m p o n e n t S y s t e m s ”
d ia g n o s is . I f a ll v a lu e s a re w it h in th e r a n g e illu s t r a t e d , refer to " D r i v e a b i l i t y S y m p t o m s ” S e c t io n " 2 ” .

TECH 1 TOOL DATA

Test U n d e r F o llo w in g C o n d it io n s :
• E n g i n e a t O p e r a t in g T e m p e r a t u r e • E n g i n e Id lin g in " C lo s e d L o o p ” • C lo s e d T h r o t t le • N e u t r a l
• A l l A c c e s s o r ie s " O F F ”

"SCAN" Position Units Displayed Typical Data V alue Refer to Section

ENGINE SPEED Rpm ± 50 rpm from desired "4 "
rpm in drive (A/T)
DESIRED IDLE Rpm ECM idle command "3 "
(varies w ith temp)
COOLANT TEMP °C, °F 85°C - 105°C/190°F - 210°F "3 "
MAP kPa/Volts 29-48 kPa/1 - 2 volts (varies w ith «2" *
m anifold and barometric pressures)
THROT POSITION Volts .35- 1.28 "3 "
THROTTLE ANGLE 0 - 100% 0-1% "3 "
OXYGEN SENSOR M illivolts 100-999 (varies continuously) "3 "
RICH/LEAN FLAG Rich/Lean Rich/lean changing constantly "3 "
0 2 CROSS COUNTS Counts Always changing "3 "
FUEL INTEGRATOR Counts 40-170 "3 "
BLOCK LEARN Counts 90-170 "3 "
KNOCK SIGNAL No No "7 "
OPEN/CLOSED LOOP Open/Closed "Closed Loop" (may enter "3 "
"Open Loop" w ith extended idle)
AIR CONTROL SOL Port/ Atmosphere Atmosphere "8 "
IDLE AIR CONTROL Counts (Steps) 0-90 “ 4"
PARK/NEUTRAL PN/RDL Park/neutral "3 "
MPH/KPH 00 0 "3 "
TCC/SHIFT LIGHT O n/O ff O ff "10"
4TH GEAR SWITCH Yes/No No "10"
A/C REQUEST No/Yes No "3 "
A/C CLUTCH On/Off O ff "3 "
BATT/IGN VOLTAGE Volts 13.5 - 14.5 "3 "**
FUEL PUMP VOLTS Volts 13.5 - 14.5 "3 " * * ,tt
FUEL SUPPLY CIRCUIT VOLTS
PROM ID 0 - 999 Internal ID only "3 " (t)

★ Varies with manifold and barometric pressures.

** Section "4" or Section "6D" (Engine Electrical) of appropriate service manual,
t The PROM identification parameter describes the particular PROM used in the ECM being tested,
ft Tech 1 indicates "Fuel Pump Volts", actual circuit indicated is "Fuel Supply Circuit Volts".
6-11-91
M S 11730-CNG
 TYPICAL TECH 1 DATA DEFINITIONS
"SCAN" TOOL MODES - Normal (Open) Mode -
N o t a l l s y s t e m s w i l l t r a n s m i t in f o r m a t io n o n t h e
s e r ia l d a t a lin e w h ile i n t h is m ode.
O n s y s t e m s t h a t c a n b e m o n it o re d in th e o p e n
m o d e , i t a l l o w s c e r t a i n p a r a m e t e r s to be o b t a in e d
w it h o u t c h a n g in g th e e n g in e o p e r a t in g
c h a r a c t e r is t ic s . T h e p a r a m e t e r s c a p a b le o f b e i n g
r e a d v a r y f r o m e n g i n e f a m i l y to e n g i n e f a m i l y .
M o s t “S c a n ” t o o l s a r e p r o g r a m m e d so t h a t t h e
s y s t e m w i l l g o d ir e c t ly in t o th e s p e c ia l m o d e i f th e
“o p e n ” m o d e i s n o t a v a ila b le .
ALDL (10K, or Special) Mode - (not used on all
e n g in e s ) - I n t h i s m o d e , a l l i n f o r m a t i o n
in c o rp o ra te d in to a s p e c ific e n g in e a n d E C M is
o b t a in a b le . H o w e v e r , i n t h is m o d e th e s y s t e m
o p e r a t in g c h a r a c t e r is t ic s a re m o d ifie d a s fo llo w s:
• “C lo s e d L o o p ” t im e r s i n E C M a re b y p a sse d .
• E S T (sp a rk ) is advanced.
• I A C w i l l c o n t r o l e n g in e id le to 1 0 0 0 r p m ± 50
rp m
• P / N r e s t r ic t f u n c t io n s w i l l b e d isa b le d .
Factory Test (Back-up or 3.9 K) Mode - W h e n i n
t h is m o d e , t h e E C M i s o p e r a t in g o n th e fu e l b a c k ­
u p l o g i c a n d c a li b r a t e d b y t h e C A L - P A K o n s o m e
v e h ic le s . T h e C A L - P A K i s u s e d to c o n tro l th e fu e l
d e l i v e r y i f t h e E C M f a ils . H o w e v e r , o n t h e 5 . 7 L
C N G e n g i n e w i t h 4 L 6 0 t r a n s m is s io n , th e C a l - P a k
i s n o t d e s ig n e d to c o n t r o l fu e l d e liv e r y o p e ra tio n i n
th e e ve n t o f a n E C M fa ilu r e , o r w h e n i n th e “T e c h
I ” F u e l B a c k - u p m o d e . T h e p a r a m e t e r s th a t c a n b e
r e a d o n a “T e c h I ” s c a n t o o l i n t h i s m o d e a r e n o t
o f m u c h u s e fo r se rv ic e . R e f e r to C h a r t A - 3 o r th e
p r o p e r t e s t p r o c e d u r e s fo r a “N o S t a r t ” c o n d itio n .
"S C A N " TOO L L IM IT A T IO N S AND USE - T h e
“S c a n ” t o o l a l l o w s a q u i c k c h e c k o f s e n s o r s a n d
s w it c h e s w h i c h a r e i n p u t s to t h e E C M . H o w e v e r ,
o n s o m e a p p l ic a t i o n s t h e d a t a u p d a t e r a t e m a k e s
t h e to o l n o t a s e ffe c tive a s a v o lt m e t e r w h e n t r y i n g
to d e t e c t a n i n t e r m i t t e n t w h i c h l a s t s fo r a v e r y
s h o r t tim e . H o w e v e r , t h e T e c h 1 “S c a n ” to o l a llo w s
m a n ip u la t io n o f w ir in g h a rn e sse s o r co m p o n e n ts
u n d e r t h e h o o d w h i le o b s e r v in g th e T e c h 1 “S c a n ”
t o o l’s re a d o u t. T h i s h e lp s i n lo c a t in g in t e r m it t e n t s
w i t h t h e e n g in e n o t r u n n i n g .
INTERMITTENT CONDITIONS - T h e T e c h 1 “S c a n ”
to o l i s h e l p f u l i n c a s e s o f i n t e r m it t e n t o p e r a t io n .
T h e to o l c a n be p lu g g e d in a n d o b se rv e d w h ile
d r i v i n g t h e v e h i c l e u n d e r t h e c o n d it io n w h e r e t h e
l i g h t c o m e s “O N ” m o m e n t a r ily , o r th e e n g in e
d r i v e a b i l i t y i s p o o r m o m e n t a r il y . I f th e p r o b le m
s e e m s to b e r e l a t e d to c e r t a in a r e a s t h a t c a n b e
c h e c k e d o n t h e T e c h 1 “S c a n ” to o l, t h e n t h o s e a r e
th e p o s it io n s t h a t s h o u l d b e c h e c k e d w h i le d r i v i n g
th e v e h ic le . I f t h e r e d o e s n o t se e m to b e any
c o r r e la t io n b e t w e e n th e p r o b le m a n d
a n y s p e c if ic c ir c u it , t h e T e c h 1 “S c a n ” t o o l c a n b e
c h e c k e d o n e a c h p o s it io n , w a t c h i n g fo r a p e r io d o f
t im e to se e i f t h e r e is a n y c h a n g e i n t h e r e a d in g s
t h a t in d ic a t e s in t e r m it t e n t o p e ra tio n .
T h e “S c a n ” to o l i s a ls o a u s e f u l a n d q u i c k w a y
o f c o m p a r in g o p e r a t in g p a r a m e t e r s o f a p o o r ly
o p e r a t in g e n g in e w it h a k n o w n g o o d one. F o r
e x a m p le ; A s e n s o r m a y s h if t i n v a l u e b u t n o t se t a
code. C o m p a r i n g w i t h a k n o w n g o o d v e h i c l e m a y
u n c o v e r t h e p ro b le m .
T h e “S c a n ” to o l h a s t h e a b i l i t y to s a v e t im e i n
d ia g n o s is a n d p r e v e n t th e r e p la c e m e n t o f g o o d
p a rt s . T h e k e y to u s i n g th e “S c a n ” to o l s u c c e s s f u lly
fo r d ia g n o s is lie s in th e t e c h n ic ia n s a b ilit y to
u n d e r s t a n d t h e s y s t e m h e i s t r y i n g to d ia g n o s e a s
w e l l a s a n u n d e r s t a n d i n g o f t h e T e c h 1 “S c a n ”
to o l’s lim it a t io n s . T h e re fo re , t h e t e c h n ic ia n s h o u l d
r e a d t h e to o l o p e r a t in g m a n u a l to b e c o m e f a m i l i a r
w i t h t h e t o o l. T h e f o l l o w i n g i n f o r m a t i o n w i l l
d e s c r ib e m o s t o f t h e “S c a n ” to o l p o s it io n s a n d h o w
t h e y c a n b e h e lp f u l i n d ia g n o s is .
"SCAN" TOOL POSITIONS
T h e f o l l o w i n g p o s i t i o n s m a y n o t b e a p p l ic a b le
to a l l e n g in e s :
ENGINE SPEED - E n g i n e s p e e d is c o m p u t e d b y t h e
EC M fro m th e fu e l c o n tro l re fe re n c e in p u t. It
s h o u l d r e m a i n c lo s e to d e s i r e d i d le u n d e r v a r i o u s
e n g in e lo a d s w i t h e n g in e id lin g .
DESIRED IDLE - T h e id le sp e e d t h a t is c o m m a n d e d
b y t h e E C M . T h e E C M w i l l c o m p e n s a t e fo r v a r i o u s
e n g in e lo a d s to k e e p th e e n g in e a t t h e d e s ir e d id le
speed.
C O O LA N T T E M P - T h e C o o l a n t T e m p e r a t u r e
Se n so r (C T S ) is m o u n te d in th e in t a k e m a n ifo ld
a n d s e n d s e n g i n e t e m p e r a t u r e i n f o r m a t i o n to t h e
E C M . T h e E C M s u p p lie s 5 v o lt s to th e c o o la n t
t e m p e r a t u r e s e n s o r c ir c u it . T h e s e n s o r is a
t h e r m is t o r w h ic h c h a n g e s in t e r n a l r e s is t a n c e a s
t e m p e r a t u r e c h a n g e s . W h e n t h e s e n s o r is c o ld
( in t e r n a l r e s is t a n c e h ig h ), th e E C M m o n it o r s a
h i g h s i g n a l v o l t a g e w h i c h it i n t e r p r e t s a s a c o ld
e n g in e . A s t h e s e n s o r w a r m s ( i n t e r n a l r e s i s t a n c e
d e c re a se s), t h e v o lt a g e s i g n a l w i l l d e c re a s e a n d th e
E C M w i l l i n t e r p r e t t h e lo w e r v o l t a g e a s a w a r m
e n g in e .
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
T h e M A P s e n s o r p r o d u c e s a lo w s ig n a l v o lt a g e
w h e n m a n if o ld p r e s s u r e i s lo w ( h ig h v a c u u m ) a n d
a h i g h v o lt a g e w h e n t h e p r e s u r e i s h i g h (lo w
v a c u u m ) . W i t h t h e i g n i t i o n “O N , ” a n d t h e e n g i n e
s t o p p e d , t h e m a n i f o l d p r e s s u r e i s e q u a l to
a t m o s p h e r ic p r e s s u r e a n d t h e s i g n a l v o lt a g e w i l l b e
h ig h . T h i s i n f o r m a t io n i s u s e d b y t h e E C M / P C M a s
a n in d ic a t io n o f v e h ic le a lt it u d e a n d is re f e r r e d to
a s B A R O . C o m p a r is o n o f t h is B A R O r e a d in g w it h
a k n o w n g o o d v e h ic le w i t h th e s a m e s e n s o r * * i s a
g o o d w a y to c h e c k a c c u r a c y o f a “s u s p e c t ” s e n s o r .
R e a d in g s s h o u l d b e t h e s a m e ± .4 vo lt.
THROT POSITION - U s e d b y t h e E C M to d e t e r m in e
t h e a m o u n t o f t h r o t t le d e m a n d e d b y th e d r iv e r .
S h o u l d r e a d .3 3 -1 .2 5 v o l t s a t i d le to a b o v e 4 v o l t s
a t W i d e O p e n T h r o t t le ( W O T ) .
THROTTLE ANGLE - C o m p u t e d b y t h e E C M fro m
T P S v o lt a g e ( T h r o t p o s it io n ) s h o u l d r e a d 0 - 1 % a t
id le , 1 0 0 % a t W i d e O p e n T h r o t t le ( W O T ) .
OXYGEN SENSOR - R e p r e s e n t s t h e e x h a u s t o x y g e n
s e n s o r o u t p u t v o lt a g e . S h o u l d f lu c t u a t e c o n s t a n t l y
w i t h i n a r a n g e b e t w e e n 1 0 0 m V ( le a n e x h a u s t ) a n d
1 0 0 0 m V ( r ic h e x h a u s t ) w h e n o p e r a t in g i n “C lo s e d -
Lo o p .”
RICH/LEAN FLAG - I n d i c a t e s w h e t h e r e x h a u s t
oxygen s e n s o r v o lt a g e is above ( r ic h ) o r b e lo w
(le a n ) t h e 4 5 0 m V o x y g e n s e n s o r t h r e s h o ld v o lt a g e .
S h o u l d c h a n g e c o n s t a n t ly i n d i c a t in g t h a t t h e E C M
i s c o n t r o lli n g t h e a ir/ fu e l m ix t u r e p ro p e rly .
Oz CROSS CO UNTS - T h e n u m b e r o f t i m e s t h e
o x y g e n s e n s o r v o lt a g e c r o s s e s o v e r th e r ic h / le a n
t h r e s h o ld d u r i n g a o n e se c o n d in t e r v a l.
FUEL INTEGRATOR - F u e l in t e g r a t o r r e p r e s e n t s a
s h o r t - t e r m c o r r e c t io n to f u e l d e l i v e r y b y t h e E C M
i n r e s p o n s e to t h e a m o u n t o f t im e th e o x y g e n
s e n s o r v o l t a g e s p e n d s a b o v e o r b e lo w t h e 4 5 0 m V
t h r e s h o ld . I f t h e o x y g e n s e n s o r v o lt a g e h a s m a i n l y
b e e n b e lo w 4 5 0 m v , i n d i c a t in g a le a n a ir/ fu e l
m ix t u r e , f u e l i n t e g r a t o r w i l l in c r e a s e to t e ll t h e
E C M to a d d fu e l. I f t h e o x y g e n s e n s o r v o l t a g e
s t a y s m a i n l y a b o v e t h e t h r e s h o ld , t h e E C M w i l l
re d u c e fu e l d e l iv e r y to c o m p e n s a te fo r t h e in d ic a t e d
r i c h c o n d it io n .
BLOCK LEARN MULTIPLIER (BLM) CELL - OR -
BLOCK LEARN MEM ORY (BLM) - B l o c k l e a r n i s
d e r iv e d fr o m t h e fu e l in g e t r a t o r v a l u e a n d i s u s e d
fo r lo n g - t e r m c o rre c tio n o f fu e l d e liv e ry . A v a l u e o f
1 2 8 c o u n t s in d ic a t e s t h a t fu e l d e liv e r y r e q u ir e s n o
c o m p e n s a t io n to m a i n t a i n th e c o rre c t a ir/ fu e l ra tio .
A v a lu e b e lo w 128 c o u n ts m e a n s th a t th e fu e l
syste m is to o r ic h and fu e l d e liv e r y is b e in g
re d u c e d (d e c r e a s e d in j e c t o r p u l s e w id t h ). A v a l u e
a b o v e 1 2 8 c o u n t s i n d i c a t e s t h a t a le a n c o n d it io n
e x is t s a n d th e E C M is c o m p e n s a t in g b y a d d i n g fu e l
(in c re a se d in je c to r p u ls e w id th ).
KNOCK SIGNAL - Tech 1 Displays " N O " - O n
v e h ic le s w it h 5 . 7 L C N G e n g in e s w it h 4 L 6 0
t r a n s m is s io n . T h e K n o c k S e n s o r a n d t h e E S C
S y s t e m a re p r e s e n t o n th e v e h ic le , b u t a n y s e n s o r
s ig n a l is m a s k e d b y th e P R O M a n d ig n o r e d b y t h e
E C M . T h e “s c a n to o l” d is p la y h o w e v e r, w i l l a lw a y s
re a d “N O ”.
CLOSED LOOP/OPEN LOOP - T h i s p o s i t i o n w i l l
in d ic a t e w h e t h e r t h e e n g in e c o n t r o l s y s t e m is
o p e r a t in g i n “O p e n ” o r “C lo s e d L o o p . ” M o s t s y s t e m s
g o “C l o s e d L o o p ” a f t e r a c e r t a i n a m o u n t o f r u n
tim e , w h e n c o o la n t t e m p e r a t u r e i s h i g h e n o u g h ,
a n d th e o x y g e n s e n s o r b e c o m e s a c tiv e .
IDLE AIR CONTROL (IAC) - T h i s s y s t e m i s u s e d to
c o n tro l e n g in e id le sp e e d to th e d e s ir e d r p m fo r
d iffe r e n t o p e r a t i n g c o n d it io n s . I n t h i s m o d e , t h e
n u m b e r s w i l l in d ic a t e w h a t p o s it io n t h e E C M / P C M
t h i n k s t h e v a l v e i s in . T h e E C M / P C M m o v e s t h e
IA C in c o u n ts a n d th e se c o u n ts a re w h a t is
d is p la y e d o n a T e c h 1 “S c a n ” tool.
PARK/NEUTRAL SWITCH - T h e i n d i c a t i o n i n t h i s
m o d e m a y v a r y w i t h m a n u f a c t u r e r so t h e t y p e o f
r e a d in g fo r a p a r t i c u l a r t o o l s h o u l d b e c h e c k e d i n
th e o p e ra to rs m a n u a l. T h e i m p o r t a n t t h i n g i s t h a t
th e r e a d in g c h a n g e s sta t e (s w it c h e s ) w h e n t h e g e a r
s e le c t o r i s m o v e d f r o m p a r k / n e u t r a l to d r i v e o r
reverse.
MPH KPH - V e h i c l e s p e e d i s a n E C M i n t e r n a l
p a ra m e te r. I t i s c o m p u t e d b y t i m i n g p u ls e s c o m in g
fro m th e V e h ic le S p e e d S e n s o r ( V S S ) . V e h ic l e sp e e d
is u s e d in c h e c k in g T C C lo c k - u p sp e e d o r
s p e e d o m e te r a c c u r a c y . S p e e d i s d i s p l a y e d i n b o t h
m ile s p e r h o u r ( M P H ) and k ilo m e t e r p e r h o u r
(K P H ).
TORQUE CONVERTER CLUTCH (TCC) - I n t h i s
p o s it io n , t h e t o o l w i l l i n d i c a t e w h e n t h e T C C h a s
b e e n c o m m a n d e d b y t h e E C M to t u r n “O N . ” T h i s
does n o t n e c e s s a r ily m e a n t h a t th e c lu t c h w a s
e n g a g e d b u t o n ly t h a t th e E C M g r o u n d e d th e
c ir c u it in t e r n a lly . T h e b e s t w a y to d e t e r m in e i f th e
c lu tc h h a s e n g a g e d i s to m o n it o r e n g in e R P M w h e n
th e T C C co m e s “O N . ”
FOURTH GEAR - F o u r t h g e a r ( A T ) r e f e r to t h e
fo u r t h g e a r s w it c h fr o m a n a u t o m a t ic t r a n s m is s io n .
W h e n th e c a r i s i n f o u r t h g e a r, t h e p a r a m e t e r w i l l
re a d “Y E S . ”
A/C REQUEST - D i s p l a y s t h e s t a t e o f t h e A / C
s i g n a l l i n e to t h e E C M . S h o u l d re a d “Y E S ”
w h e n e v e r t h e A / C i s re q u e ste d .
BATT/IGN VOLTS - B a t t e r y / Ig n i t i o n v o lt a g e i s a n
a n a lo g in p u t s ig n a l re a d b y th e E C M . It is th e
i g n i t i o n s w i t c h e d b a t t e r y v o l t a g e a n d is m a i n l y
u s e d fo r d ia g n o s t ic s . C e r t a in E C M fu n c t io n s w i l l be
m o d if ie d i f t h e b a t t e r y v o lt a g e f a lls b e lo w o r r is e s
a b o v e p r o g r a m m e d t h r e s h o ld s .
FUEL P U M P V O LTS - A l t h o u g h t h e “T e c h I ”
in d ic a t e s “F u e l P u m p V o l t s ” i n t h i s p o s it io n , o n
5 . 7 L C N G e n g in e s w it h 4 L 6 0 t r a n s m is s io n t h is
p a r a m e t e r i s a r e a d in g o f th e v o lt a g e fo u n d a t th e
fu e l c y lin d e r s o le n o id v a lv e s . It is u se d b y th e
ECM a s t h e s y s t e m v o l t a g e a n d i s a re f e re n c e to
d e t e r m in e e le c tr ic a l lo a d in g .
PROM ID - T h e P R O M id e n t if ic a t io n p a r a m e t e r
d e s c r ib e s t h e p a r t i c u l a r P R O M u s e d i n t h e E C M
b e in g te ste d . T h e P R O M c o n t a in s th e E C M
p r o g r a m . P R O M I D i s u s e d w h e n it is n e c e s s a r y to
r e p la c e t h e P R O M . P R O M I D m u s t b e s p e c ifie d
w h e n o r d e r in g n e w P R O M s . P R O M I D s h o u ld n o t
b e c o n fu s e d w it h “P a r t N u m b e r . ”
ELECTRONIC CONTROL MODULE (ECM)
T h e d i a g n o s i s o f t h e E le c t r o n ic C o n t r o l M o d u l e
( E C M ) s t a r t s w it h th e D ia g n o s t ic C ir c u it C h e c k .
T h e c o d e s y s t e m in d i c a t e s a f a i l u r e o f a s p e c if ic
c i r c u i t a n d d i a g n o s i s m a y in d ic a t e r e p la c e m e n t o f
t h e E C M . A C o d e 5 5 i n d ic a t e s t h a t t h e E C M h a s
fa ile d a n d m u s t b e re p la ce d .
I f t h e E C M h a s b e e n re p la c e d a n d th e c o n d it io n
w a s n o t c o rre c te d , t h e f o l l o w i n g i n f o r m a t io n m a y
b e t h e cau se :
• A n in c o r r e c t E C M or P R O M / M E M -C A L
a p p l ic a t i o n m a y c a u s e a m a lf u n c t io n a n d m a y
o r m a y n o t se t a code.
• I f th e c o n n e c t o r a t th e E C M is th e p o s s ib le
p ro b le m , t h e t e r m in a l m a y h a v e to be r e m o v e d
f r o m t h e c o n n e c t o rs i n o rd e r to p r o p e r ly c h e c k
th e m .
• A l t h o u g h t h e P R O M / M E M - C A L r a r e l y f a ils , it
o p e ra te s a s p a r t o f t h e E C M , th erefore, it c o u ld
b e t h e c a u s e o f t h e p ro b le m .
• A l t h o u g h a r a r e c o n d it io n , th e re p la c e m e n t
ECM m a y b e fa u lty .
• I n t h e c a se o f a n in t e r m it t e n t p ro b le m , r e f e r to
“D r i v e a b i l i t y S y m p t o m s , ” S e c t io n “2 ” a n d m a k e
a c a r e f u l p h y s ic a l in s p e c t io n o f th e s y s t e m
in v o lv e d .
• A s h o r t e d s o le n o id , r e l a y c o il o r h a r n e s s m a y
c a u s e a n E C M to f a il a n d a re p la c e m e n t E C M
to f a i l w h e n i t i s in s t a l le d . U s e a s h o r t t e s t e r
J 34636, B T -8 4 0 5 , or e q u iv a le n t as a fa st,
a c c u ra t e m e a n s o f c h e c k in g fo r a s h o r t c irc u it .
• R e f e r to E C M Q u a d - D r i v e r ( Q D R ) c h e c k b e fo re
r e p la c in g E C M .
ECM Quad Driver (QDR) Check
The E C M u s e s a n In t e g r a t e d C i r c u i t ( IC ) c a lle d
a Q u a d - D r iv e r (Q D R ) in p la c e of se p a ra te
t r a n s is t o r s to t u r n “O N ” o r “O F F ” d iffe r e n t c ir c u it s
c o n t r o lle d b y th e E C M . E a c h Q D R h a s fo u r
s e p a r a t e o u t p u t s t h a t c a n in d e p e n d e n t ly t u r n “O N ”
o r “O F F ” f o u r d iffe r e n t c irc u it s .
EC M o n a ll e n g in e s a re fa u lt p ro te cte d ,
th e re fo re , a s in g le f a u lt y c ir c u it m a y c a u s e a l l f o u r
Q D R o u t p u t s to b e i n o p e r a t i v e o r “ O N ” a l l t h e
t im e . A f a i l e d Q D R u s u a l l y r e s u l t s i n e i t h e r a
sh o rte d or open E C M o u tp u t. B e c a u se of th e
in c r e a s e d c u r r e n t flow , tw o Q D R o u t p u t s a r e u s e d
to d r iv e t h e T C C so le n o id .
R e f e r to t h e E C M Q D R c h e c k p r o c e d u r e . T h i s
c h e c k w i l l n o t t e s t a l l E C M f u n c t io n s b u t i t w i l l
d e t e r m in e i f a sp e c ific c ir c u it h a s c a u s e d a s p e c ific
Q D R to f a il i n th e E C M .
A f a u lt y c ir c u it i s t h e la r g e s t c a u s e o f a fa ile d
Q D R , th e re fo re , t h e c h e c k p ro c e d u re s h o u l d b e u s e d
i f t h e r e i s a n i n d i c a t i o n o f a n E C M r e p la c e m e n t ,
e s p e c ia lly if th e re m o v e d E C M e x h ib it s
c h a r a c t e r is t ic s o f a d a m a g e d Q D R s u c h as:
• “S E S ” l i g h t w i t h n o c o d e s sto re d .
• E n g in e w ill n o t sta rt and/or E C M w i l l n o t f la s h
C o d e 12.
• F li c k e r i n g , in t e r m it t e n t , o r d im “S E S ” lig h t .
• O u t p u t , s u c h a s T C C c ir c u it , i s i n o p e r a t i v e o r
“O N ” a t a l l tim e s.
• E n g i n e m is f ir e s , s u r g e s o r sta lls.
• “S c a n ” to o l i s e r r a t ic o r in o p e r a t iv e .
T h e E C M u se d o n a ll e n g in e s h a s I C c ir c u it s
t h a t a r e f a u lt p ro tected , th e re fo re , i f a c ir c u it h a s
fa ile d , t h e I C m a y n o t b e d a m a g e d a n d w i l l k e e p
t h e c i r c u it o p e n u n t i l t h e f a u l t i n t h e c i r c u it h a s
b e e n co rre cte d . W h e n t h e f a u lt h a s b e e n co rre cte d ,
r e i n s t a l l E C M a n d c h e c k c irc u it. R e p la c e E C M o n l y
i f t h e c ir c u it i s s t i l l in o p e r a tiv e .
PROM (calibrator)
A P R O M t h a t h a s fa ile d o r w a s in s t a lle d
i m p r o p e r ly w i l l g e n e r a lly se t a C o d e 51.
CAL-PAK
T h e C a l- P a k o n th e 5 .7 L C N G e n g in e is n o t
d e s i g n e d to c o n t r o l f u e l d e l i v e r y o p e r a t i o n i n t h e
event of a n E C M fa ilu r e , o r w h e n i n t h e “T e c h I ”
F u e l B a c k - u p m o de. I f t h e E C M fa ils , t h e r e w i l l b e
a “N o R u n / N o S t a r t ” c o n d itio n .
CNG FUEL CONTROL
C N G fu e l d e liv e r y is c o n t r o lle d by th e
C o m p u t e r C o m m a n d C o n t r o l s y st e m .
T h e d ia g n o s is o f fu e l c o n tro l sta rts w it h
“E n g i n e C r a n k s B u t W i l l N o t R u n ” C H A R T A - 3 .
T h i s c h a r t w i l l te s t t h e fu e l s y s t e m a n d i f t h e r e i s
a p r o b le m , w i l l le a d y o u to c h e c k in g t h e f u e l
s u p p l y r e l a y c irc u it , d i a g n o s i n g t h e in je c t o r c ir c u it
o r d i a g n o s i n g t h e fu e l sy st e m .
CNG Fuel Injectors
'T e s t i n g t h e f u e l in j e c t o r c i r c u i t i s i n C H A R T
A - 3 w i t h a d d it io n a l d i a g n o s i s i n C H A R T A - 4 .
O n th e 5 .7 L C N G E n g in e w it h 4 L 6 0
t r a n s m i s s i o n a f u e l in j e c t o r w h i c h d o e s n o t o p e n
m a y c a u s e a “n o s t a r t ” c o n d itio n .
A n in j e c t o r w h i c h i s s t u c k p a r t l y o p e n d u r i n g
e n g in e off, c o u ld c a u s e th e o d o r o f N a t u r a l G a s to
be p re se n t in th e e n g in e c o m p a rtm e n t. A ls o ,
d i e s e l i n g c o u ld o c c u r b e c a u s e s o m e f u e l c o u ld b e
d e l i v e r e d to t h e e n g i n e a f t e r t h e k e y i s t u r n e d
“O F F ” . A n in j e c t o r w h i c h i s s t u c k p a r t l y o p e n
d u r in g e n g in e r u n n in g , c o u ld c a u s e a r ic h
c o n d it io n .
I t i s a n o r m a l c o n d i t i o n to s m e l l a s l i g h t
n a t u r a l g a s o d o r a ft e r t u r n i n g t h e t r u c k off. A l e a k
m a y b e in d ic a t e d i f t h e o d o r d o e s n o t g o a w a y a ft e r
10-15 m in u t e s .
Fuel Pressure Regulator
T e s t in g th e p re ssu re r e g u la t o r c ir c u it is in
C H A R T A -6 .
I f th e p r e s s u r e r e g u la t o r s u p p lie s p r e s s u r e
w h i c h i s to o lo w , p o o r p e r f o r m a n c e a n d l e a n
m i x t u r e s c o u ld r e s u l t . I f t h e p r e s s u r e r e g u l a t o r
s u p p lie s p r e s s u r e t h a t is to o h ig h , p o o r
p e r fo rm a n c e , u n p le a s a n t e x h a u s t o d o r, a n d r ic h
m ix t u r e s c o u ld re s u lt.
Idle Air Control (IAC)
T h e d i a g n o s i s o f Id le A i r C o n t r o l ( I A C ) c a n b e
f o u n d i n “F u e l C o n t r o l, ” S e c t io n “4 ” fo r a l l e n g in e s .
I f t h e I A C v a l v e i s d is c o n n e c t e d o r c o n n e c t e d
w it h th e e n g in e r u n n in g , th e id le r p m m a y b e
w r o n g . T h e I A C v a l v e m a y b e re s e t b y t u r n i n g th e
i g n i t i o n s w it c h “O N ” a n d “O F F ” o n e tim e .
The IA C v a lv e a ffe c ts o n ly th e id le
c h a r a c t e r is t ic s o f th e e n g in e . I f it i s o p e n f u lly , too
m u c h a i r w i l l b e a llo w e d i n th e m a n if o ld a n d id le
s p e e d w i l l b e h i g h . I f it i s s t u c k c lo se d , to o li t t l e
a i r w i l l b e a llo w e d i n t h e m a n ifo ld , a n d id le sp e e d
w i l l b e to o lo w . I f it i s s t u c k p a r t w a y o p e n , t h e
id le m a y b e r o u g h , a n d w i l l n o t r e s p o n d to e n g in e
lo a d c h a n g e s.
CNG Fuel Supply Relay Circuit
T w o r e la y s a r e u s e d w i t h t h e 5 . 7 L C N G e n g in e .
A F u e l S u p p ly R e la y a n d a C N G C o n t r o l R e la y .
T h e F u e l S u p p ly R e l a y is u s e d b y th e E C M to
a c t iv a t e o r d e a c t iv a t e t h e C N G C o n t r o l R e l a y
w h i c h i n t u r n a c t iv a t e s a n d d e a c t iv a t e s t h e L o w
P r e s s u r e F u e l S h u t - o f f S o le n o id a n d th re e F u e l
C y lin d e r S o le n o id V a lv e s . T h e C N G C o n t r o l R e l a y
lo o s e s i t s gro u n d w hen th e Fuel Door Sh u t-o ff
S w it c h o p e n s ( f ill d o o r o p e n e d ). The Fuel Door
S w it c h i s a n o r m a l ly o p e n s w itc h .
T o t e s t t h e F u e l C y l i n d e r S o l e n o i d V a l v e s fo r
o p e r a t io n t h e r e is a t e s t t e r m in a l lo c a t e d i n
t e r m in a l “G ” o f t h e A L D L c o n n e c t o r. B y a p p l y i n g
v o lt a g e to t h is t e r m in a l, it c a n b e d e t e r m in e d t h a t
th e S o le n o id V a l v e s a n d th e L o w P r e s s u r e F u e l
S h u t - o f f s o le n o id w i l l o p e ra te .
In o p e r a t i v e F u e l C y l i n d e r S o l e n o i d V a l v e s o r
L o w P r e s s u r e F u e l S h u t - o f f S o le n o id c a n c a u se a
“n o s t a r t ” c o n d itio n .
A n in o p e r a t iv e F u e l S u p p l y R e l a y c a n r e s u lt i n
lo n g e r c r a n k i n g tim e s . T h e o il p r e s s u r e s w it c h w i l l
se rv e a s a b a c k - u p to k e e p t h e C N G C o n t r o l R e l a y
e n e rg iz e d w h ic h i n t u r n p o w e r s t h e F u e l C y l in d e r
S o le n o id V a l v e s a n d t h e L o w P r e s s u r e F u e l S h u t -
o ff S o le n o id . T h e O i l P r e s s u r e S w i t c h c l o s e s a t
a p p r o x im a t e ly 2 8 k P a (4 p si).
R e f e r to C h a r t A - 5 f o r d i a g n o s i s o f t h e F u e l
S u p p l y R e l a y C ir c u it . C o d e 5 4 in d ic a t e s a f a ilu r e i n
th e C N G fu e l s u p p l y c irc u it.
Low Pressure Fuel Shut-off Solenoid
A n e le ctric s o le n o id i s u s e d o n a ll 5 . 7 L N a t u r a l
G a s P o w e r e d T r u c k s . I t i s lo c a t e d n e a r t h e C N G
F u e l P r e s s u r e R e g u l a t o r a n d c o n t r o ls f u e l to t h e
injectors. T h e s o le n o id o p e ra te d v a l v e i s c lo se d w it h
ig n it io n o ff a n d o p e n w it h ig n it io n on, e n g in e
r u n n in g .
Fuel Door Shut-off Switch
T h i s s w it c h i s u s e d o n N a t u r a l G a s P o w e r e d
T r u c k s to s h u t o f f o r p r e v e n t t h e e n g i n e f r o m
r u n n in g w h e n th e fu e l fill d o o r is opened. It is a
sa fe ty fe a tu re a n d m u s t n o t be b y p a sse d . I t is
lo c a t e d b e h i n d t h e f u e l d o o r h i n g e a n d w h e n
opened, re m o v e s g r o u n d fro m th e P o w e r R e la y .
T h i s a c t io n r e m o v e s p o w e r f r o m t h e f u e l s u p p l y
c ir c u it w h ic h s u p p l y s fu e l to th e e n g in e .
Fuel Cylinder Solenoid Valves
T h e r e a re t h r e e F u e l C y l i n d e r S o l e n o id V a l v e
a s s e m b lie s u s e d o n th e N a t u r a l G a s P o w e re d
T r u c k . O n e s o le n o id v a l v e fo r e a c h f u e l c y lin d e r .
T h e y a r e e l e c t r ic s o l e n o i d s t h a t c o n t r o l t h e f u e l
s u p p l y fr o m th e c y lin d e r s . W i t h th e ig n it io n o ff th e
s o le n o id s a r e d e a c t iv a t e d a n d th e v a l v e s a re c lo s e d
to s t o p f u e l flo w . W i t h th e ig n it io n on a n d th e
e n g in e r u n n i n g t h e s o le n o id s a re a c tiv a te d a n d th e
v a l v e s a r e o p e n to a llo w fu e l flow .
I f o n e o r m o r e s o le n o id v a lv e s a re in o p e r a tiv e ,
p o o r d r i v e a b i l i t y o r “n o s t a r t ” c o n d it io n s c o u l d
o ccu r.
R e f e r to C h a r t s A - 5 a n d A - 6 fo r d i a g n o s i s o f
t h e F u e l C y l i n d e r S o le n o id V a lv e s .
Fuel Pressure Transducer
A d e v ic e t h a t m e a s u r e s t h e p e r c e n t a g e o f f u e l
p re ssu re r e m a in in g in th e C N G f u e l c y lin d e r s . I t
c o n v e r t s fu e l p r e s s u r e in t o a n e le c tric a l s ig n a l t h a t
c o n t r o ls t h e p o s it io n o f t h e f u e l le v e l g a u g e . I t i s
lo c a t e d b e t w e e n t h e 1/4 t u r n M a n u a l S h u t - o f f V a l v e
a n d t h e C N G F u e l P r e s s u r e R e g u la t o r .
R e f e r to th e E le c t r ic a l D ia g n o s is M a n u a l
(g a g e s).
COOLANT TEMPERATURE SENSOR
C o d e 14 o r C o d e 15 in d ic a t e s a f a ilu r e i n t h e
c o o la n t t e m p e r a t u r e s e n s o r c ircu it.
M o s t “S c a n ” to o ls d i s p la y e n g in e te m p e r a t u r e i n
d e g re e s c e n t ig ra d e . A f t e r e n g in e is sta rte d , th e
t e m p e r a t u r e s h o u l d r is e s t e a d ily to a b o u t 9 0 ° C t h e n
s t a b iliz e w h e n t h e r m o s t a t opens.
MAP SENSOR
C o d e 3 3 o r C o d e 3 4 in d ic a t e s a f a ilu r e i n t h e
M AP s e n s o r c i r c u it . A l s o r e f e r to “M A P O utp ut
C h e c k D i a g n o s i s ” to c h e c k th e M A P se n s o r i f t h e re
i s n o code.
OXYGEN ( 0 2) SENSOR - (HEATED)
C o d e 1 3 in d i c a t e s a n o p e n i n t h e O x y g e n ( 0 2)
s e n s o r c irc u it . C o d e 4 4 in d ic a t e s a s h o rte d O x y g e n
( 0 2) s e n s o r c i r c u i t . C o d e 4 5 i n d i c a t e s a h i g h
v o lt a g e i n t h e O x y g e n ( 0 2) s e n s o r c irc u it. I f a code
i s se t, t h e e n g i n e w i l l a l w a y s r u n i n th e “O p e n
L o o p ” m o d e . O n n o n - h e a t e d O x y g e n ( 0 2) s e n s o r s ,
t h e O x y g e n ( 0 2) s e n s o r v o l t a g e o u t p u t c a n b e
m e a s u r e d w i t h a d i g i t a l v o lt m e t e r h a v i n g a t le a s t
a 10 m e g o h m i n p u t im p e d a n c e . U s e o f a s t a n d a r d
s h o p t y p e v o lt m e t e r w i l l r e s u l t i n a n in a c c u r a t e
r e a d in g .
N o r m a l “S c a n ” v o lt a g e v a r ie s b e tw e e n 1 0 0 m V
to 9 9 9 m V (.1 a n d 1.0 v o lt ) w h ile i n “C lo s e d L o o p . ”
C o d e 13 s e ts in o n e m in u t e i f v o lt a g e r e m a in s
b e t w e e n .3 5 a n d .5 5 v o lt , b u t t h e s y s t e m w i l l g o
“O p e n L o o p ” i n a b o u t 15 seco n ds.
U s i n g t h e “S c a n , ” o b s e r v e t h e b l o c k l e a r n
v a l u e s a t d if f e r e n t r p m a n d a i r f lo w c o n d it io n s to
d e t e r m in e w h e n C o d e 4 4 o r C o d e 4 5 m a y h a v e
b e e n set. I f t h e c o n d it io n fo r C o d e 4 4 e x is t s , t h e
b lo c k le a r n v a lu e s w ill be a r o u n d 170. I f th e
c o n d it io n fo r C o d e 4 5 e x is ts , th e b lo c k l e a r n v a l u e s
w i l l b e a r o u n d 90.
T H R O T T L E P O S IT IO N S E N S O R (T P S)
W hen a code is se t, th e EC M w ill u se an
a r t if ic ia l v a lu e fo r t h r o t t le p o s it io n a n d so m e
e n g in e p e r fo r m a n c e w i l l r e t u r n .
A b r o k e n T P S c a n c a u se in t e r m it t e n t b u r s t o f
fu e l fro m th e in je c t o r(s ) a n d a n u n s t a b le id le
b e c a u s e t h e E C M t h i n k s t h e t h r o t t le i s m o v in g .
A “S c a n ” t o o l r e a d s t h r o t t le p o s i t i o n i n v o l t s
a n d s h o u l d r e a d a b o u t .60 w i t h th e t h r o t t le clo sed ,
i g n i t i o n “O N ” o r a t idle. V o l t a g e s h o u l d in c r e a s e a t
a s t e a d y r a t e a s t h r o t t le is m o v e d t o w a r d W id e
O p e n T h r o t t le ( W O T ) .
“S c a n ” T P S w h i l e d e p r e s s i n g a c c e le r a t o r p e d a l
w i t h e n g i n e s t o p p e d a n d i g n i t i o n “O N . ” D i s p l a y
s h o u ld v a r y fro m b e lo w 1.25 v o lt s (1 2 5 0 m V ) w h e n
t h r o t t l e w a s c lo s e d , to o v e r 4 . 5 v o l t s ( 4 5 0 0 m V )
w h e n t h r o t t le i s h e ld a t w id e o p e n t h r o t t le p o s it io n .
T P S O u tp u t
T h is c h e c k s h o u ld be p e rfo rm e d w hen T P S
a t t a c h i n g p a r t s h a v e b e e n r e p la c e d . A Tech 1 can
b e u s e d to r e a d t h e T P S o u t p u t v o lt a g e , or:
1. C o n n e c t d i g i t a l v o l t m e t e r J 3 4 0 2 9 - A or
e q u iv a le n t , f r o m T P S c o n n e c t o r t e r m i n a l “B ”
( B L K w i r e ) t o t e r m i n a l “C ” ( D K B L U w ir e ) .
J u m p e r s fo r t e r m in a l a c c e ss c a n b e m a d e u s i n g
t e r m in a ls “1 2 1 4 8 3 6 ” a n d “1 2 0 1 4 8 3 7 ”.
2. W i t h i g n i t i o n “O N , ” e n g i n e s t o p p e d , t h e T P S
v o lt a g e s h o u l d b e le s s t h a n 1 .2 5 v o l t s i f m o r e
t h a n 1.25 v o lt s v e r if y fre e t h r o t t le m o v e m e n t. I f
s t i l l m o r e t h a n 1.25 v o lt s , re p la c e T P S .
3. R e m o v e t h e v o lt m e t e r a n d j u m p e r s , r e c o n n e c t
t h e T P S c o n n e c t o r to t h e se n so r.
V E H IC L E S P E E D S E N S O R (V S S )
T h e v e h ic le sp e e d s e n s o r c ir c u it d i a g n o s i s is i n
C o d e 2 4 c h a rt.
“S c a n ” r e a d in g s h o u ld c lo s e ly m a tc h
s p e e d o m e te r r e a d in g s , w it h th e d r iv e w h e e ls
t u r n in g .
EGR SY ST E M
C o d e 3 2 in d ic a t e s t h a t t h e r e i s a f a i lu r e i n t h e
E G R s y s t e m c irc u it.
ID L E S P E E D
I f t h e r e i s a p r o b le m w i t h id le a i r c o n tro l, re fe r
to “D i a g n o s i s ” i n C o m p u t e r C o m m a n d C o n t r o l , ”
S e c t i o n “3 ” fo r I d l e A i r C o n t r o l ( I A C ) c h e c k f o r
o t h e r e n g in e s .
• S y s t e m too le a n (H ig h a ir / f u e l r a t i o ) - Id le
sp e e d m a y b e to o h i g h o r too low . E n g i n e sp e e d
m a y v a r y u p a n d d o w n , d is c o n n e c t in g L A C d o e s
n o t h e lp . M a y se t C o d e 44.
“S c a n ” a n d / o r v o l t m e t e r w i l l r e a d a n o x y g e n
s e n s o r o u t p u t le s s t h a n 3 0 0 m V (.3 vo lt). C h e c k
fo r lo w r e g u la t e d fu e l p re s s u re . A le a n e x h a u s t
w i t h a n O x y g e n ( 0 2) s e n s o r o u t p u t fix e d a b o v e
8 0 0 m V (.8 v o lt ) w i l l b e a c o n t a m in a t e d s e n s o r,
u s u a l l y silic o n e . T h i s m a y a ls o se t a C o d e 45.
• S y s t e m too r ic h ( L o w a ir/ fu e l ra t io ) - Id le sp e e d
to o low . “S c a n ” c o u n t s u s u a l l y a b o v e 90. S y s t e m
o b v i o u s l y r i c h a n d m a y e x h i b i t e x h a u s t o d o r.
“S c a n ” t o o l a n d / o r v o lt m e t e r w i l l r e a d a n
O x y g e n ( 0 2) s e n s o r s ig n a l fix e d a b o v e 8 0 0 m V
(.8 volt).
E L E C T R O N IC S P A R K T IM IN G (E ST )
W h e n th e sy ste m is r u n n in g on th e ig n it io n
m o d u le , t h a t is, n o v o lt a g e o n t h e b y p a s s lin e , th e
i g n i t i o n m o d u le g r o u n d s t h e E S T s ig n a l. T h e E C M
e x p e c t s to s e e n o v o l t a g e o n t h e E S T li n e d u r i n g
t h i s c o n d it io n . I f it se e s a v o lt a g e , it s e ts C o d e 4 2
a n d w i l l n o t g o in t o t h e E S T m ode.
W h e n t h e r p m fo r E S T i s r e a c h e d ( a b o u t 4 0 0
r p m ) , a n d b y p a s s v o lt a g e i s a p p lie d , t h e E S T
s h o u ld n o lo n g e r be g r o u n d e d in th e ig n it io n
m o d u le so t h e E S T v o lt a g e s h o u l d b e v a r y in g .
I f th e b y p a s s lin e is o p e n o r g ro u n d e d , th e
i g n i t i o n m o d u l e w i l l n o t s w i t c h to E S T m o d e so
t h a t E S T v o lt a g e w i l l b e lo w a n d C o d e 4 2 w i l l b e
set.
I f th e E S T lin e is g ro u n d e d , th e ig n it io n
m o d u le w i l l s w it c h to E S T , b u t b e c a u s e th e lin e is
g r o u n d e d t h e r e w i l l b e n o E S T s ig n a l . A C o d e 4 2
w i l l b e set.
C o d e 4 2 s e t s i f t h e r e i s a n o p e n o r a s h o r t to
g r o u n d i n t h e E S T o r b y p a s s c irc u it.
E L E C T R O N IC S P A R K C O N T R O L (E S C )
T h e E S C sy ste m is p re se n t o n th e 5 .7 L C N G
E n g i n e w it h 4 L 6 0 T r a n s m i s s i o n . H o w e v e r , I t i s n o t
u s e d b y th e E C M to r e t a r d i g n i t i o n t i m i n g d u e to
sp a rk knock. C o m p re sse d N a t u r a l G a s h a s a h ig h
O c t a n e r a t i n g a n d i s le s s l i k e l y to p r o d u c e s p a r k
k n o c k . T h e E S C s y s t e m , i f le f t o p e r a t in g , w o u l d
red uce p e rfo rm a n c e o f th e 5 . 7 L C N G e n g in e . A n y
K n o c k S e n so r in p u t is m a s k e d b y th e P R O M .
T h e “T e c h I ” s c a n t o o l w h e n i n t h e K n o c k
S i g n a l p o s it io n w i l l a lw a y s d is p la y “N O ” . N o
d ia g n o s is s h o u ld b e n e c e s s a r y .
SY ST EM OVER VO LTAGE
C o d e 5 3 se ts i f th e re is v o lt a g e g r e a te r t h a n
17.1 v o l t s fo r t w o s e c o n d s a t E C M t e r m i n a l “B l ”.
T h is in d ic a t e s t h a t th e re is a b a s ic g e n e r a t o r
p ro b le m .
P A R K /N E U T R A L (PIN) S W IT C H
R e f e r to P a r k / N e u t r a l (P / N ) s w it c h d ia g n o s is .
C R A N K S IG N A L
R e f e r to “C r a n k S i g n a l D i a g n o s i s . ” I f t h e r e i s
n o c r a n k s i g n a l to t h e E C M , t h e e n g i n e m a y b e
h a r d to sta rt.
D IS T R IB U T O R R E F E R E N C E S IG N A L
T h e d is t r ib u t o r re fe re n ce s ig n a l is c o v e re d in
“I g n i t i o n S y s t e m / E S T , ” S e c t i o n “6 ” o f t h e i g n i t i o n
s y s t e m a n d E le c t r o n ic S p a r k C o n t r o l ( E S C ) .
A/C S IG N A L R E Q U E S T
R e f e r to “A / C ” R e q u e s t S ig n a l D ia g n o s is ” on
5 . 7 L C N G e n g in e s .
EXH AU ST SY ST E M
R e f e r to “R e s t r ic t e d E x h a u s t S y s t e m C h e c k . ”

T h e “S e r v i c e E n g i n e S o o n ” l i g h t w i l l o n ly b e “O N ” i f t h e m a l f u n c t i o n e x i s t s u n d e r t h e c o n d it io n s
lis t e d b e lo w . I f t h e m a lf u n c t io n c le a rs, th e l i g h t w i l l g o o u t a n d t h e co d e w i l l b e s to re d i n t h e E C M .
A n y c o d e s s to re d w i l l b e e ra se d i f n o p ro b le m r e o c c u r s w i t h i n 5 0 e n g in e s ta rts.
C O D E A N D C IR C U IT
C o d e 13 - O x y g e n O 2 S e n s o r
C ir c u i t (O p e n C ir c u it )
C o d e 14 - C o o la n t
T e m p e ra tu re S e n so r (C T S )
C ir c u it ( H ig h T e m p e ra tu re
In d ic a te d )
C o d e 15 - C o o la n t
T e m p e ra tu re S e n so r (C T S )
C ir c u it (L o w T e m p e ra tu re
In d ic a te d )
C o d e 21 - T h r o t t le P o s it io n
S e n so r (T P S ) C ir c u it
( S ig n a l V o lt a g e H ig h )
C o d e 2 2 - T h r o t t le P o s it io n
S e n so r (T P S ) C ir c u it
( S i g n a l V o lt a g e L o w )
C o d e 2 4 - V e h ic le S p e e d
Se n so r (V S S )
C ode 32 - E x h a u s t G a s
R e c ir c u la t io n ( E G R )
Syste m
DIAGNOSTIC CODE IDENTIFICATION
P R O B A B LE C A U S E
In d ic a te s th a t the
o x y g e n s e n s o r c ir c u it o r
s e n s o r w a s open for o ne
m in u t e w h ile o ff idle.
S e t s if the s e n s o r o r
s ig n a l lin e becom e s
g ro u n d e d fo r 3 se co n d s.
S e t s if the se n so r,
co n n e c tio n s, or w ir e s
o p en fo r 3 seconds.
T P S v o lta g e g r e a te r
th a n 2.5 v o lt s fo r 3
se c o n d s w ith le ss t h a n
1200 R P M .
A s h o rte d to g r o u n d o r
o p en s ig n a l c ir c u it w ill
set code in 3 secon ds.
N o v e h ic le speed p re s e n t
d u r in g a ro a d lo ad decel.
V a c u u m s w it c h s h o r t e d
to g r o u n d o n s ta rt u p
OR
S w it c h no t clo se d a fte r
the E C M h a s
c o m m a n d e d E G R fo r a
sp e c ifie d p e rio d o f tim e.
OR
E G R s o le n o id c ir c u it
o p en fo r a sp e cifie d
p e rio d o f tim e.
C O D E A N D C IR C U IT
C o d e 3 3 - M a n if o ld
A b s o lu t e P r e s s u r e ( M A P )
S e n s o r C ir c u i t ( S ig n a l
V o lt a g e H ig h - L o w
Vacuum )
C od e 3 4 - M a n if o ld
A b s o lu t e P r e s s u r e ( M A P )
S e n s o r C ir c u i t ( S ig n a l
V o lt a g e L o w - H i g h
Vacuum )
C o d e 4 2 - E le c t r o n ic S p a r k
T im in g (E S T )
C o d e 4 3 - E le c t r o n ic S p a r k
C o n tro l ( E S C ) C ir c u it
C o d e 4 4 - O x y g e n ( O 2)
S e n s o r C ir c u i t ( L e a n
E x h a u s t In d ic a te d )
C o d e 4 5 - O x y g e n ( O 2)
S e n s o r C ir c u i t ( R ic h
E x h a u s t In d ic a te d )
C o d e 51 - F a u l t y P R O M
C ode 52 - F u e l C A L P A K
M is s in g
C ode 53 - S y s te m O v e r
V o lt a g e
Code 54 - F u e l S u p p ly
C irc u it (L o w V o lta ge)
C ode 55 - F a u lty
ECM
PROBABLE C A U SE
M A P s e n s o r o u t p u t to
h i g h fo r 5 s e c o n d s o r
a n o p e n s ig n a l c irc u it .
L o w o r no o u t p u t fr o m
s e n s o r w it h e n g in e
r u n n in g .
E C M h a s seen a n
open or grou n d e d E S T
o r b y p a s s c irc u it.
S i g n a l to th e E C M
h a s r e m a in e d lo w
fo r too lo n g o r th e
s y s t e m h a s fa ile d a
f u n c t io n a l ch e ck .
S e ts if o x y g e n s e n so r
v o lt a g e r e m a i n s b e lo w
.2 v o lt fo r a b o u t 2 0
se co n d s.
Se ts if o xyge n se n so r
v o lt a g e r e m a i n s
a b o v e .8 v o lt fo r
a b o u t 1 m in u t e .
F a u lty P R O M , or
ECM
Fuel C A L - P A K
m i s s i n g o r fa u lty .
S y s t e m o v e r v o lt a g e .
In d ic a t e s a b a s ic
g e n e r a t o r p ro b le m .
Se ts w h e n the fuel
su p p ly vo ltage is le ss
th a n 2 vo lts w h e n
reference p u lse s are
b e in g received
F a u lty E C M
5-13-91
7S 3337-6E-CNG
 CHART A-1
NO "SERVICE ENGINE SOON" LIGHT
5.7L NATURAL GAS POWERED TRUCK WITH 4L60 TRANSMISSION
Circuit D escrip tion:
T h e r e s h o u ld a lw a y s be a s te a d y " S e r v ic e E n g i n e S o o n ” lig h t w h e n the i g n it io n is " O N ” a n d e n g in e stopped.
B a t t e r y v o lt a g e is s u p p lie d to the lig h t bu lb. T h e E C M w ill c o n tro l the lig h t a n d t u r n it " O N ” b y p r o v id i n g a
g r o u n d p a t h t h r o u g h C K T 4 1 9 to the E C M .

Test D escrip tion: N u m b e r ( s ) b e lo w re fe r to c irc le d D ia g n o stic A id s:

n u m b e r ( s ) o n th e d ia g n o s t ic c h a rt.
1. T h i s ste p w ill iso la te th e p ro b le m in C K T 419.
2. I f C K T ’s 4 4 0 a n d 4 3 9 h a v e v o lt a g e , th e E C M
c o n n e c tio n s, g r o u n d s , o r E C M is fa u lty .
3. U s i n g a te st lig h t co n n e c te d to 12 vo lts, p ro b e e a ch
o f th e s y s t e m g r o u n d c ir c u it s to be s u r e a g o o d
g r o u n d is p re se n t. R e fe r to E C M t e r m in a l e n d
v ie w i n t h i s s e c t io n fo r E C M p in l o c a t i o n s o f
g r o u n d c irc u it s .
4. I f th e f u s e / fu s ib le l i n k is b lo w n , r e f e r to E C M
w i r i n g d ia g r a m fo r c o m p le te c irc u it.
I f the e n g in e r u n s O K , ch eck:
• F a u lt y lig h t bu lb.
• C K T 4 i 9 open, s h o rt e d to g r o u n d o r b lo w n fu se
I f the e n g in e c r a n k s b u t w ill n o t ru n , ch eck:
• C o n t in u o u s b a t te r y -fu s e o r fu s ib le li n k open.
• E C M ig n it io n fu se open.
• B a t t e r y C K T 4 4 0 to E C M open.
• Ig n it io n C K T 4 3 9 to E C M open.
• P o o r c o n n e c tio n to E C M .
 CHART A-1
NO "SERVICE ENGINE SOON" LIGHT
NATURAL GAS POWERED TRUCK WITH
4L60 TRANSMISSION

DOES THE ENGINE START?

NO
nz
o •
•
IGNITION "OFF."
DISCONNECT ECM CONNECTORS.
© •
•
IGNITION "OFF."
DISCONNECT ECM CONNECTORS.
• IGNITION "O N ." • IGNITION "O N."
• PROBE CKT 4 19. W ITH TEST LIGHT TO GROUND. • PROBE CKT 440 8. CKT 439 WITH
IS THESES LIGHT "O N"? TEST LIGHT TO GROUND.
IS THE LIGHT "O N " ON BOTH CIRCUITS?

1
YES NO YES NO

FAULTY ECM
CONNECTION OR ECM.
CHECK:
- FAULTY BULB
© FAULTY ECM
GROUNDS, POOR
© REPAIR OPEN IN CIRCUIT THAT
DID NOT LIGHT THE TEST LIGHT.
BEFORE REPLACING - OPEN CKT 419 OR BLOWN FUSE. CONNECTIONS IF A FUSIBLE LINK OR FUSE WAS
ECM. REFER TO "ECM - CKT 419 SHORTED TO VOLTAGE OR BLOWN. LOCATE AND CORRECT
QDR CHECK." - IGNITION FEED TO BULB OPEN FAULTY ECM. THE SHORT TO GROUND ON
OR SHORTED TO GROUND. THAT CIRCUIT.

4-26-91
'AFTER R E P A IR S " CONFIRM "CLOSED LOOP" OPERATION AND NO "SERVICE ENGINE SOON" LIGHT. 7S 3687-6E-CNG
 ECM

12 VOLT TO OIL PRESS SW

JUNCTION & FUEL SUPPLY RELAY 440 ORN
BLOCK v BATTERY
I-------------1 FEED
-------------ir !fir 440 ORN - T bI

FUSIBLE LINK OR FUSE*

FUSIBLE LINK
*
• — f ------- - 439 PNK/BLK A6 IGNITION FEED
IGNITION
SWITCH 419 BRN/WHT A5
BATTERY SES LIGHT
- 451 WHT/BLK 5-6 VOLT

DIAGNOSTIC
GROUND
M I
ALDLCONNECTOR

o
♦REFER TO ECM WIRING
DIAGRAM IN THIS SECTION

461 ORN OR ORN/BLK SERIAL DATA

(EXCEPT ABOVE)

4-11-91
7S 3686-6E-CNG

CHART A-2
NO ALDL DATA OR W O N T FLASH CODE 12
"SERVICE ENGINE SOON" LIGHT "ON" STEADY
NATURAL GAS POWERED TRUCK WITH 4L60 TRANSMISSION
Circuit D escription:
There should always be a steady "Service Engine Soon” light when the ignition is "ON” and engine stopped.
Battery voltage is supplied to the light bulb. The ECM will turn the light "ON” by grounding CKT 419 at the
ECM.
W ith the diagnostic term inal grounded, the light should flash a Code 12, followed by any trouble code(s)
stored in memory.
A steady light suggests a short to ground in the light control CKT 419, or an open in diagnostic CKT 451.

T e st D escrip tion: Number(s) below refer to circled
number(s) on the diagnostic chart.
1. If there is a problem with the ECM th at causes a
Tech 1 "Scan” tool to not read serial data then the
ECM should not flash a Code 12. If Code 12 does
flash, be sure th a t the "Scan” tool is w orking
properly on a n o th e r vehicle. If the " S c a n ” is
functioning properly and CKT 461 is OK, the
PROM/MEM-CAL or ECM may be at fault for the
No ALDL symptom.
2. If the light goes "OFF” when the ECM connector is
disconnected, then CKT 419 is not sh o rte d to
ground.
3. This step will check for an open diagnostic CKT
451.
4. At this point the "Service Engine Soon” lig h t
wiring is OK. The problem is a faulty ECM or
PROM/MEM-CAL. If Code 12 does not flash, the
ECM should be rep la ce d u s in g t h e o r i g i n a l
PROM/MEM-CAL. Replace the PROM/MEM-CAL
only a f t e r t r y i n g a n ECM, a s a d e f e c t i v e
PROM/MEM-CAL is an u n lik e ly c a u s e of th e
problem.
 CHART A-2
NO ALDL DATA OR WON'T FLASH CODE 12
"SERVICE ENGINE SOON"
LIGHT "ON" STEADY
NATURAL GAS POWERED TRUCK WITH
4L60 TRANSMISSION

7-13-90
 ECM
468 DK GRN D14
INJECTOR
482 W HT I - 481 RED 467 DK BLU D16 DRIVERS
fi B CNG FUEL
I INJECTORS

TO
INJ. A-B 5.7L CNG ENGINE
IGNITION 481 RED
SWITCH 10A

5-18-91
7S 3777-CNG

CHART A-3
ENGINE CRANKS BUT WILL NOT RUN
5.7L CNG ENGINE WITH 4L60 TRANSMISSION
Circuit D escription:
T h i s c h a r t a s s u m e s t h a t b a t t e r y c o n d it io n a n d e n g in e c r a n k i n g sp e e d a r e O K , a n d t h e r e i s a d e q u a t e
fu e l i n th e fu e l c y lin d e r s . T h i s c h a r t s h o u l d b e u s e d o n e n g in e s u s i n g t h e M o d e l 2 2 0 t h r o t t le b o d y .

T e s t D e s c r ip t io n : N u m b e r ( s ) b e lo w r e f e r to
c irc le d n u m b e r ( s ) o n th e d ia g n o s t ic c h a rt.
1. A “S e r v ic e E n g i n e S o o n ” l i g h t “O N ” i s a b a s ic
t e s t to d e t e r m in e i f t h e r e i s a 12 v o l t s u p p l y
a n d i g n i t i o n 12 v o l t s to E C M . N o A L D L m a y
b e d u e to a n E C M p r o b l e m a n d C H A R T A - 2
w i l l d ia g n o s e th e E C M . I f T P S i s o v e r 2 .5 v o lt s
t h e e n g in e m a y b e i n t h e c le a r flo o d m o d e
w h i c h w i l l c a u s e s t a r t i n g p r o b le m s . I f c o o la n t
s e n s o r i s b e l o w -3 0 ° C , t h e E C M w i l l p r o v i d e
fu e l fo r t h is e x t r e m e ly c o ld t e m p e r a t u r e w h ic h
w i l l s e v e r e ly flo o d t h e e n g in e .
2. V o lt a g e a t th e s p a r k p lu g is checked u s in g
sp a rk te ste r to o l ST -1 2 5 (J 26792) or
e q u iv a le n t . N o s p a r k in d ic a t e s a b a s ic i g n i t i o n
p ro b le m .
3. In s t a ll a p r e ss u r e g a u g e , th e n t u r n o n th e
i g n i t i o n k e y to b u i l d s y s t e m p r e s s u r e . S y s t e m
p r e s s u r e s h o u l d b e m a i n t a i n e d a n d n o in j e c t o r
s h o u l d r e l e a s e fu e l. R e p l a c e a n in j e c t o r i f i t
re le a s e s fu e l o r d e t e r m in e th e c a u se fo r th e
d ro p i n s y s t e m p re ss u re .
4. U s e a n in je c t o r t e st l i g h t B T - 8 3 2 9 A , o r
e q u i v a l e n t , to t e s t e a c h i n j e c t o r c i r c u i t . A
b l i n k i n g l i g h t in d ic a t e s th e E C M is c o n t r o llin g
th e in je cto rs.
5. T h e in je c to rs s h o u l d b e h o l d in g s y s t e m p r e s s u r e
w h e n v e h i c le i s r u n n i n g . T h i s t e s t d e t e r m i n e s
t h a t s y s t e m p r e s s u r e i s co rre ct. I t i s n o r m a l fo r
in je c to r fu e l p r e s s u r e to b le e d d o w n w h e n t r u c k
i s n o t r u n n i n g . I f s y s t e m p r e s s u r e i s in c o r r e c t
re fe r to F u e l S y s t e m D i a g n o s i s ( C H A R T A - 6 ) .
6. U s i n g in je c t o r t e s t e r ( J - 3 4 7 3 0 - 3 ) o n b o t h
in j e c t o r s w i l l d e t e r m i n e t h a t t h e in j e c t o r s a r e
c a p a b le o f o p e n in g to r e le a s e fu el. I f t h e r e i s a
u n if o r m d ro p i n p r e s s u r e a c r o s s b o t h in je c to rs,
re fe r to “D i a g n o s t ic A i d s ” o n t h i s p a g e b e lo w to
d e t e r m i n e t h e c a u s e o f “E N G I N E C R A N K S
B U T W I L L N O T R U N ”.
D ia gn o stic A id s:
I f n o tr o u b le i s fo u n d i n t h e fu e l s u p p l y c ir c u it
o r i g n i t i o n s y s t e m a n d t h e c a u s e o f a “E n g i n e
C r a n k s B u t W i l l N o t R u n ” h a s n o t b e e n fo u n d ,
c h e c k for:
• F o u le d s p a r k p lu g s .
• E G R v a l v e s t u c k open.
• L o w fu e l p r e s s u r e . R e f e r to C H A R T A - 6 .
• A g r o u n d e d C K T 4 2 3 ( E S T ) m a y c a u s e a “N o
S t a r t ” o r a “S t a r t t h e n S t a l l ” c o n d itio n .
• B a s i c e n g in e p ro b le m .
 ENGINE CRANKS BUT WILL NOT RUN
5.7L CNG ENGINE WITH 4L60 TRANSMISSION

IF CODE 54 IS STORED. USE THAT CHART FIRST

® IGN "ON" - IF S.E.S. LIGHT IS "OFF," SEE CHART A-1.

INSTALL "SCAN" TOOL - IF "NO ALDL," SEE CHART
A-2.
CHECK THE FOLLOWING:
• TPS - IF OVER 2.5V AT CLOSED THROTTLE, SEE
CODE 21.
• COOLANT - IF BELOW -30°C, SEE CODE 15.
IGNITION "OFF" FOR 10 SECONDS. IGN. "ON".
• LISTEN FOR EACH FUEL CYLINDER SOLENOID
VALVE (ONE PER CYLINDER) AND THE LOW
PRESSURE FUEL SHUT-OFF SOLENOID TO CLICK.
DO THEY?

YES NO
ZE=
• DISCONNECT ONE SPARK PLUG WIRE. | SEE FUEL SUPPLY RELAY CIRCUIT j
• INSTALL A SPARK TESTER (ST 125 OR EQUIVALENT). I CHART A-5. I
• CRANK ENGINE AND CHECK FOR SPARK. 1___________________________ I
IS THERE SPARK?

YES NO

© ZEZ
•
•
RECONNECT SPARK PLUG WIRE.
DISCONNECT INJECTOR CONNECTORS.
SEE IGNITION SYSTEM !
! CHECK IN SECTION 6. Il
• INSTALL LOW PRESSURE GAGE.
• CYCLE THE KEY TO "ON".
• WAIT 5 SECONDS.
DOES GAGE PRESSURE READ ZERO?

I
YES NO
HZ X
® CONNECT INJECTOR TEST LIGHT TO ONE HARNESS k FAUTY INJECTOR
CONNECTOR. SEAL OR INJECTOR
CRANK ENGINE. OR FUEL SYSTEM LEAK.
REPEAT TEST ON OTHER CONNECTOR.
DOES TEST LIGHT BLINK ON BOTH TESTS?

YES NO

j DIAGNOSIS CHART A-4. |

(CONT.)
 ENGINE CRANKS BUT WILL NOT RUN
5.7L CNG ENGINE WITH 4L60 TRANSMISSION (CONT.)
COMPUTER COMMAND CONTROL 3-27
 ECM

468 LTGRN D14

467 LTBLU D16

12V

TO IGNITION
SWITCH 5.7L CNG

423 W HT D4 EST

430 PPL/WHT- B5 REFERENCE HIGH

424 TAN/BLK D5 BYPASS

V 'X ' 453 BLK/RED- B3 REFERENCE LOW

TO IGNITION
COIL

4-16-91
8S 4382-6E-CNG

CHART A-4
INJECTOR CIRCUIT DIAGNOSIS
5.7L CNG ENGINE WITH 4L60 TRANSMISSION
Circuit D escription:
T h i s c h a r t s h o u ld o n ly be u se d if d ia g n o s is in C H A R T A - 3 in d ic a te d a n in je c to r c ir c u it p ro b le m . I f b o th
in je c to r c ir c u it s fa il to b li n k w h e n tested, d ia g n o s e o n e injecto r c ir c u it at a tim e.

Test D escrip tion : N u m b e r ( s ) b e lo w re fe r to c irc le d T h i s step te sts fo r 12 v o lt s to th e injector. It w ill

n u m b e r s o n th e d ia g n o s t ic c h a rt. a lso d e te rm in e if th e re is a s h o r t to v o lt a g e o n th e
1. T h i s te st w ill d e t e r m in e if th e ig n it io n m o d u le is E C M sid e o f th e c irc u it.
g e n e r a t in g a re fe re n c e p u lse , if th e w i r i n g is a t T h i s te st c h e c k s fo r c o n t in u it y to th e E C M .
f a u lt o r if th e E C M is a t fa u lt. B y t o u c h in g a n d
r e m o v in g a te st lig h t, c o n n e c t e d to 12 v o lt s , to
C K T 4 3 0 , a re fe re n c e p u ls e s h o u ld be g e n e ra te d . I f
in je cto r te st lig h t b lin k s , th e E C M a n d w i r i n g a re
OK.
 INJECTOR CIRCUIT DIAGNOSIS
5.7L CNG ENGINE WITH 4L60 TRANSMISSION

| FROM CHART A-3 J

i INJECTOR TEST LIGHT i
J DOES NOT FLASH. |

©
CNG CONTROL RELAY
14089936

TO FUEL
G AUG E

HEATED
0 2 SENSOR

10A
ECM B

EGR SOLENOID
O XY G EN SENSO R SIG NAL
5.7L C N G ENG INE
FUEL SUPPLY
RELAY DRIVE
FUEL CONTROL SIG NAL

IG N ITIO N FEED

IG N ITIO N FEED

~ G108 7S 3804-6E-CNG

CHART A-5
Fuel Supply Relay Diagnosis
 CHART A-5
FUEL SUPPLY RELAY CIRCUIT DIAGNOSIS
NATURAL GAS POWERED TRUCK WITH 4L60 TRANSMISSION
Circuit D escrip tion:
W h e n t h e i g n i t i o n s w it c h i s t u r n e d “O N , ” t h e E l e c t r o n i c C o n t r o l M o d u l e ( E C M ) w i l l t u r n “O N ” t h e
F u e l S u p p l y R e l a y c ir c u it . I t w i l l r e m a i n “O N ” a s l o n g a s t h e e n g i n e i s c r a n k i n g o r r u n n i n g , a n d t h e
E C M i s r e c e i v i n g d i s t r i b u t o r re fe re n c e p u lse s. I f t h e r e a r e n o re fe re n c e p u ls e s , t h e E C M w i l l s h u t “O F F ”
t h e F u e l S u p p l y R e l a y c ir c u it w i t h in 2 se c o n d s a ft e r i g n i t i o n “O N ” o r e n g in e sto p s.
T h e C N G f u e l c y li n d e r s , u n d e r e x t r e m e ly h i g h p r e s s u r e , s u p p l y t h e C N G F u e l P r e s s u r e R e g u l a t o r
w h i c h r e d u c e s t h e p r e s s u r e to a p p r o x im a t e ly 1 1 4 7 -1 2 6 7 k P a (1 6 6 -1 8 4 p si). T h e F u e l C y l i n d e r s h a v e s o le n o id
v a l v e s t h a t close, a l o n g w it h a L o w P r e s s u r e F u e l S h u t - o f f s o le n o id , w h e n t h e e n g in e i s t u r n e d off. T h e
g a s e o u s f u e l in j e c t o r s a r e p u ls e d b y t h e E C M to p r o v id e t h e c o r r e c t a m o u n t o f f u e l to r u n t h e e n g i n e
e ffic ie n tly .

T e s t D e s c r ip t io n : N u m b e r ( s ) b e lo w r e f e r to D ia g n o stic A id s:
c irc le d n u m b e r ( s ) o n t h e d ia g n o s t ic ch a rt.
1. T h i s p r o c e d u r e d e t e r m i n e s t h a t B + v o lt a g e i s The Fuel S u p p ly R e la y has th e p r im a r y
p r e s e n t a t t h e F u e l S u p p l y R e l a y to e n e r g iz e f u n c t io n o f p o w e r i n g u p t h e C N G C o n t r o l R e l a y .
th e e n t ir e c irc u it. H o w e v e r th e o il p r e s s u r e s w it c h is u s e d a s a
2. T h is ste p d e t e rm in e s th a t th e F u e l S u p p ly b a c k u p i n c a s e o f F u e l S u p p l y R e l a y m a l f u n c t io n .
R e l a y i s o p e r a t in g to a llo w v o lt a g e to th e C N G I f t h e o il p r e s s u r e s w it c h i s f u n c t i o n i n g c o r r e c t l y
C o n t r o l R e la y . a n d t h e c i r c u it i s O K to t h e C N G C o n t r o l R e l a y ,
3. W i t h p o w e r p r e s e n t a t th e C N G C o n t r o l R e l a y t h e v e h i c le s h o u l d s t a r t a n d r u n , b u t w i t h lo n g e r
t h is ste p d e t e r m in e s th a t s y st e m g r o u n d c r a n k i n g p e rio d s.
t h r o u g h t h e F u e l F i l l D o o r S w it c h to th e T h e F u e l S u p p ly C ir c u it re c e iv e s it s g r o u n d
g r o u n d l u g o n t h e i n t a k e m a n if o ld i s O K . t h r o u g h t h e F u e l F i l l D o o r S w it c h . T h i s i s a s a fe t y
4. T h i s p r o c e d u r e i s to d e t e r m in e t h a t B + is f e a t u r e a n d i s n o t to b e b y p a s s e d . I f t h e f u e l f i l l
p re se n t a t th e C N G C o n tro l R e la y th ro u g h th e d o o r i s le f t o p e n o r t h e s w it c h i s m i s a d j u s t e d o r
15 a m p fu se . d e fe c tiv e a n o s t a r t c o n d it io n w i l l e x ist. M a k e s u r e
5. T h i s ste p d e t e r m in e s t h a t C N G C o n t r o l R e l a y th e F u e l C y l i n d e r s a r e f u ll a n d th e F u e l F i l l D o o r
v o lt a g e is p re s e n t t h r o u g h th e 5 am p fu se a n d t h e F u e l D o o r S h u t - o f f S w i t c h a r e c lo s e d w h e n
(lo c a te d u n d e r t h e v e h ic le o n C N G h a r n e s s . d i a g n o s i n g a “N O S T A R T ” c o n d itio n .
6. T h e l a s t s t e p i s to d e t e r m i n e t h a t t h e L o w
P r e s s u r e F u e l S h u t - o f f s o le n o id a n d th e t h r e e
C N G F u e l C y l i n d e r S o le n o id V a l v e s h a v e p o w e r
a n d g r o u n d p re se n t.
 FROM CHART A-3
CHART A-5
FUEL CYLINDER SOLENOID
VALVES AND LOW PRESSURE CNG FUEL SUPPLY RELAY
FUEL SHUT-OFF SOLENOIDS.
DO NOT CLICK. CIRCUIT DIAGNOSIS
5.7L NATURAL GAS POWERED
TRUCK WITH 4L60 TRANSMISSION
• TURN IGNITION "O N"
• LISTEN FOR LOW PRESSURE FUEL SHUT-OFF AND
FUEL CYLINDER SOLENOID VALVES TO CLICK FOR
TWO SECONDS.
DO THEY CLICK?

NO YES

® X
DISCONNECT FUEL SUPPLY RELAY CONNECTOR
(RELAY CLOSEST TO FENDER).
m
• VERIFY FUEL PRESSURE CHART A-6.

PROBE BETWEEN TERMINAL CAVITY A (CKT440) AND

A GOOD GROUND.
IS 12 VOLTS PRESENT?

YES NO
=xz ~T
® RECONNECT FUEL SUPPLY RELAY CONNECTOR.
DISCONNECT CNG CONTROL RELAY CONNECTOR
• CHECK AND REPLACE 10A ECM/IGN FUSE OR REPAIR
OPEN CIRCUIT (440) BETWEEN FUEL SUPPLY RELAY
{NEXT TO FUEL SUPPLY RELAY). CAVITY A AND FUSE BLOCK.
IGNITION "O N" - VERIFY VOLTAGE (2 SECONDS) AT • VERIFY FUEL SUPPLY CIRCUIT OPERATION.
CAVITY D (CKT120) OF CNG CONTROL RELAY
CONNECTOR AND GOOD GROUND.
IS 12 VOLTS PRESENT?

YES NO

® X
IGNITION "OFF".
USE DVOM, PROBE CAVITIES D (CKT120) AND F
zr
KEY "OFF" APPLY FUSED 12V TO ALDL CAVITY "G '
(FUEL SUPPLY TEST TERMINAL).
(CKT920) OF CNG CONTROL RELAY CONNECTOR. VERIFY 12 VOLTS AT CAVITY D (CKT120) OF CNG
IGNITION "ON". WATCH FOR 12 VOLTS (2 SECONDS). CONTROL RELAY CONNECTOR.
IS 12 VOLTS PRESENT? IS 12 VOLTS PRESENT?

YES NO YES NO
I I m
© • IGNITION "OFF". VERIFY FUEL FILL REMOVE FUSED 12V CHECK CONTINUITY
• VERIFY VOLTAGE AT DOOR SWITCH IS FROM ALDL CAVITY (CKT120).
CAVITY A (CKT2) OF CLOSED. "G" REPLACE 20 AMP IN­
NG CONTROL RELAY. REPAIR OPEN OR IGNITION "OFF" LINE FUSE OR REPAIR
IS 12 VOLTS PRESENT? POOR GROUND DISCONNECT FUEL OPEN IN CKT120 FROM
CIRCUITS. FROM CNG SUPPLY RELAY CAVITY D OF NG
CONTROL RELAY CONNECTOR POWER CONTROL
CAVITY F (CKT920) PROBE CAVITY F (CKT RELAY TO CAVITY E
THROUGH REAR LAMP 465) AND GROUND. OF FUEL SUPPLY
HARNESS CONNECTOR IGNITION "O N" WATCH RELAY.
(CKTS450/120) TO FUEL IF 12 VOLTS IS VERIFY FUEL SUPPLY
FILL DOOR SWITCH PRESENT FOR 2 RELAY CIRCUIT
(CKTS 450/921). SECONDS. OPERATION.
CHECK CONTINUITY OF IS 12 VOLTS PRESENT?
FUEL FILL DOOR
SWITCH. ADJUST OR
REPLACE.
REPAIR OPEN OR
POOR GROUND TO
ENGINE INTAKE
MANIFOLD GROUND.
VERIFY FUEL SUPPLY
YES
CIRCUIT OPERATION.

(CONT.) (CONT.) 7S 3805-6E-CNG

 CHART A-5
CNG FUEL SUPPLY RELAY
CIRCUIT DIAGNOSIS
5.7L NATURAL GAS POWERED
TRUCK WITH 4L60 TRANSMISSION
(CONT.)

YES NO YES NO
n z
® IGNITION "OFF". • CHECK OR REPLACE 15 • IGNITION "OFF" PROBE • CHECK ECM
RECONNECT CNG AMP IN-LINE FUSE CAVITYS D (CKT 450) CONNECTOR PIN
CONTROL RELAY. (NEXT TO CNG AND F (CKT 465) TERMINAL A1 FOR
VERIFY VOLTAGE AT CONTROL RELAY), OR • IGNITION "O N" WATCH GOOD CONTACT.
CAVITY B (CKT440B) 5 REPAIR CKT FROM IF 12 VOLTS IS • REPAIR OPEN CIRCUIT
AMP FUSE (LOCATED CNG CONTROL RELAY PRESENT FOR TWO BETWEEN CAVITY F
BETWEEN PRESSURE CAVITY A TO SECONDS (CKT 465) FUEL
TRANSDUCER AND FIREWALL JUNCTION IS 12 VOLTS PRESENT? SUPPLY RELAY
LOW PRESSURE FUEL BLOCK B+ LUG. CONNECTOR AND PIN
SHUTOFF SOLENOID). • VERIFY FUEL SUPPLY A1 ECM CONNECTOR
IGNITION "ON". RELAY CIRCUIT OR REPLACE ECM.
VERIFY VOLTAGE FOR OPERATION. • VERIFY FUEL SUPPLY
2 SEC. CIRCUIT OPERATION.
IS 12 VOLTS PRESENT?

YES YES NO
I3 Z .T ..
• VERIFY VOLTAGE AT • CHECK AND REPLACE FUEL SUPPLY RELAY • IGNITION "OFF"
LOW PRESSURE SHUT- 5 AMP IN-LINE FUSE COIL IS DEFECTIVE • REPAIR OPEN GROUND
OFF SOLENOID OR REPAIR CIRCUIT REPLACE FUEL SUPPLY CKT 450C BETWEEN
HARNESS CONNECTOR 902 FROM FUSE RELAY AND VERIFY CAVITY D OF FUEL
CAVITY A (CKT440A) CAVITY A TO CNG FUEL SUPPLY RELAY SUPPLY RELAY
AND GOOD GROUND. CONTROL RELAY CIRCUIT OPERATION. CONNECTOR AND
• VERIFY VOLTAGE AT CAVITY E. IF ORIGINAL SYMPTOM INTAKE MANIFOLD
CAVITY A OF ALL FUEL • IF OK, REPLACE CNG WAS "ENGINE CRANKS GROUND LUG (G108)
CYLINDER (TANK) CONTROL RELAY. BUT WILL NOT RUN", LEFT BANK FRONT.
SOLENOID HARNESS • VERIFY FUEL SUPPLY CONTINUE TESTING • VERIFY FUEL SUPPLY
CONNECTORS (CKT440 CIRCUIT OPERATION. OIL PRESSURE CIRCUIT OPERATION.
C, E, or F) AND GOOD SWITCH.
GROUND. ENGINE AT NORMAL
• IS 12 VOLTS PRESENT? OPERATING
TEMPERATURE.
OIL PRESSURE
NORMAL.
DISCONNECT FUEL
SUPPLY RELAY.
ENGINE SHOULD
CONTINUE TO RUN.
DOES IT?

(CONT.) (CONT.)
 CHART A-5
CNG FUEL SUPPLY RELAY
CIRCUIT DIAGNOSIS
5.7L NATURAL GAS POWERED
TRUCK WITH 4L60
TRANSMISSION (CONT.)
C O M P U T E R C O M M A N D C O N T R O L 3-35
 NATURAL GAS VEHICLE

LOW PRESSURE FUEL

SHUT-OFF SOLENOID CNG FUEL CYLINDERS

TRANSDUCER CUT-OFF SWITCH

8S 4331-6E-CNG

CHART A-6
FUEL SYSTEM DIAGNOSIS
WITH 5.7L CNG ENGINE
Circuit D escription:
W h e n th e 1/4 t u r n s h u t - o f f v a l v e is o p e n a n d th e e n g in e is r u n n in g , C o m p r e s s e d N a t u r a l G a s ( C N G )
f lo w s fro m th e C N G fu e l c y lin d e r s , t h r o u g h th e fu e l c y lin d e r s o le n o id v a l v e s in t o th e s t a in l e s s ste e l fu e l
lin e s . C N G t h e n flo w s t h r o u g h th e o p e n 1/4 t u r n s h u t-o ff v a lv e , th e fu e l p r e s s u r e tr a n d u c e r, t h e C N G fu e l
p r e s s u r e r e g u la t o r a n d th e lo w p r e s s u r e s h u t - o f f s o le n o id to th e C N G fu e l in je cto rs.

F u e l C y lin d e r S o le n o id V a lv e s — E le c t r ic CNG F u e l P re ssu re R e g u la t o r — M a in t a in s

s o le n o id s t h a t c o n t r o l t h e g a s s u p p l y f r o m th e sp e c ific C N G fu e l p r e s s u r e , a p p r o x im a t e ly 1 2 0 7
C N G f u e l c y lin d e r s . S o l e n o id s a r e c lo s e d w i t h k P a (175 p s i) to t h e C N G fu e l in je c to rs.
th e ig n it io n o ff o r open w it h th e e n g in e Low P re ssu re S h u t - O f f S o le n o id — E le c t ric
ru n n in g . s o le n o id lo c a t e d a t th e N G fu e l p r e s s u r e
1/4 T u r n S h u t - O f f V a l v e — M a n u a l n atu ral gas r e g u la t o r . C o n t r o l s s u p p l y to t h e in j e c t o r s .
v a l v e lo c a te d i n th e fu e l lin e . S o le n o id is c lo se d w it h th e i g n i t i o n o ff o r o p e n
F u e l P re ssu re T ra n sd u c e r — M e a s u r e s th e w h e n th e e n g in e is r u n n in g .
p r e s s u r e o f fu e l i n th e C N G fu e l c y lin d e r s a n d C N G F u e l In j e c t o r s — S p e c ia l fu e l in j e c t o r s
s i g n a l s t h e fu e l le v e l g a g e . d e s ig n e d s p e c if ic a lly fo r c o m p re s s e d n a t u r a l g a s.
T e s t D e s c r ip t io n : N u m b e r ( s ) b e lo w re fe r to
c irc le d n u m b e r ( s ) o n th e d ia g n o s t ic ch a rt.
1. P r e s s u r e m e a s u r e m e n t s fa ll in to th re e a re as:
• Z e r o k P a ( 0 p s i ) - a z e r o k P a (0 p s i )
p r e s s u r e r e a d i n g w it h t h e k e y “O N ”, a n d
t h e lo w p r e s s u r e f u e l s h u t - o f f s o le n o id a n d
fu e l c y lin d e r s o le n o id v a lv e s o p e r a t in g
( c l i c k i n g w h e n t h e k e y i s t u r n e d “O N ”),
i n d i c a t e s a r e s t r ic t i o n to f u e l flo w t h r o u g h
t h e C N G fu e l p r e s s u r e re g u la to r.
• B e l o w 11 4 7 k P a (1 6 6 p s i) a n d a b o v e z e ro -
A S t e a d y p r e s s u r e r e a d i n g a b o v e ze ro k P a
(0 p s i ) a n d b e l o w 1 1 4 7 k P a (1 6 6 p s i )
in d ic a t e s a n o p e r a t io n a l c o n tro l p ro b le m
w it h th e C N G fu e l p r e s s u r e r e g u la t o r .
S y s t e m w i l l b e le a n r u n n i n g a n d m a y s e t
C o d e 4 4 . A l s o h a r d s t a r t i n g c o ld a n d p o o r
o v e r a ll p e rfo rm a n c e .
• A b o v e 1 2 6 7 k P a (1 8 4 p s i) - A s t e a d y
p r e s s u r e r e a d in g a b o v e 1 2 6 7 k P a (184 p s i) -
i n d i c a t e s a n o p e r a t io n a l p r o b le m w i t h t h e
C N G f u e l p r e s s u r e r e g u la t o r . S y s t e m m a y
b e r ic h r u n n i n g a n d m a y se t a C o d e 45.
E n g i n e c o u ld id le p o o r ly o r s t a l l a t i d le i n
D r i v e g e a r.
2. A p p l y i n g fu se d 12 v o lt s to A L D L te st t e r m in a l
G , a llo w s s y s t e m fu e l p r e s s u r e t e s t in g to o c c u r
w h ile k e e p i n g th e s o le n o id s i n th e fu e l s y s t e m
e n e rg iz e d . T h i s a llo w s fo r a c c u ra te fu e l p r e s s u r e
g a g e re a d in g s .
D ia g n o stic A id s:
• I f t h e f o u r f u e l s y s t e m s o le n o id v a l v e s d o n o t
o p era te, re fe r to C h a r t A - 5 “F u e l S u p p ly R e l a y
C i r c u i t D i a g n o s i s ” i n S e c t io n “3 ” fo r t e s t in g a n d
m a k i n g re p a irs .
• F u e l s y s t e m i s u n d e r h i g h p r e s s u r e , r e f e r to
p r o c e d u r e s i n “F u e l C o n t r o l ” S e c t i o n “4 ” f o r
t e s t i n g p ro c e d u re s o r m a k i n g r e p a ir s r e q u i r in g
d is a s s e m b l y o f fu e l lin e s o r fitt in g s .
• 1/4 t u r n fu e l s h u t - o f f v a l v e s h o u ld b e i n th e f u ll
“O P E N ” p o s i t i o n w hen p e r fo r m in g th e fu e l
p r e s s u r e test.
C A U T IO N :
• DO NOT SMOKE when servicing any part
of the fuel system.
• Natural gas is toxic when concentrated in
a s m a ll a re a . A lw a y s w o rk in a w e ll-
ventilated area when releasing natural gas
fuel into the air. If possible, release as
much fuel pressure as you can outside of
the shop.
• Alw ays w o rk aw ay from open flam es or
sparks. Do not w e ld or carry an open
flam e near the fuel system if you sm ell
gas or otherwise suspect a leak.
• Compressed natural gas fuel systems are
under extremely high pressure at all times.
W h e n e ve r w o rk in g on a hig h -p ressu re
com ponent, alw ays relieve pressure by
slightly loosening the component.
• W h e n w o r k in g on a l o w - p r e s s u r e
component, always shut off fuel pressure
at the manual shut-off valve first.
• W hen replacing th re a d ed co m p o n e n ts ,
a lw a y s a p p ly SW AK® A n a e ro b ic Pipe
Sealant or an equivalent sealer to the new
com ponent threads except com pression
fittings.
• As w ith any vehicle, always route vehicle's
exhaust outside the shop if you need to
run the engine.
• Facilities using open flame heaters must
have a w a y of v en tin g th e n a tu ra l gas
outside to prevent ignition of the natural
gas. Remember natural gas rises quickly.
 CHART A-6
FUEL SYSTEM DIAGNOSIS
WITH 5.7L CNG ENGINE
 ECM

CODE 13
OXYGEN (0 2) SENSOR CIRCUIT
(O P E N CIR C U IT )
5.7L CNG ENGINE WITH 4L60 TRANSMISSION
Circuit D escription:
T h e E C M a p p lie s a b ia s v o lt a g e o f a p p r o x im a t e ly 4 5 0 m illiv o lt s (3 5 0 -5 5 0 m V is n o r m a l b ia s v o lt a g e ) b e tw e e n
t e r m in a ls " D 7 ” a n d " D 6 ”. T h e O x y g e n ( O 2 ) s e n s o r v a r ie s the v o lta g e w it h in a r a n g e o f a b o u t 1 v o lt i f th e e x h a u s t
is ric h , a n d d o w n t h r o u g h a b o u t .010 v o lt if e x h a u s t is lean. C o d e 13 is set w h e n th e v o lt a g e d o e s n o t v a r y o n C K T
4 1 2 w it h in a p r e d e t e r m in e d a m o u n t o f tim e.
T h e s e n s o r is lik e a n o p e n c ir c u it a n d p ro d u c e s n o v o lta g e w h e n it is b e lo w 3 1 5 ° C (6 0 0° F ). A n open se n so r
c irc u it, o r a co ld s e n s o r c a u s e s " O p e n L o o p ” o p e ra tio n .

Test D escrip tion :T e st D escription: N u m b e r(s) 5. I f th e fu se w a s o p e n , c h e c k t h e E C M w ir in g

b e lo w re fe r to c ir c le d n u m b e r ( s ) o n th e d i a g n o s t ic d ia g r a m fo r c o m p le te w i r i n g c irc u it.
ch a rt.
1. C o d e 13 w ill set: D ia g n o stic A id s:
• E n g in e h a s been r u n n in g lo n g e r th a n 2
m in u te s. I f the o x y g e n s e n s o r h e a t e r s a r e n o t o p e r a t i n g
• E n g i n e c o o la n t t e m p e ra t u re g r e a te r t h a n 70°C p r o p e r ly , s y s t e m m a y g o i n t o " O p e n L o o p ” a f t e r
(158°F). e x te n d e d idle.
• T h r o t t le p o s it io n s e n s o r s ig n a l h a s b e e n a b o v e N o r m a l T e c h 1 " S c a n ” tool v o lt a g e v a r ie s b e tw e e n
5 % fo r 6 0 s e c o n d s o r lo n g e r. 10 0 m V to 1 0 0 0 m V (.1 a n d 1.0 volt), w h ile in " C lo s e d
• O 2 s ig n a l v o lt a g e s te a d y b e tw e e n .35 a n d .55 L o o p .” C o d e 13 se ts in o n e m in u t e if v o lt a g e r e m a in s
volt. b e tw e e n .35 a n d .55 vo lt, h o w e v e r th e s y s t e m w ill g o
I f t h e c o n d i t i o n f o r a C o d e 13 e x i s t s , t h e " O p e n L o o p ” in a b o u t 15 se c o n d s.
s y s t e m w i l l n o t g o in t o “C lo s e d L o o p . ” R e f e r to " I n t e r m i t t e n t s ” i n " D r i v e a b i l i t y
2. T h i s te st c h e c k s t h e o x y g e n s e n s o r ’s h e a t i n g S y m p t o m s , ” S e c t io n " 2 ” .
ele m ent. T h e h e a t in g e le m e n t re s is t a n c e s h o u ld A n o x y g e n s u p p ly in s id e th e O 2 s e n s o r is n e c e s s a r y
be 3.5 o h m s a t 2 0 ° C (6 8 °F ) o r 14 o h m s a t 3 5 0 ° C for p ro p e r O 2 s e n s o r o p e ra tio n . T h i s s u p p ly o f o x y g e n
(662°F). is s u p p lie d t h r o u g h th e O 2 s e n s o r w ire s. A l l O 2 s e n s o r
3. T h i s w ill d e t e rm in e i f th e s e n s o r is a t fa u lt. w ir e s a n d c o n n e c t io n s s h o u ld be in s p e c t e d fo r b r e a k s
4. F o r t h is te st u s e o n ly a h i g h im p e d a n c e D i g i t a l o r c o n t a m in a t io n th a t c o u ld p r e v e n t re fe re n c e o x y g e n
V o lt O h m m e te r ( D V M ) . T h i s t e s t c h e c k s th e fro m r e a c h in g th e O 2 se n s o r.
c o n t in u it y o f C K T 4 1 2 a n d C K T 413. I f C K T 4 1 3 is
open, the E C M v o lt a g e o n C K T 4 1 2 w ill be o v e r
.6 v o lt (6 0 0 m V ).
 CODE 13
OXYGEN (0 2) SENSOR CIRCUIT
(O P E N C IR C U IT )
5.7L CNG ENGINE WITH 4L60 TRANSMISSION

1-16-91
 COOLANT TEMPERATURE
SENSOR

ECM

COOLANT SENSOR
SIGNAL

5 VOLT
410 YEL C10 MAAT

452 BLK { dT — I SENSOR

I GROUND
— 4-30-91
7S 3690-6E-CNG

CODE 14
COOLANT TEMPERATURE SENSOR (CTS) CIRCUIT
(HIGH TEMPERATURE INDICATED)
5.7L CNG ENGINE WITH 4L60 TRANSMISSION
Circuit Description:
T h e C o o la n t T e m p e r a t u r e S e n s o r ( C T S ) is a t h e r m is t o r th a t c o n tro ls th e s ig n a l v o lt a g e to the E C M . T h e
E C M a p p lie s a v o lt a g e o n C K T 4 1 0 to th e s e n s o r. W h e n the e n g in e is cold, th e s e n s o r ( t h e r m is t o r ) r e s is t a n c e is
h ig h , th e re fo re th e E C M w ill see h i g h s ig n a l v o lta g e .
A s th e e n g in e w a r m s , th e s e n s o r r e s is t a n c e b e c o m e s le ss a n d the v o lta g e d ro p s. A t n o r m a l e n g in e o p e r a t in g
te m p e r a t u r e (8 5 °C to 95°C), th e v o lt a g e w ill m e a s u r e a b o u t 1.5 to 2.0 volts.

Test Description: N u m b e r ( s ) b e lo w re fe r to c irc le d Diagnostic Aids:

n u m b e r ( s ) o n th e d ia g n o s t ic c h a rt.
1. C h e c k s to see i f code w a s se t a s r e s u lt o f a h a r d C h e c k h a r n e s s r o u t i n g fo r a p o t e n t ia l s h o r t to
f a ilu r e o r in t e r m it t e n t c o n d itio n . g r o u n d in C K T 410.
• C o d e 14 w ill se t if: T e c h 1 " S c a n ” tool d i s p la y s e n g in e t e m p e r a t u r e in
S i g n a l v o lt a g e in d ic a t e s a c o o la n t d e g r e e s c e n t ig r a d e . A f t e r e n g in e is s t a r t e d , th e
te m p e ra tu re a b o ve 135°C (2 7 0 ° F ) fo r 6 te m p e ra t u re s h o u ld ris e s t e a d ily to a b o u t 9 0 ° C t h e n
se co n d s. s ta b iliz e w h e n t h e r m o s t a t o p en s.
2. T h i s te st s im u la t e s c o n d it io n s fo r a C o d e 15. I f the R e f e r to " E C M In t e r m it t e n t C odes or
E C M re c o g n iz e s th e o p e n c ir c u it ( h ig h v o lt a g e ) a n d P e r f o r m a n c e ” in " D r i v e a b i l i t y S y m p t o m s , ” S e c t io n
d i s p la y s a lo w te m p e ra t u re , th e E C M a n d w ir in g " 2” .

a re O K . T h e "T e m p e r a t u r e to R e s is t a n c e V a l u e ” s c a le a t
the r ig h t m a y be u se d to te st th e c o o la n t s e n s o r a t
v a r io u s te m p e ra t u re le v e ls to e v a lu a t e th e p o s s ib ilit y
o f a " s k e w e d ” (m is -s c a le d ) se n s o r. A " s k e w e d ” s e n s o r
c o u ld r e s u lt in p o o r d r i v e a b il it y c o m p la in t s .
 CODE 14
COOLANT TEMPERATURE SENSOR (CTS) CIRCUIT
(L O W T E M P E R A T U R E IN D IC A T E D )
5.7L CNG ENGINE WITH 4L60 TRANSMISSION

D IA G N O S T IC A ID
COOLANT SENSOR
TEMPERATURE VS. RESISTANCE VALUES
(APPROXIMATE)
°C °F OHMS
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
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700
 CODE 15
COOLANT TEMPERATURE SENSOR (CTS) CIRCUIT
(L O W T E M P E R A T U R E IN D IC A T E D )
5.7L CNG ENGINE WITH 4L60 TRANSMISSION
Circuit D escription:
T h e C o o la n t T e m p e r a t u r e S e n s o r ( C T S ) is a t h e r m is t o r th a t c o n tro ls th e s ig n a l v o lt a g e to th e E C M . T h e
E C M a p p lie s a v o lt a g e o n C K T 4 1 0 to th e se n so r. W h e n the e n g in e is cold, th e s e n s o r ( t h e r m is t o r ) r e s is t a n c e is
h ig h , th e re fo re th e E C M w ill see h ig h s ig n a l vo lta ge .
A s th e e n g in e w a r m s , th e s e n s o r re s is t a n c e b e c o m e s le ss a n d the v o lt a g e d ro p s. A t n o r m a l e n g in e o p e r a t in g
t e m p e ra t u re (8 5 °C to 95°C), th e v o lt a g e w ill m e a s u r e a b o u t 1.5 to 2.0 volts.

Test D escrip tion: N u m b e r ( s ) b e lo w re fe r to c irc le d D ia g n o stic A id s:

n u m b e r ( s ) o n th e d ia g n o s t ic ch a rt.
1. C h e c k s to see i f code w a s set a s r e s u lt o f a h a r d
f a ilu r e o r in t e r m it t e n t co n d itio n .
• C o d e 15 w ill set if:
S i g n a l v o lt a g e in d ic a t e s a c o o la n t
t e m p e r a t u r e le s s t h a n -3 3 °C (-27 ° F ) fo r 30
se co n d s.
2. T h i s t e s t s i m u l a t e s a C o d e 14. I f th e E C M
r e c o g n i z e s th e lo w s i g n a l v o l t a g e ( h i g h
te m p e ra tu re ), a n d the T e c h 1 " S c a n ” r e a d s 130°C
A T e c h 1 " S c a n ” tool re a d s e n g in e te m p e r a t u r e in
d e g r e e s c e n t ig r a d e . A f t e r e n g in e is s ta rt e d , th e
te m p e ra tu re s h o u ld r is e s t e a d ily to a b o u t 9 0 ° C t h e n
s ta b iliz e w h e n t h e r m o s t a t op en s.
A fa u lty c o n n e c tio n , o r a n o p e n in C K T s 4 1 0 o r 4 5 2
w ill r e s u lt in a C o d e 15.
R e f e r to " E C M In t e r m it t e n t Codes on
P e r f o r m a n c e ” in " D r i v e a b i l i t y S y m p t o m s , ” S e c t i o n
" 2” .

(2 6 6 ° F ) o r a b o ve , th e E C M a n d w i r i n g a re O K .
3. T h i s te st w ill d e t e rm in e i f C K T 4 1 0 is open. T h e r e
s h o u ld be 5 v o lt s p r e s e n t a t s e n s o r c o n n e c t o r i f
m e a s u r e d w it h a D V O M . T h i s w ill d e t e rm in e if
th e re is a w i r i n g p ro b le m o r a f a u lt y E C M .
T h e " T e m p e r a t u r e T o R e s is t a n c e V a l u e ” s c a le a t
the r ig h t m a y be u s e d to te st th e c o o la n t s e n s o r a t
v a r io u s te m p e ra t u re le v e ls to e v a lu a t e th e p o s s ib ilit y
o f a " s k e w e d ” (m is -sc a le d ) se n s o r. A " s k e w e d ” s e n s o r
c o u ld r e s u lt in p o o r d r iv e a b il it y c o m p la in t s .
 CODE 15
COOLANT TEMPERATURE SENSOR (CTS) CIRCUIT
(L O W T E M P E R A T U R E IN D IC A T E D )
5.7L CNG ENGINE WITH 4L60 TRANSMISSION

D IA G N O S T IC A ID
COOLANT SENSOR
TEMPERATURE VS. RESISTANCE VALUES
(APPROXIMATE)
°C °F OHMS
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
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
-15 5 21450
-20 -4 28680
-30 -22 52700
-40 -40 100700

4-12-91
 ECM

5 VOLTS
C14 - V W W - REFERENCE

C13 TPS SIGNAL

D2 SENSOR GROUND

5-30-90
7S 3691-6E-CNG

CODE 21
THROTTLE POSITION SENSOR (TPS) CIRCUIT
( S IG N A L V O L T A G E H IG H)
5.7L CNG ENGINE WITH 4L60 TRANSMISSION
Circuit D escrip tion:
T h e T h r o t t le P o s it io n S e n s o r ( T P S ) p r o v id e s a v o lt a g e s ig n a l th a t c h a n g e s re la t iv e to th e t h ro tt le b la d e a n g le
S i g n a l v o lt a g e w ill v a r y fro m a b o u t .5 v o lt a t id le to a b o u t 4.0 v o lt s a t W id e O p e n T h r o t t le ( W O T ) .
T h e T P S s ig n a l is o n e o f th e m o s t im p o r t a n t in p u t s u se d b y the E C M fo r fu e l c o n tro l a n d fo r m o s t o f th e E C M
c o n tro l o u tp u ts.
O n n o n a d ju s ta b le T P S s w it c h e s , e a c h tim e v o lt a g e d ro p s b e low 1.25 v o lt s a n d sto p s, th e E C M a s s u m e s t h is
v a lu e is 0 th ro ttle a n g le a n d m e a s u r e s p e rc e n t th ro tt le fro m t h is p o in t on.

T est D escrip tion: N u m b e r ( s ) b e lo w re fe r to c irc le d D ia g n o stic A id s:

n u m b e r ( s ) o n the d ia g n o s t ic c h a rt.
1. T h i s ste p c h e c k s to see if C o d e 21 is the r e s u lt o f a
h a r d f a ilu r e o r a n in t e r m it t e n t c o n d itio n .
• C o d e 21 w ill se t if:
E n g i n e r u n n in g .
T P S s ig n a l v o lt a g e is g r e a t e r t h a n a b o u t
2.5 vo lts.
M A P s e n s o r le s s t h a n 2 vo lts.
A l l c o n d it io n s m e t fo r 8 se co n d s.
W i t h th ro tt le clo sed , the T P S s h o u ld re a d le s s t h a n
1.25 vo lts. R e f e r to " D i a g n o s t ic A i d s . ”
2. W i t h th e T P S s e n s o r d isc o n n e c te d , the T P S v o lt a g e
s h o u ld go lo w i f th e E C M a n d w i r i n g is O K .
3. P r o b i n g C K T 4 5 2 w it h a te st lig h t c h e c k s th e 5 v o lt
r e t u r n c irc u it. T h i s ste p is o la t e s a f a u lt y s e n s o r
E C M o r a n o p e n C K T 452.
A T e c h 1 " S c a n ” tool r e a d s t h r o t t le p o s it io n in
volts. S h o u ld re a d a b o u t .45 to .95 v o lt w it h th ro tt le
clo se d a n d ig n it io n " O N ” o r a t idle. V o lt a g e s h o u ld
in c re a s e a t a s te a d y ra te a s th ro ttle is m o v e d to w a r d
W id e O p e n T h r o t t le (W O T ) .
A ls o , so m e T e c h 1 " S c a n ” to o ls w ill re a d th ro ttle
a n g le .0% = c lo se d th ro ttle 1 0 0 % = W O T .
" S c a n ” tool T P S w h ile d e p r e s s in g a c c e le ra t o r p e d a l
w it h e n g in e sto p p e d a n d i g n i t i o n " O N . ” D i s p l a y
s h o u ld v a r y fro m b e lo w 1.25 v o lt s ( 1 2 5 0 m V ) w h e n
th ro ttle w a s clo sed, to o v e r 4.5 v o lt s (4 5 0 0 m V ) w h e n
th ro ttle is h e ld a t W id e O p e n T h r o t t le ( W O T ) p o sitio n .
A C o d e 21 w ill r e s u lt if C K T 4 5 2 is o p e n o r C K T
4 1 7 is s h o rte d to vo lta ge .
R e fe r to " D r i v e a b i l i t y S y m p t o m s , ” S e c t io n " 2 ” fo r
" E C M In t e r m it t e n t C o d e s o r P e r f o r m a n c e . ”
 CODE 21
THROTTLE POSITION SENSOR (TPS) CIRCUIT
( S IG N A L V O L T A G E H IG H )
5.7L CNG ENGINE WITH 4L60 TRANSMISSION

4-19-90
 ECM

C14 U A A A A ^ 5V0LTS
— v W V V - REFERENCE

C13 TPS SIGNAL

02 SENSORGROUND

5-30-90
7S 3691-6E-CNG

CODE 22
THROTTLE POSITION SENSOR (TPS) CIRCUIT
( S IG N A L V O L T A G E LO W )
5.7L CNG ENGINE WITH 4L60 TRANSMISSION
Circuit D escrip tion:
T h e T h r o t t le P o s it io n s e n s o r ( T P S ) p r o v id e s a v o lta g e s ig n a l th a t c h a n g e s r e la t iv e to th e th ro tt le blade.
S i g n a l v o lt a g e w ill v a r y fro m a b o u t .5 v o lt a t id le to a b o u t 4.0 v o lt s a t W id e O p e n T h r o t t le ( W O T ) .
T h e T P S s ig n a l is o n e o f the m o st im p o r t a n t in p u t s u se d b y the E C M fo r fu e l c o n tro l a n d fo r m o st o f th e E C M
c o n t r o l o u t p u t s e v e r y tim e v o lt a g e d r o p s b e lo w 1.25 v o lts a n d stops, the E C M a s s u m e s t h is v a lv e is 0 th ro ttle
a n g le a n d m e a s u r e s p e rc e n t th ro tt le fro m t h is p o in t on.

T est D escrip tion: N u m b e r ( s ) b e lo w re fe r to c irc le d D ia g n o stic A id s:

n u m b e r ( s ) o n th e d ia g n o s t ic c h a rt.
1. T h i s ste p c h e c k s to see i f C o d e 2 2 is th e r e s u lt o f a A T e c h 1 " S c a n ” tool r e a d s t h r o t t le p o s it io n in
h a r d f a ilu r e o r a n in t e r m it t e n t c o n d itio n . v o lts. S h o u ld re a d a b o u t .45 to .95 v o lt w it h th ro ttle
• C o d e 2 2 w ill se t if: c lo se d a n d ig n it io n " O N ” o r a t idle. V o lt a g e s h o u ld
E n g i n e r u n n in g . in c re a s e a t a s te a d y ra t e a s th ro tt le is m o v e d to w a r d
T P S s ig n a l v o lt a g e is le s s t h a n a b o u t .2 W id e O p e n T h r o t t le ( W O T ) .
v o lt for 2 seco n d s. A n o p en o r s h o r t to g r o u n d in C K T s 4 1 6 o r 4 1 7 w ill
2. S i m u la t e s C o d e 21: ( h ig h v o lta g e ) - I f th e E C M r e s u lt in a C o d e 22.
r e c o g n iz e s th e h i g h s ig n a l vo lta g e , th e E C M a n d R e fe r to " D r i v a b i l i t y s y m p t o m s , ” S e c t io n " 2 ” fo r
w i r i n g a re O K . " E C M In t e r m it t e n t C o d e s o r P e r fo r m a n c e . ”
3. T h e E C M re c o g n iz e s the v o lt a g e a s o v e r 4 v o lts, " S c a n ” T P S w h ile d e p r e s s i n g a c c e le r a t o r p e d a l
in d ic a t in g th e C K T 4 1 7 a n d th e E C M a re O K . w it h e n g in e s t o p p e d a n d i g n i t i o n " O N ” . D i s p l a y
4. T h i s s im u la t e s a h i g h s ig n a l v o lt a g e to c h e c k fo r s h o u ld v a r y fro m b e lo w 1.25 v o lt s ( 1 2 5 0 m V ) w h e n
a n o p e n in C K T 417. th ro ttle w a s clo sed , to o v e r 4.5 v o lt s ( 4 5 0 0 m V ) w h e n
5. I f C K T 4 1 6 is s h o r t e d to g r o u n d , th e re m a y a ls o be th ro ttle is h e ld a t W id e O p e n T h r o t t le ( W O T ) p o sitio n .
a s to re d C o d e 34.
 CODE 22
THROTTLE POSITION SENSOR
(TPS) CIRCUIT
(S IG N A L V O L T A G E L O W )
5.7L CNG ENGINE WITH 4L60
TRANSMISSION

1-23-91
 VEHICLE 822 LT GRN/BLK ECM
SPEED
SIGNAL (VSS)
TO ENGINE GROUND
VSS INPUT C7

GROUND C8 -450 BLK/WHT CNG-

IGNITION FEED C9 - W » - T O IGNITION

VEHICLE SPEED * SWITCH
SENSOR BUFFER C10
(DRAC) MODULE VSS SIGNAL
VSS OUTPUT C11 - 4 3 7 BRN
EH
VSS INPUT C12

C13

VSS OUTPUT C14

VSS OUTPUT C15 - 8 2 4 LT BLU/BLK- -►TO SPEEDO

PREFER TO ECM WIRING 4-30-91
DIAGRAM IN THIS SECTION. 821 PPL/WHT
7S 3302-6E-CNG

CODE 24
VEHICLE SPEED SENSOR (VSS) CIRCUIT FAULT
5.7L CNG ENGINE WITH 4L60 TRANSMISSION
Circuit D escrip tion:
T h e E C M a p p lie s a n d m o n it o r s 12 v o lt s o n C K T 437. C K T 4 3 7 c o n n e c ts to th e V e h ic le S p e e d S e n s o r ( V S S )
b u ffe r ( D R A C ) m o d u le , w h ic h a lt e r n a t e ly g r o u n d s C K T 437, w h e n r e c e iv in g v o lt a g e p u ls e s fro m V e h ic le S p e e d
S e n s o r ( V S S ) w h e n d r iv e w h e e ls a re t u r n in g . T h i s p u ls in g a c tio n t a k e s p la c e a b o u t 2 0 0 0 t im e s p e r m ile a n d th e
E C M w ill c a lc u la t e v e h ic le sp e e d b a s e d o n th e tim e b e tw e e n " p u ls e s . ”
A T e c h 1 " S c a n ” tool r e a d in g s h o u ld c lo s e ly m a t c h th e sp e e d o m e te r r e a d in g w it h d r iv e w h e e ls t u r n in g .

T e st D escrip tion: N u m b e r ( s ) b e lo w re fe r to c irc le d D ia g n o stic A id s:

n u m b e r ( s ) o n th e d ia g n o s t ic c h a rt.
1. C o d e 2 4 w ill se t if: 1. T e c h 1 " S c a n ” to o l r e a d in g s h o u ld c lo s e ly m a t c h
• C K T 4 3 7 v o lt a g e is c o n sta n t. sp e e d o m e te r re a d in g , w it h d r iv e w h e e ls t u r n in g .
• E n g i n e sp e e d is m o re t h a n 1 2 0 0 rp m . 2. C h e c k P a r k / N e u t r a l (P / N ) s w it c h d i a g n o s i s c h a r t
• V e h ic le sp e e d s ig n a l in d ic a t e s le s s t h a n 2 m p h if v e h ic le e q u ip p e d w it h a u t o m a t ic t r a n s m is s io n .
(3 k m /h ) o n T e c h 1. 3. I f P a r k / N e u t r a l (P / N ) s w it c h is O K , re fe r to " E C M
• A u t o m a t ic t r a n s m is s io n in d riv e . In t e r m it t e n t C o d e s o r P e r f o r m a n c e ” in
• A l l c o n d it io n s m u s t be m e t fo r 5 se co n d s. " D r i v e a b il it y S y m p t o m s , S e c t io n " 2 ” .
T h e s e c o n d it io n s a re m e t d u r i n g a ro a d lo a d
d e c e le r a t io n w h i c h s e t s o n a c c e le r a t io n o r a t
h i g h w a y speed.
2. T h i s te st d e t e r m in e s i f th e D R A C is r e c e iv in g th e
A / C s ig n a l fro m th e V S S .
3. T h i s te st m o n it o r s th e D R A C v o lt a g e o n C K T 437.
W i t h th e w h e e ls t u r n in g , th e p u l s in g a c t io n w ill
r e s u lt in a v a r y i n g v o lta g e . T h e v a r ia t io n w ill be
g r e a t e r a t lo w w h e e l sp e e d s to a n a v e r a g e o f 4 -6
v o lt s a t a b o u t 2 0 m p h (3 2 km /h).
 CODE 24
VEHICLE SPEED SENSOR (VSS)
CIRCUIT FAULT
5.7L CNG ENGINE WITH 4L60
TRANSMISSION

o RAISE DRIVE WHEELS.

NOTICE: DO NOT PERFORM THIS TEST WITHOUT SUPPORTING THE AXLE.
CRUISE CONTROL "OFF."
WITH ENGINE IDLING IN GEAR, "SCAN" TOOL SHOULD DISPLAY VEHICLE
SPEED ABOVE OMPH.
DOES IT?

NO YES
I X
DOES SPEEDOMETER WORK? CODE 24 IS INTERMITTENT. IF NO ADDITIONAL
CODES WERE STORED, REFER TO "DIAGNOSTIC
AIDS" ON FACING PAGE.

NO YES
u= nz
CONNECT TEST LIGHT ACROSS WITH D VO M ON 20 VOLT DC SCALE, BACKPROBE
©
CONNECTOR PIN "C8" AND "C9. CKT 437 AT DRAC FOR VOLTAGE VARIATION
IS THERE BATTERY VOLTAGE? WHILE DRIVE WHEELS STILL TURNING.
DOES IT VARY?

YES NO YES NO
m
© W ITH D VO M ON 20 VOLT A/C SCALE,
BACKPROBE ACROSS CKT 821 AND
CONNECT TEST LIGHT TO
AN ALTERNATE GROUND.
CKT 437 OPEN, FAULTY
CONNECTIONS. IF OK,
CKT 437 SHORTED TO
GROUND. FAULTY
CKT 822 AT DRAC. FOR VOLTAGE IS THERE VOLTAGE ON REPLACE ECM. CONNECTIONS. IF OK,
VARIATION WHILE DRIVE WHEELS PIN "C9." REPLACE DRAC.
STILL TURNING.
DOES IT VARY?

NO YES NO YES
m
CK T821 OR C K T822 FAULTY CONNECTIONS. REPAIR OPEN OR REPAIR OPEN IN GROUND
OPEN. SHORTED TO IF OK, REPLACE DRAC. SHORT TO GROUND CIRCUIT TO PIN "C8."
GROUND, SHORTED IN BATTERY FEED
TOGETHER, OR HAS CIRCUIT TO PIN "C9."
FAULTY
CONNECTIONS. IF
OK. REPLACE VSS.

6-18-90
MS 9231-6E-CNG
 CODE 33
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT
( S IG N A L V O L T A G E H IG H - L O W V A C C U M )
5.7L CNG ENGINE WITH 4L60 TRANSMISSION
Circuit D escription:
T h e M a n if o ld A b s o lu t e P r e s s u r e ( M A P ) s e n s o r re s p o n d s to c h a n g e s in m a n if o ld p r e s s u r e (v a c u u m ). T h e E C M
r e c e iv e s t h is in f o r m a t io n a s a s ig n a l v o lt a g e th a t w ill v a r y fro m a b o u t 1-1.5 v o lt s a t c lo se d th ro ttle (id le ) to 4 -4 .6
v o lt s a t W id e O p e n T h r o t t le ( W O T ) (lo w v a c u u m ).
I f the M A P s e n s o r fa ils, th e E C M w ill s u b s t it u t e a fixe d M A P v a lu e a n d u s e th e T h r o t t le P o s it io n S e n s o r
( T P S ) to c o n tro l fu e l d e liv e ry .

Test D escrip tion: N u m b e r ( s ) b e lo w re fe r to c irc le d
n u m b e r ( s ) o n the d ia g n o s t ic c h a rt.
1. T h i s ste p w ill d e t e r m in e if C o d e 3 3 is th e r e s u lt o f
a h a r d fa ilu r e o r a n in t e r m it t e n t c o n d itio n .
A C o d e 3 3 w ill se t u n d e r th e f o llo w in g c o n d it io n s:
• M A P s ig n a l v o lt a g e is too h i g h (lo w v a c u u m ).
• T P S le s s t h a n 4 % .
• T h e s e c o n d it io n s e x is t lo n g e r t h a n 5 se co n d s.
• E n g i n e m is f ir e o r a lo w u n s t a b le id le m a y se t
C o d e 33.
2. T h i s s te p s im u la t e s c o n d it io n s fo r a C o d e 3 4 . I f
t h e E C M r e c o g n iz e s t h e c h a n g e , t h e E C M a n d
C K T 4 1 6 a n d C K T 4 3 2 a r e O K . I f C K T 4 5 5 is
open , t h e r e m a y a ls o b e a s to re d C o d e 23.
D ia g n o s tic A id s:
A Code 33 will result if CKT 455 is open or if
CKT 432 is shorted to voltage or to CKT 416.
I f C o d e 3 3 is in te rm it te n t, re fe r to " D r i v e a b i l i t y
S y m p t o m s / ’ S e c t io n " 2 ”.
• C h e c k a ll c o n n e c tio n s.
• D is c o n n e c t s e n s o r fro m b r a c k e t a n d t w is t s e n s o r
co n n e ctio n s. O u t p u t c h a n g e s g r e a t e r t h a n .1 v o lt
in d ic a te s a b a d c o n n e c t o r o r c o n n e c tio n . I f O K ,
rep la ce se n so r.
N O TICE: M a k e s u r e e le c tr ic a l c o n n e c t o r r e m a in s
se c u re ly faste n e d .
• R e f e r to " M A P O u t p u t C h e c k ” i n " C o m p u t e r
C o m m a n d C o n t r o l,” S e c t io n " 3 ” fo r f u r t h e r
d ia g n o s is .

W i t h th e i g n it io n " O N ” a n d th e e n g in e s to p p e d ,
th e m a n ifo ld p r e s s u r e is e q u a l to a t m o s p h e r ic p r e s s u r e
a n d the s ig n a l v o lt a g e w ill be h ig h . T h i s in f o r m a t io n
is u s e d b y th e E C M a s a n in d ic a t io n o f v e h ic le a ltitu d e .
C o m p a r is o n o f t h is r e a d in g w it h a k n o w n g o o d v e h ic le
w it h th e s a m e s e n s o r is a g o o d w a y to c h e c k a c c u r a c y
o f a " s u s p e c t ” se n s o r. R e a d in g s s h o u ld be th e s a m e +
.4 volt.
 CODE 33
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR CIRCUIT
( S IG N A L V O L T A G E H IG H - L O W V A C U U M )
5.7L CNG ENGINE WITH 4L60
TRANSMISSION

7-14-90
 M AP SENSOR m
ECM
m m
H j £

\
MANIFOLD
432 LTGRN
OR LT GRN/BLK
£ 7 7 M AP SIGNAL
ABSOLUTE
PRESSURE 5.7L CNG
(VA CU UM ) SENSOR
GROUND

5-7-91
7S 3697-6E-CNG

CODE 34
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT
( S IG N A L V O L T A G E L O W - H IG H V A C C U M )
5.7L CNG ENGINE WITH 4L60 TRANSMISSION
Circuit D escription:
T h e M a n if o ld A b s o lu t e P r e s s u r e ( M A P ) s e n s o r re s p o n d s to c h a n g e s in m a n ifo ld p r e s s u r e (v a c u u m ). T h e E C M
r e c e iv e s t h is in f o r m a t io n a s a s ig n a l v o lt a g e t h a t w ill v a r y fro m a b o u t 1-1.5 v o lt s a t id le to 4 -4 .6 v o lt s a t W id e
O p e n T h r o t t le ( W O T ) .
A T e c h 1 " S c a n ” tool d is p la y s m a n if o ld p r e s s u r e in volts. L o w p r e s s u r e ( h ig h v a c u u m ) re a d s a lo w v o lt a g e
w h ile a h ig h p r e s s u r e (lo w v a c u u m ) r e a d s a h i g h v o lta g e .
I f th e M A P s e n s o r f a ils th e E C M w ill s u b s t it u t e a fix e d M A P v a lu e a n d u se th e T h r o t t le P o s it io n S e n s o r ( T P S )
to c o n t ro l fu e l d e liv e ry .

T est D escrip tion: N u m b e r ( s ) b e lo w re fe r to c irc le d W i t h the ig n it io n " O N ” a n d th e e n g in e " O F F , ” th e

n u m b e r ( s ) o n th e d ia g n o s t ic c h a rt.
1. T h i s ste p d e t e r m in e s if C o d e 3 4 is th e r e s u lt o f a
h a r d f a ilu r e o r a n in t e r m it t e n t c o n d itio n . A C o d e
3 4 w ill se t w he n:
• W h e n e n g in e is le s s t h a n 1 2 0 0 rp m .
• M a n if o ld p r e s s u r e r e a d in g le s s t h a n 14 k P a ,
c o n d it io n s m e t fo r 1 secon d.
OR
• E n g i n e sp e e d is g r e a t e r t h a n 1 2 0 0 rp m .
• T h r o t t le a n g le o v e r 2 1 % .
• M a n if o ld p r e s s u r e le s s t h a n 14 k P a , c o n d it io n s
m e t fo r 1 second.
2. J u m p e r i n g h a r n e s s t e r m in a ls " B ” to " C ” (5 v o lt s to
s ig n a l c irc u it ) w ill d e t e r m in e i f th e s e n s o r is a t
fa u lt, o r i f th e re is a p r o b le m w it h th e E C M o r
w ir in g .
3. T h e T e c h 1 " S c a n ” tool m a y n o t d is p la y 5 v o lts.
T h e im p o r t a n t t h in g is th a t th e E C M re c o g n iz e d
th e v o lt a g e a s m o re t h a n 4 v o lts, in d ic a t in g th a t
th e E C M a n d C K T 4 3 2 a re O K .
D ia g n o s tic A id s:
m a n ifo ld p r e s s u r e is e q u a l to a t m o s p h e r i c p r e s s u r e
a n d the s ig n a l v o lt a g e w ill be h ig h . T h i s in f o r m a t io n
is u se d b y th e E C M a s a n in d ic a t io n o f v e h ic le a ltitu d e .
C o m p a r is o n o f t h is r e a d i n g w it h a k n o w n g o o d
v e h ic le w it h th e s a m e s e n s o r is a g o o d w a y to c h e c k
a c c u ra c y o f a " s u s p e c t ” s e n so r. R e a d in g s h o u ld be th e
s a m e ± .4 volt. A ls o , M A P o u t p u t c h e c k in " C o m p u t e r
C o m m a n d C o n t r o l, ” S e c t io n " 3 ” c a n be u s e d to te st th e
M A P se n so r.
R e f e r to " I n t e r m i t t e n t s , ” i n " D r i v e a b i l i t y
S y m p t o m s , ” S e c t io n " 2 ”.
• D is c o n n e c t s e n s o r fr o m b r a c k e t a n d t w is t se n so r
b y h a n d ( o n l y ) to c h e c k f o r i n t e r m it t e n t
c o n n e c tio n s. O u t p u t c h a n g e s g r e a t e r t h a n .1 v o lt
in d ic a t e s a b a d c o n n e c t o r o r c o n n e c tio n . If O K ,
re p la ce se n so r.
NO TICE: M a k e s u r e e le c t r ic a l c o n n e c t o r r e m a in s
s e c u re ly fa ste n e d .
R e f e r to " M A P O u t p u t C h e c k ” in "C o m p u te r
C o m m a n d C o n t r o l, ” S e c t io n " 3 ” fo r f u r t h e r d ia g n o s is .

A n in t e r m it t e n t o p e n in C K T 4 3 2 o r C K T 4 1 6 w ill
r e s u lt in a C o d e 34.
 CODE 34
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT
(S IG N A L V O L T A G E L O W - H IG H V A C C U M )
5.7L CNG ENGINE WITH 4L60 TRANSMISSION

5-1-90
 PICK-UP
PR COIL
CONN
IGN
cz o
CONN k + c G B R E
IGNITION COIL
CONNECTOR
TACH
uu numi ECM

GRY — IGN
CONN J
------------------------------------------- , r A
B ll
B
•423 W HT* 04 EST OUTPUT
r N BLK ■430 P P L/W H T - 85 REFERENCE HIGH
| I CONN SET TIMING
CONNECTOR
l. L -1 ------ « ------ 424 T A N /B L K - 0 5 BYPASS CONTROL
TO 453 BLK/RED— B3
•INSTRUMENT REFERENCE LOW
PANEL

GRYCONN 5.7L CNG ENGINE 5-20-91

TACH LEAD 7S 3700-6E-CNG

CODE 42
ELECTRONIC SPARK TIMING (EST)
5.7L CNG ENGINE WITH 4L60 TRANSMISSION
T e st D escrip tion: N u m b e r ( s ) b e lo w re fe r to c irc le d 4. T h e m o d u le d id n o t s w it c h a n d t h is s te p c h e c k s for:
n u m b e r ( s ) o n th e d ia g n o s t ic c h a rt. • E S T C K T 4 2 3 s h o r t e d to g r o u n d .
1. C o d e 4 2 m e a n s th e E C M h a s se e n a n o p e n o r s h o r t • B y p a s s C K T 4 2 4 open.
to g r o u n d in th e E S T o r b y p a s s c irc u it s . T h i s te st • F a u l t y i g n i t i o n m o d u le c o n n e c t io n o r m o d u le .
c o n f ir m s C o d e 4 2 a n d th a t th e f a u lt c a u s i n g th e 5. C o n f ir m s th a t C o d e 4 2 is a f a u lt y E C M a n d n o t a n
code is p re se n t. in t e rm it t e n t i n C K T s 4 2 3 o r 4 24.
2. C h e c k s fo r a n o r m a l E S T g r o u n d p a t h t h r o u g h th e
ig n it io n m o d u le . A n E S T C K T 4 2 3 s h o r t e d to D ia g n o stic A id s:
g r o u n d w ill a ls o re a d le s s t h a n 5 0 0 o h m s ; h o w e v e r,
t h is w ill be c h e c k e d later. T h e T e c h 1 d o e s n o t h a v e a n y a b i l i t y to h e lp
3. A s th e te st lig h t v o lt a g e t o u c h e s C K T 4 2 4 , th e d ia g n o s e a C o d e 4 2 p ro b le m .
m o d u le s h o u ld s w it c h c a u s i n g th e o h m m e t e r to R e fe r to " D r i v e a b i l i t y S y m p t o m s , ” S e c t io n " 2 ” fo r
" o v e r r a n g e ” i f th e m e te r is in th e 1 0 0 - 2 0 0 o h m " E C M In t e r m it t e n t C o d e o r P e r f o r m a n c e . ”
p o sitio n .
S e le c t in g th e 1 0 -2 0 ,0 0 0 o h m s p o s it io n w ill in d ic a t e
a b o v e 5 0 0 0 o h m s. T h e im p o r t a n t t h in g is th a t th e
m o d u le "s w it c h e d . ”
 CODE 43
ELECTRONIC SPARK CONTROL (ESC) CIRCUIT
5.7L CNG ENGINE WITH 4L60 TRANSMISSION
Circuit D escription:

I n th e E le c t r o n ic S p a r k C o n t r o l ( E S C ) C ir c u it , O n th e 5 .7 L C N G e n g in e w it h th e 4 L 6 0
o n a ll e n g in e s E X C E P T th e 5 . 7 L C N G e n g in e w it h t r a n s m is s io n , t h e E S C s y s t e m t h o u g h p r e s e n t , i s
th e 4 L 6 0 a u t o m a t ic t r a n s m is s io n , th e E S C K n o c k n o t u s e d b y t h e E C M to r e t a r d s p a r k t i m i n g . T h e
S e n s o r s ig n a ls th e E C M t h r o u g h th e E S C sy ste m E S C s ig n a l is m a s k e d b y th e P R O M .
to r e t a r d i g n i t i o n t i m i n g d u r i n g e n g in e k n o c k . T h i s
a l l o w s t h e E C M to m a i n t a i n m a x i m u m t i m i n g
a d v a n c e u n d e r m o s t c o n d it io n s.
C O M P U T E R C O M M A N D C O N T R O L 3-59
 ECM
USED ON HEATED
OXYGEN ( 0 2)SENS0RS

D7 OXYGEN ( 0 2) SENSOR SIGNAL

D6 OXYGEN ( 0 2) SENSOR GROUND

5 - 22-41
MS 10851-CNG

CODE 44
OXYGEN (0 2) SENSOR CIRCUIT
(L E A N E X H A U S T IN D IC A T E D )
5.7L CNG ENGINE WITH 4L60 TRANSMISSION
Circuit D escrip tion:
T h e E C M s u p p lie s a v o lt a g e o f a b o u t .45 v o lt betw een t e r m in a ls " D 6 ” a n d " D 7 ” . ( If m e a s u r e d w it h a 10
m e g o h m d ig it a l v o ltm e te r, t h is m a y re a d a s lo w a s .32 volt.) T h e O x y g e n ( O 2 ) s e n s o r v a r ie s th e v o lt a g e w i t h in a
ra n g e o f a b o u t 1 v o lt if th e e x h a u s t is rich , d o w n t h r o u g h a b o u t .10 vo lt if e x h a u s t is lean.
T h e s e n s o r is lik e a n op en c ir c u it a n d p ro d u c e s n o vo lta g e w h e n it is b e lo w a b o u t 3 1 5 ° C (600°F). A n open
s e n s o r c ir c u it o r cold s e n s o r c a u s e s " O p e n L o o p ” o p e ra tio n .

Test D escrip tion: N u m b e r ( s ) b e lo w re fe r to c irc le d • C h e c k for in t e r m it t e n t g r o u n d i n w ir e b e t w e e n

n u m b e r ( s ) o n the d ia g n o s t ic c h a rt.
1. C o d e 4 4 is set w h e n the O x y g e n ( O 2 ) s e n s o r s ig n a l
v o lt a g e o n C K T 412:
• R e m a i n s b e lo w .2 v o lt fr o m 2 0 se co n d s.
• A n d t h e s y s t e m is o p e r a t i n g i n “C lo s e d
L o o p .”
D ia g n o s tic A id s:
U s i n g t h e T e c h 1, o b s e r v e t h e b l o c k l e a r n
v a l u e s a t d iffe r e n t r p m a n d a i r flo w c o n d it io n s. T h e
T e c h 1 a ls o d i s p l a y s t h e b lo c k c e lls , so t h e b l o c k
le a r n v a l u e s c a n b e c h e c k e d i n e a c h o f t h e c e lls to
d e t e r m in e w h e n t h e C o d e 4 4 m a y h a v e b e e n set. I f
t h e c o n d it io n s fo r C o d e 4 4 e x is t s , t h e b l o c k l e a r n
v a l u e s w i l l b e a r o u n d 170.
c o n n e cto r a n d se n so r.
• F u e l P r e s s u r e - S y s t e m w i ll b e le a n i f p r e s s u r e
is too low . R e f e r to “F u e l S y s t e m D i a g n o s i s , ”
C H A R T A -6 .
• E x h a u s t L e a k s - I f th e re is a n e x h a u s t le a k , th e
e n g in e c a n c a u se o u t s id e a i r to be p u lle d in to th e
e x h a u s t a n d p a s t the se n s o r. V a c u u m o r c r a n k c a s e
le a k s c a n c a u se a le a n c o n d itio n .
• C K T 4 1 3 - I f C K T 4 1 3 is o p e n , th e v o lt a g e a t
t e r m in a l " D 7 ” w ill be a b o u t .45 volt. T h i s m a y a ls o
c a u se C o d e 13 to set.
• I f a ll c h e c k O K , th e O x y g e n ( O 2 ) s e n s o r is f a u lty .

• O x y g e n (O ?) S e n s o r W i r e - S e n s o r p ig t a il m a y be
m is p o s it io n e d a n d c o n t a c t in g th e e x h a u s t
m a n ifo ld .
• H e a t e d O ? S e n s o r W ir e - A n o x y g e n s u p p ly in s id e
th e O 2 s e n s o r o p e ra tio n . T h i s s u p p ly o f o x y g e n is
s u p p lie d t h r o u g h th e O 2 s e n s o r w ire s . A ll O 2
s e n s o r w ir e s a n d c o n n e c t io n s s h o u ld be in s p e c t e d
fo r b r e a k s o r c o n t a m in a t io n t h a t c o u ld p r e v e n t
re fe re n c e o x y g e n fro m r e a c h in g th e O 2 se n so r.
 CODE 44
OXYGEN (02) SENSOR CIRCUIT
(L E A N E X H A U S T IN D IC A T E D )
5.7L CNG ENGINE WITH 4L60
TRANSMISSION

2-12-91
 ECM
USEDON HEATED
OXYGEN ( 0 2) SENSORS

D7 OXYGEN ( 0 2) SENSOR SIGNAL

D6 OXYGEN ( 0 2) SENSOR GROUND

5-22-91
MS 10851-CNG

CODE 45
OXYGEN ( 0 2) SENSOR CIRCUIT
(R IC H E X H A U S T IN D IC A T E D )
5.7L CNG ENGINE WITH 4L60 TRANSMISSION
Circuit D escrip tion:
T h e E C M s u p p lie s a v o lt a g e o f a b o u t .45 v o lt b e tw e e n t e r m in a ls " D 6 ” a n d " D 7 ”. ( I f m e a s u r e d w it h a 10
m e g o h m d ig it a l v o ltm e te r, t h is m a y re a d a s lo w a s .32 volt.) T h e O x y g e n ( O 2 ) s e n s o r v a r ie s th e v o lt a g e w it h in a
r a n g e o f a b o u t 1 v o lt if the e x h a u s t is ric h , d o w n t h r o u g h a b o u t .10 vo lt if e x h a u s t is lean.
T h e s e n s o r is lik e a n o p e n c ir c u it a n d p ro d u c e s no v o lta g e w h e n it is b e lo w a b o u t 3 1 5 ° C (6 0 0° F ). A n open
s e n s o r c ir c u it o r co ld s e n s o r c a u s e s " O p e n L o o p ” o p e ra tio n .

Test D escrip tion: N u m b e r ( s ) b e lo w re fe r to c irc le d H E I S h ie ld in g - A n o p e n g r o u n d C K T 4 5 3 ( ig n it io n

n u m b e r ( s ) o n th e d ia g n o s t ic ch a rt.
1. C o d e 4 5 is se t w h e n the O x y g e n ( 0 9 ) s e n s o r s ig n a l
v o lt a g e o r C K T 412:
• R e m a i n s a b o v e .8 v o l t fo r 6 0 s e c o n d s , a n d
in “C lo s e d L o o p . ”
• E n g i n e tim e a fte r s t a r t is 1 m in u t e o r m ore.
• T h r o t t le a n g le g r e a t e r t h a n 5 % (a b o u t .2 v o lt
a b o v e id le vo lta ge ).
D ia g n o s tic A id s:
U s i n g t h e “S c a n , ” o b s e r v e th e b lo c k le a r n
v a l u e s a t d if f e r e n t r p m a n d a i r flo w c o n d it io n s to
d e t e r m in e w it h th e C o d e 4 5 m a y h a v e b e e n set. I f
t h e c o n d it io n s fo r C o d e 4 5 e x is t , t h e b lo c k l e a r n
v a l u e s w i l l b e a r o u n d 115. T h e “S E S ” l i g h t w i l l
r e m a i n “O N ” u n t i l t h e i g n i t i o n is t u r n e d “O F F , ”
d u e to p o s s ib le h i g h fu e l p re ss u re .
A n o x y g e n s u p p ly in s id e th e O 2 s e n s o r is n e c e s s a r y
fo r p ro p e r O 2 s e n s o r o p e ra tio n . T h i s s u p p ly o f o x y g e n
is s u p p lie d t h r o u g h th e O 2 s e n s o r w ire s. A l l O 2 s e n s o r
w ir e s a n d c o n n e c t io n s s h o u ld be in sp e c te d fo r b r e a k s
o r c o n t a m in a t io n t h a t c o u ld p re v e n t re fe re n c e o x y g e n
fr o m r e a c h in g th e O 2 se n so r.
• F u e l P r e s s u r e - S y s t e m w ill go r ic h i f p r e s s u r e is
too h ig h . T h e E C M c a n c o m p e n s a t e fo r s o m e
in c re a se . H o w e v e r , i f it g e ts too h ig h , a C o d e 4 5
m a y be set.
R e f e r to " F u e l S y s t e m D i a g n o s i s ” ch a rt.
s y s t e m re fe re n c e lo w ) m a y r e s u l t i n E M I , o r
in d u c e d e le c tric a l " n o is e . ” T h e E C M lo o k s a t t h is
" n o i s e ” a s re fe re n c e p u lse s. T h e a d d it io n a l p u ls e s
r e s u lt in a h ig h e r t h a n a c t u a l e n g in e sp e e d s ig n a l.
T h e E C M th e n d e l iv e r s too m u c h fu e l, c a u s i n g
s y s t e m to go rich . E n g i n e t a c h o m e t e r w i ll a ls o
sh o w h ig h e r t h a n a c t u a l e n g in e sp e e d w h ic h c a n
h e lp in d ia g n o s in g t h is p ro b le m .
M A P S e n s o r - A n o u t p u t th a t c a u s e s th e E C M to
s e n s o r a h ig h e r t h a n n o r m a l m a n i f o l d p r e s s u r e
(lo w v a c u u m ) c a n c a u s e th e s y s t e m to g o r ic h .
D is c o n n e c t in g th e M A P s e n s o r w ill a llo w th e E C M
to set a fix e d v a lu e for th e M A P s e n s o r. S u b s t it u t e
a d iffe re n t M A P s e n s o r i f th e r ic h c o n d it io n is g o n e
w h ile the s e n s o r is d isc o n n e c te d .
T P S - A n in t e r m it t e n t T P S o u t p u t w ill c a u s e th e
s y s t e m to go ric h , d u e to a fa ls e in d ic a t io n o f th e
e n g in e a c c e le ra tin g .
C T S - C h e c k fo r a s h ifte d s e n s o r t h a t c o u ld c a u s e a
ric h e x h a u s t b u t se t C o d e 15. R e f e r to c h a r t fo r
C o d e 15.
 CODE 45
OXYGEN (0 2) SENSOR CIRCUIT
(R IC H E X H A U S T IN D IC A T E D )
5.7L CNG ENGINE WITH 4L60
TRANSMISSION

4-25-90
 'B " +
BATTERY 15 AM P 5 AMP
J U N C T IO N 450 BLK/WHT A A
BLOCK
------30 P P L ------ B B
A B
NG CONTROL RELAY c C
14089936
L REDJ

\
c N O T USED r 450 BLK/WHT

E — 902 RED
------2 RED - 440 ORN
FUEL FILL
F 920 GRA 440 ORN
13 DOOR S W
h 120 GRA o 1-440 ORN NO RM ALLY
D
OPEN SW

450 BLK/WHT ■
450 BLK/WHT-
450 BLK/WHT ■
450 BLK/WHT -
TO FUEL
A FUEL G AUG E
CYL
B SOL
B

LOW PRESS FUEL

FUEL SHUT-OFF PRESSURE
TRANSDUCER

FUEL
CYL
ENGINE REAR LAMP SOL

BIA1
B
m
FUEL CYL SOL

------------------ 120 GRA

-450 BLK/WHT
L 439 PNK/BLK-,
439 PNK/BLK 439 PN K /B LK i
HEATED 439
— 150 BLK — ECM /IG N
02 SENSOR 439 PNK/BLK PNK/BLK
— 412 PPL — 439 FUSE
-PNK /■ IG N ITIO N
FUEL SUPPLY A SW ITCH
EGR S152A BLK
TO JUNCTION RELAY SOL 10A
BOX 14089936 B -435 G R A - B

10A
ECM B TO GAUGE d
m ECM
0 0 2 SENSOR

>
5 < oc
z O
oc o ENG
0 ?i
GRD 435 GRA A4 EGR SOLENOID
^ I
■Q-----1 G106
S135 Lf) O XY G EN SENSO R SIG NAL
(O -4 1 2 PPL - D7
120 GRA J 5 .7 L C N G ENG IN E
440 ORN 7 \ ____ 1
/ S136
Cl
465 G R N /W H T A1 FUEL SUPPLY
RELAY DRIVE
-----120 GRA — B2 FUEL CONTROL SIG NA L
----- 440 ORN — B1 IG N ITIO N FEED

440 ORN C16 IG N ITIO N FEED

G109
G E N G IN E
ALDL GROUND

G108 7S 3804-6E-CNG
CODE 54 - FUEL SUPPLY CIRCUIT
 CODE 54
FUEL SUPPLY CIRCUIT
(L O W V O L T A G E )
5.7L CNG ENGINE WITH 4L60 TRANSMISSION

Circuit D escrip tion

T h e s t a t u s o f t h e f u e l s u p p l y C K T 120 is m o n it o r e d b y t h e E C M a t t e r m i n a l “B 2 ” a n d i s u s e d to
c o m p e n s a t e f u e l d e l i v e r y b a s e d o n s y s t e m v o lt a g e . T h i s s i g n a l i s a ls o u s e d to s t o r e a c o d e i f t h e f u e l
s u p p l y r e l a y is d e fe c tiv e o r fu e l s u p p ly c irc u it v o lt a g e is lo s t w h ile th e e n g in e is r u n n i n g . T h e r e s h o u l d b e
a b o u t 12 v o lt s o n C K T 12 0 for a t le a st 2 se c o n d s a ft e r th e ig n i t i o n is t u r n e d “O N , ” o r a n y t im e re fe re n c e
p u ls e s a re b e i n g re c e iv e d b y th e E C M .
C o d e 5 4 w i l l s e t i f t h e v o lt a g e a t t e r m in a l “B 2 ” i s le s s t h a n 2 v o lt s fo r 1.5 s e c o n d s s in c e t h e l a s t
re fe re n c e p u ls e w a s re c e ive d . T h i s code is d e s ig n e d to d etect a f a u lt y re la y , c a u s i n g e x t e n d e d c r a n k tim e ,
a n d th e code w i l l h e lp th e d ia g n o s is o f a n e n g in e t h a t “C r a n k s B u t W i l l N o t R u n . ”
I f a f a u lt is d e te cte d d u r i n g sta rt-u p , th e “S e r v ic e E n g i n e S o o n ” l i g h t w i l l s t a y “O N ” u n t i l th e i g n i t i o n
i s c irc le d “O F F . ”

D ia g n o stic A id s:

• R e f e r to “ E C M In t e r m it t e n t C o d e s o r
P e r f o r m a n c e ” in “D r i v e a b i l i t y S y m p t o m s , ”
S e c t io n “2 ”.
• F o r C o d e 5 4 , T e c h 1 d i s p l a y s “F u e l P u m p
V o lt a g e . ”
FROM CHART A-3
CHART A-5
FUEL CYLINDER SOLENOID
VALVES AND LOW PRESSURE CNG FUEL SUPPLY RELAY
FUEL SHUT-OFF SOLENOIDS.
DO NOT CLICK.
CIRCUIT DIAGNOSIS
5.7L NATURAL GAS POWERED
TRUCK WITH 4L60 TRANSMISSION
TURN IGNITION "ON"
LISTEN FOR LOW PRESSURE FUEL SHUT-OFF AND
FUEL CYLINDER SOLENOID VALVES TO CLICK FOR
TWO SECONDS.
DO THEY CLICK?

NO
zc
® DISCONNECT FUEL SUPPLY RELAY CONNECTOR
(RELAY CLOSEST TO FENDER).
NO TROUBLE FOUND.
VERIFY ENGINE START AND RUN.
PROBE BETWEEN TERMINAL CAVITY A (CKT440) AND VERIFY FULL FUEL CYLINDERS.
A GOOD GROUND.
IS 12 VOLTS PRESENT?

YES NO
I r
RECONNECT FUEL SUPPLY RELAY CONNECTOR. • CHECK AND REPLACE 10A ECM/IGN FUSE OR REPAIR
DISCONNECT CNG CONTROL RELAY CONNECTOR OPEN CIRCUIT (440) BETWEEN FUEL SUPPLY RELAY
(NEXT TO FUEL SUPPLY RELAY). CAVITY A AND FUSE BLOCK.
IGNITION "O N" - VERIFY VOLTAGE (2 SECONDS) AT • VERIFY FUEL SUPPLY CIRCUIT OPERATION.
CAVITY D (CKT120) OF CNG CONTROL RELAY
CONNECTOR AND GOOD GROUND.
IS 12 VOLTS PRESENT?

YES NO
X I
IGNITION "OFF". KEY "OFF" APPLY FUSED 12V TO ALDL CAVITY "G"
USE DVOM, PROBE CAVITIES D (CKT120) AND F (FUEL SUPPLY TEST TERMINAL).
(CKT920) OF CNG CONTROL RELAY CONNECTOR. VERIFY 12 VOLTS AT CAVITY D (CKT120) OF CNG
IGNITION "ON". WATCH FOR 12 VOLTS (2 SECONDS). CONTROL RELAY CONNECTOR.
IS 12 VOLTS PRESENT? IS 12 VOLTS PRESENT?

“I
[ yes' NO YES
HI
0 • IGNITION "OFF". VERIFY FUEL FILL • REMOVE FUSED 12V • CHECK CONTINUITY
• VERIFY VOLTAGE AT DOOR SWITCH IS FROM ALDL CAVITY (CKT120).
CAVITY A (CKT2) OF CLOSED. "G" • REPLACE 20 AMP IN­
NG CONTROL RELAY. REPAIR OPEN OR • IGNITION "OFF" LINE FUSE OR REPAIR
IS 12 VOLTS PRESENT? POOR GROUND DISCONNECT FUEL OPEN IN CKT120 FROM
CIRCUITS. FROM CNG SUPPLY RELAY CAVITY D OF NG
CONTROL RELAY CONNECTOR POWER CONTROL
CAVITY F (CKT920) • PROBE CAVITY F (CKT RELAY TO CAVITY E
THROUGH REAR LAMP 465) AND GROUND. OF FUEL SUPPLY
HARNESS CONNECTOR • IGNITION "O N" WATCH RELAY.
(CKTS450 120) TO FUEL IF 12 VOLTS IS • VERIFY FUEL SUPPLY
FILL DOOR SWITCH PRESENT FOR 2 RELAY CIRCUIT
(CKTS45Q 921). SECONDS. OPERATION.
CHECK CONTINUITY OF IS 12 VOLTS PRESENT?
FUEL FILL DOOR
SWITCH. ADJUST OR
REPLACE.
REPAIR OPEN OR
POOR GROUND TO
ENGINE INTAKE
MANIFOLD GROUND,
YES VERIFY FUEL SUPPLY
CIRCUIT OPERATION.
rvBsi
T
(CONT.) (CONT.) 7S 3805-6E-CNG
 CHART A-5
CNG FUEL SUPPLY RELAY
CIRCUIT DIAGNOSIS
5.7L NATURAL GAS POWERED
TRUCK WITH 4L60
TRANSMISSION (CONT.)
t X
YES NO YES NO
I I 1 in
® •
•
IGNITION "OFF".
RECONNECT CNG
• CHECK OR REPLACE 15
AMP IN-LINE FUSE
• IGNITION "OFF" PROBE
CAVITYS D (CKT 450)
CHECK ECM
CONNECTOR PIN
CONTROL RELAY. (NEXT TO CNG AND F (CKT 465) TERMINAL A1 FOR
• VERIFY VOLTAGE AT CONTROL RELAY), OR • IGNITION "O N " WATCH GOOD CONTACT.
CAVITY B (CKT440B) 5 REPAIR CKT FROM IF 12 VOLTS IS REPAIR OPEN CIRCUIT
AMP FUSE (LOCATED CNG CONTROL RELAY PRESENT FOR TWO BETWEEN CAVITY F
BETWEEN PRESSURE CAVITY A TO SECONDS (CKT 465) FUEL
TRANSDUCER AND FIREWALL JUNCTION IS 12 VOLTS PRESENT? SUPPLY RELAY
LOW PRESSURE FUEL BLOCK B + LUG. CONNECTOR AND PIN
SHUTOFF SOLENOID). • VERIFY FUEL SUPPLY A1 ECM CONNECTOR
• IGNITION "ON". RELAY CIRCUIT OR REPLACE ECM.
VERIFY VOLTAGE FOR OPERATION. VERIFY FUEL SUPPLY
2 SEC. CIRCUIT OPERATION.
IS 12 VOLTS PRESENT?

YES NO
H
© • VERIFY VOLTAGE AT
LOW PRESSURE SHUT-
• CHECK AND REPLACE
OFF SOLENOID
HARNESS CONNECTOR
CAVITY A (CKT440A)
AND GOOD GROUND.
• VERIFY VOLTAGE AT
CAVITY A OF ALL FUEL • IF OK, REPLACE CNG
CYLINDER (TANK)
SOLENOID HARNESS • VERIFY FUEL SUPPLY
CONNECTORS (CKT440
C, E, or F) AND GOOD
GROUND.
• IS 12 VOLTS PRESENT?
YES | NO
5 AMP IN-LINE FUSE
FUEL SUPPLY RELAY
COIL IS DEFECTIVE
IGNITION "OFF"
REPAIR OPEN GROUND
OR REPAIR CIRCUIT REPLACE FUEL SUPPLY CKT 450C BETWEEN
902 FROM FUSE RELAY AND VERIFY CAVITY D OF FUEL
CAVITY A TO CNG FUEL SUPPLY RELAY SUPPLY RELAY
CONTROL RELAY CIRCUIT OPERATION. CONNECTOR AND
CAVITY E. IF ORIGINAL SYMPTOM INTAKE MANIFOLD
WAS "ENGINE CRANKS GROUND LUG (G108)
CONTROL RELAY. BUT WILL NOT RUN", LEFT BANK FRONT.
CONTINUE TESTING VERIFY FUEL SUPPLY
CIRCUIT OPERATION. OIL PRESSURE CIRCUIT OPERATION.
SWITCH.
ENGINE AT NORMAL
OPERATING
TEMPERATURE.
OIL PRESSURE
NORMAL.
DISCONNECT FUEL
SUPPLY RELAY.
ENGINE SHOULD
CONTINUE TO RUN.
DOES IT?

(CONT.) (CONT.)
 CHART A-5
CIMG FUEL SUPPLY RELAY
CIRCUIT DIAGNOSIS
5.7L NATURAL GAS POWERED
TRUCK WITH 4L60
TRANSMISSION (CONT.)
C O M P U T E R C O M M A N D C O N T R O L 3-69
CODE 51
CODE 52
CODE 53 CODE 51
CODE 55
PROM PROBLEM
(5.7L CNG ENGINE WITH 4L60 TRANSMISSION)

CHECK THAT ALL PINS ARE FULLY INSERTED IN THE SOCKET. IF OK, REPLACE PROM,
CLEAR MEM O RY, AND RECHECK. IF CODE 51 REAPPEARS, REPLACE ECM.

CODE 52
FUEL CAL-PAK MISSING

CHECK FOR MISSING CAL-PAK AND THAT ALL PINS ARE FULLY INSERTED IN THE SOCKET. IF
OK, REPLACE ECM. NOTE : ON SOME VEHICLES THE CAL-PAK IS SOLDERED IN.

CODE 53
SYSTEM OVER VOLTAGE

THIS CODE INDICATES THERE IS A BASIC GENERATOR PROBLEM.

• CODE 53 WILL SET IF VOLTAGE AT ECM TERMINAL "B1" IS GREATER THAN 17.1 VOLTS FOR 2 SECONDS.
• CHECK AND REPAIR CHARGING SYSTEM.

CODE 55
FAULTY ECM

BE SURE ECM GROUNDS ARE OK AND THAT MEM-CAL IS

PROPERLY LATCHED. IF OK, REPLACE ECM.
 RESTRICTED EXHAUST SYSTEM CHECK

P r o p e r d i a g n o s i s fo r a re s t ric te d e x h a u s t s y s t e m i s e s s e n t ia l b e fo re a n y c o m p o n e n t s a re re p la c e d . T h e
f o llo w in g p ro c e d u re m a y b e u s e d fo r d ia g n o s is :

CHECK AT 0 2 SENSOR:
1. C a r e f u lly re m o v e O 2 se n so r.
2. In s t a ll B o r r o u g h s e x h a u st b a c k p re ssu re
te ste r ( B T 8 5 1 5 o r B T 8 6 0 3 ) o r e q u iv a le n t in
p la c e o f O 2 s e n s o r (see illu s t ra tio n ).
3. A f t e r c o m p le t i n g t e st d e s c r ib e d b e lo w , be
s u r e to co a t t h r e a d s o f O 2 s e n s o r w ith a n t i-
se ize c o m p o u n d P / N 5 6 1 3 6 9 5 o r e q u iv a le n t
p r io r to r e - in s t a lla t io n .

DIAGNOSIS:
1. W i t h th e e n g in e i d l i n g a t n o r m a l o p e r a t in g te m p e ra t u re , o b s e rv e the e x h a u s t s y s t e m b a c k p r e s s u r e
r e a d in g o n th e ga g e . R e a d in g s h o u ld not e xc e e d 8 .6 k P a (1 .2 5 psi).
2. In c r e a s e e n g in e sp e e d to 2 0 0 0 rp m a n d o b s e rv e ga g e . R e a d in g s h o u ld n o t e xce e d 2 0 .7 k P a (3 psi).
3. I f th e b a c k p r e s s u r e a t e ith e r sp e e d exceed s s p e c ific a tio n , a re s t ric te d e x h a u s t s y s t e m is in d ic a te d .
4. In s p e c t th e e n t ire e x h a u s t s y s t e m fo r a c o lla p se d pipe, h e a t d is t r e s s , o r p o s s ib le in t e r n a l m u f f le r fa ilu r e .
5. I f th e re a re n o o b v io u s re a s o n s fo r the e x c e s s iv e b a c k p r e s s u r e , th e c a t a ly t ic c o n v e r t e r is s u s p e c te d to be
r e s t r ic t e d a n d s h o u ld be re p la c e d u s in g c u r r e n t re c o m m e n d e d p ro c e d u re s.

7-18-90
7S 3340-6E-CNG
 MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK
5.7L CNG ENGINE WITH 4L60 TRANSMISSION
Circuit D e scrip tion :
T h e M a n i f o l d A b s o lu t e P r e s s u r e ( M A P ) s e n s o r m e a s u r e s th e c h a n g e s in th e in t a k e m a n if o ld p r e s s u r e w h ic h
r e s u lt fr o m e n g in e lo a d ( in t a k e m a n if o ld v a c u u m ) a n d rp m c h a n g e s; a n d c o n v e r t s th e se in to a v o lt a g e ou tp u t.
T h e E C M s e n d s a 5 v o lt re fe re n c e v o lt a g e to th e M A P se n so r. A s the m a n if o ld p r e s s u r e c h a n g e s , th e o u t p u t
v o lt a g e o f th e s e n s o r a ls o c h a n g e s . B y m o n it o r in g the s e n s o r o u t p u t v o lta g e , th e E C M k n o w s th e m a n ifo ld
p r e s s u r e . A t lo w e r p r e s s u r e o u t p u t v o lt a g e w ill be a b o u t 1 to 2 v o lt s a t idle. W h i l e a t h ig h e r p r e s s u r e o r a t W id e
O p e n T h r o t t le ( W O T ) o u t p u t v o lt a g e w ill be a b o u t 4 to 4.8 volts. T h e M A P s e n s o r is a ls o use d , u n d e r c e r t a in
c o n d it io n s , to m e a s u r e b a r o m e t r ic p r e s s u r e , a llo w i n g the E C M to m a k e a d j u s t m e n t s fo r d iffe r e n t a lt it u d e s . T h e
E C M u s e s th e M A P s e n s o r to c o n tro l fu e l d e liv e r y a n d ig n it io n tim in g .

Test D escrip tion : N u m b e r ( s ) b e lo w re fe r to c irc le d 3. C h e c k v a c u u m h o s e to s e n s o r f o r l e a k i n g o r

n u m b e r ( s ) o n th e d ia g n o s t ic c h a rt. re stric tio n . B e s u r e t h a t n o o t h e r v a c u u m d e v ic e s
a re c o n n e cte d to th e M A P hose.
Im p o rta n t
• B e s u r e to u s e t h e s a m e D i a g n o s t i c T e st
N O TIC E: M a k e s u r e e le c tr ic a l c o n n e c t o r r e m a in s

E q u ip m e n t fo r a ll m e a s u r e m e n t s . s e c u re ly fa ste ned .

4. D is c o n n e c t s e n s o r fro m b r a c k e t a n d t w is t se n so r
1. C h e c ks M A P se n so r o u t p u t v o lt a g e to th e E C M .
b y h a n d ( o n l y ) to c h e c k f o r i n t e r m it t e n t
T h i s v o lta g e , w it h o u t e n g in e r u n n in g , r e p r e s e n t s a
co n n e ctio n . O u t p u t c h a n g e s g r e a t e r t h a n .1 v o lt
b a r o m e t e r r e a d in g to th e E C M .
in d ic a te a b a d c o n n e c t o r o r c o n n e c t io n . If O K ,
• W h e n c o m p a r in g T e c h 1 " S c a n ” r e a d in g s to a
re p la c e se n so r.
k n o w n g o o d v e h ic le , it is im p o r t a n t to c o m p a re
v e h ic le s th a t u s e a M A P s e n s o r h a v i n g th e
s a m e c o lo r i n s e r t o r h a v i n g th e s a m e " H o t
S t a m p e d ” n u m b e r. R e f e r to f ig u r e s o n f a c in g
page.
2. A p p l y i n g 3 4 k P a ( 1 0 ” H g ) v a c u u m to th e M A P
s e n s o r s h o u l d c a u s e t h e v o l t a g e to c h a n g e .
S u b t r a c t se c o n d r e a d in g fro m th e first. V o lt a g e
v a l u e s h o u l d be g r e a t e r t h a n 1.5 v o lt s . Upon
a p p l y i n g v a c u u m to th e s e n s o r , th e c h a n g e in
v o lt a g e s h o u ld be in s t a n t a n e o u s . A s lo w v o lt a g e
c h a n g e in d ic a t e s a f a u lt y s e n so r.
MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK
5.7L CNG ENGINE WITH 4L60 TRANSMISSION

NOTICE: THIS CHART ONLY APPLIES TO MAP SENSORS

HAVING GREEN OR BLACK COLOR KEY INSERT (SEE BELOW).

COLOR
KEYED INSERT

LS 8963-6E LS 9045-6E

Figure 1 - Color Key Insert Figure 2 - Hot Stamped Number

 IDLE AIR CONTROL (IAC) SYSTEM DIAGNOSIS
5.7L CNG ENGINE WITH
4L60 TRANSMISSION
Circuit D escrip tion:
T h e E C M c o n t r o ls id le r p m w it h th e I A C v a lve . T o in c re a se id le rp m , th e E C M m o v e s th e I A C v a le a w a y f r o m
it ’s se at, a llo w in g m o re a ir to p a s s b y th e th ro tt le plate. T o d e c re a se rp m , it m o v e s th e I A C v a lv e t o w a r d it ’s seat,
r e d u c in g a ir flo w b y the th ro ttle plate. A T e c h 1 " S c a n ” tool w ill re a d the E C M c o m m a n d s to th e I A C v a lv e in
c o u n ts. T h e h ig h e r th e c o u n ts, th e m o re a ir a llo w e d (h ig h e r idle). T h e lo w e r th e c o u n ts, th e le s s a i r a llo w e d
( lo w e r idle).
T e st D escrip tion: N u m b e r ( s ) b e lo w re fe r to c irc le d
n u m b e r ( s ) o n th e d ia g n o s t ic c h a rt.
1. T h e I A C te ste r is u s e d to e x te n d a n d re t ra c t th e
I A C v a lv e . V a l v e m o v e m e n t is v e r if ie d b y a n
e n g in e sp e e d c h a n g e . I f no c h a n g e in e n g in e sp e e d
o c c u rs, th e v a lv e c a n be re te ste d w h e n r e m o v e d
fro m th e th ro tt le body.
2. T h i s ste p c h e c k s th e q u a lit y o f th e I A C m o v e m e n t
in S te p 1. B e t w e e n 7 0 0 rp m a n d a b o u t 1 5 0 0 rp m ,
th e e n g in e s p e e d s h o u l d c h a n g e s m o o t h ly w it h
e a c h f la s h o f th e te ste r lig h t in b o th e x te n d a n d
re tra ct. I f th e I A C v a lv e is re tra c te d b e y o n d th e
c o n tro l r a n g e (a b o u t 1 5 0 0 rp m ), it m a y ta k e m a n y
f la s h e s in th e e x te n d p o s it io n b efore e n g in e sp e e d
w i l l b e g in to d ro p . T h i s is n o r m a l o n c e r t a in
e n g in e s , f u lly e x t e n d in g th e I A C m a y c a u se e n g in e
sta ll. T h i s m a y be n o rm a l.
3. S t e p s 1 a n d 2 v e r if ie d p ro p e r I A C v a lv e o p e ra tio n
w h ile t h is ste p c h e c k s th e I A C c irc u it s . E a c h la m p
o n the n o d e lig h t s h o u ld f la s h re d a n d g r e e n w h ile
th e I A C v a lv e is cycled. W h il e th e s e q u e n c e o f
c o lo r is n o t im p o r t a n t i f e ith e r lig h t is " O F F ” o r
d o e s n o t f la s h re d a n d g re e n , c h e c k th e c ir c u it s fo r
fa u lts , b e g in n i n g w it h p o o r t e r m in a l co n ta cts.
IA C V A L V E R E SE T P R O C E D U R E
• Ig n i t i o n " O F F ” fo r 10 se co n d s.
• S t a r t a n d r u n e n g in e fo r 5 seco n d s.
• I g n i t i o n " O F F ” fo r 10 seco n d s.
D ia g n o s tic A id s:
A slo w , u n s ta b le , o r fa s t id le m a y be c a u se d b y a
n o n - I A C s y s t e m p ro b le m th a t c a n n o t be o v e rc o m e b y
th e I A C va lve . O u t o f c o n tro l r a n g e I A C T e c h 1 " S c a n ”
too l c o u n ts w ill be a b o v e 6 0 i f id le is too low , a n d ze ro
c o u n t s if id le is too h ig h . T h e fo llo w in g c h e c k s s h o u ld
be m a d e to r e p a ir a n o n - I A C s y s t e m p ro b le m .
• V a c u u m L e a k ( H i g h Id le ) - I f id le i s too h ig h , sto p
the e n gin e . F u l l y e x te n d (lo w ) I A C w it h te ste r.
S t a r t e n g in e . I f id le sp e e d is a b o v e 8 0 0 rp m , lo cate
a n d co rre ct v a c u u m le a k i n c l u d i n g P C V s y s t e m .
A l s o c h e c k fo r b i n d i n g o f th ro tt le b la d e o r lin k a g e .
• S y s t e m too le a n ( H i g h A ir / F u e l R a t io ) - T h e id le
speed m a y be too h i g h o r too low. E n g i n e sp e e d
m a y v a r y u p a n d d o w n a n d d is c o n n e c t in g th e I A C
v a lv e does n o t help. C o d e 4 4 m a y be s e t " S c a n ” O 2
v o lta g e w ill be le s s t h a n 3 0 0 m V (.3 volt). C h e c k
for low re g u la t e d fu e l p r e s s u r e w a t e r in th e fu e l o r
a re stric te d injector.
• S y s t e m too r ic h ( L o w A ir / F u e l R a t io ) - T h e id le
speed w ill be too low . " S c a n ” tool I A C c o u n t s w ill
u s u a lly be a b o v e 80. S y s t e m is o b v io u s ly r ic h a n d
m a y e x h ib it b la c k e x h a u s t sm o k e .
T e c h 1 " S c a n ” to o l O 2 v o lt a g e w ill be fix e d a b o v e
8 0 0 m V (.8 volt).
C h e c k fo r h i g h fu e l p r e s s u r e , le a k i n g o r s t i c k in g
injector. S ilic o n e c o n t a m in a t e d O 2 s e n s o r s " S c a n ”
vo lta g e w ill be s lo w to re sp o n d .
• T h r o t t le b o d y - R e m o v e I A C a n d in s p e c t b o re fo r
fo re ig n m a te ria l.
R e f e r to " R o u g h , U n s t a b l e , I n c o r r e c t I d l e o r
S t a l l in g S y m p t o m ” in " D r i v e a b i l i t y S y m p t o m s , ”
S e c t io n " 2 ”.
• A / C C o m p r e s s o r - R e f e r to " A / C D i a g n o s i s ” i f
c ir c u it is s h o rt e d to g r o u n d . I f th e r e l a y is fa u lty ,
id le p ro b le m m a y e xist.
R e f e r to " R o u g h , U n s t a b l e , I n c o r r e c t I d l e o r
S t a l l in g S y m p t o m s ” in " D r i v e a b i l i t y S y m p t o m s , ”
S e c tio n " 2 ” .
• I f in t e r m it t e n t p o o r d r i v e a b i l i t y s y m p t o m s a r e
r e s o lv e d b y d i s c o n n e c t i n g t h e I A C , c a r e f u l l y
re c h e c k c o n n e c tio n s , v a lv e t e r m in a l r e s is t a n c e , o r
re p la ce I A C .
 PARK/NEUTRAL (P/N) SWITCH DIAGNOSIS
5.7L CNG ENGINE WITH 4L60 TRANSMISSION
Circuit D escrip tion :
T h e P a r k / N e u t r a l (P / N ) s w it c h c o n ta c t s a re c lo s e d to g r o u n d in p a r k o r n e u t r a l a n d o p e n in d r iv e r a n g e s .
T h e E C M s u p p lie s i g n it io n v o lt a g e , t h r o u g h a c u r r e n t l im it in g re s is to r, to C K T 4 3 4 a n d s e n s e s a c lo se d
sw it c h , w h e n th e v o lt a g e o n C K T 4 3 4 d r o p s to le s s t h a n one volt.
T h e E C M u s e s th e P / N s ig n a l a s o ne o f th e in p u t s to co n tro l:
• Id le A i r C o n t r o l ( IA C ) .
• V e h ic le S p e e d S e n s o r ( V S S ) D ia g n o s t ic s .

T e st D escrip tion : N u m b e r ( s ) b e lo w re fe r to c ir c le d D ia g n o stic A id s:

n u m b e r ( s ) o n th e d ia g n o s t ic ch a rt.
1. C h e c k s fo r a c lo s e d s w it c h to g r o u n d i n p a r k I f C K T 4 3 4 a lw a y s in d ic a t e s d r iv e (open), a d ro p in
p o s it io n . D if f e r e n t m a k e s o f " S c a n ” to o ls w ill re a d th e id le m a y e x is t w h e n th e g e a r se le c to r is m o v e d in to
P / N d iffe r e n t ly . R e f e r to o p e r a t o r s m a n u a l fo r ty p e d r iv e ra n ge .
o f d is p la y u s e d fo r a sp e c ific tool.
2. C h e c k s f o r a n o p e n s w it c h i n d r i v e o r r e v e r s e
ra n g e .
3. B e s u re " S c a n ” in d ic a t e s d r iv e , e v e n w h ile
w i g g l i n g s h i f t e r to t e s t f o r a n i n t e r m it t e n t o r
m is a d j u s t e d s w it c h i n d r iv e ra n g e .
PARK/NEUTRAL (P/N) SWITCH DIAG N O SIS
5.7L CNG ENGINE WITH 4L60 TRANSMISSION
 HTR A/C ECM
FUSE A/C C O N TROL A/C PRESSURE
25A SW TCH CYCLING SWTCH
, A/C O N
59DK G R N B8 SIG N A L

CLUTCH

7-19-90
6S 2848-6E-CNG

A/C REQUEST SIGNAL DIAGNOSIS

5.7L CNG ENGINE WITH 4L60 TRANSMISSION
Circuit A n d Test D escrip tion:
T u r n i n g " O N ” th e a i r c o n d it io n in g s u p p lie s C K T 59 b a t te r y v o lta g e to th e A / C c o m p r e s s o r c lu t c h a n d to
t e r m in a l " B 8 ” o f th e E C M c o n n e c to r to in c r e a s e a n d m a in t a in id le speed.
T h e E C M d o e s n o t c o n tro l the A / C c o m p r e s s o r clu tch , th e re fo re , i f A / C d o e s n o t fu n c t io n , re fe r to th e A / C
s e c t io n o f th e s e r v ic e m a n u a l fo r d i a g n o s i s o f th e sy ste m .
I f A / C is o p e r a t in g p r o p e r ly a n d id le sp e e d d ip s too low w h e n th e A / C c o m p r e s s o r t u r n s " O N ” o r f la r e s too h i g h
w h e n th e A / C c o m p r e s s o r t u r n s " O F F , ” c h e c k fo r a n o p e n C K T 5 9 to th e E C M . I f c ir c u it s a re O K , it is a f a u lt y
E C M c o n n e c t o r t e r m in a l " B 8 ” o r E C M .
C O M P U T E R C O M M A N D C O N T R O L 3-79
 ECM

B+

o
AM M ETER

5-7-91
MS 11851-CNG

ECM QDR CHECK PROCEDURE

5.7L NATURAL GAS POWERED SIERRA TRUCK
QDR ECM
NUMBER O U TP U T CIRCUIT
TE R M IN A L

A2 N O T USED

A3 N O T USED
1
C1 N O T USED

C2 EACCONTROL

A4 EG RCO NTRO L*

A5 SES LIGHT
2
A7 TCC S O LE N O ID OR SHIFT LIG H T

B4 N O T USED

* Solid state circuitry cannot be diagnosed by resistance check.

Use DVM J 34029-A or equivalent.
 ECM QDR CHECK PROCEDURE

USE THIS CHECK PROCEDURE ONLY AFTER OTHER

D IA G N O S TIC CHARTS IN THE SERVICE M A N U A L HAVE
D E TE R M IN E D TH A T THERE W A S AN ECM FAILURE.

* U SE D V M J 3 4 0 2 9 -A O R E Q U IV A L E N T
5-7-91
8S 4335-6E-CNG
 ECM

461 ORN - |[ a T SERIAL D A TA

451 W HT/BLK -H A9 D IA G N O S TIC TEST

45 0 B LK/W HT H A 12 S YS TEM G R O U N D

F E D C B A
a H 4 1 3 TA N — D6 O X Y G E N SENSOR BACK V IE W
GROUND OF
ALDL CONNECTOR CONN EC TO R

45 0 BLK/W HT - D1 SYS TEM G R O U N D

. FUSE
150 B M M A 4 3 9 PNK/BLK IG N ITIO N 2 4 PIN A-B
BLK L— “ SWITCH CON N EC TOR
------ 10A
L 41 2 PPL OXYGEN SENSOR
- E E SIGNAL 5.7L C.N.G. ENGINE
HEATED O XY G EN
( 0 2) SENSOR

4 5 5 PPL — 1 A 11 MAP GROUND

M A N IF O L D
B 43 2 LT GRN C11 M A P SIGNAL
ABSOLUTE
PRESSURE BACK V IE W
(M A P ) SENSOR
/ i ... r OF
C O N N EC TO R

— 4 1 6 GRY + 5V REFERENCE /c \ / dK
THROTTLE
417D K B LU ~ | C13 TPS SIGNAL
POSITION
SENSOR (TPS)

C O O LA N T 45 2 BLK — | D2 SENSOR G R O U N D
TEMPERATURE
SENSOR (CTS)
4 1 0 YEL - f a O CTS SIG N A L

IDLE AIR CONTROL IA C C O IL " A " HIGH

441 LT B LU /W H T C5
(IAC)VALVM l r m v ^ 4 4 2 LT BLU/BLK C6 IAC COIL " A " L O W 32 P IN C -D
CONN EC TO R
4 4 3 LT G R N /W H T C4 IAC COIL "B " H IG H
4 4 4 LT GRN/BLK
C3 IAC COIL "B " L O W

3-25-9 1
MS 9608
 ECM
A/C
TO 66 LTGRN 59 DKGRN - | B8 A/C REQUEST
IGNITION SIGNAL
SWITCH - 0
PRESSURE CYCLING BACK VIEW
SWITCH OF
CONNECTOR

L j u u l a >t IK 150 BLK

A/C COMPRESSOR
A/C CIRCUIT
TO 440 ORN - I B1 IGNITION
BATTERY ECM JUNCTION FEED
FEED BLOCK

OIL PRESSURE SWITCH 440 ORN —I C16 IGNITION

CLOSES AT 4 psi FEED

465 DK GRN/WHT H A 1 FUEL SUPPLY

490 RED RELAY DRIVE
450 -i
ALDL I BLK/WHT H
TERMINAL 2 4 PIN A-B
CONNECTOR
ENGINE GROUND

INLINE 120 GRY BACK VIEW

FUSE 120 GRY - I B2 FUEL CONTROL OF
20A SIGNAL CONNECTOR
CNG
CONTROL RELAY
TO FUEL TANKS
AND LOW PRESS
r440B ORG*»SHUT-OFF
________ TO BATTERY
15A----- JUNCTION BLOCK P --D Q -
t— act;
—920 GRAY— Q Q -1 2 0 GRAY ^ TO FUEL
DOOR T a n
SHUT-OFF
SWITCH □ □

120 GREY ^ □ □
□□
GAUGES
TO-**—- v \ > - 39 PNK/BLK 419 BRN/WHT SERVICE ENGINE
IGNITION 20A SESLAMP SOON LIGHT
SWITCH CONTROL
ECM/IGN
C^I/IGIN
TO 4 39 PNK/BLK
IGNITION 10A
SWITCH 32 PIN C-D
CONNECTOR
BRAKE SWITCH

AUTOMATIC 446 LT BLU HIGH GEAR

TRANSMISSION SWITCH SIGNAL
TCC SOLENOID
422 TAN/BLK - I A7 A/T TCC CONTROL
(GROUND)
ALDL
4L60 TRANSMISSION

----- 3-20-91
MS 9609-CNG
 ECM
VEHICLE 8 2 2 LT GRN/BLK
SPEED
SENSOR (VSS)

VSS IN P U T C7
BACK V IE W
GROUND C8 -4 5 0 BLK/W HT TO ENGINE GROUND OF
VEHICLE SPEED TO C O N N EC TO R
IG N IT IO N FEED C9 -2 5 0 BRN
SENSOR BUFFER IG N ITIO N
(D R A C ) M O D U L E BRAKE SW ITCH
C10
15 A
VSS O U TP U T C11 - 4 3 7 BRN VSS SIGNAL

VSS IN P U T C12

C13

C14

VSS O U TP U T C15 -8 2 4 LTBLU/BLK -TO SPEEDO

-8 2 1 PPL/W HT —

4 5 0 B LK /W H T

PARK/NEUTRAL
24 PIN A-B
CONNECTOR
(P /N ) n -a
W— 4 3 4 ORN/BLK P/N SW ITC H
SW ITCH

B
439 4 3 5 GRY EGR SO LE N O ID
E XH A U S T GAS
RECIRCULATION (EGR)
S O LE N O ID

BACK V IE W *
ECM /IGN
A 1 \ C O N N E C T O R / ^ M l\
IGN
12 V 10A

4 3 9 PNK/BLK IG N IT IO N
FEED
A

ELECTRONIC 12V IGN JL oB=^=

SPARK C ----- 4 5 7 YEL/BLK ESC :- = □ C L _ _
C O N TR O L SPARK RETARD
KNOCK tz D D rr:
MODULE ESC G R O U N D D ----- 4 8 6 BRN ~ -► T O ENGINE G R O U N D RETARD
ESC SENSOR IN PU T E -- 4 9 6 DK BLU
S IG N A L :: n i= b r r
(M AS K E D
BY PROM ) u g g j
KNOCK
SENSOR 32 PIN C -D
C O N N EC TO R

5 -1 0 -9 1
9S 7611-6E-CNG
 ECM

BACK VIEW
A CONNECTOR

IN i A-B A INJ 1 B
IG N _ 481 W N TVA. INJECTOR 24 PIN A-B
12 V RED « r 467 OK BLU
- E E DRIVER CONNECTOR
10A

A INJ 2 B
482 _/WV>L.
WHT « r 468 OK GRN -fpi7 INJECTOR
DRIVER

------ 423 W HT - D4 EST

PRIMAR 430PPLyWHT - B5 REFERENCE HIGH

COIL SET TIM ING CONNECTOR
ITACH « r 4 2 4 TAN/BLK D5 BYPASS
LEAD
4 53 BLK/RED —I B3 REFERENCE LOW

BACK VIEW

32 PIN C-D
CONNECTOR

3 -2 0 -9 1
M S 9610-CNG
 ECM CONNECTOR IDENTIFICATION
This ECM voltage chart is for use with a digital voltmeter to further aid in diagnosis. The voltages you
get may vary due to low battery charge or other reasons, but they should be very close.
The "B + " symbol indicates a normal system voltage of 12-14 volts.
THE FOLLOWING CONDITIONS MUST BE MET BEFORE TESTING:
• Engine at operating temperature • "Closed Loop" • Engine idling (for "Engine Run" column)
• Test terminal not grounded • Tech 1 not installed
NORMAL NORMAL
CKT WIRE VOLTAGES CKT WIRE VOLTAGES
PIN PIN FUNCTION PIN PIN FUNCTION
# COLOR KEY ENG # COLOR KEY ENG
"ON" RUN "ON" RUN
A1 FUEL P U M P RELAY 465 DKGRN/ (1 ) B+ B1 BATTERY 12 VO LT 440 ORN B+ B+
DRIVE WHT
B2 FUEL SUPPLY SIGNAL 12 0 GRY (1) B+
A2 N O T USED - - - -

B3 EST REFERENCE 453 BLK/RED 0* 0*

A3 N O T USED - - - - LO W

A4 EG R C O N TR O L 435 GRY B+ B+ B4 N O T USED - - - -

A5 "SERVICE ENGINE 419 BRN 0* B+ B5 EST REFERENCE 430 PPL/W H T 0* 1.6

S O O N " LIGHT HIGH
CONTROL
B6 N O T USED - - - -
A6 IGN ECM FUSED 439 PNK/BLK B+ B+
B7 ESC SIGNAL 457 YEL/BLK - -
A7 TC C C O N TR O L 422 TAN/BLK B+ B+
B8 A/C SIGNAL 59 DKGRN (4 ) (4)
A8 SERIAL D A TA 461 ORN (2 ) (2 )
B9 N O T USED - - - -
A9 D IA G N O S TIC TEST 451 W H T/B LK 5 5
TE R M IN A L B10 PARK/NEUTRAL 434 ORN/BLK (5 ) (5 )
SW ITCH SIGNAL
A 10 VEHICLE SPEED 437 BRN (3 ) (3 )
SENSOR SIGNAL B11 N O T USED - - - -

A11 M A P SENSOR 455 PPL 0* 0* B12 N O T USED - - - -

GROUND

A 12 SYSTEM G R O U N D 450 B LK /W H T 0* 0*

( 1) Battery voltage first 2 seconds.

(2 ) Varies from 2 to 5 volts.
(3 ) Varies from .01 to battery voltage depending on position of drive wheels.
(4) 0 volts A/C "OFF" battery voltage A/C "O N." BACK V IE W
(5) 0 volts in P/N battery voltage in gear. OF
* Less then .5 volt. CO N N EC TO R

ENGINE 5.7L CNG

24 PIN A-B
C O N N EC TO R

6-1 0 -9 1
M S 9910-CNG
 ECM CONNECTOR IDENTIFICATION
This ECM voltage chart is for use with a digital voltmeter to further aid in diagnosis. The voltages you
get may vary due to low battery charge or other reasons, but they should be very close.
The "B + " symbol indicates a nominal system voltage of 12-4 volts.
THE FOLLOWING CONDITIONS MUST BE MET BEFORE TESTING:
• Engine at operating temperature • "Closed Loop" • Engine idling (for "Engine Run" Column)
• Test terminal not grounded • Tech 1 not installed
NORMAL NORM AL
PIN CKT WIRE VOLTAGES CKT WIRE VOLTAGES
PIN PIN PIN FUNCTION
FUNCTION # COLOR KEY ENG # COLOR KEY ENG
"ON" RUN "O N " RUN
Cl NOT USED - - - - D1 SYSTEM GROUND 450 BLK/WHT 0* 0*

C3 IAC "B " LOW 444 LTGRN/ NOT USABLE D2 TPS & CTS 452 BLK 0* 0*
BLK SENSOR GROUND

C4 IAC "B " HIGH 443 LTGRN/ NOT USABLE D3 NOT USED - - - -
WHT
D4 EST 423 WHT 0* 1.0
C5 IAC "A " HIGH 441 LTBLU/ NOT USABLE
WHT D5 EST BYPASS 424 TAN/BLK 0* 4.75

C6 IAC "A " LOW 442 LTBLU/ NOT USABLE D6 OXYGEN 413 TAN 0* 0*
BLK SENSORGROUND

C7 HIGH GEAR 446 LTBLU B+ B+ D7 OXYGEN 412 PPL (4) (5)

SWITCH SIGNAL SENSOR SIGNAL

C8 NOT USED - - - - D8 NOT USED - - - -

C9 CRANK SIGNAL 806 PPL/WHT (1) 0* D9 NOT USED - - - -

C10 CTS SIGNAL 410 YEL (2) (2) D10 NOT USED - - - -

C11 MAP SIGNAL 432 LTGRN 4.8 1.0t D11 NOT USED - - - -

C12 NOT USED - - - - D12 NOT USED - - - -

C13 TPS SIGNAL 417 DK BLU (3) .6 D13 NOT USED - - - -

C14 MAP & TPS 416 GRY 5 5 D14 INJECTOR 2 DRIVER 468 GRN B+ B+
5 VOLT REF.
D15 NOT USED - - - -
C15 NOT USED - - - -
D16 INJECTOR 1 DRIVER 467 BLU B+ B+
C16 BATTERY 440 ORN B+ B+
12 VOLT

OF
C O NNECTOR

( 1 ) Battery voltage when cranking.

(2) A bout 1.0 volt, varies w ith temperature.
(3) .6 V olt to about 4.8 vo lt at Wide Open Throttle (WOT).
(4) Non- heated O 2 .26 to .46 volt, heated O2 .26 to .46 volt w ith in
10 seconds the voltage goes near 0 volt as O 2 heater warms up.
(5) Varies from . 1 vo lt to .9 volt.
* Less than .5 volt.
t Varies w ith m anifold pressure.

ENGINE 5.7L CNG

32 PIN C-D
CO NNECTOR

6-1 1 -9 1
M S 9911-CNG
 ON-VEHICLE SERVICE

W IR E H A R N E S S
T h e E C M h a r n e s s e le c t r ic a lly c o n n e c ts th e
E C M to th e v a r io u s s o le n o id s , s w itc h e s, a n d s e n s o r s
i n t h e v e h ic le e n g in e a n d p a s s e n g e r c o m p a rt m e n t .
W i r e h a r n e s s e s s h o u l d be r e p la c e d w i t h p r o p e r
p a rt n u m b e r h a rn e sse s. W h e n s ig n a l w ire s a re
s p lic e d , in t o a h a rn e ss, u se w ir e w it h h ig h
t e m p e r a t u r e in s u la t i o n o n ly .
W i t h th e lo w c u r r e n t a n d v o lt a g e le v e ls fo u n d in
th e s y s t e m , it is im p o r t a n t t h a t th e b e s t p o s s ib le b o n d
a t a ll w ir e s p lic e s be m a d e b y s o ld e r in g th e s p lic e s , a s
s h o w n i n F i g u r e 3-18.
M o l d e d o n c o n n e c t o r s r e q u ir e c o m p le t e
r e p la c e m e n t o f th e co n n e cto r. T h i s m e a n s s p li c i n g a
n e w c o n n e c t o r a s s e m b ly in t o th e h a r n e s s .
R e p la c e m e n t c o n n e c t o rs a n d t e r m in a ls a re lis t e d
i n G r o u p 8 .9 6 5 , o f th e S t a n d a r d P a r t s C a ta lo g .
C O N N E C T O R S A N D T E R M IN A L S
U s e care , w h e n p r o b in g a c o n n e c t o r o r r e p la c in g
t e r m in a ls in th em . It is p o s s ib le to s h o r t b e t w e e n
o p p o s it e t e r m in a ls .
I f t h is h a p p e n s, to th e w r o n g t e r m in a l p a ir, it is
p o s s ib le to d a m a g e c e r t a in c o m p o n e n ts. A l w a y s u se
ju m p e r w ir e s b e tw e e n c o n n e c to rs, fo r c ir c u it c h e c k in g .
N E V E R pro b e t h r o u g h th e W e a t h e r - P a c k se a ls. U s e
ta c h o m e t e r a d a p t e r J 3 5 8 1 2 , o r e q u iv a le n t , w h ic h
p r o v id e s a n e a s y h o o k u p o f th e ta c h . le a d . The
c o n n e c t o r te st a d a p t e r k i t J 3 5 6 1 6 , o r e q u iv a le n t ,
c o n t a in s a n a s s o r t m e n t o f fle x ib le c o n n e c to rs, u s e d to
pro b e t e r m in a ls d u r i n g d ia g n o s is . F u s e r e m o v e r a n d
te st tool B T 8 6 1 6 , o r e q u iv a le n t , is u s e d fo r r e m o v in g a
fu s e a n d to a d a p t f u s e h o ld e r , w i t h a m e t e r , fo r
d ia g n o s is .
W h e n d ia g n o s in g , o p e n c ir c u it s a re o fte n d iffic u lt
to locate b y s ig h t, b e c a u s e o x id a t io n , o r t e r m in a l m i s ­
a l i g n m e n t a re h id d e n b y th e c o n n e c t o r s . M e r e ly
w i g g l in g a c o n n e c to r o n a s e n s o r , o r i n th e w i r i n g
h a r n e s s , m a y c o rre c t th e o p e n c ir c u it c o n d itio n . T h i s
s h o u ld a lw a y s be c o n sid e re d , w h e n a n o p e n c irc u it , o r
fa ile d s e n s o r is in d ic a te d . In t e r m it t e n t p r o b le m s m a y ,
also , be c a u se d b y o x id iz e d o r lo o se c o n n e c tio n s.
B e fo re m a k in g a c o n n e c t o r r e p a ir, be c e r t a in o f the
type o f co n necto r. W e a t h e r - P a c k a n d C o m p a c t T h r e e
c o n n e c to rs lo o k s im ila r , b u t a re s e r v ic e d d iffe re n tly .

TWISTED/SHIELDED CABLE TWISTED LEADS

DR A IN WIRE

OU TER JA C K ET
I
M Y LA R

1. REM O VE OUTER JA C K ET. 1. LOCATE D A M A G E D W IRE.

2. U N W R A P A L U M IN U M /M Y L A R TAPE. D O N O T 2. REMOVE IN S U LA TIO N AS REQUIRED.
R EM O VE M Y LA R .

SPLICE A N D SOLDER

3. SPLICE TW O W IRE TO GETHER U S IN G SPLICE

3. U N T W IS T C O N D U C TO R S . STRIP IN S U LA TIO N AS
CUPS A N D ROSIN CORE SOLDER.
NECESSARY.

DR A IN WIRE

I 2
4 . SPLICE W IRES USIN G SPLICE CLIPS A N D ROSIN CORE
SOLDER. W R A P EACH SPLICE TO INSU LA TE.
4. COVER SPLICE W IT H TAPE TO INSULATE
5. W R AP W IT H M Y LA R A N D D R A IN (U N IN S U L A T E D ) W IR E. FR O M OTHER W IRES.
5. RETW IST AS BEFORE A N D TAPE W IT H

I V 2
ELECTRICAL TAPE A N D H O LD IN PLACE.

6. TAPE OVER W H O LE BUNDLE TO SECURE AS BEFORE. 4S 0570-6E-CNG

M icro-Pack T o re m o v e a te rm in a l:
1. S lid e the se a l b a c k o n th e w ire.
R e f e r to F i g u r e 3 -1 9 a n d r e p a ir p r o c e d u r e fo r 2. I n s e r t t o o l (3 ) B T - 8 5 1 8 , o r J 3 5 6 8 9 , o r
r e p la c e m e n t o f a M ic r o - P a c k te rm in a l. e q u iv a le n t, a s s h o w n in in s e r t " A ” a n d " B , ” to
r e le a s e th e t e r m in a l lo c k in g ta b (2).
3. P u s h the w ire a n d t e r m in a l o u t t h r o u g h th e
c o n n e cto r.
I f r e u s in g th e t e r m in a l, r e s h a p e th e lo c k i n g t a n g (2).

W e ath e r-P a ck

1 CABLE 3 LOCKING TANG
2 T E R M IN A L 4 TO O L J 3 3 0 9 5 /B T 8 2 3 4 -A _,c
7S 3 5 4 8 -6 E
Figure 3-19 - Micro-Pack Connector
M etri-Pack
S o m e c o n n e c t o r s u s e t e r m i n a l s c a ll e d M e t r i -
P a c k S e r ie s 150. ( F ig u r e 3-20). T h e s e m a y be u s e d
a t th e c o o la n t se n s o r, a s w e ll a s T B I / C P I u n its.
T h e y a r e a ls o c a lle d " P u l l - T o - S e a t ” t e r m in a ls ,
b e c au se , to in s t a l l a t e r m in a l o n a w ire, the w ire is
f ir s t in s e r t e d t h r o u g h th e se a l (5) a n d c o n n e c to r (4).
T h e t e r m in a l is t h e n c r im p e d o n th e w ir e a n d th e
t e r m in a l p u lle d b a c k in t o th e co n n e c to r to se a t it in
place.
A W e a t h e r - P a c k c o n n e c t o r c a n be id e n t ifie d b y a
r u b b e r s e a l, a t th e r e a r o f t h e c o n n e c t o r . T h is
c o n n e c to r, w h ic h is u s e d in th e e n g in e c o m p a rt m e n t ,
p ro te c ts a g a in s t m o is t u r e a n d d irt, w h ic h c o u ld c re a te
o x id a t io n a n d d e p o s it s o n th e t e r m in a ls . T h is
p r o t e c t io n i s i m p o r t a n t , b e c a u s e o f t h e v e r y lo w
v o lt a g e a n d c u r r e n t le v e ls f o u n d i n th e e le c t r o n ic
sy ste m .
R e p a ir o f a W e a t h e r - P a c k t e r m in a l i s s h o w n i n
cc F i g u r e 3-21. U s e to o l J M 2 8 7 4 2 , o r B T 8 2 3 4 - A to
r e m o v e th e p in a n d s le e v e t e r m in a ls .
I f re m o v a l is a t t e m p t e d w i t h a n o r d i n a r y p ic k ,
th e re is a go o d c h a n c e t h a t th e t e r m in a l w ill be bent,
o r d e fo rm e d . U n l i k e s t a n d a r d b la d e ty p e t e r m in a ls ,
th e se t e r m in a ls c a n n o t be s t r a ig h t e n e d o n c e th e y a re
bent.
M a k e c e r t a in t h a t th e c o n n e c t o r s a r e p r o p e r ly
se a te d a n d a ll o f th e s e a l i n g r i n g s in p la c e , w h e n
c o n n e c t in g le a d s. T h e h i n g e t y p e f la p p r o v id e s a
b a c k u p , o r s e c o n d a r y lo c k in g fe a t u r e fo r th e co n n e c to r.
T h e y a re u se d to im p r o v e th e c o n n e c t o r r e l ia b i li t y b y
r e t a i n i n g th e t e r m in a ls , i f th e s m a l l t e r m i n a l lo c k
t a n g s a re n o t p o s it io n e d p ro p e rly .
W e a t h e r - P a c k c o n n e c t io n s c a n n o t be re p la c e d w it h
s t a n d a r d c o n n e c tio n s. In s t r u c t i o n s a re p r o v id e d w it h
W e a t h e r - P a c k c o n n e c t o r a n d t e r m in a l p a c k a g e s .

1. M ETRI-PACK SERIES 3. TO O L J3 5 6 8 9 OR B T-8446

15 0 FEMALE TER M IN A L 4. C O N N EC TO R BODY
2. LOCKING TA N G 5. SEAL
2-5-90
*7S 3213-6E-CNG
 1. OPEN SECONDARY LOCK HINGE ON CONNECTOR.
E L E C T R O N IC /P O W E R T R A IN C O N T R O L
FEMALE M ALE
M O DULE
C O N N EC TO R C ONNECTOR
R e p la c e m e n t o f t h e E l e c t r o n i c C o n t r o l M o d u l e
( E C M ) c o n s is t s o f a s e r v ic e c o n t r o lle r , w i t h o u t a
•SEC O N D A RY- PROM .
LOCK HINGE I f th e d ia g n o s t ic p ro c e d u re s r e q u ir e th e E C M to
R EM O VE TE R M IN A L USIN G TO O L. be r e p la c e d , t h e E C M a n d P R O M , s h o u l d b e
PUSH TO c h e c k e d fo r th e c o rre c t p a r t n u m b e r. I f it i s corre ct,
RELEASE
re m o v e th e P R O M a n d i n s t a l l it i n t h e s e r v ic e
co n tro lle r. T h e s e r v ic e c o n t r o lle r w i l l n o t c o n t a in a
TE R M IN A L TO O L J 2 8 7 4 2 /B T 8 2 3 4 -A
PROM .
CUT W IRE IM M E D IA T E L Y B EHIND CABLE SEAL.

WIRE
Im portant
SEAL
W h e n r e p la c in g a p r o d u c t io n E C M w it h a
4. REPLACE TE R M IN A L s e r v ic e c o n t r o lle r , t r a n s f e r t h e b r o a d c a s t co d e
A. SLIP N E W SEAL O N T O W IRE.
B. STRIP 5 m m (.2 " ) OF IN S U LA TIO N FR O M W IRE. a n d p r o d u c t io n E C M p a r t n u m b e r to t h e
C. CRIMP TE R M IN A L OVER WIRE A N D SEAL. c o n t r o lle r la b e l. D o n o t r e c o r d i n f o r m a t io n o n
th e a cc e ss cover.

SEAL N O T IC E : T h e i g n i t i o n m u s t b e “O F F , ” w h e n
d is c o n n e c t in g o r r e c o n n e c t in g th e E C M
PUSH TE R M IN A L A N D CONNECTOR A N D c o n n e c to r, to p r e v e n t i n t e r n a l d a m a g e to t h e
ENGAGE LOCKING TA N G S. ECM .
6. CLOSE SECONDARY LOCK HINGE.
7S 3542-6E-CNG
N O T IC E : T o p r e v e n t p o s s i b l e E l e c t r o s t a t i c
Figure 3-21 - Weather-Pack Terminal Repair
D i s c h a r g e d a m a g e to t h e E C M , D o N o t t o u c h
th e c o n n e c t o r p i n s o r s o ld e r e d c o m p o n e n t s o n
C o m p a c t Three th e c ir c u it b o a rd .

T h e C o m p a c t T h r e e c o n n e c to r, w h ic h lo o k s s i m i l a r E C M Connector Term inal V o lta g e s

to a W e a t h e r - P a c k c o n n e c to r, is n o t s e a le d a n d is u se d
w h e re r e s is t a n c e to th e e n v ir o n m e n t is n o t re q u ire d . R e f e r to F i g u r e s 3 - 1 6 and 3 -1 7 fo r v o lt a g e
T h i s ty p e o f co n n e c to r, m o s t lik e ly , is u se d a t th e a ir c h a r t s to a id i n d ia g n o s is .
c o n t r o l s o le n o id . U s e th e s t a n d a r d m e t h o d , w h e n
r e p a ir i n g a te r m in a l. D o n o t u s e th e W e a t h e r - P a c k
t e r m in a l tool J 2 8 7 4 2 , o r B T - 8 2 3 4 - A , a s t h e s e w ill
d a m a g e th e t e r m in a ls .
E C M R ep lacem ent - W ith P R O M & C A L -P A K
(N atural G a s Pow ered Truck)
Figures 3-22 and 3-23

R e m o v e o r D isco n n e ct
1. N e g a t iv e b a t t e r y c a b le o r E C M B fuse.
2. C o n n e c t o r s f r o m th e E C M .
3. ECM .

|+4*| Install or C o n n e ct
1. E C M in t o v e h ic le .
2. C o n n e c t o r to th e E C M .
1 ELECTRONIC CONTROL M O D U L E
3. N e g a t iv e b a t t e r y c a b le o r E C M B fuse.
4. P e r f o r m s y s t e m ch eck. 2 FUEL M O D U LE

PROM ELECTRONIC CONNECTOR 8S 4613-6E-C N G

Figure 3-22 - Electronic Control Module 5.7L Natural

R e f e r to F i g u r e 3 - 2 3 , fo r re m o va l and Gas Powered Truck With 4L60 Transmission
i n s t a l la t io n o f a P R O M .
C A L -P A K
N O T IC E : T o p r e v e n t p o s s ib l e E l e c t r o s t a t i c
D i s c h a r g e d a m a g e to th e P R O M , D o N o t to u c h R e f e r to F i g u r e 3 - 2 3 , f o r r e m o v a l a n d
t h e c o m p o n e n t le a d s , a n d D o N o t r e m o v e i n s t a l l a t i o n o f a C A L - P A K . S o m e C A L - P A K ’s a r e
in t e g r a t e d c ir c u it fro m c a rrie r. s o ld e re d i n a n d , th e re fo re , n o n -re p la c e a b le .
1. Remove ECM access cover. Inspect reference end o f the CALPAK carrier and carefully set
aside. Do not re m o v e CALPAK fro m c a rrier to c o n firm
ACCESS COVER CALPAK correctness. Notch in CALPAK re fe re n c e to sm all
notch in carrier and the small notch of carrier must be aligned
w ith small notch in socket. Press on PROM or CALPAK carrier
until it is firm ly seated in the socket. Do n ot press on PROM
or CALPAK, only carrier.

PROM

2 . Remove PROM using the rocker-type PROM rem oval to o l

shown. Engage one end of the PROM carrier w ith the hook
end of th e tool. Press on the vertical bar end of the tool and
rock the engaged end o f the PROM carrier up as fa r as
possible. Engage the opposite end of the PROM carrier in
the same m anner and rock this end up as fa r as possible.
Repeat this process until the PROM carrier and PROM are
fre e of the PROM socket. The PROM carrier w ith PROM in it
CALPAK
should lift o ff o f the PROM socket easily.

CALPAK CARRIER

6. If a service controller is being installed, check th e service

number on the controller to m ake sure it is the same as th e
rem oved ECM. Remove access cover.

ACCESS
COVER

SERVICE
NUMBER
Inspect reference end of the PROM carrier and carefully set
aside. Do not rem ove PROM from the carrier to confirm
PROM correctness. Notch in PROM re fe re n c ed to sm all
notch in carrier and th e sm all notch o f c a rrier m u st be
aligned w ith sm all notch in socket. Press on PROM or Im portant (Before installing PROM)
CALPAK carrier until it is firm ly seated in the socket. Do not
press on PROM or CALPAK, only carrier. ANY TIME THE PROM IS INSTALLED BACKWARDS A N D THE
IGNITION SWITCH TURNED ON, THE PROM IS DESTROYED.
PROM
Im portant

PROM CARRIER
DO NOT press on PROM or CALPAK - ONLY CARRIER.

7. Install PROM and CALPAK (if used). If a service PROM or

CALPAK is being installed, m ake sure th e y have th e sam e
Remove CALPAK (if used) using rem oval tool shown. Grasp
part num ber as the rem oved PROM or CALPAK.
the CALPAK carrier of th e narrow ends only. Gently rock the
8. Install ECM access cover.
carrier from end to end w h ile applying a firm upw ard force.
9. Install ECM in p asseng er c o m p a r tm e n t and p e r fo rm a
" D IA G N O S T IC C IR C U IT C H E C K " t o c o n f ir m p r o p e r
installation.
8-15-90
6S 2511-6E-CNG
 N O T IC E : T o p r e v e n t p o s s i b l e E l e c t r o s t a t i c -►<- Install or C o n n e c t
D i s c h a r g e d a m a g e to t h e C A L - P A K , D o N o t
1. B o l t s o r s n a p s e n s o r o n b ra c k e t.
t o u c h th e c o m p o n e n t le a d s, a n d D o N o t re m o v e
2. E le c t r ic a l co n n e cto r.
in t e g r a t e d c ir c u it fro m c a rrie r.
3. V a c u u m harn e ss.
CO O LANT TEM PERATURE SEN SO R 4. N e g a t iv e b a t t e r y cable.
Figure 3-24

N O T IC E: C a r e m u s t be ta k e n , w h e n h a n d l i n g
c o o la n t s e n s o r . D a m a g e to c o o la n t s e n s o r w i l l
affect p ro p e r o p e r a t io n o f the fu el c o n tro l sy ste m .

R e m o v e or D isco n n e ct
1. N e g a t iv e b a t t e r y cable.
2. D r a i n c o o lin g s y s t e m b e lo w le v e l o f se n so r.
3. E le c t r ic a l c o n n e c t o r r e le a s in g lo c k in g tab.
4. C o o la n t se n s o r.

Install o r C o n n e c t
1. S e n s o r i n e n g in e .
2. E le c t r ic a l c o n n e cto r.
3. R e f ill c o o la n t s y ste m .
4. N e g a t iv e b a t t e r y cable.

Truck

O X Y G E N ( 0 2) S E N S O R
1 C O O L A N T TEMPERATURE SENSOR
Figure 3-26
2 INLET M A N IF O L D 7 S 3 8 1 5 -6 E

Figure 3-24 - Coolant Sensor N O T IC E : The O xyge n (O 2) se n so r u se s a

p e r m a n e n t ly a tta c h e d p ig t a il a n d c o n n e c to r. T h i s
p ig t a il s h o u ld n o t be r e m o v e d f r o m th e O x y g e n
M AP SEN SO R
( O 2 ) se n s o r. D a m a g e o r r e m o v a l o f th e p ig t a il o r
Figure 3-25
c o n n e c t o r c o u ld a ffe c t p r o p e r o p e r a t i o n o f t h e
o x y g e n s e n so r.
O t h e r t h a n c h e c k in g fo r lo o se h o se s a n d e le c tric a l
c o n n e c t io n s , th e o n l y s e r v ic e p o s s ib le is u n it
T a k e c a re w h e n h a n d li n g th e O x y g e n ( 0 2 )s e n s o r .
re p la c e m e n t, i f d i a g n o s i s s h o w s s e n s o r to be fa u lty.
T h e in - lin e e le c t r ic a l c o n n e c t o r a n d lo u v e r e d e n d m u s t
be k e p t free o f g re a se , d irt, o r o t h e r c o n t a m in a n t s .
R e m o v e o r D isc o n n e ct
A ls o , a v o id u s i n g c le a n in g s o lv e n t s o f a n y type. D o n o t
1. N e g a t iv e b a t t e r y cab le. d ro p o r r o u g h ly h a n d le th e o x y g e n s e n so r.
2. V a c u u m h a r n e s s a s s e m b ly .
3. E le c t r ic a l c o n n e c t o r r e le a s in g lo c k in g tab.
4. B o l t s o r r e le a s e lo c k t a b s a n d re m o v e se n so r.
 TH R O T T LE P O S IT IO N S E N S O R
Replacem ent - TBI
Figure 3 -2 7

Rem ove or D isco n n e ct

1. A i r c le a n e r , a d a p t e r , a n d g a sk e ts. D is c a r d
g a sk e ts.
2. E le c t r ic a l c o n n e c to r r e l e a s in g lo c k in g tab.
3. T w o T P S a t t a c h in g sc re w a s s e m b lie s .
4. T P S fro m th ro ttle b o d y a s s e m b ly .
5. T P S Seal.

NO TICE: T h e T P S is a n e le c tric a l c o m p o n e n t a n d
m u s t n o t be s o a k e d in a n y l i q u i d c l e a n e r , o r
so lv e n t, a s d a m a g e m a y re su lt.

Figure 3-26 - Oxygen ( 0 2) Sensor 5.7L Natural Gas Install or C o n n e c t

Powered Truck
1. T P S se a l o v e r t h r o t t le s h a f t a s s h o w n in
F i g u r e 3-27.
2. W it h th ro ttle v a lv e clo se d , in s t a ll T P S o n th ro tt le
R e m o v e or D isco n n e ct shaft. R o ta te c o u n t e r c lo c k w is e to a l i g n m o u n t in g
holes.
T h e O x y g e n ( O 2 ) s e n s o r m a y be d iffic u lt to re m o v e ,
3. T w o T P S a t t a c h in g s c re w a s s e m b lie s .
w h e n e n g in e te m p e r a t u r e is b e lo w 4 8 ° C (1 2 0 ° F ).
• R e fe r to " T h r e a d - L o c k i n g M a t e r i a l s . ”
E x c e s s iv e force m a y d a m a g e t h r e a d s in e x h a u s t
m a n if o ld o r e x h a u s t pipe.
^ T igh te n
l. N e g a t iv e b a t t e r y cable.
2. E le c t r ic a l c o n n e c t o r r e l e a s in g lo c k in g tab. • S c re w a s s e m b lie s to 2.0 N - m (1 8 .0 in. lb.).
3. C a r e f u lly b a c k o u t o x y g e n s e n so r. 4. E le c t r ic a l co n n e cto r.
5. A i r cle a n e r, a d a p te r, a n d n e w g a s k e t s.
+«- In stall o r C o n n e c t

Im p o rta n t
A s p e c ia l a n t i- s e iz e c o m p o u n d is u s e d o n th e
O x y g e n ( O 2) s e n s o r th re a d s. The com pound
c o n s is t s o f liq u id g r a p h it e a n d g l a s s b e a d s. T h e
g r a p h it e w ill te n d to b u r n a w a y , b u t th e g l a s s
b e a d s w ill r e m a in , m a k in g th e s e n s o r e a s i e r to
re m o ve .

N e w , o r s e r v ic e re p la c e m e n t s e n s o r s w ill a lr e a d y
h a v e th e c o m p o u n d a p p lie d to th e th re a d s. I f a s e n s o r
i s re m o v e d fr o m a n e n g in e , a n d if fo r a n y r e a s o n it is to
be r e i n s t a lle d , t h e t h r e a d s m u s t h a v e a n t i - s e i z e
1 SENSOR -THROTTLE P O S ITIO N (TPS)
c o m p o u n d a p p lie d b e fo re r e in s t a lla t io n .
2 SCREW A S S E M B L Y -T P S A TT A C H IN G
1. C o a t t h r e a d s o f o x y g e n s e n s o r w it h a n t i - s e i z e
c o m p o u n d ( G M P / N 5 6 1 3 6 9 5 o r e q u iv a le n t ) , i f 3 S E A L -T H R O T T L E P O S ITIO N SENSOR
M P 1 2 0 5 -A S
n e c e s s a ry .
2. S e n s o r , a n d to rq u e to 41 N - m (3 0 ft. lb.).
3. E le c t r ic a l c o n n e cto r.
4. N e g a t iv e b a t t e r y cable.
IN T A K E A IR T E M P E R A T U R E (IAT) S E N S O R V E H IC L E S P E E D S E N S O R B U F F E R (D R A C )
Figure 3-28 M ODULE
Figure 3-30
R e m o v e or D iscon n e ct
R e fe r to S E C T I O N 8 C , in th e a p p r o p r ia t e s e r v ic e
1. N e g a t iv e b a t te r y cable. m a n u a l fo r V e h ic le S p e e d S e n s o r B u f f e r ( D R A C )
2. E le c t r ic a l c o n n e c t o r r e le a s in g lo c k in g tab. M o d u le .
3. I A T se n so r. O n th e N a t u r a l G a s P o w e r e d T r u c k m o d e l t h e
D R A C is lo c a te d i n th e i n s t r u m e n t p a n e l n e a r th e
+ 4- Install or C o n n e ct ECM .
1. I A T se n so r.
2. E le c t r ic a l co n n e cto r.
3. N e g a t iv e b a t t e r y cable.

KN O CK SEN SO R

R e fe r to " E le c t r o n i c S p a r k C o n t r o l, ” S e c tio n " 7 ” fo r

re p la c e m e n t o f th e k n o c k se n so r.

Figure 3-28 - IAT Sensor

V E H IC L E S P E E D S E N S O R (V S S )
Figure 3-29

R e f e r to S E C T I O N 8 C , in S e r v ic e M a n u a l , fo r
V e h ic le S p e e d S e n s o r ( V S S ) se rv ic e , w h ic h is lo ca te d
o n th e t r a n s m is s io n .
Figure 3-30 - DRAC Module 5.7L Natural Gas Powered
Truck
P A R K /N E U T R A L (P/N) S W IT C H R e m o v e o r D isc o n n e ct
Figure 3-31
1. P la c e g e a r se le c to r in " n e u t r a l. ”
T h e P a r k / N e u t r a l (P / N ) s w it c h is lo ca te d o n th e 2. E le c t r ic a l c o n n e c to rs.
s t e e r in g c o lu m n . 3. S p r e a d t a n g s o n h o u s i n g a n d p u ll sw itc h .

♦«- Install a n d C o n n e c t
1. A l i g n a c t u a t o r o n s w itc h , w it h h o le in s h if t tube.
2. P o s it io n r e a r w a r d p o r t io n o f th e s w it c h (c o n n e c t o r
sid e ) to fit in to c u to u t in lo w e r ja c k e t.
3. P u s h d o w n o n fro n t o f s w it c h to e n g a g e th e tw o
ta n g s.
4. M o v e g e a r s e le c t io n to " p a r k ” a n d s w it c h is
adjusted.
5. E le c t r ic a l c o n n e c to rs.

PARTS INFORM ATIO N

PA R T N A M E GROUP

S e n so r, T h r o t t le P o s it io n : P a r t o f
S e n s o r K it , T h r o t t le P o s it io n . . . 3 .4 4 0

Figure 3-31 - Park/Neutral Switch

 SECTION 4

FUEL CONTROL SYSTEM

CNG TBI MODEL 220

CONTENTS
G en eral D escription ...............................................4-02 On-Vehicle Service ............................................4-12
D escription (TBI 2 2 0 ) ............................................... 4-02 General Service M a n u a l.............................. 4-12
M o d e s of O p e r a t i o n ...........................................4-02 CNG Fuel Injection and Service
S tartin g M o d e ...............................................4-02 Information ...............................................4-12
C lear Flood M o d e ....................................... 4-02 CNG Fuel Cylinder Pressure
Run M o d e .......................................................4-02 Relief Procedure ........................... ... . 4-15
O pen Loop ...................................................4-02 CNG Fuel Line Pressure
Closed Loop ...............................................4-03 Relief Procedure ..................................4-15
A cceleration M o d e ....................................... 4-03 Fuel System Pressure T e s t .................... 4-14
D eceleratio n M o d e ....................................... 4-03 TBI Unit Replacement ........................... 4-14
Decel E n-Lean m en t ...........................................4-03 Controlled Idle Speed Check ................. 4-15
Decel E n -L ean m en t O p eratio n ....................4-03 CNG Fuel Injection and TBI
B attery V o lta g e C orrection M o d e . . . 4-03 Component Service ..................................4-15
Fuel C ut-o ff M o d e ....................................... 4-03 Throttle Position Sensor (TPS) ................. 4-15
Fuel C ontrol O p eratio n ....................................... 4-04 Idle Air Control (IAC) V a l v e ........................4-15
T h ro ttle Body Injection (TBI) U nit . . . . 4-04 Throttle Body A s s e m b ly .............................. 4-16
V a c u u m P o r t s ...................................................4-04 CNG Fuel Injectors ..................................... 4-16
C NG Fuel Injectors ....................................... 4-05 CNG Injector P l a t e ........................................ 4-17
Fuel Pressure R egulator ........................... 4 -05 Fuel Supply Relay .............................. ... . . 4-18
Idle A ir C ontrol S ystem ........................... 4-05 CNG Control Relay .....................................4-18
T h ro ttle Position S enso r (TPS) . . . . 4-05 Oil Pressure Switch .....................................4-18
Fuel S u p p ly C ircuit ...........................................4-06 Fuel Cylinder Solenoid Valves ................. 4-19
CNG Fuel C ylin d ers ........................................... 4-06 Fuel Door Shut-Off Switch ........................4-19
Fuel Fill V a lv e ...............................................4-06 1/4 Turn Shut-Off Valve .............................. 4-19
A ccelerato r C ontrol ........................................... 4-06 Fuel Pressure Transducer ........................... 4-20
Fuel C ontrol S ystem (TBI 220) ....................... 4-06 CNG Fuel Pressure Regulator ................. 4-20
C N G Fuel Injectors ....................................... 4-07 Low Pressure Fuel Shut-Off Solenoid . . 4-21
Pressure R eg u lato r ....................................... 4-07 CNG Fuel Line and Hose Assemblies . . 4-21
Idle A ir C ontrol ...............................................4-07 Materials .................................................. 4-21
T h ro ttle Position S enso r (TPS) . . . . 4-07 Fuel Fill Valve ........................................ 4-21
D riv e a b ility S y m p to m s ............................... 4-08 Fuel Fill Valve to Fuel "T " Line . . . . 4-22
Fuel S u p p ly C ircuit ........................................... 4-08 Fuel Supply Hose ..................................4-23
Fuel S u p p ly R elay ....................................... 4-08 Fuel Injector Plate Supply Line . . . . 4-23
Oil Pressure S w itch ................................... 4-08 CNG Fuel Cylinders ..................................... 4-24
Fuel Pipes and Hoses ............................... 4-08 Right Side ...............................................4-24
C N G Fuel C ylinders ................................... 4-08 Left Side Dual ........................................ 4-24
A ccelerato r C ontrol ........................................... 4-08 Accelerator Control ..................................... 4-26
Idle A ir C ontrol (IAC) S ystem Check Accelerator Control Cabel .................... 4-26
5.7L C N G w ith 4L 60 Transm ission . . . . 4-10 Accelerator Pedal ..................................... 4-26
IAC V alve Reset Procedure ........................... 4-10 Parts In fo r m a tio n ...............................................4-27
1992 Controlled Idle Speed ........................4-27
Minim um Idle Speed ..................................4-27
 GENERAL DESCRIPTION
T h e fu e l c o n tro l s y s t e m fo r th e C N G t r u c k i s a
T h r o t t l e B o d y I n j e c t i o n ( T B I ) 2 2 0 m o d if ie d fo r
c o m p r e s s e d n a t u r a l g a s . T h e t h r o t t le b o d y fo r t h e
5 . 7 L C N G e n g in e o n ly c o n t r o ls a i r flow . T h e C N G
fu e l in je c t o rs lo c a te d i n th e in je c to r p la t e b e lo w th e
t h r o t t le b o d y c o n t r o ls fu e l d e liv e ry .
T h i s s e c t io n w i l l c o v e r D e s c r ip t io n , M o d e s o f
O p e r a t io n , F u e l C o n t r o l a n d A c c e le r a t o r C o n t r o l o f
t h e c o m p re s s e d n a t u r a l g a s ( T B I ) 2 2 0 .
DESCRIPTION (TBI 220)
Figure 4-1
The fu e l c o n tro l sy ste m is c o n t r o lle d by an
E l e c t r o n i c C o n t r o l M o d u l e ( E C M ) lo c a t e d i n t h e
p a s s e n g e r c o m p a rtm e n t. T h e E C M is th e c o n tro l
c e n te r o f th e c o m p u te r c o m m a n d c o n tro l sy ste m
f o u n d i n “C o m p u t e r C o m m a n d C o n t r o l, ” S e c t io n “3 ”
w h i c h p r o v id e s a d d i t i o n a l i n f o r m a t i o n a b o u t f u e l
c o n t r o l a n d d e liv e ry .
T h e b a s ic fu n c t io n o f th e fu e l c o n tro l s y s t e m is
to c o n t r o l f u e l d e l i v e r y to t h e e n g i n e . F u e l i s
d e l iv e r e d to t h e e n g in e by a T h r o t t le Body
In j e c t io n ( T B I ) u n it.
T h e m a i n c o n t r o l s e n s o r i s t h e O x y g e n ( 0 2)
s e n s o r , w h i c h i s lo c a t e d i n t h e e x h a u s t m a n if o ld .
T h e 0 2 s e n s o r t e lls th e E C M th e a m o u n t o f o x y g e n
i n th e e x h a u s t g a s, a n d th e E C M c h a n g e s th e a i r /
f u e l r a t i o to t h e e n g i n e b y c o n t r o l l i n g t h e f u e l
in je c t o r. B e c a u s e t h e c o n s t a n t m e a s u r in g a n d
a d j u s t i n g o f t h e a ir / f u e l r a t io , t h e f u e l i n j e c t io n
s y s t e m i s c a lle d a “C lo s e d L o o p ” s y s t e m ( F i g u r e
4-1).
S e v e r a l o th e r im p o r t a n t e n g in e o p e r a t io n
p a r a m e t e r s in c lu d e : e n g in e sp e e d , m a n if o ld
p r e s s u r e , e n g i n e c o o la n t t e m p e r a t u r e a n d t h r o t t le
p o sitio n . T h e s e p a r a m e t e r s d e t e r m in e th e “m o d e ” o f
e n g in e o p e ra tio n .
M O D E S OF O P E R A T IO N
T h e E C M m o n it o r s v o lt a g e s fro m s e v e r a l
s e n s o r s to d e t e r m i n e h o w m u c h f u e l to g i v e t h e
e n g in e . T h e f u e l i s d e l iv e r e d u n d e r o n e o f s e v e r a l
c o n d it io n s c a ll e d “m o d e s ” A l l t h e m o d e s a r e
co n tro lle d b y th e E C M .
Startin g M o d e
W h e n th e k e y i s f i r s t t u r n e d “O N , ” t h e E C M
t u r n s o n th e fu e l s u p p l y r e l a y fo r tw o se c o n d s, a n d
th e s y s t e m b u ild s u p p r e s s u r e to th e T B I u n it . T h e
E C M c h e c k s th e C o o la n t T e m p e ra tu re S e n s o r
(C T S ), T h r o t t le P o s it io n S e n s o r ( T P S ) , M a n if o ld
A b s o lu t e P r e s s u r e ( M A P ) se n s o r, a n d c r a n k s ig n a l,
th e n d e t e r m in e s th e p r o p e r a ir / fu e l r a t io fo r
s t a rt in g .
T h e E C M c o n t r o ls th e a m o u n t o f fu e l d e liv e r e d
in th e s t a r t in g m od e b y c h a n g in g h o w lo n g th e
in je cto r is t u r n e d “O N ” a n d ”O F F ” T h i s is d o n e b y
“p u l s i n g ” th e in je c to r fo r v e r y s h o r t tim e s.
Clear Flood M o d e
H o l d d o w n t h e a c c e le r a t o r p e d a l a s d e s c r ib e d
fo r th e ( T B I) 2 2 0 g a s o lin e e n g in e .
Run M o d e
T h e R u n M o d e is th e m o d e u n d e r w h ic h th e
e n g in e o p e ra te s m o s t o f th e tim e . I n t h is m ode, th e
e n g i n e o p e r a t e s i n o n e o f t w o c o n d i t i o n s : “O p e n
L o o p ” a n d “C lo s e d L o o p . ”
Open Loop
W h e n th e e n g in e is f ir s t s ta rt e d , a n d it is
a b o v e 4 0 0 rp m , t h e s y s t e m g o e s i n t o “O p e n L o o p ”
o p e ra tio n . I n “O p e n L o o p , ” t h e E C M i g n o r e s th e
s i g n a l fr o m t h e 0 2 s e n s o r , a n d c a lc u la t e s t h e a ir/
fu e l r a t io b a s e d o n in p u t s fro m th e C o o la n t
T e m p e ra tu re S e n s o r ( C T S ) a n d M a n if o ld A b s o lu t e
P r e s s u r e ( M A P ) se n so r.
 On a heated Oxygen ( 0 2) sensor, w h e n t h e
ig n it io n i s t u r n e d to t h e “O N ” p o s it io n , b a t t e r y
v o lt a g e i s a p p l ie d to t h e O x y g e n s e n s o r ’s b u i l t - i n
h e a t e r e le m e n t . A p p r o x i m a t e l y 3 0 s e c o n d s a f t e r
v o lt a g e i s a p p lie d to th e he a ter, th e s e n s o r re a c h e s
a te m p e ra t u re a b o v e 500°C . T h r o u g h o u t v a r io u s
v e h ic le o p e r a t i o n a l c o n d it io n s , th e h e a t e r e le m e n t
e n s u r e s th e s e n s o r c o n s is t e n t ly o p e ra te s in th a t
t e m p e r a t u r e ra n g e .
H e a t e d s e n s o r s c o n t a in a n in te rn a l, e le c tr ic a lly
p o w e r e d h e a te r. A s su c h , t h e y a re n o t a s d e p e n d e n t
o n e n g i n e h e a t to a c h i e v e m i n i m u m o p e r a t i n g
t e m p e r a t u r e . T h e h e a t e d s e n s o r b e c o m e s a c t iv e
fa ste r d u r in g e n g in e w a r m u p th a n a n u n h e a te d
s e n s o r . T h is m a y o r m a y n o t be d e s ir a b le ,
d e p e n d in g o n t h e d e s ig n o f th e p a r t ic u la r e m is s io n
c o n t r o l s y s t e m . T h e h e a t e d s e n s o r r e m a i n s a c t iv e
d u r in g lo n g id le s o n e n g in e s w it h cool e x h a u s t
w h il e t h e u n h e a t e d s e n s o r m a y co o l b e lo w it s
m in im u m o p e r a t in g p o in t a n d sto p s a t is f a c t o r y
fu n c t io n .
Closed Loop
T h e s p e c i f i c v a l u e s fo r t h e a b o v e c o n d i t i o n s
v a r y w i t h d if f e r e n t e n g in e s , a n d a r e s to re d i n t h e
P r o g r a m m a b le R e a d O n l y M e m o r y ( P R O M ) . W h e n
t h e s e c o n d i t i o n s a r e m e t, t h e s y s t e m g o e s i n t o
“C lo s e d L o o p ” o p e ra tio n .
I n “C lo s e d L o o p , ” t h e E C M c a lc u la t e s th e a i r /
f u e l r a t i o ( in j e c t o r o n - t i m e ) b a s e d o n t h e s i g n a l
fro m th e 0 2 s e n so r. T h i s a llo w s th e air/ fu e l r a t io to
s t a y v e r y clo se to 16.3:1.
Acceleration M o d e
W h e n th e E C M s e n s e s r a p id c h a n g e s in th ro tt le
p o s it io n a n d m a n i f o l d p r e s s u r e , t h e s y s t e m e n t e r s
th e A c c e le r a t io n M o d e a n d p r o v id e s th e e x t ra fu e l
n e e d e d fo r s m o o t h a c c e le ra tio n .
Deceleration M o d e
W h e n d e c e le r a tio n o ccu rs, th e fu e l r e m a i n i n g i n
th e in t a k e m a n if o ld c a n c a u s e e x c e s siv e e m is s io n s
a n d b a c k fir in g . W h e n th e E C M o b se rv e s a fa st
r e d u c t io n i n t h r o t t le o p e n in g a n d a s h a r p d e c re a se
i n m a n if o ld p r e s s u r e , it c a u s e s th e s y s t e m to e n te r
t h e D e c e le r a t io n M o d e , r e d u c in g th e a m o u n t o f fu e l
d e liv e r e d to th e e n g in e . W h e n d e c e le ra tio n is v e r y
fa st, th e E C M c u t s o f f f u e l c o m p le t e ly fo r s h o r t
p e rio d s.
Decel E n-leanm ent
O n d e c e le r a t io n , t h e E C M s e n s e s a h i g h M A P
v a c u u m ( lo w v o l t a g e o r k P a ) a n d l e a n s t h e f u e l
s p r a y fo r e m is s io n re a so n s, b u t it s h o u l d b e n o t e d
t h a t th e E C M c a n t r ig g e r t h is c o n d it io n (D e c e l E n -
L e a n m e n t ) w h ile th e v e h ic le is n o t m o v in g . O n
5 . 7 L a p p lic a t io n , w h ile h o l d in g th e t h r o t t le s t e a d y
a b o v e 1 4 7 5 rp m , th e E C M c a n b e fo o le d in t o D e c e l
E n -L e a n m e n t.
T e c h 1 r e a d in g s w o u ld b e th e s a m e fo r b lo c k
le a r n , i n t e g r a t o r a n d o x y g e n s e n s o r , a s w o u l d b e
s e e n fo r t h e H i g h w a y F u e l M o d e o r s e m i - “C l o s e d
L o o p ” m e n t io n e d a b o ve . I f it is d e t e r m in e d t h a t th e
E C M i s i n t h i s f u e l i n g m o d e , l o w e r t h e r p m to
1 0 0 0 a n d c h e c k t h e o x y g e n s e n s o r a c t iv it y . I f t h e
s e n s o r n o w h a s v o lt a g e m o v e m e n t a n d a c t i v i t y o n
c ro s s c o u n ts, th e s y s t e m is o p e r a t in g n o r m a l. I f th e
s e n s o r is s t i l l r e a d in g lo w v o lt a g e , lo o k fo r a n o t h e r
cau se .
Decel E n-leanm ent O peration
T h i s m o d e o f o p e r a t io n c a n b e m is - d ia g n o s e d a s
a l e a n c o n d it io n . T h e E C M w i l l r u n t h e s y s t e m
le a n o n d e c e l, o r i f t h e M A P s e n s o r s e n s e s a lo w
v o lt a g e ( h ig h e n g in e v a c u u m ), w it h th e v e h ic le
s t a n d in g s till, it w i ll le a n o u t th e fu e l d e liv e r y . I f
it i s n o t e d w h ile t e s t in g a n E C M s y s t e m ( w it h
T e c h 1) a n d t h e t r a n s m i s s i o n i s i n p a r k , t h a t t h e
0 2 r e a d in g is lo w ( u s u a l ly b e lo w 1 00 m V ) a n d t h e
b lo c k le a r n a n d in t e g r a t o r a re b o t h a r o u n d t h e 12 8
c o u n ts, lo w e r th e e n g in e sp e e d to 1 0 0 0 rp m .
I f t h e o x y g e n s e n s o r a n d b lo c k l e a r n n u m b e r s
r e s p o n d n o r m a l l y a t th e rp m , i t ’s p o s s ib le t h a t th e
s y s t e m w a s f o o le d i n t o t h e D e c e l E n - L e a n m e n t
m o d e o f o p e r a t io n . I f t h e o x y g e n s e n s o r a n d b l o c k
n u m b e r s do n o t r e s p o n d a t th e lo w e r r p m r e a d in g s ,
t h e r e a re o t h e r p r o b le m s w it h th e v e h ic le .
Battery V o lta g e Correction M o d e
W hen b a t t e r y v o lt a g e i s lo w , t h e E C M can
c o m p e n sa te fo r a w e a k sp a rk d e liv e r e d to t h e
d is t r ib u t o r by:
• In c r e a s i n g in je c to r o n tim e.
• I n c r e a s i n g th e id le rp m .
• I n c r e a s i n g ig n i t i o n d w e ll tim e.
Fuel Cut-off M o d e
N o f u e l i s d e l iv e r e d b y t h e in j e c t o r s w h e n t h e
ig n i t i o n is “O F F . ” T h i s p r e v e n t s d ie s e lin g .
 A l s o , fu e l is n o t d e liv e r e d i f n o re fe re n c e p u ls e s
a re se e n fro m th e d is trib u t o r, w h ic h m e a n s th e
e n g i n e i s n o t r u n n i n g . F u e l c u t - o f f a ls o o c c u r s a t
h i g h e n g i n e r p m , to p r o t e c t i n t e r n a l e n g i n e
c o m p o n e n t s fro m d a m a g e .
FUEL CONTROL OPERATION
V a cu u m Ports
T h e th ro tt le b o d y p o r t io n o f th e T B I u n i t m a y
c o n t a in p o r t s lo c a t e d a b o v e , o r b e lo w t h e t h r o t t le
v a lv e . T h e s e p o r t s g e n e r a t e t h e v a c u u m s i g n a l s fo r
t h e E x h a u s t G a s R e c i r c u l a t i o n ( E G R ) v a lv e , a n d
t h e M A P se n so r.

T h e fu e l c o n tro l s y s t e m c o n s is t s o f th e f o llo w in g
c o m p o n e n ts:
• T h r o t t le B o d y In je c t io n ( T B I ) u n it.
• C N G F u e l c y lin d e rs .
• F u e l c y lin d e r s o le n o id v a lv e .
• 1/4 t u r n s h u t - o f f v a lv e .
• C N G F u e l p r e s s u r e r e g u la t o r.
• L o w p r e s s u r e fu e l s h u t - o f f so le n o id .
• C N G fu e l in je cto rs.
• A c c e le r a t o r co n tro l.
• F u e l lin e s.
1 THROTTLE BODY ASSEM BLY
T h e f u e l c o n t r o l s y s t e m h a s t h r e e p r e s s u r iz e d
C N G f u e l c y l i n d e r s t h a t d e l i v e r t h e f u e l. T h e 2 THROTTLE POSITION SENSO R (TPS)
c y lin d e r s a re f u lly p r e s s u r iz e d a t 3 6 0 0 p s i a n d th e 3 IDLE AIR CONTROL (IAC) VA LVE ASSEM BLY
p r e s s u r e w ill d ro p a s fu e l is re le a s e d fro m th e
c y lin d e r s . M P1191-A S -C N G
T h e c o m p re sse d n a t u r a l g a s c y lin d e r s a re
o p e r a t e d w i t h f u e l c y l i n d e r s o le n o id v a l v e s . T h e s e Figure 4-2 - TBI Unit
v a l v e s a r e n o r m a l l y c lo s e d u n t i l t h e i g n i t i o n i s
t u r n e d to th e “O N ” p o s it io n . T h e v a l v e s w i l l clo se
u n l e s s c r a n k s ig n a l s o r o il p r e s s u r e s i g n a l s a re
re c e iv e d w i t h in 2 seco n d s. 4
A C N G fu e l p r e s s u r e r e g u la t o r i n th e fu e l lin e
s y s t e m k e e p s c o m p r e s s e d n a t u r a l g a s a v a i l a b l e to
t h e C N G in je c to rs a t a c o n s t a n t p r e s s u r e o f 17 5 psi.
T h e p r e s s u r e r e g u la t o r is h e a te d w it h e n g in e
c o o la n t to k e e p th e fu e l s u p p lie d to th e in je c to rs a t
a c o n s t a n t te m p e ra t u re .
F u e l i s a ls o c o n t r o lle d a f t e r t h e f u e l p r e s s u r e
r e g u l a t o r b y a lo w p r e s s u r e f u e l s h u t - o f f s o le n o id .
T h i s s o le n o id is n o r m a l l y c lo se d u n t i l th e i g n i t i o n
i s t u r n e d to t h e “O N ” p o s it io n . T h e s o le n o id w i l l
c lo s e w i t h i n 2 s e c o n d s i f n o c r a n k o r o il p r e s s u r e
s i g n a l s a re re c e iv e d b y th e E C M .
T h e E C M c o n t r o ls th e C N G in je c to r t h a t is
lo c a te d i n th e fu e l m e t e r b o d y a s s e m b ly o f th e T B I .
T h e in je c to r d e liv e r s fu e l i n o n e o f s e v e r a l m o des,
d e s c r ib e d p r e v io u s ly .
2 FUEL INJECTOR

T H R O T T L E B O D Y IN J E C T IO N (TBI) U N IT 3 CNG INJECTOR PLATE

F ig u re 4 -2 4 THROTTLE BODY ASSEM BLY

A THROTTLE VALVE
T h e T B I u n it c o n s is t s o f a:
• T h r o t t le b o d y w ith :
Id le A i r C o n t r o l ( I A C ) V a l v e A s s e m b ly . 8P 0320-SY-C N G
T h r o t t le P o s it io n S e n s o r ( T P S ) .
Figure 4-3 - TBI Unit Operation
C N G Fuel Injectors
Figure 4-3
1
T h e C N G fu e l in je c t o r ( F ig u r e 4 -3 ) is a
s o le n o id - o p e r a t e d d e v ic e , c o n t r o lle d b y th e E C M .
T h e E C M t u r n s “O N ” t h e s o le n o id , w h ic h l i f t s a
n o r m a l l y c lo s e d b a l l v a l v e o ff a seat. C o m p r e s s e d
n a t u r a l g a s i s in j e c t e d in t o t h e t h r o t t le b o d y b o r e
b e lo w t h e t h r o t t le v a lv e .

Fuel Pressure R egu lato r

T h e C N G f u e l p r e s s u r e r e g u l a t o r is a p i s t o n
t y p e r e g u l a t o r . I t i s lo c a t e d o n t h e d r i v e r s id e
f r a m e ra il. T h e r e g u la t o r ’s fu n c t io n is to m a in t a in
a c o n s t a n t fu e l p r e s s u r e to th e C N G fu e l injectors.
T h e s y s t e m o p e r a t e s i n a n a c c e p t a b le p r e s s u r e
r a n g e o f 1147 to 1 2 6 7 k P a (166 to 184 p si) a t idle. 1 THRO TTLE BODY ASSEM BLY
I f t h e fu e l p r e s s u r e is too lo w (b elo w 1147 k P a
2 ID LE A IR C O N T R O L V A L V E A S S E M B L Y
o r 1 6 6 p s i), p o o r p e r f o r m a n c e c o u ld r e s u l t w i t h a
A FILTE R E D A IR IN L E T
le a n code. I f t h e p r e s s u r e i s to o h i g h (a b o v e 1 1 4 7
kPa o r 1 8 4 p s i), e x c e s s iv e e m is s io n s , u n p l e a s a n t B P IN TL E

o d o r a n d p o o r i d le q u a l i t y m a y r e s u l t w i t h a r i c h C THRO TTLE VA LVE

code.
Idle A ir C o n tro l S y ste m
Figure 4-4
A l l e n g i n e i d l e s p e e d s a r e c o n t r o lle d b y t h e
E C M t h r o u g h th e Id le A i r C o n t r o l ( IA C ) v a lv e
m o u n t e d o n t h e t h r o t t l e b o d y ( F i g u r e 4 -4 ). T h e
EC M send s v o lt a g e p u ls e s to th e IA C m o to r
w i n d i n g s c a u s i n g t h e I A C m o to r s h a ft a n d p in t le to
m o v e “I N ” o r “O U T ” a g i v e n d is t a n c e ( n u m b e r o f
ste p s) fo r e a c h p u ls e (c a lle d co u nts).
T h is m ovem ent c o n t ro ls a ir flo w a ro u n d th e
t h r o t t le p la t e , w h i c h i n t u r n , c o n t r o ls e n g in e id le
speed, e it h e r c o ld o r hot. I A C v a lv e p in t le p o s it io n
c o u n t s c a n b e s e e n u s i n g a T e c h 1 “S c a n ” tool. Z e r o
(0) c o u n t s c o r r e s p o n d to a f u l l y c lo s e d p a s s a g e ,
w h ile 140 c o u n t s o r m o re (d e p e n d in g on th e
a p p lic a t io n ) c o r r e s p o n d s to f u ll flow .
• A c t u a l o r “c o n t r o lle d ” id le sp e e d i s o b ta in e d b y
th e E C M p o s it io n in g th e I A C v a lv e p in t le .
R e s u l t i n g id le sp e e d is g e n e ra te d fro m th e t o t a l
id le a ir flo w ( IA C / p a s s a g e + P C V + t h ro t t le
v a lv e + v a c u u m le a k s ).
• C o n t r o l l e d i d l e s p e e d i s a l w a y s s p e c if ie d f o r
n o r m a l o p e r a t in g c o n d it io n s. N o r m a l o p e r a t in g
c o n d it io n i s c o o la n t t e m p e r a t u r e i n o p e r a t i n g
ra n g e , th e A / C is “O F F , ” a u t o m a t ic
t r a n s m is s io n i n d r iv e w i t h p ro p e r P a r k / N e u t r a l
(P / N ) s w it c h a d ju s t m e n t. A h i g h o r lo w c o o la n t
te m p e ra t u re , o r A / C c lu t c h e n g a g e m e n t m a y
s i g n a l th e E C M to c h a n g e th e I A C counts.
D V A C U U M P O R TS - FO R E N G IN E O R
E M IS S IO N C O N T R O L S
8P 0 3 1 9 -S Y -C N G
Figure 4-4 - Idle Air Control System
• T h e m i n i m u m id le s p e e d i s s e t a t t h e f a c t o r y
w i t h a s t o p sc re w . T h i s s e t t i n g a l l o w s e n o u g h
a i r flo w b y th e t h r o t t le v a l v e s to c a u s e t h e I A C
v a l v e p i n t l e to b e p o s i t i o n e d a c a l i b r a t e d
n u m b e r o f ste p s (co u n ts) fro m th e s e a t d u r in g
n o r m a l c o n t r o lle d id le o p e r a t io n . T h e I A C
c o u n t s w i l l b e h i g h e r t h a n n o r m a l o n a n e n g in e
w it h le s s t h a n 5 0 0 m ile s , o r a n e n g in e
o p e r a t in g a t h i g h a lt it u d e o r a n e n g i n e w i t h a n
a c c e s s o ry lo a d s u c h a s th e a lt e r n a t o r , A / C ,
p o w e r s t e e r in g o r h y d r a - b o o s t b r a k e s a c t iv a te d .
Throttle P o sitio n S e n s o r (T PS)
Figure 4-5
T h e n o n -a d ju s t a b le T h r o t t le P o s it io n s e n s o r
(T P S ) , i s m o u n t e d o n th e s id e o f t h e t h r o t t le b o d y
o p p o site t h e t h r o t t le le v e r a s s e m b ly . I t s f u n c t io n i s
to s e n s e t h e c u r r e n t t h r o t t l e v a l v e p o s i t i o n a n d
r e l a y t h a t in f o r m a t io n to th e E C M (re fe r to F i g u r e
4-5). T P S in f o r m a t io n a llo w s th e E C M to g e n e r a t e
th e r e q u ir e d in je c t o r c o n t ro l s i g n a l s (b a s e p u lse ).

Figure 4-5 - Throttle Position Sensor (TPS)
A s t h e t h r o t t l e v a l v e r o t a t e s i n r e s p o n s e to
m o v e m e n t o f t h e a c c e l e r a t o r p e d a l, t h e t h r o t t l e
s h a f t t r a n s f e r s t h is r o t a t io n m o v e m e n t to t h e T P S .
A p o t e n t io m e t e r ( v a r ia b le r e s is t o r ) w i t h in th e
T h r o t tle P o s it io n S e n s o r a s s e m b ly c h a n g e s it s
re s is t a n c e (a n d v o lt a g e d ro p ) in p r o p o r t io n
t h r o t t le m o v e m e n t.
B y a p p l y i n g a r e f e r e n c e v o lt a g e (5 .0 v o lt s ) to
th e T P S in p u t , a v a r y in g v o lt a g e ( r e f le c t in g
t h r o t t le p o s it io n ) i s a v a i l a b l e a t t h e T P S o u t p u t .
F o r e x a m p le , a p p r o x im a t e ly 2 .5 v o lt s r e s u lt s fr o m a
5 0 % t h r o t t le v a lv e o p e n in g ( d e p e n d in g o n T P S
c a lib r a t io n ) . T h e v o lt a g e o u tp u t fro m th e T P S
a s s e m b ly is ro u te d to th e E C M fo r u se
d e t e r m i n i n g t h r o t t le p o s it io n .
F U E L S U P P L Y C IR C U IT
F ig u re 4 -6
T h e co m p re sse d n a t u r a l g a s tr u c k does not
h a v e a fu e l p u m p . T h e C N G fu e l c y lin d e r s p r o v id e
t h e r e q u i r e d f u e l p r e s s u r e . F u e l c y l i n d e r s o le n o id
v a l v e s o n th e c y lin d e r s c o n tro l fu e l s u p p ly . T h e
f u e l s u p p l y r e l a y o p e ra te s th e s o le n o id v a lv e s .
W h e n th e k e y is f ir s t t u r n e d “O N ” w it h o u t th e
e n g in e r u n n i n g , th e E C M t u r n s a fu e l s u p p l y r e la y
“O N ” f o r t w o s e c o n d s . T h i s b u i l d s u p t h e f u e l
p r e s s u r e q u ic k ly . I f th e e n g in e i s n o t s t a r t e d w i t h in
tw o se c o n d s, th e E C M s h u t s th e fu e l s o le n o id
v a l v e s “O F F ” a n d w a it s u n t i l th e e n g in e s ta rts. A s
s o o n a s th e e n g in e is c ra n k e d , th e E C M t u r n s th e
r e l a y “O N ”.
W h e n th e e n g in e is c r a n k in g o r r u n n in g , th e
E C M re c e iv e s d is t r ib u t o r re fe re n c e p u ls e s w h ic h i n
t u r n e n e rg iz e th e fu e l in je cto rs.
A s a b a c k u p s y s t e m to t h e f u e l s u p p l y r e la y ,
t h e f u e l s u p p l y i s a l s o t u r n e d “O N ” b y a n o i l
p r e s s u r e s w it c h . W h e n t h e e n g i n e o i l p r e s s u r e
re a c h e s a b o u t 2 8 k P a (4 p si), t h r o u g h c r a n k in g , th e
o il p r e s s u r e s w it c h w i l l clo se to c o m p le te th e c ir c u it
to th e C N G c o n tro l re la y .
A n in o p e r a tiv e fu e l s u p p ly r e la y c a n r e s u lt in
l o n g c r a n k i n g t im e s , p a r t i c u l a r l y i f t h e e n g i n e i s
cold. T h e o il p r e s s u r e s w it c h w i l l t u r n “O N ” t h e
fu e l s u p p ly s o le n o id s a s so o n as o il p re ssu re
re a c h e s a b o u t 2 8 k P a (4 psi).
C N G FU EL C Y L IN D E R S
T h e th re e C N G f u e l c y lin d e r s , at th e re a r o f
th e u n d e r b o d y , a r e h e ld i n p la c e b y m e t a l s t r a p s
w it h r u b b e r iso la to rs .
Fuel Fill Valve
T h e fu e l f ill v a lv e is w h e re y o u c o n n e c t th e
f u e l f i l l l i n e to r e f u e l. T h e f u e l f i l l v a l v e h a s a
q u ic k c o n n e c t f it t in g a n d a o n e w a y v a lv e . T h e
o n e -w a y v a lv e w i l l o n ly a llo w fu e l in t o th e s y ste m .
ACCELERATOR CO NTRO L
to
T h e a c c e le ra to r c o n tro l s y s t e m is a c o n t ro l c a b le
type, a tta c h e d to a n a c c e le ra t o r p e d a l a s s e m b ly .
FU EL C O N T R O L S Y S T E M (TBI 220)
A l w a y s b e g in d i a g n o s i s w i t h t h e "Diagnostic
Circuit Check" f o u n d i n “C o m p u t e r C o m m a n d
in C o n t r o l , ” S e c t i o n “3 ”, b e f o r e p r o c e e d i n g to a n y
o t h e r d ia g n o s t ic s . T h i s w i l l r e d u c e d i a g n o s i s t im e
a n d p re v e n t u n n e c e s s a r y re p la c e m e n t o f p a rt s . T h e
"Diagnostic Circuit Check" w i l l g i v e d ir e c t io n to
f u r t h e r d ia g n o s t ic s , s u c h a s "Engine Cranks But
W o n 't R un" a n d Fuel S y s te m D ia g n o s is , "
i n c lu d i n g d ia g n o s is o f in je cto r, p r e s s u r e re g u la t o r ,
fu e l s o le n o id v a lv e s , fu e l s u p p l y r e la y , a n d o il
p r e s s u r e sw itc h .
I f a p ro b le m o ccu rs in th e fu e l m e t e r in g
s y s t e m , it u s u a l l y r e s u l t s i n e i t h e r a r i c h o r le a n
o x y g e n s e n s o r a n d c a u s e s t h e E C M to c h a n g e t h e
fu e l c a lc u la t io n (in je c to r p u ls e w id th ). T h e c h a n g e
m a d e to t h e f u e l c a l c u l a t i o n i s i n d i c a t e d b y a
c h a n g e i n t h e i n t e g r a t o r a n d b lo c k l e a r n v a l u e s ,
w h ic h c a n b e m o n it o r e d b y a T e c h 1 “S c a n ” to o l.
W h e r e a s i n a g a s o l i n e p o w e r e d e n g i n e t h e b lo c k
le a r n v a l u e s w i l l be a r o u n d 128, n o r m a l b lo c k le a r n
v a l u e s i n t h e n a t u r a l g a s v e h ic le c a n r a n g e fr o m
100 to 160 c o u n ts.
I f b o th th e in t e g r a t o r a n d b lo c k le a r n v a lu e s
a r e f i x e d a b o v e 1 7 0 , r e f e r to C o d e 4 4 fo r i t e m s
w h ic h c a n c a u s e a le a n s y ste m .
 LO W P R E S S U R E FU E L
S H U T -O F F S O L E N O ID C N G FU E L C Y L IN D E R S

TRANSDUCER C U T -O F F S W IT C H
8S 4 3 3 1 -6 E -C N G

Figure 4-6-Fuel Supply System

I f th e in t e g r a t o r a n d b lo c k l e a r n v a l u e s a r e Idle A ir Control
fix e d b e lo w 90, r e f e r to C o d e 4 5 fo r it e m s w h i c h
c a n c a u se th e s y s t e m to r u n rich. I f a d r iv e a b ilit y T h e d i a g n o s i s o f id le a i r c o n t r o l c a n b e f o u n d
s y m p t o m e x is ts , re fe r to th e p a r t ic u la r s y m p to m i n in t h is sectio n .
“D r i v e a b i l i t y S y m p t o m ” in S e c t io n “3 ” f o r I f t h e I A C v a l v e i s d is c o n n e c t e d o r c o n n e c t e d
a d d it io n a l it e m s to ch eck. w i t h t h e e n g i n e r u n n i n g , t h e i d le r p m m a y b e
w ro n g . I n t h is case, th e I A C v a l v e m a y b e re s e t b y
C N G Fuel Injectors t u r n i n g th e e n g in e “O F F ” fo r te n s e c o n d s a n d t h e n
T e s t i n g t h e f u e l in j e c t o r c ir c u it is in C H A R T r e - s t a r t in g th e e n g in e .
A - 3 a n d a d d it io n a l d ia g n o s is in C H A R T A - 4 in T he IA C v a lv e a ffe c t s o n ly th e id le
“C o m p u t e r C o m m a n d C o n t r o l, ” S e c t io n “3 ”. c h a r a c t e r is t ic s o f t h e e n g in e . I f it is o p e n fu lly , too
A fu e l in je c to r w h ic h d o es n o t o p e n m a y c a u s e m u c h a i r w i l l b e a llo w e d to th e m a n if o ld a n d id le
a n o - s t a r t c o n d it io n . A n in j e c t o r w h i c h i s s t u c k sp e e d w i l l b e h i g h . I f it i s s t u c k c lo se d , to o li t t le
p a r t ly o p e n , c o u ld c a u s e lo s s o f p r e s s u r e a ft e r a i r w i l l b e a llo w e d i n th e m a n ifo ld , a n d id le sp e e d
s it t i n g , so l o n g c r a n k t i m e s w o u ld b e n o t ic e d o n w i l l b e to o lo w . I f it i s s t u c k p a r t w a y o p e n , t h e
s o m e e n g in e s . id le m a y be r o u g h , a n d w i ll n o t r e s p o n d to e n g in e
A l s o , d i e s e l i n g c o u ld o c c u r b e c a u s e s o m e f u e l lo a d c h a n g e s.
c o u ld b e d e l iv e r e d to t h e e n g in e a ft e r th e k e y i s T h e m i n i m u m id le s p e e d i s se t a t t h e f a c t o r y
t u r n e d “O F F . ” w i t h a s to p sc re w . T h e s t o p s c r e w s h o u l d n o t b e
a d ju ste d .
Pressure R e gu lato r V a c u u m le a k s w ill c a u se th e I A C v a lv e p in t le
T e s t in g th e p r e s s u r e r e g u la t o r is in C H A R T to b e “s t e p p e d ” c lo s e r to t h e s e a t o r to b e c lo s e d
A - 3 a n d C H A R T A - 4 i n “C o m p u t e r C o m m a n d a g a i n s t i t s s e a t i n a n a t t e m p t to m a i n t a i n
C o n t r o l, ” S e c t io n “3 .” c o n tro lle d id le speed.
I f th e p r e s s u r e r e g u la t o r s u p p lie s p r e s s u r e
w h ic h is too lo w (b e lo w 1147 k P a o r 166 psi), p o o r Throttle Po sitio n S e n so r (TPS)
p e r f o r m a n c e c o u ld r e s u l t . I f t h e p r e s s u r e i s to o
h ig h , e x c e ss e m is s io n s a n d u n p le a s a n t e x h a u s t o d o r R e f e r to “C o m p u t e r C o m m a n d C o n t r o l, ” S e c t io n
m a y re su lt. “3 ,” fo r d ia g n o s is o f th e t h ro t t le p o s it io n s e n so r.
D riveability S y m p t o m s Oil Pressure S w itc h

R e f e r to “D r i v e a b i l i t y S y m p t o m s , ” S e c t io n “2 ”, R e fe r to “F u e l S u p p l y R e l a y C i r c u i t D i a g n o s i s ”
fo r a d d it io n a l fu e l c o n t r o l d ia g n o s is . i n “C o m p u t e r C o m m a n d C o n t r o l , ” S e c t i o n “3 , ” fo r
o il p r e s s u r e s w it c h d ia g n o s is .

F U E L S U P P L Y C IR C U IT Fuel Pipes and H o se s

R e f e r to “F u e l S y s t e m D i a g n o s i s ” i n “C o m p u t e r T h e d ia g n o s is o f c o m p re sse d n a t u r a l g a s o d o r
C o m m a n d C o n t r o l , ” S e c t i o n “3 , ” f o r f u e l s u p p l y m a y b e a c o n d i t i o n o f a l e a k i n g f u e l lin e . F u e l
r e l a y c ir c u it d ia g n o s is . lin e s th a t a re p in c h e d or p lu g g e d m ay ca u se
In o p e r a t i v e f u e l s o le n o id v a l v e s w o u l d c a u s e a re s t ric te d fu e l d e liv e ry .
n o s t a r t c o n d itio n . L o w C N G fu e l c y lin d e r p r e s s u r e
c a n r e s u lt in p o o r p e rfo rm a n c e . ( R e f e r to “F u e l C N G Fuel Cylinders
S y s t e m P r e s s u r e T e s t ” p ro c e d u re .)
T h e d ia g n o s is o f c o m p re sse d n a t u r a l g a s o d o r
m a y b e a c o n d it io n o f l e a k i n g C N G fu e l c y lin d e r s ,
Fuel S u p p ly Relay fu e l fee d l i n e o r f u e l f i l l v a l v e a n d f u e l c y l i n d e r
c h e c k v a lv e s .
R e f e r to “F u e l S u p p l y R e l a y C ir c u i t C h e c k ” i n L o o s e m o u n t i n g s t r a p s , o r f o r e i g n m a t e r ia l i n
“C o m p u t e r C o m m a n d C o n t r o l, ” S e c t io n “3 ”, fo r fu e l c y lin d e r, m a y b e th e c a u s e o f a r a t t le a t th e C N G
s u p p l y r e l a y d ia g n o s is . fu e l c y lin d e r.
A n in o p e r a t iv e fu e l s u p p ly r e la y c a n r e s u lt in
l o n g c r a n k i n g t im e s , p a r t i c u l a r l y i f t h e e n g i n e i s ACCELERATOR CO NTRO L
cold . T h e o il p r e s s u r e s w it c h w i l l t u r n “O N ” t h e
fu e l s o le n o id v a l v e s a s s o o n a s o il p r e s s u r e re a c h e s C h e c k fo r c o rre c t c a b le r o u t in g , o r b in d in g , a n d
a b o u t 2 8 k P a (4 psi). co rre ct a s n e c e s s a ry .
F U E L C O N T R O L 4-9
 IDLE AIR CONTROL (IAC) S Y S T E M CHECK
5.7L CNG WITH 4L60 TRANSMISSION
Circuit D escription:
T h e E C M c o n t r o ls e n g in e id le sp e e d w it h th e I A C v a lv e . T o in c r e a s e id le speed, th e E C M r e t r a c t s th e
I A C v a l v e p i n t l e a w a y f r o m i t ’s se a t, a l l o w i n g m o r e a i r to p a s s b y t h e t h r o t t le b o re . T o d e c r e a s e id le
speed, it e x t e n d s th e I A C v a l v e p in t le t o w a r d s i t ’s seat, r e d u c in g b y p a s s a i r flow . A T e c h 1 “s c a n ” to o l w i l l
re a d th e E C M c o m m a n d s to th e I A C v a l v e i n co u n ts. H i g h e r th e c o u n t s in d ic a t e m o re a i r b y p a s s ( h ig h e r
idle). T h e lo w e r th e c o u n t s in d ic a t e le s s a i r i s a llo w e d to b y p a s s (lo w e r idle).

T e s t D e s c r i p t i o n : N u m b e r ( s ) b e l o w r e f e r to
c irc le d n u m b e r ( s ) o n th e d ia g n o s t ic c h a rt.
1. T h e I A C t e s t e r i s u s e d to e x t e n d a n d r e t r a c t
t h e I A C v a lv e . V a l v e m o v e m e n t i s v e r if ie d b y
a n e n g in e sp e e d c h a n g e . I f n o c h a n g e i n e n g in e
s p e e d o c c u rs , t h e v a l v e c a n b e r e t e s t e d w h e n
r e m o v e d fro m th e t h ro t t le b o d y.
2. T h is ste p c h e c k s th e q u a lit y of th e IA C
m o v e m e n t i n S t e p 1. B e t w e e n 7 0 0 r p m a n d
a b o u t 1 5 0 0 r p m th e e n g in e sp e e d s h o u ld c h a n g e
s m o o t h ly w it h e a c h f la s h o f th e te st e r l i g h t in
b o th e x te n d a n d re tra c t. I f th e I A C v a lv e is
re t ra c t e d b e y o n d th e c o n tro l r a n g e (a b o u t 1 5 0 0
rp m ), it m a y t a k e m a n y f la s h e s i n t h e e x t e n d
p o s it io n b e fo re e n g in e sp e e d w ill b e g in to drop.
T h is is n o r m a l o n c e r t a in e n g in e s , f u lly
e x t e n d i n g I A C m a y c a u s e e n g i n e s t a ll . T h i s
m a y b e n o r m a l.
3. S t e p s 1 a n d 2 v e r if ie d p ro p e r I A C v a lv e
o p e r a t io n w h ile t h is ste p c h e c k s th e I A C
c ir c u it s . E a c h la m p o n t h e n o d e l i g h t s h o u l d
f la s h R e d a n d G r e e n w h ile th e I A C v a l v e is
c y c le d . W h i l e t h e s e q u e n c e o f c o l o r i s n o t
i m p o r t a n t i f e i t h e r l i g h t i s “O F F ” o r d o e s n o t
f l a s h R e d a n d G r e e n , c h e c k t h e c i r c u i t s fo r
fa u lts , b e g i n n i n g w it h p o o r t e r m in a l co n ta cts.
IA C V A L V E R E S E T P R O C E D U R E
• I g n i t i o n “O F F ” fo r 10 se co n d s.
• S t a r t a n d r u n e n g in e fo r 5 seco n d s.
• I g n i t i o n “O F F ” fo r 10 se co n d s.
D ia g n o stic A id s:
A slo w , u n s t a b le , o r fa s t id le m a y b e c a u s e d b y
a n o n - I A C s y s t e m p r o b le m t h a t c a n n o t b e o v e rc o m e
b y th e I A C v a lv e . O u t o f c o n tro l ra n g e , I A C T e c h 1
“S c a n ” to o l c o u n t s w i l l be a b o v e 9 0 i f id le i s too
low , a n d z e ro c o u n ts i f id le is too h ig h . T h e
following checks should be m ade to re p a ir a non-
IAC system problem.
• V acuum L eak (H igh Idle) - If idle is too high,
stop th e engine. F u lly ex ten d (low) IAC w ith
tester. S ta rt engine. If idle speed is above 8 0 0
rpm, locate and correct vacuum leak including
PCV system. Also, check for binding of th ro ttle
blade or linkage.
• System too rich (Low A ir/Fuel Ratio) - The idle
speed w ill be too low. Tech 1 “S c a n ” tool IAC
c o u n ts w ill u s u a lly be ab o v e 9 0 . S y s te m is
obviously rich and m ay exhibit black smoke in
exhaust.
Tech 1 “S c a n ” tool 0 2 v o lta g e w ill be fixed
above 8 0 0 mV (.8 volt).
C h e c k for h ig h f u e l p r e s s u r e , l e a k i n g or
s tic k in g in je c to r. S ilic o n e c o n ta m in a te d 0 2
sensors “Scan” voltage will be slow to respond.
• T hrottle body - Remove IAC valve and inspect
bore for foreign m aterial.
• IAC V alve E le c tric a l C onnections - IAC valve
connections sh o u ld be c a re fu lly ch eck ed for
proper contact.
• PCV Valve - A n incorrect or faulty PCV valve
m ay resu lt in an incorrect idle speed.
R efer to “R ough, U n s ta b le , In c o rre c t Id le or
S talling” in “D rivability Sym ptom ,” Section “2 ”.
• A/C Compressor or relay failure - Refer to A/C
diagnosis if circuit is shorted to ground. If the
relay is faulty, idle problem m ay exist.
R efer to “R ough, U n s ta b le , In c o rre c t Id le or
S talling,” in Section “2 ”.
• I f i n t e r m i t t e n t p o o r d r i v a b i l i t y o r id le
sym ptom s a re reso lv e d by d isc o n n e c tin g th e
IA C , c a r e f u ll y r e c h e c k c o n n e c tio n s , v a lv e
term inal resistance or replace IAC.
IDLE AIR CONTROL (IAC) SYSTEM CHECK
5.7L CNG WITH 4L60 TRANSMISSION
 ON-VEHICLE SERVICE
GENERAL SERVICE MANUAL • A l w a y s a llo w fu e l p r e s s u r e to b le e d o ff b e fo r e
d is c o n n e c t in g a n y C N G fu e l c o m p o n e n t.
• C h e c k C N G fu e l c o n n e c t io n fo r le a k s u s i n g so a p
CAUTION:
a n d w a t e r s o lu t io n .
• To prevent personal injury or d a m a g e to
• D o n o t do a n y r e p a ir s o n th e fu e l s y s t e m u n t i l
the vehicle as the result of an accidental
y o u h a v e re a d th e in s t r u c t io n s a n d c h e c k e d th e
s t a r t , d i s c o n n e c t a n d r e c o n n e c t th e
p ic tu re s r e l a t i n g to t h a t re p a ir.
n e g a tiv e b a tte ry ca b le b e fo re a n d after
• O b s e r v e a ll N o t ic e s a n d C a u t io n s .
se rv ic e is p e rfo rm e d (e x ce p t fo r th o s e
• W a s h e r s lo c a te d b e t w e e n fu e l lin e f i t t in g b o d ie s
te sts w here battery v o ltage is required).
a n d n u t a r e to h e l p i n t h e m a n u f a c t u r i n g
• T o m i n im i z e t h e r is k o f fir e , a n d
pro ce ss. T h e y a re n o t n e c e s s a r y fo r se rv ic e .
p e r s o n a l in ju r y , d i s c o n n e c t n e g a t iv e
battery cable and relieve the fuel sy ste m
p r e s s u r e (w h e re a p p lic a b le ) b e fo re C N G FU EL IN J E C T IO N A N D S E R V IC E
servicing the fuel system . (Refer to "F u e l IN F O R M A T IO N
Pressure Relief P roce d u re /' below .)
The T B I u n it r e p a ir p ro ce d u re s cover
• D O N O T S M O K E w h e n s e r v ic in g a n y
c o m p o n e n t r e p la c e m e n t w it h th e u n it o n th e
part of the fuel system .
• N atural g a s is toxic w h e n concentrated v e h ic le . H o w e v e r , t h r o t t le b o d y r e p la c e m e n t
r e q u ir e s t h a t t h e c o m p le t e u n i t b e r e m o v e d f r o m
in a sm a ll area. A lw a y s w o rk in a w ell-
ventilated area w h e n releasing natural g a s th e e n gin e .
fu e l in to th e air. If p o s s ib le , re le a se a s A n e ig h t d ig it p a r t id e n t if ic a t io n n u m b e r is
m uch fuel pressure as you can o u tsid e of s t a m p e d o n t h e t h r o t t le b o d y ( F i g u r e 7). R e f e r to
t h is n u m b e r if s e r v ic in g o r p a r t re p la c e m e n t is
the shop.
re q u ire d .
• A lw a y s w o rk a w a y from open flam e s or
R e f e r to t h e d i s a s s e m b l e d v i e w s ( F i g u r e 8) fo r
sp a r k s. D o n o t w e ld or carry an o p e n
id e n t if ic a t io n o f p a r t s d u r i n g r e p a ir p ro c e d u re s.
fla m e near the fuel sy s te m if y o u sm e ll
S e r v ic e r e p a ir o f i n d i v i d u a l c o m p o n e n t s is
g a s or oth erw ise su sp e ct a leak.
p e rfo rm e d w it h o u t r e m o v i n g th e T B I u n i t fro m th e
• C o m p re s s e d natural g a s fuel s y s t e m s
e n g in e . I f r e m o v e d , i t i s e s s e n t i a l t h a t c a r e i s
are under e xtrem ely h ig h p re ssu re at all
t a k e n to p r e v e n t d a m a g e to t h e t h r o t t le v a l v e o r
t im e s . W h e n e v e r w o r k i n g o n a h ig h -
s e a lin g s u rfa c e w h ile p e r f o r m in g a n y se rv ic e .
p r e s s u r e c o m p o n e n t , a l w a y s re lie v e
W h e n e v e r s e rv ic e is p e r fo rm e d o n a T B I o r a n y
p r e s s u r e by s lig h t ly lo o s e n in g th e
o f i t s c o m p o n e n t s , f i r s t r e m o v e t h e a i r c le a n e r ,
com ponent.
a d a p t e r ( i f a p p l ic a b le ) , a n d a i r c l e a n e r g a s k e t s .
• W h e n w o r k in g on a lo w -p r e s s u r e
D i s c a r d t h e g a s k e t s a n d r e p la c e t h e m w i t h n e w
co m p onent, a lw a y s sh u t off fuel pressure
o n e s b e fo re r e p l a c i n g t h e a i r c le a n e r a f t e r s e r v ic e
at the m an u al shut-off valve first.
is com plete.
• W h e n re p lacin g th re a d e d c o m p o n e n ts,
a l w a y s a p p ly S W A K ® A n a e r o b i c P ip e
Se a la n t or an equivalent sealer to the n e w
c o m p o n e n t th re a d s except c o m p re ss io n
fittings.
• A s w it h a n y v e h ic le , a l w a y s r o u te
veh icle's e xh au st o u tsid e the sh o p if you
need to run the engine.
• Facilities u sin g open flam e heaters m u st
h av e a w a y of v e n t in g th e n a tu ra l g a s
o u tsid e to prevent ignition of the natural
gas. R em em ber natural g a s rises quickly.

T he follow ing is g e n e ra l in fo rm atio n re q u ire d

w hen w orking on th e fuel system:
• A lw a y s k e e p a d ry c h e m ic a l (C la ss B ) fire
extinguisher n ear the work area.
• Replace all CNG fuel components w ith genuine
G M parts.
C N G Fuel Cylinder Pressure Relief Procedure |j[y| Inspect
T o r e lie v e fu e l p r e s s u r e fro m th e C N G fu e l • F o r fu e l le a k s a t lin e f it t in g s w it h so a p a n d
c y lin d e r s a s p e c ia l to o l is re c o m m e n d e d , J 3 9 7 1 1 w a t e r s o lu t io n .
C N G F u e l C y l i n d e r P r e s s u r e R e lie f V a lv e .

Im p o rta n t C N G Fuel Line Pressure Relief Procedure

• T h e C N G fu e l c y lin d e r s s h o u ld o n ly be
d is c h a r g e d o u tsid e , i n a n o p e n area.
1. D i s c o n n e c t t h e n e g a t i v e b a t t e r y t e r m i n a l to
a v o i d p o s s ib le f u e l d i s c h a r g e i f a n a c c id e n t a l
a t t e m p t i s m a d e to s t a r t th e e n g in e .
2. L o o s e n t h e C N G f u e l l i n e f i t t in g s a t th e f u e l
c y lin d e r to b e re lie v e d .
3. A l l o w C N G fu e l p r e s s u r e to b le e d off.
• A fa ile d s o le n o id o r v a l v e m a y e x is t i f p r e s s u r e
d o e s n o t b le e d off. V e h ic le m u s t th e n be t a k e n
o u t s id e to a llo w C N G fu e l s y s t e m to c o m p le te ly
b le e d d o w n . L o c a t e c a u s e a n d r e p la c e f a i l e d
c o m p o n e n t.
4. I n s t a l l P A S - 5 6 0 7 3 C N G F u e l C y lin d e r P r e s s u r e
R e l i e f V a l v e i n t o t h e f u e l fe e d f i t t i n g o f t h e
fu e l c y lin d e r s o le n o id v a lv e .
5. “O P E N ” v a l v e a n d a llo w C N G c y lin d e r p r e s s u r e
to b le e d off.
6. A f t e r r e p la c in g th e C N G fu e l c y lin d e r a n d
c o n n e c t in g a ll th e fu e l lin e s , c o n n e c t th e
n e g a t iv e b a t t e r y cable.
7. T u r n t h e i g n i t i o n to th e “O N ” p o s it io n fo r tw o
se c o n d s, e n g in e n o t r u n n i n g , t h e n t u r n it to th e
“O F F ” p o s it io n . T h i s w i l l p r e s s u r iz e th e C N G
fu e l s y ste m .
1. D i s c o n n e c t t h e n e g a t i v e b a t t e r y t e r m i n a l to
a v o id p o s s ib le f u e l d i s c h a r g e i f a n a c c id e n t a l
a t te m p t is m a d e to s t a r t th e e n g in e .
2. T u r n t h e 1/4 t u r n s h u t - o f f v a l v e to “C L O S E D ”
p o s itio n .
3. L o o s e n t h e f i t t i n g o f t h e C N G f u e l l i n e to b e
se rv ic e d .
4. A l l o w C N G fu e l p r e s s u r e to b le e d off.
• A fa ile d s o le n o id o r v a l v e m a y e x is t i f p r e s s u r e
d o e s n o t b le e d off. V e h ic le m u s t t h e n b e t a k e n
o u t s id e to a llo w C N G fu e l s y s t e m to c o m p le t e ly
b le e d d o w n . L o c a t e c a u s e a n d r e p l a c e f a i l e d
c o m p o n e n t.
5. A f t e r r e p la c in g th e C N G fu e l lin e , c o n n e c t t h e
n e g a t iv e b a t t e r y c a b le a n d t u r n t h e 1/4 t u r n
s h u t - o f f v a l v e to th e “O P E N ” p o s it io n .
6. T u r n th e i g n i t i o n to th e “O N ” p o s it io n fo r tw o
se co n d s, e n g in e n o t r u n n i n g , t h e n t u r n it to t h e
“O F F ” p o s it io n . T h i s w i l l p r e s s u r i z e t h e C N G
fu e l s y ste m .
Inspect
F o r fu e l le a k s a t lin e f it t in g s w it h so a p a n d
w a t e r s o lu t io n .

PART N A M E S

1 SCREW - TBI COVER

2 TBI COVER
3 GASKET - TBI COVER
4 GASKET - AIR CLEANER
5 SCREW ASSEMBLY - TPS ATTACHING
6 SEAL - THROTTLE POSITION SENSOR
7 SENSOR - THROTTLE POSITION (TPS)
8 THROTTLE BODY ASSEMBLY
9 GASKET - FLANGE
10 IDLE AIR CONTROL VALVE
ASSEMBLY
11 GASKET - IDLE AIR CONTROL
VALVE ASSEMBLY
12 INJECTOR PLATE
13 O-RING - SMALL INJECTOR
14 O-RING - LARGE INJECTOR
15 CNG FUEL INJECTOR
16 NUT - FUEL INLET
17 GASKET - INJECTOR PLATE

L P 0 1 7 1 -X V -C N G
Fuel S y s te m Pressure Test

A fu e l s y s t e m p r e s s u r e te st is p a r t o f s e v e r a l o f
th e D ia g n o s t ic C h a r t s a n d S y m p to m ch e cks. To
p e r f o r m t h is test, fo llo w t h is p ro c e d u re .
1. T u r n e n g i n e “O F F ” a n d r e l ie v e f u e l p r e s s u r e
u s i n g F u e l L i n e P r e s s u r e R e l ie f P ro c e d u re .
2. R e m o v e p l u g fro m r e g u la t o r ’s p r e s s u r e te st port.
3. I n s t a l l J 2 1 8 6 7 C N G F u e l P r e s s u r e G a g e to
p r e s s u r e r e g u la t o r te st port.
4. T i g h t e n g a g e to e n s u r e n o l e a k s o c c u r d u r i n g
t e st in g .
5. C o n n e c t n e g a t iv e b a t t e r y cable.
6. S t a r t e n g in e a n d o b s e rv e fu e l p r e s s u r e re a d in g .
I t s h o u l d b e 1 1 4 7 to 1 2 6 7 k P a (1 6 7 to 1 8 3 p s i)
a t id le . I f n o t , r e f e r to C H A R T A - 6 i n
“C o m p u t e r C o m m a n d C o n t r o l , ” S e c t io n “3 ”
d ia g n o s is .
7. R e m o v e J 3 9 6 2 5 C N G F u e l P re ssu re G age.
8. I n s t a l l te st p o rt p lu g .
9. R e c o n n e c t n e g a t iv e b a t t e r y cable.

Jj? Inspect
F o r fu e l le a k s a t lin e f it t in g s w it h so a p a n d
w a t e r s o lu t io n .

N O T IC E : I n p r e c o a t i n g s c re w s , d o n o t u s e a
h ig h e r stre n g t h lo c k in g c o m p o u n d th a n 1 BOLT - TIG HTEN TO 16 INi-m (12 lb. ft.)
r e c o m m e n d e d , s in c e to do so c o u ld m a k e 2 TBI U N IT
r e m o v in g th e sc re w e x t r e m e ly d iffic u lt , or
3 GASKET
r e s u lt i n d a m a g i n g th e s c re w he a d .
4 INJECTOR PLATE

5 GASKET
6 ENGINE INLET M ANIFO LD
T B I U n it Replacem ent 7S 3547-6E-CNG

Figure 4-9 Figure 4-9 - Replacing TBI 220 Unit

N O T IC E : S t u f f t h e m a n i f o l d o p e n i n g w i t h a
R e m o v e or D isconnect r a g , to p r e v e n t m a t e r i a l f r o m e n t e r i n g t h e
1. A i r c le a n e r , a d a p t e r, a n d g a s k e t s . D i s c a r d e n g in e , a n d r e m o v e t h e o ld g a s k e t m a t e r i a l
g aske t. fro m s u rfa c e o f in t a k e m a n ifo ld .
2. E l e c t r i c a l c o n n e c t o r s - id le a i r c o n t r o l v a lv e ,
t h r o t t le p o s it io n se n so r. Inspect
3. T h r o t t le lin k a g e , r e t u r n s p r in g ( s ) , t r a n s m is s io n • M a n ifo ld b o re fo r lo o s e p a rts and fo r e ig n
c o n t r o l c a b le , a n d c r u i s e c o n t r o l ( w h e r e v e r
m a te ria l.
a p p lic a b le ). • In t a k e m a n if o ld s e a l i n g s u rf a c e fo r c le a n lin e s s .
4. V a c u u m h o se s, n o t in g p o s it io n s o f h o se s.
5. T B I m o u n t in g h a rd w a re . +«- Install or C o n n ect
6. T B I u n i t fr o m in t a k e m a n ifo ld .
1. N e w T B I fla n g e ( M a n if o l d m o u n t in g ) g a s k e t .
2. T B I w it h m o u n t i n g h a r d w a r e .
N O T IC E : T o p r e v e n t d a m a g e to t h e t h r o t t le
v a lv e , it is e s s e n t ia l t h a t th e u n it b e p la c e d o n
a h o l d in g fix tu re , b e fo re p e r f o r m in g se rv ice .
Tighten
H a r d w a r e o n 5 . 7 L e n g in e , 16.0 N « m (12.0 lb.
7. T B I f la n g e ( M a n if o l d m o u n t in g ) g a s k e t . ft.).
3. V a c u u m h o s e s a n d b ra c k e t. 2. T P S a t t a c h in g s c re w a s s e m b lie s , p re c o a te d w it h
4. T h r o t t le lin k a g e , r e t u r n s p rin g (s ), t r a n s m is s io n a p p r o p r ia t e t h r e a d - lo c k in g c o m p o u n d .
c o n t r o l c a b le , a n d c r u is e c o n t r o l ( w h e r e v e r
a p p lic a b le ).
5. E le c t r ic a l co n n e cto rs, m a k in g s u re co n n e cto rs
• S c r e w a s s e m b lie s to 2 .0 N » m (18.0 lb. in.).
a r e f u l l y se a te d a n d la tche d .
3. E le c t r ic a l co n n e cto r.
C h e c k to s e e i f a c c e le r a t o r p e d a l i s fre e, b y
4. C h e c k fo r T P S o u t p u t a s fo llo w s:
d e p r e s s i n g p e d a l to t h e f lo o r a n d r e l e a s i n g ,
• C o n n e c t A L D L s c a n n e r to r e a d T P S o u t p u t
w h i le e n g in e is “O F F . ”
v o lta g e .
7. A i r c le a n e r, a d a p te r, a n d n e w g a s k e t s.
• W i t h i g n i t i o n “O N ” a n d e n g i n e s t o p p e d ,
T P S v o lt a g e s h o u ld b e le s s t h a n 1.25 v o lts.
C ontrolled Idle Sp e e d Check I f m o re t h a n 1.25 v o lts, re p la c e T P S .

B e fo re p e r f o r m in g t h is check, th e re s h o u ld be
n o co d e s d is p la y e d , id le a i r c o n tro l s y s t e m h a s b e e n
c h e c k e d a n d i g n i t i o n t i m i n g correct.
1. S e t p a r k i n g b r a k e a n d b lo c k d r iv e w he els.
2. C o n n e c t a “S c a n ” t o o l to th e A L D L c o n n e c t o r
w i t h to o l i n O p e n M o d e .
3. S t a r t e n g i n e a n d b r i n g i t to n o r m a l o p e r a t i n g
te m p e ra t u re .
4. C h e c k f o r c o r r e c t s t a t e o f P a r k / N e u t r a l s w it c h
o n “S c a n ” tool.
5. C h e c k s p e c if ic a t io n s c h a r t a t th e e n d o f t h is
s e c t io n fo r c o n t ro lle d id le sp e e d a n d I A C v a l v e
p in t le p o s it io n (co un ts). 1 SENSOR -THROTTLE P O S ITIO N (TPS)
6. I f w i t h i n s p e c ific a t io n s , th e id le sp e e d is b e i n g
2 SCREW A S S E M B L Y -T P S A T T A C H IN G
c o rre c t ly c o n t ro lle d b y th e E C M .
7. I f n o t w i t h i n s p e c i f i c a t io n s , r e f e r to “R o u g h 3 S E A L -T H R O T T L E P O S ITIO N SENSOR
M P 1 2 05-A S
U n s t a b l e o r In c o r r e c t Id le , S t a l l i n g ” in
“D r i v e a b i l i t y S y m p t o m , ” S e c t io n “2 ” a n d r e v ie w Figure 4-10 - TPS Configuration
in f o r m a t io n a t th e b e g i n n i n g o f t h is check.
ID LE A IR C O N T R O L (IAC) V A L V E
C N G F U E L IN J E C T IO N A N D TBI Figure 4-11
C O M P O N E N T S E R V IC E
N O T IC E : T h e I A C v a l v e i s a n e l e c t r i c a l
c o m p o n e n t a n d m u s t n o t be s o a k e d in a n y
T H R O T T L E P O S IT IO N S E N S O R (TPS)
l i q u i d c l e a n e r o r s o lv e n t . O t h e r w i s e d a m a g e
Figure 4-10
c o u ld re su lt.

Im p o rta n t Im p o rtan t
S in c e T P S c o n f ig u r a t io n s c a n be m o u n te d T h e I A C v a lv e is th re a d -m o u n te d a n d h a s a
in t e r c h a n g e a b le , b e s u r e to o r d e r t h e c o r r e c t d u a l ta p e r, 10 m m d ia m e t e r , p in t le . A n y
o n e fo r y o u r e n g in e w it h th e id e n t ic a l p a r t r e p la c e m e n t o f t h e I A C v a l v e m u s t h a v e t h e
n u m b e r o f th e o n e b e i n g rep laced . c o rre c t p a r t n u m b e r , w i t h th e a p p r o p r ia t e p in t le
ta p e r a n d d ia m e t e r fo r p ro p e r s e a t in g o f th e
«--► R e m o v e or D iscon n e ct v a l v e i n t h e t h r o t t le b o d y.
1. !E le c t ric a l co n n e cto r.
2. T w o T P S a t t a c h in g s c r e w a s s e m b lie s . R e m o ve or D iscon n ect
3. T P S fr o m t h r o t t le b o d y a s s e m b ly . 1. E le c t r ic a l co n n e cto r.
2. I A C v a lv e .
N O T IC E : T h e T P S i s a n e le c tric a l c o m p o n e n t • O n t h r e a d m o u n t e d u n it s , u s e a 3 2 mm
a n d m u s t n o t b e s o a k e d i n a n y l i q u i d c le a n e r (1 1/4") w r e n c h ( F ig u r e 4-11).
o r so lv e n t, a s d a m a g e m a y re su lt. 3. I A C v a l v e g a s k e t o r O - r i n g a n d d is c a rd .

Install or C o n n ect
W i t h t h r o t t le v a l v e i n n o r m a l ly c lo se d p o sitio n , • T h r e a d m o u n te d v a lv e - O ld g a s k e t m a t e r ia l
i n s t a l l T P S o n t h r o t t le s h a ft a n d ro ta te c o u n te r f r o m s u r f a c e o f t h r o t t le b o d y a s s e m b ly to i n s u r e
c lo c k w is e to a l i g n m o u n t i n g hole. p ro p e r se a l o f n e w ga ske t.
 Install or C o n n e ct
1. 'A C v a lv e in t o t h r o t t le b o d y a s fo llo w s:
• T h re a d -m o u n te d v a lv e - In s t a ll w it h new
g a sk e t.

N O T IC E: N ew IA C v a lv e s h a v e been re se t at
th e fa c to ry a n d s h o u ld be in s t a lle d in th e
t h r o t t le b o d y i n a n “a s i s ” c o n d it io n , w i t h o u t
a n y a d ju stm e n t.

A DISTANCE OF PINTLE E XTENSIO N
B D IA M E TE R A N D SHAPE OF PINTLE
2.
C IAC VALVE GASKET
3.
9P 1 0 5 8 -A S
Figure 4-11 - Thread M ounted Type IAC Valve
N O T I C E .* I f th e IA C v a lv e w a s re m o ve d
d u r i n g s e r v ic e , i t ’s o p e r a t i o n m a y b e t e s t e d
e le c t r ic a l ly w i t h t h e I A C / I S C M o t o r T e s t e r (J T H R O T T LE B O D Y A S S E M B L Y
3 7 0 2 7 or B T -8 2 5 6 K ). H o w e ve r, if th e v a lv e
p i n t l e i s e x t e n d e d e le c t r ic a lly , i t m u s t a ls o b e
re t ra c t e d e le c tric a lly . B e fo r e i n s t a l l i n g a n I A C
1.
v a lv e , m e a s u r e th e d is t a n c e b e t w e e n th e t ip o f
th e v a lv e p in t le a n d th e m o u n t in g su rfa c e . I f
th e d im e n s io n i s g r e a t e r t h a n 2 8 m m (1.10"), it ❖
m u s t b e r e d u c e d to p r e v e n t d a m a g e t o t h e
v a lv e . T h i s m a y b e d o n e e le c t r ic a l l y u s i n g a n
IA C / IS C M o t o r T e ste r (J 3 7 0 2 7 o r B T -8 2 5 6 K ).
M e a su re (If In stallin g a N e w IA C V alve)
A -
Figures 4-11
• D i s t a n c e b e t w e e n t ip o f I A C v a l v e p i n t l e a n d
m o u n t i n g fla n g e .
I f g r e a t e r t h a n 2 8 m m , u s e f in g e r p r e s s u r e
to s l o w l y r e t r a c t t h e p i n t l e , T h e f o r c e 1.
r e q u ir e d to r e t r a c t th e p in t le o f a n e w v a l v e
w i l l n o t c a u s e d a m a g e to t h e v a lv e .
$ Tighten
• T h r e a d - m o u n t e d I A C v a l v e a s s e m b ly to 18.0
N * m (13.0 lb.ft.) w i t h 3 2 m m (1-1/4") w re n c h .
E le c t r ic a l c o n n e c t o r to I A C v a lv e .
R e s e t I A C v a l v e p in t le p o s it io n :
A. T u r n i g n i t i o n “O N ” fo r f iv e se co n d s.
B. T u r n i g n i t i o n “O F F ” fo r t e n se co n d s.
C. S t a r t e n g in e a n d c h e c k fo r p ro p e r id le
o p e ra tio n .
Rem ove or D isco n n e ct
T B I u n it, a s d e s c r ib e d p r e v io u s ly .
D isa sse m b le
T P S f r o m o ld t h r o t t l e b o d y , a c c o r d in g to
p r e v io u s in s t r u c t io n s , fo r r e u s e o n n e w t h r o t t le
b o d y . (T h e I A C v a l v e d o e s n o t h a v e to be
re m o v e d , s in c e a n e w o n e c o m e s w it h
re p la c e m e n t t h r o t t le b o d y.)
A sse m b le
T P S o n t o r e p la c e m e n t t h r o t t le b o d y a s s e m b ly ,
a c c o r d in g to p r e v io u s in s t r u c t io n s .
Install or Co nnect
T B I u n it o n to in t a k e m a n if o ld , a s p r e v io u s ly
de scrib e d .

Im p o rtan t
So p h y s i c a l a d j u s t m e n t o f t h e I A C v a l v e
a s s e m b ly i s r e q u ir e d a fte r in s t a lla t io n . T h e I A C
v a l v e p in t le is re s e t b y th e E C M w h ic h c a u s e s
t h e v a l v e p i n t l e to s e a t i n t h e t h r o t t le b o d y .
The E C M t h e n h a s a re s e t p ro c e d u re to se t th e
c o r r e c t p i n t l e p o s it io n . P r o p e r i d le r e g u l a t i o n
s h o u ld r e s u lt . N o p h y s ic a l a d j u s t m e n t o f th e
IA C v a lv e a s s e m b ly is r e q u ir e d a fte r
in s t a l l a t i o n . T h e I A C v a l v e p i n t l e i s r e s e t b y
t u r n i n g t h e i g n i t i o n “O N ” fo r t e n s e c o n d s a n d
t h e n “O F F . ” T h e E C M / P C M t h e n r e s e t s t h e
p in t le to t h e c o r r e c t p o s it io n . P ro p e r id le
r e g u la t io n s h o u ld re s u lt.
C N G FU EL IN J E C T O R S
E a c h C N G fu e l in je c to r (re fe r to F i g u r e 4-12) is
s e rv ic e d a s a c o m p le te a s s e m b ly o n ly .
N O T IC E : U s e c a re i n r e m o v i n g th e C N G fu e l
in j e c t o r s to p r e v e n t d a m a g e to t h e e l e c t r i c a l
c o n n e c t o r t e r m i n a l s a n d f u e l n o z z le . T h e C N G
fu e l in je c to r is s e r v ic e d a s a c o m p le te a s s e m b ly
o n ly . A l s o , s in c e t h e i n j e c t o r s a r e e l e c t r i c a l
co m p o n e n ts, t h e y s h o u ld n o t be im m e r s e d in
a n y ty p e o f li q u i d s o lv e n t o r c le a n e r a s d a m a g e
m a y occur.
 4- + R e m o v e or D isconnect
1. N e g a t i v e b a t t e r y t e rm in a l. 1 C N G IN J E C T O R PLA TE
• R e lie v e fu e l s y s t e m lin e p r e s s u r e as
2 O -R IN G - S M A L L IN J E C T O R
p r e v i o u s ly o u t lin e d i n t h is section.
3 O -R IN G - LA R G E IN J E C T O R
2. A i r c le a n e r a n d d u c t a s s e m b ly .
3. T u r n 1/4 t u r n s h u t - o f f v a l v e to “ C L O S E D ” 4 C N G FU E L IN J E C T O R S
C 0 0 0 2 -4 -C N G
p o s it io n .
Figure 4-13 - CNG Injector Plate
4. C N G fu e l in je c to r e le c tr ic a l co n necto rs.
5. C N G fu e l injecto r. 3. T u rn 1/4 t u r n sh u t-o ff v a lv e to “C L O S E D ”
6. In je c t o r O - r in g s .
p o sitio n .
4. T .V ., t h r o t t le , and c r u is e c o n t r o l c a b le s fro m
Im p o rta n t T B I.
5. V a c u u m h o s e s fro m T B I .
B e s u r e to r e p la c e th e in je cto r w it h o ne h a v i n g
6. E le c t r ic a l c o n n e c t o rs fro m I A C v a lv e , T P S , a n d
a n id e n t ic a l p a r t n u m b e r.
in je cto rs.
7. F u e l s u p p l y lin e fro m C N G in je c to r p la te .
-►«- Install or C o n n ect 8. T B I r e t a i n i n g b o lts.
1. L ig h t ly lu b r ic a t e CNG f u e l in j e c t o r O - r i n g s 9. T B I a s s e m b ly a n d g a s k e t .
w it h t r a n s m is s io n flu id . 10. C N G fu e l in je c to r p la t e a n d g a s k e t .
2. C N G fu e l injecto r.
❖ D isa sse m b le
Tigh ten 1. C N G fu e l in je c to rs fro m in je c to r p late.
• In je c t o r to 17 N * m (13 lb. ft.).
3. C N G fu e l in je c t o r e le c tr ic a l co n n e cto rs. 1QI| Clean
4. T u r n 1/4 tu rn s h u t -o ff v a lv e to “O P E N ” G a s k e t m a t i n g su rfa c e s.
p o s itio n .
5. A i r c le a n e r a n d d u c t a s s e m b ly . Inspect
6. N e g a t i v e b a t t e r y t e r m in a l.
In je c t o r p la t e p a s s a g e s fo r b lo c k a g e o r c ra c k s .

C N G IN J E C T O R P L A T E |nfe-| A sse m b le
1. L i g h t l y lu b r ic a t e C N G fu e l in je c t o r O - r in g s
«--► R e m o v e or D iscon n ect w it h t r a n s m is s io n flu id .
2. C N G fu e l in je c to rs to in je c to r p la te.
1. N e g a t i v e b a t t e r y t e r m in a l.
• R e lie v e fu e l s y s t e m lin e p r e s s u r e as
p r e v i o u s ly o u t lin e d i n t h is sectio n .
T igh ten
2. A i r c le a n e r a n d d u c t a s s e m b ly . * In je c t o r to 17 N * m (13 lb. ft.).
 Install or Connect |-»4-| Install or Co nnect
□
1. C N G fu e l in je c to r p la t e g a s k e t a n d plate. 1. R e la y .
2. T B I g a s k e t a n d T B I a s s e m b ly . 2. E le c t r ic a l co n n e cto r.
3. T B I r e t a i n i n g b o lts. 3. R e t a in e r.
4. P ro t e c t iv e cover.
Tigh ten
• B o l t s to 16 N « m (12 lb. ft.).
CN G CO N TRO L RELAY
4. F u e l s u p p l y lin e to C N G in je c to r p late.

Rem ove or D iscon n e ct

Tigh ten B
l. Pro tective cover.
• L i n e f it t in g to 2 0 N * m (15 lb. ft.).
2 . E le c t r ic a l co n n e cto r.
5. E l e c t r i c a l c o n n e c t o r s to I A C v a lv e , T P S , and
3. R e l a y b r a c k e t b o lts.
in je cto rs.
4. R e la y b y d e p r e s s in g b ra c k e t c lip at re a r of
6. V a c u u m h o s e s to T B I .
re la y .
7. T .V ., th r o t t le , a n d c r u is e c o n t r o l c a b le s fr o m
T B I.
8. T u rn 1/4 t u r n sh u t-o ff v a lv e to “O P E N ”
+«- Install or C o n n ect
p o s itio n .
9. A i r c le a n e r a n d d u c t a s s e m b ly . 1. R e l a y to b ra c k e t.
10. N e g a t i v e b a t t e r y te r m in a l. 2. R e l a y b r a c k e t bo lts.
3. E le c t r ic a l co n n e cto r.
Inspect 4. P ro t e c t iv e cover.
I9
F o r fu e l le a k s a t fu e l lin e f it t in g w it h s o a p a n d
w a t e r s o lu tio n .

FUEL SU P P LY RELAY

Figure 4-14

0 R e m o ve or D iscon n ect
1. P r o t e c t iv e cover.
2. R e t a in e r , i f in s ta lle d .
3. E le c t r ic a l con n e cto r.
4. R e l a y b y d e p r e s s i n g b r a c k e t c li p a t r e a r o f
re la y , o r r e m o v in g b o lt s fro m r e t a i n i n g b ra c k e t.

1 R E TA IN E R 3 FU E L C O N T R O L F U S E

2 C N G FU E L C O N T R O L 4 DASH PANEL
RELAY
C 0 0 0 3 -4 -C N G

Figure 4-15 - CNG Control Relay

O IL P R E S S U R E S W IT C H

Figure 4-16

Rem ove or D isco n n e ct

1. E le c t r ic a l co n n e cto r.
2. O i l p r e s s u r e s w it c h u s i n g w r e n c h J 2 8 6 8 7 - A o r
B T - 8 2 2 0 i f re q u ire d .

Install or C o n n e ct
1. O i l p r e s s u r e sw itc h .
2. E le c t r ic a l co n n e cto r.
F U E L C Y L IN D E R S O L E N O ID V A L V E S
FUEL DOOR HINGE
T h e f u e l c y l i n d e r s o le n o id v a l v e s o n th e C N G FUEL DOOR SHUT-O FF SW ITCH
f u e l c y l i n d e r s a r e n o t s e r v ic e a b le . I f a s o le n o id i s FUEL FILL VALVE
fo u n d n o t fu n c t io n in g , th e C N G fu e l c y lin d e r m u s t
FUEL FILL POCKET
b e re p la ce d .

F U E L D O O R S H U T -O F F S W IT C H C0004-4-CN G

Figure 4-17 - Fuel Door Shut-off Switch

«"► R e m o v e or D iscon n ect
R a is e th e v e h ic le a n d s u p p o rt w ith s u it a b le
s a fe t y s ta n d s .
E le c t r ic a l c o n n e c to r fro m fu e l d o o r s h u t - o f f
s w itc h .
S w i t c h b r a c k e t r e t a i n i n g n u ts.
S w it c h a n d b ra c k e t.
S w it c h r e t a i n i n g n u t.
5. S w it c h .

+ «- Install or C o n n e ct
1. S w it c h to b ra c k e t.
2. S w it c h r e t a i n i n g n u t.
3. S w it c h a n d b r a c k e t to s t u d s o n ve h icle .
4. S w it c h b r a c k e t r e t a i n i n g n u ts.
5. E le c t r ic a l co n n e cto r.
• L o w e r th e v e h ic le .

Figure 4-18 - 1/4 Turn Shut-off Valve

1/4 T U R N S H U T -O F F V A L V E

|<--»| R e m o v e or D iscon n ect

**«-| Install or C o n n ect
1. N e g a t i v e b a t t e r y te r m in a l.
1. 1/4 t u r n s h u t - o f f v a l v e to b ra c k e t.
• R a is e th e v e h ic le and su p p o rt w ith s u it a b le
s a fe t y s ta n d s . 2. F u e l o u t le t lin e to 1/4 t u r n s h u t - o f f v a lv e .

• R e lie v e fu e l s y s t e m lin e p r e s s u r e a s p r e v io u s ly
o u t lin e d i n t h is se c tio n .*
2. F u e l in le t lin e fro m 1/4 t u r n s h u t - o ff va lv e . £ Tigh ten
3. L o o s e n 1/4 t u r n s h u t - o f f v a l v e r e t a i n i n g n u t. • L i n e f it t in g to 2 0 N * m (15 lb. ft.).
4. F u e l o u t le t lin e fro m 1/4 t u r n s h u t - o ff v a lv e . 3. T i g h t e n 1/4 t u r n s h u t - o f f v a l v e r e t a i n i n g n u t.
5. 1/4 t u r n s h u t - o f f v a lv e .
4. F u e l in le t lin e to 1/4 t u r n s h u t - o f f v a lv e . 5. T u r n th e 1/4 t u r n s h u t - o f f v a l v e to th e “O P E N ”
p o sitio n .
Tigh ten • L o w e r th e v e h ic le .
6. N e g a t iv e b a t t e r y t e r m in a l.
• L i n e f i t t in g to 2 0 N * m (15 lb. ft.).
• L o w e r th e v e h ic le .
5. N e g a t i v e b a t t e r y t e r m in a l.
{? Inspect
• F o r fu e l le a k s a t fu e l lin e f it t in g s w it h so ap
L* Inspect a n d w a t e r s o lu t io n .

• F o r fu e l le a k s a t fu e l lin e f it t in g s w it h so a p
a n d w a t e r s o lu t io n .
C N G FU EL P R E S S U R E R E G U L A T O R

FUEL P R E S SU R E T R A N SD U C E R Rem ove or D isco n n e ct

1. N e g a t iv e b a t t e r y t e r m in a l.
► R e m o v e or D iscon n e ct 2. D r a i n th e c o o lin g s y ste m .
• R a is e th e v e h ic le a n d s u p p o r t w it h s u it a b le
1. N e g a t i v e b a t t e r y t e r m in a l.
sa fe ty s ta n d s.
• R a is e th e v e h ic le and su p p o rt w it h s u it a b le
• R e lie v e fu e l s y s t e m lin e p r e s s u r e a s p r e v i o u s ly
s a f e t y s ta n d s .
o u t lin e d i n t h is se ctio n .
• R e lie v e fu e l s y s t e m lin e p r e s s u r e a s p r e v i o u s ly
3. T u r n t h e 1/4 t u r n s h u t - o f f v a l v e t o t h e
o u t lin e d i n t h is se ctio n .
“C L O S E D ” p o s it io n .
2. T u r n t h e 1/4 t u r n s h u t - o f f v a l v e t o t h e
4. F u e l in le t lin e fro m CN G fu e l p re ssu re
“C L O S E D ” p o s it io n .
r e g u la to r.
3. E le c t r ic a l c o n n e c to r fro m fu e l p re s s u re
5. F u e l o u t le t h o s e f r o m lo w p r e s s u r e s h u t - o f f
tr a n s d u c e r .
so le n oid .
4. T r a n s d u c e r r e t a i n i n g s t r a p s c re w s a n d stra p .
6. C o o l a n t h o s e c la m p s a n d h o s e s f r o m p r e s s u r e
5. F u e l in le t a n d o u t le t lin e s fro m p r e s s u r e
re g u la to r.
tra n sd u c e r.
7. E le c t r ic a l c o n n e c t o r fro m lo w p r e s s u r e s h u t - o f f
6. F u e l p re ssu re tra n sd u ce r.
so le n o id .
-►4- 8. F u e l p r e s s u r e r e g u l a t o r m o u n t i n g s t r a p b o lt s
Install or C o n n ect
a n d stra p .
1. F u e l p re ssu re tra n sd u c e r. 9. C N G fu e l p r e s s u r e r e g u la t o r w it h lo w p r e s s u r e
2. F u e l in le t a n d o u t le t lin e s to p re ssu re s h u t-o ff so le n o id .
tr a n s d u c e r . 10. S o le n o id fro m th e fu e l p r e s s u r e re g u la t o r .

-►«- Install or C o n n e ct
• L i n e f i t t in g to 2 0 N * m (15 lb. ft.). 1. S o le n o id to th e fu e l p r e s s u r e re g u la t o r .
3. T r a n s d u c e r r e t a i n i n g s t r a p a n d sc re w s. 2. C N G fu e l p r e s s u r e r e g u la t o r w it h lo w p r e s s u r e
4. E le c t r ic a l c o n n e c t o r to fu e l p r e s s u r e tr a n s d u c e r . s h u t - o ff so le n o id .

1 C N G FU E L P R E S S U R E R E G U L A T O R

2 R E G U L A T O R R E T A IN IN G S T R A P

3 FU E L LIN E
1 C N G FUEL PRESSURE TR A N S D U C E R
4 CO O LAN T HOSES
C 0 0 0 6 -4 -C N G 5 T E S T P O R T____________________ C 0 0 0 7 -4 -C N G

Figure 4-19 - Fuel Pressure Transducer

3. F u e l p re ssu re r e g u la t o r m o u n t in g stra p and 4. F u e l o u t le t h o se to lo w p re ssu re sh u t-o ff
b olts. so le n o id .

T igh ten Tigh ten

• B o lt s to 2 5 N * m (18 lb. ft.). • L i n e f it t in g to 2 0 N * m (15 lb. ft.).
4. E l e c t r i c a l c o n n e c t o r to lo w p r e s s u r e s h u t - o f f F u e l in le t lin e to C N G fu e l p r e s s u r e r e g u la t o r .
so le n o id .
5. C o o la n t h o s e s a n d c la m p s to p r e s s u r e re g u la t o r. Tigh ten
6. F u e l o u t le t h o se to lo w p re ssu re sh u t-o ff • L i n e f it t in g to 2 0 N * m (15 lb. ft.).
so le n o id .
6. E l e c t r i c a l c o n n e c t o r to lo w p r e s s u r e sh u t-o ff
so le n o id .
7. T u r n th e 1/4 t u r n s h u t - o f f v a l v e to t h e “O P E N ”
• L i n e f it t in g to 2 0 N * m (15 lb. ft.). p o sitio n .
7. F u e l in le t lin e to C N G fu e l p r e s s u r e re g u la to r. • L o w e r th e ve h ic le .
8. N e g a t i v e b a t t e r y t e r m in a l.

• L i n e f it t in g to 2 0 N * m (15 lb. ft.). I? Inspect

8. T u r n th e 1/4 t u r n s h u t - o ff v a lv e to th e “O P E N ” ► F o r fu e l le a k s at fu e l lin e f it t in g s w ith so ap
p o s itio n . a n d w a t e r so lu tio n .
• L o w e r th e ve h ic le .
9. R e f ill th e c o o lin g s y ste m .
10. N e g a t i v e b a t t e r y t e rm in a l.

Inspect
• F o r f u e l l e a k s a t f u e l li n e f i t t in g s w it h so ap
a n d w a t e r so lu tio n .

L O W P R E S S U R E F U E L SH U T -O F F S O L E N O ID

R e m o v e or D isconnect
1. N e g a t i v e b a t t e r y t e rm in a l.
_____1 LOW PRESSURE FUEL SHUT-O FF SO LENO ID
• R a is e th e v e h ic le a n d s u p p o r t w it h s u it a b le
s a fe t y s ta n d s . 2 FUEL PRESSURE REGULATOR

• R e lie v e fu e l s y s t e m lin e p r e s s u r e a s p r e v io u s ly 4 3 FUEL SUPPLY HOSE

o u t lin e d i n t h is se ctio n . 4 T R A N S M IS S IO N CROSSM EM BER
2. T u r n t h e 1/4 t u r n sh u t-o ff v a lv e to th e 5 T R A N S M IS S IO N C0008-4-C NG
“C L O S E D ” p o s itio n .
Figure 4-21 - Low Pressure Fuel Shut-Off Solenoid
3. E le c t r ic a l c o n n e c t o r fro m lo w p r e s s u r e s h u t - o f f
so le n o id .
4. F u e l in le t lin e fro m CNG fu e l p re ssu re
re g u la t o r . C N G F U E L L IN E A N D H O S E A S S E M B L IE S
5. F u e l o u t l e t h o s e f r o m lo w p r e s s u r e s h u t - o f f
so le n o id . M a te rials
6. F u e l p r e s s u r e r e g u l a t o r m o u n t i n g s t r a p b o lt s
a n d stra p . T h e C N G fu e l lin e s a re s t a in le s s ste e l w it h
• P o s it i o n r e g u la t o r asid e. s p e c i a l c o m p r e s s i o n f i t t i n g s . D o n o t a t t e m p t to
r e p a ir o r m a k e C N G fu e l lin e s. A l l C N G fu e l li n e s
7. 90° r e g u l a t o r o u t le t f i t t i n g w i t h lo w p r e s s u r e
s o le n o id a tta c h e d . m u s t b e r e p la c e d w i t h i d e n t i c a l G M S P O s e r v i c e
C N G f u e l lin e s . T h e C N G f u e l s u p p l y h o s e i s n o t
8. 90° r e g u la t o r o u t le t f it t in g fro m th e lo w
p r e s s u r e fu e l s h u t - o f f so le n oid . re p a ira b le . R e p la c e th e C N G fu e l s u p p l y h o s e w i t h
a n id e n t ic a l G M S P O s e rv ic e C N G fu e l s u p p l y ho se .
Install or C o n n ect
Fuel Fill V alve
1. 90° r e g u la t o r o u t le t f it t in g to th e lo w p r e s s u r e
fu e l s h u t - o f f so le n o id .
R e m o ve or D iscon n ect
2. L o w p r e s s u r e s o le n o id a n d f i t t in g to t h e
p r e s s u r e re g u la t o r . 1. N e g a t iv e b a t t e r y te r m in a l.
3. F u e l p r e s s u r e r e g u la t o r m o u n t in g stra p a n d • R e lie v e fu e l s y s t e m lin e p r e s s u r e a s p r e v i o u s ly
b olts. o u t lin e d i n t h is sectio n .
 Fuel Fill Valve to Fuel " T " Line

Rem ove or D iscon n e ct

L e f t s id e d u a l C N G fu e l c y lin d e r s a s o u t lin e d
la t e r in t h is se ctio n .
2. Fuel f ill lin e fro m f ill v a lv e .
3. Fuel f ill lin e fr o m “T ” fitt in g .
4. Fuel f ill lin e r e t a i n i n g c la m p s a n d line .

Install or Co nnect
1. F u e l fill lin e a n d r e t a i n i n g c la m p s.
2. F u e l f ill lin e to “T ” fitt in g .

Tighten
• L i n e f it t in g to 2 0 N « m (15 lb. ft.).
3. F u e l f ill lin e to f ill v a lv e .

Tighten
1 FU E L FILL V A L V E
• L i n e f it t in g to 2 0 N * m (15 lb. ft.).
2 V A L V E M O U N T IN G B R A C K E T
4. L e f t s id e d u a l C N G f u e l c y l i n d e r s a s o u t li n e d
3 BRACKET
la t e r in t h is se ctio n .
4 FILLER PO C K ET

5 SCREW S Inspect
6 CLAM P • F o r fu e l le a k s a t fu e l lin e f it t in g s w it h soap
C 0 0 0 9 -4 -C N G a n d w a t e r s o lu t io n .

Figure 4-22 - Fuel Fill Valve

2. F u e l f ill v a lv e m o u n t in g b ra c k e t r e t a in in g
s c r e w s a t fu e l f ill door.
• R a is e th e v e h ic le a n d s u p p o r t w it h s u it a b le
s a fe t y sta n d s .
3. F u e l f ill lin e a t f ill v a lv e .
4. V a l v e a n d b ra c k e t.
5. F u e l f ill v a l v e fro m m o u n t i n g b ra c k e t.

-►4- Install or Co nnect

1. F u e l f ill v a l v e to m o u n t i n g b ra c k e t.
2. V a l v e a n d b r a c k e t a s s e m b l y to t h e fu e l fill
door.
3. F u e l f ill lin e to fu e l f ill v a lv e .

T igh ten
• L i n e f i t t in g to 2 0 N » m (15 lb. ft.)
L o w e r th e v e h ic le .
4. F u e l f ill v a lv e m o u n t in g b ra c k e t r e t a in in g
s c r e w s a t fu e l f ill door.
5. N e g a t i v e b a t t e r y t e r m in a l.

Inspect
» F o r f u e l l e a k s a t f u e l li n e f i t t i n g s w i t h so a p
a n d w a t e r s o lu t io n .
Fuel S u p p ly H ose Fuel Injector Plate S u p p ly Line

► R e m o v e or D isconnect R em ove or D isconnect

N e g a t i v e b a t t e r y te r m in a l. l. N e g a t i v e b a t t e r y t e r m in a l.
R a is e th e v e h ic le a n d s u p p o r t w it h s u it a b le R e lie v e fu e l s y s t e m lin e p r e s s u r e a s p r e v i o u s ly
s a fe t y s ta n d s . o u t lin e d i n t h is sectio n .
R e lie v e fu e l s y s t e m lin e p r e s s u r e a s p r e v io u s ly 2. A i r c le a n e r a n d d u c t a s s e m b ly .
o u t lin e d i n t h is sectio n . R a is e th e v e h ic le a n d s u p p o r t w it h s u it a b le
2. T u r n t h e 1/4 t u r n s h u t - o f f v a l v e to t h e s a fe t y sta n d s.
“C L O S E D ” p o s itio n . 3. T u r n t h e 1/4 t u r n s h u t - o f f v a l v e t o t h e
3. F u e l s u p p l y h o s e f r o m lo w p r e s s u r e s h u t - o f f “C L O S E D ” p o sito n .
s o le n o id . 4. Fuel s u p p ly h o se fro m in j e c t o r p l a t e s u p p ly
4. F u e l s u p p l y h o s e fro m in je cto r s u p p ly line. lin e .
5. F u e l s u p p l y hose. 5. U p p e r a n d lo w e r fu e l lin e r e t a in in g b ra c k e t
s c re w s a n d b r a c k e t s fro m t r a n s m is s io n .
Install or Co nnect • L o w e r th e v e h ic le .
1. F u e l s u p p l y hose. 6. F u e l lin e fro m C N G in je c to r plate.
2. F u e l s u p p l y h o s e to in je c to r s u p p ly line. 7. F u e l lin e fro m ve h icle .

Tigh ten Install or C onnect

• L i n e f i t t in g to 2 0 N * m (15 lb. ft.). F u e l lin e to ve h ic le .
3. F u e l s u p p l y h o s e to lo w p r e s s u r e sh u t-o ff F u e l lin e to C N G in je c to r p late.
so le n o id .
$ T igh ten
$ Tigh ten • L i n e f it t in g to 2 0 N * m (15 lb. ft.).
• L i n e f i t t in g to 2 0 N * m (15 lb. ft.). R a is e th e v e h ic le a n d s u p p o r t w it h s u it a b le
T u r n th e 1/4 t u r n s h u t - o ff v a lv e to th e “O P E N ” s a fe t y sta n d s.
p o sitio n . 3. U p p e r a n d lo w e r f u e l l i n e r e t a i n i n g b r a c k e t s
L o w e r th e v e h ic le . a n d s c re w s to t r a n s m is s io n .
5. N e g a t i v e b a t t e r y te r m in a l. 4. F u e l s u p p l y h o s e to in je c to r p la t e s u p p l y lin e .

1?1 Inspect & T igh ten

» F o r f u e l l e a k s a t f u e l h o s e f i t t in g s w it h s o a p
• L i n e f it t in g to 2 0 N * m (15 lb. ft.).
a n d w a t e r s o lu t io n .

5 2

IN J E C T O R PLA TE S U P P L Y LINE

FU E L S U P P L Y H O S E 3 T R A N S M IS S IO N

L O W P R E S S U R E S H U T -O F F S O L E N O ID 4 E N G IN E

FU E L P R E S S U R E R E G U L A T O R C 001 1-4 -C N G 5 IN J E C T O R P LA TE C 0 0 1 2 -4 -C N G
5. t u r n th e 1/4 t u r n s h u t - o f f v a l v e to th e “O P E N ’
p o sitio n .
L o w e r th e v e h ic le .
A i r c le a n e r a n d d u c t a s s e m b ly .
N e g a t i v e b a t t e r y t e r m in a l.

I9 Inspect
F o r f u e l l e a k s a t f u e l li n e f it t in g s w it h so ap
a n d w a t e r so lu tio n .

C N G F U E L C Y L IN D E R S

R ig h t Sid e

R e m o v e or D iscon n ect
1. N e g a t i v e b a t t e r y t e r m in a l.
• R a is e th e v e h ic le a n d s u p p o r t w it h s u it a b le
s a fe t y s ta n d s .
• R e lie v e fu e l s y s t e m lin e p r e s s u r e a s p r e v i o u s ly
o u t lin e d in t h is se ctio n .
2. T u r n t h e 1/4 t u r n s h u t - o f f v a l v e t o t h e
“C L O S E D ” p o sitio n .
3. E le c t r ic a l c o n n e c to r fro m fu e l c y lin d e r s o le n o id
v a lv e .
4. F u e l lin e s fro m C N G fu e l c y lin d e r.
• S u p p o rt fu e l c y lin d e r u s i n g t r a n s m is s io n ja c k DRIVESHAFT
a n d P A S - 5 6 0 7 4 c y lin d e r r e m o v e r a n d in s t a lle r . OVERTEMP/QVERPRESSURE RELIEF VALVE
5. F u e l c y lin d e r s t r a p r e t a i n i n g n u t s a n d b o lts.
RETAINING STRAPS
6. R e a r s u p p o r t b r a c k e t b o lt a t c e n te r o f b ra c k e t.
CNG FUEL CYLINDER
• L o w e r a n d re m o v e C N G fu e l c y lin d e r.
HEAT SHIELD
7. F u e l c y lin d e r fro m P A S - 5 6 0 7 4 .
8. H e a t s h ie ld , s t r a p s a n d b r a c k e t s fro m fu e l FUEL SO LENOID VALVE
c y lin d e r. FUEL SUPPLY LINE
8 FUEL FEED LINE
Install or Co nnect C0013-4-CNG

1. H e a t s h ie ld , s t r a p s a n d b r a c k e t s to n e w C N G Figure 4-26 - Right CNG Fuel Cylinder

fu e l c y lin d e r. 7. T u r n th e 1/4 t u r n s h u t - o f f v a l v e to th e “O P E N ”
2. F u e l c y lin d e r to t r a n s m is s io n ja c k and p o sitio n .
P A S -5 6 0 7 4 . • L o w e r th e v e h ic le .
• R a i s e a n d i n s t a l l C N G fu e l c y lin d e r. 8. N e g a t iv e b a t t e r y t e r m in a l.
3. R e a r s u p p o r t b r a c k e t b o lt a t c e n te r o f b ra c k e t.
I? Inspect
Tigh ten
• F o r fu e l le a k s a t fu e l lin e f it t in g s w it h so a p
• B o l t to 5 0 N - m (3 7 lb. ft.). a n d w a t e r s o lu t io n .
4. F u e l c y lin d e r s t r a p r e t a i n i n g n u t s a n d bo lts.

Left Sid e Dual

Q Tigh ten
• N u t to 5 0 N - m (3 7 lb. ft.). Rem ove or D iscon n e ct
• B o l t to 5 0 N - m (3 7 lb. ft.). N e g a t iv e b a t t e r y t e r m in a l.
• R e m o v e t r a n s m is s io n ja c k a n d P A S -5 6 0 7 4
R a is e th e v e h ic le a n d s u p p o r t w it h s u it a b le
c y lin d e r r e m o v e r a n d in s t a lle r .
s a fe ty sta n d s.
5. F u e l lin e s to C N G fu e l c y lin d e r.
R e lie v e fu e l s y s t e m lin e p r e s s u r e a s p r e v i o u s ly
o u t lin e d i n t h is se ctio n .
T u r n th e 1/4 t u r n sh u t-o ff v a lv e to th e
• L i n e f it t in g to 2 0 N - m (15 lb. ft.). “C L O S E D ” p o s itio n .
E l e c t r i c a l c o n n e c t o r to f u e l c y l i n d e r s o l e n o i d 3. D r i v e s h a ft b o lts.
v a lv e . 4. D r i v e s h a ft a s s e m b ly .
 1 FU E L S U P P L Y L IN E S

2 FU E L FEED L IN E S

3 FU E L S O L E N O ID V A L V E S

4 C N G FU E L C Y L IN D E R S

5 R E T A IN IN G S T R A P S

6 O V E R T E M P /O V E R P R E S S U R E RELIEF V A L V E S
C 0 0 1 4 -4 -C N G

Figure 4-27 - Left Dual CNG Fuel Cylinders

5. E le c t r ic a l c o n n e c t o rs fro m fu e l c y lin d e r s o le n o id • N u t to 5 0 N * m (3 7 lb. ft.).
v a lv e s . • B o l t to 5 0 N » m (3 7 lb. ft.).
6. F u e l li n e s fr o m C N G fu e l c y lin d e rs . • R e m o v e t r a n s m is s io n ja c k a n d P A S - 5 6 0 7 4
7. N u t s fro m c y lin d e r su p p o rt s tra p s be tw e e n c y lin d e r r e m o v e r a n d in s t a lle r .
c y lin d e r s . 5. N u t s to c y l i n d e r s u p p o r t s t r a p s b e t w e e n
• S u p p o r t fu e l c y lin d e r s u s i n g t r a n s m is s io n j a c k c y lin d e rs .
a n d P A S - 5 6 0 7 4 c y lin d e r re m o v e r a n d in s ta lle r.
8. F u e l c y l i n d e r s t r a p r e t a i n i n g n u t s , b o lt s a n d Tigh ten
stra p s.
• N u t to 5 0 N « m (3 7 lb. ft.).
• L o w e r a n d r e m o v e C N G fu e l c y lin d e rs.
6. F u e l lin e s to C N G fu e l c y lin d e rs .
9. F u e l c y lin d e r s fr o m P A S - 5 6 0 7 4 .
10. S h ie ld , s t r a p s a n d b r a c k e t s fro m fu e l c y lin d e r.
11. U p p e r m o u n t i n g b r a c k e t s a n d b o l t s , i f
$ Tighten
n e c e s s a ry . • L i n e f it t in g to 2 0 N * m (15 lb. ft.)
7. E l e c t r i c a l c o n n e c t o r s to f u e l c y l i n d e r s o le n o id
Install or C o n n ect v a lv e s .
D r i v e s h a ft a s s e m b ly .
L. U p p e r m o u n t in g b ra c ke ts and b o lt s , if
9. D r i v e s h a ft bolts.
n e c e s s a ry .

Tigh ten
T igh te n
• B o l t to 2 0 N * m (15 lb. ft.).
• B o l t to 5 0 N « m (3 7 lb. ft.).
10 . T u r n th e 1/4 t u r n s h u t - o f f v a l v e to th e “O P E N ”
2. S h i e ld , s t r a p s a n d b r a c k e t s to n e w C N G fu e l
p o s itio n .
c y lin d e r.
L o w e r th e v e h ic le .
3. F u e l c y lin d e r s to t r a n s m is s io n ja ck and
11. N e g a t i v e b a t t e r y t e r m in a l.
P A S -5 6 0 7 4 .
• R a i s e a n d i n s t a l l C N G fu e l c y lin d e r.
1? Inspect
4. F u e l c y lin d e r s t r a p r e t a in in g stra p s, n u ts a n d
bo lts. • F o r fu e l le a k s a t fu e l lin e f it t in g s w it h soap
a n d w a t e r s o lu tio n .
ACCELERATOR CONTROL Rem ove or D iscon n e ct
1. R e t a in e r fro m t h r o t t le le v e r stu d .
A ccelerator C ontrol Cable 2. R e t a in e r lo c k i n g t a n g s fro m s u p p o r t b ra c k e t.
3. R e t a i n e r f r o m a c c e le r a t o r p e d a l r o d o r r e le a s e
Figure 4-28 ca b le fro m rod.
4. R e t a in e r l o c k i n g t a n k s fro m d a s h p a n e l.
T h e r e a r e n o li n k a g e a d ju s t m e n ts . T h e t h ro t t le
c a b le m u st be r e p la c e d w it h an id e n t ic a l -►4- Install or C o n n ect
r e p la c e m e n t p art. 1. R e t a in e r to d a s h p a n e l.
A l l l i n k a g e s a n d c a b l e s m u s t b e c h e c k e d , to 2. R e t a i n e r to a c c e l e r a t o r p e d a l r o d o r c o n n e c t
a s s u r e fre e m o v e m e n t, w it h n o r u b b in g , c h a fin g , o r ca b le i n ro d slot.
b in d in g . 3. R e t a in e r to s u p p o r t b ra c k e t.
T h e t h r o t t le m u s t o p e r a t e f r e e ly , w it h o u t 4. R e t a in e r to t h ro t t le le v e r s t u d o r c o n n e c t c a b le
b i n d i n g b e tw e e n f u ll c lo se d a n d s id e o p e n th ro ttle . to p u lle y .
O b s e r v e th e fo llo w in g , w h e n p e r f o r m in g s e rv ic e
o n t h e a c c e le ra t o r c o n tro l cable. Accelerator Pedal
• T h e r e t a in e r m u s t be in s t a lle d w it h th e t a n g s
s e c u re d o v e r th e h e a d o f th e stu d . Figure 4-29
• T h e c o n d u it f it t in g , a t b o t h e n d s o f t h e c a b le ,
m u st h a v e th e lo c k in g t a n g s e x p a n d e d a n d The a c c e le r a t o r pedal c o n t r o ls th e t h r o t t le ,
lo c k e d in t o th e a t t a c h in g h o le s. t h r o u g h a cable. T h e r e a r e n o l i n k a g e a d ju s t m e n t.
• T h e b r a id e d p o r t io n o f th e c a b le m u s t n o t co m e T h e t h r o t t le c a b le m u s t be r e p la c e d w it h a n
in t o c o n ta c t w it h th e fr o n t o f d a s h s e a le r id e n t ic a l r e p la c e m e n t p a rt.
d u r i n g re p la c e m e n t. A l l l i n k a g e s a n d c a b l e s m u s t b e c h e c k e d , to
• F le x ib l e c o m p o n e n ts (h o se s, w ire s , c o n d u it, etc.) a s s u r e free m o v e m e n t w i t h n o r u b b in g , c h a fin g , o r
m u s t n o t b e r o u t e d w i t h i n 5 0 m m (2 ") o f th e b in d in g . T h e t h r o t t le m u s t o p e ra te fre e ly , w it h o u t
m o v i n g p a r t s o f th e a c c e le ra t o r lin k a g e , u n le s s b in d in g , b e t w e e n f u ll c lo s e d a n d W id e O p e n
r o u t i n g is p o s it iv e ly co n tro lle d . T h r o t t le ( W O T ).

1 R E T A IN E R

2 L U B R IC A N T

3 T H R O T T L E LE V E R S T U D 1 RETAINER 5 ROD
4 S P R IN G 2 SPRING 6 RETAINER
5 C A BLE 3 SUPPORT 7 PLATE
6 SUPPORT
7S 3 7 9 1 -6 E -C N G
4 CABLE 8 PEDAL 7S 3788-6E
 O b s e r v e th e fo llo w in g , w h e n p e r f o r m in g s e rv ic e
o n th e a c c e le ra t o r ped al.
• T h e m o u n t i n g s u rf a c e b e tw e e n th e su p p o rt a n d
th e d a s h p a n e l, m u s t b e free o f in s u la t io n . T h e
c a r p e t a n d p a d d in g in th e p e d a l a n d t u n n e l
a r e a m u s t b e p o s it io n e d to la y fla t a n d b e fre e
o f w r in k le s a n d bu nch es.
• S l i p t h e a c c e le r a t o r c o n t r o l c a b le t h r o u g h th e
s lo t i n th e rod, b e fo re i n s t a l l i n g th e r e t a in e r in
t h e ro d . M a k e s u r e it is se a t e d p ro p e rly . U s e
c a r e i n p r e s s i n g r e t a i n e r in t o th e hole , so t h e
c a b le is n o t k in k e d , o r d a m a g e d .
• T h e l i n k a g e m u s t o p e r a t e f r e e ly , w it h o u t
b in d in g , b e t w e e n c lo s e d t h r o t t le a n d f u l l
th ro ttle .
• W ir e , h o s e s , c a b le , a n d o t h e r f l e x ib l e
c o m o o n e n t s , m u s t n o t b e p la c e d w i t h i n 13 m m
(0 .5 2 ") o f th e c a b le o r rod, a t a n y p o in t, i n t h e ir
tra v e l.
PARTS INFORMATION
PART N A M E GROUP
In je cto r, F u e l ................................................3 .7 7 4
R e la y , F u e l S u p p l y .......................................3 ,9 9 0
S w it c h , O i l P r e s s ...............................................1 ,8 00
T h r o t t le B o d y In je c t io n U n i t ........................ 3 ,7 2 5
V a l v e A s m , Id le A i r C o n tr o l: P a r t o f
C o n t r o l K i t , Id le A i r V a l v e .................. 3 ,8 2 0

1992 CONTROLLED IDLE SPEED

t- __ G ear Idle Sp e e d IA C O p e n /C lo se d
E n gin e Tran sm .ss.on (Drive/Neutral) (R R M ) C o u n ts * Loop **

5.7L CNG AUTO DRIVE 650 ± 50 0-90 CL

(under 8500 (GVW)
* A dd 2 counts for engines w ith less than 500 m iles. Add 2 counts for every 1000 ft. above sea level.

** Let engine idle until prop er fuel control status (open/closed loop) is reached.

M IN IM U M IDLE SPEED

-------- - ,DrivX , t„| 0PLS,p” “ '

5.7L CNG AUTO DRIVE 650 ± 25 OL
* Let engine idle until prop er fuel control status (Open/Closed Loop) is reached.

‘* If the engine has less than 500 m iles or is checked at altitudes above 1500 feet, the idle rpm w ith a seated IAC valve should be lo w e r than values above.
4-28 F U E L C O N T R O L
 SECTION 5
EVAPORATIVE EMISSION CONTROL SYSTEM (EECS)
E v a p o r a t iv e e m is s io n c o n tro l sy ste m s w e re syste m m ean s no C N G c a n be re le a se d fro m th e
d e v e lo p e d to k e e p f r o m r e l e a s i n g g a s o lin e v a p o r s g a s c y lin d e r s u n le s s th e tr u c k is r u n n in g .
f r o m t h e f u e l t a n k in t o t h e a t m o s p h e r e . B e c a u s e T h e re fo re , th e N a t u r a l G a s P o w e r e d T r u c k d o e s n o t
c o m p r e s s e d n a t u r a l g a s is g a s e o u s, th e s t o r a g e n e e d a n e v a p o r a t iv e e m is s io n c o n tro l s y st e m .
t a n k s m u s t b e a c lo s e d s y s t e m . B e i n g a c lo s e d
5-2 E V A P O R A T IV E E M IS S IO N C O N T R O L
 SECTION 6
IGNITION SYSTEM/EST
T h e ig n it io n s y s t e m fo r th e N a t u r a l G a s
P o w e r e d T r u c k is th e s a m e s y s t e m u s e d o n th e C / K
T r u c k ’s 5 . 7 L g a s o l i n e e n g i n e . R e f e r to t h e 1 9 9 2
L i g h t D u t y T r u c k F u e l a n d E m is s io n s S e r v ic e
M a n u a l fo r f u r t h e r in fo r m a t io n .
6-2 IG N IT IO N S Y S T E M / E S T
 SECTION 7
ELECTRONIC SPARK CONTROL/ESC
W h ile th e N a t u r a l G a s P o w e re d T r u c k is re d u c e s d r iv e a b ilit y a n d p e rfo rm a n c e w it h th e
e q u ip p e d w i t h t h e s a m e E S C sy ste m u se d o n th e c u r r e n t E S C s y ste m . So, th e k n o c k s e n s o r s i g n a l to
C / K T r u c k ’s 5 . 7 L g a s o l i n e e n g i n e , i t d o e s n o t th e E C M h a s b e e n m a sk e d , a n d n o k n o c k se n so r
s u p p l y a n y i n p u t to th e E C M . B e c a u s e o f th e h i g h d a t a w i l l b e r e c e iv e d b y y o u r T E C H I o n N a t u r a l
o cta n e r a t in g o f C N G , th e k n o c k se n so r a c t u a lly G a s P o w e re d T ru c k s.
7-2 E L E C T R O N IC S P A R K C O N T R O L
 A.I.R. M A N A G E M E N T 8-1

SECTION 8
A.I.R. MANAGEMENT SYSTEM
A . I . R . m a n a g e m e n t s y s t e m s w e r e d e v e lo p e d to w it h o u t th e u se o f a n A .I.R . m a n a g e m e n t sy ste m .
h e l p r e d u c e v e h i c l e e m i s s i o n le v e ls . C o m p r e s s e d So , th e N a t u r a l G a s P o w e r e d T r u c k i s n o t e q u ip p e d
n a t u r a l g a s b u r n s m u c h c le a n e r t h a n g a s o lin e w it h a n A . I. R . m a n a g e m e n t s y ste m .
e n g i n e s a n d i s a b le to m e e t e m i s s i o n s r e g u l a t i o n s
8-2 A.I.R. MANAGEMENT
 SECTION 9
EXHAUST GAS RECIRCULATION (EGR)
C o m p re s s e d N a t u r a l G a s e n g in e s do p ro d u c e u s e d o n C / K T r u c k ’s u n d e r 8 5 0 0 G V W w i t h 5 . 7 L
N O x (o x id e s o f n it r o g e n ). T h e N a t u r a l G a s P o w e r e d g a s o lin e e n g in e s . T h e E G R is a n e g a t iv e
T r u c k i s e q u ip p e d w i t h a n E G R s y s t e m to r e g u la t e b a c k p r e s s u r e E G R v a l v e s o le n o id c o n t r o l s y s t e m .
N O x e ih is s io n le v e ls . T h e E G R s y st e m fo r th e R e f e r to t h e 1 9 9 2 L i g h t D u t y T r u c k F u e l a n d
N a tu ra l Gas P o w e re d T ru c k is th e sam e one E m i s s i o n s S e r v ic e M a n u a l fo r f u r t h e r in f o r m a t io n .
9-2 EXHAUST GAS RECIRULATION
 SECTION 10
TRANSMISSION CONTROLS
T h e N a t u r a l G a s P o w e re d T r u c k u se s th e e le c tr ic a l o p e r a t io n o f th e T o r q u e C o n v e r t e r C lu t c h
H y d r a m a t ic 4 L 6 0 a u t o m a t ic t r a n s m is s io n . T h e ( T C C ) s y ste m . R e f e r to th e 1 9 9 2 L i g h t D u t y T r u c k
t r a n s m is s io n i s t h e s a m e o n e u s e d i n C / K T r u c k ’s F u e l a n d E m is s io n s S e r v ic e M a n u a l fo r fu rth e r
w it h g a s o lin e e n g in e s . T h i s se c tio n o n ly co v e rs th e in fo r m a t io n .
10-2 TRANSMISSION CONTROLS
 SECTION 11
POSITIVE CRANKCASE VENTILATION
T h e p o s it iv e c r a n k c a s e v e n t ila t io n ( P C V ) s y s t e m
fo r t h e N a t u r a l G a s P o w e r e d T r u c k i s t h e s a m e
s y s t e m u s e d o n t h e C / K T r u c k ’s 5 . 7 L g a s o l i n e
e n g in e . R e f e r to t h e 1 9 9 2 L i g h t D u t y T r u c k F u e l
a n d E m is s io n s S e r v ic e M a n u a l fo r f u r t h e r
in fo r m a t io n .
11-2 POSITIVE CRANKCASE VENTILATION

SECTION 12
THERMOSTATIC AIR CLEANER (THERMAC)
T h e t h e r m o s t a t ic a ir c le a n e r ( T H E R M A C )
s y s t e m fo r t h e N a t u r a l G a s P o w e r e d T r u c k i s t h e
s a m e s y s t e m u s e d o n th e C / K T r u c k ’s 5 .7 L g a s o lin e
THERMOSTATIC AIR CLEANER 12-1
e n g in e . R e f e r to t h e 1 9 9 2 L i g h t D u t y T r u c k F u e l
a n d E m is s io n s S e r v ic e M a n u a l fo r f u r t h e r
in fo r m a t io n .
12-2 THERMOSTATIC AIR CLEANER
 SECTION 13
SPECIAL TOOLS
CONTENTS
General Description .......................................... 13-1
"Scan" Tool ........................................................ 13-1
GENERAL DESCRIPTION
The special tools required for service of the fuel
and emission systems are illustrated in Figures 13-1
through 13-5. These tools will be needed in specialized
procedures listed in other sections. The knowledge of
the tool’s abilities and limitations must be known
before they are used. This knowledge should include,
"Scan” tool operation, proper use of test lights, use of
jumper wires to bypass components for circuit tests
and proper usage of a Digital Volt Ohmmeter (DVOM).
"SCAN" TOOL
The Computer Command Control ALDL connector
under the dash near the steering column allows an
easy link for connecting "Scan” tools to the system.
There are several "Scan” tools available for reading
this information.
Special Tools (1 of 4)........................................... 13-2
"Scan” tools do not replace the use of diagnostic
charts or even locate exactly where a problem is in a
given circuit. However, with an understanding of the
equipment and the circuit involved, the tools can be
very useful in obtaining information which could be
more time consuming than with other equipment.
NOTICE: A "Scan” tool that displays faulty data
should not be used and the problem should be
reported to the manufacturer. The use of a faulty
"Scan” tool can result in m isdiagnosis and
unnecessary replacement of good parts.
Tree code charts incorporate diagnosis procedures
using an ALDL "Scan” tool when possible.
Some electronic control modules use three modes
for transmitting information but some only read data
in the open mode. For further information on use of
the "Scan” tool, refer to COMPUTER COMMAND
CONTROL (SECTION 3).
 V O L T M E T E R - V o ltaq e Position Measures a m o u n t o f
voltage. W h e n connected in parallel to an existing
circuit. A digital v o ltm e te r w ith 10 m e g o h m in p u t
im pedance is used because some circuits require
accurate low voltage readings, and some circuits in
th e ECM have a very high resistance.

A M M E T E R - W h e n used as a m m e te r, this m e te r also

accurately measures e xtrem ely lo w current flo w .
Refer to m eter instructions fo r m ore in fo rm a tio n .
• Selector must be set properly fo r both fu n ctio n
and range. DC is used f o r most a u t o m o t iv e
measurements.

O H M M E T E R - Measures resistance o f circuit directly

in ohms. Refer to m eter fo r m ore in fo rm a tio n .
• OL Display in all ranges indicates o pen circuit.
• Zero display in all ranges indicates a short circuit.
• I n t e r m i t t e n t c o n n e c t i o n in c ir c u it m a y be
in d ic a te d by d i g i t a l r e a d i n g t h a t w i l l n o t
stabilize on circuit.
• Range Switch.
HIGH IMPEDANCE MULTIM ETER 200Q - Reads ohms directly
(DIGITAL VO LTM E TE R -D V M ) 2K,20K,200KQ - Reads ohms in thousands
J 340 2 9 -A 2M and 20MQ - Reads ohms in millions

T EC H 1 D IA G N O S T IC C O M P U T E R
A hand-held "SCAN" tool used to analyze and
diagnose fuel and emission system. Also can be
used to analyze o th e r co m p u te r system.

TK 0 0 0 0 0 TECH 1 A/
T K 2 0 5 0 F CARTRIDGE

TACHOM ETER
f’r l Use inductive trig g e r signal pickup typ e to check
RPM.
© tJ ©
{ ] o j

C O N N E C T O R T EST A D A P T E R KIT
Used to m ake electrical test connections in
current W e a th e r Pack, M e tri - Pack and M icro-
Pack style terminals.

6 -1 1 -9 1
J 356 16 7 S 3 5 3 4 -6 E
 C IR C U IT T E ST E R
Used to check all relays and solenoids b e fo re
connecting th e m to a n e w ECM/PCM. Measures
th e circuit resistance and indicates pass or fail via
green or red LED. A m b e r LED indicates current
polarity. Can also be used as a n o n -p o w e r e d
con tinuity checker.

J 34636/BT-8405

M E T R I-P A C K T E R M IN A L R E M O V E R
Used to rem ove 150 series M etri-P ack " p u ll-to -
seat" term inals fro m connectors. Refer to w irin g
harness service in Section "3" fo r rem oval
procedure.
J 35689-A

W E A T H E R P A C K T E R M IN A L R E M O V E R
Used to rem ove term inals fro m W e a t h e r Pack
connectors. Refer to w irin g harness service in
J 28742-A Section 3 fo r removal procedure.

E C M C O N N E C T O R T E R M IN A L R E M O V E R
Used to rem ove term in al fro m M icro-Pack
connectors. Refer to w irin g harness service in
Section "6E" fo r rem oval procedure.
J 33095/BT-8234-A

IA C S Y S T E M M O N IT O R
Used to test IAC motors fo r correct fu n c tio n in g
and p ro p e r response to commands.

IG N IT IO N M O D U L E TE ST E R
Used to test ignition m o d u le in Section 6.

6-8-91
J 24642-F/BT-7220 7S3535-6E
 Used to check a v a il a b l e s e c o n d a ry i g n it i o n
voltage. Also called an ST125.
J 26792/B T-7220-1

U N P O W E R E D TEST LIG H T
Used to check w irin g fo r co m plete circuit a n d
short to ground or voltage.

J 34142-B

M I N I M U M IDLE SP E E D A D J U S T IN G W R E N C H
Used to adjust th r o ttle stop screw on TBI unit.

J 3 3 1 79-20

P O R T FUEL IN JECTIO N D IA G N O S T IC KIT

Used to diagnose p o rt fuel injection systems.
The kit includes:
• Fuel Pressure G age - used fo r checking fuel
pum p pressure and com pare injector pressure
drop fo r equal fuel distribution.
• In je c to r Test L i g h t - used f o r c h e c k in g
electrical circuit to an injector.
• Injector Tester - used fo r en e rg izin g each fuel
injecto r fo r a precise a m o u n t o f t i m e t o
perform injector balance test.

J 34 7 3 0 -A

CNG FUEL PRESSURE GAGE

Used for checking and monitoring fupl line pressure
of compressed natural gas fuel system.

J 21867

J S lL INJECTOR TEST LIGHT

Used for checking the electrical circuit to a CNG
fuel injector.
J 3 4 7 30-2

O IL P R E SSU R E S E N D IN G U N IT S O C K E T
Used to rem ove and install oil pressure sending
( J 357 4 8
unit.
 O IL P R E S S U R E S W IT C H S O C K E T
Used to rem ove or install oil pressure switch.

^ ~D
^ J 35749

V A C U U M P U M P 20 IN. HG. M I N I M U M
Use g a g e to m o n ito r m a n ifo ld e n g in e v a c u u m
and check vacuum sensors, solenoids and valves.

• J 23738

O XYG EN SEN SO R W RENCH

Used f o r r e m o v in g o r in s t a llin g t h e o x y g e n
sensor.

J 29533-A/J 391 94

ID LE A IR C O N T R O L W R E N C H
Used f o r r e m o v in g or in stallin g IAC v a lv e on
t h r o tt le body.
6-11-91
1/B T -8 130 MS 12550-CNG

Figure 13-4 - Special Tools (4 of 4)

 CNG FUEL CYLINDER REMOVER/INSTALLER
Used to remove CNG fuel cylinders. Used with a
transmission jack. Tool available on a loan basis
free of charge from PAS. Contact PAS at
313-588-9313 for arrangements.

CNG FUEL CYLINDER PRESSURE RELIEF VALVE

Used to depressurize CNG fuel cylinders, if cylinders
are damaged.

J 39711

CYLINDER SECURING STRAPS

J 39625 C0001-13-CNG

Figure 13-5 Recommended Tools

 SECTION 14
ABBREVIATIONS AND GLOSSARY OF TERMS
A b b r e v i a t io n s u s e d i n t h is m a n u a l a re lis te d b e lo w COOLANT TEMPERATURE SENSOR (CTS) - D e v ic e
i n a l p h a b e t ic a l o r d e r w i t h a n e x p la n a t io n o f t h e th a t se n se s th e e n g in e c o o la n t t e m p e r a t u r e , and
a b b r e v ia t io n . T h e r e a re s o m e v a r ia t io n s in th e u s e p a sse s th a t i n f o r m a t io n to t h e e le c t r o n ic co n tro l
o f p e r io d s a n d i n c a p i t a l iz a t io n ( a s m p h , m .p .h ., m o d u le .
M p h , a n d M P H ) fo r a b b r e v ia t io n s u se d in t h is
CONVERTER - C A T A L Y T IC CONVERTER -
se c t io n b u t a l l t y p e s a re acceptable.
C o n t a in in g p la t in u m a n d p a lla d iu m to s p e e d u p
A/F - AIR/FUEL (A/F RATIO) - T h e a m o u n t o f a ir-to - c o n v e r s io n o f H C a n d C O .
fu e l fo r c o m b u s t io n of C N G .
CO - CARBON MONOXIDE - O n e o f th e p o llu t a n t s
AIR - AIR INJECTOR REACTION SYSTEM - A i r fo u n d i n e n g in e e x h a u s t .
f lo w f r o m p u m p i s d ir e c t e d i n t o e n g i n e e x h a u s t
CURRENT OR AMPERAGE - T h e r a t e o f f l o w o f
m a n i f o l d a n d / o r c o n v e r t e r to r e d u c e e x h a u s t
e le c tr o n s is s i m i l a r to g a l lo n s o f w a t e r p e r m in u t e
e m is s io n s .
f lo w in g i n a w a t e r pipe.
ALDL - ASSEMBLY LINE DIAGNOSTIC LINK - U s e d
CYLINDERS, CNG FUEL - T h e s t o r a g e d e v ic e u s e d
a t a s s e m b l y to e v a l u a t e C o m p u t e r C o m m a n d
fo r c o m p re s s e d n a t u r a l g a s.
C o n t r o l a n d fo r s e r v ic e to f la s h th e “S e r v ic e E n g i n e
S o o n ” l i g h t i f t h e r e a re tr o u b le codes. A l s o u s e d b y DIAGNOSTIC CODE - P a i r o f n u m b e r s o b t a i n e d
“S c a n ” to o ls to o b t a in E C M s e r ia l data. f r o m f l a s h i n g “S e r v i c e E n g i n e S o o n ” l i g h t , o r
d i s p l a y i n g o n a “S c a n ” tool. T h i s code c a n b e u s e d
ANALOG SIGNAL - A n e le c tric a l s ig n a l th a t v a r ie s
to d e t e r m in e th e s y s t e m m a lfu n c t io n .
i n v o lt a g e w i t h i n a g i v e n p a ra m e te r.
DIAGNOSTIC TERMINAL - G r o u n d i n g t e r m in a l “B ”
BAT + - B a t t e r y P o s it i v e T e r m in a l (12 V o lt s )
o f A L D L c o n n e c t o r w i l l f l a s h o r d i s p l a y a cod e.
BARO - A m e a s u r e m e n t o f a t m o s p h e ric p re ssu re . W h e n g r o u n d e d w it h th e e n g in e r u n n i n g w i l l e n te r
t h e “F i e l d S e r v ic e M o d e . ”
BLOCK LEARN - E C M m e m o ry th a t a d ju sts th e
a ir/ fu e l r a t io o n a s e m ip e r m a n e n t b a sis. DIGITAL RATIO ADAPTER - DIGITAL SIGNAL - A n
e le c tr ic a l s i g n a l t h a t i s e it h e r “O N ” o r “O F F ” w it h
CAPACITOR - A n e le c t r ic a l d e v ic e u s e d to s t o r e a
n o i n b e tw e e n .
t e m p o r a r y c h a rg e .
DIODE - A n e le c tr ic a l d e v ic e t h a t r e s t r ic t s c u r r e n t
CALPAK - A d e v ic e u s e d w it h f u e l i n j e c t io n to
flo w i n o n e d ire c tio n .
a llo w fu e l d e liv e r y in th e e ve n t o f a P R O M or
E C M m a lf u n c t io n . DRIVER - A n e l e c t r i c a l d e v ic e , u s u a l l y a p o w e r
t r a n s i s t o r , t h a t o p e r a t e s l i k e a s w it c h ; t h a t is, it
CALIBRATOR - (PROM) - A n e le c t r o n ic c o m p o n e n t
t u r n s s o m e t h in g “O N ” o r “O F F ”.
w h i c h c a n b e s p e c i f i c a l l y p r o g r a m m e d to m e e t
e n g in e o p e r a t in g r e q u ir e m e n t s fo r e ach v e h ic le DVM (10 Meg.) - D i g i t a l V o lt m e t e r w it h 10 M i l l i o n
m o d e l. I t p l u g s i n t o t h e E n g i n e C o n t r o l M o d u l e ohm s r e s is t a n c e - used fo r m e a su re m e n t in
(E C M ). e le c tr o n ic s y st e m s .

CCC - COMPUTER COMMAND CONTROL - H a s a n EAC - ELECTRIC AIR CONTROL - U s e d o n A I R

e l e c t r o n ic c o n t r o l m o d u l e to c o n t r o l a ir / f u e l a n d s y s t e m to d ire c t a i r flo w to A i r S w i t c h i n g v a l v e o r
e m is s io n sy ste m s. a tm o s p h e re .

CID - CUBIC INCH DISPLACEM ENT - U s e d to ECM - ELECTRONIC ENGINE CONTROL MODULE -
d e s c r ib e e n g in e size. A m e t a l c a s e (lo c a t e d i n p a s s e n g e r c o m p a r t m e n t )
c o n t a i n i n g e le c t r o n ic c i r c u i t r y w h i c h e l e c t r ic a l l y
C/LOOP - CLOSED LOOP - D e s ig n e d w it h fe e d b a c k
c o n t r o ls a n d m o n it o r s a ir/ fu e l a n d e m is s io n s y s t e m s
i n f o r m a t i o n to t h e E C M to m a i n t a i n a n o p t im u m
o n C o m p u t e r C o m m a n d C o n t r o l, a n d t u r n s “O N ”
a ir/ fu e l r a t io (16.3:1), o u tp u t.
th e “S e r v ic e E n g in e S o o n ” lig h t w h e n a
CNG - COMPRESSED NATURAL GAS - T h e f u e l m a lf u n c t io n o c c u rs i n th e sy ste m .
u s e d i n th e c o m p re s s e d n a t u r a l g a s tr u c k s .
ECU - ENGINE CALIBRATION UNIT - A n e le c tro n ic
c o m p o n e n t w h ic h c a n b e s p e c if ic a lly p r o g r a m m e d to
th e d e s ig n o f e a c h v e h ic le m o d e l to c o n tro l th e M / C
s o le n o id . T h e E C U p lu g s in t o th e E l e c t r o n ic
C o n t r o l M o d u le ( E C M ) . T h e E C U is u s u a l l y c a lle d
a PROM.
EFI - ELECTRONIC FUEL INJECTION - C o m p u t e r
Com m and C o n tro l u s in g th r o t t le body fu e l
in je ctio n .
EGR - EXHAUST GAS RECIRCULATION - M e t h o d
o f r e d u c in g N O x e m is s io n le v e ls.
EECS - EVAPO RATIVE E M IS S IO N S CONTROL
SYSTEM - U s e d to p r e v e n t g a s o l i n e v a p o r s i n th e
fu e l t a n k fro m e n t e r in g th e a tm o sp h e re .
EMI OR NOISE - A n u n w a n t e d s i g n a l i n t e r f e r i n g
w it h a n o t h e r n e e d e d s ig n a l; li k e a n e le c tr ic a l r a z o r
u p s e t s a t e l e v is i o n p ic t u r e , o r d r i v i n g u n d e r h i g h
v o lt a g e p o w e r lin e s u p se ts th e A M r a d io in a
v e h ic le .
ENERGIZE/DE-ENERGIZE - W h e n c u r r e n t is p a s s e d
t h r o u g h a c o il ( e n e r g iz e d ) s u c h a s a s o le n o i d , a
p l u n g e r i s p u lle d o r p u s h e d . W h e n t h e v o lt a g e to
t h e s o le n o id is t u r n e d off, (d e -e n e rg iz e d ), a s p r i n g
r a is e s o r lo w e r s th e p lu n g e r .
ESC - ELECTRONIC SPARK CONTROL - U s e d to
s e n s e d e t o n a t io n a n d r e t a r d s p a r k a d v a n c e w h e n
d e t o n a t io n o ccu rs.
EST - E LE C TR O N IC SPARK T IM IN G - EC M
c o n tro lle d t i m i n g o f ig n i t i o n s p a r k .
E VR V - ELECTRO NIC V A C U U M REG ULATO R
VALVE - C o n t r o ls E G R v a c u u m .
FED - FEDERAL - V e h i c l e / E n g i n e a v a i l a b l e i n a l l
s ta t e s e xc e p t C a lif o r n ia .
FI - FUEL IN J E C T IO N - C o m p u t e r C o m m a n d
C o n t r o l u s i n g fu e l in je ctio n .
F ITTIN G , SW AG LOK CO M PRESSIO N - S p e c i a l
c o m p r e s s io n f it t in g s u s e d fo r C N G fu e l lin e s.
GROUND - A w i r e s h o r t e d to g r o u n d . A c o m m o n
r e t u r n p a t h fo r a n e le c t r ic a l c ir c u it . A re f e r e n c e
p o in t fro m w h ic h v o lt a g e m e a s u r e m e n t s m a y be
m ade.
HC - HYDROCARBONS - O n e o f t h e p o l l u t a n t s
fo u n d in e n g in e e x h a u st. H y d r o g e n a n d c a rb o n in
CNG.
HIGH - A v o lt a g e m o re t h a n g r o u n d o r 0, li k e th e
o u t p u t w ir e o f a n o x y g e n s e n s o r i s c a lle d v o lt a g e
h ig h , a s c o m p a r e d to t h e g r o u n d , w h i c h i s c a lle d
v o lt a g e lo w . I n d i g i t a l s ig n a l s , h i g h i s “O N ” a n d
lo w is “O F F . ”
HIG H IM P E D A N C E V O L T M E T E R - H a s h ig h
o p p o s it io n to th e flo w o f e le c tr ic a l c u rre n t. G o o d fo r
r e a d i n g c i r c u i t s w i t h lo w c u r r e n t flo w , s u c h a s
fo u n d in e le c tro n ic s y st e m s .
HEI - HIGH ENERGY IGNITION - A d is t r ib u t o r t h a t
u s e s a n e le c tro n ic m o d u le a n d p ic k - u p c o il i n p la c e
o f co n ta ct p o in ts.
Hg - MERCURY - A c a lib r a t io n m a t e r ia l u s e d a s a
s t a n d a r d fo r v a c u u m m e a s u r e m e n t .
HOSE, FUEL PRESSURE REGULATOR COOLANT -
T h e h o se th a t s u p p lie s c o o la n t to th e fu e l p r e s s u r e
r e g u la t o r . K e e p s t h e r e g u l a t o r f r o m f r e e z in g a n d
h e lp s m a in t a in c o n s t a n t fu e l te m p e ra t u re .
IAC - IDLE AIR CONTROL - In s t a ll e d i n th e t h r o t t le
b o d y o f a fu e l in je cte d s y s t e m a n d c o n t ro lle d b y th e
E C M to re g u la t e id le speed.
IDEAL MIXTURE - T h e a ir/ fu e l r a t io w h ic h p r o v id e s
th e b e st p e rfo rm a n c e , w h ile m a i n t a i n i n g m a x i m u m
c o n v e r s io n o f e x h a u s t e m is s io n s , t y p i c a l ly 16.3:1.
IGN - IGNITION - R e f e r s to i g n i t i o n s w i t c h a n d
lock.
INJECTOR, CNG FUEL - S p e c i a l f u e l i n j e c t o r s
d e s ig n e d s p e c ific a lly fo r c o m p re s s e d n a t u r a l g a s.
INPUTS - I n f o r m a t i o n fro m so u rce s (su c h a s,
c o o la n t t e m p e ra t u re s e n s o rs , e x h a u s t o x y g e n se n s o r,
e tc.) t h a t t e ll t h e E C M h o w t h e s y s t e m s a r e
p e rfo rm in g .
IN T E R M IT T E N T - O c c u r s now and th e n ; not
c o n t in u o u s ly . In e le c t r ic a l c ir c u it s , re fe rs to
o c c a s io n a l open, sh o rt, o r g r o u n d .
I/P. - INSTRUMENT PANEL - C o n t a i n s i n s t r u m e n t
g a g e s a n d in d ic a t o r l i g h t s to in d ic a t e p e r fo rm a n c e
o f th e ve h icle .
KM/H - KILOMETER PER HOUR - A m e t r i c u n i t
m e a s u r in g d is t a n c e (1 0 0 0 m e te rs ) i n o n e h o u r.
L - LITER - A m e t r ic u n i t o f c a p a c ity .
LINE, STAINLESS STEEL FUEL - S p e c ia l s t a i n l e s s
ste e l lin e u s e d fo r c o m p re sse d n a t u r a l g a s fu e l
lin e s.
LOW - O p e r a t e s t h e s a m e a s g r o u n d a n d m a y , o r
m a y not, b e c o n n e c te d to c h a s s is g r o u n d .
MALFUNCTION - A p r o b le m t h a t c a u s e s th e s y s t e m
to o p e ra te in c o r r e c t ly . T y p i c a l m a l f u n c t io n s a re ;
w i r i n g h a r n e s s o p e n s o r s h o r t s , f a ile d s e n s o r s , o r
c ir c u it c o m p o n e n ts.
MAP - MANIFOLD ABSOLUTE PRESSURE SENSOR -
R e a d s p r e s s u r e c h a n g e s i n i n t a k e m a n if o ld w it h
r e f e r e n c e to z e r o p r e s s u r e . I t p u t s o u t a v o l t a g e
w h ic h is h i g h e s t w h e n th e p r e s s u r e is h ig h e s t. T h e
m a x i m u m v o lt a g e i s b e tw e e n 4 -5 vo lts.
MEM-CAL - C o n t a i n s s p e c ific c a li b r a t i o n s to m e e t
t h e r e q u ir e m e n t s o f a sp e c ific e n g in e .
MODE - A p a r t ic u la r s ta te o f o p e ra tio n .
MPH - MILES PER HOUR - A u n it m e a s u r in g
d is t a n c e (5 2 8 0 feet) i n o n e h o u r.
N.C . - N O R M A LLY CLOSED - S t a t e o f r e l a y
c o n t a c t s o r s o l e n o i d p l u n g e r w h e n n o v o l t a g e is
ap p lie d .
N«m - NEW TON METERS (TORQUE) - A m e t r ic
u n i t w h ic h m e a s u r e s force.
N.O. - NORMALLY OPEN - S t a t e o f r e la y c o n ta c ts
o r s o le n o id p lu n g e r w h e n n o v o lt a g e is a p p lied .
N O x - N IT R O G E N , O X ID E S OF - O n e o f t h e
p o llu t a n t s fo u n d in e n g in e e x h a u st. N it r o g e n th a t
c o m b in e s w it h o x y g e n to fo rm o x id e s o f n itro g e n .
RELAY, FUEL SUPPLY - A c t i v a t e s o r d e a c t iv a t e s
C N G fu e l c y lin d e r s o le n o id v a l v e s a n d lo w p r e s s u r e
fu e l s h u t - o ff so le n o id .
RESISTANCE - T h e a b i l i t y o f a c i r c u i t to l i m i t
c u r r e n t flow ; li k e a r e s t r ic t io n i n a w a t e r pipe.
RPM - REVOLUTIONS PER MINUTE - A m e a s u r e o f
ro t a t io n a l speed.
SELF-DIAGNOSTIC CODE - T h e E C M c a n d e te ct
m a lf u n c t io n s in th e s y ste m . I f a m a lf u n c t io n o c c u rs,
th e E C M t u r n s “O N ” t h e “S e r v ic e E n g i n e S o o n ”
lig h t . A d i a g n o s t ic c o d e c a n b e o b t a in e d f r o m t h e
E C M t h r o u g h th e “S e r v ic e E n g i n e S o o n ” lig h t . T h i s
code w i l l in d ic a t e th e a r e a o f th e m a lf u n c t io n .
SES - SERVICE ENGINE SOON LIGHT - L i g h t s
w h e n a m a lf u n c t io n o c c u rs i n C o m p u t e r C o m m a n d
C o n t r o l sy ste m .
SOLENOID, LOW PRESSURE FUEL SHUT-OFF -
E le c t r ic s o le n o id lo c a te d a t th e C N G fu e l p r e s s u r e
re g u la t o r . C o n t r o ls fu e l s u p p l y to in je c to rs. S o le n o id
is c lo se d w it h i g n i t i o n o ff o r o p e n w h e n v e h ic le is
r u n n in g .

0 2 - O X Y G E N ( 0 2) (S E N S O R ) - M o n i t o r s t h e SWITCH, FUEL DOOR SHUT-OFF - S w i t c h lo c a t e d

o x y g e n c o n te n t of th e e x h a u st sy ste m a n d o n t h e b a c k o f t h e f u e l d o o r h in g e . S h u t s o f f f u e l
g e n e r a t e s a v o lt a g e s i g n a l to th e E C M . s u p p l y w h e n d o o r is i n th e o p e n p o s it io n .

O /LO O P - OPEN LOOP - D e s c r i b e s E C M fu e l TACH - TACHOMETER - A d e v ic e f o r i n d i c a t i n g

c o n t r o l w it h o u t u s e o f o x y g e n s e n s o r in fo rm a t io n . sp e e d fo r ro ta tio n .

OUTPUT - F u n c t i o n s , t y p i c a l l y s o le n o id s , t h a t a r e TBI - THROTTLE BODY INJECTION (U N IT) - I s

c o n t r o lle d b y th e E C M . c o n t r o lle d b y t h e E C M to s u p p l y p r e c is e a ir / f u e l
m ix t u r e in t o th e i n t a k e m a n ifo ld .
OXYGEN SENSOR, EXHAUST - D e v ic e t h a t d e te cts
th e a m o u n t o f o x y g e n ( 0 2) i n th e e x h a u s t stre a m . TCC - TRANSMISSION I TRANSAXLE CONVERTER
CLUTCH - E C M c o n tro lle d s o le n o id i n t r a n s m is s io n
POSITIVE CRANKCASE VENTILATION - P r e v e n t
w h ic h p o s it iv e ly c o u p le s t h e t r a n s m is s io n to t h e
fu m e s i n c r a n k c a s e fr o m p a s s in g in t o a tm o sp h e re .
e n g in e .
P/N - PARK/NEUTRAL - R e f e r s to s w it c h u s e d to
TH E R M A C - T H E R M O S T A T IC AIR C LEANER -
in d ic a t e to th e E C M th e p o s it io n o f th e a u t o m a t ic
P r o v i d e s p r e h e a t e d a i r to i n t a k e m a n i f o l d to
t r a n s m is s io n .
p r o v id e b e tte r d r i v e a b il it y w h e n e n g in e i s cold.
PORT - EXHAUST OR INTAKE PORT
TPS - THROTTLE POSITION SENSOR - D e v ic e t h a t
PROM - PROGRAMMABLE READ ONLY MEMORY - te lls th e E C M th e t h r o t t le p o sitio n .
A n e l e c t r o n ic t e r m u se d to d e s c r ib e t h e e n g i n e
TR A N S D U C E R , FUEL PRESSURE - M e a s u r e s
c a lib r a t io n u n it .
p e rc e n ta g e of fu e l in CNG fu e l c y lin d e r s and
PULSE WIDTH MODULATED - A d e v ic e o p e r a t e d s i g n a l s fu e l le v e l ga g e .
b y a d i g i t a l s i g n a l t h a t i s c o n t r o lle d b y t h e t im e
TVS - THERM AL V A C U U M SW ITCH - U s e d to
d u r a t io n th e d e v ic e i s t u r n e d “O N ” o r “O F F . ”
control va c u u m in relationship to engine
QUAD DRIVER - A “c h ip ” d e v ic e th a t is c a p a b le o f te m p e ra tu re .
o p e r a t in g f o u r s e p a r a t e o u tp u ts. S o m e h a v e d ig it a l
V-VOLT - A m e a s u r e m e n t o f e le c tr ic a l p re s s u re .
a n d s o m e h a v e p u ls e w id t h m o d u la t e d o u tp u ts.

REGULATOR, CNG FUEL PRESSURE - M a i n t a i n s

sp e c ific C N G fu e l p re ssu re ^ a p p r o x im a t e ly 175 p si,
to t h e C N G fu e l in je cto rs.
VO LTAG E - The pressure of force pushing the VALVE, FUEL FILL - A CNG fitting to connect a
current in a circuit; like pressure in a water pipe. compressed natural gas fuel fill line. The fitting is
a one way valve that only allows CNG to enter the
V6 ■ SIX CYLINDER ENGINE - Arranged in a “V”.
fuel system.
V8 - EIGHT CYLINDER ENGINE ■ Arranged in a
VALVE, OVER TEMPERATURE / OVER PRESSURE
“V”. RELIEF ■ V alve located at rear of CNG fuel
VACUUM - Negative pressure; less than atmospheric cylinders. V alves are norm ally closed unless
pressure. activated by high tem peratures or high gas
pressures.
VACUUM, MANIFOLD - Vacuum source in manifold
below throttle plate. V IN - VEHICLE ID E N T IF IC A T IO N NUMBER -
Appears on a plate attached to the windshield
V A C U U M , PORTED - A vacuum source above
pillar.
(atmospheric side) of closed throttle plate.
VSS - VEHICLE SPEED SENSOR • Sensor which
VALVE, 1/4 TURN SHUT-OFF - Manual natural gas
sends vehicle speed information to the ECM.
valve located in fuel line.
W O T ■ WIDE OPEN THROTTLE - Refers to the
VALVE, CHECK - Valve located in fuel cylinder fill
throttle valve or accelerator pedal when fully open
fittin g . A one-w ay v a lv e th a t only allow s or depressed.
compressed natural gas into the fuel cylinders.
V A LV E, FUEL CYLINDER SO LEN O ID - Electric
solenoids that control gas supply from CNG fuel
cylinders. Solenoids are closed with ignition off or
open when vehicle is running.
 A Mechanical, Gasoline Engine...................................... 6A-2
Abbreviations............................................................... OA-12
Anaerobic Gasket Eliminator, U se................................. 6A-2
Approximate Fluid Capacities........................................ OB-6
Auxiliary Cooling Fan Replacement........................... 6B1-13
B Electrostatic Discharge (ESD), Handling
Belt Tensioner Inspection...........................................6B1-17
Belt Tensioner Replacement...................................... 6B1-17
Belt, Drive — Replacement....................................... 6B1-18
Bushing Replacement....................................................3D-5
Bypass Valve, Oil Filter..............................................6A4-22
c Oil Cooler Line Replacement................................... 6B1-19
Camshaft Lobe Lift Measuring................................... 6A4-18
Camshaft Replacement..............................................6A4-18
Capacities, Fluid............................................................ OB-6
Catalytic Converter Replacement................................... 6F-3
Certification label, Vehicle..............................................OA-2
Chassis Lubrication........................................................ 0B-2
Cleanliness and Care.....................................................6A-1
Clutch:
Fan Diagnosis.......................................................... 6B1 -3
Fan Replacement...................................................6B1-12
Code Listing, RPO (Regular Production Option)...........OA-14
Coding, Lock Cylinder....................................................0A-5
Compression Check, Gasoline Engine........................... 6A-5
Connecting Rod and Piston Replacement..................6A4-20
Conversions, Metric-English........................................ OA-10
Converter, Catalytic — Replacement............................. 6F-3
Coolant:
Diagnosis................................................................. 6B1-3
Fuel Pressure Regulator Hose............................... 6B1-23
Level Indicator Diagnosis......................................... 6B1 -8
Pump....................................................................... 6B1-2
Pump Replacement................................................6B1-16
Recovery Tank......................................................... 6B1-2
Recovery Tank Replacement................................. 6B1-10
Cooling Fan, Auxiliary — Replacement...................... 6B1-13
Cooling System............................................................ 6B1-1
Cooling System Diagnosis............................................6B1 -5
Cooling System Problems............................................6B1-7
Cooling System, Draining and Filling.......................... 6B1-10
Cooling System, Flushing...........................................6B1-10
Cover, Front — Replacement.................................... 6A4-15
Cover, Rocker Arm — Replacement............................ 6A4-7
Crankshaft Front Seal and Torsional Damper
Replacement.......................................................... 6A4-14
Crankshaft Rear Oil Seal Replacement...................... 6A4-17
Crankshaft Rear Oil Seal Retainer Replacement........6A4-17
Crankshaft Replacement............................................6A4-23
Cylinder Head Replacement...................................... 6A4-13
D Front Cover Replacement........................................... 6A4-15
Decimal and Metric Equivalents................................... OA-11
Diagnosis:
Charts, 4L60 Automatic Transmission...................... 7A1 -9
Drive Belt System..................................................... 6B1 -9
Engine Cooling......................................................... 6B1 -2
Exhaust System ......................................................... 6F-2
Fan Clutch................................................................ 6B1-3
Hydraulic Lifters.......................................................... 6A-5
Oil Leaks.................................................................... 6A-7
Draining and Filling the Cooling System.......................6B1-10
Drive Belt Replacement...............................................6B1-18
E
EGR System Service......................................................0B-2
Sensitive Parts............................................................OA-1
Engine:
Gaskets, Replacement............................................... 6A-2
Identification Number...................................................0A-2
Lubrication................................................................6A4-5
Mountings................................................................6A4-24
Oil and Filter Change...................................................0B-1
Replacement............................................................6A4-25
Special Tools, 5.7L V8 RPO L05 (VIN K ).................6A4-31
Specifications, 5.7L V8 RPO L05 (VIN K ) ................6A4-31
Engine Cooling System:
Checks..................................................................... 6B1-2
Diagnosis.................................................................. 6B1-2
General Information...................................................6B1-1
Service.................................................................... 6B1-10
Special Tools...........................................................6B1-24
Specifications...........................................................6B1 -24
Engine, Driveability, and Diagnosis General
Information.................................................................. 6A-1
Engine, Driveability, and Diagnosis Special Tools.......... 6A-7
Engine (Gasoline) Compression Check..........................6A-5
Engine (Gasoline) Mechanical Diagnosis........................6A-2
English-Metric Conversions.......................................... 0A-10
Exhaust Manifold Replacement................................... 6A4-13
Exhaust Parts, Installing..................................................6F-3
Exhaust Parts, Removal..................................................6F-3
Exhaust Pipe, Intermediate — Replacement...................6F-4
Exhaust System
Inspection................................................................... 6F-3
Service....................................................................... 6F-3
Specifications..............................................................6F-7
Explanation of Scheduled Maintenance Services........... 0B-1
F
Fan and Fan Clutch Replacement............................... 6B1 -12
Fan Clutch Diagnosis................................................... 6B1-3
Fan, Auxiliary Cooling — Replacement........................6B1 -13
Fastener Strength Identification...................................... 0A-7
Fastener, Strength Identification..................................... 0A-7
Fasteners, Metric............................................................0A-7
Fasteners, Prevailing Torque......................................... 0A-7
Filling and Draining the Cooling System.......................6B1-10
Fluid Capacities..............................................................OB-6
Flushing the Cooling System....................................... 6B1-10
Flywheel Replacement, Automatic and Manual
Transmission...........................................................6A4-23
Fuel Pressure Regulator Coolant Hose........................6B1 -23
G
Gasket Eliminator (Anaerobic)........................................ 6A-2
Gaskets, Engine — Replacement...................................6A-2
Gasoline Engine Compression Check............................6A-5
Gasoline Engine Mechanical Diagnosis..........................6A-2
General Vehicle Lifting and Jacking................................OA-4
 H P
Handling Sensitive Parts, Electrostatic Pan, Oil — Replacement..............................................6A4-16
Discharge (ESD).........................................................OA-1 Parts Identification label (Service)................................ OA-13
Head, Cylinder — Replacement.................................. 6A4-13 Piston and Connecting Rod Replacement....................6A4-20
Hose, Radiator— Replacement................................ . 6B1-11 Pressure Switch, Valve Body — Replacement............ 7A1 -67
Hydraulic Lifter Replacement...................................... 6A4-11 Prevailing Torque Fasteners.......................................... OA-7
Hydraulic Lifters, Diagnosis o f ........................................ 6A-5 Pump, Coolant.............................................................. 6B1-2
Pump, Coolant— Replacement........................... .......6B1-16
i Pump, Oil — Replacement.......................................... 6A4-16
Identification: Pushrod and Rocker Arm Replacement........................6A4-8
Engine Number...........................................................OA-2
Model.......................................................................... OA-2
R
Service Parts Label................................................... OA-13 Radiator Hose Replacement....................................... 6B1 -11
Transmission Number................................................. 0A-4 Rear Suspension On-Vehicle Service.............................3D-1
Vehicle Number (VIN)................................................. OA-2 Recovery Tank, Coolant................................................6B1-2
Indicator Diagnosis, Coolant Level................................6B1-8 Recovery Tank, Coolant — Replacement....................6B1-10
Inspection, Exhaust System........................................... 6F-3 Replacement Labels.....................................................OA-13
Installing Exhaust Parts.................................................. 6F-3 Retainer Replacement, Crankshaft Rear Oil Seal........ 6A4-17
Intake Manifold Replacement..................................... 6A4-10 Rocker Arm and Pushrod Replacement........................6A4-8
Intermediate Exhaust Pipe Replacement.........................6F-4 Rocker Arm Cover Replacement.................................. 6A4-7
Rocker Arm Stud Replacement................................... 6A4-12
j RPO Code Listing (Regular Production Option) ........... OA-14
Jacking and Lifting, General Vehicle...............................0A-4 RTV Sealant, Use........................................................... 6A-2

L s
Label, Vehicle Certification............................................. OA-2
Labels, Replacement........ ............................................OA-13
Leaf Spring Replacement............................................... 3D-2
Lifter, Hydraulic— Replacement................................6A4-11
Lifters, Hydraulic — Diagnosis........................................ 6A-5
Lifting and Jacking, General Vehicle...............................OA-4
Lock Cylinder Coding..................................................... OA-5
Lubrication, Engine...................................................... 6A4-5
Lubrication, Chassis....................................................... OB-2
M
Main Bearing Replacement........................................ 6A4-22
Maintenance Items......................................................... OB-6
Maintenance Schedule 1 ................................................ OB-1
Maintenance Schedule 2 ................................................ OB-1
Manifold, Exhaust — Replacement.............................6A4-13
Manifold, Intake — Replacement................................6A4-10
Measuring Camshaft Lobe Lift.................................... 6A4-18
Metric and Decimal Equivalents.................................... OA-11
Metric Fasteners.............................................................OA-7
Metric-English Conversion............................................ 0A-10
Model Identification.........................................................OA-2
Scheduled Maintenance Services................................... OB-1
Seal Retainer Replacement, Crankshaft Rear O il........ 6A4-17
Seal, Crankshaft Rear Oil — Replacement..................6A4-17
Sealant (RTV), Use.........................................................6A-2
Sensitive Parts Handling, Electrostatic Discharge (ESD). OA-1
Service Parts Identification Label.................................. OA-13
Shackle Replacement.....................................................3D-4
Shock Absorber Replacement........................................ 3D-1
Spring, Leaf Replacement...............................................3D-2
System Checks, Engine Cooling.................................. 6B1 -2
T
Tensioner, Belt — Replacement.................................. 6B1-17
Thermostat................................................................... 6B1-2
Thermostat Diagnosis...................................................6B1-3
Thermostat Replacement............................................ 6B1-16
Thread Repair....... ..................................................... 6A4-27
Torsional Damper and Crankshaft Front Seal
Replacement............................................................ 6A4-14
Transmission:
Replacement.............................................................7A1-1
Tune-Up Information.......................................................6A-1

N u
Normal Vehicle U se........................................................OB-1 Use of RTV Sealant and Anaerobic Gasket Eliminator.... 6A-2

o V
Oil and Filter Change (Engine)........................................ OB-1 Valve Adjustment, 5.7L RPO L05 (VIN K )....................6A4-8
Oil Cooler Line (Engine) Replacement........................6B1-19 Valve Spring and Valve Stem Seal Replacement......... 6A4-9
Oil Filter Bypass Valve............................................... 6A4-22 Valve Stem Seal and Valve Spring Replacement......... 6A4-9
Oil Leak Diagnosis..........................................................6A-7 Vehicle Certification Label.............................................. OA-2
Oil Pan Replacement................................................. 6A4-16 Vehicle Identification Number (VIN)................................ OA-2
Oil Pump Replacement............................................... 6A4-16
 A Fuel Control General Information.............................. .....3-5
A.I.R. Management System Information........................... 8-1
A/C Request Signal........................................................3-18
Diagnosis............ ...................................................... 3-80
Input Information........................................................... 3-7
Abbreviations and Glossary of Terms............................ 14-1
Accelerator Control...............................................................
General TBI.................................................................. 4-6
Service....................................................................... 4-26
TBI 220 ........................................................................ 4-8
ALDL Connector..............................................................3-3
B D
Backfire......................................................................... 2-19
Basic Electrical Circuits....................................................1-2
Bulb Check Diagnosis......................................................3-9
CAL-PAK ® Diagnostic Code Identification.................. ...................... 3-19
Diagnosis............................................................ ...... 3-15
General Description, 5.7L CNG Engine With 4L60
Transmission............................................................ ..3-5
Chart A-1:
No “Service Engine Soon” Light ..................................3-20
Chart A-2:
No ALDL Data Or Won’t Flash Code 12 Or “Service
Engine Soon” Light On Steady................................. 3-22
Chart A-3:
Engine Cranks But Will Not Run................................ 3-24
Chart A-4:
Injector Circuit Diagnosis........................................... 3-28
Chart A-5:
Fuel Supply Relay Circuit Diagnosis........................... 3-30
Chart A-6:
Fuel System Diagnosis.............................................. 3-36
Clearing Codes, Input Information.................................... 3-8
CNG Control Relay................. ......................................4-18
CNG Fuel Control Diagnosis.......................................... 3-16
CNG Fuel Cylinders
Description................................................................... 4-6
Sen/ice............................................................ .......... 4-24
CNG Fuel Injection and Service Information................... 4-12
CNG Fuel Injectors, Service.......................................... 4-16
CNG Fuel Line and Hose Assemblies............................ 4-21
CNG Fuel Pressure Regulator....................................... 4-20
CNG Injector Plate...................................... .................. 4-17
Code 13............................................ ............................ 3-40
Code 14........................................................................ 3-42
Code 15................................................... ..................... 3-44
Code 21........................................................................ 3-46
Code 22........................................................................ 3-48
Code 24........................................................................ 3-50
Code 33........................................................................ 3-52
Code 34........................................................................ 3-54
Code 42........................................................................ 3-56
Code 43................................................................. ...... 3-58
Code 44 ........................................................................ 3-60
Code 45........................................................................ 3-62
Code 54........................................................................ 3-64
Codes 51, 52, 53,55...................................................... 3-70
Component Locations......................................................1-3
Computer Command Control
Description....................................................................3-3
Diagnosis..................................................................... 3-9
Input Information.................. ......................................... 3-6
Connectors and Terminals, Service................................. 3-90
Controlied Idle Speed (1 9 9 2 )................................................... 4-27
Coolant Temperature Sensor (CTS)
Diagnosis.... .................................................................3-17
Input Information............................................................ 3-6
Service........................................................................ 3-95
Crank Signal.................................................................... 3-18
Diagnosis..................................................................... 3-78
Input Information............................................................ 3-7
Cuts Out, Misses..... ................ ....................................... 2-13
Detonation/Spark Knock..................................................2-10
Diagnostic Circuit Check
General Description........................................................ 3-9
Input Information......... .................................................. 3-8
Diagnostic Code System, Input Information....................... 3-8
Dieseling, Run-On........................................................... 2-18
Distributor Reference Signal
Diagnosis........................................................................ 3-18
Input Information............... ............................................ 3-7
E
ECM Connector Terminal End View, 5.7L CNG Engine
With 4L60 Transmission............................................. 3-88
ECM QDR Check............................................................ 3-82
ECM Wiring Diagrams, 5.7L CNG Engine
With 4L60 Transmission............................................. 3-84
EGR System Diagnosis ................................................... 3-17
Electronic Control Module (ECM) .................. .................. 3-4
Diagnosis.....................................................................3-15
Service.................. ..................................................... 3-92
Electrostatic Discharge Damage....................................... 3-4
Electronic Spark Control (ESC) Information....................... 7-1
Diagnosis.................................................. .................. 3-18
Electronic Spark Timing (EST) Diagnosis....................... 3-18
Emissions....... .................................................................. 1-2
Emissions, Exhaust (Odors)............................................ 2-17
Engine Does Not Start, Input Information........................... 3-8
Evaporative Emission Control System
(EECS) Information....................................................... 5-1
Exhaust Gas Recirculation (EGR) Information...................9-1
Exhaust System Diagnosis..................... ........................ 3-18
F
Field Service Mode, Input Information................................3-8
Fuel Control Operation.......................................................4-4
Fuel Control System (TBI 2 2 0 ) .................................................. 4-6
Fuel Cylinder Solenoid Valves......................................... 4-19
Fuel Door Shut-Off Switch.......... ..................... ............... 4-19
Fuel PressureTransducer................................................ 4-20
Fuel Supply Circuit
General................... ...................................................... 4-6
TBI 2 2 0 ....................................................................................... 4-8
Fuel Supply Relay................. ......................................... 4-18
G
General Description of Sections....................................... 1-2
Glossary of Terms................... ............... ....................... 14-1
 H R
Hard Start.................................................. ...................... 2-5 Restricted Exhaust System ..................... ........................ 3-71
Hesitation, Sag, Stumble................................................ 2-12 Rough Idle...................... ................................................2-15

s
I “Scan” Tool Information............... ................ ................... 13-1
IAC Sensor, Diagnosis................................................... 3-74 “Scan” Tool Modes .................................... .................. ...3-13
Idle Air Control (IAC) System Check “Scan” Tool Positions........... ..........................................3-13
With 4L60 Transmission............................................. 4-10 Shut-Off Valve, 1/4 T u rn ............... ................................... 4-9
Idle Air Control (IAC) Valve............................................. 4-15 Sluggish, Spongy............................... ............................... 2-8
Idle Speed Diagnosis.....................................................3-18 Spark Knock/Detonation ...................... .................... .......2-10
IgnitionSystem/ESTInformation........................ ............. 6-1 Special Tools Information......... ............... ....................... 13-1
Intake Air Temperature (IAT) Sensor Service................. 3-97 Stalling.............. .................... .........................................2-15
Intermittents......................................................................2-3 Stumble........................................ ................................. 2-12
Surges and/or Chuggles........ ...........................................2-7
K System Over Voltage Diagnosis ............................. .........3-18
Knock Sensor
Input Information..................................................... ......3-7 T
Service........................................................................3-97 TBI 220 Description.............................. ................... .........4-2
Tech 1
L Data Definitions........ .............. .....................................3-13
Lack of Power................................................ ..................2-8 “Scan" Values........... ................................................. 3-12
Low Pressure Fuel Shut-Off Solenoid................... .........4-21 Input Information...... .....................................................3-8
Thermostatic Air Cleaner (THERMAC) Information......... 12-1
M Throttle Body Assembly............... ............... ................ ...4-16
Throttle Body Injection (TBI) Unit....................................... 4-4
Maintenance Schedule.....................................................1-2 Throttle Position Sensor (TPS)................... ....................4-15
Manifold Absolute Pressure (MAP) Sensor
Diagnosis.................................. ..................................3-17
Diagnosis............................................... ....................3-17 Input Information..... ............................................. ........3-7
Input Information..... ......................................................3-6 TBI 220 Service........ ...................... ............................... 3-96
Output Check..............................................................3-72 Transmission Controls Information............... .................. 10-1
Service....................................................................... 3-95 Transmission Gear Position Signal, Input Information ..... ..3-7
Minimum Idle Speed....................................................... 4-27

o u
Underhood Inspection, Visual/Physical........ ..................... 1-2
Oil Pressure Switch............................................... .........4-18 Unstable Idle ................ ............... ........................ ...........2-15
Oxygen Sensor
Diagnosis...................................................... .............3-17
Input Information........................................................... 3-6
¥
Service........................................................................3-95 Vehicle Emission Control Information Label.......................1-2
Vehicle Speed Sensor (VSS)
P Diagnosis...... .......................... ................... ................3-17
Input Information.......... .................. .................. ............3-7
Park/Neutral (P/N) Switch............................................... 3-18 Service .........................................................................3-97
Diagnosis....................................................................3-76 Vehicle Speed Sensor Buffer (DRAC) Module Service.... 3-97
Service...................................... ................................. 3-98
Signal, Input Information............................................... 3-7 w
Parts Information, Computer Command Control............. 3-98
Parts Information, Fuel Control...................................... 4-27 Wire Harness Service....... ................... .................... ......3-90
Poor Fuel Economy........................................................ 2-14
Positive Crankcase Ventilation Information......................11 -1
Preliminary Checks.......................................................... 2-2
PROM, 5.7L CNG Engine With 4L60 Transmission.......... 3-5
PROM, Diagnosis .......................................................... 3-15
Battery Junction Block....................................................... 18
CNG Control Relay 15 Amp Fuse ......................................18
CNG Injector..................................................................... 16
Component Locator Views.... ........................................... 16
Coolant Temperature Sensor............................................ 17
Electronic Control Module (ECM)............ ............................1
Electronic Spark Control (ESC) Module............................ 16
Electronic Spark Timing (EST) Module.............................. 17
Engine Temperature Sensor............................................. 17
Exhaust Gas Recirculation (EGR) Solenoid........ .............. 16
Fuel Controls, 5.7L CNG Engine With 4L60 Transmission ... 9
Fuel Cylinder Solenoids.......................................................1
Fuel Cylinder Solenoid Feed 5 Amp Fuse.........................19
Fuel Fill Door Switch.........................................................19
Fuel Pressure Transducer.................................................19
Fuel Supply Oi! Pressure Switch........................ .............. 17
Fuel Supply Relay............................................................. 18
Gages, 5.7L CNG Engine With 4L60 Transmission........... 13
Ground Distribution, 5.7L CNG Engine
Harness Routing Views ...................... ................................ 1
Heated Oxygen Sensor...................................................... 17
Idle Air Control (IAC) Motor................................................ 16
Injector, C N G ..................................................................... 16
Junction Block, Battery...................................................... 18
Knock Sensor..................................................................... 16
Low Pressure Fuel Shut-Off Solenoid................................. 19
Manifold Absolute Pressure (MAP) Sensor........................ 16
Oil Pressure Switch............................................................17
Oxygen Sensor, Heated......................................................17
Pressure Transducer, Fuel................................................. 19
Relay, Fuel Supply.............................................................. 18
Routing Views, Harness.......................................................1
Solenoid
Exhaust Gas Recirculation (EGR)...................................16
Fuel Cylinder.................................................................... 1
Low Pressure Fuel Shut-Off............................................ 19
Temperature Sensor
Coolant........................................................................... 17
Engine..... .................................................... ................. 17
Throttle Position Sensor (TPS)........................................... 16
 NOTICE

CONTENTS SENSITIVE
TO
STATIC ELECTRICITY

ELECTROSTATIC DISCHARGE (ESD) NOTICE

When handling an electronic part that has an ESD sensitive sticker, the service technician should
follow these guidelines to reduce any possible electrostatic charge build-up on the service
technician’s body and the electronic part in the dealership.

1. Do not open the package until it is time to install the part.

2. Avoid touching the electrical terminals of the part.
3. Before removing the part from Its package, ground the package to a known good ground on the
vehicle.
4. Always touch a known good ground before handling the part. This should be repeated while
handling the part and more frequently after sliding across the seat, sitting down from a standing
position, or walking a distance.
 PART III
N A TU R A L G AS PO W ER ED T R U C K
E LE C TR IC A L D IA G R A M S A N D D IA G N O S IS
MANUAL SUPPLEM ENT

INTRODUCTION
Page
Harness Routing V ie w s .................................................................................. 1
Component Locator Views ...................................................... 16, 17, 18, 19

Component Circuit
Location Diagram
Page Page
Electronic Control Module (ECM) ......................................................................... ...3 -
Electronic Control Module (ECM) - Inputs - 5.7L CNG E ngine ........................... ...- 5
Electronic Control Module (ECM) - Outputs - 5.7L CNG E n g in e ....................... ...- 7
Electronic Control Module (ECM) - Pinouts - 5.7L CNG Engine ....................... ...- 4
Fuel Controls 5.7L CNG Engine w/4L60 Auto Trans .......................................... ...9 —
Fuel Controls 5.7L CNG Engine w/4L60 Auto Trans ..............................................- 10
Gages 5.7L CNG Engine w/4L60 Auto Trans ...................................................... ...13 —
Gages 5.7L CNG Engine w/4L60 Auto Trans ...................................................... ...— 14
Ground Distribution 5.7L CNG Engine .....................................................................- 2
 REAR
POWER FUEL DOOR EXTERIOR
DOOR LOCKS DOME LAMP SHUT-OFF
WIPER MOTOR LAMPS
CNG CONTROL SWITCH
RELAY (PAGE 9)

FUEL SUPPLY RELAY

(PAGE 9)

UNDERHOOD LAMP
ASSEMBLY

BATTERY

HEADLAMP

FUEL CYLINDER
SOLENOID VALVES
(PAGE 9)

FRONT EXTERIOR LOW PRESSURE

LAMPS SHUT-OFF SOLENOID
(PAGE 9)

FOG LAMPS

WINDSHIELD WASHER
PUMP MOTOR
HARNESS ROUTING VIEWS 1
REGULAR CAB PICKUP
 450-.8 BLK/WHT l 450 .8 BLK/WHT

GT101
12041304 (UPPER)
12041305 (LOWER)

C200
12020213

450-.8 BLK/WHT FUEL SUPPLY RELAY 8 0 e )[ 434 || 420 J[ 437 | [ 450 |f 121 || 461
(PAGE 10) C200B
12041254
~ '
450 BLK - C420
/ (PAGE 19)

ECM
r ~
•(PAGES 75, 87, 103) 450-.8 BLK/WHT 450 BLK - FUEL DOOR SHUT-OFF SWITCH
(PAGE 12)
I
450 BLK - FUEL CYLINDER SOLENOID
I (PAGE 12)

5451A V
450-.8 BLK/WHT 450 BLK - FUEL CYLINDER SOLENOID
(PAGE 12)
t / PARK/NEUTRAL
450-.8 BLK/WHT I SWITCH
450 BLK - FUEL CYLINDER SOLENOID *(PAGE 75)
, « (PAGE 12)

S136 < 'X 450 BLK - PRESSURE TRANSDUCER

I/ VEHICLE SPEED SENSOR
(PAGE 12) S240 450-.8 BLK/WHT BUFFER (DRAC)
•(PAGE 130)
I \_ 450 BLK - LOW PRESSURE SHUT-OFF
(PAGE 12)

ECM
•(PAGES 75,87)
ECM
* (PAGES 75,87,103)
I_______ 450 BLK - C450A
450-.8 BLK/WHT
ALDL
(PAGE 19) •(PAGE 95)

I
k
CONVENIENCE
CENTER
•(PAGE 28)

ENGINE
[O ) GROUND
■=• G109
 Locater
Com ponent View
Page Figure
ALDL ............................................... . Under dash L H ............................................. * *

Battery Junction Block ................. . RH rear in engine compartment, at cowl . 18 6 C114 ................................................ Center of cowl, under battery junction block
Coolant Temperature S e n so r........ . RH top front of engine ............................... 17 4 cover ................................................................ ......... * *
ECM/IGN 10 Amp Fuse ................ . At fuse b lo c k ................................................ 1 C200 .................................................Under RH side of l/P, near blower m o to r......... ......... * *
Electronic Control Module (ECM) . . Under RH side of l/P ................................. 1 C200A ...............................................Behind RH side of l/P, near blower m o to r___ ____ * *
Electronic Spark Control Module RH top of engine ......................................... C200B ...............................................Behind RH side of l/P, near blower m o to r___ ____ * *
(ESC) ........................................... 16 1 C147 ................................................ On RH side of engine rocker c o v e r............................ 16 1
Electronic Spark Timing Module Center rear of engine C156A ...............................................LH side of engine near firewall .................................. 17 4
(EST) ........................................... 17 4 C157A ...............................................LH side engine compartment near firewall . . . 17 4
Exhaust Gas Recirculation (EGR) LH rear top of engine .................................
S olen o id ....................................... 16 1 G R O M M E TS :
Fuel Supply R e la y ......................... . RH rear in engine compartment at cowl .. 18 6 GT101 ...............................................RH lower cowl (engine compartment) ............. ......... 16 1
Idle Air Control (IAC) M o to r.......... . RH rear of TBI unit ..................................... 16 1
l/P cluster ....................................... . LH upper dash above steering clumn — *
GROUNDS:
Knock Sensor ................................. . RH side of engine, below exhaust G106 .................................................Rear of RH cylinder head .................................. ......... 17 4
m a n ifo ld .................................................... 16 1
G108 .................................................LH top front of engine ........................................ ......... 17 4
(MAP) S e n s o r................................ . RH rear top of e n g in e ................................. 16 1
G109 ................................. .............. Top front center of e n g in e .................................. ......... 17 4
Oil Pressure S w itc h ....................... . LH rear of engine under exhaust
m a n ifo ld .................................................... 17 4 S P LIC E S :
Heated Oxygen Sensor (0 2) ........ . LH exhaust p ip e ........................................... 17 4
S 1 1 4 .................................................. RH rear engine compartment, near A/C
Park/Neutral S w itc h ....................... . In passenger compartment bottom of
* accumulator .................................................... 16 1
steering column .......................................
S 1 3 6 .................................................. Rear of engine compartment, near c e n te r___ 16 1
Throttle Position (TP) Sensor ___ . RH side of T B I ............................................. 16 1
S152A ...............................................CNG harness RH engine rocker c o v e r............. 16 1
S 1 5 3 .................................................. Center of cowl, below battery junction block .. 18 6
S 2 1 4 .................................................. Courtesy lamp harness, near ashtray
compartment le a d ...........................................
S222 .................................................. Engine harness, near GT101 .............................
S224 .................................................. Engine harness, near GT101 .............................
S238 Engine harness, near E C M ................................
S 2 9 1 .................................................. Behind LH side of l / P ..........................................
 RPO CODES

L05 - ENGINE, 5.7L (350 CID) V8 CNG ENGINE

CIRCUIT WIRE COLOR CAVITY DESCRIPTION CIRCUIT WIRE COLOR CAVITY DESCRIPTION
NO. SIZE NO. SIZE
465 .8 DK GRN/WHT A1 FUEL SUPPLY RELAY DRIVE C1 NOT USED
A2 NOT USED C2 NOT USED
A3 NOT USED 444 .8 LT GRN/BLK C3 IAC “B” LOW
435 .8 GRA A4 EGR CONTROL 443 .8 LT GRN/WHT C4 IAC “B” HIGH
419 .8 BRN A5 SYSTEM CHECK “SES” LAMP 441 .8 LT BLU/WHT C5 IAC “A” HIGH
439 .8 PNK/BLK A6 12V IGNITION (FUSED) 442 .8 LT BLU/BLK C6 IAC “A” LOW
*422 .8 TAN/BLK A7 TCC CONTROL (MD8) *446 .8 LT BLU C7 HIGH GEAR SWITCH SIGNAL
461 .8 ORN A8 ALDL SERIAL DATA C8 NOT USED
451 .8 WHT/BLK A9 ALDL DIAGNOSTIC TEST 806 .8 PPL/WHT C9 CRANK SIGNAL (FUSED)
437 .8 BRN A10 VEHICLE SPEED SENSOR SIGNAL 410 .8 YEL C10 CTS SIGNAL
455 .8 PPL A11 MAP SENSOR GROUND 432 .8 LT GRN C11 MAP SIGNAL
450 .8 BLK/WHT A12 SYSTEM GROUND C12 NOT USED
440 .8 ORN B1 12V BATTERY (FUSED) 417 .8 DK BLU C13 TPS SIGNAL
120 .8 GRY B2 FUEL CONTROL SIGNAL 416 .8 GRA C14 MAP & TPS 5V REFERENCE
453 .8 BLK/RED B3 EST REF LOW C15 NOT USED
B4 NOT USED 440 .8 ORN C16 12V BATTERY (FUSED)
430 .8 PPL/WHT B5 EST REF HIGH 450 .8 BLK/WHT D1 SYSTEM GROUND
B6 NOT USED 452 .8 BLK D2 TPS & CTS GROUND
457 .8 YEL/BLK B7 ESC SIGNAL D3 NOT USED
59 .8 DKGRN B8 A/C SIGNAL 423 .8 WHT D4 EST
B9 NOT USED 424 .8 TAN/BLK D5 EST BYPASS
*434 .8 ORN/BLK B10 PARK/NEUTRAL SWITCH 413 .8 TAN D6 OXYGEN SENSOR GROUND
B11 NOT USED 412 .8 PPL D7 OXYGEN SENSOR SIGNAL
B12 NOT USED D8 NOT USED
*AUTO T R A N S ONLY D9 NOT USED
E L E C T R O N IC C O N T R O L M O D U L E C O N N E C T O R D10 NOT USED
D11 NOT USED
D12 NOT USED
D13 NOT USED
468 .8 GRN D14 INJECTOR B (2) DRIVE
D15 NOT USED
467 .8 BLU D16 INJECTOR A (1) DRIVE
*AUTO T R A N S ONLY
E L E C T R O N IC C O N T R O L M O D U L E C O N N E C T O R

4 ELECTRONIC CONTROL MODULE (ECM) PINOUTS

 yVW W W VW W V*
^ HOT IN START OR RUN ^

ECM-IGN
10 AMP
MAP
SENSOR
439-.8 PNK/BLK V STOP/TCC SWITCH
*(PAGE 54)

439- 8 PNK/BLK I

BATTERY
JUNCTION 440-1.0 ORN I
S153
BLOCK

452-.8 BLK

\
- I - 452-.B BLK
455-.S PPL
432-.S LT GRN 432-.8 LT GRN
417-.8 DK BLU 417-.8 DK BLU

TP
452-.8 BLK =(: 416- 8 GRA

410-.8 YEL
416-.8 GRA
410-. 8 YEL
417-.8 DK BLU
SENSOR 439-.8 PNK/BLK 439-.S PNK/BLK
416-.8 GRA
-I 440-.8 ORN 440-.0 ORN M i
457- 8 YEL/BLK ■ 457-.8 YEL/BLK ■
I .— - I 450-1.0 BLK/WHT 450-1.0 BLK/WHT I
412-. 8 PPL 412-.8 PPL M M

I 440-.8 ORN 440-.8 ORN M M

416-.8 GRA 416-.8 GRA
COOLANT
TEMP I- 450-.8 BLK/WHT 450-.8 BLK/WHT I

413-.8 TAN 413-.8 t a n mmm

SENSOR
450-.8 BLK/WHT 450-.8 BLK/WHT

439-.8 PNK/BLK I

KNOCK
SENSOR
496-.8 DK BLU
□
C144
12015375
I 439C-.8 PNK SPLICE-S152A
(PAGE 7)

ESC MODULE I
440-.8 ORN I FUEL SUPPLY RELAY
(PAGE 10)

12V IGNITION FUSED 439 I ^ rp \r 440-.8 ORN I OIL PRESSURE SWITCH

SPARK RETARD 457 A 439-.8 PNK/BLK , (PAGE 14)

ESC GROUND 486 A 457-.S YEL/BLK u HEATED

OXYGEN SENSOR
ESC SENSOR INPUT 496
486-.8 BRN I

496-.8 DK BLU

WATER LH CYLINDER
OUTLET ( q J Q ) HEAD
G109 - = - =■ G108
 RPO CODES
PARK/NEUTRAL
L05 - ENGINE, 5.7L (350 CID) V8 CNG
SWITCH
(CLOSED IN PARK
OR NEUTRAL)

451-.8 WHT/BLK
S240
♦(PAGE 32)

451-.8 WHT/BLK r
 f^ M A / W W ^ V W V V W
J HOT IN START >
S OR RUN >
K V W W V ^W vV V W ^

ECM-IGN S153
•- 440-1.0 ORN 440-.8 ORN
10 AMP TCC/STOP SWITCH .
439-.8 PNK/BLK *(PAGE 54) I C133 439-.8 PNK/BLK
12015798
439-.8 PNK/BLK
441 ( 4 ^ ) ^ G £ D ^ 440-.8 ORN
BATTERY 443-.8 LT GRN/WHT
2-.5 GRAI
JUNCTION FUSIBLE LINK I 444-.8 LT GRN/BLK ,
BLOCK IDLE AIR W 443-.8 LT GRN/WHT ,
A 441-.8 LT BLU/WHT ■
CONTROL 442 WU f eh) - *
( 0 * ^ * 441-.8 LT BLU/WHT

A (5.7L CNG) 443 B\ t | A *t ^442-.8 LT BLU/BLK I

o 444 (4 4 p ■ 442- 8 LT BLU/BLK| r I 450-.8 BLK/WHT M

o 444-.8 LT GRN/BLK
■ 423-.8 w ht

o 430-.8 PPL/WHT

o | w arn . 424-.8 TAN/BLK

t a n / b lk

O — I-{ 0 ^ 3 — I -453-.8 BLK/RED

V
V ■435-.8 GRA mmm

423-.8 WHT
i ! r'
HEI-EST __________________________________ - n
ELECTRONIC
SPARK
TIMING
DIST. REF. HIGH
430-.8 PPL/WHT

I \_ 413-.8 TAN

(EST) HEI BYPASS

DIST. REF. LOW

453-.8 BLK/RED j 450-.8 BLK/WHT M T

424-.8 TAN/BLK 450-.8 BLK/WHT

S136
424-.8 TAN/BLK 450-1.0 BLK/WHT ' 4 V jM % *(PAGE 32)

4 450 - 1.0 b lk / w h t m m r m
I
m r 4m w
J
A

413-.8 t a n m rnm t
450-1.0 BLK/WHT
'■ 439-.8 PNK/BLK

450-1.0 BLK/WHT
O
CO
in
5

435-.8 GRAI I435-.8 GRA

|
S152A
I439-.8 PNK/BLK , • ■ I439A.8 PNK/BLK I 439-.8 PNK/BLK ■

EXHAUST / \ 486-.S BRN r

GAS
RECIRCULATION ENGINE f \ ENGINE
(EGR)
HEATED
OXYGEN
SENSOR
CNG FUEL
PRESSURE
TRANSDUCER GROUND ( Q j GROUND
i
ELECTRONIC SPARK
SOLENOID (PAGE 5) (PAGE 12) = * G108 ■=" G109 CONTROL ‘ (PAGE 74)
 Locater
Component View
Page Figure
ALDL Connector ........................... Under LH side of l/P ................................................. * * G RO M M ETS:
Battery Junction Block ................. RH rear engine compartment, at c o w l.................... 18 6 GT101 ............................................ RH lower cowl (engine compartment) ......... 16
CNG Injector #1 ........................... Top of Engine ................................................ ............ 16 1
CNG Injector # 2 ........................... Top of engine ................................................ ............ 16 1 G R O U N D S:
Electronic Control Module Behind RH side of l/P above l/P G108 .............................................. LH top front of e n g in e .................................... 17
(ECM) ......................................... compartment box lamp ............................. ............ 1 — G109 .............................................. Top front center of engine ............................ 17
Fuel Cylinder Solenoid Feed
5 Amp Fuse ............................... LH frame rail under vehicle ......................... ............ 19 7 S PLIC E S :
Fuel Cylinder S olen o ids................ On fuel cylinder ............................................ ............ 1 —
5 1 14 RH rear engine compartment, near A/C
Fuel Door Shut-off Switch ............ On fuel fill door hinge ............................................... 19 7
accum ulator................................................ 16
Fuel Pressure Transducer ............ LH frame rail under vehicle ......................... ............ 19 7
5 1 15 LH side of engine, near bulkhead
Fuel Supply Oil Pressure Switch .. LH rear of engine under exhaust manifold . 17 4 *
c o n n e cto r....................................................
Fuel Supply R e la y ......................... RH rear engine compartment, near battery
S127 .............................................. RH rear engine compartment, near A/C
junction block c o v e r............................................... 18 6
accum ulator................................................ 16
Low Pressure Fuel Shut-Off
S135 .............................................. Engine harness, near convenience center
Solenoid ..................................... LH frame rail under vehicle ......................... ............ 19 7
le a d s ............................................................ 18
CNG Control Relay 15 Amp RH rear engine compartment, near battery
S153 .............................................. Center of cowl, below battery junction
F u s e ............................................. ju n c tio n .................................................................... 18 6
block ............................................................ 18
S153A ............................................ Fuel injector harness between GT101 and
CONNECTORS:
injectors ...................................................... 16
C100 ............................................... At bulkhead connector ............................................. * * S154A ............................................ Fuel injector harness between GT101 and
C 1 0 6 A ............................................. Near bulkhead co n n e cto r............................. ............ 19 7 injectors ............................... ....................... 16
C 1 5 0 A ....................... Near bulkhead co n n e cto r............................. ............ 19 7 S155A ............................................ Fuel injector harness between GT101 and
C 1 5 2 A ....................... At fuel injector................................................ ............ 16 1 injectors ...................................................... 16
C 1 5 3 A ....................... At fuel injector................................................ ............ 16 1 S156A ............................................ Fuel injector harness between GT101 and
C200 ............................................... Under RH side of l/P, near blower motor .. * * injectors ...................................................... 16
C 2 0 0 A ............................................. Behind RH side of l/P, near blower motor .. * * S220 .............................................. Engine harness, near GT101 ....................... *
C200B ............................................. Behind RH side of l/P, near blower motor .. * * S224 .............................................. Engine harness, near GT101 ....................... *
C420 ............................................... On rear harness near fuel cylinder 5238 Engine harness, near ECM ........................... *
solenoid.................................................................... 19 7 5239 Engine harness, near GT101 ....................... *
C 4 5 2 A ............................................. LH frame rail near low pressure fuel 5240 Behind LH side of l/P .................................... *
shut-off so le n o id ..................................................... 19 7 S244 .............................................. Engine harness, near GT101 ....................... *
C 4 5 3 A ............................................. Near fuel cylinder solenoid valves .......................... 19 7 S291 .............................................. Behind LH side of l/P .................................... *
C 4 5 4 A ............................................. Near fuel cylinder solenoid valves ............. ............ 19 7 S450A ............................................ LH frame rail between fuel cylinder solenoid
C 4 5 5 A ............................................. Near fuel cylinder solenoid valves .......................... 19 7 and low pressure fuel shut-off solenoid .. 19
C 4 5 6 A ............................................. Near fuel cylinder solenoid valves .......................... 19 7 S451A ............................................ LH frame rail between fuel cylinder solenoid
C 4 5 7 A ............................................. Near fuel door shut-off switch ..................... ............ 19 7 and low pressure fuel shut-off solenoid .. 19
WvWvWWWW
< HOT AT ALL TIMES ^
/A W v W W V V S

I W *
CNG
CONTROL
RELAY
(PAGE 12)

C153A ENGINE
12084428 GROUND
G108
C O M P O N E N T LOCATIO N Locater
Component View
Page Figure
Engine Temperature Sensor ........LH cylinder head ............................................ 17 4
Fuel Door Shut-off Switch ............In fuel fill door hinge ...................................... 19 7
Fuel Pressure Transducer ............LH frame rail under vehicle ........................... 19 7
Fuel Supply Oil Pressure LH rear of engine under exhaust 17 4
Switch ......................................... manifold ......................................................

CO NNECTO RS:
C100 .............................................. At bulkhead connector .................................. ............. * *
C102 ...............................................At bulkhead connector .................................. 19 7
C200 ...............................................Under RH side of l/P, near blower motor .. * *
C 2 0 0 A .............................................Under RH side of l/P, near blower motor .. * *
C255 ...............................................At ignition switch ......................................................... * *
C256 .............................................. At ignition switch ......................................................... * *
C406 .............................................. RH upper rear b o d y ........................................ ............. * *
C420 ...............................................On CNG h a rn e ss......................................................... * *

GRO M M ETS:
GT101 .............................................RH lower cowl engine compartment ........... 16 1

GRO U ND S:
G108 ...............................................LH top front of e n g in e .................................... 17 4
G202 .............................................. At ALDL connector (l/P ground) ................... * *

S P L IC E S :
S160 ...............................................Engine harness, near c o il.............................. ............ 16
S207 .............................................. Under LH side of l/P ...................................... ............ *
S213 ......................... .....................Under LH side of l/P ...................................... ............ *
S239 Engine harness, near GT101 ................................... *

GAGES
*REFER TO 1992 ELECTRICAL DIAGRAMS AND DIAGNOSIS MANUAL
 HOT IN START OR RUN

GAGES
20 AMP

450-1.0 BLK/WHT r 450-1.0 BLK/WHT I

■ 121-.8 WHT

121-.8 WHT
ENGINE

GT100
12041304 (UPPER)
IGNITION COIL ----- 1 12041305 (LOWER)
‘ (PAGE 96)
$

O
3
rs.
TACHOMETER L c 9
PROBE r
O
C\J
■<*

FUEL
SUPPLY 1\ CD
O

OIL PRESSURE
SWITCH
(CLOSES ABOVE
4 PSI) 30-.8 PPL

ENGINE

6 75
I 696 19 2A \
696 39

ENGINE in 2
9
18f 35-.8 DK GRN
35- 8 DK GRN 250 35
mm*

ii
TEMPERATURE 852 14C
35- 8 DK GRN

SENSOR 12
n :
3
98
93
92 25
7 9

I25 I 92 r 29 94 :

C169
FL G E I ill 31 490 33

12089494

C100
12020183
C100
12020184

24 30 19
ECM :
*(PAGE 75) 18 9
C102
i

30 .8 PPL
 . 39-.8 PNK/BLK 39 .8 PNK/BLK

a 39-.8 PNK/BLK 35- 8 DK GRN

A 39- 8 PNK/BLK

’ 450-1.0 BLK/WHT '

121-.8 WHT I

IGNITION
SWITCH

S207 150-.8 BLK

X
*(PAGE 34)

39- 8 PNK/BLK

35- 8 DK GRN ■

824-.8 LT BLU/BLK
■ 121- 8 WHT \m
- 1 = .

_ l_ I 39-.8 PNK/BLK 39
0 39 j 39-.8 PNK/BLK

_ l_ 30-.8 PPL
8

30
0
0
33

237 419
0
< 0
15 25
0
VEHICLE SPEED
SENSOR BUFFER
(DRAC)
'(PAGE 130)
r>—nr
V J
l/P CLUSTER
CONNECTOR
M i/ p
‘ (PAGE 120)
(q ) g r o u n d
■=* G202
 S353A S356A
S354A S357A
C153A
C110
(W /A C )

1. Cruise Control Throttle Cable

2. Cruise Control Module
3. RWAL Module
6N4-1

Figure 2 - Cruise Control Module

GT101 C110
(W /0 A /C ) FRONT
OF VEHICLE

12H12-CNG

C147 S352A FRONT

1. MAP Sensor OF VEHICLE
2. Idle Air Control Motor
3. TP Sensor
4. CNG Fuel Injectors
5. Generator
6. A/C Compressor Clutch
7. ESC Module
8. ESC Knock Sensor
9. Starter
10. A/C Pressure Cycling Switch
11. EGR Solenoid Valve

V IE W
12H13-CNG
 G109

1. Battery Junction Block

2. Starter
3. Battery
4. Forward Lamp Harness

12A2

G100

1. Generator
2. Coolant Temperature Sensor
3. Ignition Coil FRONT
4. EST Module and Distributor OF VEHICLE
5. Oil Pressure Sender/Switch
6. Oxygen Sensor - Heated
7. Coolant Temperature Switch 5.7L (350 CID) CNG

FRONT
OF VEHICLE
V IE W A
V IE W A
12H15
 S 1 5 0 S151 S1 5 2
S 1 5 3 S 1 5 4 S1 5 5 S1 5 6
S 1 5 7 S 1 5 8 S1 5 9 S161

VIEW A
1. Underhood Lamp FRONT
2. Battery Junction Block OF VEHIC LE
3. Fuel Supply Relay FRONT
OF VEHICLE
4. CNG Control Relay
5. In-Line Fuse
6. Underhood Reel Lamp Harness
7. In-Line Fuse
8. Underhood Reel Lamp

C186

V IE W
 FRONT
OF %
VEHICLE

1. Low Pressure Fuel Shut-Off Solenoid

2. Fuel Pressure Transducer
3. Fuel Cylinder Solenoid Valve
4. Fuel Door Shut-Off Switch
5. Rear Lamp Wiring Harness
6. CNG Wiring Control Harness
7. Fuel Fill Door
8. Bulkhead Connector

12H124-CNG

Figure 47 - Fuel Supply/Transducer Wiring