Professional Documents
Culture Documents
Dies Sel
Dies Sel
Dies Sel
PNK 39-
Fuse Block
i 1 -------- Details PCM
Cell 11 Cl =32 BRN
PNK 39 02 = 24 BRN
C3 = 32 BLU
r — — — — -
22.
1 Instrument A
1 Instrument^- Malfunction
I Clyster ^ SERVICE Indicator
[ Cluster
Cell 81 ( T ) THROTTLE
\~ t s o g n
0 Lamp (MIL)
(SERVICE 1 ; -
| Lamp ENGINE SOON)
21 23'
WHT/BLK 178 BRN/WHT 419
D11 G14 C3
Sen/ice Throttle MIL 11 Powertrain
Soon Lamp Control 1 Control A
Control * Module (PCM) ittA
185027
PCM
= 32 BRN
= 24 BRN
= 32 BLU
■ r u w e r ifc iin
. Engine Engine Fuel Fuel Closure Closure
1 Shut Off Shutoff Injection Injection Signal Ground 1 Control
I Solenoid Solenoid Control Control 1Module A
| Control Control
. J (PCM) l i t A
185026
185071
PNK 539
PCM
Fuse Block
Details C1=32 BRN
Cell 11 C2 = 24 BRN
PNK 539 C 3=32 BLU
C
Mass
Air Flow
, (MAF)
j Sensor
PNK 539 PNK 539 PNK 539
I. L5.S..... I
A
185071
DTC P0103 Mass Air Flow (MAF) Sensor Circuit High Frequency
Step Action Value(s) ■ Yes No
Powertrain
. Ground Control
j A
I _______J Module (PCM) i a A
185072
Sensor Powertrain
Ground
I: Control A
L _ - _ - J Module (PCM) i& A
185072
DTC PQ113 Intake Air Temperature (IAT) Sensor C ircuit High Voltage
Step Action Value(s) Yes No
Important: Before clearing the DTCs, use the scan tool
Capture Info to save the Freeze Frame and Failure Go to A
Records for reference. The control module’s data is Powertrain On
1 —
deleted once the Clear Info function is used. Board Diagnostic
Did you perform the Powertrain On-Board Diagnostic (OBD) System
(OBD) System Check? Go to Step 2 Check
r Sensor 1 Powertrain
Ground Control
J Module (PCM) M S
185072
I Sensor ■ Powertrain
------------ - A
Ground Control m
I ______ J Module (PCM) M k
185072
DTC P0118 Engine Coolant Temperature (ECT) Sensor Circuit High Voltage
Step Action Value(s) Yes No
* >V ^* N f A
F> k' C'
>1 >f \r \
I 1r 1r 1r ~ Sf/ >*
T
185076
1
J' R A' C'
\/ > f \f Nt --------
,C1
ocn
B1 A12yvC2
TO
D6
K>
w
'o
q
s.
185076
Conditions for Running the DTC • The PCM records the operating conditions at the
time the diagnostic fails. This information will
• The PCM performs this DTC diagnostic store in the Failure Records.
continuously.
• The ignition switch in the ON position.
Conditions for Clearing the MIL/DTC
• A History DTC clears after forty consecutive
Conditions for Setting the DTC warm-up cycles, if this or any other emission
• The voltage on the APP 1 sensor is less related diagnostic does not report any failures
than 0.25 volts. • The use of a scan tool.
• All of the diagnostic set conditions met for
2 seconds.
Diagnostic Aids An intermittent may be caused by any of the following
conditions:
There are no driveability issues associated with the
APP module unless a DTC is present. The most likely • A poor connection
causes of this DTC are poor connections or the • Rubbed through wire insulation
sensor itself. The least likely is a PCM problem. • A broken wire inside the insulation
A scan tool reads APP 1 position in volts. It should Thoroughly check any circuitry that is suspected of
read about 0.45 to 0.95 volt with the throttle closed and causing the intermittent complaint. Refer to
the ignition ON or at idle. Voltage should increase at In te rm itte n ts a n d P o o r C o n n e c tio n s D ia g n o s is in
Wiring Systems.
a steady rate as the throttle is moved toward wide
open throttle (WOT). Also, 90 percent pedal travel is If a repair is necessary, then refer to W irin g R e p a irs or
acceptable for correct APP operation. Scan APP C o n n e c to r R e p a irs in Wiring Systems.
sensor while depressing the accelerator pedal with the Test Description
engine off and the ignition ON. Display should vary Number(s) below refer to the step number(s) on the
from about 0.74 volt when throttle is closed to Diagnostic Table.
about 3.7 volts when the throttle is held at wide open 2. This step determines if P0122 is the result of a
throttle (WOT). A DTC P0122 will result if the hard failure or an intermittent condition.
signal or reference circuit are open. 4. This step checks the PCM and wiring.
«i powertrain
APP 3 APP 1 app 2 i Control A
5 Volt 5 Volt
Reference Reference « £ * . ! " M u t e (PCM) i a i .
f
D3' D12 'G1 C2' C3
Nf \ r >tr ------------>
f
f f
.... ......
o
5
D4,
S
"S
/
r ——— Powertrain
. APP 3 Sensor APP 1 Sensor APP 2 Sensor
J Signal Control A
*
185076
Conditions for Running the DTC • The PCM records the operating conditions at the
time the diagnostic fails. This information will
• The PCM performs this DTC diagnostic store in the Failure Records.
continuously.
• The ignition switch in the ON position. Conditions for Clearing the MIL/DTC
• A History DTC clears after forty consecutive
Conditions for Setting the DTC warm-up cycles, if this or any other emission
• The voltage on the APP 1 sensor is more related diagnostic does not report any failures
than 4.75 volts. • The use of a scan tool.
• All of the diagnostic set conditions met for
2 seconds.
Diagnostic Aids An intermittent may be caused by any of the following
There are no driveability issues associated with the conditions:
APP module unless a DTC is present. The most likely • A poor connection
causes of this DTC are poor connections or the
• Rubbed through wire insulation
sensor itself. The least likely is a PCM problem.
An intermittent may be caused by the following: • A broken wire inside the insulation
A scan tool reads APP 1 position in volts. It should Thoroughly check any circuitry that is suspected of
read about 0.45 to 0.95 volt with the throttle closed and causing the intermittent complaint. Refer to
the ignition ON or at idle. Voltage should increase at In te rm itte n ts a n d P o o r C o n n e c tio n s D ia g n o s is in
a steady rate as the throttle is moved toward wide Wiring Systems.
open throttle (WOT). Also, 90 percent pedal travel is If a repair is necessary, then refer to W irin g R e p a irs or
acceptable for correct 0 APP operation. Scan C o n n e c to r R e p a irs in Wiring Systems.
APP 1 sensor while depressing the accelerator pedal
with the engine and the ignition ON. Display should Test Description
vary from about 0.74 volt when the throttle is closed to
Number(s) below refer to the step number(s) on the
about 3.7 volts when the throttle is held at wide
Diagnostic Table.
open throttle (WOT). A P0123 will result if the ground
circuit is open or the signal circuit is shorted to 2. This step determines if DTC P0123 is the result of
voltage. a hard failure or an intermittent condition.
Powertrain
. : Control
Ground ' ■ A
L _______ j Module (PCM) A n A
185072
Circuit Description • The DTCs P0112, P0113, P0117 and P0118 are
While the engine is warming, the PCM monitors the not set.
ECT sensor to determine how long it takes the engine • The intake air temperature is more
to reach the coolant temperature required for Closed than -7°C (20°F).
Loop operation. DTC P0126 will set if the PCM
• The total idle time since start up is less
determines that the engine does not reach Closed
Loop temperature in a specified amount of time. This than 450 seconds.
test will not run if either the intake air or engine
coolant temperature is too low at start up. The PCM • The engine operation time is more
will only run this DTC on a cold start and only once per
than 300 seconds.
cold start.
• The DTCs P0112, P0113, P0117 and P0118 are
Conditions for Running the DTC not set.
• The PCM performs this DTC diagnostic once per • The intake air temperature is more
ignition cycle until a pass or fail condition exists.
than -7°C (20° F).
• The engine operation time is more
than 600 seconds.
Conditions for Setting the DTC • If the engjne has been allowed to sit overnight,
• The fuel burned since start up is more the engine coolant temperature and intake air
than 1,000,000 cu. mm. temperature values should display within a
few degrees of each other.
• The engine coolant is less than 56°C (133°F).
or • If the engine coolant temperature exceeds 60°C
(140°F), this indicates that the engine is capable
• The fuel burned since start up is more
of reaching the proper temperature, but not
than 468,120 cu. mm.
necessarily in the correct amount of time. This
• The engine coolant temperature is less diagnostic table must be repeated on a cold
than 56°C (133°F). engine, ECT and IAT less than 50°C (122°F) and
Action Taken When the DTC Sets within 3°C (5°F) of each other, and the time
required to reach the temperature threshold must
• The PCM illuminates the malfunction indicator
be measured. When starting a cold engine,
lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails. measure the amount of time it takes the engine to
reach the specified temperature. The engine
• The PCM records the operating conditions at the
should reach the specified temperature
time the diagnostic fails. The first time the
within 8 minutes. If the specified temperature is
diagnostic fails, the Failure Records will store this
not reached within 7 minutes, check the following:
information. If the diagnostic reports a failure
on the second consecutive drive trip, the Freeze • Coolant level.
Frame records the operating conditions at the time • Thermostat operation.
of failure and updates the Failure Records.
• Cooling fan.
Conditions for Clearing the MIL/DTC • Refer to T h e rm o s ta t D ia g n o s is (O n -V e h ic le ) in
• The PCM will turn the MIL off after three Engine Cooling for additional information.
consecutive trips without a fault condition.
An intermittent may be caused by any of the following
• A History DTC clears after forty consecutive conditions:
warm-up cycles, if this or any other emission
• A poor connection
related diagnostic does not report any failures
• The use of a scan tool. • Rubbed through wire insulation
• A broken wire inside the insulation
Diagnostic Aids
Thoroughly check any circuitry that is suspected of
Important: The system must be rechecked on a causing the intermittent complaint. Refer to
cold start. In te rm itte n ts a n d P o o r C o n n e c tio n s D ia g n o s is in
• Using Freeze Frame and/or Failure Records data Wiring Systems.
may aid in locating an intermittent condition. If If a repair is necessary, then refer to W irin g R e p a irs or
the DTC cannot be duplicated, the information C o n n e c to r R e p a irs in Wiring Systems.
included in the Freeze Frame and/or Failure
Records data can be useful in determining how Test Description
many miles since the DTC set. The Fail Counter Number(s) below refer to step numbers on the
and Pass Counter can also be used to determine diagnostic table.
how many ignition cycles the diagnostic
reported a pass and/or a fail. Operate the vehicle 2. An ECT failure could cause a DTC P0126 to set,
within the same freeze frame conditions (RPM, so correct any ECT DTCs that are set.
load, vehicle speed, temperature etc.) that 6. If it is obvious that the engine is not reaching full
were noted. This will isolate when the DTC failed. operating temperature, for example the radiator
• If other DTCs are set that share the same ground hoses never gets very warm, or there is a
and/or 5.0 volt reference circuit, check for faulty complaint of little or no heat from the heater, this
connections and for faulty wiring. step could be skipped.
DTC P0126 Engine Coolant Temperature (ECT) Insufficient for Stable Operation
Step Action Value(s) Yes No
D14 oeT'C l
BT C1 D' r '
BRN/WHT 633 ORN 1799
PNK/
BLK 632
PNK/BLK 632 i
—---------— -o
PNK/BLK 632
i
■S'-----. ->f — --------
185024
C' D'
BRN/WHT 633 ORN 1799
PNK/
BLK 632
PNK/BLK 632
----- --------
PNK/BLK 632
185024
BLU/WHT 259
LT GRN 260 RED 313
DK LT GRN 260 BLK 491
BLU/WHT 259
D15 D3 C3 J sC3 C13y Cl A1 C2
. Engine Engine Fuel Fuel Closure Closure
' Powertrain
1 Shut Off Shut Off Injection Injection Signal Ground 1Control
1 Solenoid Solenoid Control Control 1Module A
| Control Control
. _ \ (PCM) ia A
185026
Circuit Description • The PCM has requested the ESO OFF and the
The injection pump fuel supply line has a solenoid control circuit voltage at the PCM is less
controlled shutoff located in the injection pump. When than 8 volts.
the solenoid is energized (key in the run position), • All of the diagnostic set conditions met for
the valve is open and fuel is supplied to the injection 2 seconds.
pump. By providing a ground path, the PCM
energizes the solenoid. Action Taken When the DTC Sets
Conditions for Running the DTC • The PCM will not illuminate the ma lfunction
indicator lamp (MIL).
The ignition switch in the ON position or the engine is
operating. • The PCM records the operating conditions at the
time the diagnostic fails. This information will
Conditions for Setting the DTC store in the Failure Records.
• The PCM has requested the ESO ON and the
control circuit voltage at the PCM is more Conditions fo r Clearing the MIL/DTC
than 8 volts. • A History DTC clears after forty consecutive
• All of the diagnostic set conditions met for warm-up cycles, if this or any other emission
2 seconds. related diagnostic does not report any failures
or • The use of a scan tool.
Diagnostic Aids Thoroughly check any circuitry that is suspected of
causing the intermittent complaint. Refer to
An open in the control circuit or the ignition feed circuit Intermittents and Poor Connections Diagnosis in
will cause a P0215. Also a no start condition will Wiring Systems.
exist. The scan tool has the ability to turn the engine If a repair is necessary, then refer to Wiring Repairs or
shutoff solenoid ON and OFF. This can be used Connector R epairs in Wiring Systems.
as a quick operational check.
Test Description
An intermittent may be caused by any of the following Number(s) below refer to the step number(s) on the
conditions: Diagnostic Table.
• A poor connection 3. This step will check the ESO control circuit for
an open.
• Rubbed through wire insulation
10. After repairing the circuit for a short to voltage,
• A broken wire inside the insulation check the solenoid for proper operation.
harness connector.
Is the test light ON? Go to Step 10 Go to Step 9
DTC P0215 Engine Shutoff (ESO) Solenoid Control Circuit (cont’d)
Step Action Value(s) Yes No
Repair the short to ground on the ESO control circuit.
8 Refer to Wiring Repairs in Wiring Systems. — ■—
Is the action complete? Go to Step 13
1. Check the ESO control circuit for the following
conditions:
• An open wire
9 • Proper connection at the PCM —
2. If an ESO control circuit problem was found, repair it
as necessary. Refer to Wiring Repairs in Wiring
Systems.
Is the action complete? Go to Step 13 Go to Step 12
1. Check the ESO control circuit for a short to voltage.
2. If an ESO control circuit problem was found, repair it
10 as necessary. Refer to Wiring Repairs in Wiring —
Systems.
Is the action complete? Go to Step 13 Go to Step 12
Important: The new injection pump must be timed. Refer
to Injection Timing Adjustment
11 Replace the injection pump. Refer to Fuel Injection Pump — —
Replacement
Is the action complete? Go to Step 13
Important: The new PCM must be programmed. Refer to
PCM Replacement/Programming.
12 — —
Replace the PCM.
Is the action complete? Go to Step 13
1. Using the scan tool, clear the DTCs.
2. Start the engine.
3. Allow the engine to idle until the engine reaches
normal operating temperature.
13 4. Select DTC and the Specific DTC function. —
5. Enter the DTC number which was set.
6. Operate the vehicle, with the Conditions for Setting
this DTC, until the scan tool indicates the
diagnostic Ran.
Does the scan tool indicate the diagnostic Passed? Go to Step 14 Go to Step 2
Does the scan tool display any additional Go to the
14 undiagnosed DTCs? — Applicable
DTC Table System OK
Ignition
Stepper Timing
0
Motor
Stepper (ITS)
Coil Coil Motor
1 2
PCM
\f C1=32 BRN
>
c' C 2=24 BRN
D A b ' C3 = 32BLU
AT, A9 fi2
I ITS ITS ITS
yTS“" “i Powertrain
1 Coil 1 Coil 1 Coil 2 coii 2 1 Control
1 High Low Low H|9h 1 Module A
1 _ _ \ (PCM) i i A
185028
LT GRN 260
DK —----- ■-------------- <►
BLU/WHT 259 LT GRN 260 RED 313
LT GRN 260 BLK 491
--------- \ /---------------- ^r ------------ *>
✓ \f
DK
BLU/WHT 259
LT GRN 260 RED 313
DK LT GRN 260 BLK 491
BLU/WHT 259
02
5✓
D3
5
D15 v.
03 J sC3 013 J
\
185026
1 Powertrain
APP 3 APP 1 app 2 1 Control A
5 Voll 5 Volt 3Volt I Module {PCM)
Reference Reference Referencej
D3 D12 ci C2 03
1
K' J' F" A' C . • B' /
Nf
\
A /
D4 v ~ ~ D6
—y\ C1 B2 J C2 C5 SC\ A12^% C2
APP 3 Sensor APP 1 Sensor APP 2 Sensor Powertrain
Signal Ground Signal Ground Signal Ground Control A
Module (PCM) M
L— _________ ______ _
185076
|
DTC P0221 APP Senso r2 Circuit Perfo rmance
' - i powertrain
APP 3 APP 1 app 2 I Control A
5 Volt 5 Volt
Reference Reference Reference ' Module (PCM) ^
I n |
D s' D12 'C t C2%'C3
1 1
KN J" F' A' C' B"
\N/ >t
f
>f
^f
%f
f
N f
f
D4y B1J
\ ______ C2 C5^vC1 A12y C2
I
185076
1 Powertrain
APP 3 APP 1 app 2 I Control £
5 Volt 5 Volt
Reference Reference Reference ! Module (PCM) ^
"t
1o
. CO
03^ D12 'C1 C2>
PCM
YEL/BLK 1275 WHT/BLK 1164 TAN 1274 G1 =32 BRN
C2=24BRN
C 3-32 BLU
E ,X G /X D.
/ Accelerator
Pedal Position
s s $ (APP) Module
F'
T
A' C'
I
.J "
f \ 'r -------- i
T >f "N f
OD
PO
185076
>
K" A ss : C' B'
\ ^ -------- ^ Yf >f \r ?
X f ~ •V
f >/
185076
PCM
YEL/BLK 1275 WHT/BLK 1164 TAN 1274 C1 =32 BRN
02 = 24 BRN
03=32 BLU
E, K G yv ■■■ D,
J y Accelerator
Pedal Position
$ (APP) Module
1
KN J' F> A" C" B"
* ■ - - ---- s t
------ ^>f----------- sVf------------ \ r -- -— ~ >Y
CM
%
185076
PCM
YEL/BLK 1275 WHT/BLK 1164 TAN 1274 C1=32 BRN
C2 = 24 BRN
C3 = 32 BLU
E, G, D,
s Accelerator
Pedal Position
(APP) Module
KN J' F"
I
h" O' /
N.t -------
% >---------- -> /------------ Nf --------~^%^ -------- ^ Jf
D4y
o
C5y^C1 A12^ C2 -
DO
CM
D6 C2
r app 3 Sensor APP 1 Sensor APP 2 Sensor 1 Powertrain
j Signal Ground Signal Ground Signal Ground * Control Jk
/
1 Module (PCM) £ tJ k
L ______ _ BH
185076
D3 “D12TC1 C 2 JC3
✓ >*
f
%j .
"si
------- f •%
185076
1 Powertrain
APP 3 APP 1 APP 2 I Control -
5 Volt 5 Volt 5 Volt
5Volt I Module (PCM) i i A
Reference Reference Reference
D3 D12 01 02 C3
PCM
1 1 ✓
K") J' F' A' C'
N/ \
' r --------------- - s --------------------------\ / -------------------------- \ ------------------------- --- f “ ** ---------------- --X f -
D4^ D 6 >S
C1 B2 ✓ B1 C2 C5y^C1 A12^S C2
APP 3 Sensor APP 1 Sensor APP 2 Sensor ' 1 Powertrain
Signal Ground Signal Ground Signal Ground 1 Control
1 Module (PCM) h J k
185076
5 Volt
"* Powertrain
Reference A 1 Control
PGM
01=32 BRN
C2=24 BRN
C3=32 BLU
ECT and
IAT Sensors
185023
ECT and
IAT Sensors
BLK 452 LT GRN 432 BLK 452
BLK 452
GRY/BLK 433
185023
v
BLK 452
GRY/BLK 433
"l Powertrain
Fuel
. 5 Volt Temperature
I Control
* Reference B Signal I Module ^
J (PCM). la A
D14 C8 C1
GRY 474 YEL 1578
PCM
C1 =32 BRN
C2 = 24 BRN
C3 = 32 BLU
B G
BRN/WHT 633 ORN 1799
PNK/
BLK 632
PNK/BLK 632
PNK/BLK 632
185024
B,
BLK 452
YEL 643 l
l
BLK 452 1
Sensors
Y
i
YEL i
r ----
j CKP Sensor
^ Powertrain
Sensor Ground ^ C o n tro l
I Signal (Module Jk
L -------—
------- J (PCM) A A
185025
1 Powertrain
5 Volt Temperature ' C o n tro 1
I Reference E signal I Module >
------------ j (pcm)
D14l C8~C1
GRY 474 YEL 1578
PCM
01=32 BRN
02=24 BRN
C3=32 BLU
B C
BRN/WHT 033 ORN 1799
PNK/
BLK 632
PNK/BLK 632
PNK/BLK .632
185024
DTC P0370 Tim ing R eference High R esolution System P erform ance
Step Action Value(s) Yes No
Important: Before clearing any DTCs, use the scan tool
Capture Info to save freeze frame and failure records for Go to A
1 reference, as the scan tool loses data when using the Powertrain On
Clear Info function. —
Board Diagnostic
Was the Powertrain On-Board Diagnostic (OBD) System (OBD) System
Check performed? Go to Step 2 Check
1. Turn the ignition OFF.
2. Disconnect the Optical/Fuel temperature sensor
electrical connector.
2 3. Turn the ignition ON leaving the engine OFF. 4.8-5.2V
4. Using a DMM J 39200, measure the voltage between
the Optical sensor 5 volt reference circuit at the
harness connector and chassis ground.
Is the voltage at specified value? Go to Step 3 Go to Step 6
1. Verify the Optical/Fuel temperature sensor electrical
connector is still disconnected.
3 2. Probe the sensor ground circuit with a test light —
connected to B+ at the harness connector.
Is the test light ON? Go to Step 4 Go to Step 7
1. Reconnect the Optical/Fuel Temperature sensor
electrical connector.
2. Start and operate the engine as close to the
conditions saved in the Freeze Frame/Failure
4 —
Records.
3. Using the Scan Tool, select DTC, specific and then
enter the DTC number. Go to
Does the scan tool display the term Last Test Failed? Go to Step 5 Diagnostic Aids
DTC P0370 Timing Reference High Resolution System Performance (cont’d)
Step Action Value(s) Yes No
Important: The scan tool must display Last Test Failed
(under DTC, Specific). This ensures the fault is active
while performing this test.
1. Maintain the engine speed at the point of failure (per
conditions saved in the Freeze Frame/Failure
5 Records). —
2. With the DMM J 39200 on the Hertz (Hz) scale,
backprobe the high resolution signal circuit at
the PCM.
Referring to the RPM vs Hertz (Hz) table, does the Hertz
reading in the table correspond (±100 Hz) with the Hertz
reading on the DMM at the designated RPM? Go to Step 16 Go to Step 9
1. Turn the ignition OFF.
2. Disconnect the PCM, and check the Optical sensor
5 volt reference circuit for an open, short to ground,
6 or short to the sensor ground circuit.
—
3. If the Optical sensor 5 volt reference circuit is open or
shorted to ground, repair the circuit as necessary.
Was the Optical sensor 5 volt reference circuit open or
shorted to ground? Go to Step 19 Go to Step 8
1. Check for an open or a proper sensor ground
terminal connection at the PCM.
7 ■—
2. If a problem is found, repair as necessary.
Was a repair performed? Go to Step 19 Go to Step 18
Check the Optical sensor 5 volt reference circuit for a
proper connection at the PCM and replace the terminal if
8 necessary. —
Did the terminal require replacement? Go to Step 19 Go to Step 18
1. Disconnect the Optical/Fuel temperature sensor
electrical connector.
2. Turn the ignition ON leaving the engine OFF.
9 4.8-5.2V
3. With a DMM J 39200 connected to ground, probe the
high resolution signal circuit at the harness connector.
Is the voltage within the specified value? Go to Step 13 Go to Step 10
10 Is the voltage greater than the specified value? 4.8-5.2V Go to Step 11 Go to Step 12
Repair the short to battery/ignition voltage on the high
11 resolution signal circuit. — —
Is the action complete? Go to Step 17
1. Turn the ignition OFF.
2. Disconnect the PCM, and check the high resolution
signal circuit for an open, short to ground, or short to
12 the sensor ground circuit. —'
3. If a problem is found, repair the problem as
necessary.
Was a repair made? Go to Step 19 Go to Step 16
With a DMM J 39200 set to the mA scale, measure the
current between the High Res signal circuit and the ground
13 circuit at the Optical/Fuel temperature sensor electrical 25 mA
connector.
Is the current less than the specified value? Go to Step 15 Go to Step 14
Repair the short to reference voltage on the high
14 resolution signal circuit. — —
Is the action complete? Go to Step 19
DTC P0370 Tim in g R eference High R esolution System P erfo rm an ce (co n t’d)
Step Action Value(s) Yes No
1. Check the high resolution signal circuit for a proper
connection at the injection pump.
15 2. If a problem is found, repair the problem as —
necessary.
Was a problem found? Go to Step 19 Go to Step 17
1. Turn the ignition OFF.
2. Disconnect the PCM, and check the high resolution
signal circuit for a proper connection at the PCM.
16 — .
3. If a problem is found, repair the problem as
necessary.
Was a problem found? Go to Step 19 Go to Step 18
Replace the injection pump. Refer to Fuel Injection Pump
Replacement
17 Important: The new injection pump must be timed. Refer :— ■— .
to Injection Timing Adjustment.
Is the action complete? Go to Step 19
Replace the PCM.
Important: The new PCM must be programmed. Refer to
18 PCM Replacement/Programming. — .—
Is the action complete? Go to Step 19
1. Using the Scan Tool, clear the DTCs.
2. Start the engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
19 which was set. —
4. Operate the vehicle, within the Conditions for Setting
this DTC, until the Scan Tool indicates the
diagnostic Ran.
Does the Scan Tool indicate the diagnostic Passed? Go to Step 20 Go to Step 2
Does the Scan Tool display any additional Go to the
20 undiagnosed DTCs? — Applicable
DTC Table System OK
DTC P0380 Glow Plug Feedback Circuit
Refer to PCM, Glow Plugs, Underhood Fuse-Relay Conditions for Clearing the MiL/DTC
Center
• The PCM will turn the MIL off after three
Circuit Description consecutive trips without a fault condition.
The glow plug system is used to assist in providing • A History DTC clears after forty consecutive
the heat required to begin combustion during cold warm-up cycles, if this or any other emission
engine temperatures. The glow plugs are heated related diagnostic does not report any failures
before and during cranking, as well as initial engine
• The use of a scan tool.
operation. The PCM controls the glow plug ON
times by monitoring coolant temperatures and glow Diagnostic Aids
plug voltage.
If glow plug relay is stuck in the ON position, check for
Conditions for Running the DTC proper operation of glow plugs, refer to Glow Plug
The ignition switch in the ON position. System Check. YJhen glow plugs are commanded ON
by the Scan tool, an internal PCM timer protects
Conditions for Setting the DTC the glow plugs from damage by cycling them ON for
• The PCM has commanded glow plugs ON and 3 seconds and the OFF for 12 seconds.
the glow plug signal voltage is less than 4.0 volts.
The glow plug output feed wire nut and battery feed
or wire nut at the relay should be checked for proper
• The PCM has commanded glow plugs OFF and torque (5 N-m 44 lb in) and for corrosion.
the glow plug signal voltage is greater
An intermittent may be caused by the following:
than 4.0 volts.
or • Poor connections.
• When the PCM has commanded glow plugs ON • Rubbed through wire insulation.
and there is more than a 2 volt difference • Broken wire inside the insulation.
between glow plug voltage and ignition voltage.
Test Description
Action Taken When the DTC Sets
The number(s) below refer to the Step number(s) on
• The PCM illuminates the malfunction indicator
the Diagnostic Table.
lamp (MIL) on the second consecutive drive
trip that the diagnostic runs and fails. 2. This step will determine if P0380 is a hard failure.
• The PCM records the operating conditions at the 3. This step will determine if the PCM is requesting
time the diagnostic fails. The first time the the glow plug system ON.
diagnostic fails, the Failure Records will store this
information. If the diagnostic reports a failure 10. This step will determine if the glow plug relay has
on the second consecutive drive trip, the Freeze been activated and the output voltage has been
Frame records the operating conditions at the time seen by the PCM.
of failure and updates the Failure Records.
PNK 539
PCM
Fuse Block
Details C1 =32 BRN
Cell 11 C2=24 BRN
PNK 539 C3=32 BLU
C
Mass
Air Flow
, (MAF)
Sensor PNK 539 PNK 539 PNK 539
L L56
Solenoid B Vent ET
Solenoid
Ground
Distribution
Cell 14 YEL 492 GRY 435 WHT 257 YEL 258
i . _____ _ — -_____
185071
Refer to Emission Hose Routing Diagram Conditions for Setting the DTC
Circuit Description • Lowest achieved EGR pressure at full EGR is less
than look up table value (internal to PCM)
The PCM operates a PWM solenoid to control the
EGR valve. This solenoid is normally open. By • All diagnostic set conditions met for 2 seconds.
providing a ground path the PCM energizes the
solenoid which then allows vacuum to pass to the EGR
Action Taken When the DTC Sets
valve. During normal operation, the PCM compares • The PCM will shut down the EGR.
its desired MAF signal with the measured MAF signal • The PCM illuminates the malfunction indicator
and makes corrections in the duty cycle accordingly. lamp (MIL) on the second consecutive drive
Conditions for Running the DTC trip that the diagnostic runs and fails.
• The PCM performs this DTC diagnostic • The PCM records the operating conditions at the
continuously. time the diagnostic fails. The first time the
diagnostic fails, the Failure Records will store this
• Baro greater than 75 kPa.
information. If the diagnostic reports a failure
• The DTCs P0405, P0406, P0102 and P0103 are on the second consecutive drive trip, the Freeze
not set. Frame records the operating conditions at the time
• MAF value is greater than or equal to 0.1484 g/cyl. of failure and updates the Failure Records,
Conditions for Clearing the MiL/DTC The Adaptive Learn Matrix (ALM) is used to adjust the
• The PCM will turn the MIL off after three EGR vacuum control based on mass air flow (MAF).
consecutive trips without a fault condition. The ALM may change as a result of back pressure
increases over the life of the vehicle or other engine
• A History DTC clears after forty consecutive system variations. The ALM is made up of sixteen cells
warm-up cycles, if this or any other emission (numbered from zero to fifteen) in which each cell
related diagnostic does not report any failures covers a range of engine speed (RPM) and
• The use of a scan tool. load (mm3).
Diagnostic Aids Test Description
The most likely cause of failure is a restricted vacuum Number(s) below refer to the step number(s) on the
line from the EGR valve to the vacuum tee (including Diagnostic Table.
the vacuum tee).
2. This step checks for the correct amount of
To run the diagnostic test the engine must be at the vacuum at the EGR valve.
operating temperature, vehicle in drive at idle for
3. At zero vacuum and at 15 in. Hg, there should be
approximately 1 minute. Then, with the vehicle in park,
a difference greater than 0.10 g/cyl. If the
hold the engine rpm steady between 1500 and
difference is not greater than 0.10 g/cyl the EGR
2100 rpm for 30 seconds. If the diagnostic test fails to
valve is malfunctioning.
run, the vehicle must be driven.
DTC P0400 Exhaust Gas Recirculation (EGR) System Performance
Step Action Value(s) Yes No
Important: Before clearing any DTCs, use the scan tool
Capture Info to save freeze frame and failure records for Go to A
reference, as the Scan tool loses data when using the — : Powertrain On
1
Clear Info function. Board Diagnostic
Was the Powertrain On-Board Diagnostic (OBD) System (OBD) System
Check performed? Go to Step 2 Check
1. Install a vacuum gage in place of the EGR valve.
2. Start and idle the engine in Park.
3. Set the parking brake.
2 4. Place the shift lever in Drive. 15 in. Hg
5. Using the scan tool, command the EGR solenoid to
100% duty cycle.
6. At idle, observe the vacuum.
Is the vacuum greater than the specified value? Go to Step 3 Go to Step 5
1. Install a vacuum pump on EGR valve.
2. Start and idle engine in park.
3 3. Monitor Cylinder Air display on scan tool. 0.10 g/cyl
4. Apply 15 in. Hg of vacuum to EGR valve.
While applying the vacuum, does Cylinder Air decrease by
greater than the specified value? Go to Step 4 Go to Step 7
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs were stored Go to the
4 refer to those table(s). —
Applicable Go to
Are any additional DTCs stored? DTC Table Diagnostic Aids
Check the vacuum source at the solenoid assembly.
5 15 in. Hg
Is vacuum at the specified value? Go to Step 6 Go to Step 8
Repair restricted or leaky vacuum hose (from solenoid
6 assembly to EGR valve). — —
Is action complete? Go to Step 9
Replace EGR valve. Refer to EGR Valve Replacement
7 — —■
Is the action complete? Go to Step 9
Repair the vacuum pump. Refer to Vacuum Pump
8 diagnosis and repair. — —
Is action complete? Go to Step 9
Important: After repairs, the EGR ALM cells must be reset
9 (under special functions in scan tool). — —
Are the EGR ALM cells reset? Go to Step 10
1. Using the Scan tool, clear the DTCs.
2. Start the engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
10 which was set. —
4. Operate the vehicle, within the Conditions for Setting
this DTC, until the Scan Tool indicates the
diagnostic Ran.
Does the Scan tool indicate the diagnostic Passed? Go to Step 11 Go to Step 2
Does the Scan tool display any additional Go to the
11 undiagnosed DTCs? — Applicable
DTC Table System OK
|Hol In Run And Start]
PNK 539
PCM
Fuse Block
Details ■ G1 =32 BRN
Cell 11 0 2 = 2 4 BRN
PNK 539 C 3=32 BLU
C
“j Mass
, Air Flow
, (MAF)
■j Sensor
PNK 539 PNK 539 PNK 539
I 156 ' I
Solenoid Vent
r “ “
i Solenoid
.1
"G round
Distribution
Cell 14 YEL 492 GRY 435 WHT 257 YEL 258
PNK 539
PCM
Fuse Block
Details G1=32 BRN
Ceil 11 C2=24 BRN
PNK 539 C3 = 32 BLU
C
Mass
Air Flow
, (MAF)
J Sensor PNK 539 PNK 539 PNK 539
I L56 I
Ground
Distribution
Cell 14 YEL 492 GRY 435 WHT 257 YEL 258
—
5;
C16 D12 C3
3
C3a C1
BLK/
WHT 451 r Mass EGR EGR Vent Wastegate Powertrain
I Air Flow Solenoid Solenoid Solenoid Control
I Sensor Control Control Control Module (PCM)
185071
I Power “j'Underhood
. Distribution ENG 1 jFuse-Relay
Cell 10
L8S# Fuse 15 Center
20 A
A
i O B D Ilk
PNK 539
PCM
Fuse Block
Details Cl = 32 BRN
Cell 11 C2 = 24 BRN
PNK 539 C 3=32 BLU
C
Mass
Air Flow
I (MAF)
-» Sensor PNK 539 PNK 539 PNK 539
I L56 I
Solenoid Vent Bw
r“ “ Solenoid
i
i
Ground
Distribution
Cell 14 YEL 492 GRY 435 WHT 257 YEL 258
185071
PCM
C1 = 32 BRN
C 2=24 BRN
C3=32 BLU
ECT and
IAT Sensors
185023
DTC P0405 Exhaust Gas Recirculation (EGR) Position Sensor Circuit Low Voltage
Step Action Value(s) Yes No
GRY 416
................. . . . ......... 4
w
ECT and
IAT Sensors
BLK 452 LT GRN 432 BLK 452
BLK 452 -
GRY/BLK 433
185023
Refer to Emission Hose Routing Diagram Action Taken When the DTC Sets
Circuit Description • The PCM will shut down the EGR.
A EGR control pressure/baro sensor is used to • The PCM illuminates the malfunction indicator
monitor the amount of vacuum in the EGR circuit. It lamp (MIL) on the second consecutive drive
senses the actual vacuum in the EGR vacuum line and trip that the diagnostic runs and fails.
sends a signal back to the PCM. This signal is used • The PCM records the operating conditions at the
to control EGR duty cycle calculated by the PCM. This time the diagnostic fails. The first time the
is a type B DTC. diagnostic fails, the Failure Records will store this
information. If the diagnostic reports a failure
Conditions for Running the DTC on the second consecutive drive trip, the Freeze
• The PCM performs this DTC diagnostic Frame records the operating conditions at the time
continuously. of failure and updates the Failure Records.
• The ignition switch is in the ON position.
Conditions for Setting the DTC
• The EGR control pressure signal is greater
than 3.96 volts (85 kPa).
• All diagnostic set conditions met for 2 seconds.
Conditions for Clearing the MIL/DTC The Adaptive Learn Matrix (ALM) is used to adjust the
• The PCM will turn the MIL off after three EGR vacuum control based on mass air flow (MAF).
consecutive trips without a fault condition. The ALM may change as a result of back pressure
increases over the life of the vehicle or other engine
• A History DTC clears after forty consecutive
system variations. The ALM is made up of sixteen cells
warm-up cycles, if this or any other emission
related diagnostic does not report any failures (numbered from zero to fifteen) in which each cell
covers a range of engine speed (RPM) and
• The use of a scan tool. load (mm3).
Diagnostic Aids Test Description
With the ignition ON and the engine OFF, the manifold
pressure is equal to atmospheric pressure with the Number(s) below refer to the step number(s) on the
signal voltage being high. This information is used by Diagnostic Table.
the PCM as an indicator of vehicle altitude. If 2. This step will check for EGR Vent Solenoid DTC.
DTC P0406 is intermittent, refer to Symptoms.
3. This step determines if DTC P0406 is a hard
To run the diagnostic test the engine must be at the
failure or an intermittent condition.
operating temperature with the vehicle in drive at
idle for approximately 1 minute. Then, with the vehicle 4. This step simulates conditions for a DTC P0405. If
in park, hold engine rpm steady between 1500 and the PCM recognizes the change, the PCM and
2100 rpm for 30 seconds. If the diagnostic test fails to the signal circuit are OK.
run, the vehicle must be driven.
DTC P0406 Exhaust Gas Recirculation (EGR) Position Sensor Circuit High Voltage
Step Action Value(s) Yes No
Important: Before clearing any DTCs, use the scan tool
Capture Info to save freeze frame and failure records for Go to A
1 reference, as the Scan tool loses data when using the Powertrain On
—
Clear Info function. Board Diagnostic
Was the Powertrain On-Board Diagnostic (OBD) System (OBD) System
Check performed? Go to Step 2 Check
Is the DTC P1653 also set? Go to
DTC P1653 EGR
2 — Vent Solenoid
Control Circuit Go to Step 3
PCM
01=32 BRN
C2=24 BRN
C3=32 BLU
I Cruise Set/Coast
j Powertrain
. On/Off Request Accelerate ■ Control
Request Signal Request Module A
' Signal
Si9"al j (PCM) is ^ ,
185074
Cruise
Control
Switch
Fuse Block
ORN 140 BRN 441 Fuse Block
BRN ~ "P" uemim
Details < -------------- i i
Cell 11 441 Cell 11
PCM
C1=32 BRN
C2 = 24 BRN
C3 = 32 BLU
; Brake Switch
Assembly
A Stoplamp TCC/ABS/
\ Switch / Cruise
* Switch
A' C
WHT 17 PPL 420
PPL EBCM
Exterior Cell 44
Lights -- 4 PPL 420 420
Cell 110
PPL 420
WHT 17 I
PPL
420
EBCM
Cell 44
7 Clutch Pedal
Position (CPP)
Switch
D
BRN/WHT 379
WHT 17 PPL 420
BRN/WHT 379
B10 C2 B9 02 B9 C2
1 Powertrain
| Sto plamp Brake Brake/CPP
, Switch Switch Switch
^Control
Input Input input • Module Jk
J (PCM) jh A
185078
Conditions for Running the DTC Action Taken When the DTC Sets
• Brake switches disagree for 10 consecutive • The PCM disallows all cruise control inputs.
minutes. • TCC shift schedules may be affected.
or • The PCM will not illuminate the Malfunction
• TCC and cruise control brake switches are not Indicator Lamp (MIL).
toggling open and closed, during 6 brake • The PCM records the operating conditions at the
applications on the same ignition cycle. time the diagnostic fails. This information stores
in the Failure Records.
Conditions for Clearing the MIL/DTC Test Description
• A History DTC clears after forty consecutive Number(s) below refer to the step nurnber(s) on the
warm-up cycles, if this or any other emission Diagnostic Table.
related diagnostic does not report any failures
4. This test checks the feed circuit.
• The use of a scan tool.
6. This test simulates brake switch closed or
Diagnostic Aids brakes ON.
Refer to PCM Intermittent Diagnostic Trouble Codes
or Performance. Check customer driving habits and/or
unusual traffic conditions (i.e. stop and go, expressway
traffic).
1 Powertrain
APP 3 APP 1 APP 2 I .Control
5 Volt 5 Volt 5 Volt
5Voit 11 Module (PCM) I s A .
Reference Reference Reference
D3 D12TC1 C2 C3
185076
PNK 539
PCM
Fuse Block
Details 01=32 BRN
Cell 11 C2=24 BRN
PNK 539 C3=32 BLU
C
l Mass
1 Air Flow
i , (MAF)
EL = , _ mmm mmm mmm mmm j Sensor
PNK 539 PNK 539 PNK 539
I .156...... 1
______ J la A
185071
PCM
C1=32 BRN
C2-24BRN
C3 = 32 BLU
— -i Powertrain
j CKP Sensor i ~ ,
Sensor Ground C o n tro l
I Signal I Module £
L ____ — .
J (PCM) ja A
185025
4 E CM -B
G2Si Fuse
G2 20 A
Center
185026
• The engine coolant temperature is greater Conditions for Clearing the MIL/DTC
than 50°C (122°F). • A History DTC clears after forty consecutive
• The engine speed is greater than 1350 RPM. warm-up cycles, if this or any other emission
• The requested fuel rate is greater than 0.0 mm related diagnostic does not report any failures
• The use of a scan tool.
Diagnostic Aids An intermittent can be caused by the following:
Intermittent DTCs (P0251, P0370 and P1216) may be • Poor connections
caused by air entering the fuel system when fuel
• Rubbed through wire insulation
levels get below 1/8 of a tank while performing hard
acceleration or turning maneuvers. It’s also possible • Broken wire inside the insulation
that a P0251, P0370 and P1216 will set if the
vehicle has run out of fuel. Customer driving habits Test Description
should be checked to determine if the vehicle has been Numbers) below refer to the step number(s) on the
performing in these manners. If the vehicle has Diagnostic Table.
been performing in these conditions, bleed the fuel
system of all air and test drive the vehicle. 2. This step will determine if the ground circuit is
open which causes the vehicle not to start.
When the PCM is in backup fuel, fast idle and poor
performance problems will exist. If P0251 is also 3. This step will determine if the signal circuit is open
stored, the snap shot mode on the scan tool should or an injection pump (fuel solenoid) is at fault.
be used to properly identify the fault. DTCs P0335,
P1216, and P1217 may set along with this DTC.
If DTC P1216 is set with any other DTCs, diagnose
them first. If the vehicle is running close to the
DTC setting closure time, the vehicle should be
checked during cold start ups and during hot
conditions.
LT GRN 260
DK — -------------- -i 1
185026
LT GRN 280
DK
BLU/WHT 259 LT GRN 260 RED 313
LT GRN 260 BLK 491
DK
BLU/WHT 259
-o LT GRN 280 RED 313
DK DK LT GRN 260 BLK 491
BLU/WHT 259 BLU/WHT 259
D15 C15 D3 03 C3 C13 01 A1 02
. Engine Engine Fuel Fuel Closure Closure
■» Powertrain
1 Shut Off Shut Off Injectio n Injection Signal Ground 1Control
I Solenoid Solenoid Control Control 1Module >
| Control Control
J (PCM)
185026
Refer to Emission Hose Routing Diagram Conditions for Setting the DTC
Circuit Description • DTCs P0405, P0406, P0102 and P0103 not set.
The mass air flow (MAF) sensor measures the amount • All MAF and EGR control pressure test complete
of air entering the engine during a given time. The (internal to PCM).
PCM uses the mass air flow information to monitor • EGR in Closed Loop.
EGR f low rates. A large quantity of air entering • IAT greater than or equal to 20°C (68°F) and less
the engine indicates an acceleration, high load than or equal to 95°C (203°F).
situation or no EGR flow, while a small quantity of air
• Fuel rate between 10 and 25 mm3.
indicates deceleration, idle or full EGR situations.
• Engine RPM between 1500 and 2100.
The PCM will monitor MAF and EGR pressures
at different ranges to determine correct EGR • Engine speed stable.
flow rates. Conditions for Setting the DTC
• ALM cells not changed for greater than 2 seconds.
• Above conditions persist for at least 3 seconds.
Action Taken When the DTC Sets Diagnostic Aids
• The PCM illuminates the malfunction indicator A vacuum leak will cause a DTC P1406. Carefully
check all vacuum lines and components connected to
lamp (MIL) on the second consecutive drive
the hoses for leaks or deformities. Check the
trip the diagnostic runs and fails. vacuum source to the EGR solenoid assembly. Also
® The PCM records the operating conditions at the check for a small leak in the EGR valve, and
time the diagnostic fails. The first time the proper vacuum line routing. Vacuum line ends can be
diagnostic fails, the Failure Records store this trimmed to ensure a tight fit if length permits.
information. If the diagnostic reports a failure on To run the diagnostic test the engine must be at the
the second consecutive drive trip, the Freeze operating temperature with the vehicle in drive at
idle for approximately 1 minute. Then, with the vehicle
Frame records the operating conditions at the time
in park, hold engine rpm steady between 1500 and
of failure and updates the Failure Records.
2100 rpm for 30 seconds. If the diagnostic test fails to
Conditions for Clearing the MIL/DTC run, vehicle must be driven.
The Adaptive Learn Matrix (ALM) is used to adjust the
• The PCM will turn the MIL off after three EGR vacuum control based on mass air flow (MAF).
consecutive trips without a fault condition. The ALM may change as a result of back pressure
increases over the life of the vehicle or other engine
• A History DTC clears after forty consecutive
system variations. The ALM is made up of sixteen cells
warm-up cycles, if this or any other emission (numbered from zero to fifteen) in which each cell
related diagnostic does not report any failures covers a range of engine speed (RPM) and
• The use of a scan tool. load (mm3).
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Table.
3. Vacuum lines should be checked carefully for
proper fit and deformities.
I Power <—
’’ Underhood
, Distribution K7 L ENG 1 ! Fuse-Relay
Cell 10 p Fuse 15 i Center
I L8>
20 A
i
PNK 539
PCM
Fuse Block
Details G1 = 32 BRN
Cell 11 C2=24 BRN
PNK 539 C3 = 32 BLU
C
I Mass
I Air Flow
i (MAF)
L. — ----------- —. . Sensor PNK 539 PNK 539 PNK 539
[_L56..
AA
Exhaust Exhaust f Wastegate
BLK/ Gas Gas i Solenoid
WHT 451 Recirculation 1 Recirculation j
.r - _ Solenoid B Vent
I Solenoid
1
"Ground
Distribution
Cell 14 YEL 492 GRY 435 WHT 257 YEL 258
hJk
185071
192130
■* Powertrain ip
! Control Fuse
Block
j Module A w
PCM PCM Serial Data , (PCM) l a A
Ground Ground (Class II)
ORN 840
D7 D6 G3 C8YC3 Fuse Block
Details
Cell 11
PPL 1807
PCM
J"Serial Data"j Electronic -32 BRN
TAN/ BLK/WHT 451 =24 BRN
Ground , (Class ii) | Brake =32 BLU
WHT 551 Distribution
Cell 14
i i Control A
h --------- mm mm J ^ 0 ^ 0
G C1 (EBCM)
PPL 1807
BLK/WHT BLK/WHT - i EV0
451 451 Passlock
I B4T- J Module
1 BLK/WHT ORN 040
Ground PPL 1807
Distribution
Cell 14
Ground
Distribution ► ---- #■ 1807
Cell 14_____
BLK 150 r i Active Transfer
BLK/WHT 451
PPL 1807 |___ Jcase {ATC)
BLK 150 BLK 150 Control Module
4 •A------- - , 2J 18 . Data Link
Connector (DLC)
192130
1Powertrain IP
Control Fuse
Block
. Module Jk
PCM PCM Serial Data
T
I (PCM) i * A
Ground Ground (Class II)
ORN 840
“D7 ' ” ”
D6TC3 C8YC3 Fuse Block
Details
Cell 11
PPL 1807
PCM
Electronic
I Serial Data |
= 32 BRN
TAN/* BLK/WHT 451 Ground j (Class ii) jBrake A = 24 BRN
Distribution =32 BLU
WHT 551 i i Control A
Cell 14
Module AbSk
C1 (EBCM)
1807
----- - -a BLK/WHT BLK/WHT ! EVO
I Passlock
I
451 451
b Jy" J Module
A BLK/WHT ORN 840
Ground PPL 1807
Distribution
Cell 14
Ground
Distribution 1807
Cell 14
BLK 150
BLK/WHT 451 “ 1 Active Transfer
I ___]c ase (ATC)
BLK 150 BLK 150 Control Module
4 16 . Data Link
■M Connector (DLC)
192130
I Power * 6 ""IP
Distribution H 8 1^ GAGES Fuse
1 Cell 10 < Fuse 4 Block
i J?s' 10 A I
PNK 39
Fuse Block
1I _ _ _ Details PCM
Cell 11 01=32 BRN
PNK 39 G2=24 BRN
C3=32 BLU
22,
Instruments —f Malfunction
Cluster X SERVICE Indicator
Cell 81 { 1 ) THROTTLE ( j ) Lamp (MIL)
Y SOON y (SERVICE
I Lamp ENGINE SOON)
21 23
WHT/BLK 178 BRN/WHT 419
j
j
D11 C14 C3
Sen/ice Throttle MIL ' Powertrain
Soon Lamp Control 1 Control
I Control i Module (PCM)
185027
Conditions for Running the DTC An intermittent can be caused by the following:
The ignition switch in the ON position. • Poor connections
The voltage on MIL control circuit high (near battery • Broken wire inside the insulation
voltage) when the MIL is requested ON. Test Description
or
Number(s) below refer to the step number(s) on the
Voltage on M IL control circuit low (near 0 volts) when Diagnostic Table.
the MIL is requested OFF.
2. Be sure that both the ON and the OFF states are
Action Taken When the DTC Sets commanded. Repeat the commands as many
• The PCM will not illuminate the malfunction times as necessary.
indicator lamp (MIL). 9. If no trouble is found in the control circuit or the
• The PCM records the operating conditions at the connection at the PCM, the PCM maybe
time the diagnostic fails. This information is malfunctioning, however, this is an extremely
stored in the Failure Records. unlikely failure.
DTC P1641 MIL Control Circuit
Step Action Value(s) ■■ Yes No
Important; Before clearing any DTCs, use the scan tool
Capture Info to save freeze frame and failure records for Go to A
1 reference, as the Scan tool loses data when using the Powertrain On
—
Clear Info function. Board Diagnostic
Was the Powertrain On-Board Diagnostic (OBD) System (OBD) System
Check performed? Go to Step 2 Check
1. Start the engine and let the engine idle.
;2 2. Using a scan tool, command the lamp ON and OFF. —
Does the lamp turn ON and OFF with each command? Go to Step 3 Go to Step 4
The DTC is intermittent. If no additional DTCs are stored,
refer to Diagnostic Aids. If additional DTCs were stored Go to the
3 refer to those table(s). —
Applicable Go to
Are any additional DTCs stored? DTC table Diagnostic Aids
1. Turn the ignition OFF.
2. Disconnect the PCM connector containing the lamp
4 control circuit. —
3. Turn the ignition ON leaving the engine OFF.
Is the lamp OFF? Go to Step 5 Go to Step 7
1. Turn the ignition ON, leaving the engine OFF.
2. With a fused jumper wire connected to ground, probe
5 the lamp control circuit in the PCM harness
connector.
Is the lamp ON? Go to Step 6 Go to Step 8
1. Check for proper connections at PCM.
6 2. If a problem was found, repair as necessary. —
Was a repair performed? Go to Step 10 Go to Step 9
The MIL control circuit is shorted to ground, repair as
7 necessary. — —
Is the action complete? Go to Step 10
Check the MIL circuit for the following:
• Open ignition feed to the bulb.
8 • Malfunctioning bulb. — —
• Control circuit open or shorted to B+.
Is the repair complete? Go to Step 10
Replace the PCM.
Important: The new PCM must be programmed.
9 — ■ —
Refer to PCM Replacement/Programming.
Is the action complete? Go to Step 10
1. Using the Scan tool, clear the DTCs.
2. Start the engine and idle at normal operating
temperature.
3. Select DTC, Specific, then enter the DTC number
10 which was set. — ■
4. Operate the vehicle, within the Conditions for Setting
this DTC, until the Scan Tool indicates the
diagnostic Ran.
Does the Scan Tool indicate the diagnostic Passed? Go to Step 11 Go to Step 2
Does the Scan tool display any additional Go the Applicable
11 ■ ■—
undiagnosed DTCs? DTC Table System OK
DTC P1643 Wait to Start Lamp Control Circuit
Refer to Glow Plug Controls Conditions for Clearing the MIL/DTC
Circuit Description • The PCM will turn the MIL off after three
consecutive trips without a fault condition.
A dash light (Wait To Start) is illuminated by the PCM
when the glow plugs are commanded ON. When • A History DTC clears after forty consecutive
the PCM is commanding the Wait To Start lamp ON, warm-up cycles, if this or any other emission
the voltage potential of the circuit will be low (near related diagnostic does not report any failures
0 volts). When the PCM is commanding the Wait To • The use of a scan tool.
Start lamp OFF, the voltage potential of the circuit
will be high (near battery voltage). The primary function Diagnostic Aids
of the PCM is to supply the ground for the Wait To A faulty bulb or the control circuit shorted to ground
Start lamp circuit. will cause a P1643 to set.
I Power 4 - ■JUnderhood
. Distribution K7 *, eng 1 nFliS© — R e la y
, CelM0 lnr Ousels .Center
1 L8V 20 A
PNK 539
PCM
Fuse Block
Details C l = 32 BRN
Cell 11 C2 = 24 BRN
PNK 539 03 = 32 BLU
C
"J Mass
, Air Flow
, (MAF)
j Sensor PNK 539 PNK 539 PNK 539
[L 5 6 I
Ground
Distribution
Cell 14 YEL 492 GRY 435 WHT 257 ' YEL 258
AA
185071
Power ^ ^— i
1 IP
Distribution H8 ‘^ GAGES *Fuse
Cell 10 ( Fuse 4 1Block
J7 ' 10 A
I
PNK 39
Fuse Block
il ---- Details PCM
Cell 11 C1=32 BRN
PNK 39 C2=24 BRN
C3=32 BLU
22,k
1Instrument A
I Instruments— —r Malfunction 1Cluster ' AsA
^ . SERVICE
I
i
Cluster
Cell 81 0 THROTTLE
Indicator
( D Lamp (MIL)
y {SERVICE
Y SOON
i I Lamp ENGINE SOON)
21 23
WHT/BLK 176 BRN/WHT 419
D11 C14 C3
I Sen/ice Throttle MIL ^ Powertrain
Soon Lamp Control 1 Control
I Control I Module (PCM)
185027
I Power 4-
"jUnderhood
. Distributio n K7 ! Fuse —Relay
Cell 10 Center
I L8'
L— _______—
PNK 539
PCM
Fuse Block
Details G1 =32 BRN
Cell 11 G2=24 BRN
PNK 539 03=32 BLU
c
’ Mass
i Air Flow
, (MAF)
tm mmm mmm mmm <=. mmm- mmm mj Sensor
PNK 539 PNK 539 PNK 539
I 156 1
j,
Exhaust Exhaust t Wastegate
BLK/ Gas j Gas j Solenoid
WHT 451 Recirculation Recirculation 1
V
r - -
, Bs Solenoid Vent
i Solenoid
1 .
Ground
Distribution
Cell 14 YEL 492 GRY 435 WHT 257 YEL 258
185071
Ground
Distribution 1807
Cell 14
BLK 150
BLK/WHT 451 r Active Transfer
PPL 1807 |__ _ J Case (ATC)
BLK 150 BLK 150 Control Module
4 16 . Data Link
Connector (DLC)
192130
G C1 (EBCM)
PPL 1807
BLK/WHT
------- BLK/WHT ii
-------« .................
-- -#■ Passlock
I 451 451 PPL 1807 n r
04V Module
1 BLK/WHT ORN 840
Ground PPL 1807
Distribution
Cell 14
Ground
Distribution 1807
Cell 14
BLK 150 r ^ctjve j ransfer
BLK/WHT 451
PPL 1807 L _ J Case (ATC)
BLK 150 BLK 150 Control Module
4 2J 16 , Data Link
Connector (DLC)
192130
Surges/Chuggles
ecks Action
Definition: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if it speeds up and slows
down with no change in the accelerator pedal.
Preliminary Checks • Refer to Symptoms.
• Be sure the driver understands the torque converter clutch (TCC) operation.
• Be sure the driver understands the A/C compressor operation.
• Use the scan tool in order to make sure the VSS reading matches the vehicle
speedometer. This excludes vehicles with electronic transmissions where some
variation between VSS and the speedometer is normal. Refer to DTC P0501
Vehicle Speed Sensor (VSS) Circuit Performance DTC P0501 Diagnostic Aid?
Fuel System Checks Check the fuel pressure while the condition exists. Refer to Fuel Supply
System Check,
Additional Checks • Check the control module grounds for being clean, tight, and in their proper
locations.
• Check the generator output voltage. Repair if less than 9 or more than 16 volts.
• Check the vacuum lines for kinks or leaks.
• Check the TCC operation.
Lack of Power, Sluggishness, or Sponginess
Checks Action
Definition: The engine delivers less than expected power. There is little or no increase in speed when partially applying the
accelerator pedal.
Preliminary Checks • Refer to Symptoms.
• Compare the vehicle with a similar unit. Make sure the vehicle has an actual
problem.
• Remove the air filter and check for dirt, or for air ducts being plugged. Replace
as necessary.
• Check for a proper transmission shift pattern and down shift operation.
• Check the fuel quality. Refer to Specific Gravity Testing.
• Check the engine oil level and quality.
Fuel System Checks • Check the fuel supply to the injection pump and the fuel return from the injection
pump. Refer to Fuel Supply System Check.
• Check the fuel pump operation.
• Check for malfunctioning fuel injection nozzles.
• Check the TDC Offset value. Refer to TDC Offset Adjustment
Exhaust System Checks • Check the exhaust system for a possible restriction. Refer to Restricted Exhaust
System Check.
• Inspect the exhaust system for leaks.
Air Intake System Checks • Check for an air leak or restriction in the air inlet ducts or the intake manifold.
• Check for a worn or damaged turbo charger turbine wheel, shaft or
compressor wheel.
Engine Mechanical Check Check the engine for the following:
• Low compression
• Improper valve timing
• Improper or worn camshaft
Additional Checks • Check the control module grounds for being clean, tight, and in their proper
location. Refer to Engine Controls Components.
• Check the torque converter clutch (TCC) operation.
• Check the A/C operation. Refer to A/C Request Circuit Diagnosis.
• Check the generator output voltage. Repair if less than 9 volts or more
than 16 volts.
Excessive Smoke
Checks Action
Definition: White, black, gray or blue smoke under load, idle or start up hot or cold.
Preliminary Check • Refer to Symptoms.
• Make sure the customer has an actual problem.
• Check the fuel quality. Refer to Specific Gravity Testing.
Fuel System Checks • Check the injection pump.
• Check the injection pump timing. Refer to Injection Timing Adjustment
• Check the injection nozzles. Refer to Injection Nozzle(s) Diagnosis.
Sensor Check • Check the engine coolant temperature (ECT) sensor. Use the scan tool in order
to compare the engine coolant temperature with the ambient air temperature on
a cold engine. If the coolant temperature reading is more than 5° greater or less
than the ambient air temperature on a cold engine, check for a high resistance
in the coolant sensor circuit or the sensor itself.
• Check the glow plug system operation. Refer to Glow Plug System Check.
Air Intake System Check • Check the air cleaner and the air intake ducts for restriction.
• Check for a restriction in the turbocharger inlet duct.
• Check for a restriction in the intake manifold.
Engine Mechanical Check • Check for incorrect basic engine parts such as the cam, the heads, the
pistons, etc.
• Check for excessive oil entering the combustion chamber.
R estricted Exhaust System Check A/C Request Circuit Diagnosis
Refer to A/C Controls.
Diagnostic Aids
Proper diagnosis for a restricted exhaust system is Circuit Description
essential before any components are rep l aced. Turning O N the air conditioning supplies ignition
The following procedure may be used for diagnosis: voltage to the A/C compressor clutch and to the PCM
to increase and maintain idle speed.
1, Inspect the entire exhaust system for a collapsed
pipe, heat distress, or a possible internal muffler The PCM does not control the A/C compressor clutch.
failure. Therefore, if the A/C system does not function,
refer to A/C Systems of the appropriate service manual
2. If there are no obvious reasons for the excessive for diagnosis of the system.
backpressure, the catalytic converter is suspected
to be restricted and should be replaced using
current recommended procedures. Refer to
Engine Exhaust.
Hot In Run And Start
PCM
Cl =32 BRN
02 = 24 BRN
C3 = 32 BLU
I Cruise Set/Coast
Powertrain
. On/Off Request Accelerate j Control
Request Signal Request , Module A
1 Signal Signal
I (PCM) l l l A
185074
Circuit Description Other conditions that will not allow the cruise control
The cruise control multi function lever is wired directly to engage that do not pertain to the cruise system.
to the PCM. The cruise on/off, set/coast and • The vehicle speed is below 25 MPH (if the
resume/accel signals are inputs to the fuel control cruise control is already set, the cruise will
portion of the PCM. These inputs allow the PCM to disengage at 20 MPH).
control and hold a requested speed. The cruise can be • The vehicle is in 4 wheel drive low.
disengaged at any time by applying the brakes. This
• Any DTC that puts the vehicle in Back Up Fuel
input is sent to the PCM by the cruise control
Mode (Back Up Fuel Mode affects the fuel
brake switch.
control portion of the PCM). Refer to the
Diagnostic Aids appropriate DTC.
If the cruise is inoperative, and no cruise control or • More than one accelerator pedal position (APP)
brake switch DTCs are stored, check for the following DTC is set.
conditions:
• A malfunctioning cruise multi function switch/
Test Description
wiring harness (opens or ma lfunctioning Number(s) below refer to step number(s) on the
connections). Diagnostic Table.
• The clutch pedal switch is stuck in the open 3. This step checks for ignition voltage to the cruise
position. control switch.
Cruise Control Diagnosis
Step Action Value(s) Yes No
Was the Powertrain On-Board Diagnostic (OBD) System Go to A
Check performed? Powertrain On
1 — Board Diagnostic
(OBD) System
Go to Step 2 Check
Are DTCs P0501, P0567, P0568, or P0571 set? Go to the
2 — Applicable
DTC Table Go to Step 3
1. Disconnect the cruise control switch connector
located on the LH side of the steering column near
the bulkhead.
2. Turn the ignition ON, leaving the engine OFF.
3 —
3. With the test light connected to ground, probe the
ignition feed circuit at the cruise control switch
harness connector.
Is the test light ON? Go to Step 4 Go to Step 13
1. Reconnect the cruise control switch connector.
2. Turn the ignition ON, leaving the engine OFF.
4 3. Using the scan tool, monitor the cruise switch while
cycling the cruise control ON/OFF switch.
Does the scan tool indicate the cruise switch is turning ON
and OFF? Go to Step 5 Go to Step 7
1. Turn the ignition ON, leaving the engine OFF.
2. Using the scan tool, monitor the set switch while
5 cycling the cruise control set/coast switch. —
Does the scan tool indicate the set switch is turning ON
and OFF? Go to Step 6 Go to Step 9
1. Turn the ignition ON, leaving the engine OFF.
2. Using the scan tool, monitor the resume switch while
6 cycling the cruise control resume/accelerate switch. —
Does the scan tool indicate the resume switch is turning
ON and OFF? Go to Step 21 Go to Step 11
1. Using a test light connected to ground, probe the
cruise ON/OFF request signal circuit at the PCM.
7 2. With the ignition still in the run position, cycle the —
cruise control ON/OFF switch.
Does the test light turn ON and OFF with each cruise
control ON/OFF switch cycle? Go to Step 19 Go to Step 8
1. Disconnect the cruise control switch connector.
2. Using a test light connected to ground, probe the
cruise ON/OFF request signal circuit.
8 3. With the ignition still in the Run position, cycle the —
cruise control ON/OFF switch.
Does the test light turn ON and OFF with each cruise
control ON/OFF switch cycle? Go to Step 15 Go to Step 18
1. Using a test light connected to ground, probe the
set/coast request signal circuit at the PCM.
9 2. With the ignition still in the Run position, cycle the —
cruise control set/coast switch.
Does the test light turn ON and OFF with each cruise
control set/coast switch cycle? Go to Step 19 Go to Step 10
Cruise Control Diagnosis (cont’d)
Step ction Value(s> Yes No
1. Disconnect the cruise control switch connector.
2. Using a test light connected to ground, probe the
cruise set/coast request signal circuit.
10 3. With the ignition still in the Run position, cycle the —
cruise control set/coast switch.
Does the test light turn ON and OFF with each cruise
control set/coast switch cycle? Go to Step 16 Go to Step 18
1. Using a test light connected to ground, probe the
resume/accelerate request signal circuit at the PCM.
11 2. With the ignition still in the Run position, cycle the —
cruise control resume/accelerate switch.
Does the test light turn ON and OFF with each cruise
control resume/accelerate switch cycle? Go to Step 19 Go to Step 12
1. Disconnect the cruise control switch connector.
2. Using a test light connected to ground, probe the
cruise resume/accelerate request signal circuit. .
12 3. With the ignition still in the Run position, cycle the —
cruise control resume/accelerate switch.
Does the test light turn ON and OFF with each cruise
control resume/accelerate switch cycle? GoJo Step 17 Go to Step 18
1. Check for a proper connection at the cruise control
switch harness connector.
13 2. If a problem is found, repair the problem as — "
necessary.
Was a problem found? Go to Step 21 t-o to Step., 14
Repair the open in the ignition feed circuit.
14 '—
Is the action complete? Go to Step 21
Repair the open or short to ground in the cruise ON/OFF
15 request signal circuit. "— —
Is the action complete? Go to Step 21
Repair the open or short to ground in the cruise set/coast
18 request signal circuit. —
Is the action complete? ■ Go to Step 21
Repair the open or short to ground in the cruise
17 resume/accelerate request signal circuit. — —
Is the action complete? Go to Step 21
Replace the cruise control switch.
18 ; —• —
Is the action complete? - Go to Step 21
1. Check for a proper connection at the PCM.
19 2. If a problem is found, repair the problem as ; _
necessary.
Was a problem found? Go to Step 21 Go to Step 20
Replace the PCM.
Important: The new PCM must be programmed. Refer to
■ 20-
PCM Replacement/Programming. — . —
Is the action complete? Go to Step 21
Operate the vehicle within the conditions under which the
21 original problem was noted. ■. —
Does the system operate properly? -System OK Go to Step 1
Fuel Tank Leak Check It is permissible to have biocide in the fuel when
starting to tow, but do not add any biocide while
The diagnosis of fuel odor may be a condition of
towing.
leaking fuel tank, filler neck or filler cap. A defective
filler cap, a plugged or pinched vent pipe can cause a Steam cleaning may be necessary if most of the
collapsed fuel tank. Loose mounting straps or fungus growth cannot be removed with biocides.
foreign material in tank may be the cause of a rattle at The presence of water or gasoline in diesel fuel may
the fuel tank. also cause injection pump and nozzle damage.
Leak Check Procedure This procedure checks for the presence of water and
gasoline in diesel fuel that may cause injection
C a u tio n : P la c e a d ry c h e m ic a l (C la s s B ) fir e pump and nozzle damage.
e x tin g u is h e r n e a r th e a re a b e fo re p e r fo r m in g a
Remove the fuel filter element and inspect it.
F u e l T a n k L e a k C h e c k . B e fo re re m o v in g th e
fu e l ta n k f o r a s u s p e c te d le a k , m a k e s u re th a t th e • If water, gasoline or fungi/bacteria are not present,
fu e l p ip e s o r th e tu b e s a r e n o t le a k in g o n to th e end the inspection.
ta n k . O n c e re m o v e d , m a k e s u re th a t th e fu e l is n o t • If water or fungi/bacteria are present, Go to
le a k in g a r o u n d th e fu e l s e n d e r O -rin g . F a ilu re to Cleaning Water from the Fuel System.
fo llo w th e s e p re c a u tio n s m a y r e s u lt in p e r s o n a l • If gasoline is present, Go to Cleaning Gasoline
in ju ry . from the Fuel System.
This check requires the fuel sender and the o-ring to
be installed. Cleaning Water from the Fuel System
1. Disconnect the battery cables. 1. Disconnect the batteries.
2. Drain the fuel tank (refer to F u e l T a n k D ra in in g 2. Drain the fuel tank.
P ro c e d u re . 3. Remove the fuel tank (Refer to Fuel Tank
3. Remove the fuel tank (refer to Fuel Tank Replacement).
Replacement). 4. Remove the fuel sender unit (Refer to Fuel
4. Cap the fuel feed tube and the fuel return tube on Sender Assembly Replacement).
the fuel sender. 5. Inspect the fuel tank and the fuel sender for rust,
5. Connect a piece of hose to the filler tube nipple fungi or bacteria.
and plug the opposite end. 6. Clean the inside of the fuel tank and the fuel
6. Submerge the tank in water or apply a soap sender with hot water.
solution to the outside of the tank. 7. Use compressed air in order to dry the fuel tank
7. Apply 35 kPa (5 psi) of air pressure to the vent and the fuel sender.
hose of the fuel tank (a leak will show up as 8. Disconnect the ends of the following lines:
bubbles). • The lift pump suction line
• The lift pump feed line
Contamination Testing • The fuel filter outlet line
Fungi and 6ther microorganisms can survive and • The fuel filter drain line
multiply in diesel fuel if water is present. The fungi can
• The fuel return line
be present in any part of the fuel handling system.
These fungi grow into long strings and will form 9. Inspect each of the pipes.
into large globules. The growths appear slimy and are 10. Replace any rusted pipes.
usually black, green, or brown. The fungi may grow 11. Clean the inside of the fuel filter housing.
anywhere in the fuel but are most plentiful where diesel 12. Dry the fuel filter housing with compressed air.
fuel and water meet. As the fuel is agitated (when
service station tanks are being filled), fungi are 13. Dry the inside of each line with low pressure air.
distributed throughout the tank and may be pumped 14. Remove the ECM 1 fuse from the underhood
into a vehicle. relay center.
Fungi use the fuel as their main energy supply and 15. Install a new fuel filter element.
need only trace amounts of water and minerals. 16. Install the fuel sender and the fuel tank (add clean
As they grow and multiply, they change fuel into water, diesel fuel to Va full).
sludge, acids, and products of metabolism. The 17. Reconnect the following lines:
most common symptom is fuel filter plugging; however,
• The lift pump suction (both ends) lines.
various metal components (fuel tank, pipes, and
injection pump) can corrode. • The lift pump feed (both ends) lines.
C a u tio n : A v o id p h y s ic a l c o n ta c t w ith th e b io c id e s
• The fuel filter drain line.
in o r d e r to a v o id p e r s o n a l in ju ry . • The fuel return (at the injection pump) line.
If fungi have caused fuel system contamination, use a 18. Connect the fuel filter outlet and the fuel return
diesel fuel biocide to sterilize the fuel system. Do line at the fuel sender to the hoses that flow to
not exceed the dosage recommended on the label. the metal containers.
Discontinue the use of a biocide when towing a trailer. 19. Connect the batteries.
20. Use the scan tool in order to command the lift warm or hot climates may result in stalling, poor
pump ON. starting when the engine is hot and may damage the
21. Operate the lift pump until clean fuel flows from fuel injection system.
the fuel filter outlet into a metal container.
Specific Gravity Testing
22 . Connect the hose from the fuel filter outlet to the
injection pump inlet. The fuel quality hydrometer provides a general
indication of fuel quality and should not be considered
23. Open each injection line at its nozzle end and scientifically accurate.
crank the engine until clean fuel flows from it.
• Use two wrenches when loosening the injection Fuel Oil Specific Gravity Requirements
line fittings.
Number Number
• Allow a maximum of 15 seconds cranking — 2-Diesel 1-Diesel Tool
time, followed by 1 minute of cranking API Gravity 30 - 39 39 - 44 J 38641 B
motor cooling time.
24. Tighten each injection line fitting at its nozzle. Use
1. Drain the fuel filter housing by following the
two wrenches when tightening the injection line
steps below:
fittings.
1.1. Stop the engine.
25. Install the ECM 1 fuse in the underhood relay
1.2. Place a container under the water drain
center.
valve exit hose at the left front side of the
26. Start and run the engine for 1 minute while the engine.
fuel flows from the fuel return line into a metal
1.3. Open the drain valve.
container.
1.4. Use a scan tool and command the fuel lift
27. Stop the engine. pump ON.
28. Connect the fuel return hose to the fuel sender. 1.5. Fill a 1 liter (0.946 quart) container with a
29. Clean any fuel spillage from the engine. sample of fuel.
30. Fill the fuel tank and add a biocide, if needed. 1.6. Close the drain valve.
2. Obtain a fuel quality hydrometer (J 38641-B).
Cleaning Gasoline from the Fuel System
3. Fill the hydrometer with the fuel sample by doing
1. Drain the fuel tank. the following:
2. Fill the fuel tank. 3.1. Squeeze the hydrometer bulb.
3. Remove the ECM 1 fuse from the underhood 3.2. Submerse the hydrometer tip into the
relay center. sample.
4. Remove the fuel filter outlet and connect it.to a 3.3. Release the bulb, allowing fuel to enter the
hose that flows to a metal container. glass tube until it completely floats the
5. Use a scan tool and command the lift pump ON glass bulb inside the tube.
until c lean fuel flows from the fuel filter outlet into 3.4. Gently spin the hydrometer to relieve the
a metal container. surface tension of the fuel sample. Read
6. Connect the hose from the fuel filter outlet to the the scale on the glass bulb at the point
injection pump inlet. where the top of the fuel sample contacts it.
By reading this value, it will give an
7. Install the ECM 1 fuse into the underhood relay approximate fuel oil specific gravity. Refer
center.
to tool instructions on how to determine API
8. Attempt to start and run the engine for 15 minutes Gravity.
(If engine does not start, purge the injection 4. Refer to Fuel Oil Specific Gravity Requirements
system). table. If the correct fuel is being used in the
9. Stop the engine. conditions listed in Fuel Quality, and meets
10. Clean any fuel spillage from the engine. number 1-Diesel or number 2-Diesel fuel oil
specific gravity requirements, fuel is OK. If not,
11. Clear the engine of any DTCs. the fuel should be replaced.
185075
Circuit Description The solid state water in fuel sensor supplies voltage to
The fuel manager/filter assembly consists of the fuel a probe. When the probe touches water, the module
heater, the water in fuel sensor and a filter. The closes a switch. This completes a circuit to ground
filter contains the coalescer (the device that combines to light the water In fuel lamp.
small droplets of water into larger ones) and the A time delay circuit in the water in fuel module
filter/separator. grounds the lamp briefly to test the bulb each time the
A fuel lift pump delivers diesel fuel from the tank to system is turned ON.
the fuel filter. As fuel enters the filter, it passes The fuel heater is operated by a built-in thermostatic
first through the fuel heater. The heater contains a
switch. The thermostatic switch completes the
thermostatic switch. The switch opens or closes to turn
circuit for the fuel heater element when it senses a
the heater OFF or ON, depending on the temperature
temperature below 8°C (46°F).
of the fuel.
The fuel then passes through the filter. Next the fuel Test Description
flows through the water coalescer. Here the droplets of
2. This step checks for a fuel heater that is ick ON.
water in the fuel combine into larger drops and fall
into the water reservoir in the filter. When fuel 3. This step checks for a thermostatic switch that
flows from the fuel manager/filter assembly to the completes the circuit.
injection pump, the fuel is clean and free of water.
Fuel Heater Functional Diagnosis
Step Action... Value(s) Yes No
Is the Water In Fuel lamp operating properly? Go to
1 Water-in-Fuel
—
Lamp Circuit
Go to Step 2 Diagnosis
1. Disconnect the fuel heater connector and remove the
fuel heater from the filter housing.
2. With the fuel heater at room temperature, connect
2 terminal C of the fuel heater to B+ and connect ' _
terminal A of the fuel heater to ground.
3. Observe the heater element.
Does heat occur? Go to Step 4 Go to Step 3
1. Cool the sensor part of the fuel heater with ice.
2. With the fuel heater below 8°C (46°F), wet the
heating element with fuel.
3 3. Connect terminal C of the fuel heater to B+ and —
connect terminal A of the fuel heater to ground.
4. Observe the heating element.
Does heat occur? Go to Step 5 Go to Step 4
Replace the fuel heater. Refer to Fuel Heater
4 Replacement — _
Is the action complete? Go to Step 5
Operate the vehicle under which the problem was noted.
5 ■—
Does the system operate properly? System OK 9? to Step -
PCM
= 32 BRN
= 2 4 BRN
= 32 BLU
185075
Circuit Description The solid state water in fuel sensor supplies voltage to
The fuel manager/filter assembly consists of the fuel a probe. When the probe touches water, the module
heater, the water in fuel sensor and a filter. The closes a switch. This completes a circuit to ground
filter contains the coalescer (the device that combines to light the water In fuel lamp.
small droplets of water into larger ones) and the A time delay circuit in the water in fuel module
filter/separator. grounds the lamp briefly to test the bulb each time the
A fuel lift pump delivers diesel fuel from the tank to system is turned ON.
the fuel filter. As fuel enters the filter, it passes The fuel heater is operated by a built-in thermostatic
first through the fuel heater. The heater contains a switch. When the switch is closed, battery voltage
thermostatic switch. The switch opens or closes to turn is supplied to the heater.
the heater O FF or ON, depending on the temperature
of the fuel. Test Description
The fuel then passes through the filter. Next the fuel 2. This step will determine if the ignition feed circuit
flows through the water coalescer. Here the droplets of is open.
water in the fuel combine into larger drops and fall
3. This step will determine if the ground circuit is OK.
into the water reservoir in the filter. When fuel
flows from the fuel manager/filter assembly to the 4. This step will determine if the fuse, bulb, and
injection pump, the fuel is clean and free of water. wiring are O K.
Water-in-Fuel Lamp Circuit Diagnosis
Step Action Vaiue(s) Yes No
Turn the ignition ON leaving the engine OFF.
1 Does the water in fuel light come ON briefly and then
turn off? Go to Step 5 Go to Step 2
1. Disconnect the water in fuel sensor.
2. With an J 34142-B unpowered test lamp connected to
2 ground, probe terminal A. —
3. Verify the ignition is ON with the engine OFF.
Is the test light ON? Go to Step 3 Go to Step 6
With an J 34142-B unpowered test lamp, jumper the
3 harness terminals A and C with the ignition still ON.
Is the test light ON? Go to Step 4 Go to Step 8
With an J 34142-B unpowered test lamp connected to
4 ground, probe terminal B of the harness connector. '—
Is the test light ON? Go to Step 11 Go to Step 10
Operate the vehicle under which the original problem by
5 the customer was noted. —
Does the system operate properly? System OK Go to Step 2
1. Check the ignition feed circuit for an open.
6 2. If a problem is found, repair the problem as —
necessary.
Did you find a problem? Go to Step 12 Go to Step 7
1. Check for a proper ignition feed connection at the
sensor.
7 2. If a problem is found, repair the problem as ■—
necessary. Refer to Wiring Repairs in Wiring
Systems.
Did you perform a repair? Go to Step 12 Go to Step 11
1. Check the ground circuit for an open.
2. If a problem is found, repair the problem as
8 necessary. Refer to Wiring Repairs in Wiring
Systems.
Did you perform a repair? Go to Step 12 Go to Step 9
1. Check for a proper ground circuit connection at the
sensor.
9 2. If a problem is found, repair the problem as
necessary. Refer to Wiring Repairs in Wiring
Systems.
Did you perform a repair? Go to Step 12 Go to Step 11
Repair the open in the lamp circuit. Refer to Wiring
10 Repairs in Wiring Systems. — —
Is the action complete? Go to Step 12
Replace the water in fuel sensor. Refer to Water-in-Fuel
11 Sensor Replacement. — —
Is the action complete? Go to Step 12
Operate the vehicle under which the original problem
12 was noted. —
Does the system operate properly? System OK Go to Step 1
Fuel Injection System Diagnosis Nozzle Opening Pressure Test
Always begin diagnosis of the electronic fuel injection Caution: Do not place your hands or arms near
system with ..the On-Board Diagnostic (OBD) System the tip of the nozzle when testing the nozzles. The
Check before proceeding to any other diagnostics. This high pressure atomized fuel spray from a nozzle
will reduce diagnosis time and prevent unnecessary has sufficient penetrating power to puncture flesh
repl acement of parts. The On-Board Diagnostic (OBD) and destroy tissue. This may result in blood
System Check will give direction to further diagnostics, poisoning. Always enclose the nozzle tip in a
such, as Engine Cranks But Will Not Run or a receptacle, preferably transparent, in order
DTC Table. Diagnosis of electronic fuel injection pump, to contain the spray.
including the fuelinjection solenoid, fuel solenoid
Important: Injector Nozzle Opening Pressure and
driver, injection timing stepper motor and engine
Leakage tests should only be performed on vehicles
shutoff solenoid also starts with the On-Board
with high mileage, engines that have been over heated
Diagnostic (OBD) System Check,
or on vehicles .that pull heavy loads. False or
If a driveabil ity symptom exists, refer to the particular inaccurate readings can occur if the following tests are
symptom in the Driveability Symptoms. not performed to the above criteria.
Damage to the injection lines including kinking that
Important: Each test should be considered
causes restrictions or leakage could effect driveability
independent of the others (for example, when checking
or cause a DTC <to-set.
opening pressure, do not check for leakage). If all of
Fuel Pipes and Hoses the following tests are satisfied, the nozzle assembly ■
The diagnosis of fuel odor may be a condition of a
can be reused. If any one of the tests is not
satisfied, the complete nozzle assembly must be
leaking fuel-feed, return pipe or hose. Fuel pipes that
replaced. When performing the injection nozzle tests,
are pinched, plugged, or misrouted may cause
refer to the instructions provided with the nozzle
restricted fuel delivery.
tester J 29075-B.
Injection Nozzle(s) Diagnosis • Position a nozzle tester on a workbench.
• Install one nozzle on the tester fitting.
If an injection nozzle is not properly delivering fuel into
the pre-combustion chamber of a cylinder, driveability • Place a container under the nozzle that will deflect
could be greatly effected, or a DTC could be set. the nozzle spray and absorb the test fluid.
If other diagnosis indicates, or if the injection nozzles • Install two clear plastic hoses (1 in. long) over the
are suspected of not properly delivering fuel, they leak-off fittings.
should be tested. Typically, a nozzle failure can • Close the shutoff valve at the pressure gauge.
be detected by using the injector balance test.
• Operate the lever of the nozzle tester repeatedly
Nozzle testing is comprised of the following checks: and briskly to fill and flush the nozzle with
• Injector Balance test (performed with scan tool). test oil.
• Nozzle opening pressure (see Important 1. Open the shutoff valve at the pressure gage
statement). one-quarter turn.
• Leakage (see Important statement). 2. Depress the tester lever slowly. Note at what
pressure the needle of the pressure gage
Injector Balance Test stopped. The maximum observed pressure is the
An injector balance test is performed with the scan opening pressure. Some nozzles may pop
tool. This test will properly identify a stuck closed while other nozzles may drip down (this is not
or noisy injector nozzle. Typically, a nozzle failure will leakage).
fall into this criteria. 3. The opening pressure should not fall below the
1. Install a scan tool. lower limit of 105 bar (1500 psi) for naturally
2. Start and idle the engine. aspirated engines and 117 bar (1700 psi)
for turbo-charged engines for used nozzles.
3. Perform the injector balance test on each cylinder
(balance test refer to a specific cylinder). 4. Replace nozzles which fall below the lower limit.
If a suspect nozzle has been located, the nozzle
can be swapped with the adjacent cylinder
and balance test can be repeated as a check to
positively identify a malfunctioning nozzle.
4. Locate and replace the malfunctioning nozzle and
glow plug.
Nozzle Leak Test Fuel Return System Diagnosis
Caution: When testing nozzles, do not place your Any restriction in the fuel return system could greatly
hands or arms near the tip of the nozzle. The effect driveability. If other diagnosis indicates or
high pressure atomized fuel spray from a nozzle the fuel return system is suspected of being restricted,
has sufficient penetrating power to puncture flesh it should be tested.
and destroy tissue and may result in blood 1. Disconnect the hose of the fuel return line at the
poisoning. The nozzle tip should always be fuel sender.
enclosed in a receptacle, preferably transparent, to
contain the spray. 2. Disconnect the hose of the fuel return line at the
injection pump, and connect a vacuum pump with
Important: Injector Nozzle Opening Pressure and gauge to the hose.
Leakage tests should only be performed on nozzles 3. Apply vacuum to the return line and observe the
with high mileage, engines that have been over heated gage reading
or on vehicles that pull heavy loads. False or
inaccurate readings can occur if the following test are • If vacuum does not build and hold, Go to
not performed to the above criteria. Step 4.
1. Open the shutoff valve at the pressure gage • If vacuum builds and holds, repair the return
(1 turn). line restriction.
2. Blow dry the nozzle tip. 4. Connect the fuel return line at the injection pump
and fuel sender.
3. Depress the lever of the manual test stand slowly
until the gage reads a pressure of 95 bar 5. Clean any fuel spillage.
(1400 psi). Observe the nozzle tip. A drop may 6. Run the engine to check for fuel leakage.
form on the end of the nozzle but should not drop
off within a period of 10 seconds.
4. Replace the nozzle assembly if a drop fails during
the 10 seconds.
Glow Plug System Check
Refer to Glow Plug Controls. failures are covered by DTC P0380. If no DTCs are
stored, the vehicle is hard to start and white smoke is
Circuit Description present during cranking or after the vehicle is
The glow plug system is used to assist in providing started, the most likely cause of failure is the
the heat required to begin combustion during engine glow plugs.
starting at cold ambient temperatures. The glow
plugs are heated before and during cranking, as well Test Description
as during the engine operation. The PCM controls Number(s) below refer to the number(s) on the
the glow plug ON times by monitoring coolant
diagnostic table.
temperatures and glow plug voltage. This system
check will check the glow plugs and the glow plug feed 1. This step will make sure OBD system check is
circuit coming from the relay. performed.
Diagnostic Aids 2. This step will make sure there are no other DTCs
If the glow plug relay is stuck in the ON position, stored that will affect the operation of the glow
check for proper operation of the glow plugs. When plug system.
the glow plugs are commanded ON by the scan 3. This step will check each glow plug for an open.
tool, an internal PCM timer protects the glow plugs
from damage by cycling them ON for 3 seconds and 4. This step will check each glow plug feed circuit for
then OFF for 12 seconds. Most glow plug system an open.
26961
PCM Programming
1. Verify the following for the setup:
• The battery is charged.
• The ignition is ON.
• The battery/cig. lighter connection is secure.
• The Data Link Connector is attached.
2. Perform the programming. Refer to the up to date
Techline terminal/equipment for user instructions.
3. Perform the Passlock Learn Procedure. Refer to
Password Learn Procedure.
4. After the vehicle has been programmed, operate 4. Disconnect the Tech 2 from the vehicle and
the vehicle until the coolant temperature is greater connect the Tech 2 to a Techline terminal.
than 77°C (170°F). This will allow the TDC 5. At the Techline terminal, select Service
Offset to be programmed (refer to Programming Programming System (SPS), select the Terminal
the TDC Offset). to Scan Tool Programming method and then
5. Check the Data list for TDC Offset. select Done.
6. If the PCM fails to reprogram, do the following: 6. Follow the instructions on the remaining screens.
• Check all the PCM connections. 7. Select Vehicle Theft Re-learn.
• Check the Techline terminal/equipment for the 8. Select Program at the summary screen. The
latest software version. terminal will download the information to the
• Try again to reprogram the PCM. If it fails Tech 2.
again, replace the PCM. Refer to PCM 9. Return the Tech 2 to the vehicle and connect the
replacement. Tech 2 to the Diagnostic Link Connector (DLC).
Programming the TDC Offset 10. Select Service Programming from the Tech 2 main
The PCM will automatically activate the TDC Offset menu. Answer the prompts regarding the model
program when the engine coolant is greater than 77°C year and vehicle type. Press the Theft Re-learn
(170°F). If the PCM is not programmed with a TDC soft key on the Tech 2.
Offset, a DTC P1214 will set. 11. Follow the instructions on the remaining screens.
• The PCM and the Passlock control module will
Password Learn Procedure prepare for re-leam.
• A security timer will be on for approximately
Passlock Learn Procedure Using a 10 minutes or until DTC P1630 sets.
T50/T60/T20+ • When the PCM and the Passlock control
Important: Performing the following procedures will module are prepared to re-learn, turn the
cause a DTC P1630 to set when they are completed. ignition OFF for 30 seconds and then start the
This is the intended functionality. Once P1630 is set, engine.
turn the ignition OFF for 30 seconds, then turn the Passlock Learn Procedure w/o Tech 2 Scan
ignition ON and P1630 will clear. If P1630 does not Tool or Techline Terminal
clear, refer to DTC P1630 Theft Deterrent PCM in
Learn Mode. Important: While the PCM is in the Auto Learn
1. Using the T50/T60/T20+, enter the Service Procedure, maintain the battery voltage at all times.
Programming System (SPS). Follow the procedure exactly as indicated or the
procedure will have to be repeated from the beginning.
2. Select Terminal to Vehicle Programming.
3. Select Done and follow instructions on Vehicle Important: Performing the following procedures will
Set-up screen cause a DTC P1630 to set when they are completed.
This is the intended functionality. Once it is set, turn the
4. Select Vehicle Theft Re-learn. ignition OFF for 30 seconds, then turn the ignition ON
5. Follow the instructions on the remaining screens. and P1630 will clear. If P1630 does not clear, refer to
• The PCM and the Passlock control module will DTC P1630 Theft Deterrent PCM in Learn Mode.
prepare for a re-learn. 1. Attempt to start the vehicle (the vehicle will start
• A security timer will be ON for approximately and stall), after the engine has stalled, leave the
10 minutes or until DTC P1630 sets. ignition ON for 10 minutes (the security light
• When the PCM and the Passlock control will remain ON for 10 minutes and then go OFF).
module are prepared to re-learn, turn the 2. After the Security lamp turns OFF, turn the ignition
ignition OFF for 30 seconds and then start the OFF for 30 seconds.
engine. 3. Again, attempt to start the vehicle (the vehicle will
Passlock Learn Procedure Using a Tech 2 start and stall), after the engine has stalled, leave
the ignition ON for 10 minutes (the security
Scan Tool light will remain ON for 10 minutes and then
Important: Performing the following procedures will go OFF).
cause a DTC P1630 to set when they are completed. 4. After the Security lamp turns OFF, turn the
This is the intended functionality. Once it is set, turn the ignition OFF for 30 seconds.
ignition OFF for 30 seconds, then turn the ignition ON
and P1630 will clear. If P1630 does not clear, refer to 5. Again, attempt to start the vehicle (the vehicle will
DTC P1630 Theft Deterrent PCM in Learn Mode. start and stall), after the engine has stalled, leave
the ignition ON for 10 minutes (the security
1. Using a Tech 2 enter the Service Programming
light will remain ON for 10 minutes and then go
System (SPS).
OFF) or until DTC P1630 sets.
2. After entering the vehicle information, choose the
6. Turn the ignition OFF for 30 seconds.
Request Info soft key on the Tech 2.
3. Select Done and follow the instructions on the 7. Turn the ignition ON and wait 30 seconds.
Vehicle Set-up screen 8. Attempt to start the engine.
ECT Sensor Replacement
Removal Procedure
Caution: Refer to Battery Disconnect Caution in
General Information.
1. Remove the negative battery cables.
2. Drain the cooling system below the level of the
sensor.
3. Remove the electrical connector by releasing the
locking tab.
Installation Procedure
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Install the sensor into the engine.
Tighten
Tighten the sensor to 25 N-m (18 lb ft).
263631
2. Install the electrical connector.
3. Refill the coolant system.
4. Install the negative battery cables.
26963
55485
4. Remove the air filter, MAF sensor, and intake
duct assembly from the air cleaner box.
5. Remove the air filter from the MAF sensor by
pulling them apart.
63699
63696
Installation Procedure
1. Install the air filter adapter to the MAF sensor.
Notice: Refer to Fastener Notice in Cautions
and Notices.
2. Install the 2 air filter adapter screws.
Tighten
Tighten the screws to 2.8 N^m (25 lb in).
3. Install the intake duct to the MAF sensor.
4. Tighten the intake duct clamp.
5. Install the air filter onto the air filter adapter.
63696
6. Install the air filter, MAF sensor, and intake duct
assembly into the air cleaner box.
63702
73425
Installation Procedure
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Install the IAT sensor.
Tighten
Tighten the IAT sensor to 25 N-m (18 lb ft).
72270
72271
72271
Notice: Refer to Fastener Notice in Cautions and
Notices.
72269
55498
55503
55505
Installation Procedure
Important: Make sure the mating surface between the
e lement assembly and the filter assembly is clean
before installation.
1. Install the new filter by aligning the widest key slot
located under the element assembly cap with the
widest key in the header assembly.
55489
55514
Installation Procedure
1. Install the fuel hoses and wiring harnesses.
2. Position the fuel manager/filter to the intake
manifold.
55514
55503
55513
55514
7. Remove the sensor mounting screws.
Installation Procedure
1. Install the new water in fuel sensor and a new
water in fuel sensor seal.
N o tic e : Refer to F a s te n e r N o tic e in Cautions and
Notices.
55496
55489
55498
3. Remove the mounting bolts that connect the fuel
manager/filter to the intake manifold.
55494
Installation Procedure
1. Install the cap sea l into filter housing.
55494
73422
55513
55498
18321
17407
Installation Procedure
1. Install the new seal ring and reinstall the sender
using the J 36608 fuel sender tool.
2. Place the tank in the shield.
3. Raise the tank slightly and reconnect the fuel feed
and vapor hoses and the electrical connections at
the sender.
18321
18442
Notice: Refer to Fuel Tank Strap Nuts Notice in
Cautions and Notices.
Installation Procedure
1. Install the new seal ring and reinstall the sender
using the J 36608 fuel sender tool.
2. Place the tank in the shield.
3. Raise the tank slightly and reconnect the fuel feed
and vapor hoses and the electrical connections at
the sender.
263632
4. Raise the tank and shield fully.
18329
8. Install the fuel tank off-road shield, if equipped.
9. Install the bolts.
Tighten
Tighten the bolts to 35 N-m (26 lb ft).
10. Replenish the fuel in the tank. Reinstall the fuel
tank filler cap.
11. Reconnect the negative battery cable. If a
memory retention device was not used, please
reset (to the extent possible) all devices that lost
their memory after the battery was disconnected.
12. Check for fuel leaks.
12.1. Turn ON the ignition switch for 2 seconds.
12.2. Turn OFF the ignition switch for
10 seconds.
12.3. Again, turn the ignition switch to the ON
position.
12.4. Check for fuel leaks.
18318
18442
18406
6. Remove the nuts from the frame mounted
bracket.
7. Remove the frame mounted bracket.
Installation Procedure
1. Install the new seal Ting:
2. Use the J 36608 fuel sender tool in order to
reinstall the sender.
3. Place the tank in the shield.
263632
18409
18442
18407
10. Install the fuel tank brackets with the insulator
strips in place.
N o t i c e : Refer to Fuel Tank Strap Nuts Notice in
Cautions and Notices.
11. Tighten the strap bolts.
Tighten
Tighten the strap bolts to 45 N-m (33 lb ft).
12. Replenish the fuel in the tank.
13. Reinstall the fuel tank filler cap.
14. Reconnect the negative battery cable. If a
memory retention device was not used, reset (to
the extent possible) all of the devices that lost
their memory after the battery was disconnected.
15. Check for leaks.
15.1. Turn ON the ignition switch for 2 seconds.
15.2. Turn OFF the ignition switch for
10 seconds.
15.3. Again, turn the ignition switch to the ON
position.
15.4. Check for fuel leaks.
18440
5. Support the fuel tank and remove the tank straps
and insulator strips, if equipped.
17407
Installation Procedure
1. Install the new seal ring.
2. Use the J 36608 fuel sender tool in order to
reinstall the sender.
3. Place the tank in the shield.
263632
18418
12. Reconnect the negative battery cable. If a
memory retention device was not used, reset (to
the extent possible) all devices that lost their
memory after the battery was disconnected.
13. Check for leaks.
13.1. Turn ON the ignition switch for 2 seconds.
13.2. Turn OFF the ignition switch for
10 seconds.
13.3. Again, turn the ignition switch to the ON
position.
13.4. Check for fuel leaks.
17407
Installation Procedure
1. Install the new seal ring.
2. Use the J 36608 fuel sender tool in order to
reinstall the sender.
3. Raise the tank slightly and reconnect the fuel
hoses, the lines, and the electrical connections
at the sender.
18440
7. Install the fuel tank brackets with the insulator
strips in place.
N o t i c e : Refer to Fuel Tank Strap Nuts Notice in
Cautions and Notices.
8. Tighten the strap bolts.
Tighten
Tighten the strap bolts to 45N m (33 lb ft).
18442
5. Support the fuel tank and remove the tank straps
and insulator strips, if equipped.
18413
Installation Procedure
1. Install the new seal ring.
2. Use the J 36608 fuel sender tool in order to
reinstall the sender.
3. Place the tank in the shield.
18442
18413
12. Reconnect the negative battery cable. If a
memory retention device was not used, please
reset (to the extent possible) all devices that lost
their memory after the battery was disconnected.
13. Check for leaks.
13.1. Turn ON the ignition switch for 2 seconds.
13.2. Turn OFF the ignition switch for
10 seconds.
13.3. Again, turn the ignition switch to the ON
position.
13.4. Check for fuel leaks.
17407
Installation Procedure
1. Insert a new O-ring seal.
Notice: Do not fold or twist the strainer when installing
the sending unit. This action restricts fuel flow.
2. Install the sending unit assembly into the fuel tank.
3. Install the hoses onto the sender assembly.
19671
Installation Procedure
1. Position the new pump in the pump bracket.
193160
12. Remove the injection pump.
13. Cap all open lines and nozzles.
14. Remove the flange gasket.
Installation Procedure
1. Install the new flange gasket on the
injection pump.
2. Adjust the locating stud (1) to the proper position
to match with the slotted/elongated hole in the
driven gear.
Important: Be sure the locating stud (1) on the
injection pump hub goes into the slotted/elongated
hole in the driven gear.
27613
N o t i c e : Refer to Fastener Notice in Cautions and
Notices.
193160
Installation Procedure
Tools Required
J 29873 Nozzle Socket
Important: When installing an injection nozzle, use
the J 29873 nozzle socket. Install the nozzle using the
30 mm hex portion. Failure to do so will result in
damage to the injection nozzle.
1. Install the injection nozzle using J 29873 (apply
anti-seize compound to threads of nozzle that
contact the cylinder).
N o t i c e : Refer to Fastener Notice in Cautions and
Notices.
2. Tighten the nozzle.
Tighten
Tighten the nozzle to 70 N-m (50 lb ft).
263638
3. Tighten the fuel injection line.
Tighten
Tighten the nut to 25 N-m (20 lb ft).
4. Install the fuel return hoses (1) on the nozzle (2).
5. Install the fuel line clip.
6. Install the negative battery cables.
27624
27615
installation Procedure
1. Install the switch (1).
2. Reconnect the electrical connector.
3. Install the fuel manager/filter. Refer to Fuel
Manager/Filter Replacement.
4. Bleed the fuel system. Refer to Fuel Feed and
Fuel Return Pipe Purge Procedure.
installation Procedure
1. Lube the new O-ring with engine oil
2. Install the sensor in the engine.
72321
26780
Installation Procedure
1. Install the glow plug relay on the mounting studs.
26782
26781
3. Install the wiring harness connector to the relay.
4. Install the glow pl ug wiring harness and nuts.
Tighten
Tighten the nuts to 5 N-m (44 lb in).
5. Install the negative battery cables.
Installation Procedure
1. Install the glow plugs.
Tighten
Tighten the glow plugs to 17 N-m (13 lb ft).
2. Install the lead wires to the glow plugs.
3. Instal l the negative battery cables.
26774
Glow Plug Replacement - Right Side
Rem oval Procedure
Tools Required
J 39083 Glow Plug Connector Remover and Installer
Right Side of Vehicle
1. Raise the vehicle.
2. Remove the right front tire.
3. Remove the splash shield from the right front
wheel well.
4. Remove the lead wire from the glow plug in the
2 cylinder.
5. Remove the lead wires for glow plugs in
cylinders 4 and 6 at the harness connectors.
6. Remove the heat shroud for the glow plug in
cylinder 4.
7. Remove the heat shroud for cylinder 6.
• Slide the shrouds back far enough to allow
access for unplugging the wires at
cylinder 4 and 6 glow plugs.
• Use the J 39083 in order to disconnect the
glow plug wires.
8. Remove the glow plugs from cylinders 2, 4,
and 6. If a glow plug is damaged during the
removal procedure, refer to Damaged Glow Plug
Removal.
9. Disconnect the lead wire at the glow plug from
cylinder 8 by reaching up from underneath the
vehicle.
10. Remove the glow plug from cylinder 8. If the glow
plug is damaged during the removal procedure,
refer to Damaged Glow Plug Removal.
For easier access to glow plugs on cylinders 6
and 8, it may be necessary to remove the exhaust
down pipe from turbocharger.
362187
Installation Procedure
N o t i c e : Refer to Fastener Notice in Cautions and
Notices.
1. Install the glow plug into cylinder 8.
Tighten
Tighten the glow plugs to 17 N-m (13 lb ft).
2. Install the lead wire to cylinder 8 glow plug.
3. Install the glow plugs into cylinders 2, 4, and 6 by
reaching through the right front wheel well.
Tighten
Tighten the glow plugs to 17 N-m (13 lb ft).
4. Install lead wire to glow plug 6.
• Slide the shroud over the wire lead and fasten
to the studs.
• Repeat Step 4 for the cylinder 4 glow plug.
Tighten
Tighten the heat shroud nuts to
23 N-m (17 lb ft).
5. Install the wires for glow plugs in cylinder 4 and 6
to connectors at the wire harness.
6. Install the lead wire for cylinder 2 glow plug.
7. Install the splash shield in the right front
wheel well.
8. Inspect the wire routing, making sure the lead
wires are not rubbing against the exhaust
manifold or any part that may harm the wire
insulation.
9. Install the right front tire.
55489
25113
Installation Procedure
1. Install the EGR valve (2) and gasket (3).
N o t i c e : Refer to F a s t e n e r N o t i c e in Cautions and
Notices.
2. Install EGR valve mounting bolts (1).
Tighten
Tighten bolts to 25 N m (18 lb ft).
3. Install the EGR valve vacuum hose.
25113
4. Install the upper intake manifold cover.
5. Install the upper intake manifold cover bolts.
Tighten
Tighten the bolts to 11 N-m (100 lb in).
6. Install negative battery cables.
7. Start and idle engine.
Important: If the ALM cells are not reset, a poor
driveability, heavy black smoke and EGR DTCs will
exist until vehicle has been driven. The ALM cells will
adjust to normal settings after the vehicle has been
driven (mileage will vary) and all DTCs are cleared.
8. Reset ALM cells using scan tool (under special
functions in scan tool).
55489
25303
Installation Procedure
1. Install the EGR solenoid (1).
N o t i c e : Refer to Fastener Notice in Cautions and
Notices.
2. Install mounting bolt (2).
Tighten
Tighten mounting bolt to 6.0 N-m (53 lb in).
3. install the vacuum hoses.
4. Install the electrical connector to the solenoid.
5. Install the negative battery cable(s).
25303
EGR Vent Solenoid Replacement
Removal Procedure
C a u tio n : R e f e r to B a t t e r y D is c o n n e c t C a u tio n in
C a u tio n s a n d N o tic e s .
1. Remove the negative battery cables.
2. Remove the electrical connector from the solenoid.
3. Remove the vacuum hoses.
4. Remove the EGR Vent solenoid mounting bolt (2).
5. Remove the EGR vent solenoid (1).
25300
Installation Procedure
1. Install the EGR vent solenoid (1).
N o t i c e : Refer to Fastener Notice in Cautions and
Notices.
2. Install EGR Vent Solenoid mounting bolt (2).
Tighten
Tighten mounting bolt to 6.0 N-m (53 lb in).
3. Install the vacuum hoses.
4. Install the electrical connector to the solenoid.
5. Install the negative battery cables.
25300
25479
Installation Procedure
1. Install the solenoid filter (1).
2. Install the filter retainer clip (2).
25479
26954
Installation Procedure
N o t i c e : Refer to Fastener Notice in Cautions and
Notices.
1. Install the mounting bolts with the sensor.
Tighten
Tighten the mounting bolts to 3.5 N-m (27 lb in).
2. Install the electrical connector.
3. Install the vacuum harness.
4. Install the negative battery cables.
263636
Vehicle Speed Signal Buffer Replacement
Removal Procedure
1. Remove the fasteners (3) that retain the vehicle
speed sensor (VSS) buffer (1) to the instrument
panel carrier.
2. Remove the VSS buffer (1) from the instrument
panel carrier.
3. Disconnect the electrical connector (2) from the
VSS buffer (1).
4. Remove the VSS buffer (1) from the vehicle.
Installation Procedure
1. Install the vehicle speed sensor (VSS) buffer (1)
to the vehicle.
2. Connect the electrical connector (2) the VSS
buffer (1).
3. Position the VSS buffer (1) to the instrument
panel carrier.
4. Install the VSS buffer fasteners (3) that retain the
VSS buffer (1) to the instrument panel carrier.
26957
Installation Procedure
1. Install the port gasket on sensor.
2. Install the sensor.
26957
Installation Procedure
1. Install the wastegate solenoid.
2. Install the wastegate mounting bolt.
3. Install the vacuum hoses.
4. Install the electrical connector.
5. Install the negative battery cables.
25616
installation Procedure
1. Install the CDR valve (1) into the valve cover.
2. Install the hose (3).
Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Install the clamp (2).
Tighten
Tighten the clamp to 1.7 N-m (15 lb in).
55474
55485
3. Remove the MAF sensor electrical connector
(L56 only).
63702
63699
Installation Procedure
1. Install the air inlet elbow on the filter by pushing
on the inlet elbow.
2. Install the air cleaner filter with the air inlet elbow
attached into the housing.
3. Install the MAF sensor electrical connector
(L56 only).
63702
4. Install the air cleaner cover into the housing and
clip into place.
55474
2. Release the clips holding the air cleaner cover to
the housing.
3. Remove the MAF sensor electrical connector
(L56 only).
4. Remove the air filter with the air cleaner inlet
elbow attached.
Installation Procedure
1. Install the air cleaner assembly.
Notice: Refer to Fastener Notice in Cautions and
Notices.
2. Install the air cleaner assembly mounting bolts.
Tighten
Tighten the mounting bolts to 25 N-m (19 lb ft).
3. Install the air cleaner filter with the inlet elbow
attached.
55483
4. Install the air cleaner cover to the housing and
clip the air cleaner cover into place.
5. Install the MAF sensor electrical connector
(L56 only).
55474
Description and Operation
Powertrain Control Module Description The PCM constantly looks at the information from
various sensors, and controls the systems that affect
The PCM processes the various input information. The vehicle performance. The PCM performs the
PCM sends the necessary electrical responses to diagnostic function of the system. It can recognize
control fuel delivery, spark timing, and other emission operational problems, a lert the driver through the MIL
c o n t r o l systems.
(Service Engine Soon), and store one or more
The input information has an interrelation to more than DTCs which identify the problem areas to aid the
one output. One failed input can affect more than technician in making repairs. See the specific
one system’s operation. diagnosis procedure for more information.
On-Board Diagnostic System Check The PCM processes the various input information and
The On-Board Diagnostic (OBD) System Check is an sends the necessary electrical responses to control
organized approach to identify a problem caused fuel delivery, timing and other emission control
b y a n e le c t r o n ic e n g i n e con trol s y s t e m m a lfu n c tio n .
systems. The input information has an interrelation to
The OBD must be the starting point for any driveability more than one output, therefore, if the one input
complaint diagnosis. The OBD directs the technician failed it could effect more than one system’s operation.
to the next logical step in diagnosing the complaint. Aftermarket (Add-On) Electrical And
U s e t h e E n g i n e S c a n T o o l D a t a D e f i n i t i o n s list Vacuum Equipment
f o r a c o m p a r i s o n a f t e r fulfilling t h e f o l l o w i n g i t e m s :
Any equipment installed on a vehicle after leaving the
• Completes the OBD System Check factory that connects to the electrical or vacuum
• T h e o n -b o a r d d i a g n o s t i c s a r e fu n c tio n in g p ro p erly systems of the vehicle defines Aftermarket (Add-On)
• D is p la y s n o d ia g n o s t ic tro u b le c o d e s Electrical and Vacuum Equipment. The vehicle
design makes no allowances for this type of
The Engine Scan Tool Definitions are an average of
equipment.
display values recorded from normal operating
v e h i c l e s . T h e D efin itio n s in ten d to r e p r e s e n t w h a t a Notice: Do not attach add-on vacuum operated
normal functioning system should display. equipment to this vehicle. The use of add-on vacuum
equipment may result in damage to vehicle
Important: D o n o t u s e a s c a n t o o l t h a t d i s p l a y s f a u l t y components or systems.
d a ta . R ep o rt t h e p ro b lem to t h e m a n u fa ctu rer.
U s i n g a m a l f u n c t i o n i n g s c a n t o o l c a n r e s u l t in Notice: Connect any add-on electrically operated
m is d ia g n o s is a n d u n n e c e s s a r y p arts r e p la c e m e n t. equipment to the vehicle’s electrical system at
the battery (power and ground) in order to prevent
U s e o n l y t h e p a r a m e t e r s l i s t e d in t h e E n g i n e S c a n T o o l
damage to the vehicle.
D efin itio n s for d ia g n o s is . W h e n a s c a n too l r e a d s
other parameters, General Motors recommends not The Add-On electrical equipment, even when installed
using the values for use in diagnosis. to these strict guidelines, may still cause the
Powertrain system to malfunction. This may also
For m o re d esc rip tio n o n th e v a lu e s a n d th e u s e of th e
include any equipment which is not connected to the
s c a n to o l to d i a g n o s e t h e P C M in p u ts, re fe r to t h e
electrical system of the vehicle such as portable
a p p l i c a b l e d i a g n o s t i c file .
telephones and radios. Therefore, the first step in
W h e n all t h e v a l u e s a r e w it h in t h e r a n g e i l l u s t r a t e d in diagnosing any Powertrain problem is to eliminate all
th e E n g in e S c a n T o o l D a ta D efin itio n s, refer to of the Aftermarket electrical equipment from the
D riveab ility S y m p t o m s . vehicle. After this is done, if the problem still exists,
Control Module Communications diagnose the problem in the normal manner.
T h e control m o d u le s y s t e m h a s a c o m p u te r , Engine Controls Information
P ow ertra in C on trol M o d u le (P C M ) to co n tro l fuel The driveability and emissions information describes
d e liv e r y , tim in g , a n d s o m e e m i s s i o n c o n tro l s y s t e m s . the function and operation of the control module.
The control module system monitors a number of The emphasis is placed on the diagnosis and repair of
engine and vehicle functions and controls the following problems related to the system.
operations;
Engine Components, Wiring Diagrams, and Diagnostic
• F u e l co n tro l. Tables (DTCs);
• F u e l in je c tio n tim in g. • The Component Locations
• E x h a u s t g a s r ecir cu la tio n .
• The Wiring Diagrams
• T r a n s m i s s i o n sh ift a n d sh ift q u a lity f u n c t io n s .
• The Control Module Terminal End View and
• S p e c ific tr a n sm iss io n control d ia g n o s tic s Terminal Definitions
a r e c o v e r e d in T r a n s m i s s i o n s .
• The On-Board Diagnostic (OBD) System Check
T h e d ie s e l P o w ertra in C on trol M o d u le (P C M ), lo c a t e d
• The Diagnostic Trouble Code Tables (DTCs)
in t h e p a s s e n g e r c o m p a r t m e n t , i s t h e c o n t r o l c e n t e r
o f t h e co n tro l m o d u le s y s t e m . T h e P o w e r tr a in C ontrol
M o d u le u s e d o n th e e le c tr o n ic fuel in je cted
6 .5 L d ie s e l is referred to a s a P C M .
The Component System includes the following items: Serial Data Communications
® The Component and circuit description
Class II Serial Data
• The On-vehicle service for each subsystem
U.S. Federal regulations require that all automobile
• The Functional checks with the Diagnostic Tables manufacturers establish a common communications
• How To Use Electrical Systems Diagnostic system. This vehicle utilizes the Class II
Information communications system. Each bit of information can
The DTCs also contain the die nostic support have one of two lengths: long or short. This allows the
information containing the circuit diagrams, the circuit vehicle wiring to be reduced by the transmission
or the system information, and helpful diagnostic and reception of the multiple signals over a single wire.
information. The messages which are carried on Class II data
streams are also prioritized. In other words, if
Wiring Harness Service two messages attempt to establish communications on
The control module harness electrically connects the the data line at the same time, only the message
control module to the various solenoids, switches, with the higher priority will continue. The device with
and sensors in the vehicle engine compartr it and the lower priority message must wait. The most
passenger compartment. significant result of this regulation is that the regulation
Replace the wire harnesses with the proper part provides the scan tool manufacturers with the
number replacement. When splicing signal wires into a capability of accessing the data from any make or
harness, use the wiring that has high temperature model vehicle sold in the United States.
insulation. The Diagnostic Executive
Consider the low amperage and voltage levels utilized The Diagnostic Executive is a unique segment of the
in the Powertrain control systems. Make the best software which is designed to coordinate and
possible bond at all splices. Use rdsin-core solder in prioritize the diagnostic procedures as well as define
these areas. the protocol for recording and displaying their
Molded-on connectors require complete replacement results. The main responsibilities of the Diagnostic
of the connector. Splice a new connector into the Executive are:
harness. Replacement connectors and terminals are • Monitoring the Diagnostic Test Enabling
listed in Group 8.965 in the Standard Parts Catalog. Conditions
For wiring repair, refer to Wiring Repairs. • Requesting the Malfunction Indicator Light (MIL)
Connectors and Terminals • Illuminating the MIL.
In order to prevent shorting between opposite • Recording Pending, Current, and History DTCs
terminals, use care when probing a connector and • Storing and Erasing Freeze Frame Data
when replacing terminals. Damage to the components
• Monitorinr nd Recording Test Status information
could result.
Always use jumper wires between connectors for On-Board Diagnostic Tests
circuit checking. A diagnostic test is a series of steps which has a
Never probe through the Weather-Pack seals. beginning and an end. The result of which is a pass or
fail reported to the Diagnostic Executive. When a
The connector test adapter kit J 35616-A, or the
diagnostic test reports a pass result, the Diagnostic
equivalent, contains an assortment of flexible
Executive records the following data:
connectors used in order to probe the terminals during
the diagnosis. The fuse remover and the test • The diagnostic test has completed since the last
tool BT-8616, or the equivalent, is used for removing a ignition cycle
fuse and to adapt the fuse holder to a meter for • The diagnostic test has passed during the current
diagnosis. ignition cycle
Open circuits are often difficult to locate by sight • The fault identified by the diagnostic test is not
because oxidation or terminal misalignment are hidden currently active
by the connectors, h' % wiggling a connector on a When a diagnostic test reports a fail result, the
sensor or in the wiri. lamess may temporarily correct Diagnostic Executive records the following data:
the open circuit. Oxidized or loose connections may
cause intermittent problems. • The diagnostic test has completed since the last
ignition
Be certain the type of connector and terminal before
making any connector or terminal repair. • The fault identified by the diagnostic test is
Weather-Pack and Com-Pack III terminals look similar, currently active
but are serviced differently. • The fault has been active during this ignition cycle
• The operating conditions at the time of the
failure
Trip Intermittent Malfunction Indicator Lamp
The ability for a diagnostic test to run depends largely In the case of an intermittent fault, the malfunction
upon whether or not a Trip has been completed. A indicator lamp (MIL) may illuminate and then after
Trip for a particular diagnostic is defined as a key ON 3 trips turn OFF. However, the corresponding
and key OFF cycle in which ail the enabling criteria diagnostic trouble code will store in the memory.
for a given diagnostic has been met. The requirements When unexpected diagnostic trouble codes appear,
for trips vary as they may involve items of an check for an intermittent malfunction.
unrelated nature; driving style, length of trip, ambient Data Link Connector (DLC)
temperature, etc. Some diagnostic tests run only
The provision for communicating with the control
once per trip (e.g. catalyst monitor) while others run module is a Data Link Connector (DLC). The DLC is
continuously (e.g. misfire and fuel system monitors). If usually located under the instrument panel. The DLC is
the proper enabling conditions are not met during used in order to connect to a scan tool. Some
that ignition cycle, the tests may not be complete or common uses of the scan tool are listed below:
the test may not have run.
• Identifying stored Diagnostic Trouble
Warm-Up Cycle Codes (DTCs)
A Warm-up cycle consists of an engine start-up and • Clearing the DTCs
vehicle operation such that the coolant temperature • Performing the output control tests
has risen greater than 40°F from the start-up • Reading the serial data
temperature and reached a minimum engine coolant
temperature of 160°F. If this condition is not met during
Reprogramming (Flashing) The
the ignition cycle, the diagnostic may not run. Control Module
Some vehicles allow the reprogramming of the control
Diagnostic Information module without removal from the vehicle. This
The diagnostic tables and the functional checks are provides a flexible and a cost-effective method of
designed in order to locate a poor circuit or a making changes in software and calibrations.
malfunctioning component through a process of logical Refer to the latest Techline information on
decisions. The tables are prepared with the reprogramming or flashing procedures.
assumption that the vehicle functioned correctly at the
time of assembly and that there are no multiple Verifying Vehicle Repair
faults present. Verification of the vehicle repair will be more
comprehensive for vehicles with OBD II system
There is a continuous self-diagnosis on certain control
diagnostics. Following a repair, the technician should
functions. This diagnostic capability is complemented
perform the following steps:
by the diagnostic procedures which are contained
in this manual. The language of communicating 1. Review the fail records and the Freeze Fame data
the source of the malfunction is a system of diagnostic for the DTC which was diagnosed. Record the fail
trouble codes. When a malfunction is detected by records or Freeze Fame data. The Freeze
the control module, a diagnostic trouble code will set Frame data will only store for an A or B type
and the malfunction indicator lamp (MIL) will diagnostic and only if the MIL has illuminated.
illuminate on some applications. 2. Clear the DTCs.
Malfunction Indicator Lamp (MIL) 3. Operate the vehicle within the conditions noted in
the fail records or the Freeze Frame data.
The malfunction indicator lamp (MIL) is on the
4. Monitor the DTC status information for the specific
instrument panel. The MIL has the following functions:
DTC which has been diagnosed until the
• The MIL informs the driver that a fault that affects diagnostic test associated with that DTC runs.
the emission levels of the vehicle has occurred.
Following these steps are very important in verifying
The owner should take the vehicle in for service as repairs on the OBD II systems. Failure to follow these
soon as possible. steps could result in an unnecessary repair.
• As a bulb and system check, the malfunction
indicator lamp (MIL) comes ON with the key Reading Diagnostic Trouble Codes
ON and the engine not running. When the engine Use a diagnostic scan tool in order to read the
is started, the MIL turns OFF if no DTCs diagnostic trouble codes. Failure to follow this step
are set. could result in unnecessary repairs.
When the MIL remains ON while the engine is
running, or when a malfunction is suspected due to a
driveability or emissions problem, perform an
On-Board Diagnostic (OBD) System Check. The
procedures for these checks are given in engine
controls. These checks expose faults which the
technician may not detect if other diagnostics are
performed first.
DTC Modes Not Run SCC (Not Run Since Code Clear)
The OBD II vehicles have three options available in This option displays up to 33 DTCs that have not run
the scan tool DTC mode in order to display the since the DTCs were last cleared. Since any
enhanced information available. A description of the displayed DTCs have not run, their condition (passing
new modes, the DTC Info and the Specific DTC, or failing) is unknown.
follows. After selecting the DTC, the following menu
appears: Test Fail SCC (Test Failed Since Code Clear)
• The DTC Info This selection displays all of the active and history
DTCs that have reported a test failure since the last
• The Specific DTC
time the DTCs were cleared. The DTCs that last failed
• The Freeze Frame over 40 warm-up cycles (before this option is
• The Fail Records selected) will not be displayed
• The Clear Info Specific DTC Mode
The following is a brief description of each of the sub
This mode is used in order to check the status of the
menus in the DTC Info and the Specific DTC. The
individual diagnostic tests by the DTC number.
order in which they appear here is alphabetical and not
This selection can be accessed if a DTC has passed
necessarily the way they will appear on the scan tool.
or failed. Many OBD II DTC mode descriptions are
DTC Info Mode possible because of the extensive amount of
Use the DTC Info mode in order to search for a information that the Diagnostic Executive monitors
specific type of stored DTC information. There are regarding each test. Some of the many possible
seven choices. The electronic service information may descriptions follow with a brief explanation.
instruct the technician to test for DTCs in a certain This selection only allows the entry of the DTC
manner. Always follow the published service numbers that are supported by the vehicle that is
procedures. being tested. If an attempt is made to enter the DTC
In order to get a complete description of any status, numbers for tests which the diagnostic executive does
press the Enter key before pressing the desired F-key. not recognize, the requested information will not be
For example, pressing enter, then an F key will displayed correctly and the scan tool may display
display a definition of the abbreviated scan tool status. an error message. The same applies to using the DTC
trigger option in the Snapshot mode. If an invalid
DTC Status DTC is entered, the scan tool will not trigger.
This selection displays any DTCs that have not run
during the current ignition cycle or have reported a test Failed Last Test
failure during this ignition up to a maximum of For type A and B DTCs, this message will display
33 DTCs. The DTC tests which run and pass removes during the subsequent ignition cycles until the
that DTC number from the scan tool screen. test passes or the DTCs are cleared. For type C
DTCs, this message clears whenever the ignition is
Fail This Ign. (Fail This Ignition) cycled.
This selection displays all of the DTCs that have failed
during the present ignition cycle. Failed Since Clear
History This message displayed indicates that the diagnostic
test failed at least once within the last 40 warm-up
This selection displays only the DTCs that are stored cycles since the last time the control module cleared
to the history memory of the control module. The the DTCs.
history memory will not display the Type B DTCs that
have not requested the MIL. The history memory Failed This Ign. (Failed This Ignition)
will display all of the type A and B DTCs that have the This message displayed indicates that the diagnostic
MIL and have failed within the last 40 warm-up test has failed at least once during the current
cycles. In addition, the history memory will display all ignition cycle. This message will clear when the DTCs
of the type C DTCs that have failed within the last are cleared or the ignition is cycled.
40 warm-up cycles.
History DTC
Last Test Fail
This message displayed indicates that the DTC has
This selection displays only the DTCs which have
stored to memory as a valid fault. A DTC displayed as
failed during the last time that the test ran. The last test
a History fault does not necessarily mean that the
may have ran during a previous ignition cycle if a
fault is no longer present. The history description
type A or B DTC is displayed. For type C DTCs, the
means that all of the conditions necessary for reporting
last failure must have occurred during the current
a fault have been met.
ignition cycle to appear as Last Test Fail.
MIL Request
This selection displays only the DTCs that are
requesting the MIL. Type C DTCs cannot be displayed
by using this option. This selection will report type B
DTCs only after the MIL has been requested.
MIL Requested ■ Information Sensors/Switches Description
T h i s m e s s a g e 1d i s p l a y e d i n d i c a t e s t h a t t h e D T C i s
Engine Coolant Temperature (ECT) Sensor
c u r r e n t l y c a u s i n g t h e MIL t o t u r n O N . R e m e m b e r t h a t
o n ly ty p e A a n d B D T C s c a n r e q u e s t t h e MIL. T h e
MIL r e q u e s t c a n n o t d e t e r m i n e if t h e D T C f a u lt
i
c o n d it io n s a r e cu r r e n tly b e i n g e x p e r e n c e d . T h is is
b e c a u s e t h e d i a g n o s t i c e x e c u t i v e r e q u i r e s u p t o 3 tr ip s
d u r i n g w h i c h t h e d i a g n o s t i c t e s t p a s s e s t o turn O F F
t h e MIL.
T h is m e s s a g e d is p la y e d in d ic a te s that t h e s e le c t e d Legend
d ia g n o s t ic t e s t h a s t h e fo llo w in g ite m s: (1) E C T E lec trica l C o n n e c t o r
• P a s s e d t h e la st t e s t (2) C on n ector T ab
• R a n a n d p a s s e d d u rin g th is ign ition c y c l e (3) E n g in e C o o la n t T e m p e r a t u r e (E C T ) S e n s o r
• R a n a n d p a s s e d s in c e th e D T C s w e r e last c le a r e d
T h e e n g i n e c o o l a n t t e m p e r a t u r e ( E C T ) s e n s o r is a
• This t e s t h a s n o t fa ile d s i n c e t h e D T C s w e r e
th e r m is to r (a r e s isto r w h ic h c h a n g e s v a lu e b a s e d o n
la st c le a r e d .
t e m p e r a t u r e ) m o u n t e d in t h e e n g i n e c o o l a n t s t r e a m .
W h e n e v e r t h e in d ic a te d s t a t u s o f t h e v e h i c l e is T e s t L o w c o o l a n t t e m p e r a t u r e p r o d u c e s a h ig h r e s i s t a n c e
R a n a n d P a s s e d a fte r a rep a ir v e r ific a tio n , t h e v e h i c l e ( 1 0 0 , 0 0 0 o h m s a t - 4 0 ° C / - 4 0 ° F ) w h ile h igh
is r e a d y to b e r e l e a s e d to t h e c u s t o m e r . te m p e r a tu r e c a u s e s lo w r e s is t a n c e (7 0 o h m s at
If t h e i n d i c a t e d s t a t u s o f t h e v e h i c l e i s F a i l e d T h i s Ig n 1 3 0 °C /2 6 6 °F ).
a fte r a rep a ir v e r ific a tio n , t h e n t h e re p a ir is in c o m p l e t e . T h e P C M s u p p l i e s a 5 volt s ig n a l t h r o u g h t h e
A f u r t h e r d i a g n o s i s is r e q u i r e d . t h e r m i s t o r in t h e e n g i n e c o o l a n t t e m p e r a t u r e ( E C T )
P r io r t o r e p a i r i n g a v e h i c l e , u s e t h e s t a t u s i n f o r m a t i o n s e n s o r a n d th e n th e PC M m e a s u r e s th e v o lta g e
in o r d e r t o e v a l u a t e t h e s t a t e o f t h e d i a g n o s t i c t e s t t o d e t e r m i n e t e m p e r a t u r e . T h e v o l t a g e will b e h i g h
a n d t o h e l p i d e n t i f y a n in t e r m i t t e n t p r o b l e m . T h e w h e n t h e e n g i n e is c o ld , a n d lo w w h e n t h e e n g i n e is
t e c h n i c i a n c a n c o n c l u d e t h a t a l t h o u g h t h e MIL is hot. B y m e a s u r i n g t h e v o l t a g e , t h e P C M k n o w s
illu m in a te d , t h e fault c o n d itio n th a t c a u s e d t h e c o d e t o th e e n g in e c o o la n t tem p era tu re. E n g in e co o la n t
s e t is n o t p r e s e n t. A n in te rm itte n t c o n d itio n m u s t b e t e m p e r a tu r e a f fe c ts fu e l co n tro l a n d t h e g lo w p lu g
th e c a u s e . system .
Mass Air Flow (MAF) Sensor
13643
Legend
(1) Intake Air Temperature (IAT) Sensor
(2) Electrical Harness Connector
27619
13693
Legend
(1) E lec trica l C o n n e c t o r
(2) M a n i f o ld A b s o l u t e P r e s s u r e (MAP) S en sor
th a t p r o c e s s e s in p u ts from t h e v e h i c l e s p e e d s e n s o r
O n v e h i c l e s e q u i p p e d w it h E G R 5 t h e E G R c o n t r o l a n d o u t p u t s v a r i o u s s i g n a l s . T h e V S S buffer
p r e s s u r e s e n s o r , m o u n t e d o n t h e left s i d e o f t h e c o w l , m o d u l e o u tp u t s a 4 0 0 0 p u l s e p e r m ile sig n a l. T h is
is u s e d t o m o n i t o r t h e a m o u n t o f v a c u u m a p p l i e d t o s ig n a l is u s e d b y t h e P C M to d e t e r m in e v e h i c l e s p e e d .
T h e P C M u s e s v e h i c l e s p e e d s i g n a l in p u t f o r c r u i s e
t h e E G R v a l v e . It s e n s e s t h e a c t u a l v a c u u m in
c o n t r o l a n d f u e l c u t o f f . T h e V S S b u f f e r m o d u l e is
t h e E G R v a c u u m lin e a n d s e n d s a s i g n a l b a c k to t h e
m a t c h e d t o t h e v e h i c l e b a s e d o n t r a n s m i s s i o n , fin a l
P C M . T h e s ig n a l is c o m p a r e d to t h e d e s i r e d E G R
d r i v e r a tio a n d tire s i z e . T h e V S S b u f f e r m o d u l e
c a l c u l a t e d b y t h e P C M . O n v e h i c l e s n o t e q u i p p e d w it h
is lo c a t e d b e h in d t h e in str u m e n t p a n e l.
E G R , t h e b o o s t s e n s o r is u s e d to m e a s u r e B A R O .
T h is s e n s o r r e a d s b a r o m e tr ic p r e s s u r e (B A R O ) u n d e r Fuel Solenoid Driver
certa in c o n d itio n s , w h ic h a llo w s t h e P C M to T h e f u e l i n j e c t o r d r i v e r r e c e i v e s a n i n je c t c o m m a n d
a u to m a t ic a lly a d ju s t for d iffe r e n t a ltitu d e s . s ig n a l from t h e P C M a n d p r o v id e s a cu rren t r e g u la te d
o u t p u t t o t h e f u e l s o l e n o i d t h a t c o n t r o l s i n j e c t i o n . It
Boost (BARO) Sensor a ls o retu rn s a fuel s o le n o id c lo s u r e tim e sig n a l b a c k to
T h e b o o s t s e n s o r m e a s u r e s t h e c h a n g e s in t h e i n t a k e t h e P C M t o in fo r m it w h e n t h e f u e l s o l e n o i d h a s
m a n ifo ld p r e s s u r e . T h e b o o s t s e n s o r c o n v e r t s l
actu al y se a te d .
e n g in e lo a d a n d s p e e d c h a n g e s , th e n c o n v e r t s t h e
c h a n g e in r e a d i n g s t o v o l t a g e o u t p u t . Brake Switch
T h e P C M s e n d s a 5 v o lt r e f e r e n c e s ig n a l to t h e b o o s t T h e T C C n o r m a lly c l o s e d b r a k e s w itc h s u p p l i e s a .
B + s i g n a l in to t h e P C M . T h e s i g n a l v o l t a g e i s o p e n e d
s e n s o r . A s th e m anifold p r e s s u r e c h a n g e s , th e
electrica l r e s is t a n c e of t h e b o o s t s e n s o r a ls o c h a n g e s . w h e n th e b r a k e s a r e ap p lied .
B y m o n ito rin g t h e s e n s o r o u tp u t v o lt a g e , t h e P C M T h e c r u is e co n tr o l n o r m a lly o p e n b r a k e s w itc h
d e t e c t s t h e b o o s t p r e s s u r e . A h ig h p r e s s u r e (high s u p p l i e s a B + s i g n a l t o t h e P C M w h e n t h e b r a k e is
v o l t a g e ) r e q u ir e s m o r e fu e l. A lo w e r p r e s s u r e a p p lie d . T h e s e s ig n a l s a r e u s e d b y th e P C M to control
(lo w v o l t a g e ) r e q u ir e s l e s s fu e l. T h e co n tro l m o d u le tr a n s m is s io n a n d c r u is e control fu n ctio n s. T h e b rak e
u s e s t h e b o o s t p r e s s u r e s ig n a l to co n tro l fu el d eliv ery . s w i t c h e s a r e part o f t h e s t o p l a m p sw itc h .
Glow Plug System APP Module Description
T h e g l o w p l u g s y s t e m i s u s e d t o a s s i s t in p r o v i d i n g T h e a c c e l e r a t o r c o n tr o l s y s t e m is a n e le c t r o n ic a lly
t h e h e a t r e q u ir e d to b e g in c o m b u s t io n d u rin g e n g i n e c o n t r o l l e d t h r o tt le t y p e w i t h a n a c c e l e r a t o r p e d a l
sta rtin g a t c o ld a m b ie n t t e m p e r a t u r e s . a tta c h e d to a n a c c e le r a to r p e d a l p osition m o d u le . T h is
T h e g lo w p lu g relay s w i t c h e s p o w e r to t h e g lo w p lu g s m o d u le s e n d s s i g n a l s to t h e p o w ertra in co n tro l
a n d i s c o m m a n d e d o n a n d off b y t h e P C M . T h e m o d u l e w h ic h c o n t r o ls t h e fu e l in je c tio n p u m p .
g lo w p lu g s a r e h e a t e d b e f o r e a n d d u rin g c r a n k in g , a s
w e l l a s initial e n g i n e o p e r a t i o n . T h e P C M m o n i t o r s Fuel System Description
t h e g l o w p l u g r e ' a y o u t p u t v o l t a g e w h i c h i n d i c a t e s if t h e
T h e fu e l in je c tio n s y s t e m h a s a P C M c o n t r o lle d fu e l
rela y is fo llo w in g t h e P C M c o m m a n d s .
in je ctio n p u m p m o u n t e d o n to p o f t h e e n g i n e u n d e r t h e
Cruise Control System in ta k e m a n if o ld . T h e p u m p is d r iv e n b y t h e c a m s h a f t
th r o u g h t w o g e a r s , o n e a t t a c h e d to t h e front of
T h e c r u is e c o n tr o l s w i t c h e s a r e part o f t h e
th e c a m s h a f t a n d t h e o th e r a t ta c h e d to th e e n d of th e
m u l t i f u n c t i o n tu r n s i g n a l l e v e r . T h e s e s w i t c h e s e n a b l e
p u m p shaft. T h e s e g e a r s a re th e s a m e s iz e an d
t h e d riv er t o co n tr o l t h e c r u i s e o n /o ff, s e t / c o a s t a n d
h a v e t h e s a m e n u m b e r o f t e e th ; th e r e fo r e , t h e in jection
r e s u m e /a c c e l s ig n a ls . T h e s e s ig n a ls a r e in p uts to th e
p u m p sh a ft turns at th e s a m e s p e e d a s th e ca m sh a ft.
fu e l c o n tr o l p o rtio n o f t h e P C M a n d a llo w t h e P C M
to m a in ta in a d e s ir e d v e h ic le s p e e d u n d e r n orm al
driving c o n d it io n s .
A/C Signal
T h is s i g n a l i n d i c a t e s th a t t h e A /C c o m p r e s s o r c lu tc h is
e n g a g e d . T h e P C M u s e s th is s ig n a l to a d ju s t t h e
id le s p e e d .
54847
Legend
(1) Fuel Solenoid Driver (5) Two Stage Housing Pressure Regulator
(2) Optical/Fuel Temperature Sensor (6) Injector Timing Stepper Motor
(3) Fuel Inlet (7) Fuel Solenoid
(4) Engine Shutoff Solenoid
Legend
(1) C y lin d er 8
(2) C y lin d er 7
(3) C y lin d er 2
(4) C y lin d er 6
(5) C y lin d er 5
(6) C y lin d er 4
(7) C y lin d er 3
(8) C y lin d er 1
T h e in je ctio n lin e s c o n n e c t th e h ig h p r e s s u r e d i s c h a r g e
fittin gs o n t h e h e a d o f t h e in je ctio n p u m p t o t h e
i n j e c t i o n n o z z l e s . T h e i n j e c t i o n l i n e s a r e p r e - b e n t fo r
c o r r e c t rou ting a n d c o n n e c t to t h e in je c tio n p u m p h e a d
a s s h o w n in t h e f i g u r e a b o v e . T h e i n j e c t i o n l i n e s a r e
e q u a l in l e n g t h a n d in te r io r v o l u m e .
Fuel Metering
27821
T h e fu e l m e te r in g is a c c o m p l i s h e d b y t h e fu e l s o l e n o i d
Legend
d r i v e r b y u s i n g t h e s i g n a l s f r o m t h e P C M in o r d e r t o
(1) Inlet
co n tro l t h e fu e l in jection s o l e n o i d .
(2 ) R eturn
(3 ) P r e s s u r e S p rin g
Injection Timing
(4 ) N o z z le Nut T h e in je c tio n tim in g s t e p p e r m o to r a d v a n c e s or r e ta r d s
t h e in je ctio n tim in g b y t h e s i g n a l s th a t a r e r e c e iv e d
(5) N e e d le V a lv e
from t h e P C M .
(6 ) P in t l e
Engine Shutoff Solenoid
E a c h c y lin d e r h a s a n id en tica l fu e l in je ctio n n o z z l e W h e n not a c tiv a te d by th e P C M , th e e n g in e sh u toff
m o u n t e d in t h e p r e - c o m b u s t i o n c h a m b e r . A s t h e s o le n o id b lo c k s t h e fuel flo w from e n te r in g t h e tr a n sfer
p r e s s u r e w a v e o f in je ctio n r e a c h e s a n o z z l e , t h e p u m p in s i d e of t h e in je c tio n p u m p a n d s t o p s t h e
n e e d l e v a l v e i s lifted a g a i n s t s p r i n g f o r c e a n d f u e l e x i t s e n g in e o p era tio n .
in to t h e p r e - c o m b u s t i o n c h a m b e r o f t h e c y l i n d e r a s
a h ig h ly a t o m i z e d sp r a y . A s m a ll a m o u n t o f fuel t r a v e ls
b e t w e e n t h e n e e d l e v a l v e a n d p in tle n o z z l e , p r o v id in g
lu b rication . T w o p a s s a g e s in s id e t h e u p p e r half o f
t h e n o z z l e b o d y a llo w fuel that h a s lu b rica ted
t h e n e e d l e v a l v e to e x it into t h e fu e l return s y s t e m .
Accelerator Control System The accelerator control system is an electronically
controlled throttle type with an accelerator pedal
attached to an accelerator pedal position module (1).
This module sends the signals to the PCM which
then controls the fuel injection pump.
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Legend
Legend
(1) Crankcase Vapors to Induction System
(2) Inlet Manifold Runners
(3) Blowby Leakage At Valves and Pistons
(4) Crankcase Vapors
J 39200 J 23738-A
Digital Multimeter (DMM) Vacuum Pump
3430 5386
7000081 J 35689-A
Tech 2 Diagnostic Metri-Pack Terminal
Scan Tool Remover
5395
5382 5397
J 35616-A J 38641-B
Connector Test Adapter Kit Diesel Fuel Quality Tester
39385
Illustration Tool Number/Description
a J 29873
Nozzle Socket
60216
J 36608
Fuel Sender Tool
5384
J 39083
Glow Plug Connector
Rmover
60207